Yanmar 3YM30, Service Manual

Page 1: ...M9961 03E101 3YM30 3YM20 2YM15...

Page 2: ...on Outline of correction Correction item No page Corrected by New edition March 2004 R1 April 25 2005 Add Eug Model 2YM15 1 Specifications table added 2 Engine outline added 3 Piping diagram added 4 O...

Page 3: ...and not just the engine itself To get maximum performance from this engine you should completely understand its functions construction and capabilities as well as proper use and servicing Use this ma...

Page 4: ...0 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 25...

Page 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...

Page 6: ...ction 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 specif...

Page 7: ...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 e...

Page 8: ...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 18...

Page 9: ...e 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 pu...

Page 10: ...ce in the manual Sufficient consideration for safety is required in addition to the matters marked Especially for safety precautions in a repair or maintenance job not described in this manual receive...

Page 11: ...l type accidents Clean orderly arranged place No dust mud oil or parts should be left on the floor surface Failure to Observe An unexpected accident may be caused Bright Safely Illuminated Area The wo...

Page 12: ...p as an attaching device Do not use rope serious injury may result To hold or support an engine secure the engine to a support stand test bed or test cart designed to carry the weight of the engine Do...

Page 13: ...f ignition away Explosion may occur causing severe personal injury Battery Electrolyte Batteries contain sulfuric acid Do NOT allow it to come in contact with clothing skin and or eyes severe burns wi...

Page 14: ...ng jewelry ties or tools may become entangled causing damage to the engine and or severe personal injury Preventing burns from scalding 1 Never open the filler cap shortly after shutting the engine do...

Page 15: ...d check the part installed state deformation damage roughening surface defect etc Arrange the removed parts orderly with clear distinction between those to be replaced and those to be used again Parts...

Page 16: ...silencer Intake manifold Fuel filter Fuel injection pump Oil filler cap Dipstick Oil filler cap Fuel feed pump Lubricating oil filter Marine gear Sea water pump Alternator V belt Shift lever Starter...

Page 17: ...b T D C FID 16 1 FIC Air 18 1 FID 22 1 FIC Air 24 1 Fuel injection opening pressure MPa kgf cm2 11 8 0 98 0 120 10 0 12 3 0 98 0 125 10 0 Main power take off At Flywheel side Direction of rotation Cr...

Page 18: ...g deg b T D C FID 21 1 FIC Air 23 1 Fuel injection opening pressure MPa kgf cm2 12 3 0 98 0 125 10 0 Main power take off At Flywheel side Direction of rotation Crankshaft Counter clockwise viewed from...

Page 19: ...temperature 25 C at the inlet of the fuel injection pump ISO 3046 1 Fuel temperature 40 C at the inlet of the fuel injection pump ISO 8665 4 The Total oil quantity includes oil in oil pan and oil in...

Page 20: ...he clean fuel 3 Fuel tank Fuel tank inside should be always clean enough and dry it inside for the first use Drain the water according to the maintenance schedule with a drain cock 1 3 2 Lubricating o...

Page 21: ...d be sure to add the Long Life Coolant Antifreeze LLC in order to prevent rust built up and freezing If there is any doubt over the water quality distilled water or pre mixed coolant should be used Th...

Page 22: ...1 General 1 4 Engine outline 1 3YM30 with KM2P 1 marine gear 6R1...

Page 23: ...1 General 2 3YM30C with SD20 sail drive 7R1...

Page 24: ...1 General 3 3YM20 with KM2P 1 marine gear 8...

Page 25: ...0C with SD20 sail drive NOTE 1 DWG SHOWS MOUNTING BLOCKS AT ORIGINAL HEIGHT 2 ENGINE WEIGHT WILL COMPRESS BLOCKS BY 4 5 mm APPROX 3 MOUNTING BLOCKS ARE EQUIPPED FOR STANDARD ACCESSORY 4 SHOWS CENTER O...

Page 26: ...1 General 5 2YM15 with KM2P 1 marine gear 9 2R1...

Page 27: ...1 General 6 2YM15C with SD20 sail drive 185 9 3R1...

Page 28: ...am shaft 8 5 8 16 5 8 9 17 17 18 Detail of part C 50 Detail of part B Detail of part D Detail of part A Screw joint Union Marks of piping Flange joint Eye joint Insertion joint Drill hole Cooling fres...

Page 29: ...8 16 5 8 9 17 17 18 Detail of part C 50 Detail of part B Detail of part D Detail of part A Screw joint Union Marks of piping Flange joint Eye joint Insertion joint Drill hole Cooling fresh water pipi...

Page 30: ...1 General 3 2YM15 with KM2P 1 marine gear 11 2R1...

Page 31: ...1 General 11 3R1 4 2YM15C with sale drive SD20...

Page 32: ...ARB label Note Emission Control is accomplished through Engine Modification EM Design The tamper resistance device is installed with EPA ARB certified 3YM30 3YM20 2YM15 series engines to prevent ille...

Page 33: ...CD 3 Do not remove the caps restricting injection quantity and engine speed 4 Perform maintenance without fail Note Inspections to be carried out by the user and by the maker are divided and set down...

Page 34: ...Inspections on the operation manual and use the table below to carry out inspections based on operation hours or time in years Whichever comes first is the guarantee period The specific emissions rel...

Page 35: ...le Visual inspection of engine outside Fuel system Check the fuel level and refill Drain the fuel tank Drain the fuel filter Replace the fuel filter Check the injection timing z Check the injection sp...

Page 36: ...air intake silencer Clean the exhaust water mixing elbow Check the exhaust gas condition During operation Diaphragm assembly inspection z Electrical system Check the alarm lamps devices Check the elec...

Page 37: ...mixed Standard The level shall be between the upper and lower limit lines on the dipstick b If the remaining engine oil level is low fill the oil pan with the specified engine oil to the specified lev...

