YANMAR OPERATION MANUAL MARINE PROPULSION ENGINE 6EY17W AEN7-Go0100All Rights Reserved, Copyright WANMAR €G., LTD.INTRODUCTION Thank you for purchasing a YANMAR marine product. This operation manual is for your safe and effective use of the product. Before you use this product, carefully read and fully understand the instructions about operation, inspection and maintenance. Keep this manual ina safe location, Make sure that the operator can always read it, Because the inspection and maintenance instructions are for professional technicians, necessary but basic knowledge has been omitted. WUsing this manual + The text and illustrations of this operation manual can partly disagree with products of some specifications. In ‘that case, refer to the separate Specification and Final Document, + The contents of this operation manual can change without prior notification to improve the quality and perfor- mance of the product and to improve safety + For some devices, refer to the separate operation manuals. + Ifyou lose or damage this operation manual, please contact YANMAR of your sales or service agent + Iyou transfer this product, also transfer this Operation Manual, Final Document and Records of Shop Trial with the product to the next owner. + The numerical values in this manual are based on the SI system (Intemational System of Units). Minquiries + Only use genuine YANMAR replacement parts or other specified parts. When you order a part, clearly give your YANMAR sales or service agent the product name (model) and serial number together with the part name (and its page in this manual) and part number. + Ifyou: - use the product differently from the intended usage purpose or conditions OR = operate the product differently from the contents of this operation manual, you can cause accidents and malfunctions. Before you make a modification to the product, contact YANMAR, ‘or your sales or service agent. Do not make @ modification that is not approved by YANMAR. + Ifyou have questions or comments about this manual, please contact YANMAR or your sales or service agentABOUT THIS OPERATION MANUAL ‘The major terms used in this operation manual are defined as follows: ‘The front of the engine: opposite side of the flywheel The back of the engine: the flywheel side ‘Operation side: on the left side as viewed from the flywheel side (fuel injection pump side) Non-operation side: on the right side as viewed from the wheel side (exhaust manifold side) ‘Turn right: clockwise rotation as viewed from the flywheel side ‘Tum left: counterclockwise rotation as viewed from the flywheel side Cylinder number: counted from the flywheel side (1, 2, 3. cytneer number — MA Mmmomnr <4 eww Driven machine > ruihnetonsine W Turn right (Clocks rotation) Tum tet «Counter clockwise retation)CONTENTS FOR YOUR SAFETY 1 About Safety Labels wa ssssermtecststenenne ugeiatenenanescineenaises A Precautions, 2 Maintenance Precautions 5 Safety Labels (Warning Labels) 8 Precautions for Lifting the Engine ..... 10 Engine Nameplate... - - "1 PRODUCT OVERVIEW 12 Principal Engine Specifications 12 Engine Component Names... 13 Functions of Major Components 8 Control System .. 19 FUEL OIL, LUBRICATING OIL & COOLING WATER Fuel Oil sesssescincensisesnessnanecmneiotaccininasinneenesnnmecasineesee 26 Lubricating Ol .os.sssssecetasessenecinesn seohianeneeacennenaeesananene BT Freshwater Cooling Water .. OPERATION ‘Operation Preparation .. Rechecking the Quantity of Lubricating Oil and Freshwater Inspection before Engine Start Starting the Engine _.... - Load Operation ....... ‘Stopping the Engine ‘Special Operation (No-Charge- Operation) Adjusting the Boost Compensator PERIODIC INSPECTIONS . Precautions for Inspections ..sse1-s-- Scheduled Inspections ......esesseeree Periodic Inspections ....... LONG-TERM STORAGE.. ‘Storing the Engine for a Long Time Restarting the Engine after Long-Term Storage ciemeseseeiencees 6M TROUBLESHOOTING ‘Troubleshooting Chart... Emergency Procedure for Marine Gear Failure... 96 ‘Troubleshooting Information - wo 98DISASSEMBLY, ASSEMBLY, ADJUSTMENT .. Precautions for Disassembly and Assembly...... Disassembling and Assembling the Cylinder Head and Accessories ... 99 101 Disassembling and Assembling the Piston and the Connecting Rod... 108 Disassembling and Assembling the Cylinder and Cylinder Liner 0.0.0. 116 Disassembling and Assembling the Main Bearing and Crankshaft... 118 Disassembling and Assembling the Timing Gear, ‘Camshaft, and Intake/Exhaust Swing Arm 127 Disassembling and Assembling the Fuel Injection Pump 128 Disassembling and Assembling the Fuel Injection Pump Drive Unit 134 ‘Govemor and Drive Unit 135 Disassembling the Lubricating Oll Pump, Lubricating Oil Cooler, ‘and Lubricating Oil Pressure Control Valve - sseeanascimeeen 138 Disassembling and Assembling the Cooling Water Pump. coe 142 Disassembling and Assembling the Fuel Feed PUuMP....ce scene 146 Intake/Exhaust System, 148 Freshwater Cooler. 150 Electric Equipment... 152 STANDARD MAINTENANCE TABLE ‘Standard Maintenance Table - ‘Standard Adjustment Value... 163 TIGHTENING TORQUE FOR MAJOR BOLTS AND NUTS .. TEST OPERATION AFTER SERVICING ... ATTACHED TABLE . 471 ‘Wire Connection Diagram... co seieeeetneeeinneene m1 Paris Number List for Daily Wear Maintenance 173FOR YOUR SAFETY —— FOR YOUR SAFETY ‘We are confident that you will be fully satisfied with this product if you use it as described in this manual. But if you do not obey all instructions, dangerous accidents and damage (e.g. injuries, burn injuries and fire) can occur. Before you use the engine, carefully read and thoroughly understand all safety precautions. About Safety Labels This manual and the engine have safety indications. They are important symbols and wamings that are necessary to operate this product safely. ‘The safety labels tell you this: This safety alert symbol is used with most safety wamings. It says: Attention! Warning! Your safety is, involved! Carefully read and obey the safely instructions after the safely alert symbol. DANGER indicates a hazardous situation which, if not avoided, will result fads in death or serious injury. WARNING indicates a hazardous situation which, if not avoided, could RAINS cesuitin dean or serous injury CAUTION indicates a hazardous situation which, if not avoided, could ACAUTION result in injury. NOTICE indicates a situation which can cause damage to the engine, NOTICE