Yanmar 2GM20(F)(V)(C), Operation Manual

Page 1: ...ed Engine It meets the low emission standards set by the EPA OPERATION MANUAL California Proposition 65 Warning Diesel engine exhaust and some of its constituents are recognized by the State of California to cause cancer birth defects and other reproductive harm J ...

Page 2: ... 3 Operating your Engine 25 3 3 1 Inspection Before Starting 26 3 3 2 How to Start the Engine 27 3 3 3 Operation 29 2 3 3 4 Cautions during Operation 30 3 3 5 Stopping the Engine 30 3 4 Long term Storage 32 4 MAINTENANCE INSPECnON 34 4 1 General Inspection Rules 34 4 2 List of Periodic Inspection ltems 35 4 3 Periodic Inspection ltems 37 4 3 1 Inspection on Initial 50 Hrs of Operation or after 1 m...

Page 3: ...anual is transfered 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 The marine gear described in t...

Page 4: ... death or serious injury A WARNING WARNING indicates a potentially hazardous situa tion which if not avoided COULD result in death or serious injury A CAUTION CAUTION indicates a potentially hazardous situa tion which if not avoided may result in minor or moderate injury This sign is also be used to alert against unsafe practices The descriptions captioned by are particularly important cautions fo...

Page 5: ...se of the wiping materials properly Wash your hands thorougly with soap and water Never place oil or other flammable material in the engine room Install a fire extinguisher near the engine room and familiarize yourself with its use Exhaust Gas Exhaust gas contains poisonous carbon monoxide and should not be inhaled Be sure to install ventilation ports or ventilators in the engine room and ensure g...

Page 6: ...cing Stop the engine before you service it Turn the battery switch off If you must inspect while the engine is in operation never touch moving parts Keep your body and clothing well clear of all moving parts Scalds If 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 ...

Page 7: ...always be visible Please replace if damaged or lost _r Lr 2GM20 C M 3GM30 C M 2GM20F C M 3GM30F C M Warning Device Labels Parts Numbers No CD Part Code No 128296 07350 128296 07260 l l E hell Aota tlno porto C n ce uee l jury Ul2tl 07 0 e DANGER iiJWt f TI RI1 g n Fi llilbl tiJ t l t T ln IJ ollovor removo tho cep whllt tho onoino 1 1 11111 hot Hot water mor 1purt out end burn you 7 ...

Page 8: ...ze and cruising area of the boat The installation fitting and surveying of this engine all require specialized knowledge and engineering skills Consult Yanmar s local subsidiary in your region or your distributor or dealer A WARNING Never modify this product or release the limit devices which limit engine speed fuel injection quantity etc Modification will impair the safety and performance of the ...

Page 9: ...ystem Type Starting motor AC generator Model Type Reduction ratio Forward Reverse Forward rpm _ _ j Propeller speed Reverse Lubricating oaf capacity Weight rpm cu an kg lb 2 75 X 3 72 2 95 X 2 83 0 636 38 81 I 0 954 58 21 11 8 3400 I 17 7 3400 16 0 3400 24 1 3400 6 66 94 71 8 16 26 77 13 4 3600 20 1 3600 18 2 3600 27 313600 7 07 100 54 8 64 28 35 23 0 15 1 18 1 170 5 2347 2489 at Flywheel side sha...

Page 10: ...00 15 t1 2 at 6 66 94 71 8 16 26 77 7 07 1 00 54 8 64 28 35 23 0 170 t5 347 2489 Flywheel side 3 0 954 58 21 17 7 3400 2A 1 3400 20 1 3600 27 3 3600 18 1 at Crankshaft V pulley side kwlse viewed from stern Counter cloc s Clockwt e viewed from stern Fresh water c Complete en ooling with heat e x c_han g er ____ t closed forced lubrication 1 Electric______ DC 12V l OkW 12V 55A _____ __ Starling tern...

Page 11: ... off at Flywheel side Front power take off at Crankshaft V puliey side _____ _CI OC kwlse viewed from Cranksh a fl 1Propeller shafl Ahead stern stern Direction of rotation Cooltng system Clockwise viewed from ling rubber im nclosed forced ectric and manu DC 12V 1 0kW Direct seawater coo peller water pump Lubnc atloo system ng m Start syste e gear m Marin syste Dimensions LubriC bng oil Cl rrnrea l...

