Yanmar 3YM20 Operation Manual

Yanmar 3YM20 Operation Manual

Marine diesel engine 3ym20; 2ym15; 3ym30
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MARINE DIESEL ENGINE
MODEL:2YM15/3YM20/3YM30
The 2YM15/3YM20/3YM30 is an EPA Certified Engine.
It meets the low emission standards set by the EPA.
California Proposition 65 Warning
Diesel engine exhaust and some of its
constituents are known to the State of
California to cause cancer, birth
defects, and other reproductive harm.
All rights reserved. This manual may not be reproduced or copied, in whole or in part, without the written per-
3YM20/3YM30
OPERATION MANUAL
compounds, chemicals known to the
State of California to cause cancer and
reproductive harm. Wash your hands
Yanmar
Yanmar
Copyright © 2004 Yanmar CO., LTD
mission of YANMAR CO., LTD.
California Proposition 65 Warning
Battery posts, terminals, and related
accessories contain lead and lead
after handling.
EN

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Summary of Contents for Yanmar 3YM20

  • Page 1 3YM20/3YM30 MARINE DIESEL ENGINE MODEL:2YM15/3YM20/3YM30 OPERATION MANUAL The 2YM15/3YM20/3YM30 is an EPA Certified Engine. It meets the low emission standards set by the EPA. California Proposition 65 Warning California Proposition 65 Warning Diesel engine exhaust and some of its Battery posts, terminals, and related...
  • Page 2: Table Of Contents

    INTRODUCTION ........... 3 4. MAINTENANCE AND INSPECTION ..36 4.1 General Inspection Rules ....36 4.2 List of Periodic Inspection Items ..37 1. FOR YOUR SAFETY ....... 4 4.3 Periodic Inspection Items ....39 1.1 Warning Symbols ......4 4.3.1 Inspection on Initial 50 Hrs. of 1.2 Safety Precautions ......
  • Page 3: Introduction

    Make sure this manual is transferred to subsequent owners. It should be considered as a permanent part of the engine and remain so. Constant efforts are made to improve the quality and performance of Yanmar products, so some details included in this Operation Manual may differ slightly from your engine. If you have any questions about this, please contact your Yanmar dealer or distributor.
  • Page 4: For Your Safety

    1. FOR YOUR SAFETY 1. FOR YOUR SAFETY 1.1 Warning Symbols Be sure to read this operation manual carefully before operating the engine and Most operation, maintenance and inspec- observe all of the instructions and precau- tion problems arise due to users' failure to tions described in this manual.
  • Page 5: Safety Precautions

    1. FOR YOUR SAFETY 1.2 Safety Precautions (Observe these instructions for your own safety!) Precautions for Operation Filler Cap of Coolant Tank DANGER Never open the cap of the coolant tank while the engine is still hot. Steam and hot water may spurt out and burn you seriously. Wait until the temperature of the coolant tank has dropped, wrap a cloth around the filler cap, loosen the cap very carefully and slowly to remove the system pressure before removing the cap.
  • Page 6 1. FOR YOUR SAFETY Moving Parts WARNING Do not touch or let your clothing get caught in the moving parts of the engine, such as the front drive shaft, V-belt or propeller shaft, during en- gine operation. You will be injured. Never operate the engine without covers on the moving parts.
  • Page 7 1. FOR YOUR SAFETY Scalds CAUTION When extracting oil from the engine while it is still hot, don't let the oil splash on you. Wait until the temperature has dropped before extracting cooling water from the engine. Don't let it splash on you. Forbidden Modifications.
  • Page 8: Warning Labels

    1. FOR YOUR SAFETY 1.3 Warning Labels DANGER Safety Precautions for Inspection WARNING To insure safe operation, warning device labels have been attached. Their location is shown below and they should always be visible. Please replace if damaged or lost. Product Safety Labels Part Code No.
  • Page 9: Product Explanation

