Yanmar 3YM30, 3YM20, 2YM15 User Manual

3YM20/3YM30

MARINE DIESEL ENGINE

MODEL:2YM15/3YM20/3YM30

OPERATION MANUAL

The 2YM15/3YM20/3YM30 is an EPA Certified Engine.

It meets the low emission standards set by the EPA.

California Proposition 65 Warning

Diesel engine exhaust and some of its constituents are known to the State of

California to cause cancer, birth

defects, and other reproductive harm.

California Proposition 65 Warning

Battery posts, terminals, and related

accessories contain lead and lead

compounds, chemicals known to the

State of California to cause cancer and

reproductive harm. Wash your hands

after handling.

YanmarYanmar

mission of YANMAR CO., LTD.

INTRODUCTION ........................................... 3

1. FOR YOUR SAFETY ...............................4

1.1 Warning Symbols .............................. 4

1.2 Safety Precautions ............................ 5

1.3 Warning Labels ................................. 8

2. PRODUCT EXPLANATION .....................9

2.1 Use, Propulsion System, Etc. ............ 9

2.2 Engine Specifications ...................... 11

2.3 Names of Parts ............................... 14

2.4 Major Service of Parts ..................... 17

2.5 Control Equipment .......................... 18

2.5.1 Instrument Panel ................... 18

2.5.2 Controls and equipment ........18

2.5.3 Meters ...................................19

2.5.4 Alarm equipment (lamps and buzzer) 19

2.5.5 Normal action of alarm devices .

2.5.6 Single Lever Remote Control Handle 20

2.5.7 Shut-down Equipment ........... 20

4. MAINTENANCE AND INSPECTION ......36

4.1 General Inspection Rules ................36

4.2 List of Periodic Inspection Items ......37

4.3 Periodic Inspection Items ................39

4.3.1 Inspection on Initial 50 Hrs. of Operation (or after 1 Month) 39

4.3.2 Inspection Every 50 Hrs. (or Monthly) 41

4.3.3 Inspection Every 100 Hrs (or six months). 43

4.3.4 Inspection Every 150 Hrs (or one year). 43

4.3.5 Inspection Every 250 Hrs (or one year). 43

4.3.6 Inspection Every 1000 Hrs (or 4 years). 45

4.3.7 Annually .................................46

4.4 EPA Requirements ..........................47

4.4.1 EPA Certification Plate ...........47

4.4.2 Conditions to Insure Compliance with Emission Standards 47

4.4.3 Inspection and Maintenance ..48

5. TROUBLE AND TROUBLESHOOTING .49

3. OPERATION .......................................... 21

3.1 Fuel Oil, Lubricating Oil, and Cooling Water 21

3.1.1 Fuel Oil ..................................21

3.1.2 Lubricating Oil ....................... 22

3.1.3 Cooling fresh water ...............24

3.1.4 Handling of Coolant ............... 24

3.2 Before Initial Operation ................... 25

3.2.1 Supply Fuel Oil ...................... 25

3.2.2 Supply Engine Lubricating Oil 25

3.2.3 Supply Marine Gear Lubricating

Oil 25

3.2.4 Supply Cooling Water ............ 26

3.2.5 Cranking ................................27

3.2.6 Check and Re-supply Lubricating

Oil and Cooling Water 28

3.3 Operating your engine .................... 28

3.3.1 Daily Start Up Inspection .......28

3.3.2 How to Start the Engine ........30

3.3.3 Operation ...............................32

3.3.4 Cautions During Operation .... 32

3.3.5 Engine shut-down .................. 33

3.4 Long Term Storage ......................... 34

6. PIPING DIAGRAMS ...............................52

7. WIRING DIAGRAMS ..............................53

INTRODUCTION

Thank you for purchasing a YANMAR Marine Diesel Engine.

This Operation Manual describes the operation, maintenance and inspection of the 2YM15/3YM20/3YM30Yanmar Marine Diesel Engines.

Read this Operation Manual carefully before operating the engine to ensure that it is used correctly and that it stays in the best possible condition.

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 dealer or distributor.

Make sure this manual is transferred to subsequent owners. It should be considered as a permanent part of the engine and remain so.

Constant efforts are made to improve the quality and performance of Yanmar products, so some details included in this Operation Manual may differ slightly from your engine. If you have any questions about this, please contact your Yanmar dealer or distributor.

