3YM20/3YM30 MARINE DIESEL ENGINE MODEL:2YM15/3YM20/3YM30 OPERATION MANUAL The 2YM15/3YM20/3YM30 is an EPA Certified Engine. It meets the low emission standards set by the EPA. California Proposition 65 Warning California Proposition 65 Warning Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm.
INTRODUCTION ........................................... 3 1. FOR YOUR SAFETY ............................... 4 1.1 Warning Symbols .............................. 4 1.2 Safety Precautions ............................ 5 1.3 Warning Labels ................................. 8 EN 2. PRODUCT EXPLANATION ..................... 9 2.1 Use, Propulsion System, Etc. ............ 9 2.2 Engine Specifications ...................... 11 2.3 Names of Parts ............................... 14 2.4 Major Service of Parts ....
INTRODUCTION Thank you for purchasing a YANMAR Marine Diesel Engine. This Operation Manual describes the operation, maintenance and inspection of the 2YM15/3YM20/3YM30Yanmar Marine Diesel Engines. Read this Operation Manual carefully before operating the engine to ensure that it 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.
1. FOR YOUR SAFETY 1. FOR YOUR SAFETY 1.1 Warning Symbols Most operation, maintenance and inspection problems arise due to users' failure to comply with the rules and precautions for safe operation described in this operation manual. Often, users do not understand or recognize the signs of approaching problems. Improper handling can cause burns and other injuries and can result in death.
1. FOR YOUR SAFETY 1.2 Safety Precautions (Observe these instructions for your own safety!) Precautions for Operation DANGER Filler Cap of Coolant Tank Never open the cap of the coolant tank while the engine is still hot. Steam and hot water may spurt out and burn you seriously. Wait until the temperature of the coolant tank has dropped, wrap a cloth around the filler cap, loosen the cap very carefully and slowly to remove the system pressure before removing the cap.
1. FOR YOUR SAFETY WARNING Moving Parts Do not touch or let your clothing get caught in the moving parts of the engine, such as the front drive shaft, V-belt or propeller shaft, during engine operation. You will be injured. Never operate the engine without covers on the moving parts. CAUTION Burns The whole engine is hot during operation and immediately after shut-down. The exhaust manifold, exhaust pipe and high pressure fuel lines are very hot. Never touch these parts with your body or clothing.
1. FOR YOUR SAFETY CAUTION Scalds When extracting oil from the engine while it is still hot, don't let the oil splash on you. Wait until the temperature has dropped before extracting cooling water from the engine. Don't let it splash on you. DANGER Forbidden Modifications. Never release the limiting devices such as the engine speed limit, fuel injection limit, etc. Modification will impair the safety and performance of the product and shorten product life.
1. FOR YOUR SAFETY 1.3 Warning Labels B A DANGER WARNING Safety Precautions for Inspection To insure safe operation, warning device labels have been attached. Their location is shown below and they should always be visible. Please replace if damaged or lost. Product Safety Labels No. Part Code No.
2. PRODUCT EXPLANATION 2. PRODUCT EXPLANATION 2.1 Use, Propulsion System, Etc. The engine is equipped with a marine gear or a sail drive unit. The marine gear output shaft connects with the propeller shaft. In order to obtain full performance from your engine, it is imperative that you check the displacement and structure of the hull and use a propeller of the appropriate size.
2. PRODUCT EXPLANATION DETAIL OF NAMEPLATE The nameplate shown below is attached to the engine. Check the engine's model, output, rpm and serial number on the nameplate. Model Gear Model rpm Continuous power rpm Speed of prop. shaft rpm Fuel stop power kW YANMAR DIESEL ENGINE YANMAR CO., LTD. MADE IN JAPAN 10 MODEL GEAR RATIO OIL OIL QTY. NO. KM SAE 20 / 30 HD LTR. KANZAKI OSAKA ENG.No. EN The nameplate shown below is attached to the marine gear.
2. PRODUCT EXPLANATION 2.2 Engine Specifications Engine Model unit 2YM15 Marine gear model - KM2P-1 SD-20 Use - Pleasure use Type - Vertical water-cooled 4-cycle diesel engine Combustion system - Swirl pre-combustion chamber Number of cylinders - 2 Bore x stroke mm(inch) 70x74(2.76x2.91) Displacement L 0.570 9.4(12.8)/3489(at Fuel temp. 25°C)[2] Continuous power Output at crankshaft/ Engine speed kW(hp)/ Fuel stop power Output at crankshaft/ Engine speed kW(hp)/ 10.3(14.
