YANMAR 3YM20 Manuals

Manuals and User Guides for YANMAR 3YM20. We have 8 YANMAR 3YM20 manuals available for free PDF download: Service Manual, Sevice Manual, Operation Manual

Yanmar 3YM20 Service Manual (231 pages)

Marine Engine

Brand: Yanmar | Category: Engine | Size: 17 MB

Table of Contents
4
1 General

16
- Exterior Views
  16
- Specifications
  17
- Fuel Oil, Lubricating Oil and Cooling Water
  20
  - Fuel Oil
    20
  - Lubricating Oil
    20
  - Cooling Water
    21
- Engine Outline
  22
- Piping Diagrams
  28
- Exhaust Gas Emission Regulation
  32
2 Inspection and Adjustment

35
3 Troubleshooting

69
4 Disassembly and Reassembly

84
- Disassembly and Reassembly Precautions
  84
- Disassembly and Reassembly Tools
  85
  - General Hand Tools
    85
  - Special Hand Tools
    88
  - Measuring Instruments
    91
  - Other Material
    95
- Disassembly and Reassembly
  97
  - Disassembly
    97
  - Reassembly
    109
5 Inspection and Servicing of Basic Engine Parts

124
- Cylinder Block
  124
  - Inspection of Parts
    124
  - Cleaning of Oil Holes
    124
  - Color Check Procedure
    124
  - Replacement of Cap Plugs
    125
  - Cylinder Bore Measurement
    126
- Cylinder Head
  127
  - Inspecting the Cylinder Head
    128
  - Valve Seat Correction Procedure
    129
  - Intake/Exhaust Valves, Valve Guides
    130
  - Valve Springs
    132
  - Assembling the Cylinder Head
    133
  - Measuring Top Clearance
    134
  - Intake and Exhaust Rocker Arms
    134
  - Adjustment of Valve Clearance
    135
- Piston and Piston Pins
  136
  - Piston
    136
  - Piston Pin
    137
  - Piston Rings
    138
- Connecting Rod
  141
  - Inspecting the Connection Rod
    141
  - Crank Pin Metal
    142
  - Piston Pin Bushing
    144
  - Assembling Piston and Connecting Rod
    144
- Crankshaft and Main Bearing
  145
  - Crankshaft
    145
  - Main Bearing
    147
- Camshaft and Tappets
  148
  - Camshaft
    148
  - Tappets
    150
- Timing Gear
  151
  - Inspecting the Gears
    151
  - Gear Timing Marks
    151
- Flywheel and Housing
  152
  - Position of Top Dead Center and Fuel Injection Timing
    152
  - Damper Disc
    153
6 Fuel Injection Equipment

154
- Fuel Injection Pump/Governor
  154
  - Fuel System Diagram
    154
  - Fuel Injection Pump Service Data and Adjustment
    155
  - Fuel Injection Pump Structure
    160
  - Removing a Fuel Injection Pump
    161
  - Installing a Fuel Injection Pump
    161
  - Adjusting Fuel Injection Timing
    161
  - Troubleshooting of Fuel Injection Pump
    162
  - Major Faults and Troubleshooting
    162
- Fuel Feed Pump
  165
- Fuel Filter
  168
  - Fuel Filter Specifications
    168
  - Fuel Filter Inspection
    168
- Fuel Tank
  169
7 Intake and Exhaust System

170
- Intake System
  170
  - Breather System (a Reductor to Intake Air System of Blowby Gas)
    170
  - Diaphragm Assy Inspection
    171
- Exhaust System
  172
  - Construction
    172
  - Mixing Elbow Inspection
    172
8 Lubrication System

173
- Lube Oil Pump
  174
  - Lube Oil Pump Construction
    174
  - Specifications of Lube Oil Pump
    174
  - Lube Oil Pump Disassembly and Reassembly
    174
  - Lube Oil Pump Inspection
    175
  - Pressure Control Valve Construction
    175
- Lube Oil Filter
  176
  - Lube Oil Filter Construction
    176
  - Lube Oil Filter Replacement
    176
- Rotary Waste Oil Pump (Optional)
  177
9 Cooling Water System