personal property andor the environment or cause the equipment to operate incorrectly.2 — FOR YOUR SAFETY Precautions POW Burns from steam @. + Never remove the: r cap from the freshwater tank while the eng is still hot. Steam and hot air will spurt out and seriously burn you. + After engine stop, wait until the temperature decreases. Wrap a cloth around the filler cap and slowly loosen the cap. + After inspection, tighten the filler cap firmly. If the cap is not secure, steam or hot air will come out during operation and cause burn injuries, Ventilation of the battery area + Make sure that the area around the battery is ventilated well and that no flammable materials are near. The battery makes hydrogen gas when it charges. The gas is very flammable. Fires from oil ignition + Make sure again that the type of fuel gasoline) can cause a fire, + Be sure to stop the engine before fueling. If you spill fuel oil, carefully wipe the spillage. + Do not put oils or other flammable materials near the engine. They can burn and cause a fire. is correct before you refuel. The wrong fuel oils (e.g. Exhaust gas poisoning + Never cover or block the windows, air vents, fans or other ventilation devices in the engine room. + Always maintain good ventilation in the engine room during operation. Breathing exhaust gas is dangerous to your health. Injury from rotating parts + Keep your hands, other body parts and clothing away from rotating parts (e.g. the front drive shaft, V-belt or propeller shaft). If they are caught, injury can occur. + Stop the engine before inspection, unless operation is absolutely necessary. + Do not operate the engine without the cover of rotating parts. + Before you start the engine, make sure that no tools or rags are near the engine. Precautions against noise 2 + Put on ear protection (ear plugs) in the engine room to prevent hearing loss.FOR YOUR SAFETY —— Precautions against opening the cylinder block side cover * Do not open the cylinder block side cover when the engine is hot. Fresh air that flows into the engine can cause an explosion, Fires from electric short-circuits + Always turn off the battery switch or detach the earth cable (-) before you inspect the electri- cal system. A short-circuit can cause a fire, Alcohol and drugs + Never operate the engine while you are under the influence of alcohol or drugs. Never oper- ate the engine when you feel ill or unwell. You may mishandle the engine, which could lead to a serious accident or injury. Ventilation of the battery area ‘+ Make sure that no flammable materials are near as the battery makes inflammable gas while charging. + Make sure that the room has good airflow. It can explode. Precautions against starting the engine + Make sure that nobody is near the engine, + Hf someone is present, give a signal and make sure that the personis safe before you start the engine. + Make sure that you remove the turning bar. Put it in the specified place. There is a risk of injury. ACAUTION Precautions against burn injury + Make sure that you (e.g. your hands, body and clothing) do not touch the exhaust manifold, exhaust pipes, turbocharger, air cooler or engine body. Be careful of burns, The entire engine and each part are very hot. Battery fluid + Be careful that the battery fluid does not get on your skin or in your eyes, The electrolyte is a strong acid and can cause inflammations. If you come in contact with the battery fluid, wash it off immediately with a lot of freshwater.4 — FOR YOUR SAFETY NOTICE No modifications To ensure safe engine operation. the fuel injection volume control and the engine speed control are sealed. If the seal is removed, the engine life decreases very much. This is because of deterioration and increased wear on the sliding and rotating parts of the engine. This can result in an increase of lubricating oil consumption and fuel consumption, seizure of all parts and damage. Never remove a seal. Removing a seal voids warranty, even before the warranty is expired, Regulation on NOx Laws on maritime pollution and hazard prevention regulate the replacement of certain parts. The laws require that you keep a record and the signature of personnel who replaces them. Our professional service technicians have the expertise and skills to help you wih the necessary tasks. Waste disposal + Never dispose of waste liquids such as lubricating oil by dumping them into a sewer, river, lake or ocean waters. + Put a container to catch any waste oil (6.g. lubricating ol) so that i does not spill into the sea. + Comply with relevant laws andor regulations for the disposal of hazardous materials such coolant, lubricating oil, fuel, fiters or batteries Use genuine parts + Not using genuine parts may shorten the machine life or cause unexpected malfunctionFOR YOUR SAFETY —— Maintenance Precautions Be sure to obey the maintenance precautions for safe maintenance, Maintenance locations = Ventilate the room well. In * + Ventilate the room well when you operate the engine, weld the parts, remove the paint with AR sandpaper and other works. Inhaling poisonous gas or dust is very harmful to the human body. ACAUTION Light the room well = + Light the work area sufficiently and safely. When you work in a dim area, use a portable \\S safety lamp. in such a case, use the lamp with the bulb covered with wire gauge. The bulb may accidentally break and ignite the leaked oil. Work in a spacious, flat location + The floor space of the workshop (location) where inspection and maintenance are conducted must be spacious and flat without any holes. An unexpected accident including falling may occur. Work in a clean, tidy location 7) z + Do not leave dust, oil, parts on the floor. An unexpected accident may occur. Have fire extinguisher i * Work with a fire extinguisher nearby in case of fire. Make sure that the fire extinguisher is appropriately inspected.6 — FOR YOUR SAFETY Precautions against work & PL % Before you start work + Disconnect the power source. You can get burned or suffer an electric shock. ‘When you check the battery system, make sure that you disconnect the earth cable (-) terminal. ‘You can cause a short circuit and a fire. Do not get caught in the engine + Be careful that your body does not touch any rotating parts when you turn the flywheel. Never put your hand into the cylinder block. + Make sure that you remove the turning bar from the flywheel after