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Yanmar 4CHL N Operation

Yanmar 6HAL - HTN Operation Manual

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Gabiriele Saulekaleka
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2K views33 pages

Yanmar 4CHL N Operation

Yanmar 6HAL - HTN Operation Manual

Uploaded by

Gabiriele Saulekaleka
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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: oe Ee) MARINE AUXILIARY ENGINE 4CHL-N 4CHL-TN 6GCHL-N GCHL-TN GCHL-HTN a ee Pee fe YANMAR MARINE AUXILIARY DIESEL ENGINE MODEL : 4CHL-(T)N, 6CHL-(T, HT)N OPERATION MANUAL Thank you for purchasing a YANMAR Marine Auxiliary Diesel Engine. [INTRODUCTION] @ This Operation Manual describes the operation, maintenance and inspection of the 4CHL-(T)N, 6CHL-(T, HT)N Yanmar marine auxiliary diesel engine. @ Read this Operation Manual carefully before operating the engine to ensure that the engine is used correctly and that it stays in the best possible condition, @ Keep this Operation Manual in a convenient place for easy access. @ If this Operation Manual is lost or damaged, order a new one from your dealer or distributor. @ Make sure this manual is transfered to subsequent owners. This manual should be considered a permanent part of the engine and remain it @ Constant efforts are made to improve the quality and performance of Yanmar products, so some details included in this Operation Manual may differ slightly from your engine. If you have any questions about such differences, please contact your Yanmar Dealer or Distributor. @ Materials are subject to change without notice. Models 4CHL-N, 4CHL-TN, 6CHL-N, 6CHL-TN, 6CHL-HTN Operation Manual Code No. 49961-300040 CONTENTS NOMENCLATURE .......... 00000 c cece cece cece een e eee e eee wee ENGINE SPECIFICATIONS ............... heen eee eee eee eee 3 INSTRUMENT PANEL - ADJUSTMENT...............20000ee eee ee 4 . SELECTION OF FUEL OIL AND LUBRICATION OIL 7 4-1 Selection and Handling of Fuel Oil.............06 . 7 4-2 Selection of Lube Oil... 20... 66... cece eee eect eee eee 7 |. OPERATION 5-1 Filling with Fuel Oil . 5-2 Filling with Lube Oil .... 5-3 Filling with Cooling Water . 5-4 Air Bleeding of Fuel System 21 5-5 Check Before Starting . 12 5-6 Starting ... 13 5-7 Confirm Immediately After Starting 13 5-8 Engine Warm-up . 13 5-9 Operation at LOW LOAD. 14 5-10 Stopping... .. : 7 7 15 5-11 Storing for Long Periods of Time . 15 . HANDLING OF SUPERCHANGER . 16 6-1 Check of Supercharger 16 62 AirCooler ................ 7 . PERIODIC CHECKING AND SERVICING . 18 7-1 Table of Periodic Checking and Servicing 18 7-2 Major Check and Servicing Points .........se0cceeeeeeeeeeeeeee 1, Fuel Oil System . 2. Lube Oil System... 3. Cooling Water System ........ 4. Electric System - Battery Check 5. Check of Fuel Injection Valve .. . SYSTEMS DIAGRAMS..........0.0.0c00ccceeeeeeeeeeeeeneeeenes 24, 8-1 Fuel Oil System Diagram .. . . 24 8-2 Cooling Water System Diagram . . 25 83 Lube Oil System........... beeeeee . vies 26 84 Electric Wiring System ....... 0.0.0.0 e cece ence eens +. 27 {) NOMENCLATURE 4CHL Operating Side Non-Operating Side f ENGINE SPECIFICATION T Model 4CHL-N | 4CHL-TN | 6CHL-N | 6CHL-TN | 6CHL-HTN Type Vertical, water-cooled 4-cycle diesel engine Combustion System Direct injection system Cylinder — bore x stroke 4108 x 128 6— 106x126 (mm) (mm) Rated speed of revolution (rpm) 1600 | 1800 | 1500 1800 | 1500 | 1800 1500 | 100 | 1500 | 1800 Rated speed of revolution (PS) 38 | 50 50 | 62 I 62 | 74 74 i 100 | 100 | 120 Direction of rotation left (viewed from flywheel side) Firing Order 1-2-4-3-1 1-4-2-6-3-5-1 Aircooting Aircooled Air-cooled System Gas Supercharger system ——_| Sesexhoust — _| Sasexhoust | exhaust | Supercharger Supercharger | anne anger Starting System Cooling System Fresh water cooling Electric starting (DC24V — 3,7kW) Lubrication System Automatic Lubrication with Gear Pump 3 @ INSTRUMENT PANEL: ADJUSTMENT Refer to the following for adjustment of the instruments of the instrument panel and other engine equipment. 1. Tachometer (with hour meter) This instrument measures the revolutions of engine. The attached hour meter converts the RPM into hours using 1800 rpm, to assist in determining check and servicing times. 