178
- Seawater Pump
  180
  - Specifications of Seawater Pump
    180
  - Seawater Pump Disassembly
    180
  - Seawater Pump Inspection
    181
  - Seawater Pump Reassembly
    182
- Fresh Water Pump
  183
  - Fresh Water Pump Construction
    183
  - Specifications of Fresh Water Pump
    183
  - Fresh Water Pump Disassembly
    184
  - Wfresh Water Pump Inspection
    184
- Heat Exchanger
  186
- Pressure Cap and Coolant Recovery Tank
  187
  - Pressure Cap Construction
    187
  - Pressure Cap Pressure Control
    187
  - Pressure Cap Inspection
    187
  - Replacing Filler Neck
    188
  - Function of the Coolant Recovery Tank
    189
  - Specifications of Coolant Recovery Tank
    189
  - Mounting the Coolant Recovery Tank
    189
  - Precautions on Usage of the Coolant Recovery Tank
    189
- Thermostat
  190
  - Functioning of Thermostat
    190
  - Thermostat Construction
    190
  - Characteristics of Thermostat
    190
  - Thermostat Inspection
    190
  - Testing the Thermostat
    190
- Bilge Pump and Bilge Strainer (Optional)
  191
  - Introduction
    191
  - Description
    192
  - Cautions
    192
  - Assembly Procedure
    193
  - Cautions for Assembling
    195
  - Troubleshooting
    196
10 Reduction and Reversing Gear

197
- Specifications
  197
11 Remote Control (Optional)

198
- Remote Control System
  198
  - Construction of Remote Control System
    198
  - Remote Control Device Components
    198
- Remote Control Installation
  200
- Remote Control Inspection
  202
- Remote Control Adjustment
  203
12 Electrical System

204
- Wiring Diagram
  205
- Battery
  206
- Starting Motor
  207
  - Specifications
    207
  - Characteristics
    207
  - Structure
    208
  - Wiring Diameter of a Starting Motor
    209
- Alternator Standard, 12V/60A
  210
  - Specifications
    210
  - Structure
    211
  - Wiring Diagram
    212
  - Standard Output Characteristics
    212
  - Inspection
    213
- Alternator 12V/80A (Optional)
  214
  - Specifications
    214
  - Structure
    215
  - Wiring Diagram
    216
  - Standard Output Characteristics
    216
- Instrument Panel
  217
  - B-Type Instrument Panel (Optional)
    217
- Warning Devices
  218
  - Oil Pressure Alarm
    218
  - Cooling Water Temperature Alarm
    219
- Glow Plug
  220
- Electric Engine Stopping Device
  221
13 Service Standards

222
- Engine Tuning
  222
- Engine Body
  223
  - Cylinder Head
    223
  - Cylinder Block
    225
- Lubricating Oil System (Trochoid Pump)
  228
14 Tightening Torque for Bolts and Nuts

229
- Main Bolt and Nut
  229
- Standard Bolts and Nuts (Without Lube Oil)
  229

Yanmar 3YM20 Sevice Manual (224 pages)

Marine Diesel engine

Brand: Yanmar | Category: Engine | Size: 14 MB

Table of Contents
4
Safety Labels
10
Safety Precautions
11
Rotating Parts
14
1 General

16
- Exterior Views
  16
- Specifications
  17
- Fuel Oil, Lubricating Oil and Cooling Water
  19
  - Fuel Oil
    19
  - Lubricating Oil
    19
  - Cooling Water
    20
- Engine Outline
  21
- Piping Diagrams
  25
- Exhaust Gas Emission Regulation
  27
2 Inspection and Adjustment

30
3 Troubleshooting

64
4 Disassembly and Reassembly

79
- Disassembly and Reassembly Precautions
  79
- Disassembly and Reassembly Tools
  80
  - General Hand Tools
    80
  - Special Hand Tools
    83
  - Measuring Instruments
    86
  - Other Material
    90
- Disassembly and Reassembly
  92
  - Disassembly
    92
  - Reassembly
    104
5 Inspection and Servicing of Basic Engine Parts

