OPERATION MANUAL MARINE PROPULSION ENGINE eee (eeYANMAR MARINE DIESEL ENGINE MODEL : 6KH(M)-STE OPERATION MANUAL Thank you for purchasing a YANMAR Marine Propulsion Diese! Engine. J [INTRODUCTION] @ This Operation Manual describes the operation, maintenance and inspection of the 6KH(M)-STE Yanmar marine propulsion 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 6KH(M)-STE Code No. 42221-555800 Operation ManualTable of Contents INTRODUCTION 1 FOR YOUR SAFETY 1.4 Warning symbols 1.2 Safety precautions 1.3 Warning labels DESCRIPTION OF PRODUCT 2.1 Specifications 2.2 Cooling water, lubrication oil capacity 2.3. Assembly parameters 2.4 Major components 2.5 Engine construction 2.5.1 Engine cut away view 2.5.2 Fuel oil system 2.5.3 Cooling water system 2.5.4 Lubricating oil system 2.6 Instruments 2.6.1 Instrument panel 2.6.2 Electric wiring diagram FUEL, LUBRICATING OIL, COOLING WATER 34 Fuel 3.4.1 Fuel 3.1.2 Precautions for handling fuel 3.2 Lubricating oil Caution 3.2.1 Engine lubricating oil 3.2.2 List of Lub.oil Brands 3.3. Cooling water (fresh water) 3.3.1. Fresh water quality 3.3.2 Antifreeze, Anti-corrosive fluids OPERATION 4.1 Pre-operation checks 4.1.1 Fuel supply 4.4.2 Bleeding airin the fuel system 4.1.3. Lubrication oil system 4.1.4 Cooling water 4.1.5 Remote control device 4.2 — Idling(Cranking) 43. Operation 43.1. Starting up 4.3.2 Warming up 4.3.3 Running 4.3.4 Check during operarion 4.3.5 Emergency Repair for Marine gear or Engine Trouble 4.4 Stopping the Engine 4.4.1 Routine stopping 4.4.2 Emergency stopping 4.5 Long term storage eRPREE fF PP ©ONAD an RONNA BRPES5 PERIODIC CHECKS AND MAINTENANCE 5.1 Precautions for inspection and maintenance 5.2 Periodic inspection schedule 5.3 Inspection procedure 53.41 5.3.2 5.3.3 5.3.4 5.3.5 5.4.6 5.47 5.4.8 5.4.9 Torque of nuts and bolts Fuel system Lubrication oil system Cooling water system Checking the fuel injection timing Checking the fuel injectors Adjusting the valve clearance Checking the turbo charger Checking the electrical system 5.4.10 Adjusting the Remote contro! handle 5.4.11 Checking the Viscous damper 6 TROUBLESHOOTING OE PERS BESOVaNNa PEOe 5-16For your safety 1.1 Warning symbols Most operation, maintenance and inspection problems arise due to user's failure to comply with the rules and precautions for safe operation described in this opera- tion manual. Often, users do not understand nor recognise the signs of approach- ing problems. Mis-handling can cause burns, other injuries and can result in death Be sure to read and understand this operation manual carefully before operating the engine and observe all of the instructions and precautions described in this manual. @ Shown below are the warning signs and their meanings used in this manual. Pay special attention to statements preceded by the signal words. DANGER-indicates an imminently hazardous situation rN DAN ic ER which, if not avoided, WILL result in death or serious injury. WARNING- indicates tentially hazardous situation A WARNING icates a potentially which, ifnot avoided, COULD result in death or serious injury. TeINEE CAUTION-indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury. It may also be used to alert against unsafe practice. y | ner @ The descriptions captioned by [NOTICE] are particularly important cautions for handling. If you ignore them, the performance of your machine may deteriorate leading to problems. WA1.2 Safety precautions lM Precautions for Operation PEE Ky a ier r e/* Ms Fresh Water Tank Filler Cap @ Never open the cap of the fresh water tank while the engine is still hot. Steam and hot water will spurt out and seriously burn you: Wait until the temperature of the fresh water tank has dropped, wrap a cloth around the filler cap and loosen the cap slowly After inspection, refasten the cap firmly. Battery @ Never smoke or permit sparks near the battery, because the battery may emit explosive hydrogen gas. Place the battery in a well ventila- ted place. Fuel @ Use only diese! fuel. Never use other fuels, including gasoline, kerosene, etc., because they could cause a fire. The wrong fuel could also cause the failure of the injection pump and injector due to lack of proper lubrication. Be sure to check that you have selected diesel fuel before filling the fuel tank. Fire Prevention @ Be sure to stop the engine and confirm that there are no open flames in the vicinity before supplying fuel @ 1f you spill fuel, wipe such spillage carefully and properly dispose of the wiping materials. Wash your hands thoroughly with soap and water. @ Never place oils or other flamable materials in the engine room. @ Install a fire extinguisher near the engine room. and familiarize yourself with its use. Exhaust Gas @ Exhaust gas contains poisénous carbon monoxide and should not be inhaled. Be sure to install ventilation ports or ventilators in the engine room and ensure good ventilation during engine operation. Moving Parts @ Donot touch or let your clothing get caught in the moving parts of the engine, such as the front pully, V-belt or propeller shaft, during engine operation. You will be injured. @ Never operate the engine without the covers on the moving parts 1-2Burns @ The whole engine is hot during operation and immediately after stopping. The turbocharger, exhaust manifold, exhaust pipe, inter- cooler and high pressure fuel pipe are very hot. Never touch these parts. Alcohol @ Never operate the engine while you are under the influence of alcohol, Never operate the engine when you are ill or feeling unwell Safety Precautions for Inspection Ms PT Ges 7 Battery Fluid @ Battery fluid is dilute sulfuric acid. It can blind you if it gets in your eyes, or burn your skin. Keep the fluid away from your body. Wash it off immediately, if you touch it, with a large quantity of fresh water and call your doctor for treatment. Fire by Electric Short-Circuits @ Always turn off the battery switch before inspecting the electrical system. Failure to do so could cause short-circuiting and fires. Stop Engine before Servicing, @ Stop the engine before you service it. Tum off the battery switch. If you must inspect it while the engine is operating, never touch mov- ing parts. Keep your body and clothing away from all moving parts. Scalds @ ‘It extracting oil from the engine while it is still hot, do not let the oil splash on you. Wait until the temperature has dropped before extracting cooling water from the engine. Do not let it splash on you.1.3 Warning labels For safe operation, the warning labels should be affixed in the correct place. Replace the labels with new ones if lost or damaged. service agents. Order them from your [se] Parts No. {@)_12ez06-07260 _| [@|_ 11616-07200 @}_ 128296-07360 |@) 1486 362 [@|_128286-07300_| @ Oo =>2. DESCRIPTION OF PRODUCT 2.1 Specifications Engine) Model 6KH-STE 6KHM-STE (without Marine gear) Type Vertical water-cooled, 4:cycle diesel engine [ Combustion system Drect injection No. of cylinders 6 Cylinder bore x stroke (mm) | 135x160 | Rated outout (kW {ps}) | 338 { 460 } M9 {475} Rated speed (min” {rpm} ) 2000 2000 Direction of rotation Ignition sequence Counterclockwise, viewed from the flywheel 1-4-2-6-3-5-1 (Cylinder 1 is the flywheel side) Turbocharger Cooled air gas turbine Lubricating system Forced lubrication system by gear pump Cooling system Fresh water and sea water cooling Fresh water : Cylinder. jackets Sea water : Boost air cooler Fresh water cooler Lubrication off cooler Dry mass (without: Marine gear) (ks) Electric starting motor 1430 Remote control Marine gear 