Page 12: ...ine weight with marine gear mm On cu in kW rpm tiP rpm kg em ObJin m sec fl sec kW rpm HP rpm kg em Ob in mlsec ftJsec kg em lb in rpm rpm cu ln g lb mm Qn mm Qn mm in cu in cu ln kg lb Note 1 Rating condition ISO 3046 1 2 1hp O 7355 kW 12 2GM20FV 3GM30FV Vertical 4 cycle water cooled diesel engine Swirl pre combustion chamber 2 l 3 75 X 72 2 95 X 2 83 0 636 38 81 0 954 58 21 11 813400 17 7 3400 1...

Page 13: ...verse mm in cu ln kW rpm HP rpm kg em lb ln m sec ft sec kW rpm HP rpm kg em Ob in m sec f1Jsec kg em lb in t rpm rpm mm in mm Qn mmOn cu tn cu ln 1kg lb Note 1 Rating condition ISO 3046 1 2 1hp 0 7355 kW 2GM20C 3GM30C Vertical 4 cycle water cooled diesel engine Swirl pre combustion chamber 2 I 3 75 X 72 2 95 X 2 83 0 636 38 81 0 954 58 21 11 8 3400 17 713400 16 0 3400 24 113400 6 66 94 71 8 16 26...

Page 14: ...eel side at Crankshaft V pulley side Direction of Crankshaft rotation propeller shaft Ahead Cooling system llubncahon system Starting r system Sail drtve ype tarting motor C generator odel ype eduction A M T R system ralio propeller peed veralllength s 0 Forward Reverse Forward Reverse rpm rpm mm in r Counter ctockwise viewed from stern Clockwlse viewed from stem Fresh water c ng w1th heat exchang...

Page 15: ...tion valve Tachometre sensor Dipstick Manne gearbox Output shaft coupling Shift lever Operation Side Heat exchanger and exhaust manifold Mixing elbow Fuel feed pump Mounting flange Dipstick I Fuel oil filter Regulator handle Exhaust side of 3GM30F with KM3P Rller cap with pressure control valve Cooling seawater pump Cooling fresh water pump Fuel injection pump Idle adjuster Fuel Injection limiter ...

Page 16: ...ystem remains fully protected cylinder hea time by ele before It is c the seawate o cooling systems fresh water and seawater There are tw The fresh wa The fresh w water pump ter pump is run by the alternator and the V belt ater in the fresh water cooler is fed to the engine by the fresh The cooling fresh water returns to the eng1ne after it is cooled with seawater in the fresh water cooler on the ...

Page 17: ...hich is hooked up by remote control cable to each of the engine control levers and the stopping equipment 2 5 1 Control Panel Electric Operation There are two control panel options The controls and alarm lamps included are shown below A a I I 0 40 I Q Water Proof sail dnve High temp cooling water G Low lube oil pressure 0 Charge Key SWitCh Buzzer B CD j Q Start switch Tachometre Illumination sw1tc...

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Page 19: ...ed can be controlled without engaging the clutch clutch remains in the NEUTRAL no load position 2 5 3 Stopping Equipment injection pump stop lever thus cutting off fuel injection Engine stopp1ng by engine stop cable Engine stop cable 2 5 4 Decompression Equipment When the decompression lever is pulled the exhaust valve opens causing decom liliil pression inside the cylinders and making hand turnin...

Page 20: ...tract the clear filtered fuel from the top of the container for use Use the clear filtered fuel from the upper middle section of the container only leaving any contaminated fuel at the bottom 20 3 Fuel Tank optional Be sure to attach a drain cock to the fuel tank to enable dirt and water to settle at the bottom of the tank to be drained off The fuel outlet should be positioned 20 30mm above the bo...

Page 21: ...l the lube oil already in the tank Use new lube oil 3 Lube oil supplied to the engine will undergo natural degeneration with time even when the engine Is not used Lube oil should be replaced at the specified intervals regardless of whether the engine is being used or not Air temperature Single grade Multi grade C 1 40 4l l 67 If you operate your equipment at temperatures below the limits shown con...