Model 2YM15/3YM20/3YM30

Operation Manual (Marine Engine)

Code. No. 49961-206364

The essentials of the sail drive are described in this manual. For further details on its use, refer to the sail drive manual.

1. FOR YOUR SAFETY

1.1 Warning Symbols

Most operation, maintenance and inspection problems arise due to users' failure to comply with the rules and precautions for safe operation described in this operation manual. Often, users do not understand or recognize the signs of approaching problems. Improper handling can cause burns and other injuries and can result in death.

DANGER

WARNING

The descriptions captioned by are particularly important cautions for handling. If you ignore them, the performance of your machine may deteriorate leading to problems.

CAUTION

DANGER indicates an imminently hazardous situation, which if not avoided, WILL result in death or serious injury.

WARNING indicates a potentially hazardous situation, which if not avoided, COULD result in death or serious injury.

CAUTION indicates a potentially hazardous situation, which if not avoided, may result in minor or moderate injury. This sign is also used to alert against unsafe practices.

NOTICE

Be sure to read this operation manual carefully before operating the engine and observe all of the instructions and precautions described in this manual. Follow the warning signs below in this manual. Pay special attention to parts containing these words and signs.

1. FOR YOUR SAFETY

1.2 Safety Precautions

(Observe these instructions for your own safety!)

Precautions for Operation

DANGER

WARNING

Filler Cap of Coolant Tank Never open the cap of the coolant tank while the engine is still hot.

Steam and hot water may spurt out and burn you seriously. Wait until the temperature of the coolant tank has dropped, wrap a cloth around the filler cap, loosen the cap very carefully and slowly to remove the system pressure before removing the cap. After inspection, refasten the cap firmly.

Battery Never smoke or permit sparks near the battery, because it may emit ex-

plosive hydrogen gas. Place the battery in a well-ventilated place.

Fuel Use only diesel fuel. Never use other fuels, including gasoline, kero-

sene, etc., because they could cause a fire. The wrong fuel could also cause the fuel injection pump and injector to fail due to lack of proper lubrication. Be sure to check that you have selected the correct diesel fuel before filling the fuel tank.

Do not use starting fluids or sprays. Their use may cause explosion, serious injury and engine damage.

Fire Prevention Be sure to stop the engine and confirm that there are no open flames in

the vicinity before fueling. If you do spill fuel, wipe such spillage carefully and dispose of the wiping materials properly. Wash your hands thoroughly with soap and water.

Never place oil or other flammable material in the engine room. Install a fire extinguisher near the engine room, and familiarize yourself

with its use.

WARNING

Exhaust Gas Exhaust gas contains poisonous carbon monoxide and should not be

inhaled. Be sure to install ventilation ports or ventilators in the engine room and

ensure good ventilation during engine operation.

1. FOR YOUR SAFETY

WARNING

CAUTION

WARNING

DANGER

Moving Parts Do not touch or let your clothing get caught in the moving parts of the

engine, such as the front drive shaft, V-belt or propeller shaft, during engine operation. You will be injured.

Never operate the engine without covers on the moving parts.

Burns The whole engine is hot during operation and immediately after

shut-down. The exhaust manifold, exhaust pipe and high pressure fuel lines are very hot. Never touch these parts with your body or clothing.

Alcohol Never operate the engine while you are under the influence of alcohol. Never operate the engine when you are ill or not feeling well.

Battery Fluid Battery fluid is dilute sulphuric acid. It can blind you if it gets in your

eyes, or burn your skin. Keep the fluid away from your body. If you touch it, wash it off immediately with a large quantity of fresh wa-

ter and call your doctor for treatment.

WARNING

Fire by Electric Short-Circuits Always turn off the battery switch before inspecting the electrical sys-

tem. Failure to do so could cause short-circuiting and fires.

Stop the engine before you service it. Turn the battery switch off. If you must inspect while the engine is in op-

eration, never touch moving parts. Keep your body and clothing well clear of all moving parts.

1. FOR YOUR SAFETY

CAUTION

DANGER

Scalds When extracting oil from the engine while it is still hot, don't let the oil

splash on you. Wait until the temperature has dropped before extracting cooling water

from the engine. Don't let it splash on you.

