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Yanmar 3GM30 Specifications

1. 39 SAFETY 39 STARTING THE ENGINE 41 If the Engine Fails to Start 42 Starting at Low Temperatures 42 After the Engine has Started 43 REMOTE CONTROL HANDLE OPERATION 44 Acceleration and Deceleration 44 Shifting the Engine 44 CAUTIONS DURING 45 SHUTTING DOWN THE 46 Normal Shutdown 46 Emergency Shutdown 47 CHECKING THE ENGINE AFTER OPERATION 48 PERIODIC 49 INTRODUCTION iue cie iere nea 49 SAFETY PRECAUTIONS see 49 YM Series Operation Manual YANMAH TABLE OF CONTENTS PRECAUTIONS ciere Dei nenne 51 The Importance of Periodic Maintenance 51 Performing Periodic Maintenance 51 The Importance of Daily Checks 51 Keep a Log of Engine Hours and Daily Checks 51 Yanmar Replacement Parts 51 Tools Required u uuu ie 51 Ask Your Authorized Yanmar Marine Dealer or Distributor for
2. I T Resistance 11 Y 12 YANMAR Series Operation Manual 95 SYSTEM DIAGRAMS 1 Instrument panel B20 2 Alarm lamps 3 to 7 3 Engine oil low pressure indicator 4 Coolant high temperature Indicator 5 Water in sail drive seal indicator 6 Battery low charge indicator Water in fuel filter indicator 8 Tachometer 9 Segmented display 10 Control unit Tacho gauge 11 Fuse 12 Buzzer 13 Switch module 14 to 18 14 Start switch 15 Stop switch 16 Glow switch 17 Power switch 18 Control unit Switch module 19 Fuel tank level sensor input 20 ACC power 21 ACC GND 22 Wire harness 23 Water in sail drive seal sensor amplifier sail drive only 24 by customer 25 Battery 26 Battery switch 27 Relay Glow plug 28 Glow plug 29 Stop relay 30 Engine stop solenoid 31 Starter relay 32 Starter 33 Coolant temperature switch 34 Engine oil pressure switch 35 Alternator 36 Ground 37 Water in sail drive seal sensor Sail drive only 38 Details of coupler Wire harness view from A A 96 YM Series Operation Manual YANMAH EPA WARRANTY USA ONLY YANMAR
3. Engine Oil Filter Filters fine metal fragments and carbon from the engine oil Filtered engine oil is distributed to the engine s moving parts The filter is a cartridge type and the element should be replaced periodically See Changing the Engine Oil on page 61 Marine Gear Filler Port Filler port for marine gear lube oil Located on top of the marine gear case Cooling System There are two cooling systems closed cooling with coolant fresh water and seawater The engine is cooled by the closed cooling circuit The closed circuit is cooled by seawater using a heat exchanger The seawater also cools the engine marine gear oil Closed Cooling Circulation Pump The centrifugal water pump circulates coolant inside the engine The circulating pump is driven by a V ribbed belt Seawater Pump Pumps seawater from outside vessel to the engine The seawater pump is gear driven and has a replaceable rubber impeller Do not operate it without seawater as this will damage the impeller Coolant Filler Cap The filler cap on the heat exchanger coolant tank covers the water supply port The cap has a pressure regulating valve When the cooling water temperature rises the pressure rises inside the coolant system Reservoir The pressure valve in the filler cap releases vapor and hot water overflow to the reservoir When the engine stops and the coolant cools the pressure in the coolant tank drops The filler
4. 3 To allow ready access to the sample port the connection should be located if possible given the constraints of vessel design approximately 0 6 to 1 8 m 2 to 6 ft above a deck or walkway 4 To facilitate insertion and withdrawal of an exhaust sample probe there should be no obstructions for at least one and one half exhaust pipe stack diameters perpendicular i e 90 degrees from the sample port and 5 If a threaded connection is used both the internal and external threads should be coated with a high temperature anti seize compound before the initial installation and at every subsequent re installation to facilitate removal of the connection for testing 54 YANMAH YM Series Operation Manual PERIODIC MAINTENANCE SCHEDULE Daily and periodic maintenance is important to keep the engine in good operating condition The following is a summary of maintenance items by periodic maintenance intervals Periodic maintenance intervals vary depending on engine application loads diesel fuel and engine oil used and are hard to establish definitively The following should be treated only as a general guideline NOTICE Establish a periodic maintenance plan according to the engine application and make sure to perform the required periodic maintenance at the intervals indicated Failure to follow these guidelines will impair the engine s safety and performance characteristics shorten the engine s life and may
5. 528 mm 20 8 in Engine Dry Mass Including Marine Gear 130 kg 287 Ib 151 kg 333 Ib Rating Condition Temperature of fuel 40 C at fuel pump inlet ISO 8665 The total oil quantity includes oil in oil pan channels coolers and filter The effective amount of oil shows the difference in maximum scale of the dipstick and minimum scale Note Density of fuel 0 842 g cm at 15 C Fuel temperature at the inlet of the fuel injection pump 1hp metric 2 0 7355 kW YANMAR Series Operation Manual 85 SPECIFICATIONS 3YM30E Engine Specifications Specification 3YM30E Marine Gear Model KM2P 1 SD 20 Use Pleasure use Type Vertical water cooled 4 cycle diesel engine Combustion System Swirl pre combustion chamber Air Charging Natural aspiration Number of Cylinders 3 Bore x Stroke 76 mm x 82 mm 2 99 in x 3 23 in Displacement 1 115 L 68 04 cu in Continuous Output at Power Crankshaft Engine Speed 19 4 kW 26 4 hp metric 3489 min 1 Fuel Stop Output at Power Crankshaft Engine Speed 21 3 kW 29 0 hp metric 3600 min Output at Propeller Engine Speed 20 7 kW 28 1 hp metric 3600 min 1 Installation Flexible mounting Fuel Injection Timing FID 18 1 BTDC Fuel Injection Opening Pressure 12 8 to 13 28 MPa Main Power Take Off At flywheel end Direction of
6. ENGINE FAMILY DYDXN1 11P3N DISPLACEMENT 1 116 LITERS ENGINE MODEL 3YM30E 5 EM IFI FUEL RATE 21 9MM STROKE 21 3kW 3600RPM 19SkW lt 37 STANDARDS NOx HC 7 5g kW hr CO 5 5g kW hr PM 0 30g kW hr APPLICATION VARIABLE SPEED PROPULSION ENGINES USED WITH FIXED PITCH PROPELLERS 128990 07712 Figure 3 YANMAR Series Operation Manual 97 EPA WARRANTY USA ONLY THIS EMISSION WARRANTY APPLIES TO THE ENGINES CERTIFIED TO UNITED STATES EPA 40 CFR Part 1042 135 AND SOLD BY YANMAR THAT ARE INSTALLED IN VESSELS FLAGGED OR REGISTERED IN THE UNITED STATES Your Warranty Rights and Obligations Yanmar warrants to the first user and each subsequent purchaser the emission control system on your engine for periods of time listed below provided the engine has been installed according to Yanmar installation requirements and there has been no abuse neglect or improper maintenance of your Yanmar Marine engine Yanmar warrants that the engine is designed built and tested using genuine parts and equipped so as to conform to all applicable emission requirements of the U S Environmental Protection Agency and is free from defects in material and workmanship which would cause this engine to fail to conform to the applicable emission regulations over its limited emission control system warranty period Where a warrantable emissions condition exi
7. Engine Oil Dipstick 6 Engine Oil Filler Cap 7 Fuel Feed Pump 8 Engine Oil Filter 9 Marine Gear Left Side Viewed from Flywheel 3YM20 Figure 4 1 Seawater Pump 051099 00X00 2 Coolant Filler Cap 3 Engine Nameplate on rocker arm cover 4 Coolant Tank Heat Exchanger 5 Exhaust Manifold 6 Starter Motor 7 Shift Lever 8 Alternator 14 YM Series Operation Manual YANMAH PRODUCT OVERVIEW Right Side Viewed from Left Side Viewed from Flywheel Flywheel 3YM30 E 3YM30 E Figure 5 and Figure 6 illustrate a typical version of a 3YM30 E engine Your engine may have different equipment from that illustrated 051100 00X00 Figure 6 1 Seawater Pump 2 Coolant Filler Cap lt 3 Engine Nameplate on rocker 9 arm cover 4 Coolant Tank Heat Exchanger Figure 5 5 Exhaust Manifold 1 Intake Silencer air cleaner 6 Starter Motor 2 Intake Manifold 3 Fuel Filter 4 Fuel Injection Pump 5 Engine Oil Dipstick 6 Engine Oil Filler Cap 7 Fuel Feed Pump 8 Engine Oil Filter 9 Marine Gear YANMAR Series Operation Manual 15 PRODUCT OVERVIEW NAMEPLATES The nameplates of Yanmar YM series engines are shown in Figure 7 Check the engine s model output min 1 and serial number on the nameplate Please replace if damaged or lost The engine nameplate is attached to the engine rocker arm cover Model Gear Mod
8. If the engine will not be used for an extended period of time special measures should be taken to protect the cooling system fuel system and combustion chamber from corrosion and the exterior from rusting The engine can normally stand idle for up to 6 months If it remains unused for longer than this please contact your authorized Yanmar Marine dealer or distributor Before performing any storage procedures within this section review the Safety section on page 5 In cold temperatures or before long term storage be sure to drain the seawater from the cooling system NOTICE Do not drain the coolant system A full coolant system will prevent corrosion and frost damage If seawater is left inside of the engine it may freeze and damage parts of the cooling system when the ambient temperature is below 0 C 32 F PREPARE ENGINE FOR LONG TERM STORAGE Note If the engine is close toa periodic maintenance interval perform those maintenance procedures before putting the engine into long term storage 1 Wipe off any dust or oil from the outside of engine 2 Drain water from fuel filters 3 Drain fuel tank completely or fill the tank to prevent condensation 4 Grease the exposed areas and joints of the remote control cables and the bearings of the remote control handle 5 Seal the intake silencer exhaust pipe etc to prevent moisture or contamination from entering engine 6 Completely drain bilge in hul
9. Name Yukio Kikuchi Signature and title 4 identification of the person empowered to sign or an equivalent marking behalf of the engine manufacturer or his authorised representative enior Manager Application Engineering Dept Marine Operations Division Date yr month day 2012 12 25 Yanmar Co Ltd 106 YM Series Operation Manual YANMAR YANMAR CO LTD Marine Operations Division Quality Assurance Dept 5 3 1 Tsukaguchi honmachi Amagasaki Hyogo 661 0001 Japan Phone 81 6 6428 3251 Fax 81 6 6421 5549 Overseas Office E Yanmar Europe B V YEU Brugplein 11 1332 BS Almere de Vaart Netherlands Phone 31 36 5493200 Fax 31 36 5493209 E Yanmar Asia Singapore Corporation Pte Ltd YASC 4 Tuas Lane Singapore 638613 Phone 65 6595 4200 Fax 65 6862 5189 Yanmar America Corporation YA 101 International Parkway Adairsville GA 30103 U S A Phone 1 770 877 9894 Fax 1 770 877 9009 Yanmar Engine Shanghai Co Ltd 10F E Block POLY PLAZA No 18 Dongfang Road Pudong Shanghai CHINA P R C 200120 Phone 86 21 6880 5090 Fax 86 21 6880 8090 OPERATION MANUAL 2YM15 2YM20 3YM30E 3YM30 1st edition November 2007 2nd edition 1st rev March 2012 2nd edition 2nd rev July 2012 3rd edition February 2013 8rd edition 1st rev June 2013 Issued by YANMAR CO LTD Marine Operations Division Edited by YANMAR TECHNICAL SERVICE CO LTD G00202 OAYMM YANMAR
10. fuel from the top of the container Figure 3 Fuel Tank Optional 1 Fuel Filter 2 Fuel Feed Pump priming lever 3 Fuel Water Separator optional 4 Approximately 20 to 30 mm 0 75 to 1 125 in 5 Within 500 mm 20 6 Drain Cock 7 Fuel Cock 8 Fuel Return Line 9 To Fuel Injection Pump 10 Fuel Tank Install the fuel line from the fuel tank to the fuel injection pump as shown in Figure 3 The recommended fuel water separator 0004542 Figure 2 Figure 3 3 optional is installed at the 1 Sediment Bowl center section of that line 2 Drain Cock 3 Fuel Line to Engine Install a drain cock Figure 2 2 at the bottom of the fuel tank to remove water and contaminants from the sediment bowl Figure 2 1 28 YM Series Operation Manual YANMAR Filling the Fuel Tank Before filling fuel tank for the first time Fire and Explosion Hazard Never refuel with the engine running Rinse fuel tank with kerosene or diesel fuel Dispose of waste properly To fill the fuel tank Fire and Explosion Hazard Operate bilge ventilation blowers for a minimum of 5 minutes to purge fumes from engine compartment after refueling Never operate bilge blower while refueling Doing so can pump explosive fumes into the engine compartment and result in an explosion Clean the area around the fuel cap Remove the fuel cap from the fuel tank Fill the tank w
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12. CO LTD LIMITED EMISSION CONTROL SYSTEM WARRANTY USA ONLY 2YM15 EPA and CARB Nameplate For Example EMISSION CONTROL INFORMATION THIS ENGINE COMPLIES WITH U S EPA MARINE AND CALIFORNIA OFF ROAD REGULATIONS FOR 2013 M Y DIESEL ENGINES ULTRA LOW SULFUR DIESEL FUEL ONLY ENGINE FAMILY DYDXN0 57P2N DISPLACEMENT 0 570 LITERS ENGINE MODEL 2YM15 E C S EM IFI FUEL RATE 17 4MM STROKE 10 0kW 3600RPM 8SkW lt 19 STANDARDS NOx HC 7 5g kW hr CO 6 6g kW hr PM 0 40g kW hr APPLICATION VARIABLE SPEED PROPULSION ENGINES USED WITH FIXED PITCH PROPELLERS YANMAH YaNvAnco rp 128790 07712 Figure 1 3YM20 EPA and CARB Nameplate For Example EMISSION CONTROL INFORMATION THIS ENGINE COMPLIES WITH U S EPA MARINE AND CALIFORNIA OFF ROAD REGULATIONS FOR 2013 M Y DIESEL ENGINES ULTRA LOW SULFUR DIESEL FUEL ONLY ENGINE FAMILY DYDXNO 85P3N DISPLACEMENT 0 854 LITERS ENGINE MODEL 20 E C S EM IFI FUEL RATE 17 2MM STROKE 15 3kW 3600RPM 8SkW lt 19 STANDARDS NOx HC 7 5g kW hr CO 6 6g kW hr PM 0 40g kW hr APPLICATION VARIABLE SPEED PROPULSION ENGINES USED WITH FIXED PITCH PROPELLERS YANMAR vw 128890 07712 Figure 2 3YM30E EPA and CARB Nameplate EMISSION CONTROL INFORMATION THIS ENGINE COMPLIES WITH U S EPA MARINE AND CALIFORNIA OFF ROAD REGULATIONS FOR 2013 M Y DIESEL ENGINES ULTRA LOW SULFUR DIESEL FUEL ONLY
13. CONTENTS BEFORE YOU 25 INTRODUCTION 25 SAFETY PRECAUTIONS 25 DIESEL FUEL eed tree ree 26 Diesel Fuel Specifications 26 Filling the Fuel 29 Bleeding the Fuel System 30 ENGINE Oll inertiae t cai te he Sin 31 Engine Oil Specifications 31 Engine Oil Viscosity 31 Checking the Engine Oil 32 Adding Engine Oil 32 MARINE GEAR OR SAIL DRIVE OIL 33 Marine Gear Oil Specifications 33 Sail Drive Oil Specifications SD20 33 Checking Marine Gear Oil 33 Adding Marine Gear 33 Checking and Adding Sail Drive Oil 33 ENGINE COOLANT etn 34 Engine Coolant Specifications 34 Coolant Closed Cooling System 34 Checking and Adding Coolant 35 CRANKING THE ENGINE eee 37 ENGINE 39 INTRODUCTION
14. Help 51 Tightening 52 EPA MAINTENANCE REQUIREMENTS 53 EPA Requirements for USA and Other Applicable Countries 53 Conditions to Ensure Compliance with EPA Emission Standards 53 Inspection and Maintenance 53 Installing Sample Port 54 PERIODIC MAINTENANCE SCHEDULE 55 Inspection and Maintenance of EPA Emission Related Parts 58 PERIODIC MAINTENANCE PROCEDURES 59 Daily Checks iere dr rrt 59 After Initial 50 Hours of Operation 60 Every 50 Hours of Operation 65 Every 100 Hours of Operation 67 Every 150 Hours of Operation 67 Every 250 Hours of Operation 68 Every 1000 Hours of Operation 71 75 SAFETY PRECAUTIONS 75 TROUBLESHOOTING AFTER STARTING 75 TROUBLESHOOTING INFORMATION 76 TROUBLESHOOTING CHART 77 LONG TERM STORAGE 79 PREPARE EN
15. KM2P 1 S G or GG API Service Categories CD or higher SAE Viscosity 20 or 30 Sail Drive Oil Specifications SD20 Refer to the Sail Drive Operation Manual for the procedure to fill or replace the sail drive oil SD20 API Service Category GL4 5 SAE Viscosity 90 or 80W90 Checking Marine Gear Oil 054316 00X00 Figure 7 1 Dipstick Filler cap combined type 2 Marine Gear Filler Port 3 Upper Limit 4 Lower Limit Dipstick end BEFORE YOU OPERATE 1 Make sure the engine is off Make sure the engine is as level as possible and wipe area clean around the marine gear filler port Figure 7 2 2 Remove the filler cap at the top of the housing 3 Remove the dipstick Figure 7 1 and wipe with a clean cloth 4 Re insert the dipstick without screw in please see illustration Figure 7 5 Remove the dipstick The oil level should be between the upper Figure 7 3 and lower Figure 7 4 lines on the dipstick 6 Screw in the dipstick Adding Marine Gear Oil 1 Make sure the engine is as level as possible 2 Remove the filler cap at the top of the housing NOTICE Never overfill the marine gear with oil 3 Fill with oil to the upper limit on the dipstick Figure 7 3 See Marine Gear Oil Specifications on page 29 4 Screw the dipstick 5 Hand tighten the filler port cap Checking and Adding Sail Drive Cil Refer to the Sail Drive Operatio
16. Signature YANMAR Series Operation Manual 105 EMISSION SYSTEM WARRANTY Declaration of Conformity for Recreational Craft Propulsion Engine with the Exhaust emission requirements of Directive 94 25 EC as amended by 2003 44 EC To be completed by manufacturer of inboard engines without integral exhaust Name of engine manufacturer Yanmar Co Ltd Street _1 9 Post Code 530 8311 Town Tsuruno cho Kitaku Osaka City Country Japan Name of Authorised Representative Yanmar Co Ltd Marine Operations Division Street 5 3 1 Post Code 661 0001 Town Tsukaguchi Honmachi Amagasaki Hyogo Country Japan Name of Notified Body for exhaust emission assessment Soci t Nationale de Certification et d Homologation Street 11 route de Luxembourg Post Code L 5230 Town Sandweiler Country Luxembourg ID Number 0499 Module used for exhaust emission assessment B C B or engine type approved according to Other Community Directives applied 2004 108 EC L stage II of Directive 97 68 EC L Directive 88 77 EC DESCRIPTION OF ENGINE s AND ESSENTIAL REQUIERMENTS ENGINE S COVERED BY THIS Engine Type Fu
