Yanmar Engine 3YM30 3YM20 2YM15 Service Manual M9961-03E101

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Yanmar Engine 3YM30 3YM20 2YM15 Service Manual M9961-03E101
Size: 15.71 MB
Format: PDF
Language: English
Brand: Yanmar
Type of Machine: Engine
Type of Manual: Service Manual, Wiring Diagram
Model: Yanmar 3YM30 3YM20 2YM15 Engine
Part Number: M9961-03E101
Number of Pages: 231 Pages

Contents:
1. General

1.1 Exterior views​

1.2 Specifications​

1.3 Fuel oil, lubricating oil and cooling water​

1.3.1 Fuel oil​

1.3.2 Lubricating oil​

1.3.3 Cooling water​

1.4 Engine outline​

1.5 Piping diagrams​

1.6 Exhaust gas emission regulation​

1.6.1 Engine identification (EPA/ARB)​

1.6.2 Exhaust gas emission standard (EPA/ARB)​

1.6.3 Guarantee conditions for emission standard (EPA/ARB)​

2. Inspection and adjustment

2.1 Periodic maintenance schedule​

2.2 Periodic inspection and maintenance procedure​

2.2.1 Check before starting​

2.2.2 inspection after initial 50 hours or one month operation​

2.2.3 Inspection every 50 hours or monthly​

2.2.4 Inspection every 100 hours six months​

2.2.5 Inspection every 150 hours or one year​

2.2.6 Inspection every 250 hours or one year​

2.2.7 Inspection every 1,000 hours or four years​

2.3 Adjusting the no-load maximum or minimum speed​

2.4 Sensor Inspection​

2.4.1 Oil pressure switch​

2.4.2 Thermo switch​

2.5 Thermostat inspection​

2.6 Adjusting operation​

2.6.1 Preliminary precautions​

2.6.2 Adjusting operation procedure​

2.6.3 Check points and precautions during running​

2.7 Long storage​

3. Troubleshooting

3.1 Preparation before troubleshooting​

3.2 Quick reference chart for troubleshooting​

3.3 Troubleshooting (Concerning engine and fuel injection equipment)​

3.4 Troubleshooting by measuring compression pressure​

4. Disassembly and reassembly

4.1 Disassembly and reassembly precautions​

4.2 Disassembly and reassembly tools​

4.2.1 General hand tools​

4.2.2 Special hand tools​

4.2.3 Measuring instruments​

4.2.4 Other material​

4.3 Disassembly and reassembly​

4.3.1 Disassembly​

4.3.2 Reassembly​

5. Inspection and servicing of basic engine parts

5.1 Cylinder block​

5.1.1 Inspection of parts​

5.1.2 Cleaning of oil holes​

5.1.3 Color check procedure​

5.1.4 Replacement of cap plugs​

5.1.5 Cylinder bore measurement​

5.2 Cylinder head​

5.2.1 Inspecting the cylinder head​

5.2.2 Valve seat correction procedure​

5.2.3 Intake/exhaust valves, valve guides​

5.2.4 Valve springs​

5.2.5 Assembling the cylinder head​

5.2.6 Measuring top clearance​

5.2.7 Intake and exhaust rocker arms​

5.2.8 Adjustment of valve clearance​

5.3 Piston and piston pins​

5.3.1 Piston​

5.3.2 Piston pin​

5.3.3 Piston rings​

5.4 Connecting rod​

5.4.1 Inspecting the connection rod​

5.4.2 Crank pin metal​

5.4.3 Piston pin bushing​

5.4.4 Assembling piston and connecting rod​

5.5 Crankshaft and main bearing​

5.5.1 Crankshaft​

5.5.2 Main bearing​

5.6 Camshaft and tappets​

5.6.1 Camshaft​

5.6.2 Tappets​

5.7 Timing gear​

5.7.1 Inspecting the gears​

5.7.2 Gear timing marks​

5.8 Flywheel and housing​

5.8.1 Position of top dead center and fuel injection timing​

5.8.2 Damper disc​

6. Fuel injection equipment

6.1 Fuel Injection pump/governor​

6.1.1 Fuel system diagram​

6.1.2 Fuel injection pump service data and adjustment​

6.1.3 Fuel injection pump structure​

6.1.4 Removing a fuel injection pump​

6.1.5 Installing a fuel injection pump​

6.1.6 Adjusting fuel injection timing​

6.1.7 Troubleshooting of fuel injection pump​

6.1.8 Major faults and troubleshooting​

6.2 Fuel feed pump​