2 lever push pull remote control cable (Operation side O@OOSO! (eee [Non-operation side [ Meaet YX-161L-1 | Type Muti.dise,wet, hydraulic clutch Gheadasern) | 3.6573.65 | 4.08/4,08 | 4,85/4,55 piosiorshae Counterclockwise, viewed from stern Ory mass _(kg) I 470 |2.2 Cooling water, lubrication oil capacity 23 Cc tem [Unit 7 Capacity Lubrication oil | Engine (Oil pan) ] L i 60 Reverse(Marine) gear | 7 (vx-t61l-1) | Fresh water | Cylinder block & Fresh | 43 water cooler | ‘Subiank ii Assembly parameters item Unit Setting value Intake/exhaust valve clearance (at engine cold) mm 0.35/0,40 Fuel injection timing (Before T.D.C.) degree( ° ) 1841 Fuel injection beginning 5 (28045) Pressure MPa (haf /omn?) |} Engine oil 0,54+0.05 (5,540.5) Cooling fresh water e0+5 Temperature aan °c Engine Oil (at cooler inlet) below 952.4 Major components Operation side Boost air Cooler Sub Tank Reverse (Marine) Gear Turbocharger Fresh water Cooler ‘Stop motor (Option) Alternator Sea water Pump2.5 Engine construction ‘The cylinder block is a cast iron monoblock with the main crankshaft bearing in hung metal form with an oil pan underneath. The crankcase has a side cover on the. operating side. 2.5.1 Engine cut away view (A) Operating side (©) Camshaft (@) Lubricating of pump (8) Cylinder head (©) Cooling nozzle (H) Oltpan (C)_Fiston (F)_Crankshaft 2-42.5.2 Fuel oil system uel injection nozzle =< Over flow fuel 26 A Fuel Tank2.5.3 Cooling water system Fresh water Sea water from Fresh water pump 1 +S, Oe 1 1 ' A i Lube oll cooler 1 nee ' Emergency cooling Swater inlet Sea water 2-62.5.4 Lubricating oil system Of] Main Gallery Lubricating Oil Cooter Piston-pin Cransart 1._| Thermostat Crankpin < Crank journal —frecrer aim bf camshars fe Pressure [zie a ee 1 valve + Nozzle suey C) ete” tH pecenesee | aaeeeeeren WA Gime TIE ae2.6 Instruments 2.6.1 Instrument panel Instruments When the key is turned to the “ON” posi- tion, the instrument panel is as follows. (1) Lube oil pressure gauge and air intake pressure gauge will be at “O”. (2) Cooling water temperature gauge will be at 40°C or lower. (3) The lights of the lube oil gauge, air intake pressure gauge, cooling water temperature gauge, and the tachom- eter will come on when the panel light switch is turned on. (4) The operating hour meter should be working, Warning devices (1) When the starter switch is turned to “ON", an automatic check of the alarm sytem is conducted, and for a period of 3 seconds, the buzzer will sound and the following lights will go on -—— Battery Charging Cooling water temperature ube oil pressure © Lube oil temperature Cooling water level @Lube oil fitter @@00000000 Boost air pressure Lub.Oi Pressure Cooling Water Temperature Tachometer Buzzer Switch Mumination Switch ‘Stop Switch (Option) Starter Switch Hour Meter Clock ‘Nar Lamp leans Fresh Water Coter Lab. OF Fiter Senery Charging Coding Water Engine Lub. Oi Detect Pressure Oop (ea Te \e Water Covet Drop Clogged [Sn |B! “ueven | PATER (2) Start the engine after both the buzzer and warning lamps go off. Note 1: If the buzzer and/or warning lamp stays on after three seconds, see your YANMAR dealer for servicing. Note 2: The charge warning lamp (CHARGE) stays on until the engine is started and the battery is charged.2.6.2 Electric wiring diagram instrument Panel Starter Switch feo aye Sse CHE? Hate uzer “HF Ma Detail of Connector oP) (rr Eng, Oto, CW. Tere Saal ee isles CW. Leel Erg. OF Te, (em) oF Fite Color coding reat CW Trp Eng Ol Pressure} Sah Se Teg he 4 CYlteme tmOlTine CHLLec! TatnSenar City LP Sent SS 1 ob Ferapess ee ele3. FUEL, LUBRICATING OIL,COOLING WATER 3.1. Fuel oil mmended fuel for this engine is Heavy cil A (ISO-F-DMB, JISK2205, Class i (ISO-F-DMA, JISK220¢, No: 2), or the equivalent as shown Visessiy | Cetan | Wobiity | Resiiual [~ Ash Si Moisture | ‘Specie | | fs0c} | value | point | carbon | content | (mass %) ) (val %) gravity [qum?/stese))! | cy imass %) | (mass %) | O)_ T5740) 20-35 [iS5! 210) <0.7 0.03 |< O11 > 60) 2086 | NOTE: If fuet is to be stored curing the winter, select a fuel with a freezing point below the lowest ambient temperature. 3.2 Lubricating oil (1) Selection of lubricating oil is very important for a diesel engine. If improper lubricating oil is used or change of lubricating oi! is neglected, it causes sticking of piston rings, seizure or early wear of pistons and cylinder liners and faster wear of bearings and various other working parts that reduce the durability of the engine. Referring to the table below, select the appropriate API service grace CE and SAE 30 or SAE 40 viscosity for your conditior Specie | Fiasn Viscosity Viscosity Total akeinty gravity | point | (mm/s (eS) Ong} [szaea) © | wm | we Tore | | A < (a 0.g05 5 2a 40 (2) Recommended oil brands f | TDEMCTSU ADSAN j DAPHNE MARINE OTL sx30. s%40 | BRI ert BP ENERGOL DS3-153, DS3-1 | casrRo1 | CASTROL wic3o wiceo / I ECON ERQMAR 12TP30, 40 | CALTEX |pexa 1000 MARINE OIL 30.40 | MIBIL MOBIL GARD 912, | our | cour venrnas pposo, 2p0s0, | Japa JOM) WARINE D-13, D-14 | f ~ ENERCY/ELF DISOLA M0: | | COS) OLL jcosio NARENE SUPSR 30, 40 T 1 + NIPPON } NISSERT MITSUBISHI | Teaco | razo x020, 40 | MITSUBISH | SAREE | FUJI XOSAN | PURKOL MARINE 312, 412 GADINIA OIL 30, SELL RIMILA CT OIL 30,40 | CeBVRON [ea 1000 MARINE OIL 30,40 | RIMILA OF 20, 40 | Note: SAE#30 of lub.oil for Reverse(Marine)gear [YX-161L) . @ Do not mix different brand oils.|f mixed,oil will be deteriorate. 343.3 3.3.4 Cooling water (Fresh water) Use clean soft water (tap water] as the cooling water. CAUTION © Do not use water with a high mineral content (hard water). It can cause scale in the cylinder head and cylinder jacket, leading to overheating. © Add antifreeze or an anti-corrosive agent to the fresh cooling water. Otherwise. scale or rust can buiid up in the water lines. © Do not use antifreeze and anti-corrosive agents at the same time. Fresh water quality ‘The fresh water used for cooling should have the following properties: { Quality T Value [Quality Value H [| S5:8.5@5°) | Nite acid ions <5 0pm [Conductivity @5°C) | <0.04 sim (400umho) | isolated carson | < 10 ppm residual carbon <2pom___| (Hardness, total I = 10 ppm Total iron’ [<1 ppm Alkalinity i = 150 pom Silica [<50 pom [Ammonia fons i 0.05 ppm Tron sulfids__|___< 1 ppm (Chiorine ions, t < 100 ppm [Residual vapors |< 400 pom Sulfur ions i ‘= 100 pom T 3.3.2 Antifreeze, Anti-corrosive fluids ‘When using commercially available antifreeze or an anti-corrosive agent, follow the manufacturer's instructions regarding mixing ratio, temperature considerations, and general remarks. CAUTION This engine uses aluminum components. Do not use an anti-corrosive containing nitrites, since it may corrode these parts Antifreeze fluid It is recommended that you use Yanmar “Royal Freeze” antifreeze fluid. This also has an anti-corrosive effect and can be used year round. The mixing ratio should be based on the lowest temperature expected. In any case, the ratio should be between 30% and 55%. (Minimum temperature (°C) 1 >-15 [20 | -2 | [Mixing ratio (in %) I 30 iseeee cp besres eseeer10/ase0@]| CAUTION A low ratio (less antifreeze fiuid) will allow damage to occur from freezing at low temperatures. On the other hang, an high antifreeze ratio can reduce the cooling of the engine.4. OPERATION 4.1 Pre-operation checks When operating the engine for the first time, or after a lengthy period of storage, observe the following precautions. (1) There should not be any tools or parts left in the crankcase. (2) There should not be any