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Table Of Contents

MARINE ENGINES

2YM15

3YM20

3YM30E

3YM30

OPERATION MANUAL

English

Summary of content (114 pages)

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OPERATION MANUAL MARINE ENGINES 2YM15 3YM20 3YM30E 3YM30 en English
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Disclaimers: All information, illustrations and specifications in this manual are based on the latest information available at the time of publishing. The illustrations used in this manual are intended as representative reference views only. Moreover, because of our continuous product improvement policy, we may modify information, illustrations and/or specifications to explain and/or exemplify a product, service or maintenance improvement. We reserve the right to make any change at any time without notice.
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YM OPM_EN.book 1 ページ２０１３年６月７日金曜日午前１１時１１分 TABLE OF CONTENTS INTRODUCTION .............................................................. 1 YM SERIES EMISSION CONTROL SYSTEM WARRANTY-USA, THE ENVIRONMENTAL PROTECTION AGENCY (EPA) ONLY ...................... 2 RECORD OF OWNERSHIP ...................................... 3 SAFETY ........................................................................... 5 SAFETY PRECAUTIONS .......................................... General Information ...................
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YM OPM_EN.book 2 ページ２０１３年６月７日金曜日午前１１時１１分 TABLE OF CONTENTS BEFORE YOU OPERATE .............................................. 25 INTRODUCTION ...................................................... 25 SAFETY PRECAUTIONS......................................... 25 DIESEL FUEL........................................................... Diesel Fuel Specifications .................................. Filling the Fuel Tank........................................... Bleeding the Fuel System ...................
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YM OPM_EN.book 3 ページ２０１３年６月７日金曜日午前１１時１１分 TABLE OF CONTENTS 12/05 PRECAUTIONS ....................................................... The Importance of Periodic Maintenance .......... Performing Periodic Maintenance ..................... The Importance of Daily Checks ....................... Keep a Log of Engine Hours and Daily Checks Yanmar Replacement Parts .............................. Tools Required ..................................................
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YM OPM_EN.book 4 ページ２０１３年６月７日金曜日午前１１時１１分 TABLE OF CONTENTS SPECIFICATIONS .......................................................... 83 PRINCIPAL ENGINE SPECIFICATIONS ................. 2YM15 Engine Specifications ............................ 3YM20 Engine Specifications ............................ 3YM30E Engine Specifications .......................... 3YM30 Engine Specifications ............................ Marine Gear and Sail Drive Specifications......... 83 84 85 86 87 88 SYSTEM DIAGRAMS.....
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YM OPM_EN.book 1 ページ２０１３年６月７日金曜日午前１１時１１分 INTRODUCTION Welcome to the world of Yanmar Marine! Yanmar Marine offers engines, drive systems and accessories for all types of boats, from runabouts to sailboats, and from cruisers to mega yachts. In marine leisure boating, the worldwide reputation of Yanmar Marine is second to none. We design our engines to respect nature. This means quieter engines, with minimal vibrations, cleaner than ever.
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YM OPM_EN.book 2 ページ２０１３年６月７日金曜日午前１１時１１分 INTRODUCTION YM SERIES EMISSION CONTROL SYSTEM WARRANTY-USA, THE ENVIRONMENTAL PROTECTION AGENCY (EPA) ONLY YM series engines come with an emission control system warranty. In all states, 2009 and later compression-ignition engines must be designed, built and equipped to meet the United States EPA emissions standards. Yanmar warrants the emission control system on your YM series engine for the periods of time listed below.
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YM OPM_EN.book 3 ページ２０１３年６月７日金曜日午前１１時１１分 INTRODUCTION 12/05 RECORD OF OWNERSHIP Take a few moments to record the information you need when you contact Yanmar for service, parts or literature. Engine Model: __________________________________________________________ Engine Serial No.
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YM OPM_EN.
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YM OPM_EN.book 5 ページ２０１３年６月７日金曜日午前１１時１１分 SAFETY Yanmar considers safety of great importance and recommends that anyone that comes into close contact with its products, such as those who install, operate, maintain or service Yanmar products, exercise care, common sense and comply with the safety information in this manual and on the machine’s safety decals. Keep the labels from becoming dirty or torn and replace them if they are lost or damaged.
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YM OPM_EN.book 6 ページ２０１３年６月７日金曜日午前１１時１１分 SAFETY SAFETY PRECAUTIONS General Information There is no substitute for common sense and careful practices. Improper practices or carelessness can cause burns, cuts, mutilation, asphyxiation, other bodily injury or death. This information contains general safety precautions and guidelines that must be followed to reduce risk to personal safety. Special safety precautions are listed in specific procedures.
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YM OPM_EN.book 7 ページ２０１３年６月７日金曜日午前１１時１１分 SAFETY 12/05 WARNING Sever Hazard Rotating parts can cause severe injury or death. Never wear jewelry, unbuttoned cuffs, ties or loose-fitting clothing and always tie long hair back when working near moving / rotating parts such as the flywheel or PTO shaft. Keep hands, feet and tools away from all moving parts. Exhaust Hazard Never block windows, vents or other means of ventilation if the engine is operating in an enclosed area.
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YM OPM_EN.book 8 ページ２０１３年６月７日金曜日午前１１時１１分 SAFETY CAUTION The safety messages that follow have CAUTION level hazards. Poor Lighting Hazard Ensure that the work area is adequately illuminated. Always install wire cages on portable safety lamps. Tool Hazard Always use tools appropriate for the task at hand and use the correct size tool for loosening or tightening machine parts.
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YM OPM_EN.book 9 ページ２０１３年６月７日金曜日午前１１時１１分 SAFETY 12/05 NOTICE If you have an installation with two or three engines and only one engine is operating, the water pickup (thru-hull) of the non-running engine(s) should be closed. This will prevent water from being forced past the seawater pump and eventually finding its way into the engine. The result of water entering the engine could cause seizure or other serious problems.
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YM OPM_EN.book 10 ページ２０１３年６月７日金曜日午前１１時１１分 SAFETY LOCATION OF SAFETY DECALS Figure 1, show the location of safety decals on Yanmar YM series marine engines.