you finish your task. If you start the engine with the turning bar attached, it can come off and cause fatal accident. Work with sufficient holding and lifting conditions + Do not hold the engine with blocks or wood blocks, Never work while holding the engine only with the jack. Be sure to use the specified metal fittings to lift and hold the engine to the specified location. It can cause fatal accident. + When you work with heavy parts, use the specified tools and a safe wire rope.FOR YOUR SAFETY —— ACAUTION Work with safe equipment and clothing + Put on the correct protective equipment for your task (e.g. helmet, work uniform and safety shoes). Wear work uniform that fits your body. Wearing loose work uniform can cause fatal accident including getting caught in the machine. Battery fluid + Battery fluid is a strong acid and causes inflammation. + Ifyou get it on your skin or eyes, immediately flush the area with a lot of fresh water. Get medical aid. Work with correct tools + Use the appropriate tools for work. Use the tools with the correct size for loosening and tight- ening the machine. Using the tools with the incorrect size may cause serious injury or dam- age to the machine. For the specified parts in the manual, be sure to tighten the bolts to the specified torque. + Loosened or missing bolts may cause damage to the parts and accident. Do not work in an unnatural posture + An unexpected injury may occur. When you use organic solvents + Organic solvent can turn into a gas easily, It is dangerous to breathe the gas. Make sure that the area where you use this solvent has sufficient airflow. + Highly-concentrated organic solvent can dissolve fats and oils and is absorbed by the skin. This is dangerous. Put on protective gear when you use such a solvent. NOTICE Checks after work + All removed parts are installed again In their correct position. + All damaged parts are replaced. + Put back all tools (e.g. lifting gear and wires) to their correct location. + All lubricating oil is removed from the engine room. + The engine room is clean. Nothing prevents you from your routine work. + Before you start the engine, make sure that all parts are in a good condition. + Start the engine and look for leaks of fuel, lubricating oil, cooling water or air. + Start a load run and check that the engine performance is the same as before servicing. If you find an unusual difference, immediately stop the engine. Adjust or repair the engine. + When the load run is finished, record the performance values and the contents of your servicing in the ‘engine log. (First finish the records, then report that you are finished with your work.) + Remove standing signboard. Contact all related personnel that you are finished with your work,8 — FOR YOUR SAFETY Safety Labels (Warning Labels) ‘These are the locations of the safety labels (warning labels), ‘© Carefully read all safety labels to prevent accidents. ‘@ Also, if you need to replace a part that has a label, make sure that you order the new part together with the label. Ifa safety label is dirty or missing: Find the part number and send an order for a new safety label to your YANMAR sales agent. Attach the new safety label. Operation side rg os re essed seh — 214 1616-07200 socomFOR YOUR SAFETY — 9 Ml Non-operation side 114164 a 1at616-0721010 — FOR YOUR SAFETY Precautions for Lifting the Engine Falling of the engine during its lifting is very dangerous if so happened. When you lil, obey the following precautions to prevent an accident: + The specified license and certification are required for the lifting work depending on the lifting appliance + Check the engine lifting metal fittings and the mounting bolts for failure and damage before starting work. I any problems are found, stop the work immediately and consult your YANMAR dealer or distributor. + Select the lifting tools including wire rope and shackle in accordance with the weight of heavy parts. + Adjust the length of the wire rope so that the engine does not lean to one side, + Inspect the lifting tools for failure and damage before starting work. + Make sure that the wire rope does not directly touch the engine or driven machine. Use a wooden block as padding to protect them. + The tension of the wire rope changes depending on the lifting angle. Make sure that the lifting angle of the wite rope is less than 60°. + When you use the marine gear not described in this operation manual, separate the engine from the marine gear before lifting them. + Do not stand under or near the engine while lifting or moving the engine. toon an 66g i | i a £9. ~ o * iG) TUT) ul WE AIR UE TE, : For mass, referto the specifications of the approval drawings.FOR YOUR SAFETY — 11 Engine Nameplate The serial number of your engine is required when you request maintenance, repair or order a part. Have it ready beforehand. l§ Location of the engine nameplate The engine nameplate Is on the fuel injection pump side of the flywheel housing. con, ween ||P MODEL rari saan ma} || REDUCTION RATIO absee AHEAD _____ ASTERN__ nine 4. }] || MFG..No. Mea. os ° YANMAH CO.LTO. O} (© KANZAKI KOKYUKDKI MFO CO.LTD. © XY To)12 — PRODUCT OVERVIEW PRODUCT OVERVIEW Principal Engine Specifications ‘Model Unit SEYITW Type = Vertical, water-cooled, 4-oycle diesel engine [Combustion chamber - Direct injection No. of lingers : 8 [Cylinder bore ram 170 [Stroke mam 230 Displacement @ 31.30 [Compression ratio = 62 ‘Specified engine rotation speed mint “460 oF 1406 (eter to the separate paper) Direction of crankshaft rotation = ‘Counterclockwise 2s viewed from the flywheel [Operation side = Left as viewed from the flywheel Firing order = TA2OS SA [Type of turbocharger = Exhaust gas turbocharger (with air cooler) Type of cooling = Constant high temperature cooling (with freshwater cooler) Lubiating oi = Lubrication: Selfdubricating by integrated oil pump z Oil pan: wet sump Type of staring = lactic start (call motor) Overall length mm 2908 Engine size ‘Overall wiath mm 1305, ‘Overall height mam 1882 Engine mass 1g 3880 (Configuration of Cylinders] QOOOOOOFH |PRODUCT OVERVIEW — 13 Engine Component Names Operation side Seawaiee pump Fyveat ows I Non-operation side ‘Turbocharger Exhaust outlet bond Ae mer ‘turbocharger Exhaust manifold Air coat Freshwater cooker Leb. cll pressure coat valve Staner moter 04 pan dain pg Lr i ie14 — PRODUCT OVERVIEW B® Longitudinal view No2 Not (Cynder head bot Exhaust vatve Intake valve (Cam gear |Govasner dive gear \camahatt Flywhec Main bearing metat Crankshaft gear (Thrust metal Turbocharger Exhaust maniold ust No6 NoS Nod Nod valve Piston! Piston pia Cylinder tne m e Fost iter Crankpin mata rankehatt Dampert TT Main bearing cap! @ Horizontal view Valve brig Rocker ann Vale bridge guide (Cylinder heaat Push rot Saing arm 4 (otake Fextaust vale) Connecting raat Cormecting rod bat Balance woight Lub. ol cooler : Lub. oi ‘bypass titer to oi ltsr Lub. ofPRODUCT OVERVIEW — 15 Functions of Major Components Fuel system ‘The fuel oil flows from the tank through the fuekwater separator (option), fuel feed pump, fuel filer, fuel injection, pump and fuel injection pipes into the fuel injection valve. The collection pipe returns excess fuel cil from the fuel injection valve and the fuel injection pump to the fuel tank. Foot inlet © 2Cock (valve) ‘Fuskwaler separator Fuel ter Fuel fee0 pump Ful pring pusnp Leakage of cutot Foo nr a ‘€qupman mane) ae con ad ym ao severe Ful injocton valve ‘Fuel feed pump This mechanical fuel pump sends fuel oil fo the fuel injection pump. ‘Fuel priming pump This manual fuel pump sends fuel oil to the fuel injection pump. Use it when you release air from the fuel system. Move the piston to send the fuel oil ‘Fuel filter This pump removes unwanted material from the fuel, Repiace the fier at regular intervals before the intemal ele- ‘ment gets clogged. © Fuel-water separator (option) This device separates water from fuel. Drain the excess water from the drain plug.16 — PRODUCT OVERVIEW Cooling water system ‘The cylinder and the cylinder head are cooled by a constant high-temperature freshwater cooling system (freshwater circulation with indirect seawater cooling). This keeps the temperature of the cooling water nearly constant at any engine load, Thus the engine performance is kept stable. i Seawater system The seawater pump sends seawater to the air cooler, the lubricating oil cooler and the freshwater cooler. Then it dis- charges back into the sea. The seawater pump sends part of the seawater to the lubricating oil cooler for the marine gear. @ Freshwater system The freshwater pump sends freshwater to the cylinder block jacket. There it cools the cylinder, cylinder finer and cyt inder head, Then it flows through the exhaust manifold into the cooling water thermostat and retums to the freshwa- ter pump from the freshwater tank. Ifthe freshwater is warmer than the specified temperature, the thermostat sends, part ofthe freshwater to the freshwater cooler. This way, the freshwater temperature is automatically adjusted i ood {Lib of exci Freshwater pump Seawater tet fuera Eshavelgas maniet TavaTCRaRa]_ Seawater out the mate gearf—— Freshwater cooler | | ‘Seawater | ho.t | | Seamaster pump’ ‘themosiaa—! | @ Freshwater tank © Seawater strainer (option) This freshwater storage tank has a builtin freshwater ‘cooler. The cooler uses seawater to cool the freshwa- ter. Filler cap This is the cover of the water supply port on the top of the freshwater tank. It has a pressure valve, © Freshwater pump This central pump sends freshwater to cool the engine, ‘The freshwater flows through the engine and cools it. Then it retums to the freshwater tank. ‘@ Seawater pump ‘This rubber-impeller pump takes in seawater, sends it to all coolers and returns it to the sea. This strainer separates and removes dirt from the sea~ water with a fiter net. Do periodic inspections and clean the seawater strainer before its fter net gets logged. @ Engine lubricating oll cooler This cooler cools the lubricating oil of the engine with seawater, © Lubricating oil cooler of the marine gear This cooler cools the lubricating oll of the marine gear with seawater. © Anti-corrosive zine Anti-corrosive zinc is attached to the pipes of the sea- water passages and the cooler and prevents the elec- trical corrosion. Check and replace the anti-conrosive zinc at regular Intervals.PRODUCT OVERVIEW — 17 Lubricating device The lubricating oil pump is ¢ gear-type pump with a built-in relief valve. It is on the bottom of the cylinder block, ‘The lubricating oll pump compresses the lubricating oll and sends It through the cooler and the filter to the inside of the engine. A pressure control valve keeps the specified oil pressure, The oil cools all parts and returns to the oil gallery of the cylinder block. The lubricating oll fiter is a cartridge-type paper element with a main fier and a bypass fitter. a (erg SI Hines Lab. bypass fter Qpsh oa pump ‘Engine lubricating oil fitter This fiter removes small metal particles and carbon from the lubricating oll. Replace the fier (cartridge type) at reg- ular intervals. ‘Engine lubricating oil bypass filter This fiter removes sludge and metal powder with the use of centrifugal force by constantly bypassing a small quan- {ity of lubricating oil. Replace the filer (cartridge type) at regular intervals. ‘Lubricating oil filter of the marine gear This fiter removes small metal particles from the lubricating oil. Inspect and replace the filter at regular intervals before the internal element gets clogged.18 — PRODUCT OVERVIEW Intake/exhaust gas syste! Turbocharger This air-teed device sends air to the combustion chamber. Exhaust gas turns the turbine and the blower. The turbo- charger compresses the supply air and sends It to the combustion chamber. B Air cooler This cooler cools the air that comes from the turbocharger with seawater. Electrical equipment B Alternator The alternator is driven by the V-belt. I creates electricity during operation and charges the battery. @ Starter The starter is a DC motor for electric starting. powered by a battery, Marine gear Marine gear ‘The marine gear uses the hydraulic mulli-dise clutch to reduce the engine speed and transmits to the propeller shaft ‘The marine gear switches from forward gear to reverse gear. It reduces the engine speed, disengages the propeller shaft and switches its rotation into the desired direction (clockwise or counterclockwise). Trolling device The trolling device slips the clutch to reduce the propeller speed.PRODUCT OVERVIEW — 19 Control System ‘The control system is the main control for engine operation. Gauge panel (instrument panel specifications) ‘The gauge panel is in the control room, separate from the engine. You can remotely start and stop the engine and ‘monitor its condition