Page 22: ...ould result 1 a I Excessive use of antifreeze also lowers the cooling efficiency of the engine Be sure to use the mixing ratios specified by the antifreeze maker for your temper ature range 3 2 Before Initial Operation Perform the following before using the engine for the first time 22 3 2 1 Supply Fuel Oil Using gasoline etc may cause a fire To avoid mistakes be sure to double check the kind of f...

Page 23: ...ler port cap 0 3 I 0 8 I 0 35 I G Upper lim1Vlower limit Dipstick 3 2 4 Supply Cooling Water For Fresh Water Cooling Type Only Supply cooling water according to the following procedures Be sure to add antirust or antifreeze to the cooling water 1 Be sure to close the 3 water drain cocks See illustration right Note The water drain cocks are opened before shipping from the plant I Water drain co DFr...

Page 24: ...cting the subtank to the fresh water cooler Be sure the hose is securely connected and there is no looseness or damage When the hose is not watertight an excessive amount of cooling water will be used 24 D DTo fresh water cooter Lower hm1t 3 2 5 Cranking Upper limit Cap When the engine has not been used for a long period of time lube oil will not be distributed to all of the operating parts Using ...

Page 25: ...ling water The trial engine operation will send the lube oil and cooling water to the parts so the lube oil and cooling water levels will drop Check and resupply as necessary 1 Supplying engine lube oil See 3 2 2 2 Supplying marine gear lube oil See 3 2 3 3 Supplying cooling water See 3 2 4 3 3 Operating your engine A WARNING To prevent exhaust gas poisoning ensure good ventilation during operatio...

Page 26: ...lube oil using the filler port Supply oil up to the top mark on the oil dipstick See 3 2 3 5 Checking and Resupplying Fresh Water For Fresh Water Cooling System Check the fresh water level before operation while the engine is cold Checking the water level while the engine is hot is dangerous and the cooling water reading will be misleading due to thermal expansion 26 Check and supply cooling water...

Page 27: ...ation When operating the key switch check that the alarm devices work normally See 2 5 1 3 8 Preparing Fuel Lube Oil and Cooling Fresh Water in Reserve Prepare sufficient fuel for the day s operation Always store lube oil and cooling fresh water in reserve for at least one refill onboard to be ready for emer gencies 3 3 2 How to Start the Engine 1 Start the engine according to the following proced...

Page 28: ...re Before pushing the start button again be sure to confirm that the engine has stopped completely If the engine is restarted while the engine still has not stopped the pinion gear of the starter motor will be damaged Electric Operation rl Do not hold the start button on for more than 15 seconds at a time If the engine does not start the first time wait for about 15 seconds before trying again Aft...

Page 29: ...uges and alarm devices on the instrument panel are normal 2 Check for water or oil leakage from the eng1ne 3 Check that exhaust colour engine vi brations and sound are normal 4 When there are no problems keep the engine at low speed with the boat still stopped to send lube oil to all parts of the engine 5 Check that sufficient cooling water is discharged from the seawater outlet pipe Operation wit...

Page 30: ...ust indicates engine overloading This shortens the engine s life and should be avoided 30 3 Are there abnormal vibrations or noise Do not operate at speeds which produce violent vibrations Depending on the hull structure engine and hull resonance may suddenly become great at a certain engine speed range causing heavy vibrations Avoid operation in this speed range If you hear any abnormal sounds st...

Page 31: ... minutes Stopping the engine suddenly while operating at high speed will cause the engine temperature to rise quickly causing deterioration of the oil and stic king of parts Engine stopping by engine stop cable Engine stop cable 4 Continue to pull out the engine stop knob stop lever until the engine is completely stopped If you release the knob before the engine has completely stopped it may resta...

Page 32: ...ain water from the cooling system after the engine has cooled down Be careful to avoid burns 32 I l If water is left inside it may freeze and damage parts of the cooling system fresh water cooler sea water pump etc 1 Loosen the drain cocks at the side of the cylinder block and drain off the water inside 2 Loosen the 6 bolts fixing the side cover of the seawater pump remove the cover and drain the ...