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YM OPM_EN.book 11 ページ２０１３年６月７日金曜日午前１１時１１分 PRODUCT OVERVIEW YANMAR YM SERIES FEATURES AND APPLICATIONS Failure to do so can lead to reduced vessel performance, lead to increased smoke levels and cause permanent damage to your engine. The YM series are four-stroke swirl pre-combustion chamber diesel engines equipped with liquid coolant systems. The engine must be installed correctly with coolant lines, exhaust gas lines and electrical wiring.
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YM OPM_EN.book 12 ページ２０１３年６月７日金曜日午前１１時１１分 PRODUCT OVERVIEW New Engine Break-In As with all reciprocating engines, the way your engine is operated during its first 50 hours of operation plays a very significant role in determining how long it will last and how well the engine will perform over its lifetime.
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YM OPM_EN.book 13 ページ２０１３年６月７日金曜日午前１１時１１分 PRODUCT OVERVIEW 12/05 COMPONENT IDENTIFICATION Left Side (Viewed from Flywheel) - 2YM15 3 Right Side (Viewed from Flywheel) - 2YM15 4 5 Figure 1 and Figure 2 illustrate a typical version of a 2YM15 engine. Your engine may have different equipment from that illustrated.
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YM OPM_EN.book 14 ページ２０１３年６月７日金曜日午前１１時１１分 PRODUCT OVERVIEW Right Side (Viewed from Flywheel) - 3YM20 Left Side (Viewed from Flywheel) -3YM20 Figure 3 and Figure 4 illustrate a typical version of a 3YM20 engine. Your engine may have different equipment from that illustrated.
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YM OPM_EN.book 15 ページ２０１３年６月７日金曜日午前１１時１１分 PRODUCT OVERVIEW 12/05 Right Side (Viewed from Flywheel) - 3YM30(E) Left Side (Viewed from Flywheel) - 3YM30(E) Figure 5 and Figure 6 illustrate a typical version of a 3YM30(E) engine. Your engine may have different equipment from that illustrated.
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YM OPM_EN.book 16 ページ２０１３年６月７日金曜日午前１１時１１分 PRODUCT OVERVIEW NAMEPLATES The nameplates of Yanmar YM series engines are shown in Figure 7. Check the engine’s model, output, min-1 and serial number on the nameplate. Please replace if damaged or lost. The engine nameplate is attached to the engine rocker arm cover. The marine gear nameplate (Figure 8) is attached to the marine gear. Check the marine gears model, gear ratio, oil used, oil quantity and serial number.
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YM OPM_EN.book 17 ページ２０１３年６月７日金曜日午前１１時１１分 PRODUCT OVERVIEW 12/05 FUNCTION OF MAJOR COMPONENTS Name of Component Function Fuel Filter Removes dirt and water from the fuel. Drain the filter periodically. The filter element should be replaced periodically. The water separator (if equipped) should be drained periodically. See Draining Fuel Filter / Water Separator on page 65. Fuel Feed Pump Pumps fuel from the tank to the fuel injection system.
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YM OPM_EN.book 18 ページ２０１３年６月７日金曜日午前１１時１１分 PRODUCT OVERVIEW CONTROL EQUIPMENT The equipment in the control room makes remote control operation possible. It consists of the instrument panel, which is connected to the engine by a wire harness, and the remote control handle, which is connected by control cables to the engine control lever and marine gear. Instrument Panel Equipment and Functions The instrument panel is located at the helm.
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YM OPM_EN.book 19 ページ２０１３年６月７日金曜日午前１１時１１分 PRODUCT OVERVIEW 12/05 Meters Instrument Function Tachometer Shows engine rotation speed. Hourmeter Shows number of operating hours. Can be used as a guide for periodic maintenance checks. The hourmeter is located at the bottom of the tachometer. Panel Lights When the power switch is pushed, the gauges will illuminate for easier viewing. Note: The LCD on the instrument panel show hourmeter, display brightness and battery voltage.
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YM OPM_EN.book 20 ページ２０１３年６月７日金曜日午前１１時１１分 PRODUCT OVERVIEW LCD control (hourmeter, display brightness, battery voltage) You can switch (scroll) between displays by pressing the buttons on the bottom. Figure 1 • Switching screens by pressing the right button (Pressing the left button switches the screens in the opposite direction.) Press the power switch. • After 4 seconds, the LCD shows the hourmeter.
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03-Product Overview.fm 21 ページ２０１３年９月１２日木曜日午後３時１３分 PRODUCT OVERVIEW 12/05 Setup Screen Access and Control (Setting the engine speed pulse value for B20/C30 type panel) Use the buttons on the bottom of the LCD display to set the instrument panel. Press the left button to switch between displays. Figure 2 Press and hold both buttons until “SET UP” appears. Press the left button and go to the screen “UNIT”. 1 2 Scroll Press the left button and go to the next screen “ENGINE”.
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YM OPM_EN.book 22 ページ２０１３年６月７日金曜日午前１１時１１分 PRODUCT OVERVIEW Alarms Checking the Warning Devices Before and after engine start, make sure that the instruments and warning devices operate correctly. If the engine runs out of coolant or lubricating oil and the instruments and warning devices fail, they can not give you warning to prevent accidents. This can also lead to incorrect operation and cause further malfunctions of the engine. Before Engine Start 1. Turn on the battery switch. 2.
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YM OPM_EN.book 23 ページ２０１３年６月７日金曜日午前１１時１１分 PRODUCT OVERVIEW 12/05 Accessory power output The harness attached to the panel has a terminal where the signal that is synchronized to the panel power supply can be taken off. (Figure 13) ( Refer to the Wiring Diagrams on page 94.) The maximum current of this output terminal is 3 A. Do not use a current higher than 3 A. For the content of the output terminal, refer to the Wiring Diagrams on page 94.
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YM OPM_EN.book 24 ページ２０１３年６月７日金曜日午前１１時１１分 PRODUCT OVERVIEW Single-Handle Remote Control Head 2 Figure 4 3 2 5 1 1 4 0004511 Figure 15 0004504 Figure 14 Note: Direction of travel will vary depending on installation location.