with the following instruments and alarm devices. @ Boost pressure meter ‘The boost pressure meter indicates the pressure of the air that flows to the combustion chamber Monitor the condition of the turbocharger to prevent accidents. Engine lubricating oil pressure meter This meter indicates the pressure of the engine lubri- cating oil. The red range on the scale indicates dangerous condi- tions. Monitor the condition of engine lubrication to prevent accidents. © Freshwater temperature meter The cooling water temperature meter shows the fresh- water temperature. ‘The red range on the scale indicates dangerous conci- tions. Monitor the condition of the engine temperature to pre- vent defects. G Tachometer The tachometer indicates the rotation speed of the engine. You can monitor load conditions and speed.20 — PRODUCT OVERVIEW G@ Hourmeter ‘The hourmeter indicates the total time of engine opera- tion Use it to schedule periodic inspections accordingly. G Buzzer stop switch This switch momentarily stops the buzzer sound, Only turn off the buzzer when you investigate a defect. Light switch This is the light switch for the gauge panel. @ Engine stop button This red button stops the engine. Itis above the starter switch. If you push the engine stop button, the stop device actuates and the engine stops. Press down the button untilthe engine comes to a complete stop, @ Starter switch Three-step rotary switch The key switch starts the engine. OFF = Thisis the stop position ‘The electric system of the engine is cut off, ON = This is the position during engine oper- ation. ‘The Instruments and alarms are on. START: Start the engine, ‘This starts the engine, After the engine starts and you release the key, it goes back to ON automatically. GLOW : Tum onthe air heater. Increases the temperature of the intake air before engine start to assist an engine start in cold climate. + You can only start the engine when the clutch lever is in neutral. A safety device prevents the engine ‘rom starting + You cannot stop the engine with the starter switch. Bolere stading ‘on During operation \eo Release your hand ofr * hon tho engine starts ‘SiarPRODUCT OVERVIEW — 21 + The air heater pre-heats the intake air warmer when in cokd operating conditions. This makes the engine start easier. Be sure to start the engine within 1 minute after ‘switching fo the GLOW position, Ifyou start the engine without switching to the GLOW position, the air heater will not tum on. Alarm buzzers ‘The alam buzzers repeatedly make an alarm sound ‘when an alarm lamp comes on. Only the charge lamp and the oil fiter clogging alarm lamp do not start the alarm buzzer. @ Alarm lamp Ifa defect occurs, an alarm lamp will indicate the defective device. oreo22 — PRODUCT OVERVIEW Alarm de es Ifa defect oceurs during operation, an alarm buzzer and alarm lamp operates. BATTERY CHARGE LUB. ONL, FILTER Charge lamp ‘The lamp indicates a low battery charge. The alarm buzzer does nat sound. Check the alternator for defects. Engine lubrication oil pressure alarm lamp: This lamp indicates that the pressure of the engine lubricating ollis low. Ifthe engine continues to operate, it wil run out of oi ‘and seizure will occur Check the level of the lubricating oll and raf i necessary. Engine lubricating ol iter clogging alarm lamp ‘This tamp indicates clogging of the lubricat- Ing oil iter. The alarm buzzer does not sound. Replace the filer element Engine lubricating oil temperature alarm lamp. This lamp indicates that the temperature of the lubricating ollis too high. Ifthe engine continues to operate, it will overheat and seizure will occur. Check the seawater oocl- ing system for defects, 2 Normal operation of alarm devices Ifthe engine runs out of water or lubricating oil and the instruments or alarms are defective, itis not possible to pre- vent accidents. Apart from accidents, wrong operation or malfunctions can result. Be sure to check that the alarm devices operate normally before and after you start the engine. ‘You can determine whether the electronic circuits for the buzzers and lamps operate normally. Ifthe alarm devices operate as follows, they operate correctly. Ifthey do not operate correctly, consult your YANMAR = C.WATER TEMP C.WATEA LEVEL Freshwater temperature alarm lamp ‘This lamp indicates thatthe freshwater is too hot. Ifthe engine continues to operate, Iwill overheat and seizure will occur. ‘Check the load condition and the freshwa- ter cooling system for defects. Freshwater quantity alarm lamp This lamp indicates a low level of frashwra- ter in the freshwater tank. If the engine con- tinues to operate, it will overheat and ‘damage will occur. Check the freshwater ‘quantity. Check the freshwater system for, defects, Clutch lubricating oil pressure alarm lamp This lamp indicates low lubricating oll pres- ‘sure. Ifthe engine continues to operat, it will run out of cil and seizure wil occur. ‘Check the level ofthe lubricating oil of the marine gear and refllf necessary. dealer or distributor. Before staring ‘Aer starting Operation of starter switch crenon | START con [Alarm buzzers Buzzer sounds | Buzzerstops [Alarm lamps [Charge lamp Continuously Bt OFF Freshwater temperature Temporal it OFF Engine lubricating oll pressure Temporal it OFF [Clutch lubricating ol pressure Temporarily lit OFF Freshwater level Temporal lit OFF [Clogged lubricating oil iter Temporary it OFF Engine lubricating oll temperature Temporatiy it OFFPRODUCT OVERVIEW — 23 Starter ‘There are two starting devices: the electric starter and the air starter (option). Both types can be operated locally, remotely or automatically (option). @ Electric start ‘The electric stant system has a battery, battery switch, starting motor and starter switch. Tum the starter switch on the instrument panel in the control cabin to start the motor. The altemator recharges the batteries. ‘Start owt Startareelay a charge imp mal sf W790 a Atornaior @ Air start (option) The air starting system has an air reservoir, pressure regulating valve, air fiter. quick valve (starting valve), oiler, a starter and silencer. Compressed air lows from the air reservoir. The reducing valve decreases the pressure of the air. The filter cleans the air. ‘When the quick valve (starting valve) opens, the oiler mixes lubricating oil into the low pressure air. The air drives the air starter and discharges through the slencer, 7 cm he Ne O48 