loose bolts or nuts. (3) _ Ifa valve has been dismantled or when bolts are refastened, check the clearance at the top of the intake and exhaust valve heads. (4) Make sure that the deflection of the crankshaft is normal. (5) Starting system checks: © Electric starter: Battery voltage (6) Prior to tuming the engine over, make sure all moving parts are not in contact with any other parts. Make sure the engine can not hurt anyone in the vicinity. Announce that you are about to turn the engine over. When turning the flywheel,set the decompression handle to g.'Non-compression position: Aes non-compression position. win - Re? c [NOTE] we When turning flywheel by hand rotate ay in the engine rotating direction (count- MMAR E er clockwise as seen from the stern) a Pag Direction of rotation ee This is important to prevent early break- down of the impellar of the sea water pump.444 Fuel supply Nee Check the type of fuel. Never use gasoline or other fuel. It can cause a fire. Wipe up any spills completely. Rinse the inside of the fuel tank and fuel lines with clean diesel fuel before filling the tank, 4.1.2 Bleeding air in the fuel system Bleed any air in the fuel system as described in the following procedure. © Place the throttle handle in the normal position “5”. (1) Remove the priming pump cover on the fuel feed pump. Turn the knob counterclockwise slowly and move the knob up and down to feed fuel. (2) Loosen the air bleeder plug at the top of the fuel fitter. Leave it loose until bubbles stop coming out of the fuel. When there are no more bubbles, tighten the air bleeder plug and the priming pump knob. Reattach the cover on the priming pump. Bleeding air from the system (A) Air bieeder plug (8) Fuel fiter (©) Priming pump (©) Fuel teed pump Fuel injection Pump4.1.3 Lubrication ofl system Operation side (1) Remove the oil filler cap from’ the filler neck on the side plate as shown in the figure. (2) Fill recommended oil up to the upper level mark on the dipstick while check- ing the level with the dipstick. Install the oil filler cap. Note: When checking the oil level, insert the dipstick fully. Oil capacity : 60. (at upper level mark) (A) Lubrication oil Filler cap (3) Fill the reverse gear housing with re- (8) Dipstick commended oil up to the proper level (C) Upper level mark (D) Lower level mark Oi capaci 178 (at r_ level mark Hand Lubricating Oil the fuel injection pump governor, clutch control lever and remote con- { Bisus ool eeacon [Control cable trol wire ball joints. Boll Joint.4.1.4 Cooling water a) (2) (3) (4) 6) Usea solution of clean soft water and YANMAR antifreeze agent to fill the fresh water system. Tighten the fresh water drain cocks as shown in the figure before filling the fresh water system with coolant. Make sure the clamps at both ends of the rubber tube between the reserve tank and the fresh water tank are secure- ly tightened, The reserve tank should be installed so that its top is positioned between the top of the fresh water andapproximately 5 cm (2 in.) below the tank top surface. Remove the filler cap from the fresh water tank, and fill the fresh water tank with coolant up to the filler neck. Fresh water cooler Fill the reserve-tank with coolant up to the upper level mark Filler cap. Tighten the filler cap securely. Adssicer Tighten the cap securely. A loose water cap can cause steam and hot water to spurt out and scald you. Coolant capacity : Engine : 430 Reserve tank : 1.12 444.1.5 Remote control device a) (2) Operate the throttle handle from the position “0” to the (full) position "10", and check that the governor lever at the governor, moves into correct positions. Operate the clutch control handle into “AHEAD”, "NEUTRAL" and “ASTERN” and check that the clutch control lever at the reverse gear moves into the correct positions. 4.2. Idling(Cranking) - - ~ - 1 Prior to starting the engine, check to see if there is anything nearby the engine, par- ticularly the rotating parts that may cause damage. 7 | © Reinstall all covers, shields and any other protective devices in their originalpositions, © Return the turning bar to the correct position, Perform the following cranking sequence to ensure safe operation (1) Crank the engine while standing next to it, (2) Limit the cranking time to 5 seconds. Make sure that no abnormal sound is heard. (3) Pull out the engine stop knob to interrupt the fuel flow. - Starting motor: Turn the starter key to the START position. (4) Checking the lubricating oil and heat exchanger water level: Whenever the engine lubricating oil or cooling water is topped off or replaced, check the lubricating oil and cooling water level once more after running the engine for § minutes. After a 5 minute trial run, the lubrivating oil and cooling water levels will drop as they circulate in the engine. 454.3 Operation 4.3.1. Starting up Pre-operation check (1) Kingston valve is fully open (2) All drain cocks are closed. (3) put the marine gear handle in NEUTRAL position. (4) Put the throttle handle in low speed position. [High speed] Throttle handle Marine gear Handle Low speed) [NeUTRA NEUTRAL Starter motor precautions: © Do not hold the starting switch in the start position for more than 15 seconds. Wait at least 30 seconds before trying to start the engine again. © Wait until the engine has come to a complete stop before trying to start it again. Attempting to turn the engine over before has stopped will damage the starter gear. © As soon as the engine starts, return the key switch and battery switch to the ON position. The charger and the instrument panel will not start to work. (1) Tum on the battery switch, (2) Tum the key to the START position to start the engine. (3) Release the key immediately as soon as the engine has started. The key will Tetum to ON position automatically. (A) Starter switch {B) Before startup (C) Run a a | (0) Release the key after starting (c) the engine (B) (Dp)4.3.2 Warming up (1) After starting the engine, warm up the engine without any load for about 10 minutes. (Warm-up operation at 700-800 min-“rpm),) NOTE: When lubricating oil or cooling water is supplied for the first time, or when the fluids are replaced with new oil or water, warm up the engine for about 10 minutes and check the fluid levels in the engine once again. A DANGER EEMGMGS] © Never open the pressure cap while the engine is hot. Steam and hot water can spurt out and burn you badly. Wrap the cap with a rag and open the slowly after the engine has cooled &. down, Fasten the filler cap tightly after checking and adding water. (2) Check the following items while warming up the engine: ©Check that the meters and alarm devices on the instrument panel are normal @Check for water or oil leakage from the engine. @Check that exhaust color, engine vibrations and sound are normal. @Check that sutficient cooling water is discharged trom the seawater outlet pipe. 4.3.3 Running (1) Handling the Throttle handle Adjust the speed of the engine by moving the (NOTICE) throttle handle slowly and smoothly. For a new engine be especially careful | Loosen the handle knob, then move not to change speeds abruptly or attach ‘the handle and adjust the speed. a heavy load for the first 50 hours of operation. Doing so will result in dam- | age and shorten the ite of the engine. | (2) Handling the Marine gear handle Use the marine gear handle to operate the clutch for the marine gear(AHEAD.NEUTRAL, [~ INOTICE] ASTERN). | Never operate the clutch when the © When changing the setting of marine | engine is running at high speed. Doing gear handle from the NEUTRAL posi. | $0 Will put stress on the engine, driving | device, and propeller and result in dam- tion to AHEAD/ASTERN position and ° A Po age. Additionally, never change speeds abruptly. AHEAD to ASTERN,operate the handle when the engine is running below 1000 min-(rpm). Be sure to securely position the handle in AHEAD,NEUTRAL,or ASTERN. 