Page 33: ...er drain off the fuel or fill the tank 5 Grease the exposed area and joints of the remote control cable and the bearings of the remote control handle 6 Cover the intake silencer exhaust pipe etc with vinyl sheets and seal them to prevent moisture from entering 7 Drain bilge in the hull bottom com pletely Water may leak into the boat when it is moored and whenever possible it should be landed B Wat...

Page 34: ...nicians are ready to assist you with periodic inspections and mainte nance Consult your YANMAR dealer or distributor in accordance with the service agreement Servicing Tools Prepare servicing tools onboard to be ready for inspecting and servicing the engine and other equipment Tightening Torque of Bolts Nuts Over tightening of bolts and nuts causes them to come off or their threads to be damaged I...

Page 35: ...d to establish definitively The following should be treated as a general standard only Section 4 3 gives a detailed explanation of which parts must be inspected and the procedure for doing so for each interval Schedule your own periodic inspection plan according to the operational conditions of your engine and inspect every item Neglect of periodic inspection may lead to engine troubles and shorte...

Page 36: ...nt of the air Intake silencer clean the exhausVwater mix1 ng elbow Alr intake and Clean the breather p1pe exhaust system c c f Eiectrical system C heck the exhaust gas condition heck the charge lamp function heck the electrolyte level in the battery djust the tension of the alternator driv1ng belt A f c heck the wiring connectors check for leakage of water and oil Cylinder head etc lfi e Jghten al...

Page 37: ...UTION Beware of oil splashes if extracting the lube oil while it is hot 2 Replacing the Clutch Lube Oil 1st time During Initial operation the oil is quickly contaminated due to the initial wear of internal parts The lube oil must therefore be replaced early 1 Remove the cap from the filler port and attach the oil drain pump Drain off oil 2 Fill with new lube oil See 3 2 3 3 Perform a trial run and...

Page 38: ...nnect the terminal of the earth cable Otherwise a short circuit could cause a fire Ensure good ventilation when charging the battery The use of open flames is strictly prohibited Hydrogen gas may also catch fire 38 Battery fluid is diluted sulfuric acid It can blind you or burn your eyes or skin Wear goggles and gloves when handling battery fluid Should the fluid be deposited on your skin wash wit...

Page 39: ...water Engine over heating and seizure will result When there is too much tension in the V belt the belt will become damaged more quickly and the bearing of the cooling water pump may be damaged 1 Check the tension of the V belt by pressing down on the middle of the belt with your finger With proper flexion the V belt should sink 8 1Omm 2 Loosen the set bolt and move the cooling water pump to adjus...

Page 40: ...er open the cooling water cocks three places as shown in 3 4 2 Refer to 3 2 4 for resupplying cooling water 40 2 Inspecting Inner Parts of the Sea water Pump Depending on the use the inside parts of the seawater pump deteriorate and dis charge performance drops At the specified interval or when the volume of seawater discharged is reduced inspect the seawater pump in accordance with the following ...

Page 41: ... V 2GM20F C V series attached to the intake air silencer side of the bonnet 4 Inspecting and Adjusting the Fuel Injection Spray Condition Adjustment is necessary to obtain the optimal fuel injection to ensure the best possible engine performance This inspec tion requires specialized knowledge and techniques Consult your Yanmar dealer or distributor 5 Adjusting the Remote Control Cable See page 38 ...

Page 42: ...on for Certification Plate 3GM30 C V attached to the exhaust side of the bonnet 3GM30F C V attached to the top of the fresh water cooler 42 IMPORT ANl ENGINE UIS fNG IN mfOINS 1 G NON Ok COP l SSIOX IGH1110N IN FORMATION lEAR US PA tfGUIAIIOMS IS F 7 1 tfffi 01NFI SFANUAl FO i INilHANC SP CIFICATIOHS AND YANMAR DI SEl ENGIN Co Lid EPA certification ...

Page 43: ...jection pump assembly 1 Fuel injection valve assembly Do not remove the seals limiting the amount of fuel injected and the speed Be sure to carry out inspections Follow the basic guidelines outlined in 4 3 Periodic Inspection Items of this manual and keep a record of the results Pay particular attention to these important po1nts replacing the lube oil lube oil lilter the fuel filter and cleaning t...