a ea { ner, Foi at Fete ae smnhes q se Lise a24 — PRODUCT OVERVIEW Navigation control syste! ‘The govemor lever and the clutch lever (to switch from, forward to reverse) on the engine side ere connected via the respective cables to the remote controller heads. Ifyou use a different type of remote controller that var= ies from the one below, obey all instructions in its oper- ation manual. @ 2-handle remote controller head ‘The controller has one handle for the governor and one handle for the clutch, The right handle is the gov- emor handle. It adjusts the engine speed. ‘The left handle is the clutch handle. It disengages the propeller shaft and changes the direction of move- ment. ‘© Governor handle ‘On the handle, H is for high speed, L Is for low speed. ‘The movement of the handle from minimum speed to maximum speed is locked To unlock the handle, loosen the handle grip by turning it counterclockwise. Tolock the handle, tighten the handle grip by tuming it clockwise. The govemor lever can only move between a certain minimum and maximum engine speed. This range is limited by bots, ‘The maximum speed bolt is sealed, Do not remove It Clutch handle AHEAD is for forward movernent, N is neutral, and ASTERN is for reverse movement ‘When you stat the engine, set itto N (neutral) @ Clutch neutral switch ‘The clutch lever on the clutch side has the neutral switch as a safety device. It starts the engine with the clutch handle in the neutral position.Trolling handle (option) ‘The trolling handle is a 1-handle remote controller head (On the handle, H is for high speed (regular cruise mode), L is for low speed (trolling mode). To unlock the trolling handle, turn the grip counter- clockwise. To lock the trolling handle, tum the grip clockwise. 1 Trolling dial {Electronic trolling available as an option) The trolling dial adjusts the propeller speed during troll- ing Diet oupled is for direct-coupled operation, direct- coupled side is for high speed, SLOW side is for slow speed. i 1st/2nd gear switch (YXH2.500 marine gear option) Use the 1s¥2nd gear switch in the control room to operate the reduction ratio solenoid valve. The {st gear switch is for the high speed side (cruise mode), the 2nd gear switch is for the low speed side (raw! mode). PRODUCT OVERVIEW — 25 H (high speech Normal erasing Troting dal Source switch SS26 — FUEL OIL, LUBRICATING OIL & COOLING WATER FUEL OIL, LUBRICATING OIL & COOLING WATER Fuel Oil @ Selection of the Fuel Oil + Only use the specified fuel oils. Other fuel oils can cause bad performance and matfunctions. + Do not use fuel oll that is contaminated with water or dirt, The fuel injection system has many precision parts. ‘They can malfunction if contaminated Appropriate fuel oils are: + M.D.O. (IS K-2208 class 1, type 2 equivalent). + Diesel fuel (JIS K-2204 type 2 equivalent). Recommended properties of M.D.O, or equivalent fuel oils Fuel properties are highly uncertain and the specifications cover a wide range. Refer to this table forthe recom mended properties of fuel oil Kinematic vscoiy | caine | acupoint] eaten | “ASS | conten | content [pas pn] TOSHY mmtis_| number (Mass) (Mase) Mass) | (Ca Te (Wass (Mass) | (Capacity) eo 2.010 11.0 | 45.0r more “10°C oF 0.3%orless | 0.01 %orless 10 %or | 0.4 %or | 80°C or $00 or ese fess loss more | lower Diesel fuel Use diesel fuel of JIS K2204 or equivalent. Diesel fuel is categorized into different types depending on the pour point. It gets thicker and does not circulate well at low temperatures. Make sure that you choose a type that is appropriate for the outdoor air temperature. Diesel fuel types and outdoor air temperature ‘Outdoor air temperature: -5°C or higher: Diesel fuel No. 2 “15°C or higher: Fuel oil No.3 -25°C o higher: Fuel oil No.3 specialFUEL OIL, LUBRICATING OIL & COOLING WATER — 27 Lubricating Oil + Only use the specified lubricating oil. A different oil results in seizure of engine perts and irregular weer, and short ens the engine life, + Avoid using @ lubricating oll with a high total base number (T.B.N.) together with a fuel oll with low suffur content. ‘The additives in the lubricating oil (calcium carbonate) cause carbon residue on the top of the piston and the com- bustion chamber. This resutts in shortening the engine life and causing the engine failures. Use the appropriate fuel oil + Do not mix different lubricating oils. Selection of engine lubricating Recommended lubricating oils: choose lubricating oll with an API quality classification service grade of CE or CD and an SAE viscosity of 40, Viscosity | Specie [Flash point | a, point | Kinematic viscosity mnvis | Viscosity | Basenumber (sae) | gravity | (open type) aoc 100°C index | (mgkoHig) 40 0803 | 240°C ormore [7.6 °Corkess| t40t0165 | 1at1ss | sett | 9t015 ‘The commonly sold lubricating oil brands with an API service grade of CE or CD are indicated. Company ane Fredicnane Company nae Predict ane cori aan [ARPA ERRESTER OT occ ot COSMO WARNE SUPER 10 ISEWTSUKGEAN.——DAPAME NARRE OL B20 — | SHO FELL SaonAGLw OOH WOR, Wabi a2 BF ENERCOL OSH OREN OL TARO SUPER FURROSAT ROL ANE ore BELO TOO UAE PH Nippon 1 Enerey | MARINE 7704 CALTEX, TEXACO) TARO 12 XD 40 TOTAL Lubmarine DISOLA M4015 |CASTROL MCL40 CASTROL MHP 154 /SEAMAX EXTRA 40 KYGNUS O1L KYGNUS MARINE DXA0 NOTICE + To lubricate the governor, use an oll that is equivalent to the oils listed above. Do not mix it with olls by other man- ufacturers. + When you replace the lubricating oil, carefully remove all unwanted material that collected in the filter, lubricating oll cooler and oil pan. + Use the YANMAR marine gear lubricating oil with a viscosity of SAE 40 and API service grade of CE or CD. 8 Selection of lubricating oil for the air starter (option) For engines with an air starter, select a lubricating oil for the oiler based on the ambient temperature. “Ambient temperature Lubricating oll in use Eg. Turbine of #90 {spindle oll nt applicable) Eg. Refrigerating machine oil class 90 {spindle oil nt applicable) 5°C1060°C Turbine oll, catagory 1, 1SO VG 32 18 °Ct0+5°C | Refrigerating machine oil, category 1, ISO VG1S28 — FUEL OIL, LUBRICATING OIL & COOLING WATER IB Handling lubricating oil + Be careful to avoid burns when you handle lubricating oil inside the engine immediately after engine stop. + Wear safety goggles and rubber gloves if there is a risk that lubricating oil gets into your eyes or on your skin + If ubricating oil contacts the eyes or skin, flush the affected area with clean water. It can cause inflammation. If there are any Irregular reactions, go to @ doctor. += The disposal of waste oil is regulated by law. Dispose waste oll correctly according to the law. If you are uncertain how to correctly dispose of oil, contact the seller. Filling the lubricating oil (where and how much) ‘Where to fill the lubrication oll Filling amount (@) open To the bottom line of the ol dipstick 132 ‘etal 200 {from bottom fine to the top line ofthe oll dipstick 8 [Govemor (before the frst start and after disassembly) 08 Labricating oil cooler, fiter and piping Appto. 