2. PRODUCT EXPLANATION Engine Model unit 3YM30 - Use - Pleasure use Pleasure use Type - Vertical water-cooled 4-cycle diesel engine Vertical water-cooled 4-cycle diesel engine Combustion system - Swirl pre-combustion chamber Swirl pre-combustion chamber Number of cylinders - 3 3 mm(inch) 70x74(2.76x2.91) 76x82(2.99x3.23) Bore x stroke Displacement KM2P-1 SD-20 KM2P-1 SD-20 L 1.115 1.115 Continuous power Output at crankshaft/ Engine speed kW(hp)/ min-1[1] 14.7(20.
2. PRODUCT EXPLANATION Marine gear or Sail Drive Model Unit KM2P-1(S) KM2P-1(G) KM2P-1(GG) SD20 (coupled at boat builder) Mechanical cone clutch Dog clutch Type - Reduction ratio (Forward/Reverse) - 2.21/3.06 2.62/3.06 3.22/3.06 2.64/2.64 Propeller speed (For- min-1 1580/1140 1332/1140 1083/1140 1322 ward/Reverse) [1] Lubrication system - Lubricating oil capacity L (quart) Mass kg Splash Oil bath 0.3 (0.32) 2.2 (2.3) 9.
2. PRODUCT EXPLANATION 2.
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2. PRODUCT EXPLANATION 2.4 Major Service of Parts Name of part Function Fuel filter Removes dirt and water from fuel. Drain the filter periodically. The element (filter) should be changed. See maintenance section 4.3.5 Fuel feed pump Pumps fuel from tank to the fuel injection pump. Priming lever Moving the priming lever up and down feeds the fuel. The priming lever is used to bleed air from the fuel system after running out of fuel. Filler port (engine) Filler port for engine lubricating oil.
2. PRODUCT EXPLANATION 2.5 Control Equipment B type The equipment in the control room, making remote control possible, consists of the instrument panel, which is connected by wire harness and the remote control handle, which is hooked up by remote control cables to the engine control lever and marine gear. H I J K STOP 20 30 -1 min Mpa 40 10 0 50 2.5.1 Instrument Panel SLOW OFF ON START trancasers 2.5.1.1 Controls and equipment The instrument panel is located in the control room.
2. PRODUCT EXPLANATION 2.5.1.2 Meters B type panels use analog electric systems and have a pointer indicator. Instruments, equipment Functions Tachometer The engine’s rotation speed is indicated. Hour meter The number of hours of operation is indicated, and can be used as a guide for periodic maintenance checks. The hour meter is at the bottom of the tachometer. Panel lights When turning the key switch to ON, the meters light, for easy viewing. 2.5.1.
2. PRODUCT EXPLANATION 2.5.2 Single Lever Remote Control Handle 2.5.3 Shut-down Equipment This remote control system uses a singlehandle to operate the marine gear-clutch (neutral, forward, reverse) and to control the engine speed. Engine shut-down by stop button Electric Operation A NEUTRAL: Power to the propeller shaft is cut off and the engine idles. A D C A Stop button on the instrument panel B Push the stop button on the instrument panel when the key is in the ON position.
3. OPERATION 3. OPERATION 3.1 Fuel Oil, Lubricating Oil, and Cooling Water 3.1.1 Fuel Oil NOTICE Only use the recommended fuel to obtain the best engine performance and to keep the durability of the engine, also to comply with the emission regulations. (1) Selection of Fuel Oil Diesel fuel oil should comply with the following specifications. • The fuel specifications need to comply with each national standard or international standards. • ASTM D975 No.1-DNo.2-D ... for USA • EN590:96 .......................
3. OPERATION (3) Fuel Tank The inside of the fuel tank should always be clean enough and it should be dry for the first use. Drain the water according to the maintenance (section 5) with a drain valve. NOTICE When other than the specified fuel oil is used, the engine will not perform to full capacity and parts may be damaged. 3.1.2 Lubricating Oil NOTICE Using other than the specified lubricating oil will lead to seizure of parts, abnormal wear, and shorten engine life.
3. OPERATION Selection of viscosity (SAE Service grade) 9 9 or QuickSilver® High Performance Gear Lube QuickSilver® is a registered trademark of the Brunswick Corporation. (4) Handling the Lubricating Oil 1. When handling and storing lubricating oil, be careful not to allow dust and water to enter the lubricating oil. Clean around the filler port before refilling. 9 9 ޓ ޓ ޓ ޓ ޓ ޓ ޓ Atmospheric temperature (°C) 10W-30 can be used almost throughout the year.