119
- Cylinder Block
  119
  - Inspection of Parts
    119
  - Cleaning of Oil Holes
    119
  - Color Check Procedure
    119
  - Replacement of Cap Plugs
    120
  - Cylinder Bore Measurement
    121
- Cylinder Head
  122
  - Inspecting the Cylinder Head
    123
  - Valve Seat Correction Procedure
    124
  - Intake/Exhaust Valves, Valve Guides
    125
  - Valve Springs
    127
  - Assembling the Cylinder Head
    128
  - Measuring Top Clearance
    129
  - Intake and Exhaust Rocker Arms
    129
  - Adjustment of Valve Clearance
    130
- Piston and Piston Pins
  131
  - Piston
    131
  - Piston Pin
    132
  - Piston Rings
    133
- Connecting Rod
  136
  - Inspecting the Connection Rod
    136
  - Crank Pin Metal
    137
  - Piston Pin Bushing
    139
  - Assembling Piston and Connecting Rod
    139
- Crankshaft and Main Bearing
  140
  - Crankshaft
    140
  - Main Bearing
    142
- Camshaft and Tappets
  143
  - Camshaft
    143
  - Tappets
    145
- Timing Gear
  146
  - Inspecting the Gears
    146
  - Gear Timing Marks
    146
- Flywheel and Housing
  147
  - Position of Top Dead Center and Fuel Injection Timing
    147
  - Damper Disc
    148
6 Fuel Injection Equipment

149
- Fuel Injection Pump/Governor
  149
  - Fuel System Diagram
    149
  - Fuel Injection Pump Service Data and Adjustment
    150
  - Fuel Injection Pump Structure
    154
  - Removing a Fuel Injection Pump
    155
  - Installing a Fuel Injection Pump
    155
  - Adjusting Fuel Injection Timing
    155
  - Troubleshooting of Fuel Injection Pump
    156
  - Major Faults and Troubleshooting
    156
- Fuel Feed Pump
  159
- Fuel Filter
  162
  - Fuel Filter Specifications
    162
  - Fuel Filter Inspection
    162
- Fuel Tank
  163
7 Intake and Exhaust System

164
- Intake System
  164
  - Breather System (a Reductor to Intake Air System of Blowby Gas)
    164
  - Diaphragm Assy Inspection
    165
- Exhaust System
  166
  - Construction
    166
  - Mixing Elbow Inspection
    166
8 Lubrication System

167
- Lube Oil Pump
  168
  - Lube Oil Pump Construction
    168
  - Specifications of Lube Oil Pump
    168
  - Lube Oil Pump Disassembly and Reassembly
    168
  - Lube Oil Pump Inspection
    169
  - Pressure Control Valve Construction
    169
- Lube Oil Filter
  170
  - Lube Oil Filter Construction
    170
  - Lube Oil Filter Replacement
    170
- Rotary Waste Oil Pump (Optional)
  171
9 Cooling Water System

172
- Seawater Pump
  174
  - Specifications of Seawater Pump
    174
  - Seawater Pump Disassembly
    174
  - Seawater Pump Inspection
    175
  - Seawater Pump Reassembly
    176
- Fresh Water Pump
  177
  - Fresh Water Pump Construction
    177
  - Specifications of Fresh Water Pump
    177
  - Fresh Water Pump Disassembly
    178
  - Fresh Water Pump Inspection
    178
- Heat Exchanger
  180
- Pressure Cap and Coolant Recovery Tank
  181
  - Pressure Cap Construction
    181
  - Pressure Cap Pressure Control
    181
  - Pressure Cap Inspection
    181
  - Replacing Filler Neck
    182
  - Function of the Coolant Recovery Tank
    183
  - Specifications of Coolant Recovery Tank
    183
  - Mounting the Coolant Recovery Tank
    183
  - Precautions on Usage of the Coolant Recovery Tank
    183
- Thermostat
  184
  - Functioning of Thermostat
    184
  - Thermostat Construction
    184
  - Characteristics of Thermostat
    184
  - Thermostat Inspection
    184
  - Testing the Thermostat
    184
- Bilge Pump and Bilge Strainer (Optional)
  185
  - Introduction
    185
  - Description
    186
  - Cautions
    186
  - Assembly Procedure
    187
  - Cautions for Assembling
    189
  - Troubleshooting
    190
10 Reduction and Reversing Gear

191
- Specifications
  191
11 Remote Control (Optional)

192
- Remote Control System
  192
  - Construction of Remote Control System
    192
  - Remote Control Device Components
    192
- Remote Control Installation
  194
- Remote Control Inspection
  196
- Remote Control Adjustment
  197
12 Electrical System