Page 44: ...ranty period Specific emissions related parts and components are warranted for the period of 5 years or 3 000 hours whichever comes first after the date of delivery to the initial owner If any emissions related part is defective during the warranty period the part will be repaired or replaced by Yanmar To maintain engine performance and compliance with the regulations the owner is responsible for ...

Page 45: ...sufficient seawater causing temp to Check seawater system rise Ask for repairs Contamination Inside cooling system Faulty Warning Devices el E Do not operate the engine if alarm devices are not repaired Serious accidents may result if difficulties are not spotted due to faulty alarm lamps When switch is turned ON Alarm buzzer does not sound Circuit broken or buzzer defective Ask for repairs Warnin...

Page 46: ...ack smoke Contaminated 1ntakesilencer Clean element Improper fuel Replace with recommended fuel Faulty spraying ot fuel Injection valve Ask for repairs Incorrect intake exhaust valve head Ask for repairs clearance Wh1te smoke Improper fuel Ask for repairs Faulty spraying of fuellnjeclion valve Ask tor repairs Fuel injection timing off Ask for repairs Lube oil bums excessiVe consumption Ask for rep...

Page 47: ...vice Manager contact the owner of the dealership or the General Manager If your problem still has not been resolved to your satisfaction contact your local Yanmar Subsidiary Company See the back of this manual for addresses We will need the following information in order to assist you Your name address and telephone number Product model and serial number Purchase date Dealer s name and address Nat...

Page 48: ...ng valve 18 Lubricating oil outlet filter 19 Lubricaling oil pressure switch 20 To main bearing 21 To valve rocker arm 22 Exhaust manifold 11 4 3GM30F 1 Fuel Injection valve 2 Fuel oil return pipe 3 Exhaust gas and cooling water outlet 4 Mixing elbow 5 Heat exchanger 6 Fuel inlet pipe 7 Fuel feed pump 8 Fuel filter 9 Cooling water pump seawater 10 Seawater 11 Kingston cock 12 Cooling water pump fr...

Page 49: ...cating oil filter 19 Lubricating oil pressure switch 20 To main bearing 21 To valve rocker arm 22 Exhaust manifold 11 10 2GM20C 1 Fuel injection valve 2 Fuel oil return pipe 3 Exhaust gas and cooling water outlet 4 Mixing elbow 5 Fuel inlet pipe 6 Fuel feed pump 7 Fuel filter 8 Lubricating oil strainer 9 Fuel injection pump 10 Lubricating oil pump 11 Kingston Cock 12 Cooling water pump seawater 13...

Page 50: ...ew A A 22 Adapter Wire harness 23 Sail dnve 24 Buzzer 25 Sail drive only 26 Rubber seal 27 Oil pressure 28 Cool Fresh Water Temp 29 Charge 30 Push button sw1tch 31 Key switch 32 Detail of connector View B B 12 2 For the B type instrument panel NEW B PANEL 1 Procured by customer 2 Battery 3 Battery swrtch 4 Option 5 Neutral switch 6 For 2GM20 3GM30 7 Fuse 8 Sore 9 Starter 10 Earth bolt 11 Alternato...

Page 51: ...APPENDIX A 11 1 2GM20 I I e e I c I X 0 020 x 13 5 RH y r r a X o 1 I I II II I I I I I e I I I I ll o4 76 X 10 7 STP Piping diagrams 1 r a A 1 ...

Page 52: ...N T 920 13 5 RH Y c t J f v r II I I lo r4o I I 1 I I 1 I I I I f 1 i l I I I 1I I 1 e IL t II r t 1 t 0 If Q _ II I 1 1 I I w I l1 fH _ g II X X 11 I t CD 0 It e I I l l __ l I I 1 I I r I I I I e 1 _ _ _ II n I L t i r 1 r t c I e o Q13 xt3 RH 0 C iJ C X c a U X ...

