YANMAR 3YM30 3YM20 2YM15 MARINE DIESEL ENGINE SERVICE MANUAL 0BYMM-G00100 – PDF DOWNLOA

Description

YANMAR 3YM30 3YM20 2YM15 MARINE DIESEL ENGINE SERVICE MANUAL 0BYMM-G00100 – PDF DOWNLOAD

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DESCRIPTION:

YANMAR 3YM30 3YM20 2YM15 MARINE DIESEL ENGINE SERVICE MANUAL 0BYMM-G00100 – PDF DOWNLOA

FOREWORD:
This service manual has been complied for engineers engaged in sales, service, inspection and
maintenance. Accordingly, descriptions of the construction and functions of the engine are emphasized
in this manual, while items, which should already be common knowledge, are omitted.
One characteristic of a marine diesel engine is that its performance in a vessel is governed by the
applicability of the vessel’s hull construction and its steering system.

TABLE OF CONTENTS:

YANMAR 3YM30 3YM20 2YM15 MARINE DIESEL ENGINE SERVICE MANUAL 0BYMM-G00100 – PDF DOWNLOA

1 General 1
1 1 Exterior views 1
1 2 Specifications 2
1 3 Fuel oil, lubricating oil and cooling water 4
1 3 1 Fuel oil 4
1 3 2 Lubricating oil 4
1 3 3 Cooling water 5
1 4 Engine outline 6
1 5 Piping diagrams 10
1 6 Exhaust gas emission regulation 12
1 6 1 Engine identification (EPA/ARB) 12
1 6 2 Exhaust gas emission standard (EPA/ARB) 13
1 6 3 Guarantee conditions for emission standard (EPA/ARB) 13
2 Inspection and adjustment 15
2 1 Periodic maintenance schedule 15
2 2 Periodic inspection and maintenance procedure 17
2 2 1 Check before starting 17
2 2 2 inspection after initial 50 hours or one month operation 20
2 2 3 Inspection every 50 hours or monthly 25
2 2 4 Inspection every 100 hours six months 30
2 2 5 Inspection every 150 hours or one year 30
2 2 6 Inspection every 250 hours or one year 31
2 2 7 Inspection every 1,000 hours or four years 37
2 3 Adjusting the no-load maximum or minimum speed 44
2 4 Sensor Inspection 44
2 4 1 Oil pressure switch 44
2 4 2 Thermo switch 44
2 5 Thermostat inspection 45
2 6 Adjusting operation 46
2 6 1 Preliminary precautions 46
2 6 2 Adjusting operation procedure 46
2 6 3 Check points and precautions during running 47
2 7 Long storage 48
3 Troubleshooting 49
3 1 Preparation before troubleshooting 49
3 2 Quick reference chart for troubleshooting 50
3 3 Troubleshooting (Concerning engine and fuel injection equipment) 59
3 4 Troubleshooting by measuring compression pressure 62
4 Disassembly and reassembly 64
4 1 Disassembly and reassembly precautions 64
4 2 Disassembly and reassembly tools 65
4 2 1 General hand tools 65
4 2 2 Special hand tools 68
4 2 3 Measuring instruments 71
4 2 4 Other material 75
4 3 Disassembly and reassembly 77
4 3 1 Disassembly 77
4 3 2 Reassembly 89
5 Inspection and servicing of basic engine parts 104
5 1 Cylinder block 104
5 1 1 Inspection of parts 104
5 1 2 Cleaning of oil holes 104
5 1 3 Color check procedure 104
5 1 4 Replacement of cap plugs 105
5 1 5 Cylinder bore measurement 106
5 2 Cylinder head 107
5 2 1 Inspecting the cylinder head 108
5 2 2 Valve seat correction procedure 109
5 2 3 Intake/exhaust valves, valve guides 110
5 2 4 Valve springs 112
5 2 5 Assembling the cylinder head 113
5 2 6 Measuring top clearance 114
5 2 7 Intake and exhaust rocker arms 114
5 2 8 Adjustment of valve clearance 115
5 3 Piston and piston pins 116
5 3 1 Piston 116
5 3 2 Piston pin 117
5 3 3 Piston rings 118
5 4 Connecting rod 121
5 4 1 Inspecting the connection rod 121
5 4 2 Crank pin metal 122
5 4 3 Piston pin bushing 124
5 4 4 Assembling piston and connecting rod 124
5 5 Crankshaft and main bearing 125
5 5 1 Crankshaft 125
5 5 2 Main bearing 127
5 6 Camshaft and tappets 128
5 6 1 Camshaft 128
5 6 2 Tappets 130
5 7 Timing gear 131
5 7 1 Inspecting the gears 131
5 7 2 Gear timing marks 131
5 8 Flywheel and housing 132
5 8 1 Position of top dead center and fuel injection timing 132
5 8 2 Damper disc 133
6 Fuel injection equipment 134
6 1 Fuel Injection pump/governor 134
6 1 1 Fuel system diagram 134
6 1 2 Fuel injection pump service data and adjustment 135
6 1 3 Fuel injection pump structure 139
