Yanmar Marine Diesel Engine 3YM30, 3YM20, 2YM15 Service Manual
Complete repair service manual with electrical wiring diagrams for Yanmar Marine Diesel Engine 3YM30, 3YM20, 2YM15, with all the technical information to maintain, diagnose andrepair like professional mechanics.
Yanmar Marine Diesel Engine 3YM30, 3YM20, 2YM15 workshop service repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
MANUAL LIST:
0AYMM-G00200 - Yanmar Marine Diesel Engine YM-series (3YM30, 3YM20, 2YM15) Operation Manual.pdf
0BYMM-G00100 - Yanmar Marine Diesel Engine 3YM30, 3YM20, 2YM15 Service Manual.pdf
M9961-03E101 - Yanmar Marine Diesel Engine 3YM30, 3YM20, 2YM15 Service Manual.pdf
OCR10-G56000 - Yanmar 3YM30 Parts Catalog.pdf
Total Pages: 631 pages
File Format: PDF (Windows & Mac & Linux)
Language: English
TABLE OF CONTENTS
Cover...1
History of Revision...2
FOREWORD...3
CONTENTS...4
FOR SAFETY...10
1. General...16
1.1 Exterior views...16
1.2 Specifications...17
1.3 Fuel oil, lubricating oil and cooling water...20
1.3.1 Fuel oil...20
1.3.2 Lubricating oil...20
1.3.3 Cooling water...21
1.4 Engine outline...22
1.5 Piping diagrams...28
1.6 Exhaust gas emission regulation...32
1.6.1 Engine identification (EPA/ARB)...32
1.6.2 Exhaust gas emission standard (EPA/ARB)...33
1.6.3 Guarantee conditions for emission standard (EPA/ARB)...33
2. Inspection and adjustment...35
2.1 Periodic maintenance schedule...35
2.2 Periodic inspection and maintenance procedure...37
2.2.1 Check before starting...37
2.2.2 inspection after initial 50 hours or one month operation...40
2.2.3 Inspection every 50 hours or monthly...45
2.2.4 Inspection every 100 hours six months...50
2.2.5 Inspection every 150 hours or one year...50
2.2.6 Inspection every 250 hours or one year...51
2.2.7 Inspection every 1,000 hours or four years...57
2.3 Adjusting the no-load maximum or minimum speed...64
2.4 Sensor Inspection...64
2.4.1 Oil pressure switch...64
2.4.2 Thermo switch...64
2.5 Thermostat inspection...65
2.6 Adjusting operation...66
2.6.1 Preliminary precautions...66
2.6.2 Adjusting operation procedure...66
2.6.3 Check points and precautions during running...67
2.7 Long storage...68
3. Troubleshooting...69
3.1 Preparation before troubleshooting...69
3.2 Quick reference chart for troubleshooting...70
3.3 Troubleshooting (Concerning engine and fuel injection equipment)...79
3.4 Troubleshooting by measuring compression pressure...82
4. Disassembly and reassembly...84
4.1 Disassembly and reassembly precautions...84
4.2 Disassembly and reassembly tools...85
4.2.1 General hand tools...85
4.2.2 Special hand tools...88
4.2.3 Measuring instruments...91
4.2.4 Other material...95
4.3 Disassembly and reassembly...97
4.3.1 Disassembly...97
4.3.2 Reassembly...109
5. Inspection and servicing of basic engine parts...124
5.1 Cylinder block...124
5.1.1 Inspection of parts...124
5.1.2 Cleaning of oil holes...124
5.1.3 Color check procedure...124
5.1.4 Replacement of cap plugs...125
5.1.5 Cylinder bore measurement...126
5.2 Cylinder head...127
5.2.1 Inspecting the cylinder head...128
5.2.2 Valve seat correction procedure...129
5.2.3 Intake/exhaust valves, valve guides...130
5.2.4 Valve springs...132
5.2.5 Assembling the cylinder head...133