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YM OPM_EN.book 25 ページ２０１３年６月７日金曜日午前１１時１１分 BEFORE YOU OPERATE INTRODUCTION SAFETY PRECAUTIONS This section of the Operation Manual describes the diesel fuel, engine oil and engine coolant specifications and how to replenish them. Before performing any operations within this section, review the Safety section on page 5.
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04-Before You Operate.fm 26 ページ２０１３年６月２１日金曜日午後４時３分 BEFORE YOU OPERATE DIESEL FUEL B7 diesel fuels must meet certain specifications. Diesel Fuel Specifications The biodiesel fuels must meet the minimum specifications for the country in which they are used: WARNING Fire and Explosion Hazard. Diesel fuel is flammable and explosive under certain conditions. • In Europe, biodiesel fuels must comply with the European Standard EN590-2009, EN14214.
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YM OPM_EN.book 27 ページ２０１３年６月７日金曜日午前１１時１１分 BEFORE YOU OPERATE 12/05 • Even biodiesel fuels that comply with a suitable standard as delivered will require additional care and attention to maintain the quality of the fuel in the equipment or other fuel tanks. It is important to maintain a supply of clean, fresh fuel. Regular flushing of the fuel system, and / or fuel storage containers, may be necessary.
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YM OPM_EN.book 28 ページ２０１３年６月７日金曜日午前１１時１１分 BEFORE YOU OPERATE The fuel outlet should be positioned 20 to 30 mm (0.75 to 1.125 in.) above the bottom of the tank so that only clean fuel is distributed to the engine. Fuel System 1 8 2 3 9 10 0004512 5 Figure 1 2. Keep the fuel container stationary for several hours to allow any dirt or water to settle to the bottom of the container. Use a pump to extract the clear, filtered fuel from the top of the container.
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YM OPM_EN.book 29 ページ２０１３年６月７日金曜日午前１１時１１分 BEFORE YOU OPERATE 12/05 Filling the Fuel Tank Before filling fuel tank for the first time: WARNING Fire and Explosion Hazard. Never overfill the fuel tank. WARNING Fire and Explosion Hazard. Never refuel with the engine running. 5. Replace the fuel cap and hand-tighten. Over-tightening the fuel cap will damage it. Rinse fuel tank with kerosene or diesel fuel. Dispose of waste properly. To fill the fuel tank: WARNING Fire and Explosion Hazard.
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YM OPM_EN.book 30 ページ２０１３年６月７日金曜日午前１１時１１分 BEFORE YOU OPERATE Bleeding the Fuel System The fuel system has an automatic air bleeding device that purges air from the fuel system. No manual air bleeding is required for normal operation. Bleeding must be done if any fuel system maintenance has been performed (replacement of fuel filter, etc.) or if the engine does not start after several attempts. 1 2 3 1. Check the fuel level in the fuel tank. Refill if necessary. 2.
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YM OPM_EN.book 31 ページ２０１３年６月７日金曜日午前１１時１１分 BEFORE YOU OPERATE 12/05 ENGINE OIL Engine Oil Specifications NOTICE Only use the engine oil specified. Other engine oils may affect warranty coverage, cause internal engine components to seize and / or shorten engine life. Never mix different types of engine oil. This may adversely affect the lubricating properties of the engine oil.
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YM OPM_EN.book 32 ページ２０１３年６月７日金曜日午前１１時１１分 BEFORE YOU OPERATE NOTICE If you intend to operate your equipment at temperatures outside the limits shown, you must consult your authorized Yanmar Marine dealer or distributor for special lubricants or starting aids. 4. Remove the dipstick. The oil level should be between upper (Figure 6, (4)) and lower (Figure 6, (5)) lines on the dipstick. 5. Add oil if necessary. See Adding Engine Oil on page 32. 6. Fully reinsert dipstick.
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YM OPM_EN.book 33 ページ２０１３年６月７日金曜日午前１１時１１分 BEFORE YOU OPERATE 12/05 MARINE GEAR OR SAIL DRIVE OIL Marine Gear Oil Specifications 1. Make sure the engine is off. Make sure the engine is as level as possible and wipe area clean around the marine gear filler port (Figure 7, (2)). Use marine gear oil that meets or exceeds the following guidelines and classifications: 2. Remove the filler cap at the top of the housing. KM2P-1 (S), (G) or (GG): 3.
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YM OPM_EN.book 34 ページ２０１３年６月７日金曜日午前１１時１１分 BEFORE YOU OPERATE ENGINE COOLANT Engine Coolant Specifications Note: In the U.S., LLC is required for the warranty to be valid. • Texaco Long Life Coolant (LLC), both standard and premixed, product code 7997 and 7998 • Havoline Extended Life Antifreeze / Coolant, product code 7994 Following the manufacturer’s recommendations, use a proper LLC which will not have any adverse effects on the materials (cast iron, aluminum, copper, etc.
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YM OPM_EN.book 35 ページ２０１３年６月７日金曜日午前１１時１１分 BEFORE YOU OPERATE 12/05 Checking and Adding Coolant Figure 1 Figure 2 1 1 5 3 4 2 0004793 Figure 10 3 2 051169-00X00 Figure 8 1 2 3 4 5 – Coolant Tank / Heat Exchanger – Coolant Drain Plug – Seawater Drain Plug – Seawater Pump – Coolant Pump 1 1 – Stop Solenoid 2 – Coolant Drain Cock 3 – Flywheel Housing 1. Allow the engine to cool. Note: The drain cocks are opened before shipping from the factory.
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YM OPM_EN.book 36 ページ２０１３年６月７日金曜日午前１１時１１分 BEFORE YOU OPERATE Figure 3 Figure 4 1 2 4 1 3 2 4 FULL 3 LOW 0004493 054720-00X00 Figure 11 1 2 3 4 – Filler Cap Tabs – Coolant Filler Cap – Filler Port Notches – Coolant Tank / Heat Exchanger 4. Pour coolant slowly into the coolant tank / heat exchanger (Figure 11, (4)) to avoid air bubbles. Fill until coolant overflows from the filler port. NOTICE Never pour cold coolant into a hot engine. 5.
