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Yanmar M220 M220L M220AL Marine Diesel Engine Operation & Overhaul Manual

Yanmar M220 M220L M220AL Marine Diesel Engine Operation & Overhaul Manual

Name: Yanmar M220 M220L M220AL Marine Diesel Engine Operation &amp; Overhaul Manual
SKU: HD-YAN-M220-OPR-OVH
Availability: InStock

Original price was: $39.95.Current price is: $24.95.

Comprehensive Yanmar M220-series diesel engine operation and overhaul reference covering M220, M220L and M220AL variants. Includes engine operation, fuel and lubrication requirements, cooling water, periodic maintenance, cylinder head and piston work, crankshaft and bearing service, fuel injection equipment, turbocharger servicing, tightening torques, wear limits and troubleshooting.

SKU: HD-YAN-M220-OPR-OVH Category: Marine Engine Manuals Tags: Yanmar M220 Marine Diesel Engine Manual, Yanmar M220 Operation Overhaul Manual, Yanmar M220AL Marine Diesel Engine Manual, Yanmar M220L Marine Diesel Engine Manual Vendor: Ignition Service Docs

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Description

Yanmar M220 M220L M220AL Marine Diesel Engine Operation & Overhaul Manual

This Yanmar M220 M220L M220AL Marine Diesel Engine Operation & Overhaul Manual provides detailed operating, maintenance, inspection and internal engine servicing information for the M220 family of six-cylinder diesel engines. Coverage extends from routine starting, running and shutdown procedures through scheduled checking and major dismantling and reassembly work, giving technicians a single reference for both day-to-day engine care and deeper mechanical service.

The manual covers marine main-engine configurations as well as marine auxiliary and land-engine versions identified within the document. Individual model designations include M220-UN, M220-SN, M220-EN, M220L-UN, M220L-SN, M220L-EN, M220AL-UN, M220AL-SN, M220AL-EN, M220L-UX, M220L-SX and M220L-EX.

File Details

Manual type: Operation manual with overhaul, adjustment and troubleshooting procedures
Brand: Yanmar
Engine family: M220, M220L and M220AL
Language: English
Page count: 307 pages
File format: PDF

Engine Operation and Service Information

The Yanmar M220 manual begins with extensive safety guidance for operation and maintenance, then moves into engine descriptions and essential check points. Separate engine-description tables identify the marine main-engine and marine auxiliary/land-engine arrangements, including cylinder configuration, bore, stroke, displacement, compression ratio, rotation, firing order, cooling arrangement, lubricating system, starting system and principal dimensions.

Operating instructions cover preparation before starting, oil-system priming, cooling-water preparation, fuel-system preparation, starting-air checks, initial starting, warming-up, load running and confirmation of engine performance. The manual also explains operating observations such as combustion pressure, exhaust temperature, lubricating-oil temperature, cooling-water temperature and indicated pressures. Procedures for turbocharger washing, fuel injection adjustment, injection timing, rocker-arm lubrication and shutdown are included alongside precautions for heavy-fuel operation.

Maintenance, Inspection and Overhaul Depth

A substantial part of the Yanmar M220 M220L M220AL Marine Diesel Engine Operation & Overhaul Manual is devoted to scheduled inspection and mechanical overhaul. Periodic checking tables are provided for engines using diesel oil, intermediate fuel oil and heavy fuel oil, with separate provisions for emergency-engine service. The schedules cover fuel injection equipment, lubricating systems, pistons, connecting rods, cylinder liners, bearings, crankshaft, cooling-water components, governor equipment, starting-air components, cylinder-head mechanisms, turbochargers, camshaft and associated systems.

The dismantling and reassembly section goes well beyond basic maintenance. It includes cylinder-head removal, valve and valve-seat work, valve guides, fuel injection valves, starting valves and cylinder valves. Piston and connecting-rod servicing addresses removal, carbon cleaning, ring inspection, piston-pin measurement and connecting-rod checks. Cylinder-liner removal and installation, bed-plate inspection, main-bearing and thrust-bearing work, crankshaft inspection and crank deflection measurement are also covered with diagrams and dimensional guidance.