5.2.6 Measuring top clearance...134
5.2.7 Intake and exhaust rocker arms...134
5.2.8 Adjustment of valve clearance...135
5.3 Piston and piston pins...136
5.3.1 Piston...136
5.3.2 Piston pin...137
5.3.3 Piston rings...138
5.4 Connecting rod...141
5.4.1 Inspecting the connection rod...141
5.4.2 Crank pin metal...142
5.4.3 Piston pin bushing...144
5.4.4 Assembling piston and connecting rod...144
5.5 Crankshaft and main bearing...145
5.5.1 Crankshaft...145
5.5.2 Main bearing...147
5.6 Camshaft and tappets...148
5.6.1 Camshaft...148
5.6.2 Tappets...150
5.7 Timing gear...151
5.7.1 Inspecting the gears...151
5.7.2 Gear timing marks...151
5.8 Flywheel and housing...152
5.8.1 Position of top dead center and fuel injection timing...152
5.8.2 Damper disc...153
6. Fuel injection equipment...154
6.1 Fuel Injection pump/governor...154
6.1.1 Fuel system diagram...154
6.1.2 Fuel injection pump service data and adjustment...155
6.1.3 Fuel injection pump structure...160
6.1.4 Removing a fuel injection pump...161
6.1.5 Installing a fuel injection pump...161
6.1.6 Adjusting fuel injection timing...161
6.1.7 Troubleshooting of fuel injection pump...162
6.1.8 Major faults and troubleshooting...162
6.2 Fuel feed pump...165
6.2.1 Construction of fuel feed pump...165
6.2.2 Fuel feed pump specifications...165
6.2.3 Disassembly and reassembly of fuel feed pump...166
6.2.4 Fuel feed pump inspection...166
6.3 Fuel filter...168
6.3.1 Fuel filter specifications...168
6.3.2 Fuel filter inspection...168
6.4 Fuel tank...169
7. Intake and exhaust system...170
7.1 Intake system...170
7.1.1 Breather system (A reductor to intake air system of blowby gas)...170
7.1.2 Diaphragm assy inspection...171
7.2 Exhaust system...172
7.2.1 Construction...172
7.2.2 Mixing elbow inspection...172
8. Lubrication system...173
8.1 Lubrication system...173
8.2 Lube oil pump...174
8.2.1 Lube oil pump construction...174
8.2.2 Specifications of lube oil pump...174
8.2.3 Lube oil pump disassembly and reassembly...174
8.2.4 Lube oil pump inspection...175
8.2.5 Pressure control valve construction...175
8.3 Lube oil filter...176
8.3.1 Lube oil filter construction...176
8.3.2 Lube oil filter replacement...176
8.4 Rotary waste oil pump (Optional)...177
9. Cooling water system...178
9.1 Cooling water system...178
9.2 Seawater pump...180
9.2.1 Specifications of seawater pump...180
9.2.2 Seawater pump disassembly...180
9.2.3 Seawater pump Inspection...181
9.2.4 Seawater pump reassembly...182
9.3 Fresh water pump...183
9.3.1 Fresh water pump construction...183
9.3.2 Specifications of fresh water pump...183
9.3.3 Fresh water pump disassembly...184
9.3.4 WFresh water pump inspection...184
9.4 Heat exchanger...186
9.4.1 Heat exchanger construction...186
9.4.2 Disassembly and reassembly of the heat exchanger...186
9.4.3 Heat exchanger inspection...186
9.5 Pressure cap and coolant recovery tank...187
9.5.1 Pressure cap construction...187
9.5.2 Pressure cap pressure control...187
9.5.3 Pressure cap inspection...187
9.5.4 Replacing filler neck...188
9.5.5 Function of the coolant recovery tank...189
9.5.6 Specifications of coolant recovery tank...189
9.5.7 Mounting the coolant recovery tank...189