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YM OPM_EN.book 37 ページ２０１３年６月７日金曜日午前１１時１１分 BEFORE YOU OPERATE 12/05 9. Check the rubber hose (Figure 12, (1)) connecting the reservoir to the coolant tank / heat exchanger. Replace if damaged. CRANKING THE ENGINE Note: If the coolant runs low too often or the coolant level in the coolant tank drops without any change in the level in the reservoir, there may be water or air leaks in the cooling system. Consult authorized Yanmar dealer or distributor.
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YM OPM_EN.book 38 ページ２０１３年６月７日金曜日午前１１時１１分 BEFORE YOU OPERATE Figure 5 Stop solenoid Push (emergency stop) 006224-01E Figure 13 6. Continue cranking the engine for about 5 seconds, checking for abnormal sounds. If you cannot find any abnormal sounds, push the power switch and turn off the engine. Start switch Power switch 042590-00E00 Figure 14 WARNING Never touch or allow your clothes to touch the moving parts of the engine during operation.
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YM OPM_EN.book 39 ページ２０１３年６月７日金曜日午前１１時１１分 ENGINE OPERATION INTRODUCTION SAFETY PRECAUTIONS This section of the Operation Manual describes the diesel fuel, engine oil and engine coolant specifications and how to replenish them. It also describes the daily engine checkout. Before performing any operations within this section, review the Safety section on page 5.
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05-Engine Operation.fm 40 ページ２０１３年６月１８日火曜日午後５時２７分 ENGINE OPERATION WARNING FireandExplosionHazard Never jump-start the engine. Sparks caused by shorting the battery to the starter terminals may cause a fire or explosion. ONLY use the start switch on the instrument panel to start the engine. Sudden Movement Hazard Be sure the boat is in open water away from other boats, docks or other obstructions before increasing engine speed. Avoid unexpected equipment movement.
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YM OPM_EN.book 41 ページ２０１３年６月７日金曜日午前１１時１１分 ENGINE OPERATION 12/05 NOTICE STARTING THE ENGINE • Contact your authorized Yanmar Marine engine dealer or distributor if the engine will be operated outside of this standard temperature range. 1. Open the seacock (if equipped). Never engage the starter motor while the engine is running. Damage to the starter motor pinion and / or ring gear will result.
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YM OPM_EN.book 42 ページ２０１３年６月７日金曜日午前１１時１１分 ENGINE OPERATION If the Engine Fails to Start Before pushing the start switch again, be sure to confirm that the engine has stopped completely. If an attempt to restart is made while the engine is running, the pinion gear of the starter motor will be damaged. NOTICE Never hold for longer than 15 seconds or the starter motor will overheat. Never attempt to restart the engine if the engine has not stopped completely.
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YM OPM_EN.book 43 ページ２０１３年６月７日金曜日午前１１時１１分 ENGINE OPERATION 12/05 Starting with Glow plug (If Equipped) 1. Open the seacock (if equipped). 2. Open the fuel tank cock. 3. Put remote control handle in NEUTRAL. 4. Turn the battery switch on (if equipped). 5. Push the power switch on. Ensure that the instrument panel indicators light and the alarm sounds. This shows that indicators and alarm are working correctly. Note: The coolant high temperature alarm indicator does not come on during start-up. 6.
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YM OPM_EN.book 44 ページ２０１３年６月７日金曜日午前１１時１１分 ENGINE OPERATION REMOTE CONTROL HANDLE OPERATION Acceleration and Deceleration 2 1 3 4 0004513 Figure 2 1 2 3 4 – FORWARD or REVERSE – NEUTRAL – REVERSE or FORWARD – Throttle Handle / Shifting Handle Note: Direction of travel will vary depending on installation location.
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YM OPM_EN.book 45 ページ２０１３年６月７日金曜日午前１１時１１分 ENGINE OPERATION 12/05 CAUTIONS DURING OPERATION NOTICE Engine trouble can arise if the engine is operated for a long time under overloaded conditions with the control handle in the full throttle position (maximum engine speed position), exceeding the continuous rated output engine speed. Operate the engine at about 100 min-1 lower than the full throttle engine speed.
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YM OPM_EN.book 46 ページ２０１３年６月７日金曜日午前１１時１１分 ENGINE OPERATION NOTICE Racing the engine: With the gear in NEUTRAL, accelerate from the low-speed position to the high-speed position and repeat this process about five times. This is done to clean out carbon from the cylinders and the fuel injection valve. Neglecting to race the engine will result in poor smoke color and reduce engine performance. • If possible, periodically operate the engine at near maximum engine speed while underway.
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YM OPM_EN.book 47 ページ２０１３年６月７日金曜日午前１１時１１分 ENGINE OPERATION 12/05 NOTICE Figure 2 Continue to hold the stop switch in until the engine is completely stopped. If the switch is released before the engine has completely stopped, it may restart. If the engine does not shut down, see Emergency Shutdown on page 47 . 5. Turn off the battery switch (if equipped). 6. Close the fuel cock. 7. Close the seacock (if equipped). NOTICE •Be sure to close the seacock.
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YM OPM_EN.book 48 ページ２０１３年６月７日金曜日午前１１時１１分 ENGINE OPERATION CHECKING THE ENGINE AFTER OPERATION • Check that the power switch is off and that the battery switch (if equipped) is turned to off. • Fill the fuel tank. See Filling the Fuel Tank on page 29. • Close seawater cock(s). • If there is a risk of freezing, check that the cooling system contains enough coolant. See Engine Coolant Specifications on page 34. • If there is a risk of freezing, drain the seawater system.
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YM OPM_EN.book 49 ページ２０１３年６月７日金曜日午前１１時１１分 PERIODIC MAINTENANCE INTRODUCTION SAFETY PRECAUTIONS This section of the Operation Manual describes the procedures for proper care and maintenance of the engine. Before performing any maintenance procedures within this section, read the following safety information and review the Safety section on page 5. WARNING Crush Hazard If the engine needs to be transported for repair, have a helper assist you attach it to a hoist and load it on a truck.
