Yanmar 0A2V000-U0000, Operation Manual

Page 1: ...2V series OPERATION MANUAL 2V Operation Manual P N 0A2V000 U0000 INDUSTRIAL ENGINES 2V750 V ...

Page 2: ...d trademarks of Yanmar Co Ltd in Japan the United States and or other countries All Rights Reserved No part of this publication may be reproduced or used in any form by any means graphic electronic or mechanical including photocopying recording taping or information storage and retrieval systems without the written permission of Yanmar Co Ltd 2005 Yanmar Co Ltd ...

Page 3: ...operate the machine to ensure that you follow safe operating practices and maintenance procedures 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 authorized Yanmar industrial engine dealer or distributor Make sure this manual is transferred to subsequent owners This manual should be considered a permanent part o...

Page 4: ...______________________________________________________ Engine Serial No _____________________________________________________________________ Date Purchased _____________________________________________________________________ Dealer ______________________________________________________________________________ Dealer Phone ________________________________________________________________________ ...

Page 5: ...aler or distributor THIS WARRANTY IS PROVIDED IN LIEU OF ALL OTHER WARRANTIES EXPRESS OR IMPLIED YANMAR SPECIFICALLY DISCLAIMS ANY IMPLIED WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE except where such disclaimer is prohibited by law IF SUCH DISCLAIMER IS PROHIBITED BY LAW THEN IMPLIED WARRANTIES SHALL BE LIMITED IN DURATION TO THE LIFE OF THE EXPRESS WARRANTY How Long is the ...

Page 6: ...he Yanmar product is still within the warranty period Thus Yanmar strongly recommends you register your engine as soon as possible after purchase in order to facilitate any future warranty matters You are responsible for the transportation of the engine to and from the repair location as designated by Yanmar To Locate an Authorized Yanmar Industrial Engine Dealer or Distributor You can locate your...

Page 7: ... only obligation to you and your exclusive remedy for breach of warranty Failure to follow the requirements for submitting a claim under this Warranty may result in a waiver of all claims for damages and other relief In no event shall Yanmar or any authorized industrial engine dealer or distributor be liable for incidental special or consequential damages Such consequential damages may include but...

Page 8: ... authorized facility Customer registration is very important for the original retail purchaser to enable Yanmar to provide the best support for your engine At the time of purchase Yanmar highly recommends registering the customer s information through website http www yanmar co jp as soon as possible If it is not possible to access the website please contact the nearest authorized Yanmar industria...

Page 9: ...no charge to you including diagnosis parts and labor Manufacturer s Warranty Period The model year 1998 or later certified and labeled non road compression ignition engines are warranted for the periods listed below If any emission related part on your engine is found to be defective during the applicable warranty period the part will be replaced by Yanmar Engine Type Warranty Period by Number of ...

Page 10: ... by the failure of any warranted part during the warranty period Any replacement part which is functionally identical to the original equipment part in all respects may be used in the maintenance or repair of your engine and shall not reduce Yanmar s warranty obligations Add on or modified parts that are not exempted may not be used The use of any non exempted add on or modified parts shall be gro...

Page 11: ...manual Yanmar recommends that you retain all documentation including receipts covering maintenance on your non road compression ignition engine but Yanmar cannot deny warranty solely for the lack of receipts or for your failure to ensure the performance of all scheduled maintenance Yanmar may deny your warranty coverage of your non road compression ignition engine if a part has failed due to abuse...

Page 12: ...YANMAR WARRANTIES xii 2V Operation Manual This Page Intentionally Left Blank ...

Page 13: ...er or Distributor vi What Yanmar Will Do vii What is Not Covered by this Warranty vii Warranty Limitations vii Warranty Modifications vii Questions viii Customer Registration viii Emission System Warranty ix Yanmar Co Ltd Limited Emission Control System Warranty USA Only ix Your Warranty Rights and Obligations ix Manufacturer s Warranty Period ix Warranty Coverage x Warranted Parts x Exclusions xi...

Page 14: ...s Swirl Pre Combustion 23 Engine Stop Solenoid 24 Governor Lever 24 Before You Operate 27 Diesel Fuel 31 Diesel Fuel Specifications 31 Filling The Fuel Tank 32 Priming The Fuel System 34 Engine Oil 36 Engine Oil Specifications 36 Engine Oil Viscosity 36 Checking Engine Oil 37 Adding Engine Oil 37 Engine Oil Capacity 38 Engine Coolant 38 Engine Coolant Specifications 39 Filling Radiator With Engine...

Page 15: ...uired EPA ARB Maintenance 68 EPA ARB Installation Requirements 68 Tightening Fasteners 69 Standard Torque Chart 69 Periodic Maintenance Schedule 70 Periodic Maintenance Procedures 72 After Initial 50 Hours of Operation 72 Every 200 Hours of Operation 77 Every 400 Hours of Operation 78 Every 1000 Hours of Operation 81 Every 2000 Hours of Operation 83 Troubleshooting 85 Troubleshooting Chart 85 Trou...

