Yanmar Marine Diesel Engine 3YM30, 3YM20, 2YM15 Service Repair Workshop Manual
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Printed in Japan
Publication No. 0BYMM-G00100
History of Revision
Manual Name Service Manual for Marine Diesel Engine
Engine Model: 3YM30/3YM20/2YM15
Number
of
revision
Date of
revision
Reason for
correction
Outline of correction
Correction item
No (page)
Corrected by
New edition March 2004
R1 April 25,
2005
Add : Eug.
Model 2YM15
1. Specifications table added.
2. Engine outline added.
3. Piping diagram added.
4. Other data added.
Quality Control
Dept. Marine
Factory
Corrected
data.
(3YM30,
3YM20)
1. Front cover added to engine
outline.
2. Notice on seawater pump
rotating direction was changed.
3. Incorrect word corrected.
P6-P9
P32
R2 Nov.
2006
Corrected
data.
1. Engine mounting bolt side pitch
(3YM30 with KM2P-1).
2. Engine mounting bolt side pitch
(3YM30C with SD20).
3. No-load max. speed (3YM20).
P6
P7
P44
YMI Business
Development
Department
R2
FOREWORD
This service manual has been complied for engineers engaged in sales, service, inspection and
maintenance. Accordingly, descriptions of the construction and functions of the engine are emphasized
in this manual, while items, which should already be common knowledge, are omitted.
One characteristic of a marine diesel engine is that its performance in a vessel is governed by the
applicability of the vessel's hull construction and its steering system.
Engine installation, fitting out and propeller selection have a substantial effect on the performance of the
engine and the vessel. Moreover, when the engine runs unevenly or when trouble occurs, it is essential
to check a wide range of operating conditions - such as installation to the full and suitability of the ship's
piping and propeller - and not just the engine itself. To get maximum performance from this engine, you
should completely understand its functions, construction and capabilities, as well as proper use and
servicing.
Use this manual as a handy reference in daily inspection and maintenance, and as a text for engineering
guidance.
Model 3YM30 has been used for the illustrations in this service manual, but they apply to other models in
the 3YM series engines.
2005 YANMAR CO., LTD
All rights reserved. This manual may not be
reproduced or copied, in whole or in part,
without the written permission of YANMAR
CO., LTD.
c
California
Proposition 65 Warning
Diesel engine exhaust and some of its
constituents are known to the State of
California to cause cancer, birth de-
fects, and other reproductive harm.
California
Proposition 65 Warning
Battery posts, terminals, and related ac-
cessories contain lead and lead com-
pounds, chemicals known to the State
of California to cause cancer and repro-
ductive harm.
Wash hands, after handling.
R1
CONTENTS
1. General ............................................................................................................................ 1
1.1 Exterior views ........................................................................................................................... 1
1.2 Specifications ........................................................................................................................... 2
1.3 Fuel oil, lubricating oil and cooling water ................................................................................. 4
1.3.1 Fuel oil .............................................................................................................................................. 4
1.3.2 Lubricating oil .................................................................................................................................... 4
1.3.3 Cooling water .................................................................................................................................... 5
1.4 Engine outline .......................................................................................................................... 6
1.5 Piping diagrams ..................................................................................................................... 10
1.6 Exhaust gas emission regulation ........................................................................................... 12
1.6.1 Engine identification (EPA/ARB) ..................................................................................................... 12
1.6.2 Exhaust gas emission standard (EPA/ARB) ................................................................................... 13
1.6.3 Guarantee conditions for emission standard (EPA/ARB) ............................................................... 13
2. Inspection and adjustment ............................................................................................. 15
2.1 Periodic maintenance schedule ............................................................................................. 15
2.2 Periodic inspection and maintenance procedure ................................................................... 17
2.2.1 Check before starting ...................................................................................................................... 17
2.2.2 inspection after initial 50 hours or one month operation ................................................................. 20
2.2.3 Inspection every 50 hours or monthly ............................................................................................. 25
2.2.4 Inspection every 100 hours six months........................................................................................... 30
2.2.5 Inspection every 150 hours or one year .......................................................................................... 30
2.2.6 Inspection every 250 hours or one year .......................................................................................... 31
2.2.7 Inspection every 1,000 hours or four years..................................................................................... 37
2.3 Adjusting the no-load maximum or minimum speed .............................................................. 44
2.4 Sensor Inspection .................................................................................................................. 44
2.4.1 Oil pressure switch.......................................................................................................................... 44
2.4.2 Thermo switch................................................................................................................................. 44
2.5 Thermostat inspection ............................................................................................................ 45
2.6 Adjusting operation ................................................................................................................ 46
2.6.1 Preliminary precautions .................................................................................................................. 46
2.6.2 Adjusting operation procedure ........................................................................................................ 46
2.6.3 Check points and precautions during running................................................................................. 47
2.7 Long storage .......................................................................................................................... 48
3. Troubleshooting ............................................................................................................. 49
3.1 Preparation before troubleshooting ........................................................................................ 49
3.2 Quick reference chart for troubleshooting .............................................................................. 50
3.3 Troubleshooting (Concerning engine and fuel injection equipment) ...................................... 59
3.4 Troubleshooting by measuring compression pressure .......................................................... 62
4. Disassembly and reassembly ........................................................................................ 64
4.1 Disassembly and reassembly precautions ............................................................................. 64
4.2 Disassembly and reassembly tools ........................................................................................ 65
4.2.1 General hand tools.......................................................................................................................... 65