3. OPERATION 3.1.3 Cooling fresh water Use clean soft water and always be sure to add LLC (Long Life Coolant) in order to prevent rust built up and freezing. (Do not use water only.) The recommended LLC conform to the following specifications. • JIS K-2234 ambient temperature. LLC concentration should be 30% as a minimum and 60% as a maximum. • DO NOT mix the different types of brand of LLC, otherwise harmful sludge may yield. • DO NOT use hard water. • Water should be free from sludge and/ or particles.
3. OPERATION 3.2 Before Initial Operation NOTICE Perform the following before using the engine for the first time: Do not overfill. 3.2.1 Supply Fuel Oil Overfilling will cause oil to be sprayed into the cylinder and lead to engine problems. DANGER Using gasoline, etc. may A B cause a fire. To avoid mistakes, be sure to double-check the kind of fuel before filling. Wipe off any spilled fuel carefully.
3. OPERATION A A B A Oil filler cap B Dipstick B C 3.2.4 Supply Cooling Water Supply cooling water according to the following procedures. Be sure to add antifreeze to the cooling water. EN A Coolant tank C Drain cock for seawater B Drain plug for coolant (1) Be sure to close the 4 water drain cocks/plugs. Fresh water line Seawater line 2 2 A Note: The water drain cocks are opened before shipping from the plant.
3. OPERATION (3) Pour cooling water slowly into the fresh water/coolant tank so that air bubbles do not develop. Pour until the water overflows from the filler port. D A B C DANGER If the filler cap is loose, hot steam and water will spout out which may cause burns. A To fresh water cooler B Upper limit C Lower limit D Cap 3.2.5 Cranking (4) After supplying cooling water, replace the filler cap and tighten it firmly. Failure to do so will cause water leakage.
3. OPERATION (6) When the key switch is turned, the engine will begin cranking. Continue cranking for about 5 seconds, and check for abnormal noise during that time. (If you remove your hand from the stop knob or stop button while cranking, the engine will start.) 3.2.
3. OPERATION (2) Checking and Re-supplying Fuel Oil Check the fuel level inside the fuel tank and supply with the recommended fuel, if necessary. (See 3.2.1) (3) Checking and Re-supplying Engine Lubricating Oil. 1. After removing the oil filler cap, check the engine oil level with the oil dipstick. 2. If the oil level is low, supply with the recommended lubricating oil using the filler port. Supply oil up to the top mark on the oil dipstick. (See 3.2.2) (4) Check and Re-supply Marine Gear Lubricating Oil 1.
3. OPERATION (7) Check the Alarm Devices Electric Operation When operating the key switch, check that the alarm devices work normally. (See 2.5.1 (4)) (8) Prepare Fuel, Lubricating Oil, and Cooling Fresh Water in Reserve Always store lubricating oil and coolant water in reserve (for at least one refill) onboard, to be ready for emergencies. 3.3.2 How to Start the Engine (1) Start the engine according to the following procedures: Electric Operation 1. Open the seacock. EN 2. Open the fuel cock. 3.
3. OPERATION NOTICE Turn the key for a maximum of 15 seconds in the start position. If the engine does not start the first time, wait for about 15 seconds before trying again. After the engine has started, do not turn the key off. (It should remain ON.) Alarm devices will not work when the key is OFF. CAUTION If vessel is equipped with a water lift (water lock) muffler, excessive cranking could cause seawater to enter the cylinders and damage the engine.
3. OPERATION NOTICE The engine will seize if it is operated when cooling seawater discharge is too small or if load is applied without any warming up operation. 3.3.3 Operation (1) Engine acceleration and deceleration Use the throttle handle to control acceleration and deceleration. Move the handle slowly. (2) FORWARD- NEUTRAL (boat stopped) - REVERSE Clutch A EN Move the throttle handle slowly to a higher speed position after completing clutch engagement. 2.
3. OPERATION (5) Is there water, oil, or gas leakage, or are there any loose bolts? Check the engine room periodically for any problems. (6) Is there sufficient fuel oil in the fuel oil tank? Replenish fuel oil in advance to avoid running out of fuel during operation. (7) When operating the engine at low speed for long periods of time, race the engine once every 2 hours.