    2. PRODUCT EXPLANATION 2. PRODUCT EXPLANATION 2.1 Use, Propulsion System, Etc. The laws of some countries may require hull and engine inspections, depending on The engine is equipped with a marine gear the use, size and cruising area of the boat. or a sail drive unit.
  • Page 10 MODEL Model GEAR RATIO Gear Model Continuous power OIL QTY. LTR. Speed of prop. shaft KANZAKI Fuel stop power kW OSAKA JAPAN ENG.No. YANMAR DIESEL ENGINE YANMAR CO., LTD. MADE IN JAPAN...
  • Page 11: Engine Specifications

    2. PRODUCT EXPLANATION 2.2 Engine Specifications Engine Model unit 2YM15 Marine gear model KM2P-1 SD-20 Pleasure use Type Vertical water-cooled 4-cycle diesel engine Combustion system Swirl pre-combustion chamber Number of cylinders Bore x stroke mm(inch) 70x74(2.76x2.91) Displacement 0.570 Continuous Output at crankshaft/ kW(hp)/ 9.4(12.8)/3489(at Fuel temp.
  • Page 12 2. PRODUCT EXPLANATION Engine Model unit 3YM20 3YM30 Marine gear model KM2P-1 SD-20 KM2P-1 SD-20 Pleasure use Pleasure use Type Vertical water-cooled 4-cycle diesel Vertical water-cooled 4-cycle diesel engine engine Combustion system Swirl pre-combustion chamber Swirl pre-combustion chamber Number of cylinders...
  • Page 13 2. PRODUCT EXPLANATION Marine gear Model Unit KM2P-1(S) KM2P-1(G) KM2P-1(GG) SD20 (coupled or Sail Drive at boat builder) Type Mechanical cone clutch Dog clutch Reduction ratio (For- 2.21/3.06 2.62/3.06 3.22/3.06 2.64/2.64 ward/Reverse) Propeller speed (For- 1580/1140 1332/1140 1083/1140 1322 ward/Reverse) Lubrication system Splash Oil bath...
  • Page 14: Names Of Parts

    2. PRODUCT EXPLANATION 2.3 Names of Parts 2YM15 Operation Side A Intake silencer F Oil filler cap B Intake manifold G Fuel feed pump C Fuel filter H Lubricating oil filter D Fuel injection pump I Marine gear E Dipstick Non Operation Side A Seawater pump F Exhaust manifold...
  • Page 15: Operation Side

    2. PRODUCT EXPLANATION 3YM20 Operation Side A Intake silencer F Oil filler cap B Intake manifold G Fuel feed pump C Fuel filter H Lubricating oil filter D Fuel injection pump I Marine gear E Dipstick Non Operation Side A Seawater pump...
  • Page 16 2. PRODUCT EXPLANATION 3YM30 Operation Side A Intake silencer F Oil filler cap B Intake manifold G Fuel feed pump C Fuel filter H Lubricating oil filter D Fuel injection pump I Marine gear E Dipstick Non Operation Side A Seawater pump F Exhaust manifold C Filler cap G Starter motor...
  • Page 17: Major Service Of Parts

    2. PRODUCT EXPLANATION 2.4 Major Service of Parts Name of part Function Removes dirt and water from fuel. Drain the filter periodically. The element (filter) Fuel filter should be changed. See maintenance section 4.3.5 Fuel feed pump Pumps fuel from tank to the fuel injection pump. Moving the priming lever up and down feeds the fuel.
  • Page 18: Control Equipment

    2. PRODUCT EXPLANATION 2.5 Control Equipment B type The equipment in the control room, mak- ing remote control possible, consists of the instrument panel, which is connected by wire harness and the remote control han- dle, which is hooked up by remote control STOP STOP cables to the engine control lever and ma-...
  • Page 19: Meters