3000 © When the engine is operated at 1500 rpm Our x1800rpm Driving time = time shown on hour meter x 1,20 2. Lube oil pressure gauge Pressure of the lube oil should register between 3.5 — 4.Skg/cm? during operation of the engine. 3. SEA water pressure gauge Adjust the pressure of the sea water to read below 0.Skg/cm? during engine operation. 4, Fresh water pressure gauge Fresh water pressure should register between 0.7 — 1 0kg/em? during engine operation. tution: The needles of the lube oil pressure gauge, and the sea water and fresh water gauges should remain in OFF position when engine is OFF. 5. Suction pressure gauge Always check the suction pressure of the supercharger when under operation, If the pressure has dropped 10% below the initial pres- sure, clean the blower and filter. 6. Charge lamp This lamp measures the condition of the charge from the alternator to the battery. The lamp is off when the engine is running indi ting a condition of charge, and is on when the engine is not running indicating a condition of no charge. ‘This lamp helps to remind you to tum off the battery switch after engine operation is over. 7. Starter switch ©OFF....... ‘This position cuts off the electric circuit. Addi- tionally, the key can only be removed when in this position. © ON......... This position insures connection of the electric circuit, Be sure to leave the key in this position when the engine is being operated. © START ..... Engine will begin to operate in this position. The key will return to the ON position when your hand is released from the key. 8, Accelerator handle This handle adjusts the speed of the engine. When the handle is tured clockwise, speed is increased, and when the handle is tuned counterclockwise, the speed is reduced. A lock is attached. CHARGE By oom Fiedues eceleretor 9. Stop knob When the knob is fully pulled out, the fuel is cut off. Pull out the knob only after the engine has come to a complete stop. 10. Battery switch © The battery switch controls the flow of electric current, When it is in the OFF position the circuit is cut. SELECTION OF FUEL OIL AND LUBRICATIONS OIL Proper selection of fuel and lube oil is necessary to insure maximum performance and durability of engine, Read the following carefully before making selection. Selection and Handling of Fuel Oil 1. Selection of fuel oil Use fuel oil best suited for best performance of the engine. 2, Handling of fuel oil (2) Water and dust mixed in with the fuel results in poor engine performance, Additionally problems occur with the fuel inject, pump and fuel inj, valve (2) Keep a drum can containing fuel standing for several hours to allow water and dust con- ven pad] «= [ATT I= Favs tained in fuel to settle to the bottom of the a ae aes standing 3 — 4 pipe into drum can, Use cleared fuel. (see drawing to days without the drum can, moving, a litle above right.) the bottom of CAUTION: There is water and dust, in the lower portion oof the drum can, Selection of lube oil Selection of lube oil is very important for a diesel engine, When unsuitable lube oil is used or when the changing of lube oil is neglected, it causes seizure or early wear. 1. Types of lube oil It is best to use YANMAR Pure Oil. This lube oil is sold by the following three companies. Company CALTEX SHELL MOBIL | _ Product YANMAR Marine Super Oil #30, #40 If you use a lube oil other than the ones listed above, be sure to use oil of a higher classification than the API division CD class oil. ‘© When selecting a lube oil, ask your local YANMAR dealer for advice. © Do not mix lube oils of different kinds. 2. Viscosity of lube oil Selection of lube oil depending upon the temperatures under which the engine will be operated the key factors in determining the starting capacity of the engine, the amount of oil spendage, and the driving capacity. 30 Viscosity ey ep 40 _{_—;— | Temperature (°C) —20 10 0 10 20 30) 40 © OPERATION Follow the procedures below for the initial and consecutive runs of the engine. Filling with Fuel Oil Check to see that cleaning of the inside of the fuel tank and fuel system pipe has been completed. Filling with Lube 1. Filling with oil Put oil into the oil supply inlet at the top of the cylinder block side. 2. Check oil supply Insert dipstick in to upper limit of dipstick, 4CHLN 4CHL-TN Lube oil vol, 6CHLN 6CHL-TN 6CHL-HTN Filling with Cooling Water Fill with clean, soft (tap) water. Do not use hard water (well water), Use of hard water will cause deposits to collect and result in malfunctioning. 