Yanmar 3YM30 Service Manual
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Yanmar 3YM30 Service Manual

Marine engine
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M9961-03E101
3YM30/3YM20/2YM15

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Summary of Contents for Yanmar 3YM30

  • Page 1 M9961-03E101 3YM30/3YM20/2YM15...
  • Page 2 Publication No. M9961-03E101 History of Revision Manual Name Service Manual for Marine Diesel Engine Engine Model: 3YM30/3YM20/2YM15 Number Date of Reason for Correction item Corrected Outline of correction revision correction No (page) revision New edition March 2004 April Add : Eug.
  • Page 3 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.

  • Page 4: Table Of Contents

    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).....................
  • Page 5 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............................
  • Page 6 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..........................
  • Page 7 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......................
  • Page 8 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.
  • Page 9 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 ..........................
  • Page 10 FOR SAFETY 1. SAFETY LABELS • Most accidents are caused by negligence of basic safety rules and precautions. For accident prevention, it is important to avoid such causes before development to accidents. Please read this manual carefully before starting repair or maintenance to fully understand safety precautions and appropriate inspection and maintenance procedures.
  • Page 11 2. Safety Precautions (1) SERVICE AREA • Sufficient Ventilation Inhalation of exhaust fumes and dust particles may be hazardous to ones health. Running engines welding, sanding, painting, and polishing tasks should be only done in well ventilated areas. • Safe / Adequate Work Area The service area should be clean, spacious, level and free from holes in the floor, to prevent "slip"...
  • Page 12 (4) GENUINE PARTS and MATERIALS • Genuine Parts Always use genuine YANMAR parts or YANMAR recommended parts and goods. Damage to the engine, shortened engine life and or personal injury may result.
  • Page 13 (5) FASTENER TORQUE • Torquing Fasteners Always follow the torque values and procedures as designated in the service manual. Incorrect values, procedures and or tools may cause damage to the engine and or personal injury. (6) Electrical • Short Circuits Always disconnect the (-) Negative battery cable before working on the electrical system.
  • Page 14 (8) FURTHER PRECAUTIONS • Fueling / Refueling Keep sparks, open flames or any other form of ignition (match, cigarette, etc.) away when fueling/refueling the unit. Fire and or an explosion may result. • Hot Surfaces. Do NOT touch the engine (or any of its components) during running or shortly after shutting it down.
  • Page 15 3. Precautions for Service Work (1) Precautions for Safety Read the safety precautions given at the beginning of this manual carefully and always mind safety in work. (2) Preparation for Service Work Preparation is necessary for accurate, efficient service work. Check the customer ledger file for the history of the engine.

  • Page 16: General

    Engine name plate (on the rocker arm cover) Fresh water filler cap Coolant tank / Heat exchanger Cover Exhaust manifold Starter motor Shift lever Sea water pump V-belt Alternator <Note> This illustration shows the 3YM30 with Yanmar marine gear (Model:KM2P-1).

  • Page 17: Specifications

    1. General 1.2 Specifications Official engine model name unit 3YM30 3YM20 Company internal model name 3YM30 3YM30C 3YM20 3YM20C Marine gear model KM2P-1 SD20 KM2P-1 SD20 Pleasure use Type Vertical water cooled 4 cycle diesel engine Combustion system Indirect injection...
  • Page 18 1. General Official engine model name unit 2YM15 Company internal model name 2YM15 2YM15C Marine gear model KM2P-1 SD20 Pleasure use Type Vertical water cooled 4 cycle diesel engine Combustion system Indirect injection Air charging Naturally aspirated Number of cylinders Bore x stroke mm(inch) 70 x 74 (2.76 x 2.91)
  • Page 19 1. General (Note) 1. Rating condition : ISO 3046-1, 8665 2. 1HP (metric horse power) ≒ 0.7355 kW 3. Fuel condition : Density at 15°C = 0.842 * Fuel temperature 25°C at the inlet of the fuel injection pump. (ISO 3046-1) ** Fuel temperature 40°C at the inlet of the fuel injection pump.

  • Page 20: Fuel Oil, Lubricating Oil And Cooling Water

    1. General 1.3 Fuel oil, lubricating oil and cooling water 1.3.1 Fuel oil IMPORTANT: Only use the recommended fuel to obtain the best engine performance and prevent damage of parts, also prevent air pollution. (1) Selection of fuel oil Use the following diesel fuels for best engine performance: BS 2869 A1 or A2 Fuels equivalent to Japanese Industrial Standard, JIS.

  • Page 21: Cooling Water

    1. General (2) Selection of marine gear lube oil Use the following engine oil • API classification ..CD or better (Standards of America Petroleum Institute) • SAE viscosity ..#20 or #30 (Standard of Society of Automotive Engineering) (3) Selection of lube oil for sail drive unit API service grade ..

  • Page 22: Engine Outline

    1.General 1.4 Engine outline (1) 3YM30 (with KM2P-1 marine gear)
  • Page 23 1.General (2) 3YM30C (with SD20 sail drive)
  • Page 24 1.General (3) 3YM20 (with KM2P-1 marine gear)
  • Page 25 1.General (4) 3YM20C (with SD20 sail drive) NOTE 1. DWG. SHOWS MOUNTING BLOCKS AT ORIGINAL HEIGHT. 2. ENGINE WEIGHT WILL COMPRESS BLOCKS BY 4.5 mm (APPROX.). 3. MOUNTING BLOCKS ARE EQUIPPED FOR STANDARD ACCESSORY. SHOWS CENTER OF GRAVITY. 007018-00E...
  • Page 26 1.General (5) 2YM15 (with KM2P-1 marine gear) 9-2R1...
  • Page 27 1.General (6) 2YM15C (with SD20 sail drive) 9-3R1...

  • Page 28: Piping Diagrams

    1.General 1.5 Piping diagrams (1) 3YM30/3YM20 (with KM2P-1 marine gear) 7.8 x t4.5 rubber hose 7.8 x t4.5 rubber hose Fuel feed pump 7.8 x t4.5 rubber hose Marks of piping 7.8 x t4.5 rubber hose 5 x t4.5 Fuel injection pump...
  • Page 29 1.General (2) 3YM30C/3YM20C (with sale drive SD20) 7.8 x t4.5 rubber hose 7.8 x t4.5 rubber hose 7.8 x t4.5 rubber hose Fuel feed pump Marks of piping 7.8 x t4.5 rubber hose 5 x t4.5 Fuel injection pump Screw joint (Union) rubber hose Check valve Flange joint...
  • Page 30 1.General (3) 2YM15 (with KM2P-1 marine gear) 11-2R1...
  • Page 31 1.General (4) 2YM15C (with sale drive SD20) 11-3R1...

  • Page 32: Exhaust Gas Emission Regulation

    (EPA and ARB label) (Note) Emission Control is accomplished through Engine Modification (EM-Design) • The tamper resistance device is installed with EPA/ARB certified 3YM30/3YM20/2YM15 series engines to prevent illegal change of fuel injection volume and high idling speed. (Fuel injection volume : cap type, High idling speed : cap type) •...

  • Page 33: Exhaust Gas Emission Standard (Epa/Arb)

    1.General 1.6.2 Exhaust gas emission standard (EPA/ARB) Engine Power Tier Model Year NMHC + NOx 8 <= kW < 19 Tier 1 2000 9.5 (7.1) 6.6 (4.9) 0.80 (0.60) (11 <= hp < 25) Tier 2 2005 7.5 (5.6) 6.6 (4.9) 0.80 (0.60) 19<= kW <...
  • Page 34 1.General (5) Quality guarantee period for exhaust emission related parts For exhaust emission related parts, follow the inspections outlined in the "List of Periodic Inspections", on the operation manual, and use the table below to carry out inspections based on operation hours or time in years.

  • Page 35: Inspection And Adjustment

    2. Inspection and adjustment 2. Inspection and adjustment 2.1 Periodic maintenance schedule The engine periodic inspection timing is hard to determine as it varies with the application, load status, qualities of the fuel and lubricating oils used and handling status. General rules are described here. : User-maintenance : Parts replacement : Shop-inspection...
  • Page 36 2. Inspection and adjustment : User-maintenance : Parts replacement : Shop-inspection Initial Every Every Every Every Every Before System Item 50hrs. or 50hrs. or 100 hrs. or 150 hrs. or 250 hrs. or 1000 hrs. or starting one month one month six months one year one year...

  • Page 37: Periodic Inspection And Maintenance Procedure

    Standard The level shall be between the upper and lower limit lines on the dipstick. Unit : liter (quart) Model Rake angle Engine oil capacity (Full) (3.0) 3YM30 with KM2P-1 -0.2 3YM20 with KM2P-1 8 degree (2.9) -0.2 (2.1) 2YM15 with KM2P-1 -0.2...
  • Page 38 • Daily cooling water level check and replenishing shall be done only at the coolant recovery tank. Usually do not open the filler cap to check or replenish. Standard Cooling water volume Unit : liter (quart) Model Engine Coolant recovery tank 3YM30 4.9 (5.2) 0.8 (0.8) 3YM20 4.1 (4.3) 0.8 (0.8) 2YM15 3.0 (3.2) 0.8 (0.8)
  • Page 39 2. Inspection and adjustment IMPORTANT: If the cooling water runs short quickly or when the coolant tank runs short of water with the coolant recovery tank level unchanged, water may be leaking or the air tightness may be lost. Increase in the water level of the coolant recovery tank during operation is not abnormal.