Page 16: ...TABLE OF CONTENTS xvi 2V Operation Manual This Page Intentionally Left Blank ...

Page 17: ...de by the message that follows the safety alert symbol A DANGER Danger the word DANGER is in white letters with a red rectangle behind it indicates an imminently hazardous situation which if not avoided will result in death or serious injury Danger is limited to the most extreme situations 0000001en A WARNING Warning the word WARNING is in black letters with an orange rectangle behind it indicates...

Page 18: ...operating and maintenance techniques See your authorized Yanmar industrial engine dealer or distributor for additional training 0000002en A DANGER SCALD HAZARD NEVER remove the radiator cap if the engine is hot Steam and hot engine coolant will spurt out and seriously burn you Allow the engine to cool down before you attempt to remove the radiator cap Securely tighten the radiator cap after you ch...

Page 19: ...s When you remove any fuel system component to perform maintenance such as changing the fuel filter place an approved container under the opening to catch the fuel NEVER use a shop rag to catch the fuel Vapors from the rag are extremely flammable and explosive Wipe up any spills immediately Wear eye protection The fuel system is under pressure and fuel could spray out when you remove any fuel syst...

Page 20: ... certain conditions This engine is equipped with an electric fuel pump When you prime the fuel system turn the key switch to the ON position for 10 to 15 seconds to allow the electric fuel pump to prime the system Failure to comply will result in death or serious injury 0000013en2V A DANGER FIRE AND EXPLOSION HAZARD Only use the key switch to start the engine NEVER jumpstart the engine Sparks caus...

Page 21: ...entilated area away from any combustibles or sources of ignition Failure to comply will result in death or serious injury 0000005en A DANGER FIRE AND EXPLOSION HAZARD Diesel fuel is extremely flammable and explosive under certain conditions Be sure to place the diesel fuel container on the ground when transferring the diesel fuel from the pump to the container Hold the hose nozzle firmly against t...

Page 22: ...erious injury 0000015en A DANGER EXPLOSION HAZARD NEVER check the remaining battery charge by shorting out the terminals This will result in a spark and may cause an explosion or fire Use a hydrometer to check the remaining battery charge If the electrolyte is frozen slowly warm the battery before you recharge it Failure to comply will result in death or serious injury 0000007en A DANGER CRUSH HAZ...

Page 23: ...e been removed from the area Failure to comply could result in death or serious injury 0000002en A WARNING EXHAUST HAZARD NEVER operate the engine in an enclosed area such as a garage tunnel underground room manhole or ship s hold without proper ventilation NEVER block windows vents or other means of ventilation if the engine is operating in an enclosed area All internal combustion engines create ...

Page 24: ... NEVER allow battery fluid to come in contact with clothing skin or eyes Severe burns could result ALWAYS wear safety goggles and protective clothing when servicing the battery If contact with the skin and or eyes should occur flush with a large amount of water and obtain prompt medical treatment Failure to comply could result in death or serious injury 0000007en A WARNING HIGH PRESSURE HAZARD Avo...

Page 25: ... leave the key in the key switch when you are servicing the engine Someone may accidentally start the engine and not realize you are servicing it This could result in a serious injury If you must service the engine while it is operating remove all jewelry tie back long hair and keep your hands other body parts and clothing away from moving rotating parts Failure to comply could result in death or ...

Page 26: ... the equipment Failure to comply could result in death or serious injury 0000006en A WARNING BURN HAZARD Keep your hands and other body parts away from hot engine surfaces such as the muffler exhaust pipe and engine block during operation and shortly after you shut the engine down These surfaces are extremely hot while the engine is operating and could seriously burn you Failure to comply could re...

Page 27: ...r required contact your authorized Yanmar industrial engine dealer or distributor 0000045en CAUTION NEVER remove or attempt to remove the tamper proof devices from the full load fuel adjusting screw or the high speed throttle limit screw on the fuel injection pump and governor assembly These adjustments have been made at the factory to meet all applicable emissions regulations and then sealed NEVE...

Page 28: ...ne performance and avoid premature engine wear NEVER run the engine if the ambient temperature is above 113 F 45 C or below 5 F 15 C If the ambient temperature exceeds 113 F 45 C the engine may overheat and cause the engine oil to break down If the ambient temperature falls below 5 F 15 C rubber components such as gaskets and seals will harden causing premature engine wear and damage Contact your ...

Page 29: ...ix different types of engine coolants This may adversely affect the properties of the engine coolant 0000006en CAUTION NEVER overfill the engine with engine oil ALWAYS keep the oil level between the upper and lower lines on the oil cap dipstick 0000015en CAUTION For maximum engine life Yanmar recommends that when shutting the engine down you allow the engine to idle without load for five minutes T...

Page 30: ... while the engine is running This may damage the starter motor pinion and or ring gear 0000012en CAUTION NEVER attempt to modify the engine s design or safety features such as defeating the engine speed limit control or the fuel injection quantity control Failure to comply may impair the engine s safety and performance characteristics and shorten the engine s life Any alterations to this engine ma...

Page 31: ...re you perform the required periodic maintenance at intervals indicated Failure to follow these guidelines will impair the engine s safety and performance characteristics shorten the engine s life and may affect the warranty coverage on your engine See Yanmar Limited Warranty on page v Consult your authorized Yanmar industrial engine dealer or distributor for assistance when checking items marked ...

Page 32: ...ration Manual CAUTION The maximum air intake restriction shall be 0 43 psi 2 94 kPa 300 mm Aq or less Clean or replace the air cleaner element if the air intake restriction exceeds the above mentioned value 0000046en2V ...

Page 33: ...vide excellent value in an industrial diesel engine These engines are designed to deliver power to driven machines by means of a belt drive In belt drive engine applications a belt drive is used to power the driven machine The engine is designed for a wide range of applications Options are available to customize the application Since designing the application and installing the engine require spec...

Page 34: ... 6 5 4 3 2 1 Radiator Cap If Equipped 2 Cooling Fan If Equipped 3 Starter Motor 4 Air Intake Port 5 Air Cleaner If Equipped 6 No 2 Cylinder 7 Speed Control Lever 8 Muffler If Equipped 9 Exhaust Pipe If Equipped 10 No 1 Cylinder 11 Output Shaft 12 Coolant Pump 13 Oil Drain Plug 14 Oil Filter 15 Oil Cap Dipstick 16 Coolant Reserve Tank 17 Fuel Filter 18 Radiator If Equipped ...

Page 35: ...gulatory labels on Yanmar 2V series engines Figure 2 The typical location of the emission control information label Figure 2 1 and the engine nameplate Figure 2 2 for 2V750 engines is on the side of the engine with the starter motor Engine Nameplate 0002418 2 1 YANMAR DIESEL ENGINE CO LTD 0000287A ...

Page 36: ...lso refer to the Yanmar Co Ltd Limited Emission Control System Warranty USA Only on page ix EMISSION CONTROL LABELS Since emission control regulations are being issued on a global basis it is necessary to identify which regulations a particular engine complies with We have listed several different types of labels you might find on your engine EPA ARB Labels Engine Family The EPA ARB labels have an...

Page 37: ...hedule on page 70 for the replacement frequency Fuel Filter The fuel filter removes contaminants and sediments from the diesel fuel Periodic replacement of the fuel filter is necessary See the Periodic Maintenance Schedule for the replacement frequency Please note that the word diesel is implied throughout this manual when the word fuel is used Fuel Tank The fuel tank is a reservoir that holds die...

Page 38: ...oling fan circulates air through the radiator the heat is transferred to the air Radiator Cap The radiator cap controls the cooling system pressure The cooling system is pressurized to raise the boiling point of the engine coolant As the engine coolant temperature rises the system pressure and the coolant volume increase When the pressure reaches a preset value the release valve in the radiator ca...

Page 39: ...n Turn the key to the ON position This will automatically activate a glow plug timer An indicator light if equipped will go out when properly heated START Turn the key to this position to start the engine As soon as the engine starts release the key and it will automatically return to the ON position Some key switches may be equipped with a feature that prevents you from turning the key to the STA...

Page 40: ...y impair the safety and performance of the machine and shorten its life If adjustment is ever required contact your authorized Yanmar industrial engine dealer or distributor 0000045en CAUTION NEVER remove or attempt to remove the tamper proof devices from the full load fuel adjusting screw or the high speed throttle limit screw on the fuel injection pump and governor assembly These adjustments hav...

Page 41: ...maximum engine speed when the engine is operated without a load The high speed limit screw is adjusted at the factory and then is sealed and a tamper proof plug Figure 4 2 is installed The sealer and plug should not be removed If high idle speed requires an adjustment see your authorized Yanmar industrial engine dealer or distributor The low idle speed limit screw Figure 4 3 sets engine speed whil...

Page 42: ...PRODUCT OVERVIEW 26 2V Operation Manual This Page Intentionally Left Blank ...

Page 43: ...ator cap Securely tighten the radiator cap after you check the radiator Steam can spurt out during engine operation if the cap is loose ALWAYS check the level of the engine coolant by observing the reserve tank Failure to comply will result in death or serious injury 0000002en A DANGER FIRE AND EXPLOSION HAZARD Diesel fuel is extremely flammable and explosive under certain conditions This engine i...

Page 44: ...well ventilated area away from any combustibles or sources of ignition Failure to comply will result in death or serious injury 0000005en A DANGER FIRE AND EXPLOSION HAZARD Diesel fuel is extremely flammable and explosive under certain conditions Be sure to place the diesel fuel container on the ground when transferring the diesel fuel from the pump to the container Hold the hose nozzle firmly aga...

Page 45: ...5en A WARNING HIGH PRESSURE HAZARD Avoid skin contact with the high pressure diesel fuel spray caused by a fuel system leak such as a broken fuel injection line High pressure fuel can penetrate your skin and result in serious injury If you are exposed to high pressure fuel spray obtain prompt medical treatment NEVER check for a fuel leak with your hands ALWAYS use a piece of wood or cardboard Have...

Page 46: ...components to seize and or shorten engine life Prevent dirt and debris from contaminating the engine oil Carefully clean the oil cap dipstick and the surrounding area before you remove the cap NEVER mix different types of engine oil This may adversely affect the lubricating properties of the engine oil NEVER overfill Overfilling may result in white exhaust smoke engine overspeed or internal damage...

Page 47: ... volume Metal content of Na Mg Si and Al should be equal to or lower than 1 mass ppm Test analysis method JPI 5S 44 95 Lubricity Wear mark of WS1 4 should be Max 0 018 in 460 µm at HFRR test Bio Diesel Fuels In Europe and in the United States as well as some other countries non mineral oil based fuel resources such as RME Rapeseed Methyl Ester and SOME Soybean Methyl Ester collectively known as FA...

Page 48: ...el storage containers may be necessary 6 The use of bio diesel fuels that do not comply with the standards as agreed to by the diesel engine manufacturers and the diesel fuel injection equipment manufacturers or bio diesel fuels that have degraded as per the precautions and concerns above may affect the warranty coverage of your engine See Yanmar Limited Warranty on page v Filling The Fuel Tank A ...

Page 49: ...4en A DANGER FIRE AND EXPLOSION HAZARD Diesel fuel is extremely flammable and explosive under certain conditions Before you operate the engine check for fuel leaks Replace rubberized fuel hoses every two years or every 2000 hours of engine operation whichever comes first even if the engine has been out of service Rubberized fuel lines tend to dry out and become brittle after two years or 2000 hour...

Page 50: ...g The Fuel System The fuel system needs to be primed under certain conditions Before starting the engine for the first time After running out of fuel and fuel has been added to the fuel tank After the fuel system maintenance such as changing the fuel filter or replacing a fuel system component 0000002A 1 2 3 A DANGER FIRE AND EXPLOSION HAZARD Diesel fuel is extremely flammable and explosive under ...

Page 51: ...32 2 Open the fuel tank cock 3 Turn the key to the ON position The electric fuel pump feeds fuel to the system 4 When the fuel filter Figure 2 1 is free of air bubbles the engine is ready to start Figure 2 5 NEVER use the starter motor to crank the engine to prime the fuel system This may cause the starter motor to overheat and damage the coils pinion and or ring gear 0002420 1 ...

Page 52: ...not recommend the use of engine oil additives Additional Technical Engine Oil Requirements The engine oil must be changed when the Total Base Number TBN has been reduced to 2 0 TBN mgKOH g test method JIS K 201 5 2 2 HCI ASTM D4739 HCI Engine Oil Viscosity Select the appropriate engine oil viscosity based on the ambient temperature and use the SAE Service Grade Viscosity Chart in Figure 3 Figure 3...

Page 53: ... 4 3 lines on the oil cap dipstick 5 Fully reinsert oil cap dipstick Figure 4 1 and hand tighten Over tightening the oil cap dipstick will damage it Adding Engine Oil 1 Make sure engine is level 2 Remove oil cap dipstick Figure 5 1 Figure 5 3 Add indicated amount of engine oil at the side engine oil filler port Figure 5 2 4 Wait three minutes and check oil level 5 Add more oil if necessary 6 Repla...

Page 54: ...Allow the engine to cool down before you attempt to remove the radiator cap Securely tighten the radiator cap after you check the radiator Steam can spurt out during engine operation if the cap is loose ALWAYS check the level of the engine coolant by observing the reserve tank Failure to comply will result in death or serious injury 0000002en A WARNING BURN HAZARD Wait until the engine cools befor...

Page 55: ...ditional Technical Coolant Specifications ASTM D6210 D4985 US JIS K 2234 Japan SAE J814C J1941 J1034 or J2036 International Filling Radiator With Engine Coolant This procedure is for refilling the radiator for the first time or refilling it after it is flushed Note that a typical radiator is illustrated 1 Check to be sure that all hoses are connected and all clamps are in place 2 Turn the radiator...

Page 56: ... until it is at operating temperature Check the level of engine coolant in the reserve tank When the engine is running and the engine coolant is at normal temperature the coolant level in the tank should be at the FULL HOT mark Figure 6 5 If the engine coolant is not at the FULL HOT mark Figure 6 5 add additional engine coolant to the reserve tank to bring the level to the FULL HOT mark Daily Chec...

Page 57: ...inants If you find any water or contaminants drain the fuel tank and replace the fuel filter Check Diesel Fuel Engine Oil and Engine Coolant Levels Follow the procedures in Diesel Fuel on page 31 Engine Oil on page 36 and Engine Coolant on page 38 to check these levels A WARNING HIGH PRESSURE HAZARD Avoid skin contact with the high pressure diesel fuel spray caused by a fuel system leak such as a ...

Page 58: ...r smooth operation and lubricate or clean as necessary 2 Check engine speed control for proper adjustments Check Indicators Before you operate the engine you should make sure that all of the indicators and or gauges are functioning properly See your specific machine equipment operation manual for details ...

Page 59: ...e safety signs and labels are additional reminders for safe operating and maintenance techniques See your authorized Yanmar industrial engine dealer or distributor for additional training 0000002en A DANGER SCALD HAZARD NEVER remove the radiator cap if the engine is hot Steam and hot engine coolant will spurt out and seriously burn you Allow the engine to cool down before you attempt to remove the...

Page 60: ... terminals may cause a fire or explosion Failure to comply will result in death or serious injury 0000004en A DANGER FIRE AND EXPLOSION HAZARD Diesel fuel is extremely flammable and explosive under certain conditions Only fill the fuel tank with diesel fuel Filling the fuel tank with gasoline may result in a fire and will damage the engine NEVER refuel with the engine running Wipe up all spills im...

Page 61: ...material such as oil hay or dried grass close to the engine during engine operation or shortly after shutdown Failure to comply will result in death or serious injury 0000014en A DANGER FIRE AND EXPLOSION HAZARD Diesel fuel is extremely flammable and explosive under certain conditions Before you operate the engine check for fuel leaks Replace rubberized fuel hoses every two years or every 2000 hou...

Page 62: ...ce have been removed from the area Failure to comply could result in death or serious injury 0000002en A WARNING EXHAUST HAZARD NEVER operate the engine in an enclosed area such as a garage tunnel underground room manhole or ship s hold without proper ventilation NEVER block windows vents or other means of ventilation if the engine is operating in an enclosed area All internal combustion engines c...

Page 63: ...ply could result in death or serious injury 0000005en A WARNING BURN HAZARD Keep your hands and other body parts away from hot engine surfaces such as the muffler exhaust pipe and engine block during operation and shortly after you shut the engine down These surfaces are extremely hot while the engine is operating and could seriously burn you Failure to comply could result in death or serious inju...

Page 64: ...the engine speed and the load on the engine Short periods of maximum engine speed and load are desirable Avoid prolonged operation at minimum or maximum engine speeds and loads for the next four to five hours During the break in period carefully observe the engine oil pressure and engine temperature During the break in period check the engine oil and coolant levels frequently 0000011en CAUTION NEV...

Page 65: ...ubber components such as gaskets and seals will harden causing premature engine wear and damage Contact your authorized Yanmar industrial engine dealer or distributor if the engine will be operated in either temperature extreme Contact your authorized Yanmar industrial engine dealer or distributor if you need to operate the engine at high altitudes At high altitudes the engine will lose power run ...

Page 66: ... for 15 seconds or until indicator light if equipped goes out The switch is spring loaded and will automatically return to the OFF position Turn the key to the ON position This will automatically activate a glow plug timer An indicator light if equipped will go out when properly heated 8 Turn the key clockwise to the START position Release the key as soon as the engine starts It will return to the...

Page 67: ...er than 25 in any direction or if an engine runs for short periods of time less than three minutes at an angle greater than 30 in any direction engine oil may enter the combustion chamber causing excessive engine speed and generating white smoke This may cause serious engine damage 0000010en2V CAUTION New Engine Break In On the initial engine start up allow the engine to idle for approximately 15 ...

Page 68: ... necessary repairs performed 6 Check for white or black smoke from the exhaust system A small amount of white smoke is normal on start up of a cold engine Black exhaust smoke may be an indication that the engine is overloaded or is being over fueled If either condition persists contact your authorized Yanmar industrial engine dealer or distributor 7 Check the fuel level during operation If the fue...

Page 69: ...lant leaks and for proper operation of the indicators and or gauges During the first hour of operation vary the engine speed and the load on the engine Short periods of maximum engine speed and load are desirable Avoid prolonged operation at minimum or maximum engine speeds and loads for the next four to five hours During the break in period carefully observe the engine oil pressure and engine tem...

Page 70: ...n 4 Turn the key to the OFF position and remove it from the key switch 5 If the engine will not be used for six months or longer follow the additional instructions in Long Term Storage on page 89 CAUTION For maximum engine life Yanmar recommends that when shutting the engine down you allow the engine to idle without load for five minutes This will allow the engine components that operate at high t...

Page 71: ...tices and maintenance procedures Machine safety signs and labels are additional reminders for safe operating and maintenance techniques See your authorized Yanmar industrial engine dealer or distributor for additional training 0000002en A DANGER EXPLOSION HAZARD NEVER check the remaining battery charge by shorting out the terminals This will result in a spark and may cause an explosion or fire Use...

Page 72: ... operation if the cap is loose ALWAYS check the level of the engine coolant by observing the reserve tank Failure to comply will result in death or serious injury 0000002en A DANGER FIRE AND EXPLOSION HAZARD Diesel fuel is extremely flammable and explosive under certain conditions Only fill the fuel tank with diesel fuel Filling the fuel tank with gasoline may result in a fire and will damage the ...

Page 73: ...uel is extremely flammable and explosive under certain conditions NEVER remove the fuel cap with the engine running Failure to comply will result in death or serious injury 0000011en A DANGER FIRE AND EXPLOSION HAZARD Diesel fuel is extremely flammable and explosive under certain conditions Before you operate the engine check for fuel leaks Replace rubberized fuel hoses every two years or every 20...

Page 74: ...NGER FIRE AND EXPLOSION HAZARD Diesel fuel is extremely flammable and explosive under certain conditions When you remove any fuel system component to perform maintenance such as changing the fuel filter place an approved container under the opening to catch the fuel NEVER use a shop rag to catch the fuel Vapors from the rag are extremely flammable and explosive Wipe up any spills immediately Wear ...

Page 75: ... 0000013en2V A WARNING EXHAUST HAZARD NEVER operate the engine in an enclosed area such as a garage tunnel underground room manhole or ship s hold without proper ventilation NEVER block windows vents or other means of ventilation if the engine is operating in an enclosed area All internal combustion engines create carbon monoxide gas during operation Accumulation of this gas within an enclosure co...

Page 76: ... away while the engine is operating Check before starting the engine that any tools or shop rags used during maintenance have been removed from the area Failure to comply could result in death or serious injury 0000002en A WARNING BURN HAZARD Keep your hands and other body parts away from hot engine surfaces such as the muffler exhaust pipe and engine block during operation and shortly after you s...

Page 77: ...ic acid NEVER allow battery fluid to come in contact with clothing skin or eyes Severe burns could result ALWAYS wear safety goggles and protective clothing when servicing the battery If contact with the skin and or eyes should occur flush with a large amount of water and obtain prompt medical treatment Failure to comply could result in death or serious injury 0000007en A WARNING HIGH PRESSURE HAZ...

Page 78: ...t NEVER leave the key in the key switch when you are servicing the engine Someone may accidentally start the engine and not realize you are servicing it This could result in a serious injury If you must service the engine while it is operating remove all jewelry tie back long hair and keep your hands other body parts and clothing away from moving rotating parts Failure to comply could result in de...

Page 79: ...engine oil ALWAYS keep the oil level between the upper and lower lines on the oil cap dipstick 0000015en CAUTION Only use the engine coolant specified Other engine coolants may affect warranty coverage cause an internal buildup of rust and scale and or shorten engine life Prevent dirt and debris from contaminating the engine coolant Carefully clean the radiator cap and the surrounding area before ...

Page 80: ...un the engine if the ambient temperature is above 113 F 45 C or below 5 F 15 C If the ambient temperature exceeds 113 F 45 C the engine may overheat and cause the engine oil to break down If the ambient temperature falls below 5 F 15 C rubber components such as gaskets and seals will harden causing premature engine wear and damage Contact your authorized Yanmar industrial engine dealer or distribu...

Page 81: ...on chamber causing excessive engine speed and generating white smoke This may cause serious engine damage 0000010en2V CAUTION New Engine Break In On the initial engine start up allow the engine to idle for approximately 15 minutes while you check for proper engine oil pressure diesel fuel leaks engine oil leaks coolant leaks and for proper operation of the indicators and or gauges During the first...

Page 82: ...en CAUTION NEVER attempt to adjust the low or high idle speed limit screw This may impair the safety and performance of the machine and shorten its life If the idle speed limit screws require adjustment see your authorized Yanmar industrial engine dealer or distributor 0000017en CAUTION Establish a periodic maintenance plan according to the engine application and make sure you perform the required...

Page 83: ...CAUTION The tightening torque in the Standard Torque Chart Page 69 should be applied only to the bolts with a 7 head JIS strength classification 7T Apply 60 torque to bolts that are not listed Apply 80 torque when tightened to aluminum alloy 0000023en2VOM A WARNING EXHAUST HAZARD NEVER operate the engine in an enclosed area such as a garage tunnel underground room manhole or ship s hold without pr...

Page 84: ...ts are needed Genuine replacement parts help ensure long engine life Tools Required Before you start any periodic maintenance procedure make sure you have the tools you need to perform all of the required tasks Ask Your Authorized Yanmar Dealer or Distributor For Help Our professional service technicians have the expertise and skills to help you with any maintenance or service related procedures R...

Page 85: ...The tightening torque in the Standard Torque Chart Page 69 should be applied only to the bolts with a 7 head JIS strength classification 7T Apply 60 torque to bolts that are not listed Apply 80 torque when tightened to aluminum alloy 0000023en2VOM Thread size Pitch mm M6 1 0 M8 1 25 M10 1 5 M12 1 75 M14 1 5 M16 1 5 Tightening Torque in lb 96 9 ft lb 19 2 36 4 65 7 101 7 167 7 N m 10 8 1 0 25 5 2 9...

Page 86: ...nitively The following should be treated only as a general guideline CAUTION Establish a periodic maintenance plan according to the engine application and make sure you perform the required periodic maintenance at intervals indicated Failure to follow these guidelines will impair the engine s safety and performance characteristics shorten the engine s life and may affect the warranty coverage on y...

Page 87: ...Cylinder Head Adjust Intake Exhaust Valve Clearance z 1st time z 2nd after Lap Intake Exhaust Valve Seats z Electrical Equipment Check Indicators c Check Battery c Engine Oil Check Engine Oil Level c Drain Fill Engine Oil 1st time 2nd after Replace Engine Oil Filter Engine Speed Control Check Adjust Governor Lever c Check Adjust Idling Speed z Fuel Injection System Inspect Clean Test Fuel Injector...

Page 88: ...ne does not start recharge the battery After Initial 50 Hours of Operation A DANGER EXPLOSION HAZARD NEVER check the remaining battery charge by shorting out the terminals This will result in a spark and may cause an explosion or fire Use a hydrometer to check the remaining battery charge If the electrolyte is frozen slowly warm the battery before you recharge it Failure to comply will result in d...

Page 89: ...e initial 50 hour engine oil and oil filter change are very important CAUTION Only use the engine oil specified Other engine oils may affect warranty coverage cause internal engine components to seize and or shorten engine life Prevent dirt and debris from contaminating the engine oil Carefully clean the oil cap dipstick and the surrounding area before you remove the cap NEVER mix different types ...

Page 90: ...e new engine oil filter manually by turning it clockwise Figure 2 2 until it contacts the mounting surface Tighten an additional 3 4 of a turn using the filter wrench 4 Add new engine oil to the engine as specified in Adding Engine Oil on page 37 5 Warm up the engine by running it for five minutes and check for any engine oil leaks 6 After engine is warm shut it off and let it sit for 10 minutes 7...

Page 91: ...re 4 and Figure 5 for illustrative purposes only Figure 4 The engine performance is adversely affected when the air cleaner element is clogged with dust Be sure to clean the air filter element periodically A DANGER FIRE AND EXPLOSION HAZARD Diesel fuel is extremely flammable and explosive under certain conditions When you remove any fuel system component to perform maintenance such as changing the...

Page 92: ... from falling into the intake manifold 6 Install the element into the air cleaner case 7 Install the air cleaner cover and replace the cover 8 Insert the two wing bolts into the air cleaner cover Figure 4 2 and tighten the wing bolts Figure 4 1 A CAUTION FLYING OBJECT HAZARD ALWAYS wear eye protection when servicing the engine and when using compressed air or high pressure water Dust flying debris...

Page 93: ...ins with the compressed air If there is a large amount of contamination on the fins apply detergent thoroughly clean and rinse with tap water Adjust Intake Exhaust Valve Clearance First Time Proper adjustment is necessary to maintain the correct timing for opening and closing the valves Improper adjustment will cause the engine to run noisily resulting in poor engine performance and engine damage ...

Page 94: ...ine oil specified Other engine oils may affect warranty coverage cause internal engine components to seize and or shorten engine life Prevent dirt and debris from contaminating the engine oil Carefully clean the oil cap dipstick and the surrounding area before you remove the cap NEVER mix different types of engine oil This may adversely affect the lubricating properties of the engine oil NEVER ove...

Page 95: ...e Filling Radiator With Engine Coolant on page 39 Adjust Intake Exhaust Valve Clearance Second Time and After Proper adjustment is necessary to maintain the correct timing for opening and closing the valves Improper adjustment will cause the engine to run noisily resulting in poor engine performance and engine damage Consult your authorized Yanmar industrial engine dealer or distributor to adjust ...

Page 96: ...istributor to adjust the idling speed This adjustment is needed to obtain the optimum injection pattern for full engine performance A DANGER FIRE AND EXPLOSION HAZARD Diesel fuel is extremely flammable and explosive under certain conditions When you remove any fuel system component to perform maintenance such as changing the fuel filter place an approved container under the opening to catch the fu...

Page 97: ...gine dealer or distributor to flush the cooling system Every 1000 Hours of Operation A DANGER SCALD HAZARD NEVER remove the radiator cap if the engine is hot Steam and hot engine coolant will spurt out and seriously burn you Allow the engine to cool down before you attempt to remove the radiator cap Securely tighten the radiator cap after you check the radiator Steam can spurt out during engine op...