Forbidden Modifications. Never release the limiting devices such as the engine speed limit, fuel

injection limit, etc. Modification will impair the safety and performance of the product and

shorten product life. Also note that any troubles arising from modification are not covered by

our warranty.

Precautions for Treating Waste. Never dispose of waste oil or other fluid in a field, sewer, river, or the

sea. Treat waste matters safely observing regulations or laws. Ask a waste recovery company to collect it.

1. FOR YOUR SAFETY

1.3 Warning Labels

Safety Precautions for Inspection

To insure safe operation, warning device labels have been attached. Their location is shown below and they should always be visible. Please replace if damaged or lost.

Product Safety Labels

No. Part Code No.

A 128377-07260

B 128377-07350

C 196630-12980

WARNING

196630-12980

DANGER

2. PRODUCT EXPLANATION

2.1 Use, Propulsion System, Etc.

The engine is equipped with a marine gear or a sail drive unit. The marine gear output shaft connects with the propeller shaft.

In order to obtain full performance from your engine, it is imperative that you check the displacement and structure of the hull and use a propeller of the appropriate size. As new boats are used, owners add additional equipment and completely fill the fuel and water tanks adding to the overall displacement (weight) of the vessel. Extra canvas enclosures, bottom paint, and bottom fouling can add additional hull resistance. It is recommended that new vessels be propped so the engines can operate at 100-200 rpm above rated rpm to allow for some added weight and hull resistance. Failure to do so can lead to reduced vessel performance, lead to increased smoke levels and cause permanent damage to your engines.

The engine must be installed correctly with safe cooling water and exhaust piping 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 onboard equipment be sure to observe the instructions and cautions given in the operation manuals supplied by the shipyard and equipment manufacturers.

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. Consult Yanmar's local subsidiary in your region or your distributor or dealer.

NOTICE

This engine is designed for pleasure boat applications.

The engine is designed to be operated at:

Maximum throttle (3600-3800 rpm) for less than 5% of total engine time. (30 minutes out of every 10 hours)

Cruising Speed (3400 rpm or lower) for less than 90% of total engine time (9 hours out of every 10 hours)

WARNING

Never modify this product or release the limit devices (which limit engine speed, fuel injection quantity, etc.). Modification will impair the safety and performance of the product and functions and shorten the product life. Please note that any troubles arising from modification of the product will not be covered by our warranty.

2. PRODUCT EXPLANATION

DETAIL OF NAMEPLATE

The nameplate shown below is attached to the engine. Check the engine's model, output, rpm and serial number on the nameplate.

The nameplate shown below is attached to the marine gear. Check the marine gear's model, gear ratio, oil used, oil quantity and serial number.

Model

Gear Model Continuous power Speed of prop. shaft Fuel stop power kW

ENG.No.

YANMAR DIESEL ENGINE

YANMAR CO., LTD.

MADE IN JAPAN

rpm

MODEL KM GEAR RATIO OIL SAE

/30HD OIL QTY. LTR. NO.

KANZAKI

OSAKA JAPAN

2. PRODUCT EXPLANATION

2.2 Engine Specifications

Engine Model unit 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

Number of cylinders - 2

Bore x stroke mm(inch) 70x74(2.76x2.91)

Displacement L 0.570

Continuous power

Fuel stop power

Installation - Flexible mounting

Fuel injection opening pressure MPa 12.3+0.98-0

Direction of rotation

Cooling system - Fresh water-cooling with heat exchanger

Lubrication system - Complete enclosed forced lubrication

Cooling water capacity (fresh) L(quart) Engine 3.0 (3.2), Coolant recovery tank: 0.8(0.8)

Lubricating oil capacity (engine)

Starting system

Engine dimension

Engine dry mass (include marine gear)

[1] hp = 0.7355 kW [2] Fuel temperature at the inlet of the fuel injection pump. [3] The "Total" oil quantity includes oil in oil pan, channels, coolers and filter. [4] The effective amount of oil shows the difference in maximum scale of the dipstick and minimum

Output at crankshaft/ Engine speed

Output at propeller/ Engine speed

Crankshaft - Counter-clockwise viewed from stern

Propeller shaft (Ahead)

Rake angle °(deg) at rake angle 8° at rake angle 0°

[3]

Total

Effective

Type - Electric

Starting motor V-kW DC 12V - 1.4 kW

AC generator V-A 12V - 60A (12V - 80A optional)

Overall length mm(inch) 613(24.1) -

Overall width 463(18.2)

Overall height 528(20.8)

scale.