  • Page 40: Inspection After Initial 50 Hours Or One Month Operation

    2. Inspection and adjustment 2.2.2 inspection after initial 50 hours or one month operation Be sure to check the following points after initial 50 hours or one month operation, whichever comes first. Inspection Item Drain the fuel tank Replace the engine lube oil and the lube oil filter Replace the marine gear &...
  • Page 41 Standard The level shall be between the upper and lower limit lines on the dipstick. Unit : liter (quart) Model Rake angle Engine oil capacity (Full) (3.0) 3YM30 with KM2P-1 -0.2 (2.9) 3YM20 with KM2P-1 8 degree -0.2 2YM15 with KM2P-1 (2.1)
  • Page 42 V-pulley set bolts for the cooling water pump. Remove the V-belt. After replacing with a new V-belt and adjusting the tension, run the engine for 5 minutes and readjust the Belt adjuster deflection to the value in the table above. (3YM30) 22R1...
  • Page 43 2. Inspection and adjustment (5) Adjusting the intake/exhaust valve clearance Make measurement and adjustment while the engine is cold. 1) Valve clearance measurement Flywheel a) Remove the rocker arm cover above cylinder housing head. Injection b) Set the No.1 cylinder in the compression TDC timing marks Turn the crankshaft to bring the piston of the No.1 cylinder...
  • Page 44 2. Inspection and adjustment b) Measure valve clearance Insert a 0.2 mm thickness gage between the rocker arm and valve cap, and adjust the valve clearance. Tighten the adjusting bolt. Standard valve clearance (mm) 0.15-0.25 c) Apply oil to the contact surface between adjusting screw and push rod.

  • Page 45: Inspection Every 50 Hours Or Monthly

    2. Inspection and adjustment (7) Adjust the propeller shaft alignment The flexible engine mounts is compressed a little in the initial engine operation and it may cause the centering misalignment between the engine & the propeller shaft. 1) Check unusual noise and vibration of the engine / boat hull, while increasing the engine speed gradually and lowering it.
  • Page 46 2. Inspection and adjustment Cylinder head Bracket Fuel pipe Fuel filter Fuel injection pump Clamp Fuel pipe...
  • Page 47 2. Inspection and adjustment (2) Check the electrolyte level in the battery Fire due to electric short-circuit • Make sure to turn off the battery switch or disconnect the negative cable (-) before inspecting the electrical system. Failure to do so could cause short-circuiting and fires.
  • Page 48 2. Inspection and adjustment (1) Electrolyte level • Check the level of fluid in the battery. GREASE When the amount of fluid nears the lower limit, fill with battery fluid (available in the market) to the upper limit. If operation continues with insufficient battery fluid, the battery life is shortened, and the battery may overheat and explode.
  • Page 49 2. Inspection and adjustment (b) Measurement with hydrometer When using a hydrometer, the measured specific gravity must be corrected according to the temperature at the time of measurement. The specific gravity of Float battery electrolyte is defined with 20 C as the standard. °...

  • Page 50: Inspection Every 100 Hours Six Months

    The level shall be between the upper and lower limit lines on the dipstick. Unit : liter (quart) Model Rake angle Engine oil capacity (Full) (3.0) 3YM30 with KM2P-1 -0.2 (2.9) 3YM20 with KM2P-1 8 degree -0.2 2YM15 with KM2P-1 (2.1)

  • Page 51: Inspection Every 250 Hours Or One Year

    104500-55710 24341-000440 5) Bleed the fuel system. Refer to 2.2.3.(1). IMPORTANT: Retaining ring Be sure to use genuine Yanmar part (super fine mesh filter). Otherwise, it results in engine damage, (Fuel filter) uneven engine performance and shorten engine life. 31R1...
  • Page 52 2. Inspection and adjustment (3) Replace the marine gear lube oil. Refer to 2.2.2(3) for the procedure. (4) Replace the engine lube oil filter. Refer to 2.2.2(2) for the procedure. (5) Check the impeller of the cooling water pump (seawater pump). 1) Remove the seawater pump cover and take out the O-ring, impeller and wear plate.
  • Page 53 2. Inspection and adjustment (6) Replace the fresh water coolant. Be sure to replace the fresh water every year. When the long life coolant is used of the specified type, the replacement period of two years can be obtained. Use clean soft water and be sure to add the Long Life Coolant Antifreeze (LLC) to the cooling water in order to prevent rust built up and freezing.
  • Page 54 2. Inspection and adjustment 5) After supplying cooling water, fit the filler cap and tighten it firmly. To reassemble the cap, align the tabs on the bottom of the cap with the notches on the filler port and turn clockwise 1/3 of a turn. 6) Remove the coolant recovery tank cap and fill with coolant mix to the lower limit.
  • Page 55 2. Inspection and adjustment (8) Clean the exhaust/water mixing elbow. There are two types of mixing elbows, the L-type and the U-type. The mixing elbow is attached to the exhaust manifold. The exhaust gas is mixed with seawater in the mixing elbow. U-type Mixing elbow Seawater...
  • Page 56 2. Inspection and adjustment (10) Check the wiring connectors. Check whether each connection part doesn't have loosened. STOP B-type panel Glow connector GLOW START Neutral safety switch Glow plug (Fitting to marine gear) Glow relay Magnet relay Safety Extension relay wire harness Alternator To lube switch and...

  • Page 57: Inspection Every 1,000 Hours Or Four Years

    Injection timing FID (FIC-Air) Model degree bTDC 16 ± 1 (18 ± 1) 3YM30 22 ± 1 (24 ± 1) 3YM20 21 ± 1 (23 ± 1) 2YM15 8) Repeat the step 5) to 7) a few times.
  • Page 58 2. Inspection and adjustment (2) Check the injection spray condition of a fuel nozzle Wear protective glasses when testing injection from the fuel injection nozzle. Never approach the injection nozzle portion with a hand. The oil jetting out from the nozzle is at a high pressure to cause loss of sight or injury if coming into careless contact with it.
  • Page 59 2. Inspection and adjustment [Informative: Fuel injection valve structure] Fuel return pipe Nozzle holder Pressure adjusting shim Nozzle spring Nozzle spring seat Valve stop spacer Nozzle valve Nozzle Nozzle body Nozzle case nut...
  • Page 60 2. Inspection and adjustment 2) Spray pattern inspection After adjustment to the specified valve opening pressure, use a nozzle tester and check the spray pattern and seat oil-tightness. a) Seat oil tightness check • After injecting a few times, increase the pressure gradually. Hold the pressure for about 5 seconds at a little before the valve opening pressure of 1.96 MPa (20 kgf/cm ), and check to see that oil does not drip from the tip end of the nozzle.
  • Page 61 2. Inspection and adjustment 4) Nozzle punch mark NP - DN O P D N159 Design code Throttle type Size: size P Injection angle Type: pintle type N P - D N OP D N 1 5 BOSCH Identification number (3) Check the impeller of the cooling water pump (seawater pump) The impeller must be replaced with new one periodically (every 1000 hrs or four years whichever comes first).
  • Page 62 2. Inspection and adjustment 3) Heat exchanger body water leakage test a) Compressed air/water tank test Pressure gauge Fit rubber covers on the fresh water and seawater inlets and outlets. Place the heat Air hose Filler cap exchanger in a water tank, feed in compressed air from the overflow pipe and check for any (water) leakage, (air bubbles).
  • Page 63 (Refer to 5. "Flexible Engine Mount" in the installation manual for pleasure boat use.) [Notice] Be sure to replace the Yanmar flexible engine mounts every 1000 hours or 4 years, whichever comes first. 2) After replacing the flexible engine mounts, check unusual noise and vibration of the engine and the boat hull with increasing the engine speed gradually and lowering it.

  • Page 64: Adjusting The No-Load Maximum Or Minimum Speed

    2. Inspection and adjustment 2.3 Adjusting the no-load maximum or minimum speed 1) After warming the engine up, gradually raise the speed and set it at the no-load maximum speed. Remote High speed control limiting bolt 2) If the no-load maximum speed is out of the Fuel cable injection...

  • Page 65: Thermostat Inspection

    2. Inspection and adjustment 2.5 Thermostat inspection (1) Put the thermostat in a beaker with fresh water, and heat it on an electric stove. The thermostat is functioning normally if it starts to open between 75-78 deg C, and opens until 8 mm or more at 90 deg C.

  • Page 66: Adjusting Operation

    (1) Warm the engine up. (2) Remove any precipitation from the F.O. filter. water separator, and F.O. tank. (3) Use only lube oil recommended by Yanmar. (4) Be sure to add Long Life Coolant Antifreeze (LLC) to cooling fresh water.

  • Page 67: Check Points And Precautions During Running

    2. Inspection and adjustment 2.6.3 Check points and precautions during running Step Item Instructions Precautions Checks before 1) Make sure that the sea cock is open. 3) Lamp should go off operation 2) Make sure there is enough lube oil and (fresh) when engine is cooling water.

  • Page 68: Long Storage

    2. Inspection and adjustment 2.7 Long storage Observe the following instructions when the engine is to be stored for a long period without operation: 1) Do not drain cooling water in the cold season or before the long storage. [NOTICE] Negligence of adding anti-freeze will cause the cooling water remaining inside the engine to be frozen and expanded to damage the engine parts.