Page 53: ...v t II II It lo II 1 1 It 1 ti 11 It II II tf1 rtV II s io J r x D II J I 1 II JL 8 __ u r L ___ lr I I Q 0 4 76 X 10 7 STP r X e t Piping diagrams L h 1 1 J r CI o 0 I X o 0 r a lo r a e r CI o 0 i l i o if ve CD r 0 1 r t X v 13xt3RH t e e A 3 ...

Page 54: ...APPENDIX A 11 4 3GM30F I lo II I I II II 1 r P I lo Ii II II II II l J r r v II II II I II II II II I 0 X I z a a d LS L OI X 9L Piping diagrams c t z a If t ti t X e e If ti X t l A 4 z r a X e e ...

Page 55: ...APPENDIX A 11 5 2GM20V I I I I I I 76 X 10 7 STP o I e o 1 3 x acR H ___ _1 1_ if I I I Piping diagrams I cr l l M X 0 n e I e cr 3 X M A 5 ...

Page 56: ...agrams 11 6 3GM30V c I I a X 0 1 i 1 1_ f 1 r _ It 6 o Lr 1 til I I I II _ o r 11 I J l f I I I r 1 x I a 1 ID v _ e t t r A 6 t t l tJ r a M X I 8 7 1 3 x a RmH I r _ _ a M t x M I L 1 I ___ ___ 1 _ e e te e 1 e r a X M t e ...

Page 57: ...l r r I A J f t JI oJTT I _ r I II t I _ A trl 1 J rl X e 8 t II t I I I t I I a II I I Ill I I v tl II e 1t a pX II Ill t 1 II X II J Q 013xi3RH 1 t JL I 6 r t t I 9 I 1r X I II U It I t 1 II I 1 1 1 t t I e l_L_ II f ll _ _ t h I 1 1 I j Q 76 x tO 75 STP e X I e og I e te e 3x RH i I _ J j e I I e A 7 ...

Page 58: ...n 1 _ _it_ X f L I X I f 11 J I 1 T Y J I I 9 L lr 0 1 1 1 n K 1 r 1 a d X II t I t e I IL I 0 I r t I r I V a k JI 0 K r M 0 1 a n t lr 1 n I _ I 013 x t3 RH II ci _ X 1 J _ 2 1 X r X M 0 II I _ l I I Jl I i t I I II II e 1 t I e l J r 4 76 x 0 7 STP e i I I X I e e 13 RH te I _ e 1 v J e I A 8 ...

Page 59: ...2GM20FC a I I I I I I I II IL _ tr I I II I I I I II r I I I I I II e I L ll ci X J 0 X M 1 ll N i II X 0 J tla I X I I tl II 4 76 x 0 71 STP J a X M Piping diagrams J a ri X N X J a M M X a 1 X ll t e s 13 x3t RH A 9 ...

Page 60: ...APPENDIX A 11 10 2GM20C r r II I I II_ __ _ 1r II II o I t It 0 It II I II I j620 x 3 5t RH c r X I 0 I til a I I II N 4 76 X 0 7t ST of 13x3tRH of 45 A 10 Piping diagrams Q t t 0 CD I a M X M ...

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Page 62: ...APPENDIX A 11 12 3GM30C 0 A 12 4 76 x 071 STP l3 31 RH Piping diagrams z a lt t 0 X a 1 N X a t r Ul 0 X D _ ...

Page 63: ... A type instrument panel I I I I h 1 I o I I r l N 8 I j r9ii i 0 1 8 I L J 8 2 1 II I Jo I p 8 I I 18 1 i 8 I I I 1 1 v JJ t l I I I i I I tl L ___ _j 0 G BII 1 I I J I I ll I Jr l IG o l I T I l 1 0 I j I L t I j s I 1 o 1 0 r I 0 li G B 1 ...

Page 64: ...anel J i I r I I 8 I I Ell T I 1 I 1 I yj I I 8 I I r I i8 o ci __j 8 I _ L ______j s I I I 1 l t I I tl I L __ ___ _j 111 fSJ I q 1 L r I Wiring diagrams I I I I L I 0 __ I I I o 1 IIL ll 0111 Ir Qill l l r M L e 5 1 1 6 c x er u ro o o _ 0 8 2 ...

Page 65: ...CAUTION Overcranking engine with water lift muffler can cause damageI ...