    2. PRODUCT EXPLANATION 2.5.1.2 Meters B type panels use analog electric systems and have a pointer indicator. Instruments, equipment Functions Tachometer The engine’s rotation speed is indicated. The number of hours of operation is indicated, and can be used as a guide for Hour meter periodic maintenance checks.
  • Page 20: En 2.5.6 Single Lever Remote Control

    (clutch re- mains in the NEUTRAL, no load position). NOTICE Yanmar recommends the use of a sin- gle-lever type for the remote control system. If only the two-lever type is available in the market, operate the en-...
  • Page 21: Operation

    3. OPERATION 3. OPERATION 3.1 Fuel Oil, Lubricating Oil, and • Aromatics (total) content of the fuel. It Cooling Water should not exceed 35% by volume. (Preferably it should be below 30% and aromatics (PAH*) content of the 3.1.1 Fuel Oil fuel preferably it should be below 10%) NOTICE...
  • Page 22: Lubricating Oil

    3. OPERATION (3) Fuel Tank NOTICE The inside of the fuel tank should al- ways be clean enough and it should When other than the specified fuel oil is be dry for the first use. Drain the water used, the engine will not perform to full according to the maintenance (section capacity and parts may be damaged.
  • Page 23 In case CG-4, CH-4 is to be used for being used or not. YANMAR YM diesel engine series, If you operate your equipment at tem- there is a possibility that excessive peratures below the limits shown, con-...
  • Page 24: Cooling Fresh Water

    • ASTM D4985 When handling LLC, use protective gloves to avoid skin contact. Consult your Yanmar dealer or distributor on In case it comes in contact with your the use of coolant/antifreeze, and detergents. skin or eyes, wash it out with clean wa- Examples of LLC which provide good perfor- ter.
  • Page 25: Before Initial Operation

    Full 0.30 L (0.64 pints) 3YM30 with KM2P-1 Full: 2.8 L (3.0 quarts) 3YM30 with SD20 Full: 2.5 L (2.6 quarts) 3YM20 with KM2P-1 Full: 2.7 L (2.9 quarts) 3YM20 with SD20 Full: 2.4 L (2.5 quarts) 2YM15 with KM2P-1 Full: 2.0 L (2.1 quarts)
  • Page 26: Supply Cooling Water

    3. OPERATION A Oil filler cap B Dipstick 3.2.4 Supply Cooling Water A Coolant tank C Drain cock for seawater Supply cooling water according to the fol- B Drain plug for coolant lowing procedures. Be sure to add anti- freeze to the cooling water. (1) Be sure to close the 4 water drain cocks/plugs.
  • Page 27: Cranking

    3. OPERATION (3) Pour cooling water slowly into the fresh water/coolant tank so that air bubbles do not develop. Pour until the water overflows from the filler port. If the filler cap is loose, hot DANGER steam and water will spout out which may cause A To fresh water cooler C Lower limit...
  • Page 28: Check And Re-Supply Lubricating

    3. OPERATION 3.3 Operating your engine (6) When the key switch is turned, the engine will begin cranking. Contin- ue cranking for about 5 seconds, WARNING and check for abnormal noise dur- ing that time. (If you remove your To prevent exhaust gas poisoning, en- hand from the stop knob or stop sure good ventilation during operation.
  • Page 29 In such cases, (5) Check and Re-supply Fresh Water consult your Yanmar dealer or dis- (For Fresh Water Cooling System) tributor without delay. Check the fresh water level before op- eration while the engine is cold.
  • Page 30: How To Start The Engine

    3. OPERATION (7) Check the Alarm Devices Electric 6. Turn the key switch to start the engine. Operation Release the key switch when the en- When operating the key switch, check gine has started. The alarm buzzer that the alarm devices work normally. should stop and the alarm lamps go (See 2.5.1 (4)) out.
  • Page 31 3. OPERATION 5. Allow the fuel containing air bubbles to NOTICE flow out from the air vent bolt holes. When the fuel coming out no longer Turn the key for a maximum of 15 contains bubbles, tighten the air vent seconds in the start position.
  • Page 32: Operation