IMAGES PREVIEW

Yanmar M220 M220L M220AL Marine Diesel Engine Operation & Overhaul Manual — PDF page 1 preview

Yanmar M220 M220L M220AL Marine Diesel Engine Operation & Overhaul Manual — PDF page 19 preview

Yanmar M220 M220L M220AL Marine Diesel Engine Operation & Overhaul Manual — PDF page 94 preview

Chapters Covered

Precautions on Safety
- Basic precautions
Precautions on Operation
- Prior to starting the engine
- When starting the engine
- When stopping the engine
Precaution on Maintenance
- Precautions prior to maintenance servicing
- Precautions during maintenance servicing
- Precautions at completion of maintenance servicing
Engine Description
- Marine main engine
- Marine auxiliary engine / land engine
Essential Check Points
Table of Engine Standard Adjustments
Operation
- Operational preparation
- Starting
- Warming-up
- Initial running
- Load running
- Stopping
- Operation cutting off a fuel injection pump
Fuel Oil / Lub. Oil & Cooling Water
- Fuel oil
- Lubricating oil
- Guide for lubricating-oil changing time
- Cooling water
Periodical Checking
- Periodical checking for normal-service engine
- Periodical checking for emergency engine
Dismantling, Reassembling & Adjustment
- Cylinder head and accessories
- Piston and connecting rod
- Cylinder and liners
- Bed plate, main bearings and crankshaft
- Timing gears, camshaft and suction/exhaust valve tappet
- Fuel injection pump and tappet
- Governor and governor gear adjustment
- Lubricating-oil pump, oil cooler and pressure regulating valve
- Cooling-water pump overhaul
- Fuel-feed pump and rocker-arm lubricating-oil feed pump
- Suction and exhaust system
Principal Dimensions of Part Mates for Disassembly & Servicing
Table of Tightening Torques of Major Bolts
Clearances & Wear Limits of Major Parts
Troubleshootings & Counter Measures
- Troubleshooting at starting time
- Troubleshooting during operation

Taken together, these sections support inspection and servicing of the engine from external operating systems through its major internal reciprocating and rotating components. The combination of procedures, adjustment data, tightening information, wear criteria and illustrated reassembly guidance makes the manual useful when diagnosing a fault, planning an overhaul or checking whether a component remains within service limits.

Fuel, Lubrication and Cooling Guidance

The fuel and lubrication chapter covers diesel fuel, intermediate and heavy fuel operation, fuel properties, viscosity and heating guidance, lubricant selection and oil-change judgment. Separate information is given for engine lubricating oil, rocker-arm oil, governor lubrication and turbocharger lubrication. Cooling-water guidance includes recommended fresh-water properties, treatment considerations and rust-inhibitor information.

Complete PDF Bookmark Tree

Complete Bookmarks

The complete bookmarks in the “Yanmar M220 M220L M220AL Marine Diesel Engine Operation & Overhaul Manual” are as follows:

COVERp. 1

CONTENTSp. 2

PREFACEp. 6

OUTLINEp. 6

1. PRECATIONS ON SAFETYp. 8

1-1. Basic Precationp. 8

2. PRECATIONS ON OPERATIONp. 12

2-1. Prior to Starting of the Enginep. 12

2-2. When Starting the Enginep. 13

2-3. When Stopping the Enginep. 14

3. PRECATIONS ON MAINTENANCEp. 15

3-1. Precations Prior to Maintenance Servicingp. 15

3-2. Precations during Maintenance Servicingp. 17

3-3. Precations at Coplection of Maintenance Servicingp. 18

4. LIST OF SAFETY LABELSp. 19

1. ENGINE DESCRIPTIONp. 20

Marine Main Enginep. 20

Marine Auxiliary Engine/Land Enginep. 21

2. ESSENTIAL CHECK POINTS (General Instructions)p. 22

3. TABLE OF ENGINE STANDARD ADJUSTMENTSp. 26

4. OPERATIONp. 28

4-1. Operational Preparationp. 28

4-2. Startingp. 31

4-3. Warming-upp. 32

4-4. Initial Runningp. 32

4-5. Loard Runningp. 32

4-6. Stoppingp. 45

4-7. Operation Cutting Off a Fuel Injection Pumpp. 46

5. FUEL OIL / LUB. OIL & COOLIMG WATERp. 48

5-1. Fuel Oilp. 48

5-2. Lubricating Oilp. 53

5-3. Guide for Lub. Oil Changing Timep. 56

5-4. Cooling Waterp. 58

6. PERIODICAL CHECKINGp. 60

6-1. Perodical Checking (for Normal Service Engine)p. 60

6-2. Periodical Checking (for Emergency Engine)p. 73

7. DISMAINTLING REASSEMBLING & ADJUSTMENTp. 78

7-1. Dismaintling & Reassembly of Cylinder Head & Its Accessoriesp. 78

1) Cylinder headp. 79

2) Suction & exhaust valvesp. 80

3) Valve brige & its guidp. 83

4) Valve rotator (for suc./exh. valve)p. 83

5) Adjustment of suc./exh. valve head clearancep. 83

6) Fuel injection valvep. 84

7) Starting valvep. 86

8) Control valvep. 87

7-2. Removal & Reassembly of Piston & Connecting Rodp. 87

1) Piston & piston pinp. 90

2) Connecting rodp. 91

3) Crank pin metalp. 92

7-3. Withedrawal and Replacement of Cylinder & Linersp. 93

1) Cylinder blockp. 93

2) Cylinder linerp. 93

7-4. Disassembly & Reassembly of Bed Plate, Main Bearings & Crankshaftp. 95

1) Bed platep. 95

2) Main bearing & thrust metalp. 95

3) Crankshaftp. 98

4) Crank deflection measurementp. 99

5) Attaching of front driving couplingp. 100

6) Fitting of front driving coupling oil shieldp. 100

7) Disassembly & reassembly of the flywheel end crankshaft oil shield partp. 100

7-5. Removal and Replacement of Timing Gears, Cam Shaft & Suc./Exh. Valve Tappetp. 101

1) Timing gearp. 101

2) Cam shaftp. 102

3) Suc./exh. valve tappetp. 103

7-6. Overhaul of Fuel Injection Pump & Tappetp. 103

1) Fuel injection pumpp. 103

2) Tappet for fuel pumpp. 105

7-7. Adjustment of Governor & Governor Gearp. 105

1) Governorp. 105

2) Governor driving gearp. 105

3) Adjustment of linkage of governor gearp. 106

7-8. Dismaitling & Reassembling of Lub. Oil Pump, Lub. Oil Cool erp. 107

1) Lub. oil pump (gear type)p. 107

2) Lub. oil coolerp. 107

3) Lub. oil pressure regulating valvep. 108

7-9. Overhaul of Cooling Water Pumpp. 109

7-10. Overhauling of Fuel Feed Pump & Rocker Arm Lub. Feed Pumpp. 110

7-11. Removal & Reassembly of Suction & Exhaust Systemp. 111

1) Air ductp. 111

2) Exhaust manifoldp. 111

3) Turbochargerp. 112

4) Air cooler (intercooler)p. 112

8. PRINCIPAL DIMENSION OF PART MASS FOR DISASSEMBLY & SERVICINGp. 114

8-1. Principal Dimension for Disassembly & Servicingp. 114

8-2. Principal Parts Mass for Disassembly & Servicingp. 115

9. TABLE OF TIGHTENING TORUQUES OF MAJOR BOLTSp. 116

10. CLEARANCES & WEAR LIMITS OF MAJOR PARTSp. 118

11. TROUBLE SHOOTINGS & COUNTER MEASURESp. 122

11-1. Troubleshootings at Starting Timep. 122

11-2. Troubleshootings During Operationp. 123

BOOST AIR TEMPERATURE TWO-STEP CONTROL EQUIPMENTp. 126

1. Featuresp. 128

2. Function and Working of Componentsp. 128

3. Handlingp. 130

4. Maintenance Checkp. 131

5. For Your Informationp. 131

Fig.1. Inter Cooler Heaterp. 133

Fig.2. Air Duct (Inlet)p. 135

Fig.3. Control Equipmentp. 137

PARTS LIST & aTTACHED FIGURESp. 140

INDEX FIGURESp. 140

Fig. 1. Outlinep. 144

Fig. 2. Sectional Viewp. 145

Fig. 3-a). Cylinder Head (Marine Diesel Oil Spec.)p. 147

Fig. 3-b). Cylinder Head (Heavy Fuel Oil Spec.) Fuel Injection Valve (Cooling Type)p. 151