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YM OPM_EN.book 50 ページ２０１３年６月７日金曜日午前１１時１１分 PERIODIC MAINTENANCE WARNING Never use undersized wiring for the electrical system. Welding Hazard • Always turn off the battery switch (if equipped) or disconnect the negative battery cable and the leads to the alternator when welding on the equipment. • Remove the engine control unit multi-pin connector. Connect the weld clamp to the component to be welded and as close as possible to the welding point.
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YM OPM_EN.book 51 ページ２０１３年６月７日金曜日午前１１時１１分 PERIODIC MAINTENANCE 12/05 PRECAUTIONS The Importance of Periodic Maintenance Engine deterioration and wear occur in proportion to the length of time the engine has been in service and the conditions the engine is subjected to during operation. Periodic maintenance prevents unexpected downtime, reduces the number of accidents due to poor machine performance and helps extend the life of the engine. Performing Periodic Maintenance WARNING Exhaust Hazard.
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YM OPM_EN.book 52 ページ２０１３年６月７日金曜日午前１１時１１分 PERIODIC MAINTENANCE Tightening Fasteners Use the correct amount of torque when you tighten fasteners on the engine. Applying excessive torque may damage the fastener or component and not enough torque may cause a leak or component failure. NOTICE he tightening torque in the Standard Torque Chart should be applied only to the bolts with a “7” head (JIS strength classification: 7T). Apply 60% torque to bolts that are not listed.
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PERIODIC MAINTENANCE 12/05 EPA MAINTENANCE REQUIREMENTS To maintain optimum engine performance and compliance with the Environmental Protection Agency (EPA) Regulations for Engines, it is essential to follow the Periodic Maintenance Schedule on page 55 and the Periodic Maintenance Procedures on page 59 . EPA Requirements for USA and Other Applicable Countries The following are the requirements for the EPA.
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YM OPM_EN.book 54 ページ２０１３年６月７日金曜日午前１１時１１分 PERIODIC MAINTENANCE Installing Sample Port All engines subject to emission standards shall be equipped with a connection in the engine exhaust system that is located downstream of the engine, and before any point at which the exhaust contacts water (or any other cooling / scrubbing medium), for the temporary attachment of gaseous and / or particulate emissions sampling equipment.
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YM OPM_EN.book 55 ページ２０１３年６月７日金曜日午前１１時１１分 PERIODIC MAINTENANCE 12/05 PERIODIC MAINTENANCE SCHEDULE Daily and periodic maintenance is important to keep the engine in good operating condition. The following is a summary of maintenance items by periodic maintenance intervals. Periodic maintenance intervals vary depending on engine application, loads, diesel fuel and engine oil used and are hard to establish definitively. The following should be treated only as a general guideline.
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YM OPM_EN.book 56 ページ２０１３年６月７日金曜日午前１１時１１分 PERIODIC MAINTENANCE : Check or Clean : Replace ●: Contact your authorized Yanmar Marine dealer or distributor Periodic Maintenance Interval System Item Before Starting See Daily Checks on page 59.
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YM OPM_EN.book 57 ページ２０１３年６月７日金曜日午前１１時１１分 PERIODIC MAINTENANCE 12/05 : Check or Clean : Replace ●: Contact your authorized Yanmar Marine dealer or distributor Periodic Maintenance Interval Before Starting See Daily Checks on page 59.
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YM OPM_EN.
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YM OPM_EN.book 59 ページ２０１３年６月７日金曜日午前１１時１１分 PERIODIC MAINTENANCE 12/05 PERIODIC MAINTENANCE PROCEDURES WARNING Exposure Hazard. Always wear personal protective equipment when performing periodic maintenance procedures. Never check for a fuel leak with your hands. Always use a piece of wood or cardboard. Have your authorized Yanmar Marine dealer or distributor repair any damage. 3. Check for engine coolant leaks. 4. Check for damaged or missing parts. Daily Checks 5.
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YM OPM_EN.book 60 ページ２０１３年６月７日金曜日午前１１時１１分 PERIODIC MAINTENANCE Checking and Refilling Marine Gear Oil Refer to the Operation Manual for the marine gear. Checking the Battery Electrolyte Level Check the battery electrolyte level before use. See Checking the Battery Electrolyte Level (Serviceable Batteries Only) on page 66. Checking the Alternator Belt Check the belt tension before use. See Checking and Adjusting the Alternator V-ribbed belt Tension on page 62.
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YM OPM_EN.book 61 ページ２０１３年６月７日金曜日午前１１時１１分 PERIODIC MAINTENANCE 12/05 Draining the Fuel Tank WARNING Burn Hazard. If you must drain the engine oil while it is still hot, stay clear of the hot engine oil to avoid being burned. Always wear eye protection. 3 1. Turn the engine off. 1 2 0004542 Figure 1 1 – Sediment Bowl 2 – Drain Cock 3 – Fuel Line to Engine Note: Optional fuel tank shown. Actual equipment may differ. 1. Put a pan under the drain cock (Figure 1, (2)) to catch fuel. 2.
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PERIODIC MAINTENANCE Replacing the Engine Oil Filter Element 1. Turn the engine off. Checking and Adjusting the Alternator V-ribbed belt Tension WARNING 2. Turn the engine oil filter Figure 2 counterclockwise with a wrench. Sever Hazard. Perform this check with the power switch off and the battery switch turned off to avoid contact with moving parts. 3. Remove the engine oil filter. Figure 1 NOTICE 0004797 Never get any oil on the belt(s). Oil on the belt causes slipping and stretching.
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PERIODIC MAINTENANCE 12/05 1. Remove the belt cover. 2. Check the belt by pushing on the middle of the belt (Figure 3, (1)) with your finger. With proper tension, the belt should deflect 8 to 10 mm (approximately 3/8 in.). 3. Loosen the 3 bolts of alternator (Figure 3, (2) (3) (4)). 4. Screw in the adjusting bolt (Figure 3, (4)) and move the alternator to adjust the belt tension properly. 5. Tighten the 3 bolts of the alternator. 6. Install the belt cover.