3. OPERATION Emergency Stop When you can’t stop the engine by the stop button on the panel, push the button at the back of the stop solenoid.(See 2.5.3) 3.4 Long Term Storage (1) In cold temperatures or before long term storage, be sure to drain the seawater from the seawater cooling system. CAUTION 2. Loosen the 4 bolts attaching the side cover of the seawater pump, remove the cover and drain the water from inside. Retighten the bolts when finished. 3. Close the drain cocks/plugs.
3. OPERATION (5) Grease the exposed area and joints of the remote control cable and the bearings of the remote control handle. A D (6) Cover the intake silencer, exhaust pipe, etc. with vinyl sheets and seal them to prevent moisture from entering. E C B A Coolant tank D Fresh water pump B Drain plug for seawater E Seawater pump C Drain plug for fresh water (7) Drain bilge in the hull bottom completely.
4. MAINTENANCE AND INSPECTION 4. MAINTENANCE AND INSPECTION 4.1 General Inspection Rules (1) Conduct Periodic Inspection for Your Safety. The functions of engine components will degenerate and engine performance will drop according to the use of the engine. If countermeasures are not taken, you may encounter unexpected troubles while cruising at sea. Consumption of fuel or lubricating oil may become excessive and exhaust gas and engine noise may increase. These all shorten the life of the engine.
4. MAINTENANCE AND INSPECTION NOTICE Apply the following tightening torque to bolts having "7" on the head. (JIS strength classification: 7T) Tighten Bolt dia. x pitch (mm) Tightening torque M6x1.0 bolts with no "7" mark to 60% tightening torque. If the parts to be tightened are made from light alloy aluminium, tighten the bolts to 80% tightening torque. M8x1.25 M10x1.5 M12x1.75 M14x1.5 M16x1.5 (Nm) 11 ± 1 26 ± 3 50 ± 5 90 ± 10 140 ± 10 230 ± 10 (kgf-m) 1.1 ± 0.1 2.7 ± 0.3 5.1 ± 0.5 9.
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4. MAINTENANCE AND INSPECTION 4.3 Periodic Inspection Items 4.3.1 Inspection on Initial 50 Hrs. of Operation (or after 1 Month) (1) Replace the Engine Lubricating Oil and Lubricating Oil Filter (1st time) During initial operation of the engine, the oil is quickly contaminated due to the initial wear of internal parts. The lubricating oil must therefore be replaced early. Replace the lubricating oil filter at the same time.
4. MAINTENANCE AND INSPECTION EN (6) Adjusting the Remote Control Cable The various control levers on the engine side are connected to the remote control lever by remote control cables. The cables will become stretched and the attachments loose after long hours of use causing deviation. It is dangerous to control operation under these conditions, and the remote control cables must be checked and adjusted periodically. 1.
4. MAINTENANCE AND INSPECTION (7) Adjusting the Tension of Alternator Driving Belt When there is not enough tension in the V-belt, it will slip and the fresh water pump will fail to supply cooling water. Engine over-heating and seizure will result. A 4.3.2 Inspection Every 50 Hrs. (or Monthly) (1) Drain the fuel/water separator. 1. Close the fuel cock of a fuel tank. 2. Loosen the retaining ring and remove the filter cup. Drain off any water and dirt collected inside. 3.
4. MAINTENANCE AND INSPECTION 1. Check the fuel level in the fuel tank. Replenish if Insufficient 2. Loosen the air bleeding bolt at the top of the fuel filter by turning it 2 or 3 times. 3. Feed fuel with the fuel feed pump by moving the lever on the left side of the feed pump up and down. 4. Allow the fuel containing air bubbles to flow out from the air bleeding bolt hole. When the fuel no longer contains bubbles, tighten the air bleeding bolt. This completes the air bleeding of the fuel system. 5.
4. MAINTENANCE AND INSPECTION (Battery fluid tends to evaporate in high temperatures, especially in summer. In such cases, inspect the battery earlier than specified.) 4.3.3 Inspection Every 100 Hrs (or six months). GREASE B UPPER LEVEL LOWER LEVEL D may be insufficient. In such cases, consult your Yanmar dealer or distributor. (1) Replace the Sail Drive Oil Refer to the operation manual of the sail drive for the procedure of the oil replacement C F E 4.3.4 Inspection Every 150 Hrs (or one year).
4. MAINTENANCE AND INSPECTION of seawater discharged is reduced, inspect the seawater pump in accordance with the following procedures: 1. Loosen the side cover bolts and remove the side cover. 2. Illuminate the inside of the seawater pump with a flashlight and inspect. A A Fuel filter (3) Replace the Lubricating Oil Filter (See 4.3.1 (1)) (4) Adjusting the Tension of the Alternator Driving Belt (See 4.3.1 (7)).