17. YANMAR vM Series Operation Manual 57 PERIODIC MAINTENANCE Inspection and Maintenance of EPA Emission Related Parts Marine diesel engines less than 37 kW 50 hp are certified as EPA Cl marine engine and CARB non road engine Marine diesel engines greater than 37 kW 50hp are certified as EPA Cl marine engines Inspection and Maintenance of EPA Emission Related Parts for Non Road and Cl Marine Engines Parts Interval Clean fuel injection nozzle 1500 hours Check fuel injection nozzle pressure and spray pattern Check fuel injection pump adjustment Check turbocharger adjustment if equipped Check electronic engine control unit and its associated sensors and actuators if equipped 3000 hours Note The inspection and maintenance items shown above are to be performed at your Yanmar Marine dealer or distributor 58 YM Series Operation Manual YANMAR PERIODIC MAINTENANCE PROCEDURES Exposure Hazard Always wear personal protective equipment when performing periodic maintenance procedures Daily Checks Before you head out for the day make sure the Yanmar engine is in good operating condition NOTICE It is important to perform the daily checks as listed in this Operation Manual Periodic maintenance prevents unexpected downtime reduces the number of accidents due to poor engine performance and helps extend the life of the engine Make sure you check the foll
18. Yanmar Marine dealer or distributor with the following information Model name and serial number of your engine Boat model hull material size tons Use type of boating number of hours run Total number of operation hours refer to hourmeter age of boat The operating conditions when the problem occurs Engine speed min Color of exhaust smoke Type of diesel fuel Type of engine oil Any abnormal noises or vibration Operating environment such as high altitude or extreme ambient temperatures etc Engine maintenance history and previous problems Other factors that contribute to the problem 76 YANMAH YM Series Operation Manual TROUBLESHOOTING CHART Symptom Probable Cause TROUBLESHOOTING Measure Reference Indicators light on the instrument panel and alarm sounds during operation Shift to low speed operation immediately and check which indicator has come on Stop the engine and inspect If no abnormality is to port at lowest speed and consult authorized Yanmar Marine dealer or identified and there is no problem with operation return distributor Engine oil low pressure alarm indicator lights Engine oil level is low Check engine oil level Add or replace as necessary See Checking the Engine Oil on page 32 Engine oil filter is clogged Replace engine oil filter Replace engine oil See Changing the Engine Oil on page 61 Water in sail driv
19. affect the warranty coverage on your engine Consult authorized Yanmar Marine dealer or distributor for assistance when checking items marked with a e PERIODIC MAINTENANCE YANMAR Series Operation Manual 55 PERIODIC MAINTENANCE O Check or Clean O Replace 6 Contact your authorized Yanmar Marine dealer or distributor Periodic Maintenance Interval Every Every Before 100 150 Starting hours hours See Initial or six or one Daily 50 monthly months year Checks Hours which which which on ever ever ever page 59 comes comes comes first first first Visual inspection of engine exterior Check the fuel level and refill if necessary Drain water and sediment from the fuel tank Drain the fuel water separator Replace the fuel filter element Check the fuel injection timing Check the fuel injector spray pattern Lubricatin g System Check the Engine engine oil Marine level Gear Replace the Engine engine oil Marine Gear Sail Drive Replace the Engine oil filter element Cooling System Seawater outlet O During Operatio n Check coolant level Check or replace the seawater pump impeller Replace coolant Every year When Long Life Coolant LLC is used replace every two years See Engine Coolant Specifications on page 34 Clean and check the seawater pa
20. an electrical fire y Store any containers containing fuel or other flammable products in a well ventilated area away from any combustibles or source of ignition Store any equipment in a designated area away from moving parts Never use the engine compartment for storage YANMAH YM Series Operation Manual Sever Hazard L Rotating parts can cause le severe injury or death Never wear jewelry unbuttoned cuffs ties or loose fitting clothing and always tie long hair back when working near moving rotating parts such as the flywheel or PTO shaft Keep hands feet and tools away from all moving parts Alcohol and Drug Hazard Exposure Hazard fy 3 amp including appropriate clothing gloves work shoes and eye and hearing protection as required by the task at hand Never operate the engine while under the influence of alcohol or drugs or when feeling ill Always wear personal protective equipment 924630 Sudden Movement Hazard Never operate the engine while wearing a headset to listen to music or radio because it will be difficult to hear the warning signals Burn Hazard Some of the engine surfaces become very hot il Gi during operation and mam shortly after shutdown Keep hands and other body parts away from hot engine surfaces SAFETY Exhaust Hazard Never block windows vents or other means of a ventilation if the engine is operating in an enclosed area All internal
21. combustion engines create carbon monoxide gas during operation and special precautions are required to avoid carbon monoxide poisoning YANMAR Series Operation Manual SAFETY The safety messages that follow have CAUTION level hazards Poor Lighting Hazard Ensure that the work area is adequately illuminated Always install wire cages on portable safety lamps Tool Hazard Always use tools appropriate for the task at hand and use the correct size tool for loosening or tightening machine parts Flying Object Hazard Always wear eye protection when servicing the engine or when using compressed air or high pressure water Dust flying debris compressed air pressurized water or steam may injure your eyes Coolant Hazard Wear eye protection and e b rubber gloves when you handle engine coolant If contact with the eyes or skin should occur flush eyes and wash immediately with clean water NOTICE The safety messages that follow have NOTICE level hazards It is important to perform daily checks as listed in the Operation Manual Periodic maintenance prevents unexpected downtime reduces the number of accidents due to poor engine performance and helps extend the life of the engine Consult authorized Yanmar Marine dealer or distributor if you need to operate the engine at high altitudes At high altitudes the engine will lose power run rough and produce exhaust gases that exceed the design specif
22. during engine operation Pay particular attention to the following Is sufficient seawater being discharged from the exhaust and seawater outlet If the discharge is small stop the engine immediately identify the cause and repair Is the smoke color normal The continuous emission of black smoke indicates engine overloading This shortens the engines life and should be avoided Are there abnormal vibrations or noise ENGINE OPERATION NOTICE Excessive vibration may cause damage to the engine marine gear hull and onboard equipment In addition it causes able passenger and crew discomfort 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 stop the engine and inspect Alarm buzzer sounds during operation NOTICE If any alarm indicator with audible alarm sound appears on the display during engine operation stop the engine immediately Determine the cause and repair the problem before you continue to operate the engine Is there water oil or fuel leakage or are there any loose bolts Check the engine room periodically for any problems Is there sufficient diesel fuel in the diesel fuel tank Replenish diesel fuel before leaving the dock to avoid running out of fuel during operation When operating the engine at low speed for long
23. engine time 30 minutes out of every 10 hours and cruising speed 3400 min or less The laws of some countries may require hull and engine inspections depending on the use size and cruising area of the boat The installation fitting and surveying of this engine all require specialized knowledge and engineering skills See Yanmars local subsidiary in your region or your authorized Yanmar Marine dealer or distributor YANMAR Seres Operation Manual 11 PRODUCT OVERVIEW New Engine Break In As with all reciprocating engines the way your engine is operated during its first 50 hours of operation plays a very significant role in determining how long it will last and how well the engine will perform over its lifetime A new Yanmar diesel engine must be operated at suitable speeds and power settings during the break in period to make the sliding parts such as piston rings break in properly and to stabilize engine combustion During the break in period the engine coolant temperature gauge should be monitored temperature should be between 71 and 87 C 160 and 190 F During the first 10 hours of operation the engine should be run at maximum engine speed minus 400 to 500 min approximately 60 to 7096 of load most of the time This will ensure the sliding parts break in properly During this period avoid operating at maximum engine speed and load to avoid damaging or scoring sliding parts NOTICE Do n
24. failed due to abuse neglect improper maintenance or unapproved modifications Your engine is designed to operate on diesel fuel only Use of any other fuel may result in your engine no longer operating in compliance with applicable emissions requirements You are responsible for initiating the warranty process You must present your engine to a Yanmar dealer as soon as a problem exists The warranty repairs should be completed by the dealer as expeditiously as possible Customer Assistance If you have any questions regarding your warranty rights and responsibilities or would like information on the nearest authorized Yanmar dealer or distributor you should contact Yanmar America Corporation for assistance EMISSION SYSTEM WARRANTY Yanmar America Corporation Marine Engine Division 101 International Parkway Adairsville GA 30103 USA Telephone 770 877 9894 Fax 770 877 7567 Website us yanmar com E mail CS support yanmar com Toll Free Telephone Numbers 1 855 416 7091 1 800 872 2867 YANMAR Series Operation Manual 103 EMISSION SYSTEM WARRANTY Maintenance Log Date Operating Hours Maintenance Performed Dealer Name Stamp or Signature 104 YM Series Operation Manual YANMAR Operating Hours EMISSION SYSTEM WARRANTY Maintenance Performed Dealer Name Stamp or
25. for cause Alarm sounds during operation If the alarm sounds during operation lower the engine speed immediately check the warning lamps and stop the engine for repairs YANMAR Seres Operation Manual 75 TROUBLESHOOTING Is there water oil or fuel leakage Are there any loose bolts or connections Check the engine room daily for any leaks or loose connections Is there sufficient fuel in the fuel tank Refill fuel in advance to avoid running out of fuel If the tank runs out of fuel bleed the fuel system See Bleeding the Fuel System on page 30 When operating the engine at low speed for long periods of time race the engine once every 2 hours Racing the engine with the clutch in NEUTRAL accelerate from the low speed position to the high speed position and repeat this process about five times This is done to clean out carbon from the cylinders and the fuel injection valves NOTICE Neglecting to race the engine will result in poor smoke color and reduce engine performance Periodically operate the engine near maximum speed while underway This will generate higher exhaust temperatures which will help clean out hard carbon deposits maintain engine performance and prolong the life of the engine TROUBLESHOOTING INFORMATION If the engine does not operate properly refer to the Troubleshooting Chart on page 77 or consult authorized Yanmar Marine dealer or distributor Supply the authorized
26. go to the next screen ENGINE Confirm that the display says ENGINE Press the right button and amp oes appears Note The pre set value of speed pulse is indicated on the box of each panel Engine type select Next press the left button and select E pulse value for each engine ENGINE p P egy Up Wwe Engine model Speed pulse value YM with HITACHI 10 29 B alternator Scroll YM with VALEO v alternator 12 10 G After confirming the value is changed ENGINE lt P le 10 correctly press the right button to E amp E return to the ENGINE screen 2 m Press the left button again to go from the ENGINE screen to the EXIT v Select screen Exit setup B After confirming the display press the right button to re start the panel and VTT return to the hourmeter display Ae iy Return to LCD control 043719 02EN03 gt Figure 12 YANMAR Series Operation Manual 21 PRODUCT OVERVIEW Alarms Checking the Warning Devices Before and after engine start make sure that the instruments and warning devices operate correctly If the engine runs out of coolant or lubricating oil and the instruments and warning devices fail they can not give you warning to prevent accidents This can also lead to incorrect operation and cause further malfunctions of the engine Before Engine Sta
27. lamps 3 LCD 2 Tachometer 4 Switches push buttons Control panel switches All switches are push buttons Start switch Glow switch Pushing this switch operates Pushing this switch for the the starter and starts the specified time heats the glow engine plug in the combustion chamber It becomes red hot facilitating fuel ignition This assists starting in cold weather Power switch Stop switch Pushing this switch turns on or Pushing this switch stops the off the power engine 042567 00X00 042565 00X00 18 YM Series Operation Manual YANMAR Meters PRODUCT OVERVIEW Instrument Function Tachometer Shows engine rotation speed Hourmeter Shows number of operating hours Can be used as a guide for periodic maintenance checks The hourmeter is located at the bottom of the tachometer Panel Lights When the power switch is pushed the gauges will illuminate for easier viewing Note The LCD on the instrument panel show hourmeter display brightness and battery voltage Indicators and Alarms Optional When a sensor detects a problem during operation the indicator on the instrument panel will light and an alarm will sound Indicators are located on the instrument panel and the alarms are located on the back of the panel Under normal operating conditions the indicators are off Battery Low Charge Indicator When the alternator output is too low the indicator will l
28. matter and the emission of greenhouse gases compared to standard diesel fuel If the B7 biodiesel fuel used does not meet the approved specifications it will cause abnormal wear of injectors reduce the life of the engine and it may affect the warranty coverage of your engine B7 diesel fuels must meet certain specifications The biodiesel fuels must meet the minimum specifications for the country in which they are used In Europe biodiesel fuels must comply with the European Standard EN590 2009 EN14214 In the United States biodiesel fuels must comply with the American Standard ASTM D6751 Grade S15 D7467 Grade B7 S15 Biodiesel should be purchased only from recognized and authorized diesel fuel suppliers Precautions and concerns regarding the use of biofuels Biodiesel fuels have a higher content of methyl esters which may deteriorate certain metal rubber and plastic components of the fuel system The customer and or boat builder are responsible to verify the usage of biodiesel compatible components on the vessel fuel supply and return systems Free water in biodiesel may result in plugging of fuel filters and increased bacterial growth High viscosity at low temperatures may result in fuel delivery problems injection pump seizures and poor injection nozzle spray atomization Biodiesel may have adverse effects on some elastomers seal materials and may result in fuel leakage and dilution of the e
29. off Figure 13 Refer to the Wiring Diagrams on page 94 The maximum current of this output terminal is 3 A Do not use a current higher than 3 A For the content of the output terminal refer to the Wiring Diagrams on page 94 043801 00E00 Figure 13 YANMAR Series Operation Manual 23 PRODUCT OVERVIEW Single Handle Remote Control Head 0004504 Figure 14 Note Direction of travel will vary depending on installation location 1 Low Speed FWD or REV 2 Low Speed FWD or REV 3 NEUTRAL Power to the propeller shaft is cut off and the engine idles 4 Maximum Engine Speed FWD or REV 5 Maximum Engine Speed FWD or REV A single handle type Figure 14 should be used to operate the marine gear clutch NEUTRAL FORWARD and REVERSE and to control the engine speed The handle controls the direction of the boat ahead or astern and also acts as an accelerator by increasing engine speed as the control handle is pushed further in FORWARD or REVERSE directions When the handle is pulled out Figure 15 1 the engine speed can be controlled without engaging the marine gear The marine gear remains in NEUTRAL no load position Turn the knob Figure 15 2 counterclockwise to move the handle or clockwise to lock the handle 0004511 Figure 15 Note Yanmar recommends the use of a single handle type for the remote control system If only a two handle type is available in t