[4]

kW(hp)/

-1[1]

min

kW(hp)/

-1

[1]

min

kW(hp)/

min

L(quart) 2.0(2.1) 1.8(1.9)

kg 113 134(with SD20)

10.0(13.6)/3600(at Fuel temp. 25°C) [2]

-1

[1]

/9.7(13.2)/3600(at Fuel temp. 40°C) [2]

- Clockwise viewed from stern -

9.4(12.8)/3489(at Fuel temp. 25°C)

10.3(14.0)/3600(at Fuel temp. 25°C) [2]

/10.0(13.6)/3600(at Fuel temp. 40°C) [2]

0.95(1.0) 0.9(1.0)

[2]

Note: Fuel condition: Density at 15 ºC = 0.842

Rating condition ISO 3046-1, at fuel temp. 25°C ; ISO 3046-1, at fuel temp. 40°C inlet; ISO 8665. At FO pump inlet.

2. PRODUCT EXPLANATION

Engine Model unit 3YM20 3YM30

Marine gear model - KM2P-1 SD-20 KM2P-1 SD-20

Use - Pleasure use Pleasure use

Type - Vertical water-cooled 4-cycle diesel

Combustion system - Swirl pre-combustion chamber Swirl pre-combustion chamber

Number of cylinders - 3 3

Bore x stroke mm(inch) 70x74(2.76x2.91) 76x82(2.99x3.23)

Displacement L 1.115 1.115

Continuous power

Fuel stop power

Installation - Flexible mounting Flexible mounting

Fuel injection opening pressure

Direction of rotation

Cooling system - Fresh water-cooling with heat

Lubrication system - Complete enclosed forced lubrication Complete enclosed forced lubrication

Cooling water capacity (fresh)

Lubricating oil capacity (engine)

Starting system

Engine dimension

Engine dry mass (include marine gear)

Output at crankshaft/ Engine speed

Output at propeller/Engine speed

Crankshaft - Counter-clockwise viewed from stern Counter-clockwise viewed from stern

Propeller shaft (Ahead)

Rake angle °(deg) at rake angle 8° at rake angle 0° at rake angle 8° at rake angle 0°

[3]

Total

[4]

Effective

Type - Electric Electric

Starting motor V-kW DC 12V - 1.4 kW DC 12V - 1.4 kW

AC generator V-A 12V - 60A (12V - 80A optional) 12V - 60A (12V - 80A optional)

Overall length mm(inch) 693(27.3) - 715(28.1) -

Overall width 463(18.2) 463(18.2)

Overall height 528(20.8) 545(21.5)

kW(hp)/

min-

kW(hp)/ min

MPa 12.3+0.98-0 12.3+0.98-0

L(quart) Engine 4.5 (4.8), Coolant recovery tank:

L(quart) 2.7(2.85) 2.4(2.5) 2.8(3.0) 2.5(2.6)

14.7(20.0)/3489(at Fuel temp. 25°C)

1[1]

16.2(22.0)/3600(at Fuel temp. 25°C) [2]

-1

[1]

/15.3(20.8)/3600(at Fuel temp. 40°C) [2]

15.7(21.3)/3600(at

-1

[1]

Fuel temp. 25°C) [2]

/14.9(20.2)/3600(at

Fuel temp. 40°C) [2]

- Clockwise viewed

kg 130 151(with SD20) 133 154(with SD20)

from stern

1.4(1.5) 1.5(1.6) 1.4(1.5) 1.5(1.6)

engine

- 21.4(29.1)/3600(at

- Clockwise viewed

exchanger

0.8(0.8)

scale.

Vertical water-cooled 4-cycle diesel

[2]

20.1(27.3)/3489(at Fuel temp. 25°C) [2]

22.1(30.0)/3600(at Fuel temp. 25°C) [2]

/21.3(29.0)/3600(at Fuel temp. 40°C) [2]

Fuel temp. 25°C) [2]

/20.7(28.1)/3600(at

Fuel temp. 40°C) [2]

from stern

Fresh water-cooling with heat

Engine 4.9(5.2), Coolant recovery tank:

engine

exchanger

0.8(0.8)

Note: Fuel condition: Density at 15 ºC = 0.842

Rating condition ISO 3046-1, at fuel temp. 25°C ; ISO 3046-1, at fuel temp. 40°C inlet; ISO 8665. At FO pump inlet.