198
- Wiring Diagram
  199
- Battery
  200
- Starting Motor
  201
  - Specifications
    201
  - Characteristics
    201
  - Structure
    202
  - Wiring Diameter of a Starting Motor
    203
- Alternator Standard, 12V/60A
  204
  - Specifications
    204
  - Structure
    205
  - Wiring Diagram
    206
  - Standard Output Characteristics
    206
  - Inspection
    207
- Alternator 12V/80A (Optional)
  208
  - Specifications
    208
  - Structure
    209
  - Wiring Diagram
    210
  - Standard Output Characteristics
    210
- Instrument Panel
  211
  - B-Type Instrument Panel (Optional)
    211
- Warning Devices
  212
  - Oil Pressure Alarm
    212
  - Cooling Water Temperature Alarm
    213
- Glow Plug
  214
- Electric Engine Stopping Device
  215
13 Service Standards

216
- Engine Tuning
  216
- Engine Body
  217
  - Cylinder Head
    217
  - Camshaft and Gear Train
    218
  - Cylinder Block
    219
- Lubricating Oil System (Trochoid Pump)
  222
14 Tightening Torque for Bolts and Nuts

223
- Main Bolt and Nut
  223
- Standard Bolts and Nuts (Without Lube Oil)
  223

Yanmar 3YM20 Operation Manual (114 pages)

Marine Engines

Brand: Yanmar | Category: Engine | Size: 14 MB

Marine Engines
1
Table of Contents
3
Introduction

7
- Ym Series Emission Control System Warranty-Usa, the Environmental Protection Agency (Epa) Only
  8
- Record of Ownership
  9
Safety

11
- Safety Precautions
  12
  - General Information
    12
  - Before You Operate
    12
  - During Operation and Maintenance
    12
- Location of Safety Decals
  16
Product Overview

17
Before You Operate

31
- Introduction
  31
- Safety Precautions
  31
- Diesel Fuel
  32
  - Diesel Fuel Specifications
    32
  - Filling the Fuel Tank
    35
  - Bleeding the Fuel System
    36
- Engine Oil
  37
  - Engine Oil Specifications
    37
  - Engine Oil Viscosity
    37
  - Checking the Engine Oil
    38
  - Adding Engine Oil
    38
- Marine Gear or Sail Drive Oil
  39
- Engine Coolant
  40
- Cranking the Engine
  43
Engine Operation

45
- Introduction
  45
- Safety Precautions
  45
- Starting the Engine
  47
- Remote Control Handle Operation
  50
  - Acceleration and Deceleration
    50
  - Shifting the Engine
    50
- Cautions During Operation
  51
- Shutting down the Engine
  52
  - Normal Shutdown
    52
  - Emergency Shutdown
    53
- Checking the Engine after Operation
  54
Periodic Maintenance

55
Troubleshooting

81
- Safety Precautions
  81
- Troubleshooting after Starting
  81
- Troubleshooting Information
  82
- Troubleshooting Chart
  83
Long-Term Storage

85
- Prepare Engine for Long-Term Storage
  85
- Drain Seawater Cooling System
  86
Specifications

89
- Principal Engine Specifications
  89
System Diagrams

95
- Piping Diagrams
  95
- Wiring Diagrams
  100
Epa Warranty Usa Only

103
- Yanmar Co., Ltd. Limited Emission Control System Warranty - Usa Only
  103
  - Your Warranty Rights and Obligations
    104
  - Warranty Period
    104
  - Warranty Coverage
    105
  - Exclusions
    105
  - Owner's Responsibility
    105
  - Customer Assistance
    105
Emission System Warranty

107
- Non-Road Emission System Warranty
  107
  - Yanmar Co., Ltd. Limited Emission Control System Warranty - USA Only
    107
  - Maintenance Log
    110

Yanmar 3YM20 Operation Manual (112 pages)

Brand: Yanmar | Category: Engine | Size: 14 MB

Table of Contents
3
Introduction

7
- Record of Ownership
  8
Safety

9
- Safety Precautions
  10
  - General Information
    10
  - Before You Operate
    10
  - During Operation and Maintenance
    10
- Location of Safety Decals
  14
Product Overview