30. operating at high speed or not pushing the handle fully into position partial engagement will result in damage to marine gear parts and abnormal wear 1 Before using the marine gear be sure to move the throttle handle to a low idle position less than 1000 min 1 Move the throttle handle slowly to a higher speed position after completing marine gear engagement 2 When moving the handle between FORWARD Figure 2 1 or 3 and REVERSE Figure 2 3 or 1 bring the handle to NEUTRAL Figure 2 2 and pause before slowly shifting to the desired position Never shift abruptly from FORWARD to REVERSE or vice versa NOTICE Never shift the marine gear at high engine speed During normal operation the marine gear should only be shifted with the engine at idle When sailing set the remote control handle in NEUTRAL Not doing so WILL introduce slippage or any damage and void your warranty 44 YANMAH YM Series Operation Manual CAUTIONS DURING OPERATION NOTICE Engine trouble can arise if the engine is operated for a long time under overloaded conditions with the control handle in the full throttle position maximum engine speed position exceeding the continuous rated output engine speed Operate the engine at about 100 min lower than the full throttle engine speed Note If the engine is in the first 50 hours of operation see New Engine Break In on page 12 Always be on the lookout for problems
31. standard values during the warranty period The warranty period is determined by the age of the engine or the number of hours of operation YANMAR vM Series Operation Manual 53 PERIODIC MAINTENANCE Installing Sample Port All engines subject to emission standards shall be equipped with a connection in the engine exhaust system that is located downstream of the engine and before any point at which the exhaust contacts water or any other cooling scrubbing medium for the temporary attachment of gaseous and or particulate emissions sampling equipment This connection shall be internally threaded with standard pipe threads of a size not larger than 12 7 mm 0 5 in and shall be closed by a pipe plug when not in use Equivalent connections are allowed The instructions for the proper installation and location of the required sample port in addition to those specified above in the quoted federal regulation are as follows 1 The connection should be located as far downstream as reasonably practicable from any sharp bend of 30 degrees or more in the exhaust pipe to help ensure that a well mixed exhaust flow sample may be taken 2 The requirement that the connection be located before any point at which the exhaust contacts water or any other cooling scrubbing medium does not include contact with water used to cool exhaust manifolds unless the water is allowed to come into direct contact with the exhaust gases
32. when the remote control lever is moved to H high speed and L low speed respectively 2 When there is deviation loosen the bracket for the remote control cable on the engine side and adjust 3 Adjust the high speed stop position first and then adjust the low speed idling using the adjustment bolt on the remote control lever Adjusting Clutch Remote Control Cable 0004799 Figure 5 1 Marine Gear 2 Control Cable 3 Control Lever 4 Bracket cable 1 Check that the control lever Figure 5 3 moves to the correct position when the remote control cable handle is moved to the NEUTRAL FORWARD and REVERSE positions 2 Use the NEUTRAL position as the standard for adjustment When there is deviation loosen the bracket Figure 5 4 for the remote control cable on the clutch side and adjust The flexible engine mounts are compressed slightly during initial engine operation and may cause misalignment between the engine and the propeller shaft After the first 50 hours of operation the alignment should be checked and readjusted if necessary This is considered normal maintenance and the adjustment requires specialized knowledge and techniques Consult your authorized Yanmar Marine dealer or distributor 64 YANMAH YM Series Operation Manual Every 50 Hours of Operation When completing the initial 50 hour maintenance procedures perform the following procedures every 50 hours thereafter or m
33. 18 2 in Overall Height 545 mm 21 5 in Engine Dry Mass Including Marine Gear 133 kg 293 Ib 157 kg 346 Ib Rating Condition Temperature of fuel 40 C at fuel pump inlet ISO 8665 The total oil quantity includes oil in oil pan channels coolers and filter The effective amount of oil shows the difference in maximum scale of the dipstick and minimum scale Note Density of fuel 0 842 g cm3 at 15 C Fuel temperature at the inlet of the fuel injection pump 1hp metric 0 7355 kw YANMAR Series Operation Manual 87 SPECIFICATIONS Marine Gear and Sail Drive Specifications KM2P 1 S KM2P 1 G KM2P 1 GG SD20 coupled at boat builder Type Mechanical cone clutch Dog Clutch Reduction Ratio Forward Reverse 2 21 3 06 2 62 3 06 3 22 3 06 2 64 2 64 Propeller Speed Forward Reverse 1580 1140 min 1 1332 1140 min 1083 1140 min 1 1322 1322 min 1 Lubrication System Splash Oil bath Lubricating Oil Capacity Total 0 3 L 0 32 qt 2 2 L 2 3 at Standard 2 5 L 2 6 at Long Reach Lubricating Oil Capacity Effective 0 05 L 0 05 qt 0 15 L 0 16 qt Cooling System Air cooling by fan on flywheel Weight 10 3 kg 27 7 Ib At continuous power engine speed 3489 min 1 30 kg 66 1 Ib 88 YM Series Operation Manual YANMAR SYSTEM DIAGRAM
34. BEFORE YOU OPERATE PAH polycyclic aromatic hydrocarbons content should be below 1096 by volume Do not use Biocide Handling of Diesel Fuel Fire and Explosion Hazard Only fill the fuel tank with diesel fuel Filling the fuel tank with gasoline may result in a fire and will damage the engine Never refuel with the engine running Wipe up all spills immediately Keep sparks open flames or any other form of ignition match cigarette static electric source well away when refueling Fire and Explosion Hazard Always put the diesel fuel container on the ground when transferring the diesel fuel from the pump to the container Hold the hose nozzle firmly against the side of the container while filling it This prevents static electricity buildup which could cause sparks and ignite fuel vapors 1 Water and dust in the fuel may cause engine failure When fuel is stored be sure that the inside of the storage container is clean and dry and that the fuel is stored away from dirt or rain YANMAR Series Operation Manual 27 BEFORE YOU OPERATE The fuel outlet should be positioned 20 to 30 mm 0 75 to 1 125 in above the bottom of the tank so that only clean fuel is distributed to the engine Fuel System 0004512 Figure 1 2 Keep the fuel container stationary for several hours to allow any dirt or water to settle to the bottom of the container Use a pump to extract the clear filtered 0004788
35. Combustion System Swirl pre combustion chamber Air Charging Natural aspiration Number of Cylinders 3 Bore x Stroke 70 mm x 74 mm 2 76 in x 2 91 in Displacement 0 854 L 52 1 cu in Continuous Power Output at Crankshaft Engine Speed 13 9 kW 18 9 hp metric 3489 min Fuel Stop Power Output at Crankshaft Engine Speed 15 3 kW 20 8 hp metric 3600 min 1 Output at Propeller Engine Speed 14 9 kW 20 1 hp metric 3600 1 Installation Flexible mounting Fuel Injection Timing FID 22 1 BTDC Fuel Injection Opening Pressure 12 8 to 13 28 MPa Main Power Take Off At flywheel end Direction of Rotation Crankshaft Counterclockwise viewed from stern Propeller Shaft Ahead Clockwise viewed from stern Cooling System Coolant cooling with heat exchanger Lubrication System Forced lubrication system Coolant Capacity Engine 4 1 L 4 33 qt Reservoir 0 8 L 0 85 qt Lubricating Oil Capacity Engine Rake Angle at rake angle 8 at rake angle 0 Total 2 7 L 2 85 qt 2 4L 2 54 qt Effective 1 4 L 1 48 qt 1 5 L 1 59 qt Starting System Type Electric Starting Motor DC 12 V 1 4 kW AC Alternator 12 V 120A Engine Dimension Overall Length 693 mm 27 3 in Overall Width 463 mm 18 2 in Overall Height
36. Crankshaft Counterclockwise viewed from stern Rotation Propeller Shaft Ahead Clockwise viewed from stern Cooling System Coolant cooling with heat exchanger Lubrication System Forced lubrication system Coolant Capacity Engine 4 9 L 5 2 qt Reservoir 0 8 L 0 85 qt Lubricating Rake Angle at rake angle 8 at rake angle 0 Oil Capacity Total 2 8 L 2 96 qt 2 5 L 2 64 qt Engine Effective 1 4L 1 48 qt 1 5 L 1 59 qt Starting Type Electric System Starting Motor DC 12 V 1 4 kW AC Alternator 12V 120A Engine Overall Length 715 mm 28 1 in Dimension Overall Width 463 mm 18 2 in Overall Height 545 mm 21 5 in Engine Dry Mass Including Marine Gear 133 kg 293 Ib 157 kg 346 Ib Rating Condition Temperature of fuel 40 C at fuel pump inlet ISO 8665 The total oil quantity includes oil in oil pan channels coolers and filter The effective amount of oil shows the difference in maximum scale of the dipstick and minimum scale Note Density of fuel 0 842 g cm at 15 C Fuel temperature at the inlet of the fuel injection pump 1hp metric 2 0 7355 kW 86 YM Series Operation Manual YANMAH 3YM30 Engine Specifications Specification SPECIFICATIONS 3YM30 Marine Gear Model KM2P 1 SD 20 Use Pleasure use Type Vertical water cooled 4 cycle die
37. Every 150 Hours of Operation Perform the following maintenance every 100 hours or every 6 months of operation whichever comes first Changing the Sail Drive Gear Oil Changing the Sail Drive Gear Oil Refer to the Sail Drive Operation Manual for the procedure for changing gear oil Perform the following maintenance every 150 hours or every year of operation whichever comes first Changing the Engine Oil Changing the Engine Oil See Changing the Engine Oil on page 61 YANMAR Series Operation Manual 67 PERIODIC MAINTENANCE Every 250 Hours of Operation Perform the following maintenance every 250 hours or 1 year of operation whichever comes first Draining the Fuel Tank Replacing the Fuel Filter Element Replacing the Engine Oil Filter Element Changing the Marine Gear Oil Checking or Replacing the Seawater Pump Impeller Replacing the Coolant Cleaning the Intake Silencer Air Cleaner Element Cleaning or Replacing the Exhaust Water Mixing Elbow Adjusting the Alternator V ribbed belt Tension Cleaning the Breather Pipe Checking the Wiring Connectors Draining the Fuel Tank See Draining the Fuel Tank on page 61 Replacing the Fuel Filter Element Fire and Explosion Hazard When removing any fuel system component to perform maintenance such as changing the fuel filter put an approved container under the opening to catch the fuel Never use a shop rag to catch the fuel V
38. GINE FOR LONG TERM STORAGE 79 DRAIN SEAWATER COOLING SYSTEM 80 YANMAR Series Operation Manual TABLE OF CONTENTS SPECIFICATIONS sse 83 PRINCIPAL ENGINE SPECIFICATIONS 83 2YM15 Engine Specifications 84 3YM20 Engine Specifications 85 3YMSOE Engine Specifications 86 3YM30 Engine Specifications 87 Marine Gear and Sail Drive Specifications 88 SYSTEM DIAGRAMS sss 89 PIPING DIAGRAMS 89 WIRING DIAGRAMS sees 94 EPA WARRANTY USA ONLY 97 YANMAR CO LTD LIMITED EMISSION CONTROL SYSTEM WARRANTY USA ONLY 97 Your Warranty Rights and Obligations 98 Warranty Period iscsi ee iie 98 Warranty Coverage 99 EXC USIOTIS iust eot t reed 99 Owner s Responsibility 99 Customer Assistance 99 EMISSION SYSTEM 101 NON ROAD EMISSION SYSTEM WARRANTY 101 Yanmar Co Ltd Limited Emission Control System Warranty USA Only 101 Maintenance 0 104 YM Series Operation Manual YANMAR IN
39. It is recommended that the engine be as level as possible before checking the oil NOTICE Prevent dirt and debris from contaminating engine oil Carefully clean the dipstick filler port cap and the surrounding area before you remove the cap 2 Remove the dipstick Figure 6 3 and wipe with a clean cloth 3 Fully reinsert dipstick A Remove the dipstick The oil level should be between upper Figure 6 4 and lower Figure 6 5 lines on the dipstick Add oil if necessary See Adding Engine Oil on page 32 6 Fully reinsert dipstick Adding Engine Oil 1 Remove the yellow oil filler port cap from the filler port Figure 6 1 on the rocker arm cover Figure 6 1 and fill with engine oil NOTICE Prevent dirt and debris from contaminating engine oil Carefully clean the dipstick filler port cap and the surrounding area before you remove the cap N Fill with engine oil to the upper limit Figure 6 4 on the dipstick Figure 6 3 NOTICE Never overfill the engine with engine oil 3 Insert the dipstick fully to check the level NOTICE Always keep the oil level between upper and lower lines on the oil cap dipstick 4 Hand tighten the filler port cap securely 32 YANMAR YM Series Operation Manual MARINE GEAR OR SAIL DRIVE OIL Marine Gear Oil Specifications Use marine gear oil that meets or exceeds the following guidelines and classifications
40. Nozzle i 17 Oil Pressure Switch 18 Mixing Elbow 19 17 14 Rubber Hose 20 Heat Exchanger E 21 Engine Oil Inlet Filter 22 Main Bearing Xo gan 23 Seawater Inlet 24 17 x t4 Rubber Hose 25 Seawater Pump 26 28 x 14 Rubber Hose 27 28 x t4 Rubber Hose 28 Hot Water Connection Outlet R3 8 29 Thermostat 30 Coolant Pump 31 Hot Water Connection Inlet R3 8 32 Coolant Temperature Switch 33 Engine Oil Pump 34 Pressure Control Valve 35 Diesel Fuel 36 To Oil Pan 37 To Camshaft 38 From Cylinder Head YANMAR Series Operation Manual 91 SYSTEM DIAGRAMS 3YM20 and 3YM30 E with KM2P 1 Marine Gear 23 D hb wr GeF 8 14 026476 00X Figure 2 92 YM Series Operation Manual YANMAR SYSTEM DIAGRAMS Unit mm in 1 PCV 2 Overflow Detail of part A Detail of part B 3 Fuel Inlet 4 Fuel Feed Pump 5 Fuel Injection Pump 6 Engine Oil Filter cartridge type Fuel High Pressure Pipe 8 Fuel Injection Nozzle 9 Oil Pressure Switch med 10 Mixing Elbow 11 Heat Exchanger Detail of part C Detail of part D 12 Engine Oil Inlet Filter 13 Main Bearing 9 0 35 98 5 0 33 14 Seawater Inlet i 0 31 15 Seawater 28 0 31 16 Hot Water Connecti
41. RODUCTION neret et retentis 1 YM SERIES EMISSION CONTROL SYSTEM WARRANTY USA THE ENVIRONMENTAL PROTECTION AGENCY EPA ONLY 2 RECORD OF OWNERSHIP 3 SAFETY uuu etui ete tereti eh 5 SAFETY PRECAUTIONS 6 General 6 Before You 6 During Operation and Maintenance 6 LOCATION OF SAFETY DECALS 10 PRODUCT OVERVIEW 11 YANMAR YM SERIES FEATURES AND APPLICATIONS u nuna u 11 New Engine Break In 12 COMPONENT 13 Right Side Viewed from Flywheel 2YM15 13 Left Side Viewed from Flywheel 2YM15 13 Right Side Viewed from Flywheel 3YM20 14 Left Side Viewed from Flywheel 3YM20 14 Right Side Viewed from Flywheel 3YM30 E 15 Left Side Viewed from Flywheel 3YM30 E 15 NAMEPEATES 16 FUNCTION OF MAJOR COMPONENTS 17 CONTROL EQUIPMENT 18 Instrument Panel 18 Single Handle Remote Control Head 24 YANMAR Seres Operation Manual TABLE OF
42. S PIPING DIAGRAMS Piping diagrams and wiring diagrams are provided for reference only Contact your authorized Yanmar Marine dealer or distributor for the most current diagrams Notation Description Screw Joint Union Flange Joint Eye Joint Insertion Joint Drilled Hole Coolant Piping Seawater Piping Engine Oil Piping Diesel Fuel Piping Notes 1 Steel pipe shows OD x wall thickness rubber hose shows ID x wall thickness 2 Rubber fuel lines meet EN ISO7840 3 Unit mm YANMAR Series Operation Manual 89 SYSTEM DIAGRAMS 2YM15 with KM2P 1 Marine Gear wi P 2 22 21 20 19 18 26 25 24 A 23 026475 00X Figure 1 90 YM Series Operation Manual YANMAR SYSTEM DIAGRAMS Unit mm in 1 7 8 x t4 5 Rubber Hose 2 Check Valve Detail of part A Detail of part B 3 7 8 x 14 5 Rubber Hose 4 7 8 x 14 5 Rubber Hose 5 Overflow 6 Fuel Inlet 7 8 x 14 5 Rubber Hose 8 5 x t4 5 Rubber Hose IUE 9 7 8 x t4 5 Rubber Hose 10 Fuel Feel Pump X00 035620 11 Fuel Injection Pump 12 4 76 x t0 7 Steel Pipe Detail of part C Detail of part D 13 E Oil Filter cartridge ype 9 0 35 98 5 0 33 14 4 76 x t0 7 Steel Pipe I 28 0 31 15 Fuel High Pressure Pipe 28 0 31 16 Fuel Injection
43. System Positive Crankcase Ventilation System Since emissions related parts may vary slightly between models certain models may not contain all of these parts and other models may contain the functional equivalents Exclusions Failures other than those arising from defects in material and or workmanship are not covered by this warranty The warranty does not extend to the following malfunctions caused by abuse misuse improper adjustment modification alteration tampering disconnection improper or inadequate maintenance or use of non recommended fuels and lubricating oils accident caused damage and replacement of expendable items made in connection with scheduled maintenance Yanmar disclaims any responsibility for incidental or consequential damages such as loss of time inconvenience loss of use of equipment engine or commercial loss 102 YANMAH YM Series Operation Manual Owners Warranty Responsibilities As the engine owner you are responsible for the performance of the required maintenance listed in your owner s manual Yanmar recommends that you retain all documentation including receipts covering maintenance on your non road compression ignition engine but Yanmar cannot deny warranty solely for the lack of receipts or for your failure to ensure the performance of all scheduled maintenance Yanmar may deny your warranty coverage of your non road compression ignition engine if a part has
44. TRODUCTION Welcome to the world of Yanmar Marine Yanmar Marine offers engines drive systems and accessories for all types of boats from runabouts to sailboats and from cruisers to mega yachts In marine leisure boating the worldwide reputation of Yanmar Marine is second to none We design our engines to respect nature This means quieter engines with minimal vibrations cleaner than ever All of our engines meet applicable regulations including emissions at the time of manufacture To help you enjoy your Yanmar YM series engine for many years to come please follow these recommendations Read and understand this Operation Manual before you operate the machine to ensure that you follow safe operating practices and maintenance procedures Keep this Operation Manual in a convenient place for easy access If this Operation Manual is lost or damaged order a new one from your authorized Yanmar Marine dealer or distributor Make sure this manual is transferred to subsequent owners This manual should be considered a permanent part of the engine and remain with it 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 these differences please contact your authorized Yanmar Marine dealer or distributor The specifications and components instrument panel fuel tank e
