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Yanmar YM Series 3YM30 3YM20 2YM15 Engine Service & Repair Manual - IMPROVED - DOWNLOAD
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* SEARCHABLE - BOOKMARKED - INDEXED
Comprehensive illustrations, exploded diagrams, drawings and photos guide you through the service repair procedures.
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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
9.7 Bilge pump and bilge strainer (Optional) ..............................................................................170
9.7.1 Introduction .................................................................................................................................. 170
9.7.2 Description................................................................................................................................... 171
9.7.3 Cautions....................................................................................................................................... 171
9.7.4 Assembly procedure ..................................................................................................................... 172
9.7.5 Cautions for assembling ............................................................................................................... 174
9.7.6 Troubleshooting ............................................................................................................................ 175
10. Reduction and reversing gear ................................................................................... 176
10.1 Specifications .....................................................................................................................176
11. Remote control (Optional) ......................................................................................... 177
11.1 Remote control system ......................................................................................................177
11.1.1 Construction of remote control system ....................................................................................... 177
11.1.2 Remote control device components............................................................................................ 177
11.2 Remote control installation .................................................................................................179
11.3 Remote control inspection ..................................................................................................181
11.4 Remote control adjustment ................................................................................................182
12. Electrical system ........................................................................................................ 183
12.1 Electrical system ................................................................................................................183
12.1.1 Wiring diagram........................................................................................................................... 184
12.2 Battery ...............................................................................................................................185
12.3 Starting motor .....................................................................................................................186
12.3.1 Specifications............................................................................................................................. 186
12.3.2 Characteristics ............................................................................................................................ 186
12.3.3 Structure .................................................................................................................................... 187
12.3.4 Wiring diameter of a starting motor............................................................................................. 188
12.4 Alternator standard, 12V/60A .............................................................................................189
12.4.1 Specifications............................................................................................................................. 189
12.4.2 Structure .................................................................................................................................... 190
12.4.3 Wiring diagram........................................................................................................................... 191
12.4.4 Standard output characteristics .................................................................................................. 191
12.4.5 Inspection................................................................................................................................... 192
12.5 Alternator 12V/80A (Optional) ............................................................................................193
12.5.1 Specifications............................................................................................................................. 193
12.5.2 Structure .................................................................................................................................... 194
12.5.3 Wiring diagram........................................................................................................................... 195
12.5.4 Standard output characteristics .................................................................................................. 195
12.6 Instrument panel ................................................................................................................196
12.6.1 B-type instrument panel (Optional) ............................................................................................. 196
12.7 Warning devices .................................................................................................................197
12.7.1 Oil pressure alarm....................................................................................................................... 197
12.7.2 Cooling water temperature alarm................................................................................................ 198
12.8 Glow plug ...........................................................................................................................199
12.9 Electric engine stopping device ..........................................................................................200
13. Service standards ...................................................................................................... 201
13.1 Engine tuning .....................................................................................................................201
13.2 Engine body .......................................................................................................................202
13.2.1 Cylinder head............................................................................................................................. 202
13.2.2 Camshaft and gear train ............................................................................................................. 203
13.2.3 Cylinder block ............................................................................................................................. 204
13.3 Lubricating oil system (Trochoid pump) .............................................................................207
14. Tightening torque for bolts and nuts .......................................................................... 208
14.1 Main bolt and nut ................................................................................................................208
14.2 Standard bolts and nuts (without lube oil) ..........................................................................208
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This easy to follow manual is ideal for the Do-it-Yourself restorer or mechanic.
There are lots of pictures, diagrams, illustrations and charts.
Technical details and step-by-step instructions you will need are included.
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