Page 38: ...out during operation 1 Checking cooling water volume Check the cooling water level in the coolant recovery tank If the water level is close to the LOW mark open the coolant recovery tank cap and repl...

Page 39: ...he engine check the leakage of cooling water and seawater from cooling water system Also check the leakage of lube oil and fuel 8 Check adjust the remote control operation Make sure that the accelerat...

Page 40: ...ter at the same time Beware of oil splashes if extracting the Lube oil while it is hot 1 Remove the lube oil dipstick and also the oil filler cap at the top of the rocker arm cover Attach the oil drai...

Page 41: ...asure the lube oil level about 10 minutes later after stopping the engine or after removing the oil filler cap Note The yellow label shown right is attached on the dipstick 3 Replace the marine gear l...

Page 42: ...flection should be as follows New V belt refers to a V belt which has been used less than 5 minutes on a running engine Used V belt refers to a V belt which has been used on a running engine for 5 min...

Page 43: ...se it as the data for estimating the wear state d Adjusting other cylinders Turn the crankshaft 240 and make adjustment for the No 3 cylinder Then adjust the No 2 cylinder in this order The cylinder t...

Page 44: ...remote control cable must be checked and adjusted periodically 1 Adjusting the throttle remote control cable Check to see that the control lever on the engine side moves to the high speed stop positio...

Page 45: ...assembly be sure to vent air from the fuel system If air is in the fuel system fuel cannot reach the fuel injection pump Vent the air in the system according to the following procedures Fuel system ai...

Page 46: ...2 Inspection and adjustment 26 Cylinder head Bracket Fuel filter Fuel pipe Fuel injection pump Clamp Fuel pipe...

Page 47: ...connect the Negative battery cable back onto the battery LAST Proper ventilation of the battery area Keep the area around the battery well ventilated paying attention to keep away any fire source Dur...

Page 48: ...er daily use if letting the machine unit leave in the place that the ambient temperature could drop at 15 C or less And store the battery in a warm place until the next use the unit to start the engin...

Page 49: ...ic gravity and remaining battery charge 3 Terminals Clean if corroded or soiled 4 Mounting bracket Repair or replace it if corroded Retighten if loosened 5 Battery appearance Replace the battery if cr...

Page 50: ...ive pressure grows big in the crankcase and it may cause the rubber of the diaphragm cracked 2 Fill with new lube oil 3 Perform a trial run of the engine and check the oil leakage 4 Approximately 10 m...

Page 51: ...new fuel filter 4 Install the new fuel filter manually turning until it comes into contact with the mounting surface and tighten it further to one turn using a filter wrench Tightening torque 20 24N m...

Page 52: ...eassemble the cover d If any of the following problems are found take out the O ring and impeller If necessary replace with new one and reassemble the cover Impeller blades are cracked or nicked Edges...

Page 53: ...will degenerate 1 Open the two cocks for fresh water and extract the fresh water Note One drain cock is behind the belt cover Remove the belt cover and open the cock 2 Close the two cocks for fresh w...

Page 54: ...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 7 Clean the element of the air intake sile...

Page 55: ...lbow 1 Clean dirt and scale out of the air pass and seawater pass of the mixing elbow 2 Repair the crack or damage of the mixing elbow by welding or replace if necessary 3 Inspect the gasket and repla...

Page 56: ...e loosened 0 20 10 30 40 GLOW B OFF ON START STOP 50 Battery switch Battery Alternator Fitting to marine gear Neutral safety switch B type panel Extension wire harness To earth bolt Starting motor Sto...

Page 57: ...d stop turning it at the same time when the fuel comes out 7 Read the timing scale on the flywheel from the hole on the flywheel housing It is standard fuel injection timing if the timing mark positio...

Page 58: ...bove table when adjusting a new fuel nozzle of a spare part Remove carbon deposit at the nozzle hole thoroughly before measurement a Connect the fuel injection valve to the high pressure pipe of the n...

Page 59: ...nd adjustment 39 Informative Fuel injection valve structure Nozzle holder Pressure adjusting shim Nozzle spring Nozzle spring seat Fuel return pipe Valve stop spacer Nozzle valve Nozzle Nozzle body No...

Page 60: ...ver at a rate of once or twice a second and check no abnormal injection If normal injection as shown below cannot be obtained replace the fuel injection valve No extreme difference in angle Finely ato...

Page 61: ...ones 4 Replace the used hose clips with new ones if necessary b Heat exchanger inspection 1 Cooler core inspection a Inspect the inside of the tubes for rust or scale buildup from seawater and clean...

Page 62: ...essure cap while the engine is running or right after stopping because high temperature steam will be blown out Remove the cap only after the water cools down a Remove scale and rust and check the sea...

Page 63: ...the major nuts and bolts bellow by the standard tightening torques See the table in 4 5 1 Cylinder head bolts 2 Crankshaft pulley bolts 3 Fuel injection nozzle set bolts 4 Fuel pump gear set bolts 5 F...

Page 64: ...r probes in contact with the switch terminal and cylinder block while operating the engine It is abnormal if circuit is closed 2 4 2 Thermo switch Place the thermo switch in a container filled with an...

Page 65: ...ve opening temperature is carved on the flange 2 Normally the thermostat should be inspected every 500 hours or operation but it should be inspected before this if the cooling temperature rises abnorm...

Page 66: ...ation in the engine room 2 6 2 Adjusting operation procedure 1 Supply the fuel oil lubricating oil and cooling water Note Check the levels of the lube oil and cooling water again after test running fo...

Page 67: ...e intake exhaust valves fuel injection nozzle and cylinder head 3 Do not raise the engine speed abruptly 3 Cruising load operation 1 Do not operate the engine at full load yet but raise the speed grad...

Page 68: ...e silencer air cleaner and electric parts with PVC Poly Vinyl Chloride cover to prevent water and dust from depositing or entrance 7 Select a well ventilated location without moisture and dust for sto...

