Table Of Contents - Yanmar 2QM15 Service Manual

Table of Contents

Contents4
General5
Intake Side Viewed From Stern6
Exhaust Side Viewed From Bow6
Specifications7
Principal Construction8
Performance Curves9
Features10
Engine Cross-Section11
Exterior Views12
System Diagrams13
Cooling System Exploded Diagram13
Lubrication System Exploded Diagram14
Fuel System Exploded Diagram15
Electrical System Exploded Diagram16
Timing Gear Train Diagram17
Reduction Reversing Power Transmission System Diagram18
Remote Control System Diagram19
Standard Accessories20
Parts Packed With The Engine/Mounted On Engine20
Optional Accessories21
Basic Engine22
Cylinder Block Construction/Inspection23
Cylinder Bore And Ledge23
Cylinder Bore Measurement24
Cylinder Liner Construction/Inspection25
Cylinder Liner Bore Diameter Measurement25
Cylinder Liner Replacement26
Measuring Cylinder Liner Projection26
Cylinder Head Construction27
Cylinser Head Inspection And Measurement28
Cylinder Head Valve Seat28
Measuring Valve Recess29
Dismounting And Remounting The Cylinder Head30
Intake And Exhaust Valves, Valve Guide And Valve Spring31
Inspecting And Measuring The Intake And Exhaust Valves/Valve Guides31
Valve Spring32
Precombustion Chamber And Top Clearance33
Valve Stem Seal33
Spring Retainer And Spring Cotter Pin33
Intake And Exhaust Valve Rocker Arm34
Adjusting Intake And Exhaust Valve Head Clearance35
Decompression Mechanism35
Disassembling And Reassembling The Cylinder Head36
Piston37
Piston Ass'y Construction37
Piston Inspection/Replacement37
Piston Pin And Piston Pin Bushing38
Piston Rings39
Connecting Rod41
Connecting Rod Ass'y Construction41
Connecting Rod Inspection41
Crank Pin Bushing41
Tightening The Connecting Rod Bolts42
Crank Pin And Bushing Clearance (Oil Clearance)42
Crank Pin Bushing Replacement Precautions42
Connecting Rod Side Clearance43
Piston Bushing And Piston Pin43
Crankshaft44
Crankshaft Ass'y And Bearing Construction44
Crankshaft Inspection/Crank Journal And Crank Pin44
Crankshaft Side Gap45
Main Bearing45
Inspecting The Thrust Metal46
Replacing The Crank Bearing46
Crankshaft Oil Seal47
Oil Seal Type And Size/Inserting Precautions47
Camshaft Construction/Inspection48
Camshaft Ball Bearing49
Tappets49
Push Rods49
Fuel Cam Assembly Precautions50
Timing Gear Train Construction51
Timing Gear Disassembly And Reassembly52
Timing Gear Inspection52
Backlash52
Inspecting The Gear Tooth Surface/Gear Boss53
Fuel System54
Fuel System Construction/Diagram55
Fuel Injection System Specifications55
Injection Pump Construction/Diagram56
Operation Of Plunger57
Delivery Valve Fuel Suction Collar58
Injection Pump Disassembly58
Inspecting Injection Pump Parts60
Injection Pump Reassembly60
Inspection Of Injection Pump After Reassembly62
Injection Pump Adjustment62
Control Rack Resistance Test62
Fuel Injection Timing62
Setting Pump On Tester63
Adjusting The Plunger Head Gap63
Checking The Cylinder Injection Interval63
Delivery Valve Oil-Tight Test64
Plunger Pressure Test64
Measuring The Fuel Injection Volume64
Injection Nozzle Construction/Diagram65
Yanmar Throttle Nozzle65
Nozzle Operation66
Nozzle Disassembly And Assembly66
Injection Nozzle Inspection And Adjustment67
Carbon And Corrosion On The Nozzle Body67
Checking Nozzle Action/Adjusting The Nozzle Injection Pressure67
Nozzle Seat Oil Tightness Check/Checking The Spray Condition/Inspecting The Nozzle Spring67
Fuel Filter Construction/Diagram/Inspection68
Fuel Feed Pump Construction/Diagram/Inspection69
Fuel Tank Diagram70
Governor71
Governor Construction/Diagram72
Governor Operation/Performance/Disassembly74
Parts Inspection And Replacement75
Regulator Spring75
Sleeve75
Governor Weight75
Governor Lever Shaft76
Regulator Lever Shaft76
Injection Limiter Construction/Diagram/Inspectin/Adjustment77
No-Load Maximum Speed Limiter Construction/Handling Precautions78
Engine Stop Spring Diagram79
Intake And Exhaust System80
Intake And Exhaust System Exploded Diagram81
Intake Silencer Construction/Inspection82
Exhaust System83
Exhaust Manifold And Mixing Elbow83
Exhaust Manifold Inspection83
Mixing Elbow Inspection83
Breather Pipe84
Lubrication System85
Lubrication System Diagram86
Lubrication System Description87
Oil Pump Construction/Diagram/Disassembly88
Oil Pump Inspection89
Oil Filter Construction/Diagram/Replacement90
Oil Pressure Regulator Valve91
Oil Pressure Measurement92
Cooling System93
Cooling System Diagram94
Cooling System Compositin95
Cooling Water Route95
Piping95
Water Pump Construction And Operation96
Cooling Water Pump (With Bilge Pump) Diagram/Specifications97
Water Pump Disassembly/Reassembly/Handling/Inspection98
Thermostat Construction/Operation/Inspection100
Anticorrosion Zinc - Principles/Inspection101
Kingston Cock Construction/Handling Precautions/Inspection102
Bilge Strainer103
Reduction And Reversing Gear104
Reduction And Reversing Gear Construction/Specifications105
Power Transmission System106
Reduction And Reversing Gear Exploded Diagram107