9.5.8 Precautions on usage of the coolant recovery tank...189
9.6 Thermostat...190
9.6.1 Functioning of thermostat...190
9.6.2 Thermostat construction...190
9.6.3 Characteristics of thermostat...190
9.6.4 Thermostat inspection...190
9.6.5 Testing the thermostat...190
9.7 Bilge pump and bilge strainer (Optional)...191
9.7.1 Introduction...191
9.7.2 Description...192
9.7.3 Cautions...192
9.7.4 Assembly procedure...193
9.7.5 Cautions for assembling...195
9.7.6 Troubleshooting...196
10. Reduction and reversing gear...197
10.1 Specifications...197
11. Remote control (Optional)...198
11.1 Remote control system...198
11.1.1 Construction of remote control system...198
11.1.2 Remote control device components...198
11.2 Remote control installation...200
11.3 Remote control inspection...202
11.4 Remote control adjustment...203
12. Electrical system...204
12.1 Electrical system...204
12.1.1 Wiring diagram...205
12.2 Battery...206
12.3 Starting motor...207
12.3.1 Specifications...207
12.3.2 Characteristics...207
12.3.3 Structure...208
12.3.4 Wiring diameter of a starting motor...209
12.4 Alternator standard, 12V/60A...210
12.4.1 Specifications...210
12.4.2 Structure...211
12.4.3 Wiring diagram...212
12.4.4 Standard output characteristics...212
12.4.5 Inspection...213
12.5 Alternator 12V/80A (Optional)...214
12.5.1 Specifications...214
12.5.2 Structure...215
12.5.3 Wiring diagram...216
12.5.4 Standard output characteristics...216
12.6 Instrument panel...217
12.6.1 B-type instrument panel (Optional)...217
12.7 Warning devices...218
12.7.1 Oil pressure alarm...218
12.7.2 Cooling water temperature alarm...219
12.8 Glow plug...220
12.9 Electric engine stopping device...221
13. Service standards...222
13.1 Engine tuning...222
13.2 Engine body...223
13.2.1 Cylinder head...223
13.2.2 Camshaft and gear train...224
13.2.3 Cylinder block...225
13.3 Lubricating oil system (Trochoid pump)...228
14. Tightening torque for bolts and nuts...229
14.1 Main bolt and nut...229
14.2 Standard bolts and nuts (without lube oil)...229
Colophon...230
Preface.....2
Content.....4
1.CYLINDER BLOCK.....5
2.GEAR HOUSING.....6
3.FLYWHEEL HOUSING & L.O.SUMP.....7
4.MOUNTING FOOT.....8
5.LABEL.....9
6.CYLINDER HEAD & BONNET.....10
7.AIR INTAKE SILENCER.....11
8.MIXING ELBOW.....12
9.CAMSHAFT & DRIVING GEAR.....13
10.CRANKSHAFT & PISTON.....14
11.LUB.OIL DIPSTICK.....15
12.LUB.OIL SYSTEM.....16
13.COOLING SEA WATER PUMP.....17
14.COOLING FRESH WATER PUMP.....18
15.COOLING FRESH WATER COOLER.....19
16.COOLING SEA WATER PIPE.....20
17.COOLING FRESH WATER PIPE.....21
18.BILGE PUMP(STD/OPTIONAL).....22
19.BILGE PUMP(DX/OPTIONAL).....23
20.FUEL INJECTION PUMP.....24
21.GOVERNOR.....26
22.FUEL FEED PUMP.....28
23.FUEL INJECTION VALVE.....29
24.FUEL PIPE & FUEL STRAINER.....30
25.FUEL TANK(OPTIONAL).....31
26.CABLE SUPPORT.....32
27.CLUTCH.....33
28.CLUTCH REMOTE CONTROL.....34
29.COUPLING(OPTIONAL).....35
30.STARTING MOTOR.....36
31.GENERATOR.....37
32.GENERATOR(80A/OPTIONAL).....38
33.WIRE HARNESS & RELAY.....39
34.INSTRUMENT PANEL(B-TYPE/OPTIONAL).....40
35.TOOL.....41
36.GASKET SET(OPTIONAL).....42
37.V-BELT COVER.....43
PartsNo Index.....44
Yanmar Marine Diesel Engine 3YM30, 3YM20, 2YM15 Service Manual