Page 69: ...the engine number Mentioned in the engine label Examine the machine unit name and its number in the same way When was the engine maintained last time How much period and or time has it been used after...

Page 70: ...trouble in order to save time in determining their cause Begin by checking the most easily identifiable causes of difficulty Where the cause of the difficulty is not readily apparent make a thorough e...

Page 71: ...ety valve III 4 Remove and repair or replace III 5 Return to original condition I Fuel oil supply cut off III Emergency stoppage device in operation IV Miscellaneous 1 Insufficient oil in fuel oil tan...

Page 72: ...njected Countermeasure CYLINDER OUTPUT IS UNEVEN COUNTERMEASURE Chart 2 I 1 Bleed air I 2 Disassemble and clean I 3 Replace I 4 Repair or replace I 5 Replace I 6 Tighten firmly I 7 Disassemble and cle...

Page 73: ...scosity of lube oil is too high 2 Damaged holding spring of pipe 1 Not enough warp in steel plate 3 Oil leakage where there is remote control 7 Worn sliding parts of forward reverse conversion valve 8...

Page 74: ...iment to valve needle movement 1 Faulty operation of fuel pump plunger 5 Clogging of fuel filter 6 Damaged fuel cam 7 Air in fuel injection system 8 Faulty operation of adjustment rack 9 Uneven amount...

Page 75: ...ressure I 2 Replace I 3 Disassemble and lap I 4 Disassemble and repair II 1 Delay injection timing II 2 Adjust standard injection pressure 1 Low injection pressure 1 Early fuel injection III Excessive...

Page 76: ...pump 3 Plunger sticks 4 Oil leakage from exhaust valve 5 Air inside pump 6 Damaged exhaust valve spring 1 Worn plunger 2 Damaged plunger spring STARTING TROUBLE I Pinion gears do not mesh II 1 Tighte...

Page 77: ...Leakage of pressurized gas from inside cylinder 3 Worn upper part of cylinder liner 4 Worn piston ring 5 Sticking of piston ring INSUFFICIENT POWER OUTPUT I Amount of oil supply from fuel injection p...

Page 78: ...hten safety valve III 6 Change lube oil III 7 Add lube oil III 8 Replace 1 Cooling water temperature has risen 2 Overloading 3 Faulty lube oil temperature adjustment valve IV Lube oil temperature is t...

Page 79: ...ming is incorrect 1 The drive gear or belt connections are incorrect 2 The injection pump is incorrectly installed on the engine 3 The roller holder assembly s roller or pin is worn excessively 4 The...

Page 80: ...delivery valve spring is broken 10 The delivery valve is not sliding properly 11 The nozzle or the nozzle holder is not functioning properly 12 The injection timing is incorrect Clean or replace Insp...

Page 81: ...is not smooth Readjust or replace Repair or replace Idling is unstable 1 The injection quantities are not uniform the delivery valve is not operating properly 2 The governor s idling adjustment is imp...

Page 82: ...lity in the engine 1 Compression pressure measurement method 1 After warming up the engine remove the fuel injection pipe and valves from the cylinder to be measured 2 Crank the engine before installi...

Page 83: ...5 in Chapter 2 3 Valve timing Incorrect valve clearance Adjust the valve clearance See in Chapter2 4 Cylinder head gasket Gas leak from gasket Replace the gasket Retighten the cylinder head bolts to...

Page 84: ...and lube oil Close the seacock 2 Reassembly Sufficiently clean and inspect all parts to be assembled Coat sliding and rotating parts with new engine oil when assembling Replace all gaskets and O ring...

Page 85: ...wing tools are required when disassembling and reassembling the engine Please use them as instructed 4 2 1 General hand tools Name of tool Illustration Remarks Wrench Size 10 x 13 Wrench Size 12 x 14...

Page 86: ...eassembly 66 Name of tool Illustration Remarks Copper hammer Local supply Mallet Local supply Nippers Local supply Pliers Local supply Offset wrench Local supply 1 set Box spanner Local supply 1 set S...

Page 87: ...of tool Illustration Remarks Lead rod Local supply File Local supply 1 set Rod spanner for hexagon socket head screws Local supply Size 6 mm 8 mm 10 mm Stariing pliers Hole type Shaft type Local suppl...

Page 88: ...d small end bushing insertion extraction tool Locally manufactured Intake and exhaust valve insertion extraction tool Locally manufactured Crankshaft pulley insertion tool 20 12 25 80 Piston pin extra...

Page 89: ...lustration Remarks Lube oil filter case remover Piston ring replacer for removal installation of piston ring Valve lapping tool Rubber cap type Valve lapping powder Code No 28210 000070 Feeler gauge P...

Page 90: ...Press tool 1 for filler neck Press tool 2 for filler neck copper tube Stem seal insertion for inserting stem seal Tool 1 25 27 5 35 5 40 89 2 1 105 30 30 170 24 2 28 30 Tool 2 Chamfer mm d1 15 0 21 1...

Page 91: ...of tool Illustration Remarks Vernier calipers 0 05 mm 0 150 mm Micrometer 0 01 mm 0 25 mm 25 50 mm 50 75 mm 75 100 mm 100 125 mm 125 150 mm Cylinder gauge 0 01 mm 18 35 mm 35 60 mm 50 100 mm Thicknes...

Page 92: ...Keeps the dial gauge firmly in position thereby permitting it to be used at various angles 4 Micrometer Measures the outer diameter of the crank shaft piston piston pin etc 5 Cylinder gauge Measure t...

Page 93: ...for leakage in the fresh water system 13 Battery current tester Checks density of antifreeze and charging condition of battery fluid 14 Nozzle tester Checks the shape and pressure of spray emitted fro...

Page 94: ...ctor seal which is placed on the exterior of the revolving shaft High pressure fuel pipe clamp type Measures rotation speed without reference to revolving shaft center or the exterior of the revolving...

