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Yanmar 2V Series, Operation Manual

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2V Operation Manual

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We reserve the right to change specifications and to improve our products without notice or obligation.

Yanmar and 

 are registered 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.

Summary of Contents for 2V Series

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

Page 2: ...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...

Page 3: ...perate 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 da...

Page 4: ..._____________________________________________________ Engine Serial No _____________________________________________________________________ Date Purchased ____________________________________________...

Page 5: ...ler 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 PURP...

Page 6: ...e 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...

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 a...

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 recomme...

Page 9: ...o 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 period...

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 re...

Page 11: ...anual 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 re...

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

Page 13: ...r 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 Warra...

Page 14: ...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...

Page 15: ...ired 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 H...

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

Page 17: ...e 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 avoide...

Page 18: ...perating 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 engi...

Page 19: ...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 fue...

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 prim...

Page 21: ...ntilated 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...

Page 22: ...rious 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...

Page 23: ...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 undergroun...

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...

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 servi...

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 p...

Page 27: ...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...

Page 28: ...e 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 overhea...

Page 29: ...x 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 up...

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 spee...

Page 31: ...e 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...

Page 32: ...ation 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...

Page 33: ...ide 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 pow...

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...

Page 35: ...ulatory 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 th...

Page 36: ...so 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...

Page 37: ...edule 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...

Page 38: ...ling 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 boilin...

Page 39: ...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 eng...

Page 40: ...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 rem...

Page 41: ...aximum 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 p...

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

Page 43: ...tor 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 res...

Page 44: ...ell 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 fla...

Page 45: ...en 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 sk...

Page 46: ...omponents 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 mi...

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 m at HFRR test Bio Diesel...

Page 48: ...l 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 manufa...

Page 49: ...en 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 t...

Page 50: ...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...

Page 51: ...2 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 Figu...

Page 52: ...ot 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...

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 Remo...

Page 54: ...llow 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 loos...

Page 55: ...itional 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 radi...

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 shou...

Page 57: ...nants 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 Engin...

Page 58: ...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...

Page 59: ...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 D...

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 cer...

Page 61: ...aterial 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 EXPLOS...

Page 62: ...e 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 unde...

Page 63: ...ly 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 o...

Page 64: ...he 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 fiv...

Page 65: ...bber 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...

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 activ...

Page 67: ...r 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 exces...

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...

Page 69: ...ant 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 ar...

Page 70: ...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 CAUTI...

Page 71: ...ices 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 distributo...

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...

Page 73: ...el 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...

Page 74: ...GER 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 filte...

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 o...

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 serio...

Page 77: ...c 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 t...

Page 78: ...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 mus...

Page 79: ...ngine 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...

Page 80: ...n 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 ambien...

Page 81: ...n 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...

Page 82: ...n 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 adjustmen...

Page 83: ...AUTION 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...

Page 84: ...s 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 requi...

Page 85: ...he 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...

Page 86: ...itively 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 ma...

Page 87: ...ylinder 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 D...

Page 88: ...e 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 a...

Page 89: ...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...

Page 90: ...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...

Page 91: ...e 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 periodic...

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 Figur...

Page 93: ...ns 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 adj...

Page 94: ...ne 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...

Page 95: ...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 v...

Page 96: ...stributor 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...

Page 97: ...ine 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...

Page 98: ...pray 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 pro...

Page 99: ...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...

Page 100: ...PERIODIC MAINTENANCE 84 2V Operation Manual This Page Intentionally Left Blank...

Page 101: ...e 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 opera...

Page 102: ...ndicator 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 au...

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...

Page 104: ...mber 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 nu...

Page 105: ...losion 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 inju...

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 pa...

Page 107: ...s 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 min...

Page 108: ...LONG TERM STORAGE 92 2V Operation Manual This Page Intentionally Left Blank...

Page 109: ...ICATIONS 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 Confi...

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 Ou...

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 Radiato...

Page 112: ...SPECIFICATIONS 96 2V Operation Manual This Page Intentionally Left Blank...

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