    3. OPERATION Move the throttle handle slowly to a NOTICE higher speed position after completing clutch engagement. The engine will seize if it is operat- ed when cooling seawater dis- 2. When changing between FORWARD charge is too small or if load is and REVERSE, bring the clutch to applied without any warming up op- NEUTRAL and pause before slowly...
  • Page 33: Engine Shut-Down

    3. OPERATION (5) Is there water, oil, or gas leakage, or (3) Cool down the engine at low speed are there any loose bolts? (approximately 1000 rpm) for about 5 minutes. Check the engine room periodically for any problems. NOTICE (6) Is there sufficient fuel oil in the fuel oil tank? Always remember to allow engine...
  • Page 34: Long Term Storage

    3. OPERATION 1. Loosen the drain cocks/plugs at- Emergency Stop tached on the pipe and on the heat ex- When you can’t stop the engine by the stop changer, and drain off the seawater button on the panel, push the button at the inside.
  • Page 35 3. OPERATION (5) Grease the exposed area and joints of the remote control cable and the bearings of the remote control han- dle. (6) Cover the intake silencer, exhaust pipe, etc. with vinyl sheets and seal them to prevent moisture from en- tering.
  • Page 36: Maintenance And Inspection

    The standard tightening torque for (4) Use Genuine Yanmar Parts. standard bolts & nuts is listed below. Be sure to use genuine Yanmar parts for consumable and replacement parts. Use of other parts will reduce engine performance and shorten the...
  • Page 37: List Of Periodic Inspection Items

    Consult your definitively. The following should be treat- Yanmar dealer or distributor. ed as a general standard only. Section 4.3 gives a detailed explanation of which parts must be inspected and the...
  • Page 38 4. MAINTENANCE AND INSPECTION : check : Replace : Consult local dealer Every 50 Every 100 Every 150 Every 250 Every 1000 Before start- Initial System Item hrs or hrs or six hrs or one hrs or one hrs or 4 50 hrs monthly months [1]...
  • Page 39: Periodic Inspection Items

    (177-212 lb-in)) sary. This adjustment requires spe- 5. Fill with new lubricating oil. (See 3.2.2) cialized knowledge and techniques. 6. Perform a trial run and check for oil Consult your Yanmar dealer or distrib- leaks. utor.
  • Page 40 4. MAINTENANCE AND INSPECTION (6) Adjusting the Remote Control Ca- The various control levers on the en- gine side are connected to the remote control lever by remote control cables. The cables will become stretched and the attachments loose after long hours of use causing deviation.
  • Page 41: Inspection Every 50 Hrs. (Or Monthly)

    4. MAINTENANCE AND INSPECTION (7) Adjusting the Tension of Alternator 4.3.2 Inspection Every 50 Hrs. (or Driving Belt Monthly) When there is not enough tension in (1) Drain the fuel/water separator. the V-belt, it will slip and the fresh wa- 1.
  • Page 42 4. MAINTENANCE AND INSPECTION 2. 2.Loosen the drain plug and drain off 1. Check the fuel level in the fuel tank. Replenish if Insufficient any water and dirt collected inside. Note: If no drain drips when the drain plug is 2.
  • Page 43: Inspection Every 100 Hrs (Or Six Months)

    4. MAINTENANCE AND INSPECTION may be insufficient. In such cases, (Battery fluid tends to evaporate in consult your Yanmar dealer or dis- high temperatures, especially in sum- tributor. mer. In such cases, inspect the battery earlier than specified.) 4.3.3 Inspection Every 100 Hrs (or GREASE six months).
  • Page 44 (replacement of the lip seal) are necessary. When disassembly and maintenance of the seawater pump are necessary, consult your Yanmar dealer or distrib- utor. NOTICE The seawater pump turns in the di- rection as shown in the below fig-...
  • Page 45: Inspection Every 1000 Hrs