4.2.2 Special hand tools........................................................................................................................... 68
4.2.3 Measuring instruments.................................................................................................................... 71
4.2.4 Other material ................................................................................................................................. 75
4.3 Disassembly and reassembly ................................................................................................ 77
4.3.1 Disassembly.................................................................................................................................... 77
4.3.2 Reassembly .................................................................................................................................... 89
5. Inspection and servicing of basic engine parts ............................................................ 104
5.1 Cylinder block ....................................................................................................................... 104
5.1.1 Inspection of parts......................................................................................................................... 104
5.1.2 Cleaning of oil holes...................................................................................................................... 104
5.1.3 Color check procedure .................................................................................................................. 104
5.1.4 Replacement of cap plugs ............................................................................................................ 105
5.1.5 Cylinder bore measurement .......................................................................................................... 106
5.2 Cylinder head ....................................................................................................................... 107
5.2.1 Inspecting the cylinder head ......................................................................................................... 108
5.2.2 Valve seat correction procedure ................................................................................................... 109
5.2.3 Intake/exhaust valves, valve guides ............................................................................................. 110
5.2.4 Valve springs ................................................................................................................................ 112
5.2.5 Assembling the cylinder head ....................................................................................................... 113
5.2.6 Measuring top clearance............................................................................................................... 114
5.2.7 Intake and exhaust rocker arms.................................................................................................... 114
5.2.8 Adjustment of valve clearance ...................................................................................................... 115
5.3 Piston and piston pins .......................................................................................................... 116
5.3.1 Piston ............................................................................................................................................ 116
5.3.2 Piston pin ...................................................................................................................................... 117
5.3.3 Piston rings ................................................................................................................................... 118
5.4 Connecting rod ..................................................................................................................... 121
5.4.1 Inspecting the connection rod ....................................................................................................... 121
5.4.2 Crank pin metal ............................................................................................................................. 122
5.4.3 Piston pin bushing......................................................................................................................... 124
5.4.4 Assembling piston and connecting rod ......................................................................................... 124
5.5 Crankshaft and main bearing ............................................................................................... 125
5.5.1 Crankshaft ..................................................................................................................................... 125
5.5.2 Main bearing ................................................................................................................................. 127
5.6 Camshaft and tappets .......................................................................................................... 128
5.6.1 Camshaft ....................................................................................................................................... 128
5.6.2 Tappets ......................................................................................................................................... 130
5.7 Timing gear .......................................................................................................................... 131
5.7.1 Inspecting the gears...................................................................................................................... 131
5.7.2 Gear timing marks......................................................................................................................... 131
5.8 Flywheel and housing .......................................................................................................... 132
5.8.1 Position of top dead center and fuel injection timing..................................................................... 132
5.8.2 Damper disc .................................................................................................................................. 133
6. Fuel injection equipment .............................................................................................. 134
6.1 Fuel Injection pump/governor ............................................................................................... 134
6.1.1 Fuel system diagram..................................................................................................................... 134
6.1.2 Fuel injection pump service data and adjustment ......................................................................... 135
6.1.3 Fuel injection pump structure ........................................................................................................ 139
6.1.4 Removing a fuel injection pump .................................................................................................... 140
6.1.5 Installing a fuel injection pump ...................................................................................................... 140
6.1.6 Adjusting fuel injection timing........................................................................................................ 140
6.1.7 Troubleshooting of fuel injection pump ......................................................................................... 141
6.1.8 Major faults and troubleshooting ................................................................................................... 141
6.2 Fuel feed pump .................................................................................................................... 144
6.2.1 Construction of fuel feed pump ..................................................................................................... 144
6.2.2 Fuel feed pump specifications ...................................................................................................... 144
6.2.3 Disassembly and reassembly of fuel feed pump .......................................................................... 145
6.2.4 Fuel feed pump inspection ............................................................................................................ 145
6.3 Fuel filter .............................................................................................................................. 147
6.3.1 Fuel filter specifications................................................................................................................. 147