Page 95: ...100g Solvent less type silicone base sealant applicable to high temperature areas 50 C to 250 C Three Bond TB1212 100g Silicone base non fluid type thick application possible Adhesive Three Bond TB140...

Page 96: ...ght of the solvent Mix the solvent with water Just dipping disassembled part into removes scale To shorten removal time stir remover mixture If cleaning performance drops replace remover mixture with...

Page 97: ...9 If a driven coupling is mounted to the front drive coupling disassemble 10 Remove the flexible mount nut lift the engine and remove it from the engine base Leave the flexible mount attached to the...

Page 98: ...he oil hole on top of the case Refer to 2 2 2 2 3 3 Removing electrical wiring Remove the wiring from the engine Refer to 2 2 4 9 4 Removing the fuel filter fuel pipe 1 Remove the fuel pipes fuel filt...

Page 99: ...r head 6 Removing the mixing elbow 1 Remove the seawater rubber hose connecting to a heat exchanger a mixing elbow 2 Remove the mixing elbow from the exhaust manifold Intake silencer Cylinder head Int...

Page 100: ...ar case and remove the alternator from the cylinder head with bracket 8 Removing the cooling water pipes seawater fresh water 1 Remove the seawater pipe seawater pump heat exchanger 2 Remove the fresh...

Page 101: ...p Loosen the nut on the spacer bolt and remove the seawater pump 11 Removing the starting motor Remove the starting motor from the flywheel housing 12 Removing the lube oil filter Remove the lube oil...

Page 102: ...pe by hand so that the fuel return pipe may not break 3 Remove the fuel return pipe fuel nozzle fuel pump 14 Removing the fresh water pump Remove the fresh water pump and gasket No 1 No 2 No 3 Fuel in...

Page 103: ...pump drive gear flange assembly with an extraction tool Note Don t disassemble the pump flange and the pump drive gear 2 Loosen the three 3 nuts for the fuel pump and remove the fuel injection pump a...

Page 104: ...r arm shaft assembly 3 Pull out the push rods 18 Removing the cylinder head 1 Loosen the cylinder head bolts with a torque wrench and remove the cylinder head 2 Remove the cylinder head gasket 19 Remo...

Page 105: ...e the crankshaft V pulley with a pulley puller 23 Removing the oil pan Remove the oil pan and spacer 24 Removing the lube oil inlet pipe Remove the lube oil inlet pipe and O ring 25 Removing the gear...

Page 106: ...the camshaft gear and remove 3 Pull out the camshaft gear and camshaft assembly from the cylinder block NOTE The camshaft gear and camshaft are shrunk fit They must be heated to 180 200 C to disassemb...

Page 107: ...g the main bearing bolts Loosen the main bearing bolts Don t remove them 32 Turning the engine over Turn the engine over with the cylinder head mounting surface facing down NOTE Make sure that the cyl...

Page 108: ...r is mounted to the standard main bearing of the cylinder block 2 Remove the main bearing metal upper from the cylinder block 36 Removing the tappets Remove the tappets from the tappet holes in the cy...

Page 109: ...crankshaft 1 The crankshaft and the crankshaft gear are shrink fitted If the crankshaft and the crankshaft gear have been disassembled they have to be shrink fitted heat the crank shaft gear to 180 2...

Page 110: ...e clearance 3 Make sure that the crankshaft rotates smoothly and easily 6 Mounting the flywheel housing 1 Replace the used oil seal with new one Press fit the oil seal in the flywheel housing and coat...

Page 111: ...nting the piston and connecting rod 1 Reassemble the piston and connecting rod NOTE 1 When reassembling the piston and connecting rod make sure that the parts are assembled with the correct orientatio...

Page 112: ...before disassembly 10 Mounting the camshaft 1 If the camshaft and the camshaft gear have been disassembled shrink fit the camshaft and the camshaft gear heat the camshaft gear to 180 200 deg C in the...

Page 113: ...pump with bolts to the gear case cover NOTE 1 Before installing the outer inner rotors coat them with lube oil 10W30 lube oil 2 Assemble the rotor so that the mark of the rotor may come to the cover...

Page 114: ...act part of a crankshaft pulley replace the pulley with a new one Carefully install the pulley so as not to damage the oil seal 5 Apply the liquid gasket to the gear case cover Position the two knock...

Page 115: ...unt the pulley insertion tool to the crankshaft and install the pulley on the crankshaft so that the oil seal may not be damaged 4 Tighten the pulley to the specified torque 17 Mounting the engine mou...

Page 116: ...ds 1 Fit the pushrod to the tappet 2 Coat the top of the pushrod and the adjusting screw of the rocker arm with engine oil Apply lube oil to the screw and lock nut Mount the rocker arm shaft assembly...

Page 117: ...the nut 5 Measure the backlash of the fuel injection pump drive gear 23 Mounting the fuel injection nozzle 1 Replace the used fuel nozzle protector and fuel nozzle seat with new ones Put the seat in t...

Page 118: ...tighten the pipe joint nuts on both ends of the fuel injection pipe Completely tighten after adjusting the injection timing 2 Mount the fuel return pipe with the clamp fuel injection nozzle fuel inje...

Page 119: ...to the gear case cover 28 Mounting the heal exchanger exhaust manifold fresh water tank unit Mount the gasket and heal exchanger exhaust manifold Note After adjusting injection timing and tightening t...

Page 120: ...xchanger mixing elbow 30 Mounting the cooling water pipes seawater fresh water 1 Mount the seawater pipes with the hose clips seawater pump heat exchanger 2 Mount the fresh water pipes with the hose c...

Page 121: ...belt tension with the adjuster and tighten the set bolt 32 Mounting the starting motor Fit the starting motor on the flywheel housing 33 Mounting the intake silencer Mount the intake pipe on the intak...