26 Marine gear case ‘YXH2}600 : 22 YXH-500L : 45 Locations for oil filling and oil check (P34 [Filling the engine lubricating oill) Degradation check interval Do the check approximately every 100 hours or if you think thal the water or fuel is contaminated with a substance that can cause degradation of the lubricating oil. Adjust the analysis interval depending on the rate of degradation. Measurement method (guideline) ‘Old lubricating oll suffers from contamination and degradation. Oil control and purifying methods may not be able to restore the oil to the correct condition In that case, fully replace the lubricating oil ‘Make your own decision when you schedule and perform oil changes. Consider not only the time, but also the oper- ating conditions of the engine. Ask your lubricating oil supplier to make an analysis of the lubricating oil. Ask for a decision whether you can continue to use the oil or not. Ask the lubricating oil maker for a spot test kit, Use itto find the remaining total base number, degree of contamination and cleaning dispersion. {you cannot make a decision, replace the oll with new oll ater approximately 250 hours. {f auxiliary lubricating oll tanks are installed (in addition to the oll pan) and a capacity of 1.36 2/KWis kept, we recom- ‘mend that you replace with new oll ater approximately 1500 hours. il control standards for the diesel engine crankcase tem Unit Control standards: Usage limit Flash point {PM method) °C > 180 140 viscosity change (40 °C) rains (€St) New oll within #15 9% New oll= 25 % Water content vol % <04 02 [N-pentane insoluble content (A method) mass % <15 20 Toluene insoluble matter (A method) mass % 18 20 Difference Between m-pentane insoluble mass % 7 208 [content end toluene insoluble content Total base number HCI method Kon 730 10 (TEN. HCIO, method nes >60 40FUEL OIL, LUBRICATING OIL & COOLING WATER — 29 Freshwater Cooling Water + Do not use hard water. Ifyou use hard water, scale collects in the water chambers such as cylinder head and cylinder water jackets and cause overheating, + Using only freshwater causes scale and rust in the water system. This impedes cooling. Add Long Life Coolant. + Long Life Coolant has an effect to prevent rust and can be used throughout the year. Use Long Life Coolant in cold conditions. If you do not, the freshwater freezes, expands and causes damage to the water system of the engine. lm Freshwater Be sure to use clean, soft water (¢.9. tap water) as freshwater, Water quality for freshwater pH (25°C) 651080 [Ammonium ion (NH4*) 0.08 ppm or less Total hardness (CaCO) <400 ppm [sutfate fon (S042) < 100 pom [Chior fon (Gr concentra 100 ppm Evaporation residue +< 400 porn M alkalinity “100 ppm or less Long Life Coolant (LLC) Be sure to add a Long Life Coolant to the freshwater. Recommended Long Life Coolant: Yanmar Genuine Long Life Coolant (Product Name: Royal Freeze) + Yanmar Genuine Long Life Coolant has an effect to prevent rust and can be used throughout the year. + The mixture ratio must be between 30% and 55% and is determined by the minimum air temperature. + Ifthe Long Life Coolant mixture is too thin, damage or rust can occur when the temperature decreases. + If Long Life Coolant is too thick, the cooling becomes less effective. inimur temperature 06 eC oC Mixture ratio 30% 35% 40% 45% Select a commercial Long Life Coolant with a quality that is equivalent to Yanmar Genuine Long Life Coolant or bet- ter. NOTICE * This engine has aluminum materials. Do not use Long Life Coolant with ingredients that cause corrosion on alurni- ‘um. They cause corrosion on the aluminum used in the engine. + Do not mix different brands or types of Long Life Coolant. Mixing decreases the cooling effect and causes corra- sion, + Ifyou use a commercial Long Life Coolant, obey the manufacturers instruction manual for the mixture ratio and replacement periods. + Do not use commercial corrosion inhibitors (including Royal Cabiruston). Their properties are uncertain and they can cause corrosion of the aluminum material.30 — FUEL OIL, LUBRICATING OIL & COOLING WATER @ Rust inhibitor Use a rust inhibitor that does not cause damage to aluminum and copper materials and that is environmentally com- pliant. This engine has aluminum materials. Use the following rust inhibitor or equivalent Product brands Brand ‘Seller Remarks YANMAR Reyal Freeze YANMAR SANGYO ‘Cigars 6-601 ‘Organo Go, Ltd [Contact the sales agent ofthe cust inhibitor for Kurlex L601 ‘Kurta Industies Co, Ltd, [information on use and handling Naifest 9171 NALCO Japan Co, Ltd + Obey the operation manual of the rust inhibitor when you use it, + We recommend that you fully replace the cooling water (with rust inhibitor) at regular intervals. This is a simple ‘method to control the concentration of the cooling water. ACAUTION + Rust inhibitors are water treatment chemicals for industrial use. Do not use them in the drinking water system, + When you work with rust inhibitors, put on rubber gloves and a gauze mask. Avoid contact with your hands or other body parts. + If rust inhibitor comes in contact with your skin or eyes, wash the area thoroughly with fresh water. If the area has an irregular reaction after you wash it, get medical aid. NOTICE + Do not discharge cooling water with rust inhibitor into the sea or rivers. This can cause environmental pollution. How to discharge waste liquids is stipulated by law. Treat the rust inhibitor according to the instructions by the manufacturer. + Do not mix difterent brands. (If you must mix different brands of rust inhibitor, consult your rust inhibitor supplier)OPERATION — 31 OPERATION Operation Preparation Before you operate the engine for the first time after installation, a scheduled inspection and