Yanmar 3YM30, 3YM20, 2YM15 User Manual

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Page 1

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.

Page 2

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

Page 3

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.

Page 4

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.

Page 5

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.

Page 6

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.

Page 7

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.

Page 8

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

Page 9

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.

Page 10

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

Page 11

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.

Page 12

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.

Page 13

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

Page 14

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

Page 15

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

Page 16

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

Page 17

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.

Page 18

2. PRODUCT EXPLANATION

SLOW

min

-1

Mpa

trancasers

OFF

START

STOP

2.5 Control Equipment

The equipment in the control room, making remote control possible, consists of the instrument panel, which is connected by wire harness and the remote control handle, which is hooked up by remote control cables to the engine control lever and marine gear.

2.5.1 Instrument Panel

2.5.1.1 Controls and equipment

The instrument panel is located in the control room. The following instruments enable you to start / stop the engine and to monitor its condition during operation.

B type

HIJK

-1

min

Mpa

 

SLOW

trancasers

BEF G

A Tachometer H Coolant high tempera-

ture alarm

B Hour meter I Lubricating oil low pres-

sure alarm

E Key switch J Water in sail drive seal

alarm

F Moisture cap for key

switch

K Battery low charge

alarm

G Stop button switch

STOP

OFF

START

Instruments, equipment Functions

The switch key can be inserted or removed. All electric current is cut off.

The electric current to the controls and equipment is turned on. Engine keeps running. To stop the engine, the key switch should be in ON position. After stopping the engine, please turn OFF the key

Key switch Rotary switch with 4 positions

OFF

switch.

GLOW

OFF

START

The start position of the engine. The electric current to the starting motor is turned on. When you release the key, it will automatically turn to ON position.

The start aid position of the engine. The electric current to the air

GLOW

heater /glow plug is turned on. When you release the key, it will automatically turn to ON position.

Note: When you don’t use the engine, please remove the key from the key switch and cover the keyhole with the cap to protect from corrosion.

Stop button switch

Push button switch to stop the engine. The electric current to the stop solenoid is turned on.

Page 19

2. PRODUCT EXPLANATION

2.5.1.2 Meters

B type panels use analog electric systems and have a pointer indicator.

Instruments, equipment Functions

Tachometer The engine’s rotation speed is indicated.

Hour meter

Panel lights When turning the key switch to ON, the meters light, for easy viewing.

2.5.1.3 Alarm equipment (lamps and buzzer)

When the sensor detects a problem during operation, the lamp comes on and the buzzer sounds.

The alarm lamps are located on the panel, the buzzer is located on the back of panel. Under normal conditions, the monitors are off. When there is a problem, the monitors lights up.

The number of hours of operation is indicated, and can be used as a guide for periodic maintenance checks. The hour meter is at the bottom of the tachometer.

Battery low charge alarm

Coolant high temperature alarm

Lubricating oil low pressure alarm

Water in sail drive seal alarm

When the alternator output is too low, the lamp will come on. When charge begins, the lamp will turn off. (The alarm buzzer will not sound, when the lamp comes on.)

When the temperature reaches the maximum (95°C [203°F] or higher), the lamp will light and the buzzer will sound. Continuing operation at temperatures exceeding the maximum limit will result in damage and seizure. Check the load and the fresh water cooling system for any abnormalities.

When the lubricating oil pressure falls below normal, the oil pressure sensor will register this and the lamp will come on and the alarm will sound. Continuing operation with insufficient oil pressure will result in damage and seizure. Check the oil level.

When seawater is detected between the seals of the sail drive, the lamp will come on and the alarm will sound.

2.5.1.4 Normal action of alarm devices

Alarm devices act as shown below. Please check that alarm lamps and buzzer are working normally, when the key is turned on.

Key switch OFF->ON START->ON

Engine Before start Running

Alarm buzzer Sounds Stops

Alarm lamps Battery low charge alarm Lights Off

Coolant high temperature alarm Off Off

Lubricating oil low pressure alarm Lights Off

Water in sail drive seal alarm Off Off

Page 20

2. PRODUCT EXPLANATION

2.5.2 Single Lever Remote Control Handle

This remote control system uses a singlehandle to operate the marine gear-clutch (neutral, forward, reverse) and to control the engine speed.