Page 122: ...at and completion of the piping and wiring Mount the engine on the engine bed in the engine room of a boat after all engine assembly has been completed Connect the cooling water pipes fuel pipes other...

Page 123: ...fill with water 2 Fill with water until the level in the coolant recovery tank is between the full and low marks 39 Test running Refer to Adjusting operation of 2 6 in chapter 2 Model Engine capacity...

Page 124: ...an aerosol cleaner penetrant and developer 3 Clean the area to be inspected with the cleaner Either spray the cleaner on directly and wipe or wipe the area with a cloth moistened with cleaner 4 Spray...

Page 125: ...No 4 to the seat surface where the plug is to be driven in Apply over the whole outside of the plug Threebond No 4 4 Insert the plug into the hole Insert the plug so that it sits correctly 5 Place a d...

Page 126: ...ple method Measure cylinder diameters of the A direction and the B direction on each section of a b and c Roundness is the maximum value among those difference values Cylindricity Cylindricity is foun...

Page 127: ...alloy stellite with superior resistance to heat and wear is fitted on the seats and the area between the valves is cooled by the water jet Suction valve Exhaust valve Rocker arm support Valve cap Cot...

Page 128: ...agonal Measure the clearance between the straight edge and combustion surface with a feeler gauge 2 Checking for cracks in the combustion surface Remove the fuel injection nozzle intake and exhaust va...

Page 129: ...then grind the seat 2 Knead valve compound with oil and finish the valve seat with a lapping tool 3 Final finishing should be done with oil only Lapping tool Use a rubber cap type lapping tool for cy...

Page 130: ...seat contact surface is much smaller than the width of the valve seat NOTE Keep in mind the fact that the intake and discharge valve have different diameters 3 Valve sink Over long periods of use and...

Page 131: ...cohol with dry ice added in a container and put the valve guide for replacement in it for cooling Then insert it in with a valve guide inserting tool Do not touch the cooled valve guide with bare hand...

Page 132: ...is not marked a Apply lube oil to the lip b Push with the inserting tool for installation Measure and check the projection of valve stem seal to keep proper clearance between valve guide and stem sea...

Page 133: ...on the cylinder head surface where it comes in contact with the block 3 Coat the head bolt threads and nut seats with lube oil 4 Use the positioning pins to line up the head gasket with the cylinder b...

Page 134: ...engine performance according to the extent of the change 1 Rocker arm shaft and rocker arm bushing Measure the outer diameter of the shaft and the inner diameter of the bushing and replace if wear ex...

Page 135: ...closing angles for both the intake and the exhaust valves are checked when the timing gear is disassembled The gauge on the flywheel can be read mm Intake and exhaust valve clearance 0 15 0 25 deg In...

Page 136: ...tsides of the piston or ring grooves are worn 2 Measure the outside diameter in the position of 22mm from the piston bottom in the right angle direction of the piston pin If the piston outside diamete...

Page 137: ...Tolerance below 0 005 0 min below 0 0 005 min Size mark ML MS Cylinder inside diameter D1 0 030 max 0 020 min L X below 0 020 0 010 min M below 0 010 0 min S X Model Cylinder inside diameter D1 Pisto...

Page 138: ...550 1 570 Ring width 1 470 1 490 1 450 Clearance 0 060 0 100 Second ring Groove width 1 580 1 595 1 695 Ring width 1 430 1 450 1 410 Clearance 0 013 0 165 0 285 Oil ring Groove width 3 010 3 030 3 13...

Page 139: ...make sure it moves easily and smoothly 4 Stagger the piston rings at 120 intervals making sure none of them line up with the piston 3YM30 3YM20 2YM15 mm Standard Limit Top ring gap 0 15 0 30 0 390 Sec...

Page 140: ...Inspection and servicing of basic engine parts 120 5 The oil ring is provided with a coil expander The coil expander joint should be opposite staggered 180 the oil ring gap Gap Joint of coil expander...

Page 141: ...of the large and small ends Insert the measuring tool into the large and small ends of the connecting rod Measure the extent of twist and parallelism and replace if they exceed the tolerance mm Standa...

Page 142: ...ension of the below table Correct by grinding if unevenly wear roundness exceeding the limit or insufficient outside diameter is found Also use an undersized metal if necessary NOTICE When measuring t...

Page 143: ...k pin metal and make sure that it fits tightly on the large end cap 3 When assembling the connecting rod match up the large end and large end cap number Coat the bolts with engine oil and gradually ti...

Page 144: ...4 4 Assembling piston and connecting rod The piston and connecting rod should be assembled so that the match mark on the connecting rod large end faced the fuel nozzle side and the combustion chamber...

Page 145: ...fter cleaning the crankshaft and replace the crank shaft if there is any cracking or considerable damage 2 Bending of the crankshaft Support the crankshaft with V blocks at both ends of the journals M...

Page 146: ...is observed re grind the crankshaft and use an undersize metals 2 lf rust or surface roughening exists on the rear side of the metals coat it with blue or minimum Then assemble the crankpin metal to t...

Page 147: ...f necessary 2 Measuring the inner diameter of metal Tighten the cap to the specified torque and measure the inner diameter of the metal NOTE When assembling the bearing cap keep the following in mind...

Page 148: ...t gap before disassembly As the cam gear is shrink fitted to the cam be careful when replacing the thrust bearing 2 Measure the cam height and replace the cam if it is worn beyond the limit mm Standar...

Page 149: ...ce a dial gauge at the central bearing areas and measure bending Replace if excessive NOTE The reading on the dial gauge is divided by two to obtain the camshaft bend mm Standard Limit Cam height Inta...

Page 150: ...exhaust valve 2 Measure the outer diameter of the tappet and replace if worn beyond the limit 3 Measuring push rods Measure the bend of the push rods mm Standard Limit Tappet outside diameter 20 927 2...

Page 151: ...ng is pressure fitted into the idling gear Measure the bushing inner diameter and the outer diameter of the shaft and replace the bushing or idling gear shaft if the oil clearance exceeds the wear lim...