2. PRODUCT EXPLANATION

Marine gear or Sail Drive

[1] At continuous power engine speed 3489 min

Model Unit KM2P-1(S) KM2P-1(G) KM2P-1(GG) SD20 (coupled

Type - Mechanical cone clutch Dog clutch

Reduction ratio (Forward/Reverse)

Propeller speed (For-

ward/Reverse)

Lubrication system - Splash Oil bath

Lubricating oil capacity L (quart) 0.3 (0.32) 2.2 (2.3)

Mass kg 9.8 30

[1]

min

at boat builder)

- 2.21/3.06 2.62/3.06 3.22/3.06 2.64/2.64

-1

1580/1140 1332/1140 1083/1140 1322

-1

2. PRODUCT EXPLANATION

2.3 Names of Parts

2YM15 Operation Side

A Intake silencer F Oil filler cap

B Intake manifold G Fuel feed pump C Fuel filter H Lubricating oil filter D Fuel injection pump I Marine gear EDipstick

Non Operation Side

A Seawater pump F Exhaust manifold C Filler cap G Starter motor D Engine name plate (on the rocker arm cover)H Shift lever E Coolant tank / Heat exchanger I Alternator

2. PRODUCT EXPLANATION

3YM20 Operation Side

A Intake silencer F Oil filler cap B Intake manifold G Fuel feed pump C Fuel filter H Lubricating oil filter D Fuel injection pump I Marine gear EDipstick

C D

Non Operation Side

A Seawater pump F Exhaust manifold C Filler cap G Starter motor D Engine name plate (on the rocker arm cover)H Shift lever E Coolant tank / Heat exchanger I Alternator

F G

2. PRODUCT EXPLANATION

3YM30 Operation Side

A Intake silencer F Oil filler cap B Intake manifold G Fuel feed pump

C Fuel filter H Lubricating oil filter D Fuel injection pump I Marine gear EDipstick

Non Operation Side

A Seawater pump F Exhaust manifold C Filler cap G Starter motor D Engine name plate (on the rocker arm cover)H Shift lever E Coolant tank / Heat exchanger I Alternator

F G

2. PRODUCT EXPLANATION

2.4 Major Service of Parts

Name of part Function

Fuel filter

Fuel feed pump Pumps fuel from tank to the fuel injection pump.

Priming lever

Filler port (engine) Filler port for engine lubricating oil.

Filler port (marine gear)

Lubricating oil filter

Cooling System

Fresh water pump

Seawater pump

Fresh water/coolant filler cap

Coolant recovery tank

Intake silencer The intake silencer guards against dirt in the air and reduces the noise of air intake.

Nameplates

Starter Starter motor for the engine. Powered by the battery.

Alternator Rotated by belt drive, generates electricity and charges the battery.

Removes dirt and water from fuel. Drain the filter periodically. The element (filter) should be changed. See maintenance section 4.3.5

Moving the priming lever up and down feeds the fuel. The priming lever is used to bleed air from the fuel system after running out of fuel.

Filler port for marine gear lubricating oil.

Filters fine metal fragments and carbon from the lubricating oil. Filtered lubricating oil is distributed to the engine's moving parts.

There are two cooling systems: fresh water and seawater. The engine’s combustion heat is cooled by the fresh water/coolant in a closed circuit. The fresh water is cooled by seawater using heat exchanger. The seawater also cools the engine- and gear-oil (and depending on the model also intake air) through coolers in an open circuit.

The centrifugal water pump circulates fresh cooling water inside the engine. The fresh water pump is driven by the V-belt.

Pumps seawater from outside the vessel to the engine by passing through the engine’s coolers. The seawater pump is belt driven and has a replaceable rubber impeller.

The filler cap on the 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 fresh water system.

The pressure regulating valve releases vapour and hot water overflows to the coolant recovery tank When the engine stops and cooling water cools, the pressure in the cooling water tank also drops very low. The filler cap valve then opens to send water back from the coolant recovery tank. This minimizes cooling water consumption. Fresh water/coolant level can easily be checked and refilled in this tank.

Nameplates are provided on the engine and the marine gear and have the model, serial number and other data.

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