15
Before You Operate

29
- Introduction
  29
- Safety Precautions
  29
- Diesel Fuel
  30
  - Diesel Fuel Specifications
    30
  - Filling the Fuel Tank
    33
  - Bleeding the Fuel System
    34
- Engine Oil
  35
  - Engine Oil Specifications
    35
  - Engine Oil Viscosity
    35
  - Checking the Engine Oil
    36
  - Adding Engine Oil
    36
- Marine Gear or Sail Drive Oil
  37
- Engine Coolant
  38
- Cranking the Engine
  41
Engine Operation

43
- Introduction
  43
- Safety Precautions
  43
- Starting the Engine
  45
- Remote Control Handle Operation
  48
  - Acceleration and Deceleration
    48
  - Shifting the Engine
    48
- Cautions During Operation
  49
- Shutting down the Engine
  50
  - Normal Shutdown
    50
  - Emergency Shutdown
    51
- Checking the Engine after Operation
  52
Periodic Maintenance

53
Troubleshooting

79
- Safety Precautions
  79
- Troubleshooting after Starting
  79
- Troubleshooting Information
  80
- Troubleshooting Chart
  81
Long-Term Storage

83
- Prepare Engine for Long-Term Storage
  83
- Drain Seawater Cooling System
  84
Specifications

87
System Diagrams

93
- Piping Diagrams
  93
- Wiring Diagrams
  98
Warranty Usa Only

101
- Yanmar Co., Ltd. Limited Emission Control System Warranty - Usa Only
  101
Yanmar Emission Control System Warranty Statement

103
- Your Warranty Rights and Obligations
  103
  - Yanmar's Warranty Coverage
    103
  - Warranted Parts
    104
  - Exclusions
    104
  - Owners Warranty Responsibilities
    105
  - Customer Assistance
    105
  - Maintenance Log
    106

Yanmar 3YM20 Operation Manual (102 pages)

YM series

Brand: Yanmar | Category: Engine | Size: 7 MB

Table of Contents
3
Introduction

7
- Record of Ownership
  8
Safety

9
- Safety Precautions
  10
  - General Information
    10
  - Before You Operate
    10
  - During Operation and Maintenance
    10
- Location of Safety Decals
  14
Product Overview

15
- Yanmar YM Features and Applications
  15
  - New Engine Break-In
    16
- Component Identification
  17
  - Service Side - 2YM15
    17
  - Non-Service Side - 2YM15
    17
  - Service Side - 3YM20
    18
  - Non-Service Side - 3YM20
    18
  - Service Side - 3YM30
    19
  - Non-Service Side - 3YM30
    19
- Location of Nameplates
  20
- Function of Major Components
  21
- Control Equipment
  22
  - Instrument Panel (Optional)
    22
  - Single-Lever Remote Control Handle
    25
Before You Operate

27
- Diesel Fuel
  27
  - Diesel Fuel Specifications
    27
    
    Handling of Diesel Fuel
    28
    
    Fuel System
    29
  - Filling the Fuel Tank
    30
  - Bleeding the Fuel System
    31
- Engine Oil
  32
  - Engine Oil Specifications
    32
  - Engine Oil Viscosity
    32
  - Checking the Engine Oil
    33
  - Adding Engine Oil
    33
- Marine Gear or Sail Drive Oil
  34
- Engine Coolant
  35
  - Engine Coolant Specifications
    35
  - Checking and Adding Coolant
    36
- Cranking the Engine
  38
- Daily Checks
  39
Engine Operation

41
- Starting the Engine
  42
- Remote Control Handle Operation
  45
  - Acceleration and Deceleration
    45
  - Shifting the Engine
    45
- Shutting down the Engine
  46
  - Emergency Shutdown
    46
- Checking the Engine after Operation
  47
Periodic Maintenance

49
Troubleshooting

71
- Troubleshooting after Starting
  71
  - Troubleshooting Information
    72
- Troubleshooting Chart
  73
Long-Term Storage

77
- Prepare Engine for Long-Term Storage
  77
- Draining the Cooling System
  78
Specifications

81
System Diagrams

89
- Piping Diagrams
  89
- Wiring Diagrams
  94
Emission System Warranty

97
- Non-Road Emission System Warranty
  97
- Customer Assistance
  99
- 2007 Yanmar Marine International
  100
- Maintenance Log
  100