474.3.4 Check During Operation Always be on the leakaut for problems during engine operation. Pay particular attention to the following. (1) Is sutficient water being discharged from the seawater outlet pipe ? Ifthe discharge is small, stop the engine immediately, identity the cause and repair. (2)Is the exhaust color normal ? ‘The continuous emission of black exhaust shows engine overloading. This shortens the engine's life and should be avoided. (8) Are there abnormal vibrations or noise ? Do not operate at speeds which produce violent vibrations. Depending on the hull structure, engine and hull resonance may suddenly become great at a certain engine speed range, causing heavy vibrations. Avoid operation in this speed range. It you hear any abnormal sounds, stop the engine and inspect. (4) Alarm buzzer sounds during operation. If the alarm buzzer sounds during operation, lower the engine speed immediately, check the alarm lamps, and stop the engine for repairs. ) Is there water, oil, or gas leakage, or are there any loose bolts ? Check the engine room periodically for any problems (6) When operating the engine at low speed (below 600 min-(rpm)) for long periods of time (4 hours more than), race the engine once every 2 hours. Racing the Engine Put the Marine gear handle in NEUTRAL position and shift the engine speed from high to low several times. [NOTICE] Racing the engine removes carbon built up in the combustion chamber and around the fuel injection vaive. Neglecting to race the engine will cause the ‘exhaust to tum black and lower the efficiency of the engine Never turn off the battery switch or spark the battery cable during opera- tion. Damage to parts in the electric system will result. cos 484.3.5 Emergency Repairs for Marine gear or Engine Trouble Handling the Emergency Bolts of Marine gear If the trouble occur in the marine gear ILb.cil system and the clutch have not been comected, follow the following procedure for using the clutch emergency bolt to return to port [NOTICE] Using the emergency bolt directly connects the clutch to the engine making it possible to turn the propeller. However, when the engine is started and the propeller turns, the boat will only move forward. The emergency bolt should only be used in cases where it is impossible to operate the clutch and the boat must return to port. Ask your Yanmar dealer for repairs immediately after returning to port. When using the emergency bolt, set the marine gear handle at AHEAD or NEUTRAL position. © Operate at low speed, 1000min"rem) or less, and navigate carefully. | When approaching the pier, turn off the engine early and stop the boat. A sisson © itis very dangerous if the engine starts unexpectedly while disassembling parts or conducting an inspection. You may be caught in the moving parts. © Turn off the ignition switch before working. @ Stop the engine and remove the plua(Red). @ Turn the flywheel and tighten emergency Energency Bott Tightening Procedure boits(3) of the clutch everly, firmly. 7 (ae eet Exergeney Bott Location of Emergency Bolts for YX-161L-1 49(2) Towing @ When the boat is in tow with engine stopped, always lock the propeller shaft. If the propeller shatt is not locked, clutch bearing metals will seize. @ When operating one engine on boat with twit shafts, also lock the unused propeller shaft. engines and twin-propeller 4-104.4 Stopping 4.4.1 Routine stopping a) To stop the engine, set the clutch con- trol handle in the “NEUTRAL” posi- tion, and after no-load running at a low speed (500 ~ 700 min” {rpm}) for about five minutes, pull the stop lever. Stop lever NOTICE] Stopping the engine suddenly after operating at high speed without first cooling it down will cause the engine ‘temperature to rise quickly resulting in deterioration of the lube oil and sticking of parts. (2) After stopping, set the starter switch in the “OFF” position and turn off the buzzer switch. (3) Remove the key from the starter switch, and turn off the battery switch (4) Close the fuel cock. (5) Close the kingston cock. (6) While the engine is still warm, wipe off dust and dirt from the engine (7) Discharge of cooling water Because there is the possibility that cooling water (sea water) will freeze in sub- zero temperature, be sure to close the kingston cock and drain sea water after use of the engine. If the engine will not be used for a long time, also drain sea water completely. ‘If this is not done the fresh water cooler or sea water pump may be damaged by the freezing of cooling water in the sea water system. Loosen the drain plug at the reverse gear oil cooler, and loosen -also the sea water pump cover bolts to drain sea water. Sea water Pump 44.4.2 Emergency stopping If any of the following problems arises, immediately stop the engine. Any alarm has been issued. Overspeed rotation Unusual sound or unusual vibration Overheating or smoke generation 6©680e A pipe of the fuel oil, lub. oil or cooling water system has been broken. e® The supply of cooling water has stopped and it is impossible to restore the supply immediately. @® -Rattery charging defect © Fresh water temperature overheat © -Eraine 1bb.0ll pressure drop © -Water level croo(Fresh water cooler) © -Lib.oll filter clogged 1\ WARNING ‘When repairing the engine or investigating the cause of problem, observe the following items. © Afier having stopped the engine in an emergency, do not open the engine cover on the crankcase side for at least 10 minutes. Fresh air entering the crankcase while the engine is overheated, oi] mist may be. ignited, resulting in explosion. | © Donot open the cap of fresh water cooler immediately afier stopping the engine. | ‘Steam or hot water will blow up, causing a dangerous accident. Let the fresh water cooler cool for a while, then wrap the cap with cloth and slowly Joosen it. 4124.5 Long term strage Before storing for long pericds of time, Draining the cooling water perform the following, ‘When not using antifreeze, be sure to drain the water from the inside of the engine, @Drain the water from both the seawater and fresh water systems. [NOTICE] If the water is not drained, it may freeze mare Sore ‘and damage parts of the cooling water [@ Boost air cooler [A (Sea water) vee [@ Sea water pum | (Soa water) [@ Lib.oll cooler | (Sea water) ase 4 8 c Reverse(Marine) gear os — Exhaust manifold |B (Fresh water) ore QO 7 [© Cytinder block |B (Fresh water) = : @ Fresh water pump | 8 (Fresh water)| oe ioe @ater draining off the water, tighten the water drain cocks and replace the side cover on the saltwater pump, a @ j rT Ht ® remove the cover5. PERIODICAL MAINTENANCE 5A Precautions for inspection and maintenance Prior to starting any inspections or maintenance, familiarize yourseff with the design of the engine and the work that needs to be performed. An incorrect or incomplete understanding of how the engine works can lead to an accident or damage the equipment as well as wasting time and effort. Damaged components or those which have reached the end of their normal lifetime should be replaced with new ones, based on anticipated future working hours. If preventative or corrective maintenance steps are difficult to take on