    Adjustment is necessary to obtain the optimal fuel injection to ensure the best possible engine performance. This inspection requires specialized knowledge and techniques. Consult your Yanmar dealer or distrib- A Direction of Impeller B Impeller rotating direction utor. C Impeller D Seawater pump (3) Adjusting the Remote Control Ca- bles (See 4.
  • Page 46: Annually

    A Diaphragm cover E Rocker arm cover B Spring F Breather baffle Note: Be sure to replace the Yanmar flexible C Center plate G Baffle plate engine mounts every 1000 hours or 4 years, D Diaphragm H Intake manifold whichever comes first.
  • Page 47: Epa Requirements

    4. MAINTENANCE AND INSPECTION 4.4.2 Conditions to Insure Compli- Even if LLC (Long Life Coolant) or an- ance with Emission Standards tirust is added, the cooling water must be replaced periodically because the This product is an EPA approved engine. properties of the agent will degener- ate.
  • Page 48: Inspection And Maintenance

    Check fuel valve nozzle (clean) 1500 hours Check & adjustment of fuel injection pressure & atomizing condition 3000 hours Check fuel pump (adjust) 3000 hours Note: The inspection and maintenance shown above are to be performed at your Yanmar dealer or dis- tributor...
  • Page 49: Trouble And Troubleshooting

    5. TROUBLE AND TROUBLESHOOTING 5. TROUBLE AND TROUBLESHOOTING Trouble Probable Cause Measure Reference Alarm buzzer and alarm NOTICE lamps on during opera- tion Shift to low speed operation immediately, and check which lamp has come on. Stop the engine for inspection. If no abnormality is identified and there is no problem with operation, return to port at your lowest speed and request repairs.
  • Page 50 5. TROUBLE AND TROUBLESHOOTING Trouble Probable Cause Measure Reference Starting Failures Starter turns, but engine No fuel. Replenish fuel; vent air. 3.3.2(3) does not start Fuel filter is clogged. Replace element. 4.3.5(1) Improper fuel. Replace with recommended fuel. Faulty fuel injection. Ask for repairs.
  • Page 51 5. TROUBLE AND TROUBLESHOOTING Consulting Your Yanmar Dealer or Distributor Refer difficult problems and repairs to your Yanmar dealer or distributor. At the time of trouble, check and report the following: (1) Engine model and number: (2) Boat name, material of hull, size (tons): (3) Use, type of boating done, no.
  • Page 52: Piping Diagrams

    6. PIPING DIAGRAMS 6. PIPING DIAGRAMS See Appendix A. at the back of this manual. Notation Overflow Rubber hose Fuel oil inlet SGP STS Steel Pipe Fuel feed pump Fuel injection pump Screw joint (Union) Lubricating oil filter (cartridge type) Flange Joint Fuel high pressure lines Fuel injection nozzle...
  • Page 53: Wiring Diagrams

    7. WIRING DIAGRAMS 7. WIRING DIAGRAMS See Appendix B. at the back of this manual. Color coding Starter switch Stop switch Black Tachometer hour meter White Buzzer Blue Lubricating oil low pressure alarm Red/Black Coolant high temperature alarm Blue/Black Water in sail drive seal alarm Yellow/White Battery low charge alarm Yellow/Black...
  • Page 54 THIS MACHINERY PART MUST NOT BE PUT INTO SERVICE UNTIL THE MACHINERY INTO WHICH IT IS TO BE INCORPORATED HAS BEEN DECLARED IN CONFORMITY WITH THE PROVISIONS OF THE DIRECTIVE. • IMPORTER IN THE EU: YANMAR MARINE INTERNATIONAL B.V. Brugplein 11 1332 BS Almere-de Vaart, The Netherlands Nagahama, Japan, Sept. 21, 1997 Place and date issued Y.
  • Page 55 President, Yanmar Marine Int’l...
  • Page 56 President, Yanmar Marine Int’l...

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2ym153ym30

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