YANMAR 3YM20 Operation Manual (56 pages)

MARINE DIESEL ENGINE 3YM20; 2YM15; 3YM30

Brand: YANMAR | Category: Engine | Size: 15 MB

Table of Contents
2
Introduction
3
1 For Your Safety

4
- Warning Symbols
  4
- Safety Precautions
  5
- Warning Labels
  8
2 Product Explanation

9
- Use, Propulsion System, Etc
  9
- Engine Specifications
  11
- Names of Parts
  14
- Operation Side
  15
- Major Service of Parts
  17
- Control Equipment
  18
  - Instrument Panel
    18
  - Controls and Equipment
    18
  - Meters
    19
  - Alarm Equipment (Lamps and Buzzer)
    19
  - Normal Action of Alarm Devices
    19
EN 2.5.6 Single Lever Remote Control

20
- Handle
  20
- Shut-Down Equipment
  20
3 Operation

21
- Fuel Oil, Lubricating Oil, and Cooling Water
  21
  - Fuel Oil
    21
  - Lubricating Oil
    22
  - Cooling Fresh Water
    24
  - Handling of Coolant
    24
- Before Initial Operation
  25
  - Supply Fuel Oil
    25
  - Supply Engine Lubricating Oil
    25
  - Supply Marine Gear Lubricating
    25
    
    Oil
    25
  - Supply Cooling Water
    26
  - Cranking
    27
  - Check and Re-Supply Lubricating
    28
    
    Oil and Cooling Water
    28
- Operating Your Engine
  28
  - Daily Start up Inspection
    28
  - How to Start the Engine
    30
  - Operation
    32
  - Cautions During Operation
    32
  - Engine Shut-Down
    33
- Long Term Storage
  34
4 Maintenance and Inspection

36
5 Trouble and Troubleshooting

49
6 Piping Diagrams

52
7 Wiring Diagrams

53

Yanmar 3YM20 Operation Manual (116 pages)

Marine Engines

Brand: Yanmar | Category: Engine | Size: 2 MB

Yanmar 3YM20 Operation Manual (57 pages)

Marine Diesel Engine

Brand: Yanmar | Category: Engine | Size: 2 MB

YANMAR Categories

Engine Tractor Portable Generator Outboard Motor Excavators

More YANMAR Manuals

YANMAR 3YM20 Manuals

Table of Contents

1 General

2 Inspection and Adjustment

3 Troubleshooting

4 Disassembly and Reassembly

5 Inspection and Servicing of Basic Engine Parts

6 Fuel Injection Equipment

7 Intake and Exhaust System

8 Lubrication System

9 Cooling Water System

10 Reduction and Reversing Gear

11 Remote Control (Optional)

12 Electrical System

13 Service Standards

14 Tightening Torque for Bolts and Nuts

Table of Contents

1 General

2 Inspection and Adjustment

3 Troubleshooting

4 Disassembly and Reassembly

5 Inspection and Servicing of Basic Engine Parts

6 Fuel Injection Equipment

7 Intake and Exhaust System

8 Lubrication System

9 Cooling Water System

10 Reduction and Reversing Gear

11 Remote Control (Optional)

12 Electrical System

13 Service Standards

14 Tightening Torque for Bolts and Nuts

Table of Contents

Introduction

Safety

Product Overview

Before You Operate

Engine Operation

Periodic Maintenance

Troubleshooting

Long-Term Storage

Specifications

System Diagrams

Epa Warranty Usa Only

Emission System Warranty

Table of Contents

Introduction

Safety

Product Overview

Before You Operate

Engine Operation

Periodic Maintenance

Troubleshooting

Long-Term Storage

Specifications

2 YM15 Engine Specifications

3 YM20 Engine Specifications

System Diagrams

Warranty Usa Only

Yanmar Emission Control System Warranty Statement

Table of Contents

Introduction

Safety

Product Overview

Before You Operate

Engine Operation

Periodic Maintenance

Troubleshooting

Long-Term Storage

Specifications

2 YM15 Engine Specifications

3 YM20 Engine Specifications

System Diagrams

Emission System Warranty

Table of Contents

1 For Your Safety

2 Product Explanation

EN 2.5.6 Single Lever Remote Control

3 Operation

4 Maintenance and Inspection

5 Trouble and Troubleshooting