45. TY Warranty Coverage This warranty is transferable to each subsequent purchaser for the duration of the warranty period Repair or replacement of any warranted part will be performed at an authorized Yanmar Marine engine dealer or distributor Warranted parts not scheduled for replacement as required maintenance in the Operation Manual shall be warranted for the warranty period Warranted parts scheduled for replacement as required maintenance in the operation manual are warranted for the period of time prior to the first scheduled replacement Any part repaired or replaced under warranty shall be warranted for the remaining warranty period During the warranty period Yanmar is liable for damages to other engine components caused by the failure of any warranted part during the warranty period Any replacement part which is functionally identical to the original equipment part in all respects may be used in the maintenance or repair of your engine and shall not reduce Yanmar s warranty obligations Add on or modified parts that are not exempted may not be used The use of any non exempted add on or modified parts shall be grounds for disallowing a warranty Warranted Parts This warranty covers engine components that are a part of the emission control system of the engine as delivered by Yanmar to the original retail purchaser Such components may include the following Fuel Injection System Cold Start Enrichment
46. YANMAR OPERATION MANUAL MARINE ENGINES California California Proposition 65 Warning Proposition 65 Warning Diesel engine exhaust and some of its Battery posts terminals and related constituents are known to the state of accessories contain lead and lead California to cause cancer birth compounds chemicals known to the reproductive harm Wash hands after handling Disclaimers All information illustrations and specifications in this manual are based on the latest information available at the time of publishing The illustrations used in this manual are intended as representative reference views only Moreover because of our continuous product improvement policy we may modify information illustrations and or specifications to explain and or exemplify a product service or maintenance improvement We reserve the right to make any change at any time without notice Yanmar and YANMAR are registered trademarks of YANMAR CO LTD in Japan the United States and or other countries All Rights Reserved No part of this publication may be reproduced or used in any form by any means graphic electronic or mechanical including photocopying recording taping or information storage and retrieval systems without the written permission of YANMAR CO LTD MODEL 2YM15 3YM20 3YM30E 3YM30 CODE OAYMM G00202 All Rights Reserved Copyright YANMAR CO LTD OPERATION MANUAL TABLE OF CONTENTS INT
47. apors from the rag are flammable and explosive Wipe up any spills immediately Exposure Hazard Wear eye protection The fuel system is under pressure and fuel could spray out when removing any fuel system component 0004804 Figure 8 1 Housing 2 Retaining Ring 68 YANMAH YM Series Operation Manual When there is dirt in the fuel the filter becomes clogged and the fuel will not flow easily Check and replace the element 1 Close the fuel cock of the fuel tank 2 Place an approved container under the fuel filter 3 Remove the filter case by loosening the retaining ring Figure 8 2 Turn the ring counterclockwise using a filter wrench 4 Remove the housing Figure 8 1 and remove the element Replace the element with a new one 5 Apply a thin film of clean diesel fuel to the sealing surface of the new filter gasket 6 Clean the inside of the housing thoroughly install the O ring and hand tighten the retainer ring Use a filter wrench and tighten to 12 N m 106 in Ib 7 Air will enter the fuel system when the filter is disassembled Bleed the fuel system to remove any air from the system See Bleeding the Fuel System on page 30 8 Dispose of waste properly Replacing the Engine Oil Filter Element See Replacing the Engine Oil Filter Element on page 62 Changing the Marine Gear Oil See Changing the Marine Gear Oil on page 62 Checking
48. ar 2000 or later off road compression ignition engines must be designed built and equipped to meet the State s stringent anti smog standards In all states 1998 and later non road compression ignition engines must be designed built and equipped to meet the United States EPA emissions standards Yanmar warrants the emission control system on your engine for the periods of time listed below provided there has been no abuse neglect or improper maintenance of your engine Your emission control system may include parts such as the fuel injection system and the air induction system Where a warrantable condition exists Yanmar will repair your non road compression ignition engine at no charge to you including diagnosis parts and labor Manufacturer s Warranty Period The model year 1998 or later certified and labeled non road compression ignition engines are warranted for the periods listed below If any emission related part on your engine is found to be defective during the applicable warranty period the part will be replaced by Yanmar Engine Model Warranty Period 30 months or 1 500 hours of use whichever comes first 42 months or 2 500 hours of use whichever comes first 2YM15 3YM20 kW lt 19 3YM30E 19 lt kW lt 37 When a measurement device of use hours is not equipped warranties apply a period of use months YANMAR Seres Operation Manual 101 EMISSION SYSTEM WARRAN
49. arter motor damage will occur Note Push and hold the start switch for a maximum of 15 seconds If the engine does not start the first time wait for about 15 seconds before trying again NOTICE If the vessel is equipped with a water lift water lock muffler excessive cranking could cause seawater to enter the cylinders and damage the engine If the engine does not start after cranking for 15 seconds close the thru hull water intake valve to avoid filling the muffler with water Crank for 10 seconds at a time until the engine starts When the engine does start stop the engine immediately and turn off the power switch Be sure to re open the seacock and restart the engine Operate the engine normally Air Bleeding the Fuel System After Starting Failure If the engine does not start after several attempts there may be air in the fuel system If air is in the fuel system fuel cannot reach the fuel injection pump Bleed the air out of the system See Bleeding the Fuel System on page 30 Starting at Low Temperatures Comply with local environmental requirements Use engine heaters to avoid starting problems and white smoke Do not use starting aids NOTICE Never use an engine starting aid such as ether Engine damage will result To limit white smoke run the engine at low speed and under moderate load until the engine reaches normal operating temperature A light load on a cold engine provides better combustion and
50. ary to lift the marine engine and marine gear together Always use lifting equipment with sufficient capacity to lift the marine engine YANMAR Seres Operation Manual 49 PERIODIC MAINTENANCE Welding Hazard Always turn off the battery switch if equipped or disconnect the negative battery cable and the leads to the alternator when welding on the equipment Remove the engine control unit multi pin connector Connect the weld clamp to the component to be welded and as close as possible to the welding point Never connect the weld clamp to the engine or in a manner which would allow current to pass through a mounting bracket When welding is completed reconnect the alternator and engine control unit prior to reconnecting the batteries Entanglement Hazard Never leave the power switch on when you are at servicing the engine someone may accidentally start the engine and not realize you are servicing it W Always keep the electrical connectors and terminals clean Check the electrical harnesses for cracks abrasions and damaged or corroded connectors Shock Hazard Always turn off the battery switch if equipped or disconnect the negative battery cable before servicing the equipment Never use undersized wiring for the electrical system Tool Hazard Always remove any tools or shop rags used during maintenance from the area before operation NOTICE Any part whic
51. cap vacuum valve then opens to send water back from the reservoir This minimizes coolant consumption The closed cooling system coolant level can easily be checked and refilled in this tank Engine Oil Cooler A heat exchanger that cools high temperature engine oil using coolant Intake Silencer Air Cleaner The intake silencer guards against dirt in the air and reduces the noise of air intake Nameplates Nameplates are provided on the engine and the marine gear and have the model serial number and other data See Nameplates on page 16 Starter Starter motor for the engine powered by the battery Alternator Driven by a belt and generates electricity and charges the battery Engine Oil Dipstick Gauge stick for checking the engine oil level YANMAR Series Operation Manual 17 PRODUCT OVERVIEW CONTROL EQUIPMENT The equipment in the control room makes remote control operation possible It consists of the instrument panel which is connected to the engine by a wire harness and the remote control handle which is connected by control cables to the engine control lever and marine gear Instrument Panel Equipment and Functions The instrument panel is located at the helm The following instruments enable you to start or stop the engine and to monitor its condition during operation B20 Type 4 Figure 10 1 Alarm
52. e engine is being operated See Engine Oil Viscosity Figure 5 Yanmar does not recommend the use of engine oil additives Handling Engine Oil When handling and storing engine oil be careful not to allow dust and water to contaminate the oil Clean around the filler port before filling Do not mix lube oils of different types or brands Mixing may cause the chemical characteristics of the oil to change and lubricating performance to decrease reducing the engine s life Engine oil should be replaced at the specified intervals regardless of the engine s operation history See Periodic Maintenance Schedule on page 55 Engine Oil Viscosity A E 4 F 14 F 32 50 F 68 F 86 F 104 F 20 C 10 C 0 C 10 C 20 C 30 C 40 C 0000005 Figure 5 Select the appropriate engine oil viscosity based on the ambient temperature shown in the SAE Service Grade Viscosity Chart Figure 5 YANMAB Series Operation Manual 31 BEFORE YOU OPERATE NOTICE If you intend to operate your equipment at temperatures outside the limits shown you must consult your authorized Yanmar Marine dealer or distributor for special lubricants or starting aids Checking the Engine Oil 3 4 5 0004789 Figure 6 1 Filler Port 2 Rocker Arm Cover 3 Dipstick 4 Upper Limit 5 Lower Limit Note 3YM30 shown Other models are similar 1 Make sure the engine is off
53. e seal indicator lights Rubber sail drive seal is broken Consult authorized Yanmar Marine dealer or distributor Coolant high temperature alarm lights Coolant in coolant tank heat exchanger is low Check coolant level and refill See Checking and Adding Cool nt on page 35 Insufficient seawater level causing temperature to rise Check seawater system Consult authorized Yanmar Marine dealer or distributor Contamination inside cooling system Faulty Warning Devices Do not operate the engine if alarm devices are not repaired See you authorized Yanmar Marine dealer or distributor Serious accidents may result if abnormalities are not identified due to faulty indicators or alarm Indicators Do Not Go On Consult authorized Yanmar Marine dealer or distributor No electrical current available The battery switch is turned off the fuse 3 A on the instrument panel is burned out or the circuit is broken The tachometer does notturn on even though the power Switch is turned on One of the indicators does not go out Sensor switch is faulty Consult authorized Yanmar Marine dealer or distributor Battery low charge indicator does not go out during operation V ribbed belt is loose or broken Replace V ribbed belt or adjust tension See Checking and Adjusting the Alternator V ribbed belt Tension on page 62 Battery is defective Check battery flu
54. ead to seizure After a long period of no use distribute engine oil to each part by cranking Perform in accordance with the following procedures before beginning operation 1 Open seacock 2 Open fuel cock 3 Put remote control shift lever in NEUTRAL See Starting the Engine on page 41 4 Turn on the battery switch if equipped 5 Crank the engine 1 Push the power switch on the instrument panel and turn on the power 2 Operate the starter while pushing in the emergency stop button Figure 13 on the back of the fuel pump This stops the fuel supply When you push the start switch on the instrument panel while the emergency button is pushed in the starter operates and the engine cranks Crank the engine 5 seconds YANMAR vM Series Operation Manual 37 BEFORE YOU OPERATE emergency stop 006224 01E 6 Continue cranking the engine for about 5 seconds checking for abnormal sounds If you cannot find any abnormal sounds push the power switch and turn off the engine Start switch e 6 Power switch 042590 00E00 Figure 14 Never touch or allow your clothes to touch the moving e 2 parts of the engine during A operation If a part of your body or clothing is caught in the front drive shaft V ribbed belt propeller shaft etc serious injury may result Check to see that no tools pieces of cloth etc are le
55. ed belt Tension See Checking and Adjusting the Alternator V ribbed belt Tension on page 62 Cleaning the Breather Pipe Consult authorized Yanmar Marine dealer or distributor Checking the Wiring Connectors Consult authorized Yanmar Marine dealer or distributor PERIODIC MAINTENANCE Every 1000 Hours of Operation Perform the following maintenance every 1000 hours or 4 years of operation whichever comes first Checking the Fuel Injection Timing Checking the Fuel Injector Spray Pattern Replacing the Seawater Pump Impeller Cleaning and Checking the Seawater Passages Checking the Diaphragm Assembly Replacing the Alternator V ribbed belt Adjusting Intake Exhaust Valve Clearance Checking and Adjusting the Remote Control Cables Adjusting the Propeller Shaft Alignment Tightening All Major Nuts and Bolts Checking the Fuel Injection Timing Consult authorized Yanmar Marine dealer or distributor Checking the Fuel Injector Spray Pattern Consult authorized Yanmar Marine dealer or distributor YANMAR Series Operation Manual 71 PERIODIC MAINTENANCE Replacing the Seawater Pump Impeller The seawater impeller must be replaced every 1000 hours or every 4 years even if it is not damaged See Checking or Replacing the Seawater Pump Impeller on page 69 Cleaning and Checking the Seawater Passages After prolonged use clean the seawater passages to remove dirt scale rust and ot
56. ed container to catch the diesel fuel Continue pumping until a solid stream of fuel with no air bubbles begins to flow Tighten the air bleed screw Note After engine start up the automatic air bleeding device works to purge the air in the fuel system 30 YM Series Operation Manual YANMAH ENGINE OIL Engine Oil Specifications NOTICE Only use the engine oil specified Other engine oils may affect warranty coverage cause internal engine components to seize and or shorten engine life Never mix different types of engine oil This may adversely affect the lubricating properties of the engine oil Use an engine oil that meets or exceeds the following guidelines and classifications API Service Categories CD CF CF 4 Cl and Cl 4 The oil must be changed when the Total Base Number TBN has been reduced to 2 0 TBN mgKOH g test method JIS K 2501 5 2 2 HCI ASTM D4739 HCI Recommended SAE Viscosity 10W30 15W40 Engine oil 10W30 and 15W40 can be used throughout the year Never use API Service Category CG 4 or CH 4 oils NOTICE Be sure the engine oil engine oil storage containers and engine oil filling equipment are free of sediment or water Change the engine oil after the first 50 hours of operation and then at every 150 hours thereafter See Changing the Engine Oil on page 61 BEFORE YOU OPERATE Select the oil viscosity based on the ambient temperature where th
57. ed to operate on diesel fuel only Use of any other fuel may result in your engine no longer operating in compliance with applicable emission requirements You are responsible for initiating the warranty process You must present your marine engine to an authorized Yanmar dealer or distributor as Soon as a problem exists Customer Assistance If you have any questions regarding your warranty rights and responsibilities or would like information on the nearest authorized Yanmar dealer or distributor you should contact Yanmar America Corporation Marine Engine Division for assistance Yanmar America Corporation Marine Engine Division 101 International Parkway Adairsville GA 30103 USA Telephone 770 877 9894 Fax 770 877 7567 Website us yanmar com E mail CS support Q yanmar com Toll Free Telephone Numbers 1 855 416 7091 1 800 872 2867 YANMAR Series Operation Manual 99 EPA WARRANTY USA ONLY This Page Intentionally Left Blank 100 YM Series Operation Manual YANMAR EMISSION SYSTEM WARRANTY NON ROAD EMISSION SYSTEM WARRANTY Yanmar Co Ltd Limited Emission Control System Warranty USA Only Your Warranty Rights and Obligations California The Air Resources Board ARB the Environmental Protection Agency EPA and Yanmar Co Ltd hereafter referred to as Yanmar are pleased to explain the emission control system warranty on your compression ignition engine In California model ye