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YM OPM_EN.book 64 ページ２０１３年６月７日金曜日午前１１時１１分 PERIODIC MAINTENANCE 1. Check that the control lever on the engine side moves to the high-speed stop position and low-speed stop position when the remote control lever is moved to H (high speed) and L (low speed) respectively. 2. When there is deviation, loosen the bracket for the remote control cable on the engine side and adjust. 3.
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YM OPM_EN.book 65 ページ２０１３年６月７日金曜日午前１１時１１分 PERIODIC MAINTENANCE 12/05 Figure 5 Every 50 Hours of Operation 1 When completing the initial 50 hour maintenance procedures, perform the following procedures every 50 hours thereafter or monthly, whichever comes first. 2 3 • Draining Fuel Filter / Water Separator • Checking the Battery Electrolyte Level 4 Draining Fuel Filter / Water Separator WARNING Fire and Explosion Hazard.
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YM OPM_EN.book 66 ページ２０１３年６月７日金曜日午前１１時１１分 PERIODIC MAINTENANCE 5. Be sure to bleed air from the fuel system. See Bleeding the Fuel System on page 30. Checking the Battery Electrolyte Level (Serviceable Batteries Only) Never operate with insufficient battery electrolyte. Operating with insufficient electrolyte will destroy the battery. WARNING NOTICE Never attempt to remove the covers or fill a maintenance-free battery. 4.
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YM OPM_EN.book 67 ページ２０１３年６月７日金曜日午前１１時１１分 PERIODIC MAINTENANCE 12/05 Every 100 Hours of Operation Every 150 Hours of Operation Perform the following maintenance every 100 hours or every 6 months of operation, whichever comes first. Perform the following maintenance every 150 hours or every year of operation, whichever comes first.
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YM OPM_EN.book 68 ページ２０１３年６月７日金曜日午前１１時１１分 PERIODIC MAINTENANCE Draining the Fuel Tank Every 250 Hours of Operation See Draining the Fuel Tank on page 61. Perform the following maintenance every 250 hours or 1 year of operation, whichever comes first. Replacing the Fuel Filter Element • Draining the Fuel Tank Fire and Explosion Hazard. When removing any fuel system component to perform maintenance (such as changing the fuel filter), put an approved container under the opening to catch the fuel.
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YM OPM_EN.book 69 ページ２０１３年６月７日金曜日午前１１時１１分 PERIODIC MAINTENANCE 12/05 When there is dirt in the fuel, the filter becomes clogged and the fuel will not flow easily. Check and replace the element. 1. Close the fuel cock of the fuel tank. 2. Place an approved container under the fuel filter. 3. Remove the filter case by loosening the retaining ring (Figure 8, (2)). Turn the ring counterclockwise using a filter wrench. 4. Remove the housing (Figure 8, (1)) and remove the element.
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YM OPM_EN.book 70 ページ２０１３年６月７日金曜日午前１１時１１分 PERIODIC MAINTENANCE Replacing the Coolant CAUTION Coolant Hazard. Wear eye protection and rubber gloves when you handle engine coolant. If contact with the eyes or skin should occur, flush eyes and wash immediately with clean water. Cleaning the Intake Silencer (Air Cleaner) Element 1. Disassemble the intake silencer (air cleaner). 2. Remove element (Figure 10, (1)). Clean element and housing with a neutral detergent. 3. Dry completely and reassemble.
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YM OPM_EN.book 71 ページ２０１３年６月７日金曜日午前１１時１１分 PERIODIC MAINTENANCE 12/05 Adjusting the Alternator V-ribbed belt Tension See Checking and Adjusting the Alternator V-ribbed belt Tension on page 62. Cleaning the Breather Pipe Consult authorized Yanmar Marine dealer or distributor. Checking the Wiring Connectors Consult authorized Yanmar Marine dealer or distributor. Every 1000 Hours of Operation Perform the following maintenance every 1000 hours or 4 years of operation, whichever comes first.
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YM OPM_EN.book 72 ページ２０１３年６月７日金曜日午前１１時１１分 PERIODIC MAINTENANCE Replacing the Seawater Pump Impeller The seawater impeller must be replaced every 1000 hours or every 4 years even if it is not damaged. See Checking or Replacing the Seawater Pump Impeller on page 69. Figure 10Breather System Components 1 2 3 4 5 6 Cleaning and Checking the Seawater Passages After prolonged use, clean the seawater passages to remove dirt, scale, rust and other contaminants that collect in the coolant passages.
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YM OPM_EN.book 73 ページ２０１３年６月７日金曜日午前１１時１１分 PERIODIC MAINTENANCE 12/05 Checking and Adjusting the Remote Control Cables See Checking and Adjusting the Remote Control Cables on page 63. Adjusting the Propeller Shaft Alignment Consult authorized Yanmar Marine dealer or distributor. Tightening All Major Nuts and Bolts See Tightening Fasteners on page 52 or consult authorized Yanmar Marine dealer or distributor.
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YM OPM_EN.book 75 ページ２０１３年６月７日金曜日午前１１時１１分 TROUBLESHOOTING SAFETY PRECAUTIONS Before performing any troubleshooting procedures within this section, review the Safety section on page 5. If a problem occurs, stop the engine immediately. Refer to the Symptom column in the Troubleshooting Chart to identify the problem.
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YM OPM_EN.book 76 ページ２０１３年６月７日金曜日午前１１時１１分 TROUBLESHOOTING Is there water, oil or fuel leakage? Are there any loose bolts or connections? Check the engine room daily for any leaks or loose connections. Is there sufficient fuel in the fuel tank? Refill fuel in advance to avoid running out of fuel. If the tank runs out of fuel, bleed the fuel system. See Bleeding the Fuel System on page 30. When operating the engine at low speed for long periods of time, race the engine once every 2 hours.