Reduction And Reversing Gear Installation109
Reduction And Reversing Gear Operation And Maintenance110
Lube Oil110
Precautions/Side Cover110
Reduction And Reversing Gear Inspection And Servicing111
Clutch Case/Bearing111
Gear111
Steel Plate111
Friction Plate112
Pressure Plate112
Driving Plate113
Retainer113
Shift Ring114
Shift Fork And Shift Lever114
Output Shaft114
Damper Disc114
Input Shaft115
Intermediate Shaft115
Reduction And Reversing Gear Disassembly116
Disassembling The Clutch And Accessories116
Disassembling The Input Shaft/Output Shaft117
Disassembling The Intermiediate Shaft118
Disassembling The Operating System119
Reduction And Reversing Gear Reassembly120
Reassembling The Output Shaft120
Reassembling The Input Shaft/Intermediate Shaft123
Installing The Input Shaft And Output Shaft123
Reassembling And Installing The Operating System124
Installing The Output Shaft Coupling125
Remote Control System126
Remote Control System Construction/Diagram127
Clutch Regulator One-Handle Remote Control128
One-Handle Remote Control Composition128
Engine Side Installation128
Decompression Remote Control130
Engine Stop Remote Control131
Electrical System132
Electrical System Composition/Diagram133
Electrical System Schematic Diagram134
Battery Construction/View135
Battery Capacity And Battery Cables135
Battery Visual Inspection135
Checking The Electrolyte136
Voltage Test136
Washing The Battery136
Battery Charging137
Battery Storage Precautions137
Starter Motor Specifications And Performance/Construction138
Starter Motor Operation/Disassembly139
Magnetic Switch139
Rear Cover/Brush Holder140
Yoke140
Armature140
Pinion140
Starter Motor Inspection141
Armature/Field Coil Inspection141
Brush/Magnetic Switch Inspection142
Starter Motor Reassembly Precautions143
Pinion Inspection143
Starter Motor Testing144
Starter Motor: Various Problems And Their Remedies144
Alternator Specifications/Characteristics145
Alternator Construction/Exploded Diagram146
Alternator Diagrams And Parts List147
Alternator Operation148
Alternator Circuit Diagram148
Wiring (Lr135-31)149
Lr155-04 (Optional) R Terminal149
Alternator Handling Precautions149
Alternator Disassembly150
Alternator Inspection And Adjustment151
Diodes151
Rotor152
Stator Coil152
Alternator Brush152
Alternator Reassembly Precautions153
Alternator Performance Test153
Alternator Troubleshooting And Repair154
Alarm Circuit155
Oil Pressure Alarm155
Cooling Water Temperature Alarm155
Alarm Buzzer156
Tachometer156
Installation And Fitting157
Propeller Selection158
Engine Installation159
Engine Room/Bed159
Engine Dimensions160
Engine Installation Method161
Fixed Installation161
Flexible Mounting161
Engine Centering162
Coupling Mating Face Measurement162
Stern Equipment163
Stern Tube Installation163
Propeller Shaft Installation165
Propeller Installation165
Interior Piping And Wiring167
Exhaust Pipe167
Exhaust Muffler Installation167
Cooling Water Pipe168
Kingston Cock168
Fuel Tank And Fuel Piping169
Cooling Water Outlet Pipe169
Battery Installation And Wiring170
Instrument Panel170
Fuel Piping170
Remote Control Stand Installation Dimensions171
Front Power Take-Off172
Front Drive System172
Front Power Take-Off Allowable Output172
Operating Instructions173
Fuel Oil And Lubricating Oil174
Properties Of Fuel174
Recommended Fuels174
Fuel Selection Precautions174
Properties And Compositions Of Fuel Of Various National Standards Chart175
Methods Of Identifying Fuel Properties176
Relationship Between Fuel Properties And Engine Performance176
Troubles Caused By Bad Fuel176
Lubricating Oil177
Reqired Lubricating Oil Conditions177
Classification By Viscosity177
Fuel Handling Precautions177
Sae Service Classification And Api Service Classification178
Recommended Lubricating Oils179
Engine Oil Replacement And Handling179
Adding Oil179
Oil Capacity180
Engine Operating Instructions181
Preparations Before Starting The Engine181
Fueling Up/Adding Lubricating Oil181
Bleeding The Fuel System181
Starting And Warm-Up182
After Starting183
Operation183
Checks During Operation183
Stopping184
Emergency Stop184
Storage When Moored For An Extended Period184
Inspection And Procedures After Stopping184
Troubleshooting And Repair185
Troubles And Corrective Action At Starting185
Troubles And Corrective Action During Operation186
Disassembly And Reassembly188
Disassembly And Reassembly Precautions189
Disassembly And Reassembly Tools190
Supplementary Packing Agent195
Paint195
Yanmar Cleaner195
Neji Lock Super - Locking Agent For Screws195
Disassembly Steps196
Reassembly Steps204
Tightening Torque213
Main Bolt And Nut Tightening Torque213
General Bolt And Nut Tightening Torque214
Packing Supplement And Adhesive Application Points215
Inspection And Service216
Routine Inspection Chart217
Routine Maintenance And Inspection Procedures218
Daily Maintenance218
Maintenance Every 50 Engine Hours218
Maintenance Every 100 Engine Hours219
Maintenance Every 300/500 Engine Hours220