58. el Continuous power kW Speed of prop shaft Fuel stop power kW ENG No MFG DATE YANMAH The marine gear nameplate Figure 8 is attached to the marine gear Check the marine gears model gear ratio oil used oil quantity and serial number MODEL MFG NO GEAR RATIO OIL YANMAH KANZAKI KOKYUKOKI MFG CO LTD MADE IN JAPAN 177524 02903 Figure 8 The sail drive nameplate Figure 9 is attached to the sail drive Check the sail drive model and serial number 5 YANMAR CO LTD NV MADE IN JAPAN 129670 07201 PASSED Figure 7 MARK MFG No YANMAR YANMAR CO LTD Ke MADE INEU Figure 9 16 YM Series Operation Manual YANMAR PRODUCT OVERVIEW FUNCTION OF MAJOR COMPONENTS Name of Component Function Fuel Filter Removes dirt and water from the fuel Drain the filter periodically The filter element should be replaced periodically The water separator if equipped should be drained periodically See Draining Fuel Filter Water Separator on page 65 Fuel Feed Pump Pumps fuel from the tank to the fuel injection system Pushing the manual lever on the side of the feed pump supplies fuel to the engine when fuel priming is needed Fuel Feed Lever Moving the fuel feed lever up and down feeds the fuel The lever is used to bleed air from the fuel system after running out of fuel Engine Oil Filler Port Filler port for engine oil
59. el Type Combustion cycle DECLARATION z or sterndrive without integral Engine model s or EC Type certificate exhaust Dd Diese 1 2stroke engine family name s number exhaust Inboard engine C Petrol D 4stroke SNCH 94 25 2003 44 RCD 1GM10X1 0009 00 RCD 2YM15X1 0004 03 z Other 8 RCD 3YM30X1 0005 04 Essential requirements Standards Used normative 3 2 RCD UB4XI 0014 01 document used 8 4 0011 01 P m RCD 4LHAX1 0015 00 nnex LB Exhaust Emissions RCD 6LPADXI 0012700 engine identification RCD 6LPASXI 0007 00 exhaust emission requirements EN ISO 8178 1 1996 X RCD 6CXMX1 0006 00 m RCD 6LY2X1 0008 00 durabil RCD 6LY3XI 0010 04 owner s manual RCD 4JH3TX2 0016 00 Annex I C Noise Emissions see craft manufacturer s Declaration of Conformity RCD 4JH4TX2 0017 01 RCD 4JH4TX1 0018 02 RCD 6LPASX2 0023 01 RCD 4JH4AX1 0025 02 RCD 6CX53X1 0028 01 RCD 4JH5X1 0029 00 RCD 3JH5X1 0030 00 RCD 8LVX1 0038 01 I declare on behalf of the engine manufacturer that the engine s will meet the exhaust emission requirements of Directive 94 25 EC as amended by Directive 2003 44 EC when installed in a recreational craft in accordance with the engine manufacturer s supplied instructions and that this these engine s must not be put into service until the recreational craft into which it is they are to be installed has been declared in conformity with the relevant provisions of the above mentioned Directive g
60. el in the tank heat exchanger Figure 11 4 reservooir The level should be at the to avoid air bubbles Fill until coolant FULL mark Figure 12 2 overons from the ler Bart Note The coolant level rises in the NOTICE reservooir during operation After stopping the engine the Never pour cold coolant into a hot coolant will cool down and the engine extra coolant will return to the coolant tank 5 Align the filler cap tabs Figure 11 1 NOTICE with filler port notches Figure 11 3 and tighten the filler cap Never pour cold coolant into a hot Figure 11 2 engine 7 Remove reservoir cap Figure 12 4 to add coolant if necessary Do not add water 8 Replace the filler cap and tighten it firmly Failure to do so will cause coolant to leak Reservoir Capacity 0 8 L 0 8 qt 36 YM Series Operation Manual YANMAR 9 Check the rubber hose Figure 12 1 connecting the reservoir to the coolant tank heat exchanger Replace if damaged Note If the coolant runs low too often or the coolant level in the coolant tank drops without any change in the level in the reservoir there may be water or air leaks in the cooling system Consult authorized Yanmar dealer or distributor BEFORE YOU OPERATE CRANKING THE ENGINE NOTICE When the engine has not been used for a long period of time engine oil will not be distributed to all of the operating parts Using the engine in this condition will l
61. er the exhaust of the non running engine s This water could cause seizure of the non running engine s Consult authorized Yanmar Marine dealer or distributor for a complete explanation of this condition If you have an installation with two or three engines and only one engine is operating it is important to limit the amount of throttle applied to the running engine If you observe black smoke or movement of the throttle does not increase engine speed you are overloading the engine that is running Immediately throttle back to approximately 2 3 throttle or to a setting where the engine performs normally Failure to do so may cause the running engine to overheat or cause excess carbon buildup which may shorten the engine s life Never turn off the battery switch if equipped or short the battery cables during operation Damage to the electrical system will result SAFETY YANMAR vM Series Operation Manual SAFETY LOCATION OF SAFETY DECALS Figure 1 show the location of safety decals on Yanmar YM series marine engines Rotating parts Can cause injury 128377 07350 196630 12980 YM Engines gt 2222 051101 00X00 Figure 1 1 Part Number 128990 07270 2 Part Number 128377 07350 3 Part Number 196630 12980 10 YM Series Operation Manual YANMAR PRODUCT OVERVIEW YANMAR YM SERIES FEATURES AND APPLICATIONS The YM series are four stroke swirl pre comb
62. ernator to adjust the belt tension properly 5 Tighten the 3 bolts of the alternator 6 Install the belt cover Inspecting and Adjusting Intake Exhaust Valve Clearance Proper adjustment is necessary to maintain the correct timing for opening and closing the valves Improper adjustment will cause the engine to run noisily resulting in poor engine performance and engine damage Consult authorized Yanmar Marine dealer or distributor to adjust the intake exhaust valve clearance PERIODIC MAINTENANCE Checking and Adjusting the Remote Control Cables NOTICE Never adjust the high speed stop bolt Figure 4 4 on the governor This will void the engine warranty The various control levers on the engine side are connected to the remote control lever by remote control cables The cables will become stretched and the attachments loose after long hours of operation It is dangerous to control operation under these conditions and the remote control cables must be checked and adjusted periodically Adjusting the Throttle Remote Control Cable 0004798 Figure 4 1 Cable 2 Fuel Injection Pump 3 Adjustment 4 High Speed Stop Bolt 5 Low Speed Stop Bolt 6 Control Lever YANMAR Series Operation Manual 63 PERIODIC MAINTENANCE 1 Check that the control lever on the Adjusting Propeller Shaft Alignment engine side moves to the high speed stop position and low speed stop position
63. es such as the turbocharger if equipped and exhaust system to cool slightly before the engine itself is shut down Start switch Stop switch Power switch 042590 00E02 Figure 3 4 Push and hold the stop switch After the engine has stopped push the power switch off 46 YANMAH YM Series Operation Manual NOTICE Continue to hold the stop switch in until the engine is completely stopped If the switch is released before the engine has completely stopped it may restart If the engine does not shut down see Emergency Shutdown on page 47 5 Turn off the battery switch if equipped 6 Close the fuel cock 7 Close the seacock if equipped NOTICE eBe sure to close the seacock Neglecting to close the seacock could allow water to leak into the boat and may cause it to sink elf seawater is left inside the engine it may freeze and damage parts of the cooling system when the ambient temperature is below 0 C 32 F Emergency Shutdown NOTICE Never use the emergency stop switch for a normal engine shutdown Use this switch only when stopping the engine suddenly in an emergency If the engine cannot be shut down by the stop switch on the panel stop the engine by pushing the button Figure 4 1 at the back of the stop solenoid Figure 4 2 ENGINE OPERATION 0004787 Figure 4 1 Stop button 2 Stop solenoid Sever Haza
64. f each operating day See Daily Checks on page 59 PERIODIC MAINTENANCE Keep a Log of Engine Hours and Daily Checks Keep a log of the number of hours the engine is run each day and a log of the daily checks performed Also note the date type of repair e g replaced alternator and parts used for any service needed between the periodic maintenance intervals Periodic maintenance intervals are every 50 250 500 and 1000 engine hours Failure to perform periodic maintenance will shorten the life of the engine NOTICE Failure to perform periodic maintenance will shorten the life of the engine and may void the warranty Yanmar Replacement Parts Yanmar recommends that you use genuine Yanmar parts when replacement parts are needed Genuine replacement parts help ensure long engine life Tools Required Before you start any periodic maintenance procedure make sure you have the tools you need to perform all of the required tasks Ask Your Authorized Yanmar Marine Dealer or Distributor for Help Our professional service technicians have the expertise and skills to help you with any maintenance or service related procedures you need help with YANMAR Series Operation Manual 51 PERIODIC MAINTENANCE Tightening Fasteners Use the correct amount of torque when you tighten fasteners on the engine Applying excessive torque may damage the fastener or component and not enough torque may cause a leak or compone
65. faster engine warm up than no load Avoid running the engine at idling speed any longer than necessary 42 YANMAR YM Series Operation Manual Starting with Glow plug If Equipped 1 2 3 Open the seacock if equipped Open the fuel tank cock Put remote control handle in NEUTRAL Turn the battery switch on if equipped Push the power switch on Ensure that the instrument panel indicators light and the alarm sounds This shows that indicators and alarm are working correctly Note The coolant high temperature 6 7 NOTICE alarm indicator does not come on during start up Push and hold the glow switch for 10 seconds Push the start switch Release the start switch when the engine has started The alarm should stop and the indicators should go out Never hold the start switch for longer than 15 seconds or the starter motor will overheat ENGINE OPERATION After the Engine has Started After the engine has started check the following items at a low engine speed 1 Check that the gauges indicators and alarm are normal Normalcoolantoperating temperature is approximately 76 to 90 C 169 to 194 Normal oil pressure at 3000 min 1 is 0 28 to 0 54 MPa 41 to 78 psi Check for water fuel or oil leakage from the engine Check that the smoke color engine vibration and sound are normal When there are no problems keep the engine at low speed with the boa
66. ft on or around the engine 38 YM Series Operation Manual YANMAH ENGINE OPERATION INTRODUCTION SAFETY PRECAUTIONS This section of the Operation Manual Before performing any operations within describes the diesel fuel engine oil and this section review the Safety section on engine coolant specifications and how to page 5 replenish them It also describes the daily engine checkout YANMAR Seres Operation Manual 39 ENGINE OPERATION FirendxplosiorHazard Never jump start the engine Sparks caused by shorting the battery to the starter terminals may cause a fire or explosion ONLY use the start switch on the instrument panel to start the engine Sudden Movement Hazard Be sure the boat is in open water away from other boats docks or other obstructions before increasing engine speed Avoid unexpected equipment movement Shift the marine gear into the NEUTRAL position any time the engine is at idle To prevent accidental equipment movement never start the engine in gear Sever Hazard L Keep children and pets away QU while the engine is operating NOTICE If any indicator illuminates during engine operation stop the engine immediately Determine the cause and repair the problem before you continue to operate the engine If the alarm indicater with audible alarm fails to display and go out about 3 seconds after the ignition switch is turned on consult authorized Yanmar Marine deale
67. h is found defective as a result of inspection or any part whose measured value does not satisfy the standard or limit must be replaced Modifications may impair the engine s safety and performance characteristics and shorten the engine s life Any alterations to this engine may void its warranty Be sure to use Yanmar genuine replacement parts 50 YANMAR YM Series Operation Manual PRECAUTIONS The Importance of Periodic Maintenance Engine deterioration and wear occur in proportion to the length of time the engine has been in service and the conditions the engine is subjected to during operation Periodic maintenance prevents unexpected downtime reduces the number of accidents due to poor machine performance and helps extend the life of the engine Performing Periodic Maintenance Exhaust Hazard Never block windows vents or other means of ventilation if the engine is operating in an enclosed area All internal combustion engines create carbon monoxide gas during operation Accumulation of this gas within an enclosure could cause illness or even death Make sure that all connections are tightened to specifications after repair is made to the exhaust system Failure to comply could result in death or serious injury The Importance of Daily Checks The Periodic Maintenance Schedule assumes that the daily checks are performed on a regular basis Make it a habit to perform daily checks before the start o
68. he market reduce engine speed to 1000 min or less before engaging and disengaging the marine gear clutch 24 YM Series Operation Manual YANMAH BEFORE YOU OPERATE INTRODUCTION This section of the Operation Manual describes the diesel fuel engine oil and engine coolant specifications and how to replenish them SAFETY PRECAUTIONS Before performing any operations within this section review the Safety section on page 5 YANMAR Seres Operation Manual 25 BEFORE YOU OPERATE DIESEL FUEL Diesel Fuel Specifications Fire and Explosion Hazard Diesel fuel is flammable and explosive under certain conditions Only use diesel fuels recommended by Yanmar for the best engine performance to prevent engine damage and to comply with EPA warranty requirements Only use clean diesel fuel Diesel fuel should comply with the following specifications The table lists several worldwide specifications for diesel fuels DIESEL FUEL SPECIFICATION ASTM D975 No 2 D S15 USA No 1 D 15 EN590 2009 ISO 8217 DMX BS 2869 A1 or A2 JIS K2204 Grade No 2 LOCATION European Union International United Kingdom Japan Biodiesel Fuels Yanmar approves the use of biodiesel fuels that do not exceed a blend of 7 non mineral oil based fuel with 9396 standard diesel fuel Such biodiesel fuels are known in the marketplace as B7 biodiesel fuels B7 biodiesel fuel can reduce particulate
69. her contaminants that collect in the coolant passages This can cause poor engine cooling Inspect these items Heat Exchanger Pressure Cap Consult authorized Yanmar Marine dealer or distributor Checking the Diaphragm Assembly Inspect the diaphragm assembly on the rocker arm cover 1 Loosen screws and remove diaphragm assembly 2 Check for oil and contaminants between the diaphragm and cover NOTICE If oil and contaminants enter the diaphragm assembly the diaphragm will not operate properly 3 Inspect the diaphragm rubber and spring for damage If necessary replace with new ones Breather System Components 0004807 Figure 11 1 Diaphragm Cover 2 Spring 3 Center Plate 4 Diaphragm 5 Rocker Arm Cover 6 Breather Baffle 7 Baffle Plate 8 Intake Silencer air cleaner Replacing the Alternator V ribbed belt 1 Remove the V ribbed belt cover 2 Loosen the V ribbed belt tension adjusting bolt of the alternator 3 Remove the alternator V ribbed belt Install a new alternator V ribbed belt 5 Adjust the alternator V ribbed belt tension See Checking and Adjusting the Alternator V ribbed belt Tension on page 62 6 Replace the V ribbed belt cover A Adjusting Intake Exhaust Valve Clearance Consult authorized Yanmar Marine dealer or distributor 72 YANMAR YM Series Operation Manual PERIODIC MAINTENANCE Checking and Adjusting the Remote Control Cable
70. ications Always be environmentally responsible 9 Follow the guidelines of the EPA or other governmental agencies for the proper disposal of hazardous materials such as engine oil diesel fuel and engine coolant Consult the local authorities or reclamation facility Never dispose of hazardous materials by dumping them into a sewer on the ground or into ground water or waterways If a Yanmar Marine Engine is installed at an angle that exceeds the specifications stated in the Yanmar Marine nstallation Manuals engine oil may enter the combustion chamber causing excessive engine speed white exhaust smoke and serious engine damage This applies to engines that run continuously or those that run for short periods of time YANMAH YM Series Operation Manual NOTICE If you have an installation with two or three engines and only one engine is operating the water pickup thru hull of the non running engine s should be closed This will prevent water from being forced past the seawater pump and eventually finding its way into the engine The result of water entering the engine could cause seizure or other serious problems If you have an installation with two or three engines and only one engine is operating please note that if the propeller shaft thru hull stuffing box is lubricated by engine water pressure and the engines are interconnected care must be taken that water from the running engine does not ent