1. Tightening of cooling water drain plug Before putting in cooling water, be sure to tighten the water drain plugs (6CHL-HTN : 4 Places) shown in the photo. 9 water 2. Filling saeatl yy Remove radiator pressure cap and fill to a litter below the mouth of the water supply inlet, 3. Use of antirust Even when soft water is used, rusty water and rust deposits can collect in the cooling water system; therefore, use YANMAR antirust. Put in cooling water after putting in YANMAR antirust, YANMAR Antirust : Cooling Water = 1 : 10 4. Use of antifreeze Add YANMAR antifreeze to the cooling water during winter to prevent the dangers of frezing. Addition of antifreeze guards against engine damage due to freezing. Refer to the table at the right to determine the proper amount. Add cooling water after putting in antifreeze. Use antifreeze with the properities shown in the table below. Amount of YANMAR Antifreeze = —10 Temperature °C Proportion of Cooling water (%) 12 | 22 | 29 | 35 | 40 5. Firmly tighten pressure cap. Firmly tighten pressure cap after putting in cooling water. Failure to tighten firmly may result in cooling water overflowing during operation. Additionally boiling water may escape causing danger of bums, 10 Air Bleeding of Fuel System The fuel system includes the area from the fuel tank to the fuel injection valve. When air enters into the fuel system, fuel is not injected. Completely bleed the air out of the system according to the following procedures, These procedures apply to the initial engine run and to the runs below. © Fuel tank is empty. © When fuel filter is changed. [Procedures] (1) Tum accelerator handle counterclockwise (reduce speed) to position of low speed. Next, turn 2 times clockwise (increase speed) and set in this position, (2) Lossen the knob on the priming pump attached to the fuel pump and move up and down to pump fuel (3) Loosen air vent at the top part of the fuel filter, bleed until no more air bubbles are released, tighten the air vent and fully close priming pump knob while taking out fuel and cover. When this is done air bleeding is completed, Turn the starter switch to START and start the engine after 3 ~ 5 seconds. rt Check Before Starting 1, Check the following one more time before starting. (1) Is there plenty of cooling water in the fresh water tank? (2) Does the lube oil level reach the upper limit on the dipstick? (3) Is the fuel oil tank open? (4) Is the engine stop knob pushed fully in? (5) Is the battery switch in the ON position? (6) Has the accelerator handle been turned 2 ~ 3 times from the low speed position? 2, Put the starter switch in ON position, The Instrument Panel should be as below. Sea Water Pressure Gauge | [| Fresh Water Pressure Gauge © The needle reads “0' © The needle reads “0”, CHARGE: Lube Oil Pressure Gauge | Charge Lamp © The needle reads “0”, © Lamp is lit (red) 12 EEG Starting When the starter switch is tured to ON, the engine starts. As soon as the engine starts, remove hand from key, The key will turn back automatically to the ON position, When the engine has been started, set the speed at 700rpm. Check to see that the lube oil pressure is not above 1.0kg/em* Caution: 1, When starting the engine, the starter switch should be turned for a period of 15 seconds. If the motor fails to start after this time, allow a 15-second rest period before attempt- ing to start again. 2, When restarting, tum starter switch to START position after confirming that the engine has completely stopped. EB Confirm immediately After Starting Operation engine under NO LOAD condition for 1 ~ 2 minutes after starting. After stopping (about 10 minutes later) check the level of cooling water and lube oil. When the engine is new, more water and oil may be used and it is necessary to replenish the supply. EI Engine Warm-up Run the engine once more for 10 minutes at 700 ~ 800rpm to execute warm-up. Check the following during warm-up period. (1) Is the lube oil pressure higher than 1.0kg/em?. (2) Are the starter and battery switches in the ON position? (3) Is the charge lamp out? (4) Is there any oil, water, or gas leakage in any part of the engine? (5) Are there any noises, other than the normal sound of the engine running, being made? 13 EE] Operating at LOW LOAD If there were no difficulties encountered in the warm-up begin to operate the engine at LOW LOAD. Check the following items. 