  • Page 69: Troubleshooting

    3. Troubleshooting 3. Troubleshooting 3.1 Preparation before troubleshooting If the signs of a trouble appear, it is important to lecture on the countermeasure and treatment before becoming a big accident not to shorten the engine life. When the signs of a trouble appear in the engine or a trouble occurs, grasp the trouble conditions fully by the next point and find out the cause of sincerity according to the troubleshooting.

  • Page 70: Quick Reference Chart For Troubleshooting

    3. Troubleshooting 3.2 Quick reference chart for troubleshooting It is important to thoroughly under stand each system and the function of all of the parts of terse systems. A careful study of the engine mechanism will make this possible. When problems arise, it is important to carefully observe and analyze the indications of trouble in order to save time in determining their cause.
  • Page 71 Chart 1 THE ENGINE SUDDENLY STOPS. TROUBLE AND TROUBLESHOOTING (I-1) Add fuel oil and prime. (II-1) Replace. (I-2) Bleed air. (II-2) Clean carefully to insure good working order. (I-3) Remove water from drain and fuel oil system and prime. (I-4) Check and make necessary repairs. (I-5) Clean.
  • Page 72 Chart 2 Chart 3 Trouble and Troubleshooting TROUBLE AND TROUBLESHOOTING CYLINDER OUTPUT IS UNEVEN COUNTERMEASURE POOR EXHAUST COLOR (I-1) Bleed air. (I -7) Disassemble and clean (I-1) Check, repair or replace. (II-1) Clean. (I-2) Disassemble and clean. and repair replace. (I-2) Replace.
  • Page 73 Chart 4 TROUBLE AND TROUBLESHOOTING TROUBLE WITH MARINE GEAR (II-1) Review (I-1, I-11). (I-1) Disassemble and clean. (I-7) Replace. (III -1) Replace. (II-2) Reduce load. (I-2) Repair or replace. (I-8) Replace. (III -2) Replace. (II-3) Replace. (I-3) Repair or replace. (I-9) Adjust to correct position.
  • Page 74 Chart 5 TROUBLE AND TROUBLESHOOTING ROTATION IS NOT SMOOTH (I-1) Lap. (II-1) Clean. (II-7) Bleed air and prime. (I-2) Replace. (II-2) Replace. (II-8) Adjust. (II-3) Replace. (II-9) Adjust. (II-4) Correctly install pump. (II-5) Clean. (II-6) Replace. (I) Faulty operation of injection valve (II) Uneven supply of fuel oil injected (1) Faulty operation of fuel pump plunger...
  • Page 75 Chart 6 TROUBLE AND TROUBLESHOOTING KNOCKING (I-1) Increase injection pressure. (II-1) Delay injection timing. (I-2) Replace. (II-2) Adjust standard injection pressure. (I-3) Disassemble and lap. (I-4) Disassemble and repair. (I) Faulty fuel injection valve (II) Faulty fuel injected (1) Early fuel injection (1) Low injection pressure (3) Sticking of valve needle (2) Fuel pressure is too high...
  • Page 76 Chart 7 TROUBLE AND TROUBLESHOOTING TROUBLE WITH STARTING (I-1) Tighten. (II-1) Tighten. (III-1) Prime well. (IV-1) Lap. (I-2) Repair using sandpaper or replace. (II-2) Repair using sandpaper. (III-2) Adjust. (IV-2) Lap. (I-3) Replace. (II-3) Replace. (III-3) Clean out matter causing clogging. (IV-3) Replace.
  • Page 77 Chart 8 INSUFFICIENT POWER OUTPUT TROUBLE AND TROUBLESHOOTING (I-1) Replace. (II-1) Clean nozzle hole or replace. (III-1) Replace. (I-2) Disassemble and repair or replace. (II-2) Lap or replace. (III-2) Repair. (I-3) Lap valves. (II-3) Lap or replace. (I-4) Tighten firmly. (II-4) Tighten firmly.
  • Page 78 Chart 9 TROUBLE AND TROUBLESHOOTING MISCELLANEOUS TROUBLE (I-1) Tighten nuts. (II-1) Tighten adjustment valve. (III-1) Clean. (I-2) Tighten nuts and insert pins. (II-2) Check and repair. (III-2) Add cooling water. (I-3) Remove adjustment liner and adjust aperture, (II-3) Clean. (III-3) Disassemble and repair or replace. or replace.

  • Page 79: Troubleshooting (Concerning Engine And Fuel Injection Equipment)

    3. Troubleshooting 3.3 Troubleshooting (Concerning engine and fuel injection equipment) Malfunctions Causes Remedies The engine does not operate 1. Fuel oil is not injected from the 1. There is no fuel oil in the fuel Supply fuel and bleed the system injection pump tank 2.
  • Page 80 3. Troubleshooting Malfunctions Causes Remedies The engine exhaust contains 1. The injection timing is incorrect Readjust the timing smoke and the engine “knocks” 2. The nozzle or nozzle holder is Inspect, then repair or replace functioning incorrectly 3. The injection quantity is Readjust excessive The engine output is unstable...
  • Page 81 3. Troubleshooting Malfunctions Causes Remedies 4. The nozzle or the nozzle holder Inspect and then repair or replace is not functioning properly The engine cannot reach its 1. The governor spring is too weak Readjust or replace maximum speed or is improperly adjusted 2.

  • Page 82: Troubleshooting By Measuring Compression Pressure

    Deviation among cylinders Model MPa (kgf/cm MPa (kgf/cm Standard Limit 3YM30 3.43 ± 0.1 (35 ± 1) 2.75 ± 0.1 (28 ± 1) 0.2 ± 0.3 (2 ± 3) 3YM20/2YM15 3.23 ± 0.1 (33 ± 1) 2.55 ± 0.1 (26 ± 1) 0.2 ±...
  • Page 83 3. Troubleshooting (3) Engine speed and compression pressure (for reference) 3YM30 3.92 3.43 2.94 3YM20/2YM15 2.45 1.96 (MPa) Engine speed (min (4) Measured value and troubleshooting When the measured compression pressure is below the limit value, inspect each part by referring to the table below.

  • Page 84: Disassembly And Reassembly

    4. Disassembly and reassembly 4. Disassembly and reassembly 4.1 Disassembly and reassembly precautions (1) Disassembly • Take sufficient time to accurately pin-point the cause of the trouble, and disassemble only those parts which are necessary. • Be careful to keep all disassembled parts in order. •...

  • Page 85: Disassembly And Reassembly Tools

    4. Disassembly and reassembly 4.2 Disassembly and reassembly tools The following tools are required when disassembling and reassembling the engine. Please use them as instructed. 4.2.1 General hand tools Name of tool Illustration Remarks Wrench Size : 10 x 13 Wrench Size : 12 x 14 Wrench...
  • Page 86 4. Disassembly and reassembly Name of tool Illustration Remarks Copper hammer Local supply Mallet Local supply Nippers Local supply Pliers Local supply Offset wrench Local supply 1 set Box spanner Local supply 1 set Scraper Local supply...
  • Page 87 4. Disassembly and reassembly Name of tool Illustration Remarks Lead rod Local supply File Local supply 1 set Rod spanner for Local supply hexagon socket Size : 6 mm head screws 8 mm 10 mm Stariing pliers Local supply Hole type Shaft type S - 0 H4 - H8...

  • Page 88: Special Hand Tools

    4. Disassembly and reassembly 4.2.2 Special hand tools Name of tool Illustration Remarks Piston pin insertion/ extraction tool (Piston pin extractor) (Extraction of piston pin) (Insertion of piston pin) Connecting rod small end bushing insertion/extraction tool * Locally manufactured (Extraction) Intake and exhaust valve insertion/ extraction tool...
  • Page 89 4. Disassembly and reassembly Name of tool Illustration Remarks Lube oil filter case remover Piston ring replacer (for removal / installation of piston ring) Valve lapping tool (Rubber cap type) Valve lapping powder Code No. 28210-000070 Feeler gauge Pulley puller (Removing the coupling) (Local supply)
  • Page 90 4. Disassembly and reassembly Name of tool Illustration Remarks Press tool 1 for filler neck (Tool 1) Press tool 2 for filler neck copper tube (Tool 2) Stem seal insertion (for inserting stem seal) 4 or 15.0 11.0 more...

  • Page 91: Measuring Instruments

    4. Disassembly and reassembly 4.2.3 Measuring instruments (1) Application of tools Name of tool Illustration Remarks Vernier calipers 0.05 mm 0-150 mm Micrometer 0.01 mm 0-25 mm 25-50 mm 50-75 mm 75-100 mm 100-125 mm 125-150 mm Cylinder gauge 0.01 mm 18-35 mm 35-60 mm 50-100 mm...
  • Page 92 4. Disassembly and reassembly (2) Use of tools Name of tool Illustration Dial gauge Measures shaft bending, distortions of levelness, and gaps. Test indicator Measures narrow and deep places, which cannot be measured with dial gauge. Magnetic stand Keeps the dial gauge firmly in position, thereby permitting it to be used at various angles.
  • Page 93 4. Disassembly and reassembly Name of tool Illustration V Block Measures shaft distortion. Torque wrench Used to tighten bolts and nuts to standard torque. Thickness gauge Measures the distance between the ring and ring groove, and between the shaft and shaft joint at time of assembling.
  • Page 94 High pressure type the exterior of the revolving shaft. pipe Circuit tester Measures the resistance, voltage, and continuity of the electric circuit. Compression gauge Measures the pressure of the compression. Yanmar code No. TOL-97190080...