6 1 4 Removing a fuel injection pump 140
6 1 5 Installing a fuel injection pump 140
6 1 6 Adjusting fuel injection timing 140
6 1 7 Troubleshooting of fuel injection pump 141
6 1 8 Major faults and troubleshooting 141
6 2 Fuel feed pump 144
6 2 1 Construction of fuel feed pump 144
6 2 2 Fuel feed pump specifications 144
6 2 3 Disassembly and reassembly of fuel feed pump 145
6 2 4 Fuel feed pump inspection 145
6 3 Fuel filter 147
6 3 1 Fuel filter specifications 147
6 3 2 Fuel filter inspection 147
6 4 Fuel tank 148
7 Intake and exhaust system 149
7 1 Intake system 149
7 1 1 Breather system (A reductor to intake air system of blowby gas) 149
7 1 2 Diaphragm assy inspection 150
7 2 Exhaust system 151
7 2 1 Construction 151
7 2 2 Mixing elbow inspection 151
8 Lubrication system 152
8 1 Lubrication system 152
8 2 Lube oil pump 153
8 2 1 Lube oil pump construction 153
8 2 2 Specifications of lube oil pump 153
8 2 3 Lube oil pump disassembly and reassembly 153
8 2 4 Lube oil pump inspection 154
8 2 5 Pressure control valve construction 154
8 3 Lube oil filter 155
8 3 1 Lube oil filter construction 155
8 3 2 Lube oil filter replacement 155
8 4 Rotary waste oil pump (Optional) 156
9 Cooling water system 157
9 1 Cooling water system 157
9 2 Seawater pump 159
9 2 1 Specifications of seawater pump 159
9 2 2 Seawater pump disassembly 159
9 2 3 Seawater pump Inspection 160
9 2 4 Seawater pump reassembly 161
9 3 Fresh water pump 162
9 3 1 Fresh water pump construction 162
9 3 2 Specifications of fresh water pump 162
9 3 3 Fresh water pump disassembly 163
9 3 4 WFresh water pump inspection 163
9 4 Heat exchanger 165
9 4 1 Heat exchanger construction 165
9 4 2 Disassembly and reassembly of the heat exchanger 165
9 4 3 Heat exchanger inspection 165
9 5 Pressure cap and coolant recovery tank 166
9 5 1 Pressure cap construction 166
9 5 2 Pressure cap pressure control 166
9 5 3 Pressure cap inspection 166
9 5 4 Replacing filler neck 167
9 5 5 Function of the coolant recovery tank 168
9 5 6 Specifications of coolant recovery tank 168
9 5 7 Mounting the coolant recovery tank 168
9 5 8 Precautions on usage of the coolant recovery tank 168
9 6 Thermostat 169
9 6 1 Functioning of thermostat 169
9 6 2 Thermostat construction 169
9 6 3 Characteristics of thermostat 169
9 6 4 Thermostat inspection 169
9 6 5 Testing the thermostat 169
9 7 Bilge pump and bilge strainer (Optional) 170
9 7 1 Introduction 170
9 7 2 Description 171
9 7 3 Cautions 171
9 7 4 Assembly procedure 172
9 7 5 Cautions for assembling 174
9 7 6 Troubleshooting 175
10 Reduction and reversing gear 176
10 1 Specifications 176
11 Remote control (Optional) 177
11 1 Remote control system 177
11 1 1 Construction of remote control system 177
11 1 2 Remote control device components 177
11 2 Remote control installation 179
11 3 Remote control inspection 181
11 4 Remote control adjustment 182
12 Electrical system 183
12 1 Electrical system 183
12 1 1 Wiring diagram 184
12 2 Battery 185
12 3 Starting motor 186
12 3 1 Specifications 186
12 3 2 Characteristics 186
12 3 3 Structure 187
12 3 4 Wiring diameter of a starting motor 188
12 4 Alternator standard, 12V/60A 189
12 4 1 Specifications 189
12 4 2 Structure 190
12 4 3 Wiring diagram 191
12 4 4 Standard output characteristics 191
12 4 5 Inspection 192
12 5 Alternator 12V/80A (Optional) 193
12 5 1 Specifications 193
12 5 2 Structure 194
12 5 3 Wiring diagram 195
12 5 4 Standard output characteristics 195
12 6 Instrument panel 196
12 6 1 B-type instrument panel (Optional) 196
12 7 Warning devices 197
12 7 1 Oil pressure alarm 197
12 7 2 Cooling water temperature alarm 198
12 8 Glow plug 199
12 9 Electric engine stopping device 200
13 Service standards 201
13 1 Engine tuning 201
13 2 Engine body 202
13 2 1 Cylinder head 202
13 2 2 Camshaft and gear train 203
13 2 3 Cylinder block 204
13 3 Lubricating oil system (Trochoid pump) 207
14 Tightening torque for bolts and nuts 208
14 1 Main bolt and nut 208
14 2 Standard bolts and nuts (without lube oil) 208

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