1, Fresh water pressure ‘The needle on the fresh water pressure gauge should read between 0.7 ~ 1.0kglem? 2, Sea water pressure The needle on the sea water pressure gauge should read below 0.5kg/em?. 3. Lube oil pressure The needle on the lube oil pressure gauge should read between 3.5 ~ 4.Skg/em? when the engine is being operated under normal conditions, 4. Color of exhaust When the engine is operated under normal conditions the exhaust has almost no color, Emission of black smoke is a sign that the engine is over-loaded. 5. Water and oil leakage and driving con ion heck for water, oil, and gas leakage; loose bolts; and abnormal noises. Caution: 1. Operating the engine at speeds higher than those recommended for this machine is dangerous. When the temperature of the cooling water is high, some hot water may escape from the fresh water tank pressure cap (overflow pipe). This is not abnormal 3. Be sure not to open the pressure cap when the engine is under operation, If it is opened at this time boiling water will escape and may result in burns, The temperature of the cooling water remains high after the engine is stopped. Do not open the pressure cap until the temperature drops below 60°C. If the cap must be taken off while the cooling water is still hot, place a cloth over the cap. Stopping 1. Pull out the stop knob to cut off fuel. Pull the knob out only after the engine has come to a complete stop 2, Tum the starter switch off and push the battery switch to OFF. (Refer to 3.9) Storing for Long Periods of Time When the engine is to be stored for long periods ot time observe the following condi ions. (1) Store in a clean, dust-free place (2) Thoroughly drain the cooling water when storing in a cold place as freezing may occur, (3) Loosen V belt. (4) Disconnect engine from battery terminal and store the battery in condition of No Charge. To Prevent electric discharge of battery, charge the battery once every month. (5) Clean dirt and oil from the exterior parts of engine and apply rust-resistant oil or clean oil. (6) To prevent moisture from entering the exhaust valve, air purifier (suction inlet), and electric devices, cover with a vinyl convering, (7) When starting the engine after storing for more than 6 months, follow the procedures below. (a) Take off valve arm cap and oil valve arm. (b) Take off cylinder sleeve and oil pin part of crank shaft (5 HANDLING OF SUPERCHARGER Check of Supercharger 1. Clean the supercharger blower. (1) Cleaning schedute Cleaning | When the suction/exhaust pressure Time falls to about 10! below the initial Pressure or after one month (250 hrs). Remarks | Example: Initial run of engine data Suction/exhaust press 1.0kg/em? (2600 rpm) Suction/exhaust press 0.9kg/em* (2600 rpm) Perform cleaning 2. Cleaning procedure 1. Operating the engine under normal load conditions (3/4 ~ 4/4 normal load), insert $0cc of cleaning fluid (using an ordinary gasoline can and spout) over a period of 10 seconds. After pouring in the cleaning fluid, wait for a period of about 3 ~ 5 minutes to allow for loosen- ing of the dirt inside, and then add an additional 0cc of fresh water during a period of 10 seconds, 3. Use a vinyl container for the cleaning fluid, Pay particular attention to the above time limits and quantity of cleaning fluid and fresh water to be used, as failure to follow these procedures closely may result in accidents (breakage of blower). 4. Check the suction/exhaust pressure and the exhaust temperature before and after cleaning, and if there is no change repeat the above cleaning procedure after waiting for a period of about minutes. If after repeating the above cleaning procedure for 3 or 4 times there is not a change, the blower is excessively dirty or there may be other problems. In this case, dissemble the blower and clean. 