  • Page 95: Other Material

    4. Disassembly and reassembly 4.2.4 Other material Items Usual contents Features and application Liquid gasket Three Bond 200g Non-drying liquid gasket ; solvent less type, easy to No.1 (1 kg also remove, superior in seawater resistance, applicable TB1101 available) to various mating surfaces. Three Bond 200g Non-drying liquid gasket ;...
  • Page 96 4. Disassembly and reassembly Items Usual contents Features and application Scale solvent Scale solvent 1 box • The scale solvent removes scale in a short time. (1 to 10 hours) (4 kg × 4 • Prepare water (seawater is possible) in an removers) amount that is about 10 times the weight of the Neutralizer...

  • Page 97: Disassembly And Reassembly

    4. Disassembly and reassembly 4.3 Disassembly and reassembly 4.3.1 Disassembly • Preparation on a boat For engines mounted in an engine room of a ship, remove the piping and wiring connecting them to the ship. 1) Remove the remote control cable (from engine and marine gearbox). 2) Unplug the extension cord for the instrument panel from the engine.
  • Page 98 4. Disassembly and reassembly [NOTE: ] If a lube oil supply/discharge pump is used for the engine, the intake hose is placed in the dipstick guide, and for the clutch side (gearbox) it is placed in the oil hole on top of the case. (Refer to 2.2.2(2) &...
  • Page 99 4. Disassembly and reassembly (5) Removing the intake silencer 1) Remove the air intake hose attached to the intake manifold. Intake pipe 2) Remove the intake silencer from cylinder head. Cylinder head Intake silencer (6) Removing the mixing elbow 1) Remove the seawater rubber hose connecting to a heat exchanger- a mixing elbow. 2) Remove the mixing elbow from the exhaust manifold.
  • Page 100 Set bolt V-belt Belt adjuster (3YM30) (8) Removing the cooling water pipes (seawater/ fresh water) 1) Remove the seawater pipe (seawater pump-heat exchanger). 2) Remove the fresh water pipe (fresh water pump - heat exchanger, coolant tank - fresh water pump).
  • Page 101 4. Disassembly and reassembly (9) Removing the heat exchanger (exhaust manifold, coolant tank unit) Remove the heat exchanger and gasket packing from cylinder head. (10)Removing the seawater pump Loosen the nut on the spacer bolt and remove the seawater pump. Gear case cover Spacer bolt V-belt...
  • Page 102 4. Disassembly and reassembly (13)Removing the fuel injection pipe Fuel injection pipe retainer 1) Remove the fuel injection pipe retainer. 2) Loosen the cap nuts on both ends of the fuel No. 3 injection pipe and remove the fuel injection pipe. No.
  • Page 103 4. Disassembly and reassembly (15)Removing the fuel injection nozzles Fuel injection nozzle Loosen the fuel nozzles and remove them from the cylinder head. Nozzle seat Nozzle protector Nozzle seat Cylinder head (16)Remove the fuel injection pump 1) Loosen the drive gear nut for fuel pump drive gear, and pull out the fuel pump drive gear /flange assembly with an extraction tool.
  • Page 104 4. Disassembly and reassembly (17)Removing the rocker arm shaft assembly Don’t disassemble 1) Loosen the hexagon head bolts and remove the the cross-recessed-hand bolts. rocker arm cover. Note: Don't loosen the cross-recessed-head bolts on the rocker arm cover, when removing the rocker arm cover.
  • Page 105 4. Disassembly and reassembly (21)Turning the engine over Bolt 1) Place a wood block of appropriate size on the floor, and stand up the engine on the flywheel housing. Washer 2) Remove the engine mounting feet. Crankshaft V-pully (22)Removing the crankshaft V-pulley Loosen the bolt tightening the crankshaft V-pulley and Oil pan remove the crankshaft V-pulley with a pulley puller.
  • Page 106 4. Disassembly and reassembly (26)Removing the lube oil pump Cover Remove the lube oil pump from the gear case cover. Outer rotor Control Inner rotor valve Gear case cover (27)Removing the idle gear Bolt Loosen the three bolts holding the idle gear and pull out the idle gear and shaft.
  • Page 107 4. Disassembly and reassembly (30) Removing the gear case Liquid gasket 1) Remove the gear case from the cylinder block. 2) Remove the O-rings from the lube oil passage. NOTE 1) When mounting the gear case, match up the two knock pins for cylinder block.
  • Page 108 4. Disassembly and reassembly (34)Removing the main bearing 1) Remove the main bearing bolts. 2) Remove the main bearing cap and lower main bearing metal. NOTE: The thrust metal (lower) is mounted to the base main bearing cap. (35)Removing the crankshaft 1) Remove the crankshaft NOTE: Cylinder block...

  • Page 109: Reassembly

    4. Disassembly and reassembly 4.3.2 Reassembly (1) Clean all parts Clean all parts using by the cloth and diesel oil (or cleaning agent) before reassembly. NOTE: 1) If the dust remain with the parts, engine may cause the seizing or damage. 2) The cleaning agent removes even carbon adhering to disassembled parts.
  • Page 110 4. Disassembly and reassembly (5) Mounting the main bearing cap Upper main bearing metal Coat the lower main bearing metal with engine oil, and Oil hole mount it to the main bearing cap. Lower NOTE: Thrust metal 1) The lower main bearing metal does not have an oil hole.
  • Page 111 4. Disassembly and reassembly (7) Turning the engine over Cylinder block Stand up the engine on the flywheel housing. Flywheel housing (8) Mounting the gear case Apply the liquid gasket to the gear case and mount the gear case and lube oil line O-ring onto the cylinder block.
  • Page 112 4. Disassembly and reassembly 2) Coat the outside of the piston and the inside of the connecting rod crank pin metal with engine oil and Piston ID mark insert the piston with the piston insertion tool. NOTE: 1) Insert the piston so that the match mark on the large end of the connecting rod faces the fuel nozzle, and the manufacture’s embossed mark on the stem faces toward the flywheel.
  • Page 113 4. Disassembly and reassembly (11) Mounting the idling gear Upside 1) Mount the idling gear so that the mark of the idle Mark gear shaft upward. Oil hole (Idle gear shaft) 2) Align the "A" and "B" match marks of the idle gear with the match marks of the crankshaft gear and Fuel injection pump the camshaft gear.
  • Page 114 4. Disassembly and reassembly (13) Mounting the oil seal and gear case cover 1) Replace the used oil seal with a new one when the Crankshaft pulley gear case cover is disassembled. 2) Insert a new oil seal by using the oil seal insertion tool on the position of the gear case cover end face (61.5 0/-1 mm distance from the end of the cylinder 61.5...
  • Page 115 4. Disassembly and reassembly (15) Mounting the oil pan spacer and the oil pan Oil pan 1) Apply the liquid gasket to the surfaces of the gear case cover, gear case and flywheel housing that Oil pan spacer contact with the cylinder block. 2) Apply the liquid gasket to the spacer.
  • Page 116 4. Disassembly and reassembly (19) Mounting the marine gearbox 1) Mount the damper disk to the flywheel. Damper disk Align the damper disk with the input shaft spline and insert. 2) Mount the marine gearbox to the flywheel housing. Flywheel (20) Mounting the cylinder head Assembly 1) Put the cylinder head gasket on the cylinder block,...
  • Page 117 4. Disassembly and reassembly (22) Mounting the fuel injection pump Fuel injection pump 1) Lightly fit the fuel injection pump on the gear case. drive gear (After adjusting injection timing, tighten the fuel Camshaft gear injection pump. Before mounting heat exchanger to the cylinder head, adjust the injection timing.).
  • Page 118 4. Disassembly and reassembly (24) Mounting the fresh water pump 1) Thoroughly coat both sides of the gasket with adhesive. Cylinder head 2) Renew the O-ring for the connecting part of the pump, which is inserted in the cylinder block, and tighten the fresh water pump.
  • Page 119 4. Disassembly and reassembly (26) Mounting the lube oil filter. Cylinder block Mount the lube oil filter with the tool of the filter case remover. Lube oil pressure switch Lube oil filter (27) Mounting the seawater pump 1) Tighten the spacer bolt to the gear case cover. 2) Mount the bracket and the seawater pump assembly to the gear case cover.
  • Page 120 4. Disassembly and reassembly (29) Mounting the mixing elbow 1) Mount the mixing elbow on the exhaust manifold outlet. 2) Mount the cooing seawater pipe (rubber hose) with the hose clips (heat exchanger-mixing elbow). (30) Mounting the cooling water pipes (seawater / fresh water) 1) Mount the seawater pipes with the hose clips (seawater pump-heat exchanger).
  • Page 121 Bracket Set bolt V-belt Belt adjuster (3YM30) (32) Mounting the starting motor Fit the starting motor on the flywheel housing. (33) Mounting the intake silencer Mount the intake pipe on the intake manifold inlet coupling and tighten the intake silencer to the cylinder Intake pipe head.
  • Page 122 4. Disassembly and reassembly (34) Mounting the fuel filter and fuel pipe 1) Mount the fuel filter on the bracket, which is tightened to the cylinder head. 2) Mount the fuel pipe (fuel feed pump-fuel filter, fuel filter-fuel injection pump). Cylinder head Bracket Fuel pipe...
  • Page 123 4. Disassembly and reassembly (38) Filling with cooling water 1) Open the coolant (fresh water) tank cap and fill with water. Model Engine capacity L (quart) 3YM30(C) 4.9 (5.2) 3YM20(C) 4.1 (4.3) 2YM15(C) 3.0 (3.2) 2) Fill with water until the level in the coolant recovery tank is between the full and low marks.