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YM OPM_EN.book 77 ページ２０１３年６月７日金曜日午前１１時１１分 TROUBLESHOOTING 12/05 TROUBLESHOOTING CHART Symptom Probable Cause Measure Reference Indicators light on the instrument panel and alarm sounds during operation Shift to low-speed operation immediately, and check which indicator has come on. Stop the engine and inspect. If no abnormality is identified and there is no problem with operation, return to port at lowest speed and consult authorized Yanmar Marine dealer or distributor.
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YM OPM_EN.book 78 ページ２０１３年６月７日金曜日午前１１時１１分 TROUBLESHOOTING Symptom Starter does not turn or turns slowly (engine can be turned manually) Engine cannot be turned manually Probable Cause Measure Reference Faulty clutch position. Shift to NEUTRAL and start. See If the Engine Fails to Start on page 42. Insufficient battery charge. Check fluid level. Recharge or replace battery. See Checking the Battery Electrolyte Level on page 60. Cable terminal contact failure.
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YM OPM_EN.book 79 ページ２０１３年６月７日金曜日午前１１時１１分 LONG-TERM STORAGE If the engine will not be used for an extended period of time, special measures should be taken to protect the cooling system, fuel system and combustion chamber from corrosion and the exterior from rusting. The engine can normally stand idle for up to 6 months. If it remains unused for longer than this, please contact your authorized Yanmar Marine dealer or distributor.
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YM OPM_EN.book 80 ページ２０１３年６月７日金曜日午前１１時１１分 LONG-TERM STORAGE DRAIN SEAWATER COOLING SYSTEM 1 1 2 3 2 0004793 Figure 3 3 051170-00X00 1 – Stop Solenoid 2 – Coolant Drain Cock 3 – Flywheel Housing Figure 1 1 – Coolant Tank / Heat Exchanger 2 – Seawater Drain Cock 3 – Coolant Drain Plug 1 Figure 4 Note: The drain cocks are opened before shipping from the factory. Close all drain cocks before filling the system with coolant.
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YM OPM_EN.book 81 ページ２０１３年６月７日金曜日午前１１時１１分 LONG-TERM STORAGE 12/05 NOTICE Never drain engine coolant in the cold season or before long storage. If LLC (Long Life Coolant) has not been added to the cooling system, add LLC or drain the coolant from the coolant system after daily use. If the coolant without LLC is not removed, it may freeze and damage parts of the cooling system or engine when ambient temperature is below 0 °C (32 °F).
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YM OPM_EN.book 84 ページ２０１３年６月７日金曜日午前１１時１１分 SPECIFICATIONS 2YM15 Engine Specifications Specification Marine Gear Model 2YM15 KM2P-1 SD-20 Use Pleasure use Type Vertical water cooled 4-cycle diesel engine Combustion System Air Charging Swirl pre-combustion chamber Natural aspiration Number of Cylinders Bore x Stroke 2 70 mm x 74 mm (2.76 in. x 2.91 in.) Displacement 0.570 L (34.8 cu in.) Continuous Power Output at Crankshaft / Engine Speed 9.1 kW (12.
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YM OPM_EN.book 85 ページ２０１３年６月７日金曜日午前１１時１１分 SPECIFICATIONS 12/05 3YM20 Engine Specifications Specification 3YM20 Marine Gear Model KM2P-1 SD-20 Use Pleasure use Type Vertical water cooled 4-cycle diesel engine Combustion System Swirl pre-combustion chamber Air Charging Natural aspiration Number of Cylinders 3 Bore x Stroke 70 mm x 74 mm (2.76 in. x 2.91 in.) Displacement 0.854 L (52.1 cu in.) Continuous Power Output at Crankshaft / Engine Speed 13.9 kW (18.
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YM OPM_EN.book 86 ページ２０１３年６月７日金曜日午前１１時１１分 SPECIFICATIONS 3YM30E Engine Specifications Specification Marine Gear Model 3YM30E KM2P-1 SD-20 Use Pleasure use Type Vertical water cooled 4-cycle diesel engine Combustion System Air Charging Swirl pre-combustion chamber Natural aspiration Number of Cylinders Bore x Stroke 3 76 mm x 82 mm (2.99 in. x 3.23 in.) Displacement 1.115 L (68.04 cu in.) Continuous Power Output at Crankshaft / Engine Speed 19.4 kW (26.
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YM OPM_EN.book 87 ページ２０１３年６月７日金曜日午前１１時１１分 SPECIFICATIONS 12/05 3YM30 Engine Specifications Specification 3YM30 Marine Gear Model KM2P-1 SD-20 Use Pleasure use Type Vertical water cooled 4-cycle diesel engine Combustion System Swirl pre-combustion chamber Air Charging Natural aspiration Number of Cylinders 3 Bore x Stroke 76 mm x 82 mm (2.99 in. x 3.23 in.) Displacement 1.115 L (68.04 cu in.) Continuous Power Output at Crankshaft / Engine Speed 19.4 kW (26.
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YM OPM_EN.book 88 ページ２０１３年６月７日金曜日午前１１時１１分 SPECIFICATIONS Marine Gear and Sail Drive Specifications Model KM2P-1(S) KM2P-1(G) Type KM2P-1(GG) Mechanical cone clutch SD20 (coupled at boat builder) Dog Clutch Reduction Ratio (Forward / Reverse) 2.21 / 3.06 2.62 / 3.06 3.22 / 3.06 2.64 / 2.
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YM OPM_EN.book 89 ページ２０１３年６月７日金曜日午前１１時１１分 SYSTEM DIAGRAMS PIPING DIAGRAMS Piping diagrams and wiring diagrams are provided for reference only. Contact your authorized Yanmar Marine dealer or distributor for the most current diagrams. Notation Description Screw Joint (Union) Flange Joint Eye Joint Insertion Joint Drilled Hole Coolant Piping Seawater Piping Engine Oil Piping Diesel Fuel Piping Notes: 1. Steel pipe shows OD x wall thickness, rubber hose shows ID x wall thickness. 2.