Page 152: ...anced force on the shaft center must be kept below the specified value for the crankshaft as the flywheel rotates with the crankshaft at high speed To achieve this the valance is adjusted by drilling...

Page 153: ...scratches are found replace with new one 2 Spring Whenever uneven wear and or scratches are found replace with new one 3 Pin wear Whenever uneven wear and or scratches are found replace with new one 4...

Page 154: ...overnor Refer to the service manual of the YPES ML fuel injection pump for the disassembly assembly and adjustment procedure 6 1 1 Fuel system diagram Fuel injection pump Feed pump Fuel nozzle Fuel in...

Page 155: ...ection adjustment Starting Pump speed ND min 1 200 Average injection volume QD mm3 st 38 5 Rated load Pump speed NA min 1 1800 Injection volume QA mm3 st 22 4 0 75 Variation 3 Torque rise Pump speed N...

Page 156: ...min 1 200 Average injection volume QD mm3 st 30 5 Rated load Pump speed NA min 1 1800 Injection volume QA mm3 st 17 4 0 5 Variation 3 Torque rise Pump speed NC min 1 1300 Injection volume QC mm3 st 19...

Page 157: ...min 1 200 Average injection volume QD mm3 st 30 5 Rated load Pump speed NA min 1 1800 Injection volume QA mm3 st 17 9 0 5 Variation 3 Torque rise Pump speed NC min 1 1300 Injection volume QC mm3 st 20...

Page 158: ...idle set bolt at high idle speed as to get the specified injection volume B 6 Loosen the nut of the FO limiter and loosen the adjusting bolt at 360 Fix the nut 7 Screw the angleich at the torque rise...

Page 159: ...gh idle speed as to get the specified injection volume B 6 Loosen the nut of the FO limiter and loosen the adjusting bolt at 180 Fix the nut 7 Screw the angleichi at the torque rise speed to get the s...

Page 160: ...6 Fuel injection equipment 139 6 1 3 Fuel injection pump structure Section of a fuel injection pump governor for 3YM30...

Page 161: ...jection pump Leave the pump drive gear in the gear case 6 1 5 Installing a fuel injection pump NOTICE Use a new O ring on the fuel pump flange and apply grease Confirm whether the marks of the pump dr...

Page 162: ...the fuel due to defective connections in the piping from the fuel tank to the fuel pump 6 Defective valve contact of feed pump 7 Piston spring of feed pump is broken 8 Inter spindle or tappets of fee...

Page 163: ...ings are not even 5 The 1st and 2nd levers of the governor and the control rack or the injection pump are improperly lined up 6 Delivery stopper is loose 7 Delivery packing is defective 8 Delivery val...

Page 164: ...sion Adjust Adjust Adjust Adjust Repair 8 Engine exhausts too much smoke When exhaust smoke is black 1 Injection timing is too fast 2 Air volume intake is insufficient 3 The amount of injection is une...

Page 165: ...engine is stopped 6 2 1 Construction of fuel feed pump 6 2 2 Fuel feed pump specifications Head 1m Discharge volume 230 cm3 min at 1500 min 1 cam discharge pressure of 0 020 MPa 0 2 kgf cm2 Closed off...

Page 166: ...g holes are lined up do not force 5 Align the match marks on the upper body of the pump and cover and tighten the small screws evenly 6 2 4 Fuel feed pump inspection 1 Place the fuel feed pump in kero...

Page 167: ...ing Clean the valve seat and valve with air to remove any foreign matter 5 Inspect the diaphragm spring and piston spring for settling and the piston for wear and replace as necessary NOTE Replace par...

Page 168: ...d is sent to the injection pump Loosen the bolt fitted to the fuel filter body before starting or after dismantling and reassembly to bleed the air in the fuel system to the fuel filter 6 3 1 Fuel fil...

Page 169: ...models is available as an option A fuel return connection is provided on top of the tank of which a rubber hose can be connected to return fuel from the fuel nozzles Fuel return connection Tank Level...

Page 170: ...mful to natural environment Therefore blowby gas reductor is adopted as breather system Some of the combustion gas passes through the clearance between cylinder and piston and flows to the crankcase T...

Page 171: ...ill occur When a diaphragm is damaged blowby is discharged from the breathing hole on the side of diaphragm cover and not reduced in the intake manifold Therefore be careful of the diaphragm trouble 2...

Page 172: ...he exhaust manifold 7 2 2 Mixing elbow inspection 1 Clean dirt and scale out of the gas and cooling water lines 2 Repair crack or damage to welds or replace 3 Inspect the gasket packing and replace as...

Page 173: ...nal lubricates the crank pin from the crankshaft journal and a option of the oil is fed to the camshaft bearings Oil is sent from the gear case camshaft bearings through the holes in the cylinder body...

Page 174: ...r case cover Do not disassemble the inner outer rotors and check that the pump rotates smoothly 4 Remove the pressure control valve from the lube oil pump cover Note Only wash the control valve Disass...

Page 175: ...t Measure the outside diameter of inner rotor centering location part and the hole diameter of gear case cover Calculate the clearance from that difference 8 2 5 Pressure control valve construction Th...

Page 176: ...nce of the pressure in front and behind the paper element reaches 0 08 0 12 MPa 0 8 1 2 kgf cm2 the bypass valve inside the filter opens and the lube oil is sent to each part automatically as an emerg...

Page 177: ...otary waste oil pump to pump out waste oil is available as an option Rotary waste oil pump Delivery capacity per one revolution 0 057 L Delivery pressure 0 15 MPa 1 5 kg cm2 or below Suction head less...

Page 178: ...ssageway line at the cylinder head outlet and is fitted with a thermostat The thermostat is closed when the fresh water pump temperature is low immediately after the engine is started and during low l...