6.2.1 Construction of fuel feed pump​

6.2.2 Fuel feed pump specifications​

6.2.3 Disassembly and reassembly of fuel feed pump​

6.2.4 Fuel feed pump inspection​

6.3 Fuel filter​

6.3.1 Fuel filter specifications​

6.3.2 Fuel filter inspection​

6.4 Fuel tank​

7. Intake and exhaust system

7.1 Intake system​

7.1.1 Breather system (A reductor to intake air system of blowby gas)​

7.1.2 Diaphragm assy inspection​

7.2 Exhaust system​

7.2.1 Construction​

7.2.2 Mixing elbow inspection​

8. Lubrication system

8.1 Lubrication system​

8.2 Lube oil pump​

8.2.1 Lube oil pump construction​

8.2.2 Specifications of lube oil pump​

8.2.3 Lube oil pump disassembly and reassembly​

8.2.4 Lube oil pump inspection​

8.2.5 Pressure control valve construction​

8.3 Lube oil filter​

8.3.1 Lube oil filter construction​

8.3.2 Lube oil filter replacement​

8.4 Rotary waste oil pump (Optional)​

9. Cooling water system

9.1 Cooling water system​

9.2 Seawater pump​

9.2.1 Specifications of seawater pump​

9.2.2 Seawater pump disassembly​

9.2.3 Seawater pump Inspection​

9.2.4 Seawater pump reassembly​

9.3 Fresh water pump​

9.3.1 Fresh water pump construction​

9.3.2 Specifications of fresh water pump​

9.3.3 Fresh water pump disassembly​

9.3.4 WFresh water pump inspection​

9.4 Heat exchanger​

9.4.1 Heat exchanger construction​

9.4.2 Disassembly and reassembly of the heat exchanger​

9.4.3 Heat exchanger inspection​

9.5 Pressure cap and coolant recovery tank​

9.5.1 Pressure cap construction​

9.5.2 Pressure cap pressure control​

9.5.3 Pressure cap inspection​

9.5.4 Replacing filler neck​

9.5.5 Function of the coolant recovery tank​

9.5.6 Specifications of coolant recovery tank​

9.5.7 Mounting the coolant recovery tank​

9.5.8 Precautions on usage of the coolant recovery tank​

9.6 Thermostat​

9.6.1 Functioning of thermostat​

9.6.2 Thermostat construction​

9.6.3 Characteristics of thermostat​

9.6.4 Thermostat inspection​

9.6.5 Testing the thermostat​

9.7 Bilge pump and bilge strainer (Optional)​

9.7.1 Introduction​

9.7.2 Description​

9.7.3 Cautions​

9.7.4 Assembly procedure​

9.7.5 Cautions for assembling​

9.7.6 Troubleshooting​

10. Reduction and reversing gear

10.1 Specifications​

11. Remote control (Optional)

11.1 Remote control system​

11.1.1 Construction of remote control system​

11.1.2 Remote control device components​

11.2 Remote control installation​

11.3 Remote control inspection​

11.4 Remote control adjustment​

12. Electrical system

12.1 Electrical system​

12.1.1 Wiring diagram​

12.2 Battery​

12.3 Starting motor​

12.3.1 Specifications​

12.3.2 Characteristics​

12.3.3 Structure​

12.3.4 Wiring diameter of a starting motor​

12.4 Alternator standard, 12V/60A​

12.4.1 Specifications​

12.4.2 Structure​

12.4.3 Wiring diagram​

12.4.4 Standard output characteristics​

12.4.5 Inspection​

12.5 Alternator 12V/80A (Optional)​

12.5.1 Specifications​

12.5.2 Structure​

12.5.3 Wiring diagram​

12.5.4 Standard output characteristics​

12.6 Instrument panel​

12.6.1 B-type instrument panel (Optional)​

12.7 Warning devices​

12.7.1 Oil pressure alarm​

12.7.2 Cooling water temperature alarm​

12.8 Glow plug​

12.9 Electric engine stopping device​

13. Service standards

13.1 Engine tuning​

13.2 Engine body​

13.2.1 Cylinder head​

13.2.2 Camshaft and gear train​

13.2.3 Cylinder block​

13.3 Lubricating oil system (Trochoid pump)​

14. Tightening torque for bolts and nuts

14.1 Main bolt and nut​

14.2 Standard bolts and nuts (without lube oil)​

Colophon
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