Fig. 3-c). Cylinder Head (Heavy Fuel Oil Spec.) Fuel Injection Valve (Non-cooling Type)p. 155

Fig. 4. Valve Rotatorp. 158

Fig. 5. Valve Mechanismp. 159

Fig. 6. Camshaftp. 161

Fig. 7. Driving Gear Device & Gear Casep. 163

Fig. 8. Cylinder Linerp. 166

Fig. 10. Cylinder Side Cover & Relief Valvep. 167

Fig. 11. Main Bearingp. 169

Fig. 12. Main Moving Part & Flywheel Side Casep. 171

Fig. 13. Piston & Connecting Rodp. 173

Fig. 14-a). Indicator Cockp. 175

Fig. 14-b). Safety Valvep. 176

Fig. 15-a). Fuel Injection Pump (High Pressure Type)p. 178

Fig. 15-b). Fuel Injection Pump (High Pressure Type)p. 182

Fig. 15-c). Fuel Injection Pump Driving Devicep. 185

Fig. 16-a). Fuel Injection Valve (Non-Cooling Type) Marine Diesel Oil Spec.p. 187

Fig. 16-b). Fuel Injection Valve (Non-Cooling Type) Heavy Fuel Oil Spec.p. 189

Fig.16-c). Fuel Injection Valve (Cooling Type) Heavy Fuel Oil Spec.p. 191

Fig. 16-d). Fuel Injection Pipep. 193

Fig. 17-a). Fuel Feed Pumpp. 195

Fig. 17-b). Fuel Feed Pump (with Rocker Arm Oil Feed Pump)p. 199

Fig. 17-c). Fuel Feed Pump (with Rocker Arm Lub. Oil pump)p. 203

Fig. 17-d). Fuel Feed & Cooling Oil Pump (with Rocker Arm Lub. Oil Pump)p. 207

Fig. 17-e). Fuel Feed & Cooling Oil Pumpp. 211

Fig. 17-f). Fuel Feed & Cooling Oil Common Pumpp. 215

Fig. 18-a). Fuel Oil No.1 Filter (25A)p. 219

Fig. 18-b). Fuel Oil No.1 Filter (40A)p. 221

Fig. 18-c). Fuel oil No.1 Filter (50A)p. 223

Fig. 19-a). Fuel Oil No.2 Filter (Notch-wire Type)p. 224

Fig.19-b). Fuel Oil No.2 Filter (Notch-wire Type)p. 225

Fig. 19-c). Fuel Oil No.2 Filter (10μ Heat Insulating)p. 226

Fig. 19-d). Fuel oil No.2 Filter (35μ Steam Jacket)p. 227

Fig. 19-e). Fuel Oil No.2 Filter (35μ Heat Insulating)p. 228

Fig. 20. Lub. Oil Pumpp. 229

Fig. 21-a). Suction Side Lub. Oil Strainer (Single Type)p. 231

Fig. 21-b). Suction Side Lub. Oil Strainer (H Type)p. 232

Fig. 22-a). Delivery Side Lub. Oil Strainer (H Type)p. 233

Fig. 22-b). Delivery Side Lub. oil Strainer (Notch-wire Type)p. 234

Fig. 22-c). Pinion Lub. Oil Stariner (Filter Paper Type)p. 235

Fig. 22-d). Indicator for Differentional Pressurep. 236

Fig. 23-a). Lub. Oil Cooler (7.28 ㎡）p. 237

Fig. 23-b). Lub. Oil Cooler（7.28 ㎡）p. 239

Fig. 23-c). lub. Oil Cooler (10.3 ㎡）p. 241

Fig. 24-a). Lub. Oil Pressure Regulating Valve (for Main Eng.)p. 243

Fig. 24-b). Lub. Oil Pressure Regulating Valve (for Auxiliary Eng.)p. 244

Fig. 25-a). Lub. Oil Thermostatp. 245

Fig. 25-b). Priming Piston Pumpp. 246

Fig. 26-a). Cooling Water Pumpp. 250

Fig. 26-b). Cooling Water Pumpp. 254

Fig. 27-a). Fuel Oil Pressure Regulating Valvep. 257

Fig. 27-b). Cooling Oil Thermostatp. 258

Fig. 27-c). Accumulatorp. 259

Fig. 28. Fuel Injection Valve Leak Pipep. 261

Fig. 29-a). Rocker Arm Oil Feed Pipe Systemp. 263

Fig. 29-b). Pinion Feed Oil Pipe Systemp. 267

Fig. 32-a). Starting Air Distributing Valvep. 270

Fig. 32-b). Control Valvep. 271

Fig. 32-c). Control Valve (Automatic)p. 272

Fig. 33. Starting Valvep. 273

Fig. 34. Starting Air Check Valvep. 274