Page 179: ...9 Cooling water system 158R1 Cooling water line Heat exchange Cooling water pipes Mixing elbow Exhaust manifold Coolant tank Fresh water pump From seacock Seawater pump...

Page 180: ...to 2 2 5 5 1 Remove the rubber hose from the seawater pump outlet and then remove the seawater pump assembly from the gear case cover 2 Remove the seawater pump cover and take out the O ring and impe...

Page 181: ...Inspect the oil seal and replace if it is damaged Also replace the oil seal if there is considerable water leakage during operation 3 Make sure the ball bearings rotate smoothly Replace if there is e...

Page 182: ...cing the oil seal coat with grease and insert 2 Mount the pump shaft ball bearing and V pulley to the pump unit and fit the bearing retaining ring NOTE Coat the shaft with grease 3 Mount the impeller...

Page 183: ...haft bearing unit and mechanical seal The V pulley on the end of the pump shaft is driven by a V belt The bearing unit assembled in the pump shaft uses grease lubricated ball bearings and cannot be di...

Page 184: ...ue to contact with pump body 3 Check the holes in the cooling water and bypass lines clean out any dirt or other foreign matter and repair as necessary 4 Replace the pump as an assembly if there is ex...

Page 185: ...9 Cooling water system 164 Measuring side clearance between impeller and plate mm Standard Limit Side clearance between impeller and plate 0 5 Straightedge Thickness gauge...

Page 186: ...fold The pressure cap filler cap on top of the heat exchanger has a pressure valve which lets off steam through the overflow pipe when pressure in the fresh water system exceeds the specified value It...

Page 187: ...ter system When the pressure within the fresh water system exceeds the specified value the pressure valve opens and steam is discharged through the overflow pipe When the fresh water is cooled and the...

Page 188: ...valent on filler neck outside contour and press the filler neck into the fresh water cooler with the special tool 4 To fix the filler neck on the fresh water cooler press the small copper tube inside...

Page 189: ...9 5 7 Mounting the coolant recovery tank 1 The coolant recovery tank is mounted at approximately the same height as the heat exchanger fresh water tank allowable difference in height 300 mm 11 8110 i...

Page 190: ...s closed off as the thermostat valve opens and is completely closed when the fresh water temperature reaches 81 5 C valve lifts 4 mm 0 1575 in sending all of the water to the heat exchanger 9 6 2 Ther...

Page 191: ...Time 10 minutes Rotation direction Right viewed from the impeller side Weight Pump 1 4 kg Negative pressure detector Diaphragm type Temperature 30 C 80 C Pump dimensions Length 225 mm Yoke diameter 6...

Page 192: ...sure that the strainer is inserted in the drain water before pushing the switch If no water is being drawn up after a period of 10 seconds or more prime the pump Do not run the pump for longer than 1...

Page 193: ...lge water level Select the location for the bilge pump taking into consideration the length of the switch cable approx 3 m and its attachment point and the position of the battery Position at a 45 ang...

Page 194: ...d avoid sharp bends 6 Test operation Collect water in the bottom of the boat and check for any problems with the hose or wiring After doing this connect the battery Turn on the pump switch and check t...

Page 195: ...ake a longer time for the pump to operate 0 C 5 10 seconds Keep the pump in a dry place away from rain or other water Use the regulation hose do no use thin vinyl hose or hose which is not heat resist...

Page 196: ...closer to the surface of the water The pump is too high Lower the pump Position the pump so that it is 50 70 cm above the bottom of the boat Pump intake is weak If intake is still faulty after primin...

Page 197: ...ller shaft speed at continuous power Forward min 1 1580 1332 1083 Direction of rotation Input shaft Counter clockwise viewed from stern Output shaft Forward Clockwise viewed from stern Reverse Counter...

Page 198: ...ernor When warming up the engine to freely control the governor separately from the clutch put the lever in neutral the central position and pull the knob in the center of the control lever When the l...

Page 199: ...sponsive Morse Control Cables These are designed specifically for use with Morse control heads This engineered system of Worse cables control head and engine connection kits ensures dependable smooth...

Page 200: ...ote control Optional 179 11 2 Remote control installation 1 Speed control Remote control handle MT 3 Remote control handle MN Optional Clamp Cable bracket Cable joint Flywheel housing Governor Control...

Page 201: ...shed and the engine is stopped Retainer Clamp Spacer Cable bracket Clutch flange Remote control cable clamp Neutral S1 S2 Clamp To engine speed To marine gear Reverse Forward Remote control head Note...

Page 202: ...le will make it difficult to turn the handle Reroute the cable to reduce the number of bends and enlarge the bending radius as much as possible to 200 mm or more 3 Check for loose cable bracket clamp...

Page 203: ...trol lever all the way to full throttle several times and then return The throttle lever on the engine must lightly push against the idle switch when it is returned If it is property adjusted the knob...

Page 204: ...LOW B OFF ON START STOP 50 Battery switch Battery Alternator Fitting to marine gear Neutral safety switch B type panel Extension wire harness To earth bolt Starting motor Stop solenoid To lube switch...

Page 205: ...B L YG RB Section of cable Allowable Length mm2 15 mm2 0 86 m 20 mm2 1 3 m 2 3 m 30 mm2 40 mm2 2 8 m 3 5 m 50 mm2 2W 60 mm2 4 1 m CFW temp Buzzer oil press Tacho meter Instrument panel 17 G1 P G2 Key...

Page 206: ...connect the battery to the starter Using wire other than that specified may cause troubles The overall length of the wire between the battery terminal and the starter B terminal and between the batte...

Page 207: ...Nominal power kW Nominal voltage V Rating sec Direction of rotation Looking from the pinion side Number of pinion teeth Weight kg 1 4 12 30 Clockwise 11 3 0 No load Terminal voltage V Electric curren...

Page 208: ...12 Electrical System 187 12 3 3 Structure 1 Disassembly drawing Magnetic switch Internal gear Bracket Pinion Gear housing Armature Yoke Rear cover...