maintenance, or a long rest, do the checks that follow. Regarding details, consult your YANMAR desler or dis- tributor, + Make sure that there are no unwanted parts or tools inside or near the engine. + Make sure that all parts are correctly tightened. + Measure the deflection of the crankshaft. + Check the starter. Eledtric starter: Make sure that the battery for start- Ing has enough vottage. Air starter, Check the pressure of the air res- ervoir, Drain the air reservoir. Fillthe oller, Refilling the fuel ‘© Fill the tank with clean fuel that is free of water and dirt, ‘© When you fill from a barrel, let the barrel rest for one day or more. This allows dirt to settle. Fill from the top of the barrel ‘© When you fillfrom a daily tank, let the fuel oil rest for one day or more affer filing it from the storage tank to the daily tank. ‘© Ref fuel oil sufficiently to avoid running out of fuel oil during operation,32 — OPERATION Bleeding the fuel system If air enters the fuel system, the fuel injection pump does not work correctly, Bleed the fuel system and obey the procedure that fol lows when: + You fil ful oll to the fuel tank for the first time, + You do maintenance of the fuel system (e.9. servicing the fuel fiter). + The fuel oil has run out + The engine does not start 1.Check the oil level in the fuel tank and open the hulkmounted fuel cock (or valve. 2. Loosen the air vent plug (or valve) on the top of the fuel fter for 2 to 3 tums. 3.Fillthe fuel with the fuel priming pump, 1-The knob of the priming pump rises when you tur it counterclockwise. 2-Press the knob manually. Repeat the motion. 4, Fuel oll with air bubbles comes out of the air vent bott plug hole on the top of the fue! fiter. When air bubbles disappear. tighten the air vent plug.5.Bleed the fuel main pipe and the fuel injection ump in the same manner. Bleed all oylinders of the fuel injection pump. 1-Loosen the air vent plug 3 of the fuel main pipe for 2to 3 turns, 2-Operate the fuel priming pump to send the fuel oil, Fuel oil with air bubbles will come out of the air vent bolt plug hole. 3-When air bubbles disappear, tighten the air vent plug. 4-Loosen the air vent plug 4 of the fuel injection pump for 2 to 3 turns. Bleed all cylinders in the ‘same procedure as the fuel main pipe. 6, Obey this procedure to check that the air Is released from the fuel injection pump. 1-Set the startistop handle to RUN. 2-Remove the stopper 1. Set the decompression shaft 2to the DECOMP position with a wrench. 3-Loosen the cap nut (on the fuel injection pump. side) of the fuel injection pipe 4-Tum the flywheel. Make sure that fuel oil ‘comes out of all cylinders. 5-If there is a fuel injection pump that does not release fuel oll, the airis not released. Loosen the air vent plug of the fuel injection pump of that cylinder again. Operate the fuel priming ‘pump to Send the fuel oi. Fuel oil with air bub- bles comes out of the air vent bolt plug hole, ‘When air bubbles no longer come out, tighten the air vent plug 7. Tighten the cap nut of the fuel injection pipe. Tum the flywheel for3 to 5 tums 8.Move the startstop handle to STOP. Turn the fly- wheel for Sto 6 turns. Make sure that the fuel injec- tion valves make no injection sound. 9.After you discharge air from the tank, serew the fuel priming pump knob tight clockwise while pressing it down, 10.Set the decompression shaft 2 to the RUN position with a wrench. Install the stopper 1. OPERATION — 3334 — OPERATION Filling the engine lubricating oil ‘Obey this procedure when you fill the engine lubricat- ing oll 1.Check that the engine is at a complete stop, 2, Remove the cap 1 on the yellow filer port attached to the oil pan. 3.Fill with lubricating oil to the upper line of the dip- stick 2. 4-Remove the dipstick. 2-Wipe off the oill on the gauge with a clean cloth. 3-Fully insert and remove the dipstick again. 4-Make sure that the oil level is between the ‘upper and lower lines on the dipstick. Ifneces+ ‘sary, fill with lubricating oil to the upper line on the dipstick. Do not fil oll over the upper line of the dipstick, Engine lubricating oil capacity [2002 5-Fully insert the dipstick, 6-Install the cap ofthe filer port. Filling the lubricating oil of the hydraulic governor (Obey this procedure when you fil the lubricating oil to the governor, 1. Check that the engine is at a complete stop. 2. Remove the breather 1 as shown in the figure on the right and fil the lubricating oil 3.Check that the oil level is a itler higher than the center of the level gauge 2, Lubricating oll capacity 080 4. Install the breather. ‘5. You can drain the overfiled lubricating oil from the drain plug 3.OPERATION — 35 Filling the lubricating oil of the marine gear ‘Obey this procedure when you fil the lubricating cil of the marine gear, 1.Check that the engine is at a complete stop, 2, Remove the breather cap 1 of the filler port on the top of the marine gear, 3.Fill with lubricating oil to the upper line of the dip- stick 2. 4-Remove the dipstick. 2-Wipe off the oill on the gauge with a clean cloth. 3-Fully insert and remove the dipstick again. 4-Make sure that the oil level is between the ‘upper and lower lines on the dipstick. Ifneces+ ‘sary, fill with lubricating oil to the upper line on the dipstick. Do not fil oll over the upper line of the dipstick, Marine gear Lubricating oil capacity ‘YXH2-600 | 222 YXH-500L | 45@ 4. Fully insert the dipstick 2. 5.Install the breather cap of the filler port. starter (option) Filling the oiler lubricating oil for the (Obey these instructions when you fil the oiler lubricat- ing oil for the air starter 1.Remove the filler plug 2. Fill with lubricating oil to the top line (full) on the oll level meter. 3. Install the filer plug.36 — OPERATION Pri 1.Remove the bonnet and cylinder block side cover. 2,Remove the stopper 1 from all cylinders. Set the decompression shaft 2 to the DECOMP position. Use a wrench to operate the decompression shaft. g of the lubricating oil 3. Turn the flywheel of the engine. Make sure that these parts have enough oil: part A of the rocker ‘alm of the intake/exhaust valves, piston cooling nozzle and crank pin. 4,After you prime the lubricating oil, install anc tighten the bonnet and cylinder block side cover. 5. Retum the decompression shaft 2 of all oyinders to the DRIVE posttion 6. Install the stopper 1. Cheok that the © mark posi- tion is aligned with the decompression shaft 2,