71. id level specific gravity or replace battery See Checking the Battery Electrolyte Level on page 60 Alternator power generation failure Consult authorized Yanmar Marine dealer or distributor Starting Failures Starter turns but engine does not start Add fuel Bleed fuel system See Filling the Fuel Tank on page 29 and see Bleeding the Fuel System on page 30 Fuel filter is clogged Replace filter element See Replacing the Fuel Filter El ment on page 68 Improper fuel Replace with recommended fuel See Diesel Fuel Specifications on page 26 Problem with fuel injection Consult authorized Yanmar Marine dealer or distributor Compression leakage from intake exhaust valve Consult authorized Yanmar Marine dealer or distributor YANMAR YM Series Operation Manual 77 TROUBLESHOOTING Symptom Probable Cause Measure Reference Starter does not turn or turns slowly engine can be turned manually Faulty clutch position Shift to NEUTRAL and start See If the Engine Fails to Start on page 42 Insufficient battery charge Check fluid level Recharge or replace battery See Checking the Battery Electrolyte Level on page 60 Cable terminal contact failure Remove corrosion from terminals Tighten battery cables Faulty safety switch device Consult authorized Yanmar Marine dealer or distributor Fa
72. ight When charging begins the indicator will turn off Coolant High Temperature Indicator and Alarm When coolant temperature reaches the maximum allowable temperature 95 C 203 F or higher the indicator will light and the alarm will sound Continuing operation at temperatures exceeding the maximum limit will result in damage and seizure Check the load and troubleshoot the cooling system Engine Oil Low Pressure Indicator and Alarm When the engine oil pressure falls below normal the oil pressure sensor will send a signal to the indicator causing it to light and the alarm to sound Stop operation to avoid damage to the engine Check the oil level and troubleshoot the lubrication system Water in Sail Drive Seal Indicator and Alarm When water is detected between the seals of the sail drive the indicator will light and the alarm will sound YANMAR Series Operation Manual 19 PRODUCT OVERVIEW LCD control hourmeter display brightness battery voltage You can switch scroll between displays by pressing the buttons on the bottom Switching screens by pressing the right button Pressing the left button switches the screens in the opposite direction Press the power switch After 4 seconds the LCD shows the hourmeter Pressing the right button on the bottom of the LCD shows the temperature display This feature is not available on this engine Pressing the right button again shows the LCD br
73. ightness settings To set the brightness of the backlight Press the left button continuously and the digits of the LCD start flashing In this condition press the right button to decrease the brightness and the left button to increase the brightness The brightness changes in 6 steps of 20 To set the desired brightness do not touch the buttons for 3 seconds Note Continuously pressing means holding the button for approx 2 seconds Next press the right button to show the pressure display This feature is not available on this engine Press again to show the battery voltage Pressing the button once more returns the display to the initial hourmeter Coolant temperature Y Backlighting Brightness Tk 100 inn gt e cule Push and hold Scroll display will blink when 100 80 60 40 20 0 ready value will be set after 3 seconds Oil pressure Battery voltage VOLTS Return to hourmeter 051899 00 00 Figure 11 20 YM Series Operation Manual YANMAR PRODUCT OVERVIEW Setup Screen Access and Control Setting the engine speed pulse value for B20 C30 type panel Use the buttons on the bottom of the LCD display to set the instrument panel Press the left button to switch between displays a Press and hold both buttons until SET UP appears Press the left button and go to the screen UNIT Press the left button and
74. in cocks are opened before shipping from the factory Close all drain cocks before filling the system with coolant 1 Put a pan under the coolant drain cocks 2 Open all coolant drain cocks 3 Allow to drain completely Dispose of waste properly 4 Close all the drain cocks 5 Fill coolant tank and reservooir with appropriate coolant See Engine Oil Specifications on page 31 and see Checking and Adding Coolant on page 35 Cleaning the Intake Silencer Air Cleaner Element 1 Disassemble the intake silencer air cleaner 2 Remove element Figure 10 1 Clean element and housing with a neutral detergent 3 Dry completely and reassemble 0004805 Figure 10 Cleaning or Replacing the Exhaust Water Mixing Elbow There are two types of mixing elbows the L type and the U type The mixing elbow is attached to the exhaust manifold The exhaust gas is mixed with seawater in the mixing elbow 1 Remove the mixing elbow 2 Clean dirt and scale out of the exhaust and seawater passages 3 If the mixing elbow is damaged repair or replace it Consult authorized Yanmar Marine dealer or distributor 4 Inspect the gasket and replace if necessary Replace the mixing elbow with a new one every 500 hours or 2 years whichever comes first even if no damage is found Consult authorized Yanmar Marine dealer or distributor 70 YANMAH YM Series Operation Manual Adjusting the Alternator V ribb
75. ine at low speed and light load by necessity just after the low idle operation be sure to race the engine To complete engine break in perform After Initial 50 Hours of Operation maintenance procedures After Initial 50 Hours of Operation on page 60 12 YANMAH YM Series Operation Manual PRODUCT OVERVIEW COMPONENT Left Side Viewed from Flywheel IDENTIFICATION 2YM15 Right Side Viewed from Flywheel 2YM15 Figure 1 and Figure 2 illustrate a typical version of a 2YM15 engine Your engine may have different equipment from that illustrated 051098 00X00 Figure 2 1 Seawater Pump 2 Coolant Filler Cap 3 Engine Nameplate on rocker arm cover 4 Coolant Tank Heat Exchanger 5 Exhaust Manifold 6 Starter Motor 7 Shift Lever 8 Alternator 0004781 Figure 1 1 Intake Silencer air cleaner 2 Intake Manifold 3 Fuel Filter 4 Fuel Injection Pump 5 Engine Oil Dipstick 6 Engine Oil Filler Cap 7 Fuel Feed Pump 8 Engine Oil Filter 9 Marine Gear YANMAR Series Operation Manual 13 PRODUCT OVERVIEW Right Side Viewed from Flywheel 3YM20 Figure 3 and Figure 4 illustrate a typical version of a 3YM20 engine Your engine may have different equipment from that illustrated A KAN SEN h DA Figure 3 0004783 1 Intake Silencer air cleaner 2 Intake Manifold 3 Fuel Filter 4 Fuel Injection Pump 5
76. ith clean fuel free of oil and dirt Fire and Explosion Hazard Hold the hose nozzle firmly against the filler port while filling This prevents static electricity buildup which could cause sparks and ignite fuel vapors 4 Stop fueling when the gauge shows the fuel tank is full BEFORE YOU OPERATE Fire and Explosion Hazard Never overfill the fuel tank 5 Replace the fuel cap and hand tighten Over tightening the fuel cap will damage it YANMAB Series Operation Manual 29 BEFORE YOU OPERATE Bleeding the Fuel System The fuel system has an automatic air bleeding device that purges air from the fuel system No manual air bleeding is required for normal operation Bleeding must be done if any fuel system maintenance has been performed replacement of fuel filter etc or if the engine does not start after several attempts 0004801 Figure 4 1 Air Bleed Screw 2 3 O Ring 4 Fuel Filter Element 5 Fuel Filter Housing 6 Retaining Ring 1 2 Check the fuel level in the fuel tank Refill if necessary Open the fuel cock of the fuel tank 6 Exposure Hazard Always wear safety glasses when bleeding the fuel system Loosen the air bleed screw Figure 4 1 2 to 3 turns Push up and down on the manual priming lever located on the side of the fuel feed pump to release air out of the air bleed screw Always use an approv
77. l bottom 7 Waterproof the engine room to prevent rain or seawater from entering 8 Charge the battery once a month to compensate for battery s self discharge 9 Make sure the power switch is off YANMAR Series Operation Manual 79 LONG TERM STORAGE DRAIN SEAWATER COOLING SYSTEM 051170 00X00 Figure 1 1 Coolant Tank Heat Exchanger 2 Seawater Drain Cock 3 Coolant Drain Plug Figure 2 1 Coolant Tank Heat Exchanger 2 Coolant Drain Plug 3 Seawater Drain Plug 4 Seawater Pump 5 Coolant Pump 051169 00X00 0004793 Figure 3 1 Stop Solenoid 2 Coolant Drain Cock 3 Flywheel Housing Figure 4 Note The drain cocks are opened before shipping from the factory Close all drain cocks before filling the system with coolant NOTICE If seawater is left inside it may freeze and damage parts of the cooling system heat exchanger seawater pump etc when ambient temperature is below 0 C 32 F 1 Put a pan under the seawater drain cocks 2 Open the seawater drain cocks on the pipe and on the heat exchanger Allow to drain 3 Remove the four bolts fastening the side cover of the seawater pump Remove the cover and drain the seawater 4 Install the cover and tighten bolts 5 Close all drain cocks 80 YM Series Operation Manual YANMAR NOTICE Never drain engine coolant in the cold season or before long storage If LLC Long Life Coolan
78. n Manual for the procedure for checking and filling the sail drive oil YANMAR vM Series Operation Manual 33 BEFORE YOU OPERATE ENGINE COOLANT Engine Coolant Specifications Note In the U S LLC is required for the warranty to be valid Texaco Long Life Coolant LLC both standard and premixed product code 7997 and 7998 Havoline Extended Life Antifreeze Coolant product code 7994 Following the manufacturer s recommendations use a proper LLC which will not have any adverse effects on the materials cast iron aluminum copper etc of the engine s cooling system Always use the mixing ratios specified by the antifreeze manufacturer for the temperature range Coolant Closed Cooling System NOTICE Always add LLC to soft water especially when operating in cold weather Never use hard water Water should be clean and free from sludge or particles Without LLC cooling performance will decrease due to scale and rust in the coolant system Water alone may freeze and form ice it expands approximately 9 in volume Use the proper amount of coolant concentrate for the ambient temperature as specified by the LLC manufacturer LLC concentration should be a minimum of 30 to a maximum of 60 Too much LLC will decrease the cooling efficiency Excessive use of antifreeze also lowers the cooling efficiency of the engine Never mix different types or brands of LLC as a harmful sludge may form Mixing diffe
79. nd Engine Coolant Levels Follow the procedures in Diesel Fuel on page 26 Engine Oil on page 31 and Engine Coolant on page 34 to check these levels YANMAR vM Series Operation Manual 59 PERIODIC MAINTENANCE Checking and Refilling Marine Gear Oil Refer to the Operation Manual for the marine gear Checking the Battery Electrolyte Level Check the battery electrolyte level before use See Checking the Battery Electrolyte Level Serviceable Batteries Only on page 66 Checking the Alternator Belt Check the belt tension before use See Checking and Adjusting the Alternator V ribbed belt Tension on page 62 Checking the Remote Control Handle Check the operation of the remote control handle and ensure it moves smoothly If it is hard to operate grease the joints of the remote control cable and lever bearings If the lever is too loose adjust the remote control cable See Checking and Adjusting the Remote Control Cables on page 63 Checking the Alarm Indicators When operating the start switch on the instrument panel check that there is no alarm message on the display and the alarm indicators work normally See Control Equipment on page 18 Preparing Fuel Oil and Coolant in Reserve Prepare sufficient fuel for the days operation Always store engine oil and coolant in reserve for at least one refill onboard to be ready for emergencies After Initial 50 Hours of Operation Perform the following mai
80. ngine lubricating oil 26 YANMAH YM Series Operation Manual Even biodiesel fuels that comply with a suitable standard as delivered will require additional care and attention to maintain the quality of the fuel in the equipment or other fuel tanks It is important to maintain a supply of clean fresh fuel Regular flushing of the fuel system and or fuel storage containers may be necessary The use of biodiesel fuels that do not comply with the standards as agreed to by the diesel engine manufacturers and the diesel fuel injection equipment manufacturers or biodiesel fuels that have degraded as per the precautions and concerns above may affect the warranty coverage of your engine Additional Technical Fuel Requirements The fuel cetane number should be 40 or higher The sulfur content must not exceed 15 ppm by volume A higher sulfur content fuel may cause sulfuric acid corrosion in the cylinders of the engines Especially in U S A and Canada Ultra Low Sulfur fuel must be used Never mix kerosene used engine oil or residual fuels with the diesel fuel Water and sediment in the fuel should not exceed 0 05 by volume Keep the fuel tank and fuel handling equipment clean at all times Ash content not to exceed 0 0196 by volume Carbon residue content not to exceed 0 35 by volume Less than 0 1 is preferred Total aromatics content should not exceed 35 by volume Less than 30 is preferred
81. nsiders safety of great importance and recommends that anyone that comes into close contact with its products such as those who install operate maintain or service Yanmar products exercise care common sense and comply with the safety information in this manual and on the machine s safety decals Keep the labels from becoming dirty or torn and replace them if they are lost or damaged Also if you need to replace a part that has a label attached to it make sure you order the new part and label at the same time This safety alert symbol appears with most safety statements It means attention become alert your safety is involved Please read and abide by the message that follows the safety alert symbol A A DANGER Indicates a hazardous situation which if not avoided will result in death or serious injury Indicates a hazardous situation which if not avoided could result in death or serious injury Indicates a hazardous situation which if not avoided could result in minor or moderate injury NOTICE Indicates a situation which can cause damage to the machine personal property and or the environment or cause the equipment to operate improperly YANMAR vM Series Operation Manual SAFETY SAFETY PRECAUTIONS General Information There is no substitute for common sense and careful practices Improper practices or carelessness can cause burns cuts mutilation asphyxiation other bodily injur
82. nt failure NOTICE bolts with a 7 head JIS strength classification 7T Apply 60 torque to bolts 7 he tightening torque in the Standard Torque Chart should be applied only to the that are not listed Apply 80 torque when tightened to aluminum alloy Bolt Diameter x Pitch mm M6x1 0 M8x1 25 M10x1 5 M12x1 75 M14x1 5 M16x1 5 Tightening N m 11 0 1 0 26 0 3 0 50 0 5 0 90 0 10 0 140 0 10 0 230 0 10 0 Torque ft lb 8 0 0 7 19 0 2 1 37 0 3 6 66 0 7 2 103 7 2 170 7 2 52 YM Series Operation Manual YANMAR EPA MAINTENANCE REQUIREMENTS To maintain optimum engine performance and compliance with the Environmental Protection Agency EPA Regulations for Engines it is essential to follow the Periodic Maintenance Schedule on page 55 and the Periodic Maintenance Procedures on page 59 EPA Requirements for USA and Other Applicable Countries The following are the requirements for the EPA Unless these requirements are met the exhaust gas emissions will not be within the limits specified by the EPA The EPA emission regulation is applicable only in the USA and other countries that have adopted the EPA requirements in part or in whole Determine and follow the emission regulations in the country where your engine will be operating to assist you in specified compliance Conditions to Ensure Compliance with EPA Emissi
83. ntenance after the initial 50 hours of operation Draining the Fuel Tank Changing the Engine Oil and Replacing the Engine Oil Filter Element Changing the Marine Gear Oil and Replacing the Marine Gear Oil Filter If Equipped Checking and Adjusting the Alternator V ribbed belt Tension Inspecting and Adjusting Intake Exhaust Valve Clearance Checking and Adjusting the Remote Control Cables Adjusting Propeller Shaft Alignment 60 YANMAH YM Series Operation Manual Draining the Fuel Tank 0004542 Figure 1 1 Sediment Bowl 2 Drain Cock 3 Fuel Line to Engine Note Optional fuel tank shown Actual equipment may differ 1 Put a pan under the drain cock Figure 1 2 to catch fuel 2 Open the drain cock and drain water and sediment Close the drain cock when the fuel is clean and free of air bubbles Changing the Engine Oil The engine oil on a new engine becomes contaminated from the initial break in of internal parts It is very important that the initial oil replacement is performed as scheduled It is easiest and most arailable to drain the engine oil after operation while the engine is still warm PERIODIC MAINTENANCE Burn Hazard ff you must drain the engine oil while it is still hot stay clear of the hot engine oil to avoid being burned Always wear eye protection 1 Turn the engine off Remove the engine oil dipstick Attach the oil drain