4. MAINTENANCE AND INSPECTION careful to turn it in the correct direction. Incorrect turning will twist the impeller and damage it C D B A A Direction of Impeller B Impeller rotating direction C Impeller D Seawater pump (7) Clean the Exhaust/Water Mixing Elbow. There are two types of mixing elbows, the L-type and the U-type. The mixing elbow is attached to the exhaust manifold. The exhaust gas is mixed with seawater in the mixing elbow. 1.
4. MAINTENANCE AND INSPECTION Breather system component A B C D E F G A B C D Diaphragm cover Spring Center plate Diaphragm H E F G H Rocker arm cover Breather baffle Baffle plate Intake manifold NOTICE EN 1. When the diaphragm is damaged, crankcase pressure control is affected. Excessive crankcase pressure will cause leaks at seals and mating part surfaces. 2. At lubricating oil replacement or lubricating oil fill, do not fill above the standard upper limit.
4. MAINTENANCE AND INSPECTION Even if LLC (Long Life Coolant) or antirust is added, the cooling water must be replaced periodically because the properties of the agent will degenerate. To drain the fresh water/coolant, open the fresh water cocks/plugs (two places) as shown in 3.2.4 and 3.4(2). (Refer to 3.2.4 for resupplying cooling water.) 4.4 EPA Requirements 4.4.2 Conditions to Insure Compliance with Emission Standards This product is an EPA approved engine.
4. MAINTENANCE AND INSPECTION (5) Quality guarantee period for the emission related parts If the schedule of periodic maintenance outlined in 4.4.3 (Inspection and Maintenance) is followed, the quality guarantee period is determined by the age of the engine or the number of hours of operation as indicated below. Power rating Parts Quality guarantee period kW<19 Fuel nozzle, fuel pump 1500 hrs. of operation or 2 years 19=
5. TROUBLE AND TROUBLESHOOTING 5. TROUBLE AND TROUBLESHOOTING Trouble Alarm buzzer and alarm lamps on during operation Lubricating oil low-pressure alarm. Warning lamp goes on Probable Cause Measure NOTICE Shift to low speed operation immediately, and check which lamp has come on. Stop the engine for inspection. If no abnormality is identified and there is no problem with operation, return to port at your lowest speed and request repairs. Engine Lubricating Oil level low.
5. TROUBLE AND TROUBLESHOOTING Trouble Probable Cause Measure Reference No fuel. Replenish fuel; vent air. 3.3.2(3) Fuel filter is clogged. Replace element. 4.3.5(1) Improper fuel. Replace with recommended fuel. Faulty fuel injection. Ask for repairs. Compression leakage from intake/exhaust valve. Ask for repairs. Faulty clutch position. Shift to NEUTRAL and start. 3.3.2.3 Insufficient battery charge. Check fluid level; recharge; replace. 4.3.2(2) Cable terminal contact failure.
5. TROUBLE AND TROUBLESHOOTING Consulting Your Yanmar Dealer or Distributor Refer difficult problems and repairs to your Yanmar dealer or distributor. At the time of trouble, check and report the following: (1) Engine model and number: (2) Boat name, material of hull, size (tons): (3) Use, type of boating done, no. of hours run: (4) Total number of operation hours (refer to hour meter), age of boat: (5) Condition before trouble (engine rpm, type of operation, load condition, etc.
6. PIPING DIAGRAMS 6. PIPING DIAGRAMS See Appendix A. at the back of this manual.
7. WIRING DIAGRAMS 7. WIRING DIAGRAMS See Appendix B. at the back of this manual.
• • • • • MANUFACTURER’S DECLARATION FOR MACHINERY PARTS ACCORDING TO 94/25/EEC(ANNEX-15) & 89/336/EEC MANUFACTURER: YANMAR CO., LTD. 1-32, Chayamachi, Kita-ku, Osaka, Japan DESCRIPTION OF THE MACHINERY PARTS CATEGORY: Diesel engine 1. MAKE: YANMAR 2. THIS MACHINERY PART MUST NOT BE PUT INTO SERVICE UNTIL THE MACHINERY INTO WHICH IT IS TO BE INCORPORATED HAS BEEN DECLARED IN CONFORMITY WITH THE PROVISIONS OF THE DIRECTIVE. IMPORTER IN THE EU: YANMAR MARINE INTERNATIONAL B.V.
President, Yanmar Marine Int’l
President, Yanmar Marine Int’l