the spot or if no replacement paris are available, contact us, or one of our dealers. A WARNING (1) _ Itis very dangerous if the engine starts unexpectedly while disassembling parts or conducting an inspection. You may be caught in the moving parts. Make sure that all moving paris are secured before working on the engine. (2) Prior to turning the engine over, make sure all moving parts are not in contact with any other parts. Make sure the engine can not hurt anyone in the vicinity. Announce that you are about to turn the engine over. (3) Tum off the ignition switch before working on the electric circuits. Avoid electric shocks and accidental fires. (4) Strictly observe the following: © Do not allow any open flames or sparks in the area when handling fuel, lubrication oil, or other flammables. © Do not drink fresh water that contains antifreeze, anti-corrosive, or other toxic fluids. + Battery fluid Wear a mask and rubber gloves to avoid direct bodily contact with battery fluid. if any fluid gets on your skin or clothes, wash the fluid off immediately with free flowing water. Dispose of battery fluid according to the instructions of the battery fluid manufacturers. © Mercury (thermometer): Contains toxic substances. Do not put it in the mouth. ff you get mercury in your mouth wash it out right away. (6) The engine is stil hot for a while after you stop it. Be careful not to burn yourself on it. © Always make sure to wear the proper protective clothing, gloves, helmet, glasses, etc. © Residual pressure can cause heated oil or water to spurt out when filters or joints are disassembled. Release any remaining pressure. Then wrap the parts in rags to disassemble them CAUTION ‘The engine is equipped with a rubber impeller type of salt water pump, do not turn the engine in the opposite direction. The rubber impeller vanes may be twisted and damaged. 5-15.2 Periodic inspection schedule © Conduct your checks based operating hours or elapsed time, whichever comes first. The operating hours can be estimated from the hour meter. © Keep the inspection tools handy so that inspections and maintenance can be made readily. ‘© Use only genuine parts trom Yanmar. Other parts may be substandard and can reduce the Ife of the engine. ‘© items marked with a * in the maintenance list should be checked after consulting with us, or our dealers, A service contract with our dealers is highly recommended for you to receive excellent care of your engine. ©: Check or drain and clean, refill, adjust, lubricate, repair or replace if necessary. ©: Replace Service period | Every | Every | Every | Every | Every Item | Daily | 50 | 250 | 500 | 1,000] 2,500 hours | hours | hours | hours | hours Fuel Check fuel level and |G | | system | refill | Drain fuel tank ° eee (When repien: feposit and water ree 1 T — | Drain fuet filter and | fuel-water separator ° | deposit and water Replace Fuel filer element | Light (Gas)otT | 9 Heavy Diesean | i Te] ] (ice | Grek premre | | ry tion system | Cheek oil level and refill |, | (oil pan and reverse gear) Drain oil filter deposit | ° Replace oil filter elements | lo | Fin aco r | [e Replace oil pane Engine | Light (Gas)on © Heavy @ieseboil © i ® | Reverse (Marine) gear 2000 (ist rs time) 5-2Service period Every | Every | Every | Every | Every Item Daily | 50 | 250 | 500 | 1,000 | 2,500 | hours | hours | hours |hours | hours as | Cooling | Check cooling water | i seawater | discharging condi- ° | | system | tion | L |_| a Check and reptace | | sea water pump | | o |e impeller Check anticorrosive { lo | |. zine | onl ry 1 | Giean sea water system I | | 7 j | Cooling | Check cooling water | | fresh ‘temperature I | water 4 system | _Check cootant level °o | | ; Change coolant | * Clean fresh water | | | ° | system | | | Fuel Check injection timing | | injection Fy } mies Overhaul fuel feed | a and nozzle|_ PUMP Check injection pres- | ° sure and spray form | | | Replace injection | eS nozzie i Cylinder | Check Valve clearance head 1 — — Retighten head bolts | ° T 5,000 | Lap valve and seat | hrs ] 7 Turbo- | Clean prefilter and | o | | charger turbocharger | | Check air/gas teakege | © | | 5000 * Overhaul “hesService period 1 om Every | Every | Every | Every | Every Daily | 80 | 250 | 500 | 1,000 | 2,500 hours | hours | hours | hours | hours Boost air | Check anticorrosive zinc ° cooler Drain Boost air cooler > deposit Drain manifold deposit | 0 ° Check remote control wire (ise ° E time) | | Electric | Check warning lamp ° | Check battery = electrolyte level ° Check alternator drive ° belt tension Check wire harness ° ° Rexighion hose clips ne a (Fuel, ud, cooling water, breather and air ine) time} Check and replacement of rubber hoses © Check: per 2500 hrs (Fuel lub ol, cooling water, beater and airline) © Replacement : per 5000 hrs [Reverse [® ] marine) | Check oi! cooler om gear | rs toocarne Troon strainer | hs Check anticorrosive | zine | 2009.4.1R, 5-45.3 Inspection Procedure 5.3.1 Torque of nuts and bolts Overtightening nuts and bolts will damage the threads or heads of bolts. Undertightening them will cause oil to leak from the mating parts and also damage the joined parts. Nuts and bolts should be kept tightened to the proper torque. We recommend the use of torque measurring tools when tightening bolts and nuts. (1) Standard torque values The following table is the torque for bolts marked “7”. (JIS class 7T) @ © Apply 60% of the torque listed below for bolts not marked “ © Use 80% of the torque for bolts made of aluminum or aluminum alloys. © Do not apply oil on bolts, nuts or washers. “Thread diameter x oReh (ml TMEXTO [Mexize | MiOxiS | Widens] Wiexis | wisxiS Head eimension across 2 pepe] | * fe | # (om) ! ‘Torque Nem feat rm) | Teena? pos.) | sso | 4525.51 20.0 (2) Torque for pipe joint bolts [Thread diameter xpitch (mm) wax | Wie | Max | wiex | wax | Naox | MEX) 1 425 | 425 | 15 45 1s _| 15 15 Feaddmanscnacosamees [tz [17 = | 2] * | * | 8 (en) ue Wm Gm \7z: wis | aS58 | Ga78 | eeSe | TaT8e | TN OT) larson set] co_| ea | fe | pao | bee | Geert | 52 | leas | arae | weet [sess | Sees | Setar | Ll Brass ost2 | os25]eass | esualassal ean | ner | (3) Torque for major components CAUTION © Make sure there are no defects on the nuts and bolts. © Apply lubrication oil to the threads of nuts and bolts. [Parts Thread diameter! Torque N-m_(kgf-m) (A) | Fuel injector fastening nut M12 8844.9 (940.5) @) | cylinder head bolts Miz 31429.8 (3241) (cy Mi2 8844.9 (940.5) (0) | Main cap bots M22 471£20 (4842) (&) | Connecting rod bolts M18 | 294+9.8 (3041) F) | Fiywhee! fastening bolts M20 44120 (4542) 5-5[Head bolts tightening procedure} (1) Remove the intake/exhaust valve rocker arms, Ag Fuel indector Retighten the botts, in the order illustrated on Ss the right, to the torque listed below. Check the valve clearance atter tightening. (8):O0 ~ © (C):@ (2) After disessembiing the cylinder head the head gaskets with new ones. Ther the head bolts in three stages. Bolt Tightening order Torque N-mi(kgf-m) ] First round | Second round | __Finaltorque | Main bot (M 20) | O- © 98 (10) | 196 (20) | 31449.8(3247) ‘Aux bolt_(M 12) | @ | 29 (3) I 59 (6) | 8844 ,9(9+0.5)| 5-65.3.2 Fuel system 1] Fuel filter (1) Draining the filter: © Remove the plug at the bottom of the filter and drain out any water and dirt. © After draining the filter, reinstall the plug securely Service period | Every 50 hours (2) Replacing the element: © Remove the center filter bolt, then the fitter case and element. © Wash the filter case and replace the element and (O-ring with