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YM OPM_EN.book 91 ページ２０１３年６月７日金曜日午前１１時１１分 SYSTEM DIAGRAMS 12/05 Unit: mm (in.) Ø50 (1.97) Detail of part B 18 (0.71) Detail of part A X00-135620 Ø17 (0.67) X00-035620 Detail of part C Ø9 (0.35) Detail of part D Ø8.5 (0.33) Ø8 (0.31) 17 (0.67) 16.5 (0.65) Ø8 (0.31) X00-235620 X00-335620 YM Series Operation Manual 1 – 7.8 x t4.5 Rubber Hose 2 – Check Valve 3 – 7.8 x t4.5 Rubber Hose 4 – 7.8 x t4.5 Rubber Hose 5 – Overflow 6 – Fuel Inlet 7 – 7.8 x t4.5 Rubber Hose 8 – 5 x t4.
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YM OPM_EN.book 93 ページ２０１３年６月７日金曜日午前１１時１１分 SYSTEM DIAGRAMS 12/05 Unit: mm (in.) Ø50 (1.97) Detail of part B 18 (0.71) Detail of part A X00-135620 Ø17 (0.67) X00-035620 Detail of part C Ø9 (0.35) Detail of part D Ø8.5 (0.33) Ø8 (0.31) 17 (0.67) 16.5 (0.65) Ø8 (0.
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YM OPM_EN.book 94 ページ２０１３年６月７日金曜日午前１１時１１分 SYSTEM DIAGRAMS WIRING DIAGRAMS Color Coding R Red B Black W White L Blue RB Red / Black LB Blue / Black YW Yellow / White YG Yellow / Green WL White / Blue V Purple BW Blue / White O Orange WBr White / Brown Allowable Length by Cross Sectional Area of Battery Cable 94 Section of Cable mm2 (in.2) Allowable Length L = 1 + 2 + 3 m (ft) 15 (0.023) < 0.86 (0.26) 20 (0.031) < 1.3 (0.40) 30 (0.046) < 2.3 (0.70) 40 (0.062) < 2.
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1 3 4 5 6 7 2 9 8 YM Series Operation Manual 10 12 14 15 18 16 V 17 19 20 21 BW 11 B 13 G WB YB 22 YW WL WG B YG O LB RB YW WL Resistance W R L W R L B YG O LB VW WBr WBr A A 2B 23 B L YG RB 2L 5R + - 27 5R WL 28 29 38 33 2B WBr 2R 34 W RB LB O YG L YW WL WG B R A-A YW 30 W/Y 2W 31 B 26 + 1 RB 3R 12V 25 2W 2R *Self-holding * Output status table Output Panel Power ACC Power Input Power SW Glow SW Stop SW Start SW - 5R 3 24 Glow Relay 20R B
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YM OPM_EN.book 97 ページ２０１３年６月７日金曜日午前１１時１１分 EPA WARRANTY USA ONLY YANMAR CO., LTD. LIMITED EMISSION CONTROL SYSTEM WARRANTY - USA ONLY 2YM15 EPA and CARB Nameplate For Example 3YM30E EPA and CARB Nameplate EMISSION CONTROL INFORMATION THIS ENGINE COMPLIES WITH U.S.EPA MARINE AND CALIFORNIA OFF-ROAD REGULATIONS FOR 2013 M.Y. DIESEL ENGINES. ULTRA LOW SULFUR DIESEL FUEL ONLY. ENGINE FAMILY: DYDXN1.11P3N DISPLACEMENT: 1.116 LITERS ENGINE MODEL: 3YM30E E.C.S.
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YM OPM_EN.book 98 ページ２０１３年６月７日金曜日午前１１時１１分 EPA WARRANTY USA ONLY THIS EMISSION WARRANTY APPLIES TO THE ENGINES CERTIFIED TO UNITED STATES EPA 40 CFR Part 1042.135 AND SOLD BY YANMAR THAT ARE INSTALLED IN VESSELS FLAGGED OR REGISTERED IN THE UNITED STATES.
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YM OPM_EN.book 99 ページ２０１３年６月７日金曜日午前１１時１１分 EPA WARRANTY USA ONLY 12/05 Warranty Coverage: Owner’s Responsibility: Repair or replacement of any warranted parts will be performed at an authorized Yanmar dealer or distributor. This limited emission control system warranty covers engine components that are a part of the emission control system of the engine as delivered by Yanmar to the original retail purchaser.
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YM OPM_EN.book 101 ページ２０１３年６月７日金曜日午前１１時１１分 EMISSION SYSTEM WARRANTY NON-ROAD EMISSION SYSTEM WARRANTY Yanmar Co., Ltd. Limited Emission Control System Warranty - USA Only Your Warranty Rights and Obligations: maintenance of your engine. Your emission control system may include parts such as the fuel injection system and the air induction system. Where a warrantable condition exists, Yanmar will repair your non-road compression-ignition engine at no charge to you including diagnosis, parts and labor.
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YM OPM_EN.book 102 ページ２０１３年６月７日金曜日午前１１時１１分 EMISSION SYSTEM WARRANTY Warranty Coverage: Warranted Parts: This warranty is transferable to each subsequent purchaser for the duration of the warranty period. Repair or replacement of any warranted part will be performed at an authorized Yanmar Marine engine dealer or distributor. This warranty covers engine components that are a part of the emission control system of the engine as delivered by Yanmar to the original retail purchaser.
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YM OPM_EN.book 103 ページ２０１３年６月７日金曜日午前１１時１１分 EMISSION SYSTEM WARRANTY 12/05 Owners Warranty Responsibilities: As the engine owner, you are responsible for the performance of the required maintenance listed in your owner’s manual.
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‫ڦ‬Marine Operations Division Quality Assurance Dept. 5-3-1, Tsukaguchi-honmachi, Amagasaki Hyogo, 661-0001, Japan Phone: +81-6-6428-3251 Fax: +81-6-6421-5549 Overseas Office ‫ڦ‬Yanmar Europe B.V. (YEU) Brugplein 11, 1332 BS Almere-de Vaart, Netherlands Phone: +31-36-5493200 Fax: +31-36-5493209 ‫ڦ‬Yanmar Asia (Singapore) Corporation Pte Ltd.
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