NEUTRAL: Power to the propeller shaft is cut off and the engine idles.

A FWD (forward) DClutch is disengaged B REV (reverse) EPull out handle C NEUTRAL (boat is stopped)

The handle controls the direction of the boat (ahead or astern) and, at the same time, acts as an accelerator increasing the engine speed as it is pushed further in the FWD or REV direction. If the handle is pulled out, engine speed can be controlled without engaging the clutch (clutch remains in the NEUTRAL, no load position).

2.5.3 Shut-down Equipment

Electric Operation

Engine shut-down by stop button

A Stop button on the instrument panel

Push the stop button on the instrument panel when the key is in the ON position.

CAUTION

If the engine is stopped suddenly at a high temperature, the temperature of various parts will increase and engine trouble may occur.

Emergency Stop

When you can’t stop the engine by the stop button on the panel, push the button at the back of the stop solenoid.

NOTICE

Yanmar recommends the use of a single-lever type for the remote control system. If only the two-lever type is available in the market, operate the engine at 1000 rpm or lower before engaging and disengaging the marine gear-clutch.

A Emergency stop button B Stop solenoid

Page 21

3. OPERATION

3.1 Fuel Oil, Lubricating Oil, and Cooling Water

3.1.1 Fuel Oil

NOTICE

Only use the recommended fuel to obtain the best engine performance and to keep the durability of the engine, also to comply with the emission regulations.

(1) Selection of Fuel Oil

Diesel fuel oil should comply with the following specifications.

• The fuel specifications need to comply with each national standard or international standards.

• ASTM D975 No.1-DNo.2-D ... for USA

• EN590:96 ................................ for EU

• ISO 8217 DMX .............. International

• BS 2869-A1 or A2 ................... for UK

• JIS K2204 ......................... for JAPAN

The following requirements also need to be fulfilled.

• Cetane number should be equal to 45 or higher.

• Sulphur content of the fuel. It should not exceed 0.5%by volume. (Preferably it should be below 0.05 %)

• Water and sediment in the fuel oil should not exceed 0.05% by volume.

• Ash should not exceed 0.01%by mass.

• 10% Carbon residue content of the fuel. It should not exceed 0.35%by volume. (Preferably it should be below

0.1 %)

• Aromatics (total) content of the fuel. It should not exceed 35% by volume. (Preferably it should be below 30% and aromatics (PAH*) content of the fuel preferably it should be below 10%)

PAH*: polycyclic aromatic hydrocarbons

• DO NOT use Biocide.

• DO NOT use Kerosene, residual fuels.

• DO NOT mix winter fuel and summer fuel.

Note: Engine breakdown can be attributed to insufficient quality of fuel oil.

(2) Handling of Fuel Oil

1. Water and dust in the fuel oil cause engine failure. When fuel is stored, be sure that the inside of the storage container is clean, and that the fuel is stored away from dirt or rain water.

2. Keep the fuel container stationery for several hours to allow any dirt or water to settle to the bottom. Use a pump to extract the clear, filtered fuel from the top of the container for use.

Use the clear filtered fuel from the upper middle section of the container only, leaving any contaminated fuel at the bottom.

Page 22

3. OPERATION

(3) Fuel Tank

The inside of the fuel tank should always be clean enough and it should be dry for the first use. Drain the water according to the maintenance (section

5) with a drain valve.

A Sediment C To engine BDrain cock

(4) Fuel System

Install the fuel pipe from the fuel tank to the fuel pump in accordance with the diagram. The fuel/water separator (optional) is placed at the center section of the line.

Fuel System

NOTICE

When other than the specified fuel oil is used, the engine will not perform to full capacity and parts may be damaged.

3.1.2 Lubricating Oil

NOTICE

Using other than the specified lubricating oil will lead to seizure of parts, abnormal wear, and shorten engine life.