Page 209: ...ngages the ring gear because a main contact point is closed and the main electric current flows and a pull coil is short circuited by the main contact point and it stops being charged with electricity...

Page 210: ...ert AC to DC and an IC regulator that keeps the generated voltage constant even when the engine speed changes 12 4 1 Specifications Yanmar code 128271 77200 Model of alternator LR160 741 HITACHI Model...

Page 211: ...bly drawing 2 Structure 12V60A alternator Pulley Front bracket Rotor Stator Fan Ball bearing Rear bracket assembly Bracket Nut Stator assembly Rectifier assembly Rotor assembly Through bolt Nut M5 Rot...

Page 212: ...ing the alternator stop 12 4 4 Standard output characteristics The standard output characteristics of this alternator are shown as the below figure B Stator coil Diode Alternator Rotor coil S L F P E...

Page 213: ...er 2 2 Visual check of wiring and check of unusual sound 1 Confirm whether wiring is right or there is no looseness of the terminal part 2 Confirm that there is no unusual sound from the alternator du...

Page 214: ...R1Z 63 HITACHI Battery voltage 12V Nominal output 12V 80A Earth polarity Negative earth Direction of rotation viewed from pulley end Clockwise Weight 5 4 kg Rated speed 5000 min 1 Operating speed 1 20...

Page 215: ...ing Spacer Pulley Capacitor assembly Rear cover Brush regulator assembly Brush holder Diode assembly Screw M5 x 0 8 X14 Bearing retainer Front cover assembly Stator assembly Rotor assembly Brush assem...

Page 216: ...he alternator stop 12 5 4 Standard output characteristics The standard output characteristics of this alternator are shown as the below figure Stator coil Diode Sub Diode Alternator Rotor coil L F E I...

Page 217: ...ument panel is activated by the pulse from flywheel ring gear The engine speed with new panel is activated by alternator B terminal pulse 12 6 1 B type instrument panel Optional 0 10 20 30 40 50 STOP...

Page 218: ...ough the lamp J oil pressure switch J ground circuit system If the oil pressure is normal the contacts of the switch are opened by the lubricating oil pressure and the lamp remains off Rated voltage 1...

Page 219: ...ls of oil pressure switch grounded Replace lamp 2 Operation of oil pressure switch Lamp illuminated when checked as described in 2 above Replace oil pressure switch Lamp not extinguished while engine...

Page 220: ...ing in cold areas in winter The glow plug is mounted to the cylinder head The device is operated by the glow switch on the instrument panel Rated current 8 10A Rated voltage DC11V 69 17 25 18 5 12 mm...

Page 221: ...engine stop device is fitted to the governor The device is operated by the stop switch on the instrument panel The emergency stop button is integrated with the solenoid When pushing the stop button th...

Page 222: ...ty full 3YM30 Liter quart at rake angle 8 degree 2 8 0 0 2 3 0 2 2 2 2 2 2 2 3 3YM20 Liter quart at rake angle 8 degree 2 7 0 0 2 2 9 2YM15 Liter quart at rake angle 8 degree 2 0 0 0 2 2 1 Marine gear...

Page 223: ...Intake Guide inside diameter 6 000 6 012 6 08 5 2 3 Valve stem outside diameter 5 960 5 975 5 90 Clearance 0 025 0 052 0 16 Exhaust Guide inside diameter 6 000 6 012 6 08 Valve stem outside diameter 5...

Page 224: ...YM20 2YM15 34 535 34 665 34 29 Shaft outside diameter Metal inside diameter Gear side Bushing inside diameter 40 000 40 075 40 150 5 6 1 3 Camshaft outside diameter 39 940 39 960 39 905 Clearance 0 04...

Page 225: ...pin 3YM30 Pin outside diameter 41 952 41 962 41 902 5 4 2 1 5 5 1 3 Metal inside diameter 41 982 42 010 Metal thickness 1 503 1 509 Clearance 0 020 0 058 0 120 Crank pin 3YM20 2YM15 Pin outside diame...

Page 226: ...3YM20 2YM15 0 030 0 050 Piston pin hole inside diameter 22 000 22 009 22 039 5 3 2 Piston pin outside diameter 21 995 22 000 21 965 Clearance 0 000 0 014 0 074 3YM30 mm Inspection item Standard Limit...

Page 227: ...h 1 540 1 560 1 660 Ring width 1 470 1 490 1 450 Side clearance 0 050 0 090 0 210 Ring gap 0 18 0 33 0 420 Oil ring Groove width 3 010 3 030 3 130 Ring width 2 970 3 010 2 950 Side clearance 0 020 0 0...

Page 228: ...rotor 4 Outside diameter clearance of inner rotor centering location part mm Standard Limit Reference page 0 12 0 21 0 30 8 2 4 1 mm Standard Limit Reference page 0 16 8 2 4 1 mm Standard Limit Refere...

Page 229: ...nut M12 x 1 75 Coat with lube oil 58 8 68 8 6 0 7 0 7 Nozzle fastening nut M20 x 1 5 No lube oil 49 53 5 0 5 4 8 Fuel injection pipe joint nut M12 x 1 25 No lube oil 29 4 34 4 3 0 3 5 9 Glow plug M10...

Page 230: ...de No M9961 03E101 First Edition March 2004 2nd Edition April 2005 Published by Quality Control Dept Marine Factory Large Power Products Operations Division YANMAR TECHNICAL SERVICE CO LTD Edited by A...

Page 231: ...PRODUCTS OPERATIONS DIVISION 5 3 1 TSUKAGUCHI HONMACHI AMAGASAKI SHI HYOGO 661 JAPAN PHONE 81 6 6428 3123 FAX 81 6 6421 5549 URL WWW YANMAR CO JP PHONE 1 770 877 9894 FAX 1 770 877 7565 YANMAR MARINE...