  • Page 124: Inspection And Servicing Of Basic Engine Parts

    5. Inspection and servicing of basic engine parts 5. Inspection and servicing of basic engine parts 5.1 Cylinder block The cylinder block is a thin-skinned, (low-weight), short skirt type with rationally placed ribs. The side walls are save shaped to maximize rigidity for strength and low noise. 5.1.1 Inspection of parts Cap plug 45 mm Make a visual inspection to check for cracks on engines...

  • Page 125: Replacement Of Cap Plugs

    5. Inspection and servicing of basic engine parts 5.1.4 Replacement of cap plugs Step Description Procedure Tool of material used Clean and remove grease from the hole into Screw driver or saw which the cap plug is to be driven. blade (Remove scale and sealing material previously Thinner...

  • Page 126: Cylinder Bore Measurement

    In the same way measure and calculate the difference in the B direction. Cylindricity is the maximum value between those difference values. Item Model Standard Limit Cylinder bore diameter 3YM30 76.000-76.030 76.200 3YM20/2YM15 70.000-70.030 70.200 Cylinder roundness /Inclination 0.01 or less 0.03...

  • Page 127: Cylinder Head

    5. Inspection and servicing of basic engine parts 5.2 Cylinder head The cylinder head is of 3-cylinder integral construction, mounted with 14 bolts. Special alloy stellite with superior resistance to heat and wear is fitted on the seats, and the area between the valves is cooled by the water jet.

  • Page 128: Inspecting The Cylinder Head

    5. Inspection and servicing of basic engine parts 5.2.1 Inspecting the cylinder head The cylinder head is subjected to very severe operating conditions with repeated high pressure, high temperature and cooling. Thoroughly remove all the carbon and dirt after disassembly and carefully inspect all parts.

  • Page 129: Valve Seat Correction Procedure

    5. Inspection and servicing of basic engine parts 5.2.2 Valve seat correction procedure The most common method for correcting unevenness of the seat surface with a seat grinder is as follows: (1) Use a seat grinder to make the surface even. As the valve seat width will be enlarged, first use a 70 °...

  • Page 130: Intake/Exhaust Valves, Valve Guides

    5. Inspection and servicing of basic engine parts 5.2.3 Intake/exhaust valves, valve guides Measurement point Measurement point (1) Wearing and corrosion of valve stem Replace the valve stem is excessively worn or corroded. 30 mm 60 mm Valve stem Standard Limit outside dia.
  • Page 131 5. Inspection and servicing of basic engine parts (4) Valve guide 1) Measuring inside diameter of valve guide. Measure the inside diameter of the valve guide and replace it if it exceeds the wear limit. Standard Limit Intake 6.000-6.012 6.08 Valve guide inside dia.

  • Page 132: Valve Springs

    5. Inspection and servicing of basic engine parts 4) Valve stem seals Valve stem seal inserting tool The valve stem seals in the intake/exhaust valve guides cannot be re-used. When they are removed, be sure to replace them. When assembling the intake/exhaust valves, apply an adequate quantity of engine oil on the valve stem before inserting them.

  • Page 133: Assembling The Cylinder Head

    5. Inspection and servicing of basic engine parts 4) Measure spring tension. Valve spring Unit Standard Limit Free length A 37.8 36.3 Inclination B Tension (1 mm pressure) N/mm 26.6/35.4 (Smaller pitch/ (kgf/mm) (2.71/3.61) Larger pitch) Spring tension tester 5) Assembling valve springs. Up side Smaller pitch side (yellow) Down side...

  • Page 134: Measuring Top Clearance

    (3) Turn the crank, (in the direction of engine revolution), and press the fuse against the piston until it breaks. (4) Remove the head and take out the broke fuse. (5) Measure the three positions where each fuse is broken and calculate the average. Model Top clearance (mm) 3YM30 0.747-0.891 3YM20/2YM15 0.697-0.841 Fuse wire 001515-00E 5.2.7 Intake and exhaust rocker arms...

  • Page 135: Adjustment Of Valve Clearance

    5. Inspection and servicing of basic engine parts 5.2.8 Adjustment of valve clearance (1) Make adjustments when the engine is cool. (Refer to 2.2.2(8).) Intake and exhaust valve clearance 0.15-0.25 (2) Be sure that the opening and closing angles for both the intake and the exhaust valves T.D.C.

  • Page 136: Piston And Piston Pins

    Circlip Model ID marks for engine model I.D. mark 3YM30 3YM20/2YM15 5.3.1 Piston (1) Piston head and combustion surface Remove the carbon that has accumulated on the piston head and combustion surface, taking care not to scratch the piston.

  • Page 137: Piston Pin

    0 min. Model Cylinder inside diameter Piston outside diameter. 3YM30 75.970 3YM20/2YM15 69.975 (3) Removing the piston pin A floating type piston pin is used in this engine. The piston pin can be pressed into the piston pin hole at room temperature (Coat with oil to make it slide easily).

  • Page 138: Piston Rings

    Second ring Oil ring (Ring components) (1) Measuring the rings. Measure the thickness and width of the rings, and the ring-to-groove clearance after installation. Replace if wear exceed the limit. 3YM30 Standard Limit Groove width 1.550-1.570 Width Top ring Ring width 1.470-1.490...
  • Page 139 (2) Measuring piston ring gap Press the piston ring onto a piston liner and measure the piston ring gap with a gauge. Press on the ring Head surface about 30mm from the bottom of the liner. 3YM30/3YM20/2YM15 Standard Limit Cylinder block Top ring gap 0.15-0.30...
  • Page 140 5. Inspection and servicing of basic engine parts 5) The oil ring is provided with a coil expander. The coil expander joint should be opposite (staggered 180°) the oil ring gap. Joint of coil expander...

  • Page 141: Connecting Rod

    5. Inspection and servicing of basic engine parts 5.4 Connecting rod Piston pin bushing The connecting rod is made of high-strength forged carbon steel. The large end with the aluminium metal can be separated into two and the small end has a 2-layer copper alloy coil bushing.

  • Page 142: Crank Pin Metal

    N•m (kgf•m) 22.6-27.5 Rod bolt tightening torque (Rod bushing I.D. measurement) (2.3-2.8) 3YM30 Item Standard Limit Crankpin O.D. 41.952-41.962 41.902 Metal I.D.
  • Page 143 5. Inspection and servicing of basic engine parts • Other procedure of measuring crank pin oil clearance 1) Use the press gauge (Plastic gauge) for measuring the oil clearance of the crank pin. 2) Mount the connecting rod on the crank pin (tighten to specified torque).

  • Page 144: Piston Pin Bushing

    5. Inspection and servicing of basic engine parts 5.4.3 Piston pin bushing (1) Measuring piston pin clearance. Excessive piston pin bushing wear may result in damage to the piston pin or the piston itself. Measure the piston pin bushing inside diameter and the piston pin outside diameter.

  • Page 145: Crankshaft And Main Bearing

    5. Inspection and servicing of basic engine parts 5.5 Crankshaft and main bearing The crank pin and crank journal have been induction hardened for superior durability, and the crankshaft is Balance weight provided with four balance weights for optional balance. Crank shaft The crankshaft main bearing is of the hanger type.
  • Page 146 (Refer to 5.4.2(2). ) Standard Limit Crankshaft Outside dia. 41.952-41.962 41.902 Crank pin journal Crank pin 3YM30 Oil clearance 0.020-0.058 0.120 Measuring position of the crank pin Outside dia. 37.952-37.962 37.902 and crank journal Crank pin...

  • Page 147: Main Bearing

    5. Inspection and servicing of basic engine parts (4) Checking the side gap of a crankshaft After assembling the crankshaft, tighten the main bearing cap to the specified toque, and move the crankshaft to one side, placing a dial gauge on one end of the shaft to measure thrust clearance.

  • Page 148: Camshaft And Tappets

    Camshaft side gap 0.05-0.15 0.25 Side gap (Camshaft side gap) (2) Measure the cam height, and replace the cam if it is worn beyond the limit. Micrometer Cam height 3YM30 Standard Limit Intake Cam height 34.135-34.265 33.89 Exhaust 3YM20/2YM15 (Cam height)
  • Page 149 5. Inspection and servicing of basic engine parts (3) Camshaft and bearing hole measurement Flywheel side Standard Limit Micrometer Intake Cam height 34.135-34.265 33.89 Exhaust Measure the camshaft outside diameter with a micrometer. The oil clearance shall be calculated by subtracting the measured camshaft outside diameter (Camshaft outside diameter) from the inside diameter of the camshaft bearing or...

  • Page 150: Tappets

    5. Inspection and servicing of basic engine parts 5.6.2 Tappets (1) The tappets are offset to rotate during operation and thereby prevent uneven wearing. Check the contact of each tappet and replace if excessively or unevenly worn. NOTE: When removing tappets, be sure to keep them separate for each cylinder and intake/exhaust valve.

