Yanmar 3YM30, 3YM20, 2YM15 Marine Diesel Engine Service Manual

Description

• Model List:
  • 3YM30, 3YM20, 2YM15 Marine Diesel Engine

• 1. History of Revision
• 2. FOREWORD
• 3. CONTENTS
• 4. FOR SAFETY
• 5. General
• 5.1. Exterior views
• 5.2. Specifications
• 5.3. Fuel oil, lubricating oil and cooling water
• 5.3.1. Fuel oil
• 5.3.2. Lubricating oil
• 5.3.3. Cooling water
• 5.4. Engine outline
• 5.5. Piping diagrams
• 5.6. Exhaust gas emission regulation
• 5.6.1. Engine identification (EPA/ARB)
• 5.6.2. Exhaust gas emission standard (EPA/ARB)
• 5.6.3. Guarantee conditions for emission standard (EPA/ARB)
• 6. Inspection and adjustment
• 6.1. Periodic maintenance schedule
• 6.2. Periodic inspection and maintenance procedure
• 6.2.1. Check before starting
• 6.2.2. inspection after initial 50 hours or one month operation
• 6.2.3. Inspection every 50 hours or monthly
• 6.2.4. Inspection every 100 hours six months
• 6.2.5. Inspection every 150 hours or one year
• 6.2.6. Inspection every 250 hours or one year
• 6.2.7. Inspection every 1,000 hours or four years
• 6.3. Adjusting the no-load maximum or minimum speed
• 6.4. Sensor Inspection
• 6.4.1. Oil pressure switch
• 6.4.2. Thermo switch
• 6.5. Thermostat inspection
• 6.6. Adjusting operation
• 6.6.1. Preliminary precautions
• 6.6.2. Adjusting operation procedure
• 6.6.3. Check points and precautions during running
• 6.7. Long storage
• 7. Troubleshooting
• 7.1. Preparation before troubleshooting
• 7.2. Quick reference chart for troubleshooting
• 7.3. Troubleshooting (Concerning engine and fuel injection equipment)
• 7.4. Troubleshooting by measuring compression pressure
• 8. Disassembly and reassembly
• 8.1. Disassembly and reassembly precautions
• 8.2. Disassembly and reassembly tools
• 8.2.1. General hand tools
• 8.2.2. Special hand tools
• 8.2.3. Measuring instruments
• 8.2.4. Other material
• 8.3. Disassembly and reassembly
• 8.3.1. Disassembly
• 8.3.2. Reassembly
• 9. Inspection and servicing of basic engine parts
• 9.1. Cylinder block
• 9.1.1. Inspection of parts
• 9.1.2. Cleaning of oil holes
• 9.1.3. Color check procedure
• 9.1.4. Replacement of cap plugs
• 9.1.5. Cylinder bore measurement
• 9.2. Cylinder head
• 9.2.1. Inspecting the cylinder head
• 9.2.2. Valve seat correction procedure
• 9.2.3. Intake/exhaust valves, valve guides
• 9.2.4. Valve springs
• 9.2.5. Assembling the cylinder head
• 9.2.6. Measuring top clearance
• 9.2.7. Intake and exhaust rocker arms
• 9.2.8. Adjustment of valve clearance
• 9.3. Piston and piston pins
• 9.3.1. Piston
• 9.3.2. Piston pin
• 9.3.3. Piston rings
• 9.4. Connecting rod
• 9.4.1. Inspecting the connection rod
• 9.4.2. Crank pin metal
• 9.4.3. Piston pin bushing
• 9.4.4. Assembling piston and connecting rod
• 9.5. Crankshaft and main bearing
• 9.5.1. Crankshaft
• 9.5.2. Main bearing
• 9.6. Camshaft and tappets
• 9.6.1. Camshaft
• 9.6.2. Tappets
• 9.7. Timing gear
• 9.7.1. Inspecting the gears
• 9.7.2. Gear timing marks
• 9.8. Flywheel and housing
• 9.8.1. Position of top dead center and fuel injection timing
• 9.8.2. Damper disc
• 10. Fuel injection equipment
• 10.1. Fuel Injection pump/governor
• 10.1.1. Fuel system diagram
• 10.1.2. Fuel injection pump service data and adjustment
• 10.1.3. Fuel injection pump structure
• 10.1.4. Removing a fuel injection pump
• 10.1.5. Installing a fuel injection pump
• 10.1.6. Adjusting fuel injection timing
• 10.1.7. Troubleshooting of fuel injection pump
• 10.1.8. Major faults and troubleshooting
• 10.2. Fuel feed pump
• 10.2.1. Construction of fuel feed pump
• 10.2.2. Fuel feed pump specifications
• 10.2.3. Disassembly and reassembly of fuel feed pump