new ones. ‘© Do not forget to reinstall the spring and washer. Fasten the center bolt securely. © Always make sure to bieed the air after the element has been replaced. Light Every | Service (Gas) oil 1,000 hours period [Heavy Every ese!) of | 500 hours (A) Air bleeding plug (F) O-ring (8) Drain plug (G) Case (C) Element (H) Center bolt (0) Retainer O-ring © Spring Q) Washer 2| Water separator (1) Draining the separator: @ Remove the plug at the bottom of the water separator and drain any water and dirt. © Aiter draining the separator, reinstall the plug securely. (2)Replacing the element: © Remove the center separator bolt, then the filter case and element. © Wash the separator case and replace the element and O-ring with new ones. © Do not forget to reinstall the spring and washer. Fasten the center bolt securely. ‘© Always make sure to bleed the element has been replaced. after the (A) Air bleeding plug {8) Drain plug (C) Center boit (D) Rubber seat (© Element (F) Washer (@) Spring () Case 5-75.3.3 Lubrication oil system 1 Oil pan level checking Check the oil level with the dipstick. Oil level must be maintained between the upper and lower level marks on the dipstick. Add the recommended oil up to the upper level mark, if necessary. Service period Daily (prior to operation) [2] Oil fitter deposit draining Remove the drain plug from the center bolt of the filter to drain water and sediment from inside the filter. Service period Every 250 hours Oil change Wait for about one to two hours after stopping the engine, connect the end of the rotary pump vinyl tube to the oil filer port.and drain oil. Remove the drain plug’ from the oil filter to drain oil out. Fill the oil pan with recommended oil © Engine oil change List| | Every500 hours) To Service [2s of Cea eas Every 250 hours| “| (Diesel) of} )FMer cap mm U © Change reverse gear oi! [YX-161L-1] 1st time 50 hours Service period 2nd time! Every and on | 1,000 hours 5-8 Rotary pump[4] Oil filter element replacement Service period Every 500 hours (1) Remove the oil filter drain plugs to drain out oil. (2) Remove the center bolts, and pull out the filter cases and elements. (3) Replace the elements with new ones. Check that the O-rings are in good condition and wipe the fitting faces clean, and pay atten- tion not to allow dust and foreign matter to get in. Retighten oil filter cases with the center bolts, (4) Start the engine and check for oil leaks. Note: Do not lose the spring and washer, that are provided inside the filter, when replacing the element, Adjusting the lub.oil pressure (1) Remove the cap nut and loosen the Tock nut. (2) Adjust the screwing-in of the adjusting bolt to regulate the pressure. Clockwise—The pressure rises, Counterclockwise—The pressure crops. (3) Securely tighten the lock nut and cap nut. Pressure Fegulating valve 5-95.3.4 Cooling water system a) Sea water system Checking and replacement of anticorrosive zincs Service period Every 500 hours Anticorrosive zine is built into the following places: ary Fresh water cooler ...... 7 4 Boost air cooler. . . Engine oil cooler... Reverse gear oil cooler Nun Boost air cooler Fresh water cooler Label i cooler Reverse Waring) gear Remove the anticorrosive zinc and scrape or remove with a wire brush the coating on the zines. If more than 50% of the zine is corroded away, it should be replaced with new zinc. 5-10 New Zinc size Fresh water cooler [O>s, & Engine oil cooler \y Zine SEA 40x40 mm a7) 6 Boost air cooler Zine ine #20%30 mn “Oe Reverse (Marine) gear Zine oil cooler 20x37 mm ®Sep @(2) Checking and replacement of sea water pump impeller and casing Service period Checking Every 1,000 hours Impeller replacement Every 2,500 hours (3) ® Remove the sea water pump cover and pull out the impeller. Check the impeller, wear plate, cover, and mechanical seal for wear or damage. if the wear plate and cover are excessively worn, replace them with new ones. When reassembling the pump, apply grease to the fitting area of the pump shaft and impeller, both end faces of the impeller and the tip of impeller blades, When installing the impeller, posi- tion blades of the impeller as shown in figure at right. Sea water system cleaning impeller Ay impeTier direction a, As the engine is used, coolers become fouled, their cooling effect worsens, and fresh water temperature becomes abnormally high (above 85°C}. Consequently, eliminate fouling of the sea water system, coolers in particular. To clean the sea water system, consult your nearest YANMAR dealer. 5-11Fresh water system (4) Coolant change Service period Every 1,000 hours Use of antifreeze in cold regions where cooling water freezes, be sure to add YANMAR Antifreeze to fresh water cooling systems. Method of use: Minimum atomospheric 5-10 b-15 [+20 |-25 |-30 [+38 |-40 temperature | Percentage of antifreeze 15| 25/301 35/40| 4s| sol 55 to fresh water Volume of antifreeze (£) | 6,5 /10,5112.5/ 15 | 17 | 19 | 21 | 23 (2) Fresh water level checking Service period Daily @_ Remove the filler cap from the fresh water tank, and check coolant level The level should be at the filler neck. If the level is low, add soft water up to the filler neck. A DANGER ‘© Never open the pressure cap while the engine is hot. Steam and hot water can spurt out and burn you badly. Wrap the cap with a rag and open the slowly after the engine has cooled @. down. Fasten the filler cap tightly after checking and adding water. @ On the cooling system with reserve tank, check the coolant level in the re- serve tank, The level should be between the “FULL” and “LOW” level marks. Add soft water up to the “FULL” mark, 5-12®@ Fresh water pump leakage checking Leakage of fresh water may cause serious problems, such as seizure of the engine, as the volume of fresh water decreases. Check that there is no water leakage from the overflow pipe of the fresh water pump. If there is water leakage, your nearest YANMAR dealer. consult Service period | Daily Fresh water system cleaning As the fresh water system becomes dirty naturally, cooling efficiency worsens, and fresh water temperature becomes abnormally high (above 85°C) when the engine is operated for long time; clean fresh water system periodi- cally. At the same time, clean the thermostats. As for periodic servicing, consult your nearest YANMAR dealer. Fresh water pump Drain pipe Service period Every 2,500 hours 5-135.3.5 Checking the Fuel injection Timing Service period Every 5000 hours Standard injection timing (FID) *bTDC: 181° Checking the injection timing {a) Disconnect the No. 1 fuel injection pipe from the fuel injection pump. {b) Turn the flywheel manually until the No. 1 piston is about 35° before T.D.C. on the compression stroke, and then lightly turn the flywheel. Make sure that fuel flows out of the No.1 delivery holder. (d) The injection timing is read on the scale indicated by the “1-67” top mark on the flywheel. (c 2] Adjusting the injection timing (1) Align the “1-6T’mark on the flywheel with the standard injection timing on ‘the crark angle scale. (2) Loosen the two bolts securing the intermediate Joint and drive shaft cowiing. (3) Turn the injection pump shaft slowly until the fuel flow out of the No.1 delivery holder, (When turning the pump shaft,use the bolts securing the intermediate joint and pump timer. ) (4) Tighten the tow coupling bolts evenly. 