5. After inserting cleaning fluid, operate the engine for at least 15 minutes at normal load conditions to dry the blower. 16 3. Cheek joints Cheek to see if joints are loose and air is leaking Checking time Daily 4, Dissemble major parts and check. Consult your nearest service center or sales point. Checking time | Every 2500 hours (or yearly) Air Cooler (6CHL-HT) 1. Change anticorrosive zine. Remove side cover, take out anticorrosive zinc | 9 Every 500 hours ne (or 2~ 3 months) plug, and change anticorrosive zinc 2. Drain ( Remove dirt and mud from the intercooler (sea water cooler) system). Every 50 hours (or weekly) Checking Time 3. Drain (air cooler} When steam builds up in the lower portion of the exhaust manifold during engine operation, perform draining. At the same time it is possible to check for water leakage in the cooler. Drain after the engine is stopped or before starting, Checking Time Daily PERIODIC CHECKING AND SERVICING Table of Periodic Checking and Servicing To operate the engine always in a good condition, periodic checking and servicing are necessary. Refer to the table below for the number of driving hours when the check should be made and promptly replace any parts which are not in good working condition. eS Content oy | $2 | 350 | $00 | 1000 | 2500 | et, [ “Check oil tank level and ~ Tt oo | replenish. y _ | by fuel rain fue ak i fut % - ln 30 Drain fuel filter. _ (omar 20 [Replace fuel [Te 20 hock ol level in il pan and r repenin '? | _ 2 Lube [Drain tbe ol fier. [3 zi oi ees Si am | Replace lube oi iter element. ° 21 Change leo = Check ve of cooling water ° 2 cooing | anaetonsh Wer sine ote | Chane ootng water [ | az Grea cooling war pum oa Check charged tarps 3 | Le + I---—+——] Electric | Adjust tension of Alternator ‘System, (dynamo) V-belt. ° | 2 | — Check biter pe 2 ‘Check wire harness: I I I [2 I Re-tighten hose clips ° i {Foe vo, coin wate, breather and a in) checkand epiacerentofrtbernoees | © Cheek per 250 ms {Fisk uo oom wees bear ama) 6 Repacement er 00s Adjust ining of ue 1 1 ust | fection | Foote injection | jo Hine 8 Adu nition oven and Er om vaie _ pep oy" | Replace nection vale | Tighten head bolt. Ro | ° cyngor | {1 —_|— SEAge | Acjus wave clesranc. iti ° | Lap auction anal eat - 3 | valves very 2 ves Tos 6 25 supe. |" {| | yey 4 Shower | Chock for air and gs leakage in joints. ° “ Oraning of exhaust manifold @CHLHT) | _O i 26 ‘Check bolts and nuts. | 14 Check Tor water, ol, ge leakage ° | | 14 18 1, Adjustment Table Division Value lina 4CHLN | 4CHL-TN | 6CHL-N | 6CHL-TN [6CHL-HTN a = Injection Timing (F1D) | 1500rem | 185" | gus ee oot | a0! 1800rpm | 21° 24 A Eee { Fuel injection valve 220° kgfem? pressure — Valve clearance Suction valve 0.30mm Exhaust valve 0.35mm V-belt tension Belt depressed at center w/finger 10 ~ 15mm Engine lube oil press, Ata given driving time 3.5 ~ 4.5kg/em? _| Level of cooling water ACHL(TIN | eee (inside fresh water tank) 6CHL(T)(HT)N 240 ~) ACHL(TIN 142 Level of lube oil + — a — 6CHL(T)(HTIN 250 2. Tightening Torques for Main Parts Cylinder head bolt 16**kg-m Tightening power Main cap bolt 23.6""kom of Connecting rod bolt 15.5° kgm ncaelaeee Flywheel tightening bolt 23.5°"kg-m 3. Table of Tightening Torques for Standard Bolts ‘Screw bore x pitch M6x1.0 | wxt.26 | m10x1.5 | t0x1.25 | ni12Kt.26 | ne12x1.26 | Mtaxt.25 | M16%1.5 (mm Tight | on | ] - ie ‘anenina forces 0.75 | 1.80 | 285 | 375 | 620 | 675 110 | 168 (kam) Caution: 1. Tightening torque should be within #15% of the entries in the above table Example: MIOx 15 3.55x0.15=0.5 Threrefore: 3.55 £ 0.5kgam 2. When tightening bolts, except for the main bolt, it is necessary to tighten them according to the above table, When tightening according to the above table, only S45C bolt (indicated by “7” on the head) is used. 3. When the material of the tightening part is aluminum, tighten to 80% torque of this table. 19 Major Check and Servicing Points 1. Fuel Oil System (1) Drai Before putting in fuel, open the drain cock of tank and discharge drain collected in the bottom. 