Fig. 35. Boost Air Pressure Regurating Device (Optional)p. 275

Fig. 36-a). Governor Devicep. 276

Fig. 36-b). Governor Driving Devicep. 280

Fig. 37-a). Suction & Exhaust Pipe System (for Engine Equipped with Turbocharger on the Flywheel Side)p. 283

Fig. 37-b). Suction & Exhaust Pipe System (for Engine Equipped with Turbocharger on the Anti-flywheel Side)p. 287

Fig. 38-a). Air Cooler (YPC-28 Type)p. 291

Fig. 28-b). Air Cooler (YPC-40 Type)p. 292

Fig. 39. Starting Air Reservorp. 293

Fig. 40. Semi-automatic Blower Washerp. 295

Fig. 42. Rocker Arm Lub. Oil Tankp. 297

Fig. 40. Steam Trace Pipe Systemp. 299

YANMAR'S WORLDWIDE SERVICE NETWORKp. 302

The engine standard-adjustment pages provide reference values for piston top clearance, valve timing, valve-head clearances, fuel-injection timing, injection pressure, combustion pressure, fuel-feed pressure, lubricating-oil pressure, cooling-water pressure, operating temperatures and oil quantities. The later tightening-torque and clearance/wear-limit tables complement these settings with servicing data for major fasteners and engine components.

Troubleshooting and Corrective Work

Troubleshooting tables address both starting difficulties and faults that appear while the engine is running. Covered conditions include failure of the flywheel to turn, an engine that turns but does not ignite, uneven cylinder output, abnormal speed reduction, poor exhaust color, inability to reach full load, low lubricating-oil pressure, knocking, excessive lubricating-oil temperature, cooling-water temperature or pressure problems, sudden stopping and low rocker-arm lubricating-oil pressure. Causes and corresponding countermeasures are presented together so the user can move from the observed symptom toward the appropriate inspection or repair.

Get the M220 Service Information You Need

The Yanmar M220 M220L M220AL Marine Diesel Engine Operation & Overhaul Manual supports routine engine operation, scheduled maintenance, fault diagnosis, adjustment and extensive mechanical overhaul work. It gives technicians the procedures, settings, tightening torques, dimensional limits and inspection criteria needed to approach repairs with the correct reference information rather than relying on guesswork. Your manual is supplied as an instant PDF download after purchase, with no shipping required; it can be viewed on compatible computers, tablets or phones and printed when a paper working copy is useful in the workshop or engine room.

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Yanmar M220 M220L M220AL Marine Diesel Engine Operation & Overhaul Manual

Description

Yanmar M220 M220L M220AL Marine Diesel Engine Operation & Overhaul Manual

File Details

Engine Operation and Service Information

Maintenance, Inspection and Overhaul Depth

IMAGES PREVIEW

Chapters Covered

Fuel, Lubrication and Cooling Guidance

Complete Bookmarks

Troubleshooting and Corrective Work

Get the M220 Service Information You Need

Reviews

What Our Customers Say

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