5-14 No.1 Delivery holder Drive shaft coupling5.3.6 Checking the Fuel Injectors ; {st tne TSU RORS Service period |~ndtime anon every 2500 hors 1] Removing the fuel injector: (1) Remove nuts securing the fuel injection line, return line and injector retainer. (2) Install the draw tool to the injector. (3) Screw the bolt inte the cap nut and by turning the nut to remove the fuel injector. (4) Retainer 8) Cap nut (©) Injector (©) Draw tool © Bolt (F) Nut (G) washer 2 | Adjusting the injection pressure: (1) Remove the fuel injector and clean the nozzle, (2) _ install the injector on a nozzle tester to check the injection pattern and pressure. © Replace the nozzle with a new one if the pattern is not normal. © The injection pressure is adjusted by tuming the adjusting screw with a screwdriver. (A) Nozzie tester ) Injector (©) adjusting screw A CAUTION Keep your face and hands away from the injection Nozzle. Fuel is injected at high pressure. Injection pressure: 27.520.5 MPa (280=5 kgf /ca*)| Case nut torque: 68.8 - 73.4 N-m (7-7.5 kgf-m) (3) Apply molybdenum disulfide grease on the injector. injector retainer fastening nut torque: 44-54 N-m (4,5-5.Skgf-m) © Replacement Service period | Every 5000 hours Remove the injec 5-15 nN nozzle, and replace it with a new one.5.3.7 AdJjusting the Valve clearance Adjusting the valve clearance ‘Adjust the vaive clearances in the following order, when the engine is cool. Waive Clear Gn Cor 03 Jiao nan Toy SSS] Valve clearance: 0.357040 mm for intakelexhaust valves Ignition order: 1-4-2-6-3-5-1 (Cylinder No. 1 is furthest from the fywhee) (1) Tum the fywheel in the normal direction and Position the cylinder at TDC (top dead center). © Match the flywheel TOP mark to the scale. ‘© Do not confuse TOP mark with an overlap TDC. © Set the decompression lever to -RUN- = sition. ke ne Lae] Pe 1B a (2) Loosen the valve bridge lock nuts and adjusting YG, Flywhee! bolts 4-2 turns. {) Loosen the rocker. arm lock nuts and adjusting bolts. (4) Screw in the valve bridge adjusting bott a litle at a time until it just touches the top of the valve and tighten the valve bridge lock nut. (Ad Rocker arm-Exhaust (F)_ Flywheel position (5) Insert a thickness gauge between the valve (As) Rockey arm-tntake 5) Cope rocker arm and the top of the valve bridge. a eat {). Rotation dfection ©) Valve bridge () TOP mark , - ; | Thickness gauge (©) Screw in the adjusting bolt a lite at a time. ‘Secure the lock nut when there is a slight drag on the thickness gauge as it is moved in and out. (7) Tighten the lock nut and make sure the thickness gauge can stil be drawn out with litle force, 5-165.3.8 Checking the Turbo-charger If the turbocharger is fouled, boost air Pressure drops and engine performance deteriorates. Therefore, clean the prefilter and turbocharger periodically. Prefitter i, Every 250 hours Service period | When supply air pressure drops by 10 % as compared with that of trial operation [1] Prefilter cleaning (1) Remove the prefilter from the silencer, and wash it in a mild soap solution. (2) After washing, air dry the prefilter thoroughly at a well-ventilated place. 2] Blower cleaning (1) Remove the prefilter from the silencer, and remove the plug from the water feeding hole. (2) Partially open the drain cock at the bottom of the intake mani- fold. (3) Operate the engine at approxi- mately 1,800 0) (cruising). Feed in about 150 cc of Yanmar turbo- charger washing agent through the water feeding hole within ten seconds. (If Yanmar turbocharger washing agent is not available, prepare a small bottle and a crown cap of cota) Pour a crown cap full of mild soap into the bottle, fill it 70% with soft water and shake and use as washing agent. 5-17{4) Three to five minutes after feeding in washing agent, feed in about 150 ce of fresh water in the same way as step 3. (5) For at least 15 minutes feeding in fresh water, operate the engine under a load at 1,800 min” {rpm}. (6) Tighten the water feeding hole plug and drain cock securely and install prefilter. (7) Compare supply air pressure prior to and after cleaning, if no pressure change is found, repeat the cleaning ten minutes later. 3] Overhaul Consult your nearest YANMAR dealer. Service period | Every 5,000 hurs 5-185.3.9 Checking the Electrical system T] Battery electrolyte level Battery electrolyte decreases as charging and discharging are repeated. Check if = the electrolyte level is 10 ~ 20 mm (0.4 ~ 0.8 in.) above the pole plates. If z level is low, add distilled water, referring to the figure at right. =r <—S_— Service period TOTAL Insufficient 7, Proper Excessive Every 250 hours 2] Alternator drive belt tension If tension of the V-belt is too strong, Concsite/Eleneelsise) wear and tear of the V-belt are more \ rapid if too weak, V-belt slips and the alternator does not charge. Check if the belt tension is 6 ~ 10 mm (0,24~ 0.4 fea in.) by pushing the center of the belt be- t say tween the pulleys with a finger. & To adjust, loosen the alternator pivot and adjusting bolts and move the alter- () nator until the proper belt tension is obtained. AdJusting bolt Pivot Deflection | 6 ~ 10 mm ( 0.24 ~ 0.4 in)| Service period] Every 500 hours 5-195.3.10 Adjusting the Remote control handle i "i Tst time 50 hours Service period |-yrdtime and on Every 500 hours | very irs Remote control handle (B) (a) (A) Governor handle (©) Marine gear handle (©) Scale (0) Cable 1] Governor (Speed control) handle Put the speed control (governor) handle in low speed position (scale : 0). Operate the handle from the position "0" to the position "10", and check if the governor lever moves into the correct position. If there is disalignment between the handie and the governor lever in their position, adjust the control cable by changing the clamping position of the bracket. 2] Marine gear handle Put the marine gear handle in NEUTRAL (scale: N) position. Check if the selecting valve lever moves when the marine gear handle is operated in the HEAD AHEAD and ASTERN position. If there is a disalignment between the lever and [NEUTRAL the handle, adjust the control cable by chang- ASTER ing the clamping position of the bracket. 5-205.3.11 Checking the Viscous damper When the viscous camper ceases to function, the torsional vibrations of the axial systems increase with adverse effect on the engine, and this can lead to breakage of the crankshaft and other parts, Check and replace the viscous damper es follows: (1) Check the damper every 5,000hrs. operation. (2) Remove the damper from the engine, and mee- sure the expansion of the damper cover. expansion of the damper covers b —a a: Dent margin at center b: Dent margin at end (3) Replace it when the expansion of the damper cover exceeds 0.5mm or after use for over 10,000hrs. The tightening torque of the damper fixing bolt is 274.6 N-m (28 kof-m). 5-21 7 Fixing nore th mnie6. TROUBLESHOOTING For repair and maintenance of your machine, consult your Yanmar dealer or service shop. Please have the following information ready when scheduling a service call 1 Engine type and serial number 2 Working time (check the hour meter) 3° Working conditions (load, equipment type) 4 Outline of the symptoms + Exhaust color + Engine sound - Engine starting conditions Type of fuel + Lubrication oil type and viscosity 5. History of problems and repairs CAUTION Do not operate the machine while the meters and alarms are out of erder. Failure of alarm system can cause an accident when any anomaly occurs. 1. Starting troubles and countermeasures Trouble Possible Causes Countermeasures Flywheel does not turn vigorously. (1) Insufficient charge of battery. | 1) Recharge battery. 