(1) Selection of Engine Lubricating Oil

Use the following Lubricating oil:

• API Classification ........... CD or better

TBN value: 9 or more

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(HCl), ASTM

D4739(HCl)

• SAE viscosity ......... 10W30 or 15W40

If you operate your engine at temperatures below the limits shown below, consult your dealer for special lubricants and starting aids.

A Fuel filter F Drain cock B Fuel feed pump (prim-

ing lever) C Fuel/water separator H Fuel return D Approx. 20-30 mm(3/

4”-1 1/8”) E Within 500 mm(20”) J Fuel tank

G Fuel cock

I To fuel injection pump

Page 23

3. OPERATION

Selection of viscosity (SAE Service

grade)

9

9

9

9







ޓ ޓ ޓ ޓ ޓ ޓ ޓ 

Atmospheric temperature (°C)

10W-30 can be used almost throughout the year.

DO NOT use The following engine oils.

API : CG-4, CH-4 ACEA : E-1, E-2, B grade JASO : DH-2, DL-1 Reason

• API CG-4, CH-4 In case CG-4, CH-4 is to be used for

YANMAR YM diesel engine series, there is a possibility that excessive wears occur on the valve train system due to the content of oil.

or QuickSilver® High Performance Gear Lube

QuickSilver® is a registered trademark of the Brunswick Corporation.

(4) Handling the Lubricating Oil

1. When handling and storing lubricating oil, be careful not to allow dust and water to enter the lubricating oil. Clean around the filler port before refilling.

2. Do not mix lubricating oils of different types or brands. Mixing may cause the chemical characteristics of the lubricating oil to change and lubricating performance to drop, reducing the engine's life. Before supplying lubricating oil to the engine and marine gear for the first time, extract any lubricating oil remaining in the tank. Use new lubricating oil.

3. Lubricating oil supplied to the engine will undergo natural degradation with time even when the engine is not used. Lubricating oil should be replaced at the specified intervals, regardless of whether the engine is being used or not.

If you operate your equipment at temperatures below the limits shown, consult your dealer for special lubricants and starting aids.

• ACEA E-1,E-2, B These fuels are developed for the dif-

ferent type of diesel engines.

• JASO DH-2, DL-1 These fuels are developed for the dif-

ferent type of diesel engines.

(2) Selection of Oil for Marine Gear

• API Classification ........... CD or better

• SAE viscosity ................... #20 or #30

(3) Selection of Oil for Sail Drive Unit

• API service grade ....................GL4.5

• SAE Viscosity ............... 90 or 80W90

CAUTION

Contact with engine oil may result in the roughened skin. Care should be taken so as not to contact with engine oil wearing protective gloves and clothing.

When handling the engine oil, make sure to use the protective gloves at any time.

If contact, wash with soap and water thoroughly.

Page 24

3. OPERATION

3.1.3 Cooling fresh water

Use clean soft water and always be sure to add LLC (Long Life Coolant) in order to prevent rust built up and freezing. (Do not use water only.)

The recommended LLC conform to the following specifications.

• JIS K-2234

• SAE J814C, J1941, J1034, J2036

• ASTM D3306

• ASTM D4985

Consult your Yanmar dealer or distributor on the use of coolant/antifreeze, and detergents. Examples of LLC which provide good performance are:

• TEXACO LONG LIFE COOL-

ANT ANTIFREEZE, both standard and pre-mixed.

Product code 79947 and 7998.

• HAVOLINE EXTENDED LIFE ANTIFREEZE/COOLANT.

Product code 7994

NOTICE

• Always be sure to add LLC to soft water. In particular, in cold season, to add LLC is important.

Without LLC,

ambient temperature. LLC concentration should be 30% as a minimum and 60% as a maximum.

• DO NOT mix the different types of brand of LLC, otherwise harmful sludge may yield.

• DO NOT use hard water.

• Water should be free from sludge and/ or particles.

CAUTION

When handling LLC, use protective gloves to avoid skin contact.

In case it comes in contact with your skin or eyes, wash it out with clean water.

3.1.3.1 Handling of Coolant

(1) Choose LLC, which will not have

any adverse effects on the materials (cast iron, aluