MARINE AUXILIARY ENGINE GHAL2-N Cod oe GHAL2-HTN GHAL2-DTN a ee Lo Pee eeYANMAR MARINE AUXILIARY ENGINE MODEL : 6HAL2-N, TN, HTN, DTN OPERATION MANUAL ( Thank you for purchasing a YANMAR Marine Auxiliary Engine. [INTRODUCTION] @ This Operation Manual describes the operation, maintenance and inspection of the 6HAL2-N, 6HAL2-TN, 6HAL2-HTN 6HAL2-DTN Yanmar marine auxiliary 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 GHAL2-N, TN HTN, DTN Code No. OASHA-G00300 Operation ManualCONTENTS FOR YOUR SAFETY A~D 1, Location of Parts 2. Specifications .. 3. Instrument Panel and Controls 3-1, Instruments ......... 3-2, Regulator handle 3-3. Engine stop knob 3-4. Battery switch . 4, Fueland Lubricating Oil 2.1.0.0... cece ec c een e eee teens 4-1, Fuel . 4-2, Lubricating oil 5. Operation 5-1. Fuel . ‘ 5-2. Lubricating oil .. 5-3. Cooling system ..... eee 5-4.. Tightening the sea water pump cover . 5-5, Fuel system bleeding ........ 5-6. "Priming the lubricating system . 5-7. inspection before starting. .... 5-8. Starting the engine ... 5-9. Warming-up the engine . 5-10. Operation under load . 5-11, Stopping the engine 5-12. Long term storage .... 0.02... 20 6. Turbocharger .. 0... eee ee eee eee eee eee ee eee e ener ees W7 7. Maintenance . Maintenance schedule Service data and tightening torque Maintenance procedure ... 1) Fuel system. ........ 2) Lubrication system . 3) Cooling system . 4) Fuel injection timing 5) Fuel injection nozzle. .. 8) Retightening cylinder head botts « 7) Valve clearance adjustment 8) Intake manifold draining 9} Battery electrolyte check .System Diagram ....... 06.00. eee eee 8-1. Fuel system .... 8-2. Lubrication system . 83. Cooling system 8-4. Wiring diegram—_—<—<— $$$ << FOR YOUR SAFETY “The majority of problems that occur in the operation, maintenance, and inspection of an engine arise from ignoring safety rules and precautions. In many cases, the users don’t understand or recognize the signs of impending problems. Mishanding can cause burns and serious injuries, and can even lead to death. Before operating this engine, performing maintenance or inspecting this engine, be sure to read this operation manual carefully and follow all of the instructions and precautions described in this manual. 1 Warning symbols Shown below are the warning symbols used in this manual and their meanings. Pay special attention to the remarks preceded by signal words. A DANGER DANGER indicates an imminently hazardous situation which if net avoided WILL result in death or serious injury. which if not avoided COULD result in death or serious injury. A CAUTION CAUTION - indicates a potentially hazardous situation which if not avoided MAY result in minor or moderate injury. t may also be used to alert the user against unsafe practices. ‘Text in this manual that is headlined [NOTICE] contains especially important cautions about product handling, Failure to observe the advice given may cause the product to fail or could lead to damage and breakdown, 2002.7.10R2 Safety precautions 2002.7.10R To prevent being burned by steam or hot water + Never open the filler cap on the fresh water tank while the engine is hot. ‘Steam and hot water will spurt out and can burn you seriously. Wait until the engine has cooled down, wrap a cloth around the filer cap and loosen the cap slowly. + Aifer inspecting the water level, tighten the filer cap firmly Battery ventilation + Never smoke or permit sparks or open flames near the battery while it is being charged. The battery emits explosive hydrogen gas. Locate the battery in a well ventilated place. Caution when supplying fuel * Use only the specitiad fuel type. Never use any other fuel, including gasoline, kerosene, ete. The wrong fuel can cause a fire. + Make sure to stop the engine before adding fuel. Wipe up any spilled fuel. + Never leave any flammable items near the éngine room, To prevent exhaust gas poisoning + -Inhaling exhaust gases is extremely harmful to human health. Be sure to install ventilation openings, ports or ventilators in the engine room. Keep the room well ventilated while the engine is operating. To avoid being caught in moving parts + Do not touch or fet your hands, body or clothes get caught in the moving parts of the engine, such as the front ative shaft, pulley, V-belt, etc., while the engine is operating. You may be seriously inured. + Never operate the engine with the protective covers removed. + Make sure that no tools or rags are left inthe vicinity of the engine. Avoid electrical accidents + Keep your hands away from the electric cable terminals and connections. + Do not carry out any inspections if your hands or clothes are wet. + Awet generator may cause an electric shock or fire by short-ciruiting, ‘To avoid being burned + Pay attention not to touch any parts of the engine which is heated during and immediately after operation.CLES Never operate the engine while disabled + Never operate the engine while under the influence of alcohol or if you are ill or feel unwell Precautions for safe servicing works ) COIS i a a i, i 2002.7.10R Aros sua + Batlery fluid is dilute sulfuric acid. tt can blind you fgets in your eyes or burn your skin. Wash it off immediately if you touch it with a generous, quaniity of fresh water. See the doctor if necessary, Aisepenane nator conten + Be sure to stop the engine and turn off the battery switch before you service it Ifyou must inspect if under operation, never touch the moving parts. Keep your body and clothing weil clear. Mi rroveiono sect sos + To inepect the electric system, never fil to switch off the battery or disconnect the ground (-) fine. + Short-circulting can cause a fire, Mirreverion of burn while removing oll and water + If draining lubrication oil from the engine while it's hot, avoid olf splash. + Remove the cooling water after the engine has cocied down. Avoid @ burn by splashing hot water. [NOTICE] Do not modify the equipment. Never remove the interlock or limiter for speed and fuel injection. Do not modi the parts. Performance and operation Ife may be reduced. [NOTICE] Disposal of waste materials: +” Hold oil or liquids fo be disposed in a container, Never dispose of waster oll or other fuids in a sewer, river or the sea. + “Treat the waste materials observing the rules and regulations. Ask a waster recovery service to collect and dispose of3 Warning labels For safe operation, the warning labels should be aff in the correct place. Replace the labels with new ones i lost or damaged. Order them from your service agents oman (cn ee ZEM Bweran, mae Slevcersenay. ievet remove tho cap while the Gruine fg etil| bot east water Sy foutt a wd Barto ‘2002.7-1089 LOCATION OF PARTS Cooling Water Inlet Pipe _/ Fresh Water Pump_/ ‘Sea Water Pump Lubricating Oil Fitter, Fuel Injection Pum Reserve Tank _/ Pressure Cap (Filler Cap) Cooling Water Outlet Pipe Fresh Water Tank Fuel Filter Instrument PanetPressure Cap (Filler Cap) _ Pressure Cop (Fie / Fresh Water Tank Turbocharger Fuel Filter Cooling Water Inlet Pipe Fresh Water Pump wr ‘Sea Water Pump ) Lubricating Oi! Filter Inter-cooler Instrument Panel (SHAL2-HTN,DTN) | —= | \Gooling Water Outlet Pipe Fuel injection Pur mp. rs ae e Reserve Tank, VW aR Wing Pump.Model 6HAL2-N GHAL2-TN Type Vertical, 4-cycle, water cooled diesel engine Combustion system Direct injection Number of cylinders ~ bore x stroke und 6-190 165 Rated revolution speed rpm 1200 | 1,800 | - 1,200 1,500 L 1,800 Rated output kw tHe) | gotta) | nsis6) | - 120 (163) I 180 (244) 150 (204) Rotation direction (viewed from flywheel side} Firing order (from fresh water tank) ‘Turbocharging system Exhaust gas turbine turbocharger Starting system Electric starter motor or air motor (opt Cooling system Lubricating system Fresh water cooling Forced lubrication with gear pump. suolD>1jIDEds BSHAL2-HTN GHAL2-DTN Type | Vertical, 4-cycle, water cooled diesel engine ‘Combustion system Number of cylinders ~ Direct injection bore x stroke mm 6- 130% 165 Rated revolution speed rom | 1,500 1,800 w200 | 1800 1,800 Rated output Kew (HP) 160 (217) 220 (299) 265 (360) 200 (271) 1 255 (346) 305 (414) Rotation direction (viewed from flywheel side) Counterclockwise Firing order (from fresh water tank} Turbocharging system Starting system Cooling system 14-266 Exhaust gas turbine turbocharger with air cooler Electric starter motor or air motor option) Fresh water cooling Lubricating system Forced lubrication with gear pump3 Instrument Panel and Controls Instruments (1) Sea water pressure gauge (2) Fresh water pressure gauge (3) Lubricating oil pressure gauge (4) Tachometer (with hour meter) (5) Supply air pressure gauge (except HAL2-N) (6) Starter switch (7) Charge warning famp (only for engines with alternators) Sea water pressure gauge The sea water pressure gauge shows the cooling water pressure in the sea water pump outlet. The indicator needle should be above 0.2 kg/cm? (0.02 MPa) during operation. Fresh water pressure gauge ‘The fresh water pressure gauge shows the cooling water pressure in the fresh water pump outlet. The indicator needle should be between 0.7-2.0 kg/cm? (0.07-0.2 MPa) during rated operation. Lubricating oil pressure gauge The lubricating oil pressure gauge shows the engine lubricating system pressure. The indicator needle should be between 3.0-4.0 kg/cm? (0.3-0.4 MPa) during rated operation. Tachometer (with hour meter) The tachometer shows the engine revolution speed (rpm). The hour meter shows accumulated operating hours converted into rated revolution speed. Use the indi- cated operating hours as a criterion for regular maintenance and as the total of actual operating hours. Supply air pressure gauge (except 6HAL2-N) ‘The supply air pressure gauge shows the turbocharged supply air pressure. Refer © for details. Starter switch OFF ...... All electric circuits are off. The key can be removed or inserted in this position only. ON... Normal operating position after engine is started. START .... Used to start the engine. The engine will crank until the key is released. The key will then re- turn to the ON position.@ Charge warning lamp The charge warning lamp indicates the charging condition from the alternator (op- tional) to the battery. The lamp goes on when the starter switch key is turned to ON before starting the engine, and goes off when the engine is started. If the lamp lights when the engine is running, check for loose or broken alternator belt. If the belt is in good condition, check the charging system. Ea Regulator handle The regulator handle is used to regulate the engine speed. To increase engine speed, turn the handle clockwise; to decrease speed, turn it counterclock- wise. The handle is equipped with a lock device. (On engines with governor motors, the above directions are re- versed.) El Engine stop knob When this knob is pulled all the way out, the fuel supply is cut-off and the engine stops. Pull the knob until the engine stops completely. El Battery switch This switch is the battery power switch. Power from the battery is cut- off when the switch is turned OFF. Keep the battery switch ON when the engine is in operation and OFF when the engine is not being used. Turn the battery switch OFF when charging the battery with a charger.6 Fuel and Lubricating Oil Selection of fuel and lubricating oils greatly influences the performance and durability of the engine, Therefore, read the following instructions carefully and use proper fuel and lubricating oils. ea Fuel Selection of fuel Use BS CLASS B fuel, which is best for this engine, or diesel fuel oil. Handling of fuel Fuel containing water, dirt and other foreign matter causes poor engine per- formance and shortens the life of the fuel injection valve. When refueling, let the fuel container sit for several days to allow water, dirt and other foreign matter which may be in fuel to settle; then use the clear fuel, Bi Lubricating oil @ Selection of lubricating oil After purchasing After 3-4 days Set the fuel container Suck up the clear fuel aside for several days. with the pipe end above| the bottom. rt and other matter will stay on the bottom. Lubricating oil selection is very important for diesel engines. If improper lubri- cating oil is used, or the lubricating oil is not changed regularly, seizure or prema- ture wear of the parts will occur. Use CC grade oil for BHAL2-N, and CD grade oil for BHAL2-TN, BHAL2-HTN and GHAL2-DTN. Do not mix different brands of oil. If mixed, oil will deteriorate.@ Recommended oil brands API Service Grade CC orCD/ SAE 30 or 40 (FAMM, Caltex) Supplier Brands eR! [DAPHNE MARINE OIL Sx 30,40 cma. _[Sgroess COSMO OIL. | COSMO MARINE SUPER 30,40 SHEVRON | TARO-16 XO30,40 DELO 1000 MARINE OIL 30,40 FUJIKOSAN | FUKKOL MARINE 312, 412 BRITISH PETROLEUM |8P ENERGOL DS3-153,154 EXXMAR 12TP30, 40 EXXON MOBIL | MogiL GARD 312,412 JAPAN. MARINE D13.014 ENERGY/ELF | DISOLA M3015,M4015 NIPPON OiL, CoRPoRATION |MARINE 7103, T104 SHELL GADINIA OIL 30,40 KYGNUS KYGNUS MARINE DX 30, 40 IYANMAR YANMAR MARINE SUPER OIL 30,40 © _ Recommended SAE viscosity grades SAE 10W 20W T T O° 15° Atmospheric temperature (°C) SAE 20 or | SAE 30 | SAE 40 T 30°8 Operation The instructions below are for the initial starting up of the engine. However, to insure trouble-free operation, these instructions should be followed whenever you use your engine. Fuel Make sure that the inside of the fuel tank and fuel lines have been thoroughly cleaned. Then fill the tank with fuel. Eg tubricating oil @ Remove the oil filler cap from the filler neck on the cylinder block side cover. @ Fill the oil pan with recommended lubri- cating oil up to the upper level mark on the dipstick. The dipstick must be pushed in all the way. 6HAL2-N, Lubricating | 6HAL2-HTN, oil capacity | GHAL2-TN, 6HAL2-DTN 900 Cooling system Use clean soft water to fill the fresh water tank. Do not use hard water and/ or dirty water since scales will form on the inside of the fresh water lines result- ing in poor cooling efficiency. @ Before filling the fresh water system tighten the water drain plugs as shown in the figure. Number of drain plugs 5 positions 2008.9.10R@ Remove the pressure cap and fill the fresh water tank with coolant up to the lower shoulder of the filler neck. Also fill the reserve tank with coolant up to the “FULL” mark, SHALZN, Engine GHAL2-TN, eee coon GHAL2-HTN, eee l BHAL2-DTN: aot Reserve tank 118 © 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 ant-corrosive containing nitrites, since it may corrode these parts. © Antifreeze fluid Itis 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) >-15 -20 25 Mixing ratio (in %} 30 35 40 CAUTION A low ratio (less antifreeze fluid) will allow damage to occur from freezing at low temperatures. On the other hand, an high antifreeze ratio can reduce the cooling of the engine. 10 2010. 2.23R,@ Tighten the pressure cap. WARNING: The coolant is under pres- sure when the engine is hot and severe scalding may re- sult if the pressure cap is not securely tightened. El Tightening the sea water pumpcover (Optional rotary rubberpump) A rubber band has been wound inside the sea water pump cover to hold the bolts in place. Be sure to remove the rubber band before tightening the cover. Make sure that the O-ring is properly positioned in the groove; then install the cover and tighten the bolts evenly. Fuel system bleeding The fuel system goes from the fuel tank to the fuel injection valve. If air gets in the fuel system, fuel is not injected. Bleed all air from the system as follows. Rubber Band NOTE: Bleeding should also be carried out when the fuel tank runs dry or the fuel filter is replaced. @ Turn the regulator handle counterclock- wise as far as it will go, then turn it back about 2 turns, @ Loosen the priming pump knob on the fuel feed pump until the priming pump can be moved up and down. 1"Loosen the air bleed plugs on top of the fuel filter, Bleed the air by moving the priming pump’ up and down until air bubbles disappear from the fuel. After the air is completely bled, tighten the air bleed plugs while fuel flows out of the bleed hole. Tighten the priming pump knob, and in- stall the cover on the priming pump. Air bleeding is then complete. The en- gine should start in three to five seconds when the starter switch key is turned to “START”. Priming the lubricating system For the initial lubrication, prime the system as follows. Set the change cock lever on the wing pump to “PRIMING”. Move the wing pump lever until the lubri- cating oil pressure rises to 1 kg/cm? (14 psi). After priming the lubricating system, set the change cock lever to “OPERA- TION" Inspection before starting Check the following before starting the engine. 1) 2) 3) 4) 5) 6) Ei Starting the engine(’ 12 is the fresh water up to the specified level? Js the lubricating oil up to the specified level? Is the Kingston cock opened? Is the Battery switch turned “ON"? Is the engine stop knob pushed all the way in? \s the regulator handle set 2~3 turns from the slowest position? ‘On the model with alr motor, refer to the air motor operation manual The engine will crank when you turn the starter switch key to “START”. After the engine starts, release the key immediately (the key will return to “ON” auto- matically) and allow the engine to run at slowest speed.CAUTION: * Do not continue cranking for more than 15 seconds at a time, If the engine does not start within 15 seconds, release the key, wait for about 15 seconds, and try to start the engine again. * When restarting the engine, make sure that the engine stops completely; then turn the key to “START”. If the engine does not stop completely, the starter pinion and flywheel ring gear may be damaged. EI Warming-up the engine o After starting the engine, run it at no-load (700-800 rpm). about 10 minutes to allow lubricating oil to thoroughly lubricate all sliding parts and bearings and to warm-up the engine, NOTE:. After a new engine starts up, the cooling water (fresh water) and lubri- cating oil levels will drop because the water and oil circulate to the systems in the engine, Therefore stop the engine once, wait for about 10 minutes and check the cooling water and lubricating oil levels. Add if necessary. ‘Check the following items while warming up the engine. (1) Make sure that cooling water (sea water) is being discharged from the water outlet. (2) Make sure that the lubricating oil pressure is more than 1.0 kg/cm? (3) Check the engine for lubricating oil, cooling water or gas leaks. (4) Check the engine for abnormal noises or vibrations. (5) Make sure that the charge warning lamp goes off (only for engines with alter- nators). Operation under load 0 If no problems arise while warming up the engine, operate the engine under load and check the following items: Cooling water (sea water) pressure Sea water discharge is normal if the sea water pressure gauge needle indicates more than 0.2 kg/em? (0.02 MPa) and does not vary widely during rated operation. If the pressure is low or needle varies widely: (1) Check whether the kingston cock is opened all the way. (2) Check the sea water inlet for blockage. (3) Check the sea water line for clogging. Lubricating oil pressure The lubricating oil pressure is normal if the gauge needle reads between 3.0-4.0 kg/cm? (0.3-0.4 MPa) during rated operation. if the oil pressure remains low as the engine speed increases, check the oil level and for oil leakage. 134 Fresh water temperature The fresh water temperature should read between 70-85°C on the fresh water temperature gauge, which indicates the water temperature in the thermostat inlet. If the water temperature exceeds 90°C, it may be due to the following: (1) There may be some problem in the sea water system, (2) Scales may have formed inside the sea water lines (including the thermostat). Lubricating oil temperature The lubricating oil temperature should read less than 90°C on the lubricating oil temperature gauge, which indicates the oil temperature in the oi! cooler inlet. If the oil temperature exceeds 95°C, it may be due to the following: (1) Oil level may be low and/or there may be some leakage in the lubricating system. (2) There may be a problem in the cooling system. Supply air pressure (except SHAL2-N) The supply air pressure is different for each model (rated output}. Read and re- cord the supply air pressure during the initial test operation. If the supply air pressure drops by 10% of the initial test pressure, clean the pre-filter and blower. Even if the pressure doesn’t drop, the pre-filter and blower should be cleaned every 250 hours of operation. Color of exhaust gas Exhaust gas is colorless under normal operating conditions. If black exhaust is emitted, the engine is overloaded, and load must be reduced. Water, lubricating oil and gas leaks, and other operating conditions Always check for water, oil and gas leaks, loose fasteners, as well as for abnormal noises, vibrations and temperatures, CAUTION: * Avoid operating the engine at critical revolution speed. The critical revolution speed range is described on the under side of the tachometer. * Do not remove the pressure cap when the engine is hot. The coolant is under pressure and severe scalding may result. Engine protection device HAL2-N series diesel engines are equipped with switches that sense abnormal conditions (low lubricating oil pressure, high fresh water temperature) during operation. (1) The oi! pressure switch goes on if the lubricating oil pressure drops below 2.5 kg/cm? (0.25 MPa). (2) The thermoswitch goes on if the fresh water temperature (in the thermostat inlet) rises above 95°C,Ea Stopping the engine @ When the engine stop knob is pulled out, 2 3 fuel is cut-off and the engine stops. Pull the knob until the engine stops com- pletely. Remove the key from the starter switch. Close the kingston cock. Turn the battery switch to “OFF”. CAUTION: Never stop the engine with the decompressor handle. Cooling water draining in cold areas In cold areas where the cooling water may freeze, drain the cooling water to pre- vent damage to the engine. (1) Sea water draining a. Close the kingston cock after ‘operating the engine. b. Drain the sea water from the sea water pump by loosening the drain plug, as shown in the figure. ©. If your engine is equipped with optional rotary rubber pump, loosen the pump cover and drain the sea water. After di tighten the pump cover securely. (2) Fresh water draining If anti-freeze is not used in the fresh water, drain the fresh water a. Make sure that the cooling water temperature drops enough to safely remove the pressure cap. b. Drain the fresh water by loosen- ing the water drain plugs, as shown in the figure, ¢. After draining the fresh water, securely tighten the drain plugs. 1816 NOTE: If anti-freeze is used in fresh water, draining is not necessary. Long term storage @ When the engine is not used for long periods of time, it should be prepared for storage in the following manner: (4) (2) (3) (4) (5) (6) Store the engine in a dry; dust-free spot. Drain the cooling water (sea water and fresh water) completely (refer to @). Loosen the V-belt if your engine is equipped with an alternator. Disconnect the battery cables from the engine and fully charge the battery. To prevent power loss, charge the battery once a month. Wipe off the engine exterior and coat it with an anticorrosion agent or clean lubricating oil. To prevent moisture from getting inside the engine, cover the exhaust pipe outlet and intake pipe inlet with vinyl. @ If the engine has not been used for a long time, carry out the following before restarting: (1) (2) (3) Prime the lubricating system. Apply high quality silicone grease to the sea water pump impeller sliding surface. If the cooling water, lubricating oil and fuel have been drained, repeat steps [ES to EBM as explained above.6 Turbocharger sz nm An engine is greatly influenced by blower per- formance. If the blower is dirty, intake air pressure will drop, resulting in poor engine performance. Therefore, clean the prefilter and blower regularly. T | when supply air Prefitter | pressure drops by Service |} —————_ 40%; or after every period | Blower | 250 hours of opera- tion @ (1) (2) (1) (2) (3) (4) Pre filter cleaning Remove the pre filter from the in- take air silencer and wash it in a mild soapy solution. After washing the pre filter, air dry it thoroughly in a well-ventilated location. Reinstall the pre-filter. Blower cleaning Remove the pre filter. Remove the water filler plug from the intake air silencer. Partially open the drain cock on the bottom of the intake manifold (model 6HAL2-HTN and 6HAL2- DTN only). Operate the engine at 75% of load. Pour approximately 150 cc of blower washer solution into the water filler hole for about 10 seconds. NOTE: If blower washer solution is not available, dissolve 2-3 spoons of a mild soap in 1 liter of soft water and use this solution, Wait 3-5 minutes after pouring in the solution, then add clean soft water. Water Fatsing 718 (5) (6) (7) Allow the engine to run for at least 15 minutes at no-load after adding soft water. Stop the engine and tighten the water filler hole plug and drain cock securely. Compare supply air pressures before and after cleaning: If there is no change in pressure, wait 10 minutes and repeat the cleaning.7 Maintenance Maintenance schedule (1) Periodical maintenance is an important factor in keeping the engine in the best condition. in accordance with operating hours given in the following maintenance schedule, perform periodic servicing, (2) When the parts are disassembled for checking andlor servicing, reassemble them propery : Check or drain and clean, refi, adjust, lubricate, repair or replace if necessary. © : Replace @ : Please order YANMAR dealer or distributor to inspect your machine or to replace any engine parts if necessary. Service period It Every | Every | Every | Every | Every em Sons | 250nrs | S00hrs | 1000hrs | 2500hrs (or for | (orevery | (orevery | (or weekly) | monthly) | 3months) | 6months) | annually) Check fuel level and refill ° Drain fuel tank deposit and water nen rors uel (When replenished) system | Drain fuel filter and fuel-water separator deposit and water Replace fuel filter and Fuel-water separator Check oil pressure Check oil level and refill Lubrica- | Drain oil fitter deposit ° tion system — | Replace oil filter mee ® Clean oil cooler e Replace oil Refer to page 25 Check cooling water 5 = ae discharging condition Check and replace Cooling | sea water pump impeller ° e sea water | (Rubber pump) system Check anticorrosive zine ° Clean sea water system @ Every 4000 hours Check cooling water temperature | O Cooling ao — - a - fresh» |Check fresh water level ° water Syetem [Change fresh water @ Every 8000 hours Clean fresh water system @ Every 8000 hours 2009.3.12R 19‘Service period Every | Evey | Every | Even | _6ve trem aiy | S0ns | 250K | Soom | 1000hs | 2500hs (er (or | foravery | foravary | ox weekly) | monthiy) | Smonths) | Gmonths) | annually) vol e Check injection timing ae oe) e Fuel Oe injection | Overhaul fuel feed pump oe, pump and nozzle | Check injection pressure and spray e Replace injection nozzle e Check valve clearance e Cylinder head | Lap valve and valve seat Seont tordyean) Draw-out of piston & removal Oe .0y ‘of carbon corte) Piston Check of piston rings & @ ey replacement ome, (Connect- @ wey Ingrod. {Check of erankpin bearing Er, EAE | esse nr oe liner (orden) Clean prefiter and turbocharger ° Turbo arger i charger, | Check airigas leakage ° SHALZHTN. e SHALZ0TN) | Overhaul Ee, (orev) Drain water and deposits in intake manifold ° (GHAL2-HTN and 6HAL2-DTN only) Re-tighten hose clips. ° ° Fval, Tb. cooling water, breather and ait tine) (ratine) (Check and replacement of rubber hoses (O Check : per 2500 hrs (Fuel, lb.ol, cooling water, breather and airline) @ Replacement : per 5000 hrs (or 2 years) Electric | Check battery electrolyte level ° Gevice | Check alternator drive belt tension «0 Qo0) ° Check on looseness of bots & nuts | O Engine | Check on water/oll/ gas a exterior {leakage at various parts ‘Check wire harness ° 2009.4.28RService data and @ Service data tightening torque Model cHALZN | GHAL2ZTN | GHALZHTN | GHAL2-DTN T T + ——— ' | 1200 | 12°t°bTDC | 13°1°bTDC | get" pTOC | 65°21° bTDC Injection | Engine | — timing | speed | 1,500 | 14°41°bTDC | 11°21°bTDC | 12°41°bTDC | 13°41° TOC (10) rpm —+—— t = | 1,800 : 12.5717 bTDC| 14°41" bTDC | 19°41° BTOC Fuel injection pressure 240 kgiem? (23.5 MPai Intake and Exhaust vaive clearance V-belt tension Lubricating oil pressure 0.4 mm (0.016 in) 6-10 mm in center of belt 3.0-4.0 kg/em? (0.3-0.4 MPa} Fresh Engine water | capacity _ | Reserve tank Lubricating oil capacity @ Tightening torque for major parts Tightening points kg-m feb M16 bolt 28: 25 | 202 : 180 Cylinder head bolts -—— — M12 bolt 55 40 Main bearing cap bolts 35 252 Connecting rod cap bolts Method of clamping refer to page 22 Flywheel mounting bolts 28 202 Cam gear attaching nut Fuel injection valve nuts cone 6HAL2-DIN SHAL2-N, GHAL2-TN, 2008, 9 10R 2010. 2. 23R, 2© Method of Tightening Connecting Rod Nuts 22 (1) Tightening Points (Align Marking-Off) ‘As a management method of stabilizing the axial force, please exercise aligning the marking-off (fitting mark) in the following procedures: a. Apply lube oil to surface / thread portion b. Hand tighten the nut in front and back alternately and evenly with a ratchet wrench, . Tighten the nut in front and back evenly with a torque wrench matching to 118 Nem(12kgfem). d. If the nut’s marking-off is in front of the rod's marking-off, then tighten until it is in the matching position. Note * Replace the nut / bolt, when the nut's mark-ing-off exceeds the rod's marking- off at the time of tightening to 118N«m. (However, it's okay with the below- mentioned tolerance) Tighten to the specified torque (181N-m), and either mark the marking- off (fitting mark) on the nut or mark with indelible ink,when the bolt/nut are newly replaced. Nut marking - off tine Rod marking - offline Connecting rod, Rod bolt, Nut, |Opreation side(front) Apply lube oil Applying oil other than lube oil is prohibited Dislodging torelance of marking-off Nut marking - offline Replace when the nut's marking-off line exceeds the rod's marking-off lin. After replacement, tighten to 181N-m and put a marking-off punching on the nutEi Maintenance procedure ® Fuelsystem (1) Fuel tank draining Before refueling, open the drain cock and drain any deposits and water that have accumulated in the bottom of the fuel tank. (2) Fuel level check Service period | Every day After operation, check the fuel level in the tank and refill if necessary. (3) Fuel Filter and fuel/water separator draining Service period | Every 50 hours Remove the drain plugs from the fuel filter and fuel/water separator; drain deposits and water that have accumulated in the fuel filter and fuel/water separator. After draining the fuel filter and fuel/water separator, tighten the drain plugs securely. (4) Fuel filter element replacement Service period | Every 500 hours Loosen the bolt in the center of the fuel filter and remove the filter case and element. Replace the element with a new one. When installing the new ele- ment and case, use new O-rings; tighten the center bolt securely. CAUTION: * Before installing the element, clean the inside of the filter case, * Do not forget to install the spring, washer and O-rings. * After replacing the element, be sure to bleed air from the fuel system.24 e Lubrication system (1) (2) (3) Lubricating oil level check Service period | Every day Before starting the engine, pull out the dipstick. Wipe clean and reinsert as far as it will go. Pull out the dip- stick and check the oil level. The oil level should be between the upper and lower level marks. Add the re- commended lubricating oil if neces- sary. Lubricating oil filter draining Service period | Every 250 hours Remove the drain plugs from the lubricating oil filters and drain ac- cumulated deposits and water. After draining, tighten the drain plugs securely. Lubricating oil filter element re- placement Service period | Every 500 hours Loosen the bolt in the center of the lubricating oil filter and remove the filter case and element. Replace the element with a new one. Clean the inside of the filter case. When installing the new element and case, use new O-rings; tighten the center bolt securely. CAUTION: Do not forget to install the spring, washer and O-rings. Cone(4) Lubricating oil change There-after model [ 1200min7 [ 1500min-* | 1800min* Service period BHAL2-N Every 1000 hours First time 6HAL2-TN, Every 1000 hours Every 750 hours GHAL2-HTN|[ Evey 000rows] Every 500 hours. GHALZ-DIN [Even (000hous] Every 600 hours Change the lubricating oil while the yy agpeye engine is still warm for complete flakOhaigndianing Fry and rapid draining, : a. Set the change cock lever on the top of the wing pump to “DRAINING”. b, Place an oil drain pan (with ap- proximately 45 2 capacity) under the oil drain port. Drain the lubri- cating oil by moving the wing pump lever. Also drain oil from the lubricating oil filters by plugs. c. After draining completely, install and tighten the filter drain plugs and.turn the change cock lever to “OPERATION”. d. Fill the engine oil pan with the recommended through the oil filler hole, For oil filling procedures, refer to KE removing the drain lubricating oil Etdlandifel @ © Cooling system Sea water system (1) Sea water pump impeller inspec- tion/replacement (optional equip- ment) \ Service| Check Every 1,000 hours period [ Replace! Every 2,500 hours 2008.9.10 R 2526 a, Remove the sea water pump cover and check the side surface of the impeller. b. While turning the flywheel by hand, check the sliding surface of the im- peller through hole A, as shown in the figure. NOTE: When turning the flywheel by hand, set the decompressor handle to “DECOMPRESSION”. Be sure to turn the flyw- heel in the normal rotating direction, c. If any defects are found, pull the impeller out of the pump casing with a pliers and replace it with a new one. (2) Anticorrosion zinc check/replace- ment Service period | Every 500 hours The anticorrosion zinc replacement period will vary with sea water qua- lity or operating conditions, Check the anticorrosion zine regu- larly. Replace it if more than 50% has corroded away. Anticorrosion zine is installed in the following parts: Fresh water cooler .........-- 4 (3) Sea water system cleaning This servicing should be done by a qualified Yanmer dealer. Service period | Every 4,000 hours|After many hours of use, the fresh water cooler, will become clogged and dirty. Therefore clean the system regularly. Fresh water system (4) (5) (6) Fresh water level check Service period | Every day Check the fresh water level in the Reserve-tank while the engine is cool.The level should be between the “FULL” and “LOW” marks. If low, fill with soft water. Fresh water change Service period | Every 8,000 hours ‘Change the fresh water while the engine is cool. a, Remove the pressure cap from the fresh water tank, loosen the fresh water drain plugs and drain the fresh water system (refer toERig] © ). b. After draining the system completely, tighten the drain plugs securely and ill the system with soft water (refer toERR)). Fresh water system cleaning Service period | Every 8,000 hours This servicing should be done by a qualified Yanmar dealer. After many hours of use, the fresh water cooler may be clogged or dirty, inhibiting cooling. Therefore, clear the fresh water system regularly. Clean the thermostat at the same time, @ Fuel injection timing a) Service period | Every 2,500 hours Checking a. Disconnect the No. 1 fuel injection pipe from the fuel injection pump, a28 8 b, Place the decompressor handle in the “DECOMPRESSION” posi- tion. Position the No. 1 piston at about 35° before top dead center on the compression stroke. Turn the flywheel siowly by hand in the normal rotating direction. ¢. Fuel injection timing is when the fuel just begins to flow from the deliv- ery valve holder. Make sure that the 1*6T mark on the flywheel is aligned with the specified angle on the graduation plate. Fuel injection nozzle | Service period | Every 1,000 hours (1) Fuel injection nozzle removal {except GHAL2-DTN) a. Remove the fuel injection pipe, fuel return pipe and fuel injec- tion nozzle mounting nuts. b. Install the injection nozzle puller. ¢. Adjust the support bolts so that the puller body is at a right angle to the injection nozzle, and is about 5 mm (0.2 in} from the top of the injection nozzle. d.Coat the puller bolt with lubri- cating oil, Pull out the injection nozzle by screwing the puller b~ olt into the threaded hole in the valve. Pulier \ Body Support Bolts(2) Checking Install the injection nozzle in the nozzle tester and check the spray. If the spray is fine, and injection spreads in a conical shape from each nozzle hole, and the injection angle is as shown in the figure on the next page, the injec- tion nozzle is in good condition. Check the injection pressure. If it is less than the specified pressure, adjust it. WARNING: Keep hands and face away from injection spray because it is under very high pressure and can cause injury, CAUTION: * Remove carbon from the nozzle sleeve seat surface; replace the seat packing with a new one before installing the nozzle body. * Coat the injection nozzle body with molybdenum disulfide, Do not forget to in- stall the dust seal when installing the injection nozzle @ _ Retightening cylinder head bolts |_ First time | After first 50 hours Service period Thereafter | Every 1,000 hours | Tighten the cylinder head bolts to the specified torque in the sequence shown in the figure. Bot Tightening order] Tightening toraue | Nemligfem} | Main bot (Mia) 25=101 28211 245101 2521 445 (5.540.5} ‘Aux bolt (M12) “é @ © ® 2 @ [ (osa\ (aun) auen)® SOUS, 2930 Head bolts tightening procedure (1) Remove the intake/exhaust valve rocker arms. Retighten the bolts, in the order illusyrated on the right to the torque listed below. Check the valve clearance after tightening. (2) After disassembi ing the cylinder heads, replace the head gaskets with new ones. Then, tighten the heads bolts in three stages. Bolt Tightening Torque Nem (kef-a) order First round | Second round | Final torque ; O~@ | 275101281) Main bolt hi6) -—F =a wets} | 147115) piscioeeeTl Aux bolt @i2)|_©~@ 3413.5) | ——— _[S4#615. 50. 5] @ = Valve clearance adjustment To open and close the valves properly according to the crankshaft rotation, the specified valve clearance must be maintained. If the clearance is too large, it causes valve noise. If the clearance is too small, the valve will not close all the way due to the heat expansion of the valve, and insufficient compression may result. Check and adjust the valve clearance periodically. Checking or adjusting the valve clearance should be done while the engine is cold. First time | After first 50 hours Service period +——— Thereafter | Every 1,000 hours (1) Valve clearance adjustment for 6HAL2-N, GHAL2-TN and 6HAL2- HTN. a. Remove the flywheel housing turning cover, rotate the fly- wheel and align the 1+6T mark on the flywheel with the top mark “¥” on the angle gradua- tion plate. Make sure that the No.1 piston is at top dead cen- ter of the compression stroke by feeling the intake and ex- haust push rods of the No.1 cylinder with your fingers. If the push rods are free, it indicates that the piston is at top dead center. If the push rods are tight, the No.6 piston is at top dead center of the compression stroke.Check the valve clearance of No.1 or No.6 cylinder by insert- ing the feeler gauge between the valve adjusting screw and valve stem. Valve clearance: 0.4mm (0.016 in) To adjust, loosen the lock nut and turn the adjusting screw. After adjust- ment, tighten the lock nut and recheck the clearance. Rotate the flywheel in the normal rotating direction, check and adjust the remaining valve clearances according to the firing order: Fi (from fresh water tank) G6HAL2-HTN, GHAL2-DTN ‘ing order GHAL2-N, GHAL2-TN, | 1-4-2-6.3-5-1 | (2). Valve clearance adjustment for SHAL2-DTN The 6HAL2-DTN engine has four valves (two for intake and two for exhaust) per cylinder. The valve adjustment procedures differ from con- ventional two-valve engines. Carry out the following procedures for valve clearance adjustment according to the firing order. a. Valve bridge parallel adjustment (refer to Fig. 1) Adjustment procedures for the intake and exhaust valves are the same. 1 2. 3. Turn the flywheel until the No. 1 or No. 6 cylinder is at top dead center on the compression stroke. Loosen the valve bridge lock nut and screw out the adjusting screw 1-2 turns. Loosen the rocker arm adjusting screw lock nut and screw in the ad- justing screw until the rocker arm tip just touches the center of the bridge. NOTE: Do not tighten the adjusting screw or it will compress the valve spring, making parallel adjustment impossible, Screw in the valve bridge adjusting screw until it just touches the valve stem, Then loosen the adjusting screw 1/2 turn, and screw it back in until it just touches the valve stem. NOTE: Be careful not to tighten the adjusting screw since it will com- press the valve spring. 315. Keep the adjusting screw in this position and tighten the bridge lock nut with an open end wrench. b, Valve clearance adjustment After completing the valve bridge parallel adjustment, adjust the clearance between the valve bridge and rocker arm using the valve clearance adjust- ment procedures for conventional two-valve engines (refer to page 30). Rocker Acm Valve Bridge Fig. 1) 32@ intake manifold draining (6HAL2-HTN & 6HAL2-DTN only) Service period Every day ‘Vapor during operation may condense and accumulate in the bottom of the in- take manifold. Open the drain cock under the manifold and drain accumu- Jated water completely before and after operating the engine. Also check for water leakage in the inter-cooler. © _ Battéry electrolyte check T Service period i Every 250 hours (1) The battery electrolyte level should be about 10 mm (0.39 in) above = the pole plates. Check the level re- | gularly and add distilled water if LLL: Proper level the level is low. (2) Measure the battery electrolyte spe- (an cific gravity regularly to make sure the battery is charged. The specific VLEET, Too low Too high gravity of the electrolyte of a fully- charged battery is 1.26 at 20°C.SHAL-HTN 6HAL-DTN wa3sks jeng [Eg wpibpig waysks §se 6HAL2-TN, HTN, DTN only oo Connecting Rod Oiier | {for pistoo) Crankshaft Lubricating Dit Cooter ‘Lubricating Oi! Thermostat Fr] carnshatt + Bypass Valve 2 Pressure 2 Regulator 2 jaive late Gear HW 2 Lubricating — Olt Fitter ‘el injection uma. Safety Vaiva Lubricating Oil Pump, i<-——— Discharge C) wore To oll pan wa3sks uojeoiign, (eae98 Intercooler 6HAL2, HTN, DTN only Cylinder Head ‘Sea Water Outlet Fresh Water Cooler ‘Sea Water Pump waisks Sujoog [RRM“we EET 30 AC 17 Starter Switch Starter Motor Battery Switch [Remarks] Charge Lamp Alternator ‘The wiring indicated by must be prepared and routed at the shipyard. . The wire length from the battery to starter motor must be within 10m (33 ft). weszeip Suuim EEYANMAR CO.,LTD. Yanmar (Head office) 1-32, Chayamachi, Kita-ku, Osaka 530-8311, Japan Yanmar Marine System CO., LTD. 1-17, 3-Chome, Chuo, Itami, Hyogo 664-0851, Japan Phone: 81-72-773-5860 Fax: 81-72-773-5872 Marine Operations Division Production Dept. Tsukaguchi Plant Market Service Group 3-1, 5-Chome, Tsukaguchi-honmachi, Amagasaki, Hyogo, Japan 661-0001 Phone: 81-6-6428-3137 Fax: 81-6-6421-5549 Overseas Office (Al Yanmar Eurpope B.V. (YEU) Brugplein 11, 1332 BS Almere-de Vaart, Netherlands Phone: 31-36-5493200 Fax: 31-36-5493209 [© Yanmar Asia (Singapore) Corp.Pte.Ltd. (YASC) 4 Tuas Lane, Singapore 638613 Phone: 65-6595-4200 Fax: 65-6862-6189 (Yanmar America Corp. (YA) (Marine Business Unit) 401 International Parkway Adairsville, GA30103, U.S.A. Phone: 1-770-877-9894 Fax: 1-770-877-9008 1D) Yanmar Engine (Shanghai) Corporation Ltd. No.6 work shop, EUREKA City Industrial Park, Lane 333 Zhujian road, Minhang district, Shanghai, China Phone: 86-21-62210006 Fax: 86-21-62211699 Marine Auxiliary Engine GHAL2-N, GHAL2-TN GHAL2-HTN. GHAL2-DTN OPERATION MANUAL YANMAR CO.LTD. 4st Edition: September 2004 2nd Revision : April 2007 3rd Revision : November 2007 4th Revision : June 2008 5th Revision | September 2008 6th Revision | March 2009 7th Revision : April 2009 8th Revision : February 2010 Issued by : Marine Operations Division Edited by : Yanmar Technical Service Co.,Ltd.