84. nterclockwise viewed from stern Rotation Propeller Shaft Ahead Clockwise viewed from stern Cooling System Coolant cooling with heat exchanger Lubrication System Forced lubrication system Coolant Capacity Engine 3 0 L 3 17 qt Reservoir 0 8 L 0 85 qt Lubricating Rake Angle at rake angle 8 at rake angle 0 Oil Capacity Engine Total 2 01 2 1 qt 1 8L 1 9 qt Effective 0 95 L 1 0 qt 0 9 L 0 95 qt Starting Type Electric System Starting Motor DC 12V 1 4 kW AC Alternator 12V 120A Engine Overall Length 613 mm 24 1 in Dimension Overall Width 463 mm 18 2 in Overall Height 528 mm 20 8 in Engine Dry Mass Including Marine Gear 113 kg 249 Ib 134 kg 295 Ib Rating Condition Temperature of fuel 40 C at fuel pump inlet ISO 8665 The total oil quantity includes oil in oil pan channels coolers and filter The effective amount of oil shows the difference in maximum scale of the dipstick and minimum scale Note Density of fuel 0 842 g cm at 15 C Fuel temperature at the inlet of the fuel injection pump 1hp metric 2 0 7355 kW 84 YM Series Operation Manual YANMAH 3YM20 Engine Specifications Specification SPECIFICATIONS 3YM20 Marine Gear Model KM2P 1 SD 20 Use Pleasure use Type Vertical water cooled 4 cycle diesel engine
85. on Standards The 2YM15 3YM20 and 3YM3OE are EPA certified engines Note Since 2013 the 3YM30 does not comply with the EPA regulation The following are the conditions that must be met in order to ensure that the emissions during operation meet the EPA standards Ambient temperature 20 C to 40 C 4 F to 104 F Relative humidity 80 or lower PERIODIC MAINTENANCE The diesel fuel should be e ASTM D975 No 1 D S15 or No 2 D S15 or equivalent minimum of cetane No 40 The lubricating oil should be Type API Class CD CF CF 4 Cl and 4 Perform the inspections as outlined in Periodic Maintenance Procedures on page 59 and keep a record of the results Pay particular attention to these important points Replacing the engine oil Replacing the engine oil filter Replacing the fuel filter Cleaning the intake silencer air cleaner Note Inspections are divided into two sections in accordance with who is responsible for performing the inspection the user or the manufacturer Inspection and Maintenance See Inspection and Maintenance of EPA Emission Related Parts on page 58 for the EPA emission related parts Inspection and maintenance procedures not shown in the Inspection and Maintenance of EPA Emission Related Parts section are covered in Periodic Maintenance Schedule on page 55 This maintenance must be performed to keep the emission values of the engine within the
86. on Outlet 17 Thermostat 18 19 Hot Water Connection Inlet 20 Coolant Temperature Switch E 21 Engine Oil Pump 22 Pressure Control Valve at 23 Fuel Filter XD0 235620 24 To Oil Pan 25 To Camshaft 26 From Cylinder Head X00 135620 YANMAR Series Operation Manual 93 SYSTEM DIAGRAMS WIRING DIAGRAMS Color Coding Red Black White Blue Red Black Blue Black Yellow White Yellow Green White Blue Purple Blue White Orange White Brown Allowable Length by Cross Sectional Area of Battery Cable Section of Cable mm in 2 Allowable Length L 1 2 3m ft 0 023 lt 0 86 0 26 0 031 lt 1 3 0 40 0 046 lt 2 3 0 70 0 077 lt 3 5 1 07 15 20 30 40 0 062 50 60 0 093 0 40 0 70 lt 2 8 0 85 1 07 1 25 lt 4 1 1 25 94 YANMAR YM Series Operation Manual SYSTEM DIAGRAMS 2YM15 3YM20 3YM30 E B20 Type Instrument Panel 051140 00ENOO GlowRelay Stop Relay Starter Relay o o Panel Power ACC Power 2 a 8 Output sti Input Power SW Glow SW Self holding a ai s E J z E e
87. onthly whichever comes first Draining Fuel Filter Water Separator Checking the Battery Electrolyte Level Draining Fuel Filter Water Separator Fire and Explosion Hazard When removing any fuel system component to perform maintenance such as changing the fuel filter put an approved container under the opening to catch the fuel Never use a shop rag to catch the fuel Vapors from the rag are flammable and explosive Wipe up any spills immediately Exposure Hazard Wear eye protection The fuel system is under pressure and fuel could spray out when removing any fuel system component PERIODIC MAINTENANCE E 00048C Figure 6 1 Air Bleed Screw 2 Bracket O Ring 4 Fuel Filter Element 5 Fuel Filter Housing 6 Retaining Ring Close the fuel cock of the fuel tank Puta pan under the fuel water separator Loosen the retaining ring Figure 6 6 remove the filter housing Figure 6 5 and drain off any water or sediment collected inside After draining tighten the air bleed screw Figure 6 1 YANMAR Series Operation Manual 65 PERIODIC MAINTENANCE 5 Be sure to bleed air from the fuel system See Bleeding the Fuel System on page 30 Checking the Battery Electrolyte Level Serviceable Batteries Only Never operate with insufficient battery electrolyte Operating with insufficient electrolyte will destroy the battery Expo
88. or Replacing the Seawater Pump Impeller 1 Loosen side cover bolts and remove the side cover 2 Inspect the inside of the seawater pump with a flashlight If any of the following are found service the seawater pump PERIODIC MAINTENANCE Impeller blades are cracked or nicked Edges or surfaces of the blades are marred or scratched Wear plate is damaged 3 If no damage is found when inspecting the inside of the pump install the O ring and side cover 4 If a large amount of water leaks continuously from the water drain line below the seawater pump during operation replace the mechanical seal Consult authorized Yanmar Marine dealer or distributor When disassembly and maintenance of the seawater pump are necessary consult your Yanmar Marine dealer or distributor The seawater pump turns in the direction as shown in Figure 9 The impeller must be installed while considering the impeller direction 4 0004806 Figure 9 1 Impeller Vane Direction 2 Impeller Rotating Direction 3 Impeller 4 Seawater Pump YANMAR Series Operation Manual 69 PERIODIC MAINTENANCE Replacing the Coolant Coolant Hazard Wear eye protection and rubber gloves when you handle engine coolant If contact with the eyes or skin should occur flush eyes and wash immediately with clean water Replace coolant every year Note If Long Life Coolant LLC is used replace coolant every 2 years Note The dra
89. ot operate at WOT wide open throttle for more than a minute at a time during the first 10 hours of operation Do not operate the engine at low idle or at low speed and light load for more than 30 minutes at a time Since unburned fuel and engine oil will adhere to the piston rings when operating at low speeds for long periods this will interfere with proper movement of the rings and the engine oil consumption may increase Low idle speed does not allow break in of sliding parts If operating engine at low speed and light load you must race the engine to clean the carbon from the cylinders and fuel injection valve Perform this procedure in open waters e With the clutch in NEUTRAL accelerate from the low speed position to the high speed position briefly Repeat this process five times Once past the initial 10 hours until 50 hours the engine should be used over its full operating range with special emphasis on running at relatively high power settings This is not the time for an extended cruise at idle or low speed The boat should be run at maximum speed minus 400 min most of the time approximately 7096 load with a 10 minute run at maximum minus 200 min approximately 8096 load every 30 minutes and a 4 to 5 minute period of operation at WOT wide open throttle once each 30 minutes During this period be sure not to operate your engine at low speed and light load for more than 30 minutes If operating eng
90. owing items Visual Checks 1 Check for engine oil leaks 2 Check for fuel leaks Piercing Hazard Avoid skin contact with the high pressure diesel fuel spray caused by a fuel system leak such as a broken fuel injection line High pressure fuel can penetrate your skin and result in serious injury If you are exposed to high pressure fuel spray obtain prompt medical treatment PERIODIC MAINTENANCE Never check for a fuel leak with your hands Always use a piece of wood or cardboard Have your authorized Yanmar Marine dealer or distributor repair any damage 3 Check for engine coolant leaks Check for damaged or missing parts 5 Check for loose missing or damaged fasteners 6 Check the electrical harnesses for cracks abrasions and damaged or corroded connectors 7 Check hoses for cracks abrasions and damaged loose or corroded clamps 8 Check the fuel filter water separator for presence of water and contaminants If you find any water or contaminants drain the fuel filter water separator See Draining Fuel Filter Water Separator on page 65 If you have to drain the fuel filter water separator frequently drain the fuel tank and check for the presence of water in your fuel supply See Draining the Fuel Tank on page 61 NOTICE If any problem is noted during the visual check the necessary corrective action should be taken before operating the engine Check Diesel Fuel Engine Oil a
91. periods of time race the engine once every 2 hours YANMAR Series Operation Manual 45 ENGINE OPERATION NOTICE Racing the engine With the gear in NEUTRAL accelerate from the low speed position to the high speed position and repeat this process about five times This is done to clean out carbon from the cylinders and the fuel injection valve Neglecting to race the engine will result in poor smoke color and reduce engine performance f possible periodically operate the engine at near maximum engine speed while underway This will generate higher exhaust temperatures which will help clean out hard carbon deposits maintaining engine performance and prolonging the life of the engine NOTICE Never turn off the battery switch if equipped or short the battery cables during operation Damage to the electric system will result SHUTTING DOWN THE ENGINE Normal Shutdown 1 Reduce engine speed to low idle and put remote control handle in NEUTRAL Accelerate from low speed to high speed and repeat five times This will clean out the carbon from the cylinders and the fuel injection nozzles Allow engine to run at low speed approximately 1000 min without load for 5 minutes NOTICE For maximum engine life Yanmar recommends that when shutting the engine down you allow the engine to idle without load for 5 minutes This will allow the engine components that operate at high temperatur
92. pump if equipped and pump out the oil For easier draining remove the engine oil fill cap Dispose of used oil properly NOTICE Prevent dirt and debris from contaminating engine oil Carefully clean the dipstick and the surrounding area before removing the dipstick N eAlways be environmentally responsible 3 Fill with new engine oil See Adding Engine Oil on page 32 NOTICE Never mix different types of engine oil This may adversely affect the lubricating properties of the engine oil Never overfill Overfilling may result in white smoke engine overspeed or internal damage A Perform a trial run and check for oil leaks Approximately 10 minutes after stopping the engine remove the oil dipstick and check the oil level Add oil if the level is too low YANMAB YM Series Operation Manual 61 PERIODIC MAINTENANCE Replacing the Engine Oil Filter Element 1 Turn the engine off 2 Turn the engine oil filter Figure 2 counterclockwise with a wrench 3 Remove the engine oil filter Figure 2 Note 3YM20 shown 4 Install a new filter element and hand tighten until the seal touches the housing 5 Turn filter an additional 3 4 turn using a box wrench Tighten to 20 to 24 N m 177 to 212 Ib in 6 Perform a trial run and check for oil leaks Changing the Marine Gear Oil Note Refer to the Marine Gear Operation Manual for procedure During initial operation the oil is
93. quickly contaminated due to the initial wear of internal parts The marine gear oil must therefore be replaced early 1 Remove cap from the filler port and attach an oil drain pump Drain marine gear oil 2 Fill marine gear with clean marine gear oil See Marine Gear Oil Specifications on page 33 3 Perform a trial run and check for oil leaks 4 Approximately 10 minutes after stopping the engine remove the oil dipstick and check the oil level Add oil if the level is too low Checking and Adjusting the Alternator V ribbed belt Tension Sever Hazard Perform this check with the power switch off and the battery switch turned off to avoid contact with moving parts NOTICE Never get any oil on the belt s Oil on the belt causes slipping and stretching Replace the belt if it is damaged C AI A N 051168 00X01 Figure 3 1 Middle of V ribbed Belt 2 Alternator Bolt 3 Alternator Bolt 4 Alternator Adjusting Bolt Note shown 62 YANMAH YM Series Operation Manual 1 Remove the belt cover 2 Check the belt by pushing on the middle of the belt Figure 3 1 with your finger With proper tension the belt should deflect 8 to 10 mm approximately 3 8 in 3 Loosen the 3 bolts of alternator Figure 3 2 3 4 4 Screw in the adjusting bolt Figure 3 4 and move the alt
94. r or distributor for service before operating the engine If the vessel is equipped with a water lift water lock muffler excessive cranking could cause seawater to enter the cylinders and damage the engine If the engine does not start after cranking for 10 seconds close the thru hull water intake valve to avoid filling the muffler with water Crank for 10 seconds at a time until the engine starts When the engine does start stop the engine immediately and turn off the switch Be sure to re open the seacock and restart the engine Operate the engine normally Observe the following environmental operating conditions to maintain engine performance and avoid premature engine wear Avoid operating in extremely dusty conditions Avoid operating in the presence of chemical gases or fumes Never run the engine if the ambient temperature is above 40 C 104 F or below 16 C 5 F If the ambient temperature exceeds 40 C 4 104 F the engine may overheat and cause the engine oil to break down If the ambient temperature is below 16 C 5 F rubber components such as gaskets and seals will harden causing premature engine wear and damage 40 YANMAR YM Series Operation Manual NOTICE Contact your authorized Yanmar Marine engine dealer or distributor if the engine will be operated outside of this standard temperature range Never engage the starter motor while the engine is running Damage to the s
95. rd Always keep hands body parts and loose fitting clothes away from moving rotating parts such as the flywheel or PTO shaft YANMAB Series Operation Manual 47 ENGINE OPERATION CHECKING THE ENGINE AFTER OPERATION Check that the power switch is off and that the battery switch if equipped is turned to off Fill the fuel tank See Filling the Fuel Tank on page 29 Close seawater cock s If there is a risk of freezing check that the cooling system contains enough coolant See Engine Coolant Specifications on page 34 If there is a risk of freezing drain the seawater system See Drain Seawater Cooling System on page 80 At temperatures below 0 C 32 F drain seawater system and connect the engine heater if equipped 48 YM Series Operation Manual YANMAR PERIODIC MAINTENANCE INTRODUCTION This section of the Operation Manual describes the procedures for proper care and maintenance of the engine SAFETY PRECAUTIONS Before performing any maintenance procedures within this section read the following safety information and review the Safety section on page 5 Crush Hazard If the engine needs to be n transported for repair have a EN helper assist you attach it to a hoist and load it on a truck The engine lifting eyes are engineered to lift the weight of the marine engine only Always use the engine lifting eyes when lifting the engine Additional equipment is necess
96. rent brands of antifreeze may cause chemical reactions and may make the antifreeze useless or cause engine problems 34 YANMAH YM Series Operation Manual Checking and Adding Coolant 051169 00X00 Figure 8 1 Coolant Tank Heat Exchanger 2 Coolant Drain Plug 3 Seawater Drain Plug 4 Seawater Pump 5 Coolant Pump 051170 00X00 Figure 9 1 Coolant Tank Heat Exchanger 2 Seawater Drain Cock 3 Coolant Drain Plug BEFORE YOU OPERATE 0004793 Figure 10 1 Stop Solenoid 2 Coolant Drain Cock 3 Flywheel Housing 1 Allow the engine to cool Note The drain cocks are opened before shipping from the factory Close all drain cocks before filling the system with coolant 2 Ensure all drain cocks are closed 3 Loosen the coolant tank filler cap to relieve the pressure then remove the filler cap Burn Hazard Never remove the coolant filler cap if the engine is hot Steam and hot engine coolant will spray out and seriously burn you Allow the engine to cool down before you attempt to remove the cap YANMAR vM Series Operation Manual 35 BEFORE YOU OPERATE 2 gt 32 054720 00X00 0004493 Figure 11 Figure 12 1 Filler Cap Tabs 1 Rubber Hose to Coolant Tank 2 Coolant Filler Cap 2 FULL Mark 3 Filler Port Notches 3 LOW Mark 4 Coolant Tank Heat Exchanger 4 Reservoir cap 4 Pour coolant slowly into the coolant 6 Check the coolant lev
97. rt 1 Turn on the battery switch 2 Push the power switch on All alarm lamps light up for 4 seconds After 4 seconds the charge lamp and the lubricating oil pressure alarm lamp light up and the hourmeter is displayed The alarm buzzer sounds until the engine starts After Engine Start After engine start make sure that the warning devices operate correctly and according to After start in the below table All alarm lamps turn off The above check tells you whether the electric circuit for the warning lamps and alarm buzzer operate correctly If they do not operate correctly inspection and repair are required Consult your dealer or distributor for repairs Correct operation of the warning devices Instrument panel power switch Power ON Immediately After 2 seconds After 4 seconds Before start After start Starter switch OFF ON Alarm buzzer ON OFF Charge lamp ON ON ON OFF Coolant temperature lamp ON ON OFF Engine lubricating oil pressure lamp ON ON ON OFF LCD display Yanmar Full display Hourmeter NOTICE When the warning devices are activated and normal operation is impossible stop the engine and do not use it until the problem has been solved 22 YM Series Operation Manual YANMAR PRODUCT OVERVIEW Accessory power output The harness attached to the panel has a terminal where the signal that is synchronized to the panel power supply can be taken