Page 98: ...spray caused by a fuel system leak such as a broken fuel injection line High pressure fuel can penetrate your skin and result in serious injury If you are exposed to high pressure fuel spray obtain prompt medical treatment NEVER check for a fuel leak with your hands ALWAYS use a piece of wood or cardboard Have your authorized Yanmar industrial engine dealer or distributor repair the damage Failure...

Page 99: ...r distributor for this service Check and Replace Fuel Hoses and Engine Coolant Hoses Regularly check the fuel system and engine coolant system hoses If they are cracked or degraded replace them Replace the hoses at least every two years Consult your authorized Yanmar industrial engine dealer or distributor to replace fuel hoses and engine coolant system hoses Every 2000 Hours of Operation A WARNIN...

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Page 101: ...ce before operating the engine 0000028en CAUTION If any indicator illuminates during engine operation stop the engine immediately Determine the cause and repair the problem before you continue to operate the engine 0000029en SYMPTOM PROBABLE CAUSE ACTION REFER TO Indicator If Equipped Turns On Engine Running Engine oil pressure indicator Low level of engine oil Too high an oil level Check and adju...

Page 102: ...indicator See authorized Yanmar industrial engine dealer or distributor Indicator If Equipped Stays On Key Switch is Turned from Start to ON START ON Battery indicator stays ON Faulty alternator See authorized Yanmar industrial engine dealer or distributor Engine oil pressure indicator stays ON Faulty engine oil pressure switch Engine Does Not Start Starter motor operates but engine does not start...

Page 103: ... exhaust smoke Engine overloaded Reduce load Clogged air cleaner element Clean element or replace Replace Air Cleaner Element on page 78 Improper diesel fuel Replace with recommended diesel fuel Diesel Fuel Specifications on page 31 Faulty spraying of fuel injection See authorized Yanmar industrial engine dealer or distributor Excessive intake exhaust valve clearance White exhaust smoke Improper d...

Page 104: ...umber of your engine The driven machine type tractor generator skid steer loader manufacturer s name model and serial number How long the engine has been in service the number of engine hours or the number of calendar months Operating conditions when problem occurs Engine rpm Color of exhaust smoke Type of diesel fuel Type of engine oil Any abnormal noises or vibration Operating environment such a...

Page 105: ...plosion or fire Use a hydrometer to check the remaining battery charge If the electrolyte is frozen slowly warm the battery before you recharge it Failure to comply will result in death or serious injury 0000007en A WARNING BURN HAZARD Batteries contain sulfuric acid NEVER allow battery fluid to come in contact with clothing skin or eyes Severe burns could result ALWAYS wear safety goggles and pro...

Page 106: ... 6 Apply a rust preventive fogging oil into the cylinders 7 Apply a thin coat of anti rust agent to any bare steel engine surface 8 Crank the engine by hand every four to six months 9 Grease exposed parts of the engine speed control system 10 Protect the air cleaner muffler and electrical components alternator starter motor switches from water and dust 11 Disconnect the negative battery cable to p...

Page 107: ...ds for two minutes to circulate oil throughout the lubrication system 3 Prime the fuel system See Priming The Fuel System on page 34 4 Start the engine Allow the engine to idle for approximately 15 minutes while you check for a Proper oil pressure b Fuel engine oil or coolant leaks c Proper operation of the indicators and or gauges 5 Avoid prolonged operation at minimum or maximum engine speeds an...

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Page 109: ...FICATIONS 2V Operation Manual GENERAL Description of Model Number 2 V 750 x V 000 Destination Code Vertical Shaft Version Engine Speed Classification C 3200 rpm D 3000 rpm Engine Displacement Vee Configuration Number of Cylinders ...

Page 110: ... pressure 29 53 in Hg 100 kPa 750 mm Hg Relative humidity 30 Fuel Temperature at Fuel Injector Pump Inlet 104 F 40 C With Cooling Fan Air Cleaner Muffler Yanmar Standard After Engine Break In Period Output Allowable Deviation 3 1 PS 0 7355 kW 1 hp SAE Society of Automotive Engineers 0 7457 kW Type V Twin Vertical Crankshaft 4 Cycle Water Cooled Diesel Engine Combustion System Swirl Pre Combustion ...

Page 111: ... 3300 50 3500 50 Engine Weight Dry 134 7 lb 61 1 kg PTO Position Opposite Flywheel Direction of Rotation Counterclockwise Viewed From Opposite of Flywheel Side Cooling System Liquid Cooled With Radiator Lubricating System Forced Lubrication With Trochoid Pump Starting System Electric Starting Starter Motor DC12V 1 4 kW Alternator DC12V 20A Recommended Battery Capacity 12V 36 Amp Hour 5h rating or ...

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