6.3.2 Fuel filter inspection ...................................................................................................................... 147
6.4 Fuel tank .............................................................................................................................. 148
7. Intake and exhaust system .......................................................................................... 149
7.1 Intake system ....................................................................................................................... 149
7.1.1 Breather system (A reductor to intake air system of blowby gas) ................................................. 149
7.1.2 Diaphragm assy inspection ........................................................................................................... 150
7.2 Exhaust system .................................................................................................................... 151
7.2.1 Construction .................................................................................................................................. 151
7.2.2 Mixing elbow inspection ................................................................................................................ 151
8. Lubrication system ....................................................................................................... 152
8.1 Lubrication system ............................................................................................................... 152
8.2 Lube oil pump ....................................................................................................................... 153
8.2.1 Lube oil pump construction ........................................................................................................... 153
8.2.2 Specifications of lube oil pump ..................................................................................................... 153
8.2.3 Lube oil pump disassembly and reassembly ................................................................................ 153
8.2.4 Lube oil pump inspection .............................................................................................................. 154
8.2.5 Pressure control valve construction .............................................................................................. 154
8.3 Lube oil filter ......................................................................................................................... 155
8.3.1 Lube oil filter construction ............................................................................................................. 155
8.3.2 Lube oil filter replacement ............................................................................................................. 155
8.4 Rotary waste oil pump (Optional) ......................................................................................... 156
9. Cooling water system ................................................................................................. 157
9.1 Cooling water system ........................................................................................................... 157
9.2 Seawater pump .................................................................................................................... 159
9.2.1 Specifications of seawater pump .................................................................................................. 159
9.2.2 Seawater pump disassembly ........................................................................................................ 159
9.2.3 Seawater pump Inspection ........................................................................................................... 160
9.2.4 Seawater pump reassembly ......................................................................................................... 161
9.3 Fresh water pump ............................................................................................................... 162
9.3.1 Fresh water pump construction..................................................................................................... 162
9.3.2 Specifications of fresh water pump ............................................................................................... 162
9.3.3 Fresh water pump disassembly .................................................................................................... 163
9.3.4 WFresh water pump inspection .................................................................................................... 163
9.4 Heat exchanger .................................................................................................................... 165
9.4.1 Heat exchanger construction ........................................................................................................ 165
9.4.2 Disassembly and reassembly of the heat exchanger ................................................................... 165
9.4.3 Heat exchanger inspection ........................................................................................................... 165
9.5 Pressure cap and coolant recovery tank .............................................................................. 166
9.5.1 Pressure cap construction ............................................................................................................ 166
9.5.2 Pressure cap pressure control ...................................................................................................... 166
9.5.3 Pressure cap inspection................................................................................................................ 166
9.5.4 Replacing filler neck ...................................................................................................................... 167
9.5.5 Function of the coolant recovery tank ........................................................................................... 168
9.5.6 Specifications of coolant recovery tank......................................................................................... 168
9.5.7 Mounting the coolant recovery tank .............................................................................................. 168
9.5.8 Precautions on usage of the coolant recovery tank ...................................................................... 168
9.6 Thermostat ........................................................................................................................... 169
9.6.1 Functioning of thermostat ............................................................................................................. 169
9.6.2 Thermostat construction ............................................................................................................... 169
9.6.3 Characteristics of thermostat ........................................................................................................ 169
9.6.4 Thermostat inspection................................................................................................................... 169
9.6.5 Testing the thermostat .................................................................................................................. 169
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$28.99
This is a highly detailed factory service repair manual for the Yanmar Marine Diesel Engine 3YM30, 3YM20, 2YM15. The service manual provides detailed illustrations and step-by-step instructions, making it suitable for both do-it-yourself enthusiasts and experienced mechanics. It offers step-by-step instructions based on the complete disassembly of the machine, along with hundreds of photos and illustrations to guide the reader through each service and repair procedure.
Models Covered:
- Yanmar Marine Diesel Engine 3YM30
- Yanmar Marine Diesel Engine 3YM20
- Yanmar Marine Diesel Engine 2YM15
Service Repair Manual Covers:
- General
- Inspection and adjustment
- Troubleshooting
- Disassembly and reassembly
- Inspection and servicing of basic engine parts
- Fuel injection equipment
- Intake and exhaust system
- Lubrication system
- Cooling water system
- Reduction and reversing gear
- Remote control
- Electrical system
- Service standards
- Tightening torque for bolts and nuts
- And more...
File Format: PDF
Compatible: All Versions of Windows & Mac
Language: English
Requirements: Adobe Reader & WinZip
No waiting, buy from a responsible seller and get instant access. All pages are printable. It is a great resource to have the Yanmar Marine Diesel Engine 3YM30, 3YM20, 2YM15 Service Repair Workshop Manual.