98. s See Checking and Adjusting the Remote Control Cables on page 63 Adjusting the Propeller Shaft Alignment Consult authorized Yanmar Marine dealer or distributor Tightening All Major Nuts and Bolts See Tightening Fasteners on page 52 or consult authorized Yanmar Marine dealer or distributor YANMAR Series Operation Manual 73 PERIODIC MAINTENANCE This Page Intentionally Left Blank 74 YM Series Operation Manual YANMAR TROUBLESHOOTING SAFETY PRECAUTIONS Before performing any troubleshooting procedures within this section review the Safety section on page 5 If a problem occurs stop the engine immediately Refer to the Symptom column in the Troubleshooting Chart to identify the problem TROUBLESHOOTING AFTER STARTING Just after the engine has started check the following items at a low engine speed Is sufficient water being discharged from the seawater outlet pipe If the discharge is low stop the engine immediately Identify the cause and repair Is the smoke color normal The continuous emission of black exhaust smoke indicates engine overloading This shortens the engines life and should be avoided Are there abnormal vibrations or noise Depending on the hull structure engine and hull resonance may suddenly increase at certain engine speed ranges causing heavy vibrations Avoid operation in this speed range If any abnormal sounds are heard stop the engine and inspect
99. sel engine Combustion System Swirl pre combustion chamber Air Charging Natural aspiration Number of Cylinders 3 Bore x Stroke 76 mm x 82 mm 2 99 in x 3 23 in Displacement 1 115 L 68 04 cu in Continuous Power Output at Crankshaft Engine Speed 19 4 kW 26 4 hp metric 3489 min 1 Fuel Stop Power Output at Crankshaft Engine Speed 21 3 kW 29 0 hp metric 3600 min 1 Output at Propeller Engine Speed 20 7 kW 28 1 hp metric 3600 min 1 Installation Flexible mounting Fuel Injection Timing FID 16 1 BTDC Fuel Injection Opening Pressure 12 8 to 13 28 MPa Main Power Take Off At flywheel end Direction of Crankshaft Counterclockwise viewed from stern Rotation Propeller Shaft Ahead Clockwise viewed from stern Cooling System Coolant cooling with heat exchanger Lubrication System Forced lubrication system Coolant Capacity Engine 4 9 L 5 2 qt Reservoir 0 8 L 0 85 qt Lubricating Rake Angle at rake angle 8 at rake angle 0 Oil Capacity Total 2 8 L 2 96 qt 2 5 L 2 64 qt Engine Effective 1 4 L 1 48 qt 1 5 L 1 59 qt Starting Type Electric System Starting Motor DC 12 V 1 4 kW AC Alternator 12 120 A Engine Overall Length 715 mm 28 1 in Dimension Overall Width 463 mm
100. ssages 56 YM Series Operation Manual YANMAR PERIODIC MAINTENANCE O Check or Clean O Replace Contact your authorized Yanmar Marine dealer or distributor Periodic Maintenance Interval Every Every Before 100 150 Starting hours hours See iti orsix orone Daily monthly months year Checks which which which on ever ever ever page 59 comes comes comes first first first Air Intake Clean the intake silencer and air cleaner element Exhaust System Clean or replace the exhaust water mixing elbow Clean the breather pipe Check the exhaust gas condition During Operatio n Check diaphragm assembly Electrical Check the alarm and System indicators Check the electrolyte level in the battery Adjust the tension of the alternator V ribbed belt or replace V ribbed belt Check the wiring connectors Engine Check for leakage of fuel Cylinder engine oil and engine After Head and coolant Starting Block Tighten all major nuts and bolts Adjust intake exhaust valve clearance Miscellan Check the remote control e ous cables Items Adjust the propeller shaft alignment For EPA requirements see Inspection and Maintenance of EPA Emission Related Parts on page 58 Note These procedures are considered normal maintenance and are performed at the owner s expense
101. sts Yanmar will repair your engine at no charge to you for diagnosis parts and labor Warranty service or repair will be provided at authorized Yanmar Marine dealers or distributors It is recommended that any replacement parts used for maintenance repair or replacement of emission control systems are Yanmar parts The owner may elect to have maintenance replacement or repair of the emission control components and systems performed by any repair establishment or individual and may elect to use parts other than Yanmar parts for such maintenance replacement or repair However the cost of such service or parts and subsequent failures from such service or parts will not be covered under this emission control system warranty Warranty Period The warranty starts on either the date of delivery to the first end user or the date the unit is first leased rented or loaned Engine Model Warranty Period 30 months or 1 500 hours of use whichever comes first 42 months or 2 500 hours of use whichever comes first 2YM15 3YM20 kW lt 19 3YMSOE 19 kW 37 When a measurement device of use hours is not equipped warranties apply a period of use months 98 YANMAH YM Series Operation Manual Warranty Coverage Repair or replacement of any warranted parts will be performed at an authorized Yanmar dealer or distributor This limited emission control system warranty covers engine components
102. sure Hazard Batteries contain sulfuric acid Never allow battery fluid to come in contact with clothing skin or eyes Severe burns could result Always wear safety goggles and protective clothing when servicing the battery If battery fluid contacts the eyes and or skin immediately flush the affected area with a large amount of clean water and obtain prompt medical treatment NOTICE Never turn off the battery switch if equipped or short the battery cables during operation Damage to the electrical system will result Battery fluid tends to evaporate in high temperatures especially in summer In such conditions inspect the battery earlier than specified 1 Make sure the engine is off 2 Turn the battery switch to OFF if equipped or disconnect the negative battery cable 3 Remove the plugs and check the electrolyte level in all cells NOTICE Never attempt to remove the covers or fill a maintenance free battery 4 If the electrolyte level is lower than the minimum fill level Figure 7 1 fill with distilled water Figure 7 2 available locally up to the upper limit Figure 7 3 of the battery 1 Le 0004566 Figure 7 1 Lower Level 2 Water 3 Upper Level Note The maximum fill level is approximately 10 to 15 mm 3 8 to 9 16 in above the plates 66 YANMAH YM Series Operation Manual PERIODIC MAINTENANCE Every 100 Hours of Operation
103. t has not been added to the cooling system add LLC or drain the coolant from the coolant system after daily use If the coolant without LLC is not removed it may freeze and damage parts of the cooling system or engine when ambient temperature is below 0 C 32 F LONG TERM STORAGE YANMAR Series Operation Manual 81 LONG TERM STORAGE This Page Intentionally Left Blank 82 YM Series Operation Manual YANMAR SPECIFICATIONS PRINCIPAL ENGINE SPECIFICATIONS YANMAR Seres Operation Manual 83 SPECIFICATIONS 2YM15 Engine Specifications Specification 2YM15 Marine Gear Model KM2P 1 SD 20 Use Pleasure use Type Vertical water cooled 4 cycle diesel engine Combustion System Swirl pre combustion chamber Air Charging Natural aspiration Number of Cylinders 2 Bore x Stroke 70 mm x 74 mm 2 76 in x 2 91 in Displacement 0 570 L 34 8 cu in Continuous Output at Power Crankshaft Engine Speed 9 1 kW 12 4 hp metric 3489 min Fuel Stop Output at Power Crankshaft Engine Speed 10 0 kW 13 6 hp metric 3600 mint Output at Propeller Engine Speed 9 7 kW 13 2 hp metric 3600 1 Installation Flexible mounting Fuel Injection Timing FID 21 x1 BTDC Fuel Injection Opening Pressure 12 3 to 13 28 MPa Main Power Take Off At flywheel end Direction of Crankshaft Cou
104. t still stopped to distribute engine oil to all parts of the engine Check that sufficient cooling water is discharged from the seawater outlet Operation with inadequate seawater discharge will damage the impeller of the seawater pump If seawater discharge is too low stop the engine immediately Identify the cause and repair NOTICE The engine will seize if it is operated when seawater discharge is too small or if load is applied without any warming up operation For troubleshooting assistance see Troubleshooting After Starting on page 75 or Troubleshooting Chart on page 77 If necessary consult authorized Yanmar dealer or distributor YANMAR Series Operation Manual 43 ENGINE OPERATION REMOTE CONTROL HANDLE OPERATION Acceleration and Deceleration 0004513 Figure 2 1 FORWARD or REVERSE 2 NEUTRAL 3 REVERSE or FORWARD 4 Throttle Handle Shifting Handle Note Direction of travel will vary depending on installation location Use the throttle handle Figure 2 4 to control acceleration and deceleration Move the handle slowly Shifting the Engine Sudden Movement Hazard The boat will start to move when the marine gear is engaged Ensure the boat is clear of all obstacles forward and aft Quickly shift to the FORWARD position then back to the NEUTRAL position Observe whether the boat moves in the direction you expect NOTICE Shifting the marine gear while
105. tarter motor pinion and or ring gear will result ENGINE OPERATION STARTING THE ENGINE 1 Open the seacock if equipped 2 Open the fuel tank cock 3 Put remote control handle in NEUTRAL Note Safety equipment should make it impossible to start the engine in any other position than NEUTRAL Start switch Glow switch Power switch 042590 00E01 Figure 1 Turn on the battery switch if equipped Do not turn off the battery switch during engine operation Also turn it off when the engine does not operate If the alarm buzzer and all warning lamps operate when you turn on the power switch on the instrument panel the warning devices operate correctly Pushing the start switch turns on the engine Release the switch after the engine starts If the warning lamps and the alarm buzzer stops operating the warning devices operate correctly YANMAR Series Operation Manual 41 ENGINE OPERATION If the Engine Fails to Start Before pushing the start switch again be sure to confirm that the engine has stopped completely If an attempt to restart is made while the engine is running the pinion gear of the starter motor will be damaged NOTICE Never hold for longer than 15 seconds or the starter motor will overheat Never attempt to restart the engine if the engine has not stopped completely Pinion gear and st
106. tc described in this manual may differ from ones installed on your vessel Please refer to the manual provided by the manufacturer of these components Refer to the Yanmar Limited Warranty Handbook for a complete warranty description YANMAR Series Operation Manual INTRODUCTION YM SERIES EMISSION CONTROL SYSTEM WARRANTY USA THE ENVIRONMENTAL PROTECTION AGENCY EPA ONLY YM series engines come with an emission control system warranty In all states 2009 and later compression ignition engines must be designed built and equipped to meet the United States EPA emissions standards Yanmar warrants the emission control system on your YM series engine for the periods of time listed below Emission Control Certification Model Year 2012 2013 2YM15 EPA marine Cl Tier 3 3YM20 EPA marine Cl Tier 3 3YM30E EPA marine Cl Tier 3 intermediate NTE 3YM30 EPA marine Cl Tier 3 intermediate Note Since 2013 the 3YM30 does not comply with the EPA regulation 2 YM Series Operation Manual YANMAR INTRODUCTION RECORD OF OWNERSHIP Take a few moments to record the information you need when you contact Yanmar for service parts or literature Engine Model Engine Serial No Date Purchased Dealer Dealer Phone YANMAR Series Operation Manual 3 INTRODUCTION This Page Intentionally Left Blank 4 YM Series Operation Manual YANMAR SAFETY Yanmar co
107. that are a part of the emission control system of the engine as delivered by Yanmar to the original retail purchaser Such components may include the following Fuel Injection System After cooler Electronic Engine Control Units and its associated Sensor and Actuators Exclusions Failures other than those arising from defects in material and or workmanship are not covered by this limited emissions warranty This warranty does not extend to the following malfunction caused by abuse misuse improper adjustment modification alteration tampering disconnection improper or inadequate maintenance improper storage or use of non recommended fuels and lubricating oils accident caused damage and replacement of expendable and or consumable items made in connection with scheduled maintenance Yanmar disclaims any responsibility for incidental or consequential damages such as loss of time inconvenience loss of use of marine vessel engine or commercial loss EPA WARRANTY USA ONLY Owner s Responsibility As the Yanmar Marine engine owner you are responsible for the performance of the required maintenance listed in your Operation Manual Yanmar recommends that you retain all documentation including receipts covering maintenance on your marine engine but Yanmar cannot deny warranty solely for the lack of receipts or for your failure to ensure the performance of all scheduled maintenance Your engine is design
108. ulty starter switch Consult authorized Yanmar Marine dealer or distributor Power lacking due to accessory drive being engaged Consult authorized Yanmar Marine dealer or distributor Engine cannot be turned manually Internal parts seized Consult authorized Yanmar Marine dealer or distributor Abnormal Exhaust Color Black smoke Load increased Consult authorized Yanmar Marine dealer or distributor Improper propeller matching Consult authorized Yanmar Marine dealer or distributor Dirty intake silencer air cleaner Clean element See Cleaning the Intake Silencer Air Cleaner Element on page 70 Improper fuel Replace with recommended fuel See Diesel Fuel Specifications on page 26 Faulty spraying of fuel injector Consult authorized Yanmar Marine dealer or distributor Incorrect intake exhaust valve clearance Consult authorized Yanmar Marine dealer or distributor White smoke Improper fuel Replace with recommended fuel See Diesel Fuel Specifications on page 26 Faulty spraying of fuel injector Consult authorized Yanmar Marine dealer or distributor Fuel injection timing off Consult authorized Yanmar Marine dealer or distributor Excessive diesel fuel consumption Consult authorized Yanmar Marine dealer or distributor 78 YM Series Operation Manual YANMAR LONG TERM STORAGE
109. ustion chamber diesel engines equipped with liquid coolant systems The 2YM15 is a 2 cylinder engine and is naturally aspirated The 20 is a 3 cylinder engine and is naturally aspirated The 3YM30 is a 3 cylinder engine and is naturally aspirated The engines are equipped with a marine gear or sail drive unit These engines are designed for pleasure craft use and complied with EPA regulation Tier3 marine from 2009 year It is recommended that new vessels be propped so the engines can operate at 100 to 200 above the Maximum Rated output power engine speed 3700 to 3800 to allow for some added weight and hull resistance The engine must be able to reach the Maximum Rated Power engine speed 3600 under full load at all times Failure to do so can lead to reduced vessel performance lead to increased smoke levels and cause permanent damage to your engine The engine must be installed correctly with coolant lines exhaust gas lines and electrical wiring Any auxiliary equipment attached to the engine should be easy to use and accessible for service To handle the drive equipment propulsion systems including the propeller and other inboard equipment always observe the instructions and cautions given in the operation manuals supplied by the shipyard and equipment manufacturers The YM series engines are designed to be operated at maximum throttle 3600 1 for less than 596 of total
110. y or death This information contains general safety precautions and guidelines that must be followed to reduce risk to personal safety Special safety precautions are listed in specific procedures Read and understand all of the safety precautions before operation or performing repairs or maintenance Before You Operate A DANGER The safety messages that follow have DANGER level hazards Never permit anyone to install or operate the engine without proper training Read and understand this Operation Manual before you operate or service the engine to ensure that you follow safe operating practices and maintenance procedures Safety signs and labels are additional reminders for safe operating and maintenance techniques Consult authorized Yanmar Marine dealer or distributor for additional training During Operation and Maintenance The safety messages that follow have WARNING level hazards Explosion Hazard While the engine is running or the battery is charging hydrogen gas is being produced and can be easily ignited Keep the area around the battery well ventilated and keep sparks open flames and any other form of ignition out of the area Fire and Explosion Hazard Diesel fuel is flammable and explosive under certain conditions Never use a shop rag to catch the fuel Wipe up all spills immediately Never refuel with the engine running Fire Hazard Undersized wiring systems can cause

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