9 of fuel oil tank (2) Checking and replenishing of oil quantity in fuel oil tank. After operation, check oil level and replenish if necessary. (3), Draining of fuel oil fitter Remove fuel oil filter plug and discharge water and dush gathered in the filter. Be sure to tighten drain plug completely after discharge. (4) Charging of fuel filter element Loosen center bolt to remove filter. Remove @ Element 8 filter element from filter case and replace. g & =A Cc C C) Caution: Clean filter case before inserting new 7 \ aution: Clean filter inserting as I of 1 element, and be sure to remember to ery il | put in spring and metal ring, and spat ined aia /** a firmly tighten center bolt Auber packing Center bolt” 2. Lube Oil System (1) Take out dipstick and wipe clean. Reinsert dipstick to check oil level. The oil level should be between the upper and lower limits. Replenish if necessary 20 (2) (3) Replacement of lube oil filter element Remove and replace filter element. Outline for changing element (1) Take out element with element tool (2) Reassemble with new parts. At this time, clean the setting face of the packing in order not to introduce dust and foreign substances, (3) Confirm that there is no oil leakage during operation Change of lube oil Change the libe oil while the engine is warm right after stopping, when the oil flows smoothly and can be removed thoroughly. Connect vinyl tube of rotary pump to oil discharge pipe and suck up used oil, Let stand for about 2 hours. (This allows the oil re. ‘maining in engine parts to drain off almost completely.) Suck up a second time. Put new lube oil into oil supply inlet. Refer to 4-2, 5-7, 7-5 2(1) for further details, 21 Frequency First replacement, after 50 hours of ope- ration (or one week) ‘Second and subsequent replacements, every 500 hours of ‘operation (or every 2 ‘or 3 months) 3. Cooling Water System (1) Check and replenishment of cooling water Remove the pressure cap from the upper part of the radiator and check the water. The water level should be a little below the water supply inlet. Replenish if insufficient Caution: Be sure to wait until the engine has cooled off as high temperature of cooling water can be dangerous. (2) Changing cooling water Change water after engine has cooled off (a) Remove pressure cap, loosen the 3 drain plugs (6CHL-HTN : 4 Places) and drain cooling water, (b) After draining, firmly tighten drain plugs and fill with cooling water. Refer to 5-3, 5-7 for further details. (3) Adjustment of V-belt (alternator actuator and cooling water pump actuator) The sag of the belt should be 10 ~ 15mm when depressed with finger at center point. If less than this, loosen the tension pulley and attach- ment bolt and adjust. 4, Electric System * Battery Check (1) The level of fluid in the battery should be about 10mm above the electrode. Be sure to replenish if lower. Proper ievel (2) Measure the specific gravity of the battery fluid and check the charge, The specific gravity Tir ar under perfect conditions is 1.26 at 20°C "mmm °° ‘Too low 22 5. Check of Fuel Injection Valve > consult your dealer or service point. (1) Draining fuel injection valve (a) Remove the nuts of the fuel injection pipe and the oil leakage pipe. (b) Attach removal tool. (©) Adjust the length of the leg at the point where the removal tool meets at right angles with the injection valve and also the interval between it and the valve to about Smm (d) Apply tube oil to the removal bolt, insert into bolt hole of oil leakage pipe joint, and take out upper part of the valve body. (2) Check Attach nozzle tester to fuel injection valve, start fine spray of injection, The spray emitted from the mouth should be of a conical shape at an angle comparable to that in the illustration below, Check the injection and adjust if lower than stipulated level. Caution: 1. Injection spray is emitted at high pressure and is dangerous. Do not put your face or hands near the spray as injuries may result. lean carbon off the nozzle sleeve seat 2. When the fuel injection valve is removed, and replace seat packing. 23 f} SYSTEM DIAGRAMS EB] Fuel Oil system Diagram Fuel injection value trom 4 a From fuel iol on arora Fue! injection pimp! Fuel oll/water separator * Remarks: The oil leakage outlet (inside fuel oil tank) should be the same level as or lower than ‘the fuel oil outlet. 24 Cooling Water System Diagram [6CH-HTN] Air cooler a Fresh water SS

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