• 10.2.4. Fuel feed pump inspection
• 10.3. Fuel filter
• 10.3.1. Fuel filter specifications
• 10.3.2. Fuel filter inspection
• 10.4. Fuel tank
• 11. Intake and exhaust system
• 11.1. Intake system
• 11.1.1. Breather system (A reductor to intake air system of blowby gas)
• 11.1.2. Diaphragm assy inspection
• 11.2. Exhaust system
• 11.2.1. Construction
• 11.2.2. Mixing elbow inspection
• 12. Lubrication system
• 12.1. Lubrication system
• 12.2. Lube oil pump
• 12.2.1. Lube oil pump construction
• 12.2.2. Specifications of lube oil pump
• 12.2.3. Lube oil pump disassembly and reassembly
• 12.2.4. Lube oil pump inspection
• 12.2.5. Pressure control valve construction
• 12.3. Lube oil filter
• 12.3.1. Lube oil filter construction
• 12.3.2. Lube oil filter replacement
• 12.4. Rotary waste oil pump (Optional)
• 13. Cooling water system
• 13.1. Cooling water system
• 13.2. Seawater pump
• 13.2.1. Specifications of seawater pump
• 13.2.2. Seawater pump disassembly
• 13.2.3. Seawater pump Inspection
• 13.2.4. Seawater pump reassembly
• 13.3. Fresh water pump
• 13.3.1. Fresh water pump construction
• 13.3.2. Specifications of fresh water pump
• 13.3.3. Fresh water pump disassembly
• 13.3.4. WFresh water pump inspection
• 13.4. Heat exchanger
• 13.4.1. Heat exchanger construction
• 13.4.2. Disassembly and reassembly of the heat exchanger
• 13.4.3. Heat exchanger inspection
• 13.5. Pressure cap and coolant recovery tank
• 13.5.1. Pressure cap construction
• 13.5.2. Pressure cap pressure control
• 13.5.3. Pressure cap inspection
• 13.5.4. Replacing filler neck
• 13.5.5. Function of the coolant recovery tank
• 13.5.6. Specifications of coolant recovery tank
• 13.5.7. Mounting the coolant recovery tank
• 13.5.8. Precautions on usage of the coolant recovery tank
• 13.6. Thermostat
• 13.6.1. Functioning of thermostat
• 13.6.2. Thermostat construction
• 13.6.3. Characteristics of thermostat
• 13.6.4. Thermostat inspection
• 13.6.5. Testing the thermostat
• 13.7. Bilge pump and bilge strainer (Optional)
• 13.7.1. Introduction
• 13.7.2. Description
• 13.7.3. Cautions
• 13.7.4. Assembly procedure
• 13.7.5. Cautions for assembling
• 13.7.6. Troubleshooting
• 14. Reduction and reversing gear
• 14.1. Specifications
• 15. Remote control (Optional)
• 15.1. Remote control system
• 15.1.1. Construction of remote control system
• 15.1.2. Remote control device components
• 15.2. Remote control installation
• 15.3. Remote control inspection
• 15.4. Remote control adjustment
• 16. Electrical system
• 16.1. Electrical system
• 16.1.1. Wiring diagram
• 16.2. Battery
• 16.3. Starting motor
• 16.3.1. Specifications
• 16.3.2. Characteristics
• 16.3.3. Structure
• 16.3.4. Wiring diameter of a starting motor
• 16.4. Alternator standard, 12V/60A
• 16.4.1. Specifications
• 16.4.2. Structure
• 16.4.3. Wiring diagram
• 16.4.4. Standard output characteristics
• 16.4.5. Inspection
• 16.5. Alternator 12V/80A (Optional)
• 16.5.1. Specifications
• 16.5.2. Structure
• 16.5.3. Wiring diagram
• 16.5.4. Standard output characteristics
• 16.6. Instrument panel
• 16.6.1. B-type instrument panel (Optional)
• 16.7. Warning devices
• 16.7.1. Oil pressure alarm
• 16.7.2. Cooling water temperature alarm
• 16.8. Glow plug
• 16.9. Electric engine stopping device
• 17. Service standards
• 17.1. Engine tuning
• 17.2. Engine body
• 17.2.1. Cylinder head
• 17.2.2. Camshaft and gear train
• 17.2.3. Cylinder block
• 17.3. Lubricating oil system (Trochoid pump)
• 18. Tightening torque for bolts and nuts
• 18.1. Main bolt and nut
• 18.2. Standard bolts and nuts (without lube oil)
• 19. Colophon
• 20. Back cover