  • Page 151: Timing Gear

    5. Inspection and servicing of basic engine parts 5.7 Timing gear The timing gear is helical type for minimum noise and specially treated for high durability. 5.7.1 Inspecting the gears (1) Inspect the gears and replace if the teeth are damaged or worn. (2) Measure the backlash of all gears that mesh, and replace the meshing gears as a set if wear exceeds the limit.

  • Page 152: Flywheel And Housing

    5. Inspection and servicing of basic engine parts 5.8 Flywheel and housing The function of the flywheel is through inertia, to rotate the crankshaft in a uniform and smooth manner by absorbing the turning force created during the combustion stroke of the engine, and by compensating for the decrease in turning force during the other strokes.

  • Page 153: Damper Disc

    5. Inspection and servicing of basic engine parts 5.8.2 Damper disc (1) Spline part Whenever uneven wear and/or scratches are found, replace with new one. (2) Spring Whenever uneven wear and/or scratches are found, Spline replace with new one. (3) Pin wear Whenever uneven wear and/or scratches are found, replace with new one.

  • Page 154: Fuel Injection Equipment

    6. Fuel injection equipment 6. Fuel injection equipment 6.1 Fuel Injection pump/governor Refer to the service manual of the YPES-ML fuel injection pump for the disassembly, assembly and adjustment procedure. 6.1.1 Fuel system diagram Fuel nozzle Fuel injection pipe Fuel return pipe Fuel injection pump Fuel filter To fuel tank...

  • Page 155: Fuel Injection Pump Service Data And Adjustment

    6. Fuel injection equipment 6.1.2 Fuel injection pump service data and adjustment (1) Service data 1) Service data for 3YM30 Part code (Back No.) 728990-51350 (TMR1) Adjustment SPEC ENGINE SPEC SERVICE STD Item Fuel valve (Valve pressure) A (120) (170)
  • Page 156 6. Fuel injection equipment 2) Service data for 3YM20 Part code (Back No.) 728890-51300 (TMM1) Adjustment SPEC ENGINE SPEC SERVICE STD Item Fuel valve (Valve pressure) C (120) (170) Nozzle type (ID mark) NP-DN0PDN159 DN-12SD12 Fuel injection pipe Ø 2 x 300 Ø2 x 600 Injection Starting...
  • Page 157 6. Fuel injection equipment 3) Service data for 2YM15 Part code (Back No.) 728890-51300 (TMM1) Adjustment SPEC ENGINE SPEC SERVICE STD Item Fuel valve (Valve pressure) C (120) (170) Nozzle type (ID mark) NP-DN0PDN159 DN-12SD12 Fuel injection pipe Ø 2 x 300 Ø2 x 600 Injection Starting...
  • Page 158 6. Fuel injection equipment (2) Fuel adjustment procedure • Fuel adjustment for 3YM30 and 2YM15 1) Loosen the nut of the FO limiter, and screw the adjusting bolt to the bottom. Tighten the nut. 2) Adjust the rack position to R0 (15mm) with the FO limiter, and measure the injection volume (A) at the rated speed.
  • Page 159 6. Fuel injection equipment • Fuel adjustment for 3YM20 1) Loosen the nut of the FO limiter, and screw the adjusting bolt to the bottom. Tighten the nut. 2) Adjust the rack position to R0 (15mm) with the FO limiter, and measure the injection volume (A) at the rated speed.

  • Page 160: Fuel Injection Pump Structure

    6. Fuel injection equipment 6.1.3 Fuel injection pump structure Section of a fuel injection pump/ governor for 3YM30.

  • Page 161: Removing A Fuel Injection Pump

    6. Fuel injection equipment 6.1.4 Removing a fuel injection pump The procedure to remove a fuel injection pump from the gear case is shown. [NOTICE] Be sure to remove a flange and a fuel injection pump drive gear with a pair without loosening the flange Fuel injection pump bolts.

  • Page 162: Troubleshooting Of Fuel Injection Pump

    6. Fuel injection equipment 6.1.7 Troubleshooting of fuel injection pump Complete repair means not only replacing defective parts, but finding and eliminating the cause of the trouble as well. The cause of the trouble may not necessarily be in the pump itself, but may be in the engine or the fuel system.
  • Page 163 6. Fuel injection equipment Fault Cause Remedy 2. Engine starts, but (1) Fuel pipe is clogged. Clean immediately stops. (2) Fuel filter is clogged. Disassemble and clean, or replace the element Replace packing repair (3) Improper air- tightness of the fuel pipe pipe connection or pipe is broken and air is being sucked in.
  • Page 164 6. Fuel injection equipment Fault Cause Remedy 7. Loud knocking. (1) Injection timing is too fast or too slow. Adjust (2) Injection from nozzle is improper. Adjust Fuel drips after each injection. (3) Injection nozzle starting pressure is too high Adjust (4) Uneven injection.

  • Page 165: Fuel Feed Pump

    6. Fuel injection equipment 6.2 Fuel feed pump Fuel injection pump The fuel feed pump feeds fuel from the fuel tank, passes it through the fuel filter element, and supplies it to the fuel injection pump. The fuel feed pump is mounted on the side of this engine and is driven by the (eccentric) cam of the fuel pump camshaft.

  • Page 166: Disassembly And Reassembly Of Fuel Feed Pump

    6. Fuel injection equipment 6.2.3 Disassembly and reassembly of fuel feed pump (1) Disassembly 1) Remove the fuel feed pump mounting nut, and take the fuel feed pump off the fuel injection pump. 2) Clean the fuel feed pump assembly with fuel oil. 3) After checking the orientation of the arrow on the cover, make match marks on the upper body and cover, remove the small screw, and disassemble the cover, upper body and lower body.
  • Page 167 6. Fuel injection equipment (4) Valve contact/mounting Inlet valve Outlet valve Clean the valve seat and valve with air to remove any foreign matter. (5) Inspect the diaphragm spring and piston spring for settling and the piston for wear, and replace as necessary. NOTE: Replace parts as an assembly.

  • Page 168: Fuel Filter

    6. Fuel injection equipment 6.3 Fuel filter Air bleeding bolt The fuel filter is installed between the feed pump and From feed Nylon gasket injection pump, and serves to remove dirt and impurity pump from the fuel fed from the fuel tank through the feed pump.

  • Page 169: Fuel Tank

    6. Fuel injection equipment 6.4 Fuel tank A triangular 30 liter fuel tank with a 2000mm (78.7402 in.) rubber fuel hose to fit all models is available as an option. A fuel return connection is provided on top of the tank of which a rubber hose can be connected to return fuel from the fuel nozzles.

  • Page 170: Intake And Exhaust System

    7. Intake and exhaust system 7. Intake and exhaust system 7.1 Intake system Air enters in the intake silencer mounted at the end of the intake manifold (rocker arm cover). It is fed to the intake manifold and then on to each cylinder. Exhaust gas goes into exhaust manifold (in the fresh Intake pipe water tank) mounted on the cylinder head outlet.

  • Page 171: Diaphragm Assy Inspection

    7. Intake and exhaust system [NOTICE] 1) When a diaphragm is damaged, pressure control inside the crankcase becomes insufficient, and troubles occur. When the internal pressure of the crankcase decreases too much due to the damage of a spring, much blowby gas containing oil is reduced in intake air system, and it may cause the combustion defect by the early dirt of the intake valve or the urgent rotation of the engine by the oil burning.

  • Page 172: Exhaust System

    7. Intake and exhaust system 7.2 Exhaust system 7.2.1 Construction There are two types of mixing elbows, the L-type and the U-type. The mixing elbow is attached to the exhaust manifold. U-type Mixing elbow Seawater Joint Heat exchanger L-type Mixing elbow Seawater Exhaust elbow Heat exchanger...

  • Page 173: Lubrication System

    8. Lubrication system 8. Lubrication system 8.1 Lubrication system The lube oil in the oil pan is pumped up through the intake filter and intake piping by the lube oil pump, through the holes in the cylinder body and on to the lube oil pump, through the holes in the cylinder body and on to the discharge filter.

  • Page 174: Lube Oil Pump

    8. Lubrication system 8.2 Lube oil pump 8.2.1 Lube oil pump construction Cover The trochoid type lube oil pump is mounted in the gear Outer rotor Control case cover, and the inner rotor is driven by the Inner rotor valve crankshaft pulley.

  • Page 175: Lube Oil Pump Inspection

    8. Lubrication system 8.2.4 Lube oil pump inspection (1) Outside diameter clearance and side clearance of outer rotor Gear case Outer rotor Insert a gap gauge between the outer rotor and the gear case cover, and measure outside diameter gap. Put a ruler on the end face of the gear case cover, and insert a gap gauge between rotor, and measure a side gap.

  • Page 176: Lube Oil Filter

    8. Lubrication system 8.3 Lube oil filter 8.3.1 Lube oil filter construction Cylinder block The lube oil filter is a full-flow paper element type mounted to the side of the cylinder block. The cartridge type filter is easy to remove. To prevent seizure in the event of the filter clogging up, Lube oil pressure a bypass circuit is provided in the oil filter.

  • Page 177: Rotary Waste Oil Pump (Optional)

    8. Lubrication system 8.4 Rotary waste oil pump (Optional) A rotary waste oil pump to pump out waste oil is available as an option. Oil inlet pipe Outside dia. 16 mm Rotary waste oil pump Delivery capacity per one revolution 0.057 L Delivery pressure 0.15 MPa (1.5 kg/cm...