2) Check and repair of the starting motor. (2) Poor rotation of starting motor. (3) Seizure of working part. | 3) Ckeck and rapair it appropriately. (4) Too-high viscosity of lube oil. | 4) Change it with lube oil of the proper | Viscosity. Starting motor turns over well but does not ignite Fuel is not injected or fuel injection| 1) Bleed and prime injection system. spray condition is defective. 2) Test injection vaives singly and replace needle valves if defective. 3) Check clogging of fuel filter. 4) Check operation of fuel injection pump, plunger, spring and delivery valve, and replace ‘if necessary. 5) Check if fuel is cut-off because of mal- function of remote control or govenor system, Adjust if necessary. (2) Fuel injection timing is in- | 1) Adjust fuel injection timing. correct. 2) Check to see if set marks of timing gears are aligned properly and realign if neces- sary (3) Compression pressure is low. | 1) Lap valves if seal is poor, | and replace if leakage is found, 3) If piston rings are stuck, wash or re- |__ place. 14) If closing time of suction/exhaust valves is unduly retarded, correct timing. 2) Check cylinder head packing for gas leakage [(@ Compression ratio is de- 1) Replace if piston pin metal or erank pin creased, | metal are worn excessively | 2) Replace piston rings if worn excessively, 6-12. During Op erati Trouble Possible Causes Countermeasures L | Engine stopped | suddenly i t i | | G) Fuel injection interrupted due | 1) Check the govenor system and repair or | to woubie of govenor and | replace. govenor gear. | (2) Empty fuel tank, | 2) Refill the tank with (3) Air existing in fuel system. | 3) Bleed air from fuel system. (4) Seizure of working parts as 4) Check and repair or replace the | [piston and bearing | Clutch slippage | (1) Faulty remote control regu- | 1) Repair remote control regulator. and refusal lator. to engage ~ (@) Clutch oil pressure regulator | 2) Check and regulate pressure. valve is loose. G) Trouble with clutch oil sys | 3) Check and repair trouble area. tem. (When an emergency occurs while the ship| is under way, screw in the emergency bolt inside the clutch.) Engine speed | (1) Malfunction of govenor or | 1) Adjust remote control and govenor system drops spontan- ously. remote control system, Inappropriate load. 2) Adjust the load. (Examine the propeller gear and power take-off gear in use. (3) Seizure of piston. 3) Stop the engine, and repair or replace, | (4) Seizure of bearing parts. 4) Stop the engine, and repair or replace them. | (5) Clogging of fuel filter. 5) Replace fuel filter. Fuel pump and fuel injection valve tend to stick. 6) Stop engine and repair or replace. exhaust valves, (7) Output of cylinders is uneven 7) Check fuel pump and fuel injection valve. | Replace if necessary. (7) Air is mixed in fuel injection | 7) Bleed and prime. system, | (8) Water is mixed in fuel | 8) Remove drain from fuel tank and fue! | filter; if not effective. replace with new i fuel oil Color of exhaust | (1) Inappropriate load. 1) Adjust the joad. Examine the propeller | is bad. |. gear and power take-off gear in use | (2) Inappropriate fuel injection timing.| 2) Adiust to the proper fuel injection timing. | |G) Fuel oi! is not appropriate. | 3) Use proper type of fuel oil | (4) Defective injection valves. | 4) Conduct injection test and replace. | (5) Setting of suction/exhaust | 5) Correct valve setting, | valve clearances incorrect. | 1 (6) Gas is leaking from suction/ | 6) Lap valves. I | l 6-2j - 7 | Color of exhaust | Trouble Possible Causes | (8) Fuel injection pressure is too | 8) Adjust injection pressure to 27.50.5 MPa ‘Countermeasures is bad. low (28045 kaf /om*) i (9)Turbo-charger blower is dirty. 9) Clean blower, Inoperable (1) Fuel filter is clogged. 1)Replace fuel filter element. at full load — (2) Fuel pump plunger is worn. | 2) Replace plunger and barrel as @ unit Cylinder ouput |G) Air is mixed in fuel pum 1) Bleed and prime injection system. | pressure cops below specified (2) Excessive clearance in ma- Check the clearances and replace the metal if is unever, pump or fuel pipe. (2) Water is mixed in fuel. 2) Romove drain from fuel tank and fuel filter. If not effective, replace with new fuel (3) Quantity of fuel injection | 3) Check and adjust fuel injection timing, | | is uneven. | (4) Timing of fuel injection is | 4) Check and adjust fuel injection timing, uneven (5) Suction and exhaust valves | 5) Dissemble and clean. tend to stick, | | (6 Fuel injection valve is de- | 6) Check for clogged nozzel and replace if fective. necessary. 7) Check for sticking needle and replace if neces- sary. j Knocking (1) Excess bearing clearance. 1) Check, repair or replace the part (2) Loose crank pin bolts. 2) Check and retighten. | (3) Loose flywheel installment | 3) Check and retighten. Replace if necessary. bolt shaft coupling bolt. | (4) Fuel injection timing | 4) Check and adjust. | | retarded unduly. | |G) Excessive quantities of fu- | S) Check fuel injection pump and injection valve, el being injected due to | repice if necessary. malfunction of fuel injec- | tion pump or fuel injection val_| Engine side (hy Oil is kaking from lube | 1) Check pipes inside and outside engine and | lube oil oil pipes. | make necessary repairs. | level, in bearing and crank pin necessary, Replace filter element Clean and readjust oil pressure. (3) Clogged lube oil filter. 13) {(@) Loose lube oil regulating | 4) valve too ish, 1. Lube oil cooter is dirty. 2. Insufficient cooling water. © babe wapernre | | fonataae | 1. Clean lube oil cooler. 2) Cheek cooling water pump. Replace if neessary,Trouble | Possible Causes | Countermeasures | 7 j H Lube oil | () Dirty Jube oil cooler. | 1) Clean lube oi cooler. temperature u J | is too high (2) Insufficient amount of coo- | 2) Check cooling water pump. | | ling water. (sea water) | | (3) Excessive gas leakage into | 3) Check piston rings and cylinder liner. crank cace. | | (4) Excessive toad. 4) Decrease load. | (9) Thermostat is faulty | 5) Check thermostat replace if necessary. Cooling water | (1) Suction of air together | 1) Check the inlet side pipe joint, part of cool- temperature with cooling water. ing water pump. is t00 high. 5 (2) Insufficient amount of coo-| 2) Check sea water pump. ling water. (sea water) (3) Thermostat is faulty. 3) Check thermostat and replace if 1 (4) Insufficient supply of fresh | 4) Refilt with fresh water (tap water). water. (5) Cooling water pipe system | 5) Check and clean cooling water system. |” is clogged or heavy depo- sits are present, | 6-4Domestic Office YANMAR C@.LTD. Yanmar (Head office) 1-32, Chayamachi, Kita-ku, Osaka §30-8311, Japan Yanmar Marine System CO., LTD. 3-1, 6-Chome, Tsukaguchi-Honmachi, Amagasaki, Hyogo 661-0001, Japan Country Code: 81 Phone: 06-6428-0426 Fax: 06-6428-0485, 1 Marine Operations Dept. @ Production Dept. ‘Tsukaguehl Plant Market Service Group 3-1, 5-Chome, Tsukaguchi-honmachi, Amagasaki, Hyogo, Japan 681-0001 Country Code: 81 Phone: 6-6428-3137 Fax: 6-6421-5549 Overseas Office (Yanmar Eurpope B.V. (YEU) Brugplein 11, 1332 BS Almere-de Vaart, Netherlands ‘Country Code: 31 Phone: 036-5493200 Fax: 036-5493209 (@ Yanmar Asia (Singapore) Corp.Pte.Ltd. (YASC) 4 Tuas Lane, Singapore 638613 Country Code: 65 Phone: 6595-4200 Fax: 6862-5189 © Yanmar America Corp. (YA) (Marine Business Unit) 101 Intemational Parkway Adairsville, GA30103, USA Country Code: 1 Phone: 770-877-9894 Fax: 770-877-9009 Marine Propulsion Engine move. GKH-STE, GKHM-STE OPERATION MANUAL YANMAR CO.,LTD. ‘1st Edition Jan 2003 {ist Revision : April 2009 Issued by : Marine Operations Dept, Edited by : Yanmar Technical Service Co.,Ltd