  • Page 178: Cooling Water System

    9. Cooling water system 9. Cooling water system 9.1 Cooling water system The cooling water system is of the indirect seawater cooled, fresh water circulation type. The cylinders, cylinder heads and exhaust manifold are cooled with fresh water, and fresh water cooler (heat exchanger) use seawater.
  • Page 179 9. Cooling water system Cooling water line Mixing elbow Coolant tank Heat Exhaust manifold exchange Fresh water pump Seawater pump From seacock (Cooling water pipes) 158R1...

  • Page 180: Seawater Pump

    9. Cooling water system 9.2 Seawater pump The seawater pump is driven by a V-belt. Gear case cover Spacer bolt V-belt Bracket Seawater pump (Seawater pump) 9.2.1 Specifications of seawater pump Performance Flow Min. 1650 L/h at engine speed 3600 min 9.2.2 Seawater pump disassembly Refer to 2.2.5.(5).

  • Page 181: Seawater Pump Inspection

    9. Cooling water system 9.2.3 Seawater pump Inspection (Refer to 2.2.4(5).) (1) Inspect the rubber impeller, checking for splitting around the outside, damage or cracks, and replace if necessary. V-pulley Shaft Retaining ring Ball bearing Spacer Retaining ring O-ring Ball bearing Plate Cover O-ring...

  • Page 182: Seawater Pump Reassembly

    9. Cooling water system 9.2.4 Seawater pump reassembly (1) When replacing the oil seal, coat with grease and insert. (2) Mount the pump shaft, ball bearing and V-pulley to the pump unit and fit the bearing retaining ring. NOTE: Coat the shaft with grease. (3) Mount the impeller.

  • Page 183: Fresh Water Pump

    9. Cooling water system 9.3 Fresh water pump 9.3.1 Fresh water pump construction The fresh water pump is of the centrifugal (volute) type, and circulates water from the fresh water tank to the cylinder block and the cylinder head. The fresh water pump consists of the pump body, impeller, pump shaft, bearing unit and mechanical seal.

  • Page 184: Fresh Water Pump Disassembly

    9. Cooling water system 9.3.3 Fresh water pump disassembly (1) Do not disassemble the fresh water pump. It is difficult to disassemble and, once disassembled, even more difficult to reassemble. Replace the pump as an assembly in the event of trouble. When the fresh water pump and the cover are disassembled, retighten to the specified torque.
  • Page 185 9. Cooling water system Measuring side clearance between impeller and plate. Straightedge Standard Limit Side clearance between impeller and plate Thickness gauge...

  • Page 186: Heat Exchanger

    9. Cooling water system 9.4 Heat exchanger 9.4.1 Heat exchanger construction Side cover The heat exchanger cools the hot fresh water, that has Gasket O-ring cooled the inside of the engine, with seawater. Cooler core The cooler core consists of many small diameter tubes, Pressure cap baffle plates and tube cover.

  • Page 187: Pressure Cap And Coolant Recovery Tank

    9. Cooling water system 9.5 Pressure cap and coolant recovery tank 9.5.1 Pressure cap construction The pressure cap mounted on the filler neck incorporates a pressure control valve. The cap is mounted on the filler neck cam by placing it on the rocking tab and rotating.

  • Page 188: Replacing Filler Neck

    9. Cooling water system 9.5.4 Replacing filler neck 1) Take out the copper pipe inside the filler neck with striking a circumference with a driver and so on. When the filler neck is removed, remove it with being careful not to damage the fresh water cooler, and scrap it.

  • Page 189: Function Of The Coolant Recovery Tank

    9. Cooling water system 9.5.5 Function of the coolant recovery tank Coolant recovery tank Filler cap The pressure valve opens to discharge steam when the steam pressure in the fresh water tank exceeds 90 (0.9 kgf/cm This consumes water. The coolant recovery tank maintains the water level by preventing this discharge of water.

  • Page 190: Thermostat

    9. Cooling water system 9.6 Thermostat 9.6.1 Functioning of thermostat The thermostat opens and closes a valve according to changes in the temperature of the fresh water inside the engine, controlling the volume of water flowing to the heat exchanger from the cylinder head, and in turn maintaining the temperature of the fresh water in the engine at a constant level.

  • Page 191: Bilge Pump And Bilge Strainer (Optional)

    9. Cooling water system 9.7 Bilge pump and bilge strainer (Optional) 9.7.1 Introduction (1) General Introduction Name Bilge pump Time 10 minutes Rotation direction Right (viewed from the impeller side) Weight Pump 1.4 kg Negative pressure detector Diaphragm type Temperature -30°C∼80°C (2) Exterior Motor assy...

  • Page 192: Description

    9. Cooling water system 9.7.2 Description (1) Characteristics 1) Discharge at lift : 0 m discharge capacity : 20 liters/min. or greater. 2) Automatic feeding height : 1 m or greater (Limit for automatic feeding height: new pump with inside parts wet, approx. 2 m) 3) Automatic feeding time : 2 5 seconds.

  • Page 193: Assembly Procedure

    9. Cooling water system (7) The pump cannot be used to drain off rain water or large amounts of flood water. The pump can be run continuously for a period of 10 minutes. After this time it must shut off for a period of 2 hours before reusing.
  • Page 194 9. Cooling water system (4) Attaching the delivery nozzle (outlet) • Make a fixing hole of Ø21 or less for attaching the Fixing hole Hose nozzle. The hose attached at the nozzle should be 1.8 m or less and should reach without any strain, therefore care should be taken in deciding on the best position.

  • Page 195: Cautions For Assembling

    9. Cooling water system 9.7.5 Cautions for assembling Observe the following cautions for handling. • Do not use gasoline or solvents. 1) gasoline 2) ester 3) benzol 4) battery fluid 5) liquids at 70°C or greater or engine oil • Never run when there is no water in the bilge. Check to be sure that the strainer is in the water before turning on the switch.

  • Page 196: Troubleshooting

    9. Cooling water system 9.7.6 Troubleshooting Refer to the following countermeasures for difficulties that arise. Problem Cause Countermeasure 1. Pump does not turn Faulty wiring Check the wiring between the motor and battery. Faulty battery Check to see if the specific gravity of the battery fluid is greater than 1.25.

  • Page 197: Reduction And Reversing Gear

    10. Reduction and reversing gear 10. Reduction and reversing gear Marine gear KM2P-1 is applied to the 3YM30, 3YM20 and 2YM15 series engines. Refer to chapter 10 in the service manual of the GM series engines for inspection, disassembly and reassembly.

  • Page 198: Remote Control (Optional)

    Remote control cable Morse 33C x 4m Morse 33C x 7m Engine stop cable Yanmar 4m Yanmar 7m (1) Remote control handle The model MT-3 remote control has been designed so that operation of the clutch (shift) and governor (throttle) can be effected with one lever.
  • Page 199 11. Remote control (Optional) (2) Remote control cable Use only Super Responsive Morse Control Cables. These are designed specifically for use with Morse control heads. This engineered system of Worse cables, control head and engine connection kits ensures dependable, smooth operation with an absolute minimum of backlash.

  • Page 200: Remote Control Installation

    11. Remote control (Optional) 11.2 Remote control installation (1) Speed control Optional Remote control handle (MN) Remote control handle (MT-3) Clamp Governor Cable bracket Control lever Flywheel housing Cable joint...
  • Page 201 11. Remote control (Optional) (2) Clutch control Neutral Clamp Reverse Forward Retainer Remote control head Spacer Cable bracket Note : ( ) Cable shift travel S1 = More than 36 mm (1.42") S2 = More than 36 mm (1.42") Clamp Clutch flange To engine speed To marine gear...

  • Page 202: Remote Control Inspection

    11. Remote control (Optional) 11.3 Remote control inspection (1) When the control lever movement does not Neutral coincide with operation of the engine, check Reverse Forward the cable end stop nut to see whether or not Shim in it is loose, and readjust/retighten when Shim in necessary.

  • Page 203: Remote Control Adjustment

    11. Remote control (Optional) 11.4 Remote control adjustment (1) Shift lever adjustment Move the lever several times-the movement of the clutch lever on the engine from forward, neutral and reverse must coincide with the forward, neutral and reverse on the control lever. If they do not coincide, adjust the fittings as necessary (first engine side, then controller side).

  • Page 204: Electrical System

    12. Electrical system 12. Electrical system 12.1 Electrical system STOP B-type panel Glow connector GLOW START Neutral safety switch Glow plug (Fitting to marine gear) Glow relay Magnet relay Safety Extension relay wire harness Alternator To lube switch and fresh water switch To earth bolt Stop solenoid Starting motor...

  • Page 205: Wiring Diagram

    12. Electrical System 12.1.1 Wiring diagram For B-type instrument panel (Color coding) Allowable Length by Procured by customer cross sectional area of battery cable Black Section of cable Allowable Length White L=1+2+3(m) Blue 15(mm <0.86(m) Battery Red / Black 20(mm <1.3(m) Blue / Black 30(mm...

  • Page 206: Battery

    12. Electrical System 12.2 Battery The new type instrument panels are applied for 3YM30 series engines. The features are compactness, waterproof and independence from pulse by ring gear teeth number. The engine speed, indicated with the instrument panel is activated by the pulse from flywheel ring gear.

  • Page 207: Starting Motor

    A starting motor turns the ring gear installed on a engine flywheel by the pinion while overcoming resistance such as the compression pressure and the friction loss of the engine and makes the engine start. 12.3.1 Specifications YANMAR Part No. 129608-77010 HITACHI Model No. S114-817A...

  • Page 208: Structure

    12. Electrical System 12.3.3 Structure (1) Disassembly drawing Magnetic switch Internal gear Bracket Pinion Gear housing Rear cover Yoke Armature...

  • Page 209: Wiring Diameter Of A Starting Motor

    12. Electrical System (2) Structure When the starting switch is turned on, a magnet switch takes a voltage, and a pinion projects. The pinion engages with the ring gear of a engine, and the engine is started. Magnetic Switch Center Bracket (A) Torsion Spring Shift Lever Brush...

  • Page 210: Alternator Standard, 12V/60A

    The type of alternator used in this engine is ideal for high speed engines with a wide range of engine speeds. It contains diodes that convert AC to DC, and an IC regulator that keeps the generated voltage constant even when the engine speed changes. 12.4.1 Specifications Yanmar code 128271-77200 Model of alternator LR160-741 (HITACHI)

  • Page 211: Structure

    12. Electrical System 12.4.2 Structure (1) Disassembly drawing Ball bearing Stator Rotor Front bracket Pulley Rear bracket assembly (12V60A alternator) (2) Structure Bracket Stator Rotor Rectifier assembly assembly assembly Bracket Packing Ball bearing Nut M5 Pulley Through bolt...

  • Page 212: Wiring Diagram

    12. Electrical System 12.4.3 Wiring diagram Condenser 2.2 switch Rotor Diode Stator coil coil Charge lamp 12V3.4W Battery IC regulator Alternator [NOTICE] 1) Don't do mis-connecting and short-circuit of each terminal. 2) Don't remove a battery terminal and a B terminal when rotating. 3) Shut out a battery switch during the alternator stop.

  • Page 213: Inspection

    12. Electrical System 12.4.5 Inspection (1) V belt inspection Normal Defect 1) Inspect the matter whether there are not crack, stickiness and wear on the belt visually. Check that a belt doesn't touch the bottom part of the pulley groove. If necessary, replace the V belt set.

  • Page 214: Alternator 12V/80A (Optional)

    12. Electrical System 12.5 Alternator 12V/80A (Optional) 12.5.1 Specifications Yanmar code 119573-77201 Model of alternator LR180-03C (HITACHI) Model of IC regulator TR1Z-63 (HITACHI) Battery voltage Nominal output 12V/80A Earth polarity Negative earth Direction of rotation Clockwise (viewed from pulley end) Weight 5.4 kg...

  • Page 215: Structure

    12. Electrical System 12.5.2 Structure Disassembly drawing and Structure Brush regulator assy Stator Bearing retainer Rear cover Front cover Diode Condenser Capacitor assembly Brush regulator assembly Rotor Ball bearing Brush holder Spacer Pulley Rear cover assembly Diode assembly Stator assembly Front cover assembly Rotor assembly Brush assembly...

  • Page 216: Wiring Diagram

    12. Electrical System 12.5.3 Wiring diagram switch Diode Rotor Sub- Condenser Charge lamp coil Diode (3.2 12V3.4W Battery switch Battery Stator coil IC regulator Alternator [NOTICE] 1) Don't do mis-connecting and short-circuit of each terminal. 2) Don't remove a battery terminal and a B terminal when rotating. 3) Shut out a battery switch during the alternator stop.

  • Page 217: Instrument Panel

    12. Electrical System 12.6 Instrument panel The new type instrument panels are applied for 3YM30/3YM20/2YM15 series engines. The features are compactness, waterproof and independence from pulse by ring gear teeth number. The engine speed, indicated with the instrument panel is activated by the pulse from flywheel ring gear.

  • Page 218: Warning Devices

    12. Electrical System 12.7 Warning devices 12.7.1 Oil pressure alarm If the engine oil pressure is below 0.01-0.03 MPa (0.1-0.3 kgf/cm , 1.42-4.26 lb/in. ), with the main switch in the ON position, the contacts of the oil pressure are closed by a spring and the lamp is illuminated through the lamp oil pressure switch ground circuit system.

  • Page 219: Cooling Water Temperature Alarm

    12. Electrical System Inspection Problem Inspection Item Inspection method Corrective action Lamp not 1. Oil pressure lamp (1) Visual inspection. Replace lamp. illuminated when blown out. (2) Lamp not illuminated even main switch set when main switch set to ON to ON.

  • Page 220: Glow Plug

    12. Electrical System 12.8 Glow plug A glow plug is available for warming intake air when starting in cold areas in winter. The glow plug is M4 x 0.7 mounted to the cylinder head. The device is operated by the glow switch on the instrument panel. Rated current 8-10A Rated voltage...

  • Page 221: Electric Engine Stopping Device

    12. Electrical System 12.9 Electric engine stopping device The electric engine stop device is fitted to the governor. The device is operated by the stop switch on the Emergency stop button instrument panel. The emergency stop button is integrated with the solenoid.

  • Page 222: Service Standards

    Between alternator at 98N (10kgf) 2.2.2(4) and F.W. pump New part Fuel injection pressure 12.3-13.28 2.2.7(2) (125-135) MPa (kgf/cm 3.43±0.1 2.75±0.1 3YM30 (35±1) (28±1) Compression pressure (at 250 min 3YM20 3.23±0.1 2.55±0.1 MPa (kgf/cm 2YM15 (33±1) (26±1) 3YM30 4.9 (5.2)

  • Page 223: Engine Body

    13. Service standards 13.2 Engine body 13.2.1 Cylinder head (1) Cylinder head Reference Inspection item Standard Limit page Combustion surface distortion 0.05 or less 0.15 5.2.1(1) Valve sink Intake 0.4-0.6 5.2.3(3) Exhaust Intake Seat angle Valve seat 5.2.1(3) deg. Exhaust (2) Intake/exhaust valve and guide Reference Inspection item...
  • Page 224 Standard Limit page Side gap 0.05-0.15 0.25 5.6.1(1) Bending (1/2 the dial gage reading) 0.02 or less 0.05 5.6.1(4) 3YM30 34.135-34.265 33.89 Cam height 5.6.1(2) 3YM20/2YM15 34.535-34.665 34.29 Shaft outside diameter / Metal inside diameter Bushing inside diameter 40.000-40.075 40.150...

  • Page 225: Cylinder Block

    13. Service standards 13.2.3 Cylinder block (1) Cylinder block Reference Inspection item Standard Limit page 3YM30 76.000-76.030 76.200 Cylinder inside diameter 70.000-70.030 70.200 3YM20/2YM15 5.1.5 Roundness Cylinder bore 0.01 or less 0.03 Inclination (2) Crankshaft Reference Inspection item Standard Limit...
  • Page 226 13. Service standards (4) Piston and ring 1) Piston Reference Inspection item Standard Limit page Piston outside diameter 3YM30 75.965-75.975 75.920 (Measure in the direction vertical to 3YM20/2YM15 69.970-69.980 69.925 the piston pin.) Piston diameter measure position 5.3.1(1) (Upward from the bottom end of the piston) 3YM30 0.035-0.055...
  • Page 227 13. Service standards 3YM20/2YM15 Reference Inspection item Standard Limit page Top ring Groove width 1.550-1.570 Ring width 1.470-1.490 1.450 Side clearance 0.060-0.100 Ring gap 0.15-0.30 0.390 Second ring Groove width 1.540-1.560 1.660 Ring width 1.470-1.490 1.450 5.3.3(1) Side clearance 0.050-0.090 0.210 Ring gap 0.18-0.33...

  • Page 228: Lubricating Oil System (Trochoid Pump)

    13. Service standards 13.3 Lubricating oil system (Trochoid pump) (1) Outside clearance of outer rotor Standard Limit Reference page 0.12-0.21 0.30 8.2.4(1) (2) Tip clearance between outer rotor and inner rotor Standard Limit Reference page 0.16 8.2.4(1) (3) Side clearance of outer rotor Standard Limit Reference page...

  • Page 229: Tightening Torque For Bolts And Nuts

    14. Tightening torque for bolts and nuts 14. Tightening torque for bolts and nuts 14.1 Main bolt and nut Lube oil application Thread diameter Torque Name (thread portion and seat x pitch N•m(kgf•m) surface) Head bolt M9 x 1.25 Coat with lube oil 53.9-57.9 (5.5-5.9) Rod bolt M7 x 1.0...
  • Page 230 Code No. M9961-03E101 First Edition : March 2004 2nd Edition : April 2005 Published by : Quality Control Dept. Marine Factory Large Power Products Operations Division. Edited by : YANMAR TECHNICAL SERVICE CO., LTD. All Right Reserved, Copyright, c 2005...
  • Page 231 WWW.YANMARMARINE.COM YANMAR MARINE U.S.A CORPORATION 101 INTERNATIONAL PARKWAY, ADAIRSVILLE, GA 30103, USA PHONE: 1 770-877-9894 FAX: 1 770-877-7565 YANMAR ASIA (SINGAPORE) CORPORATION PTE LTD. 4 TUAS LANE. SINGAPORE 638613 PHONE: 65 6861-3855 FAX: 65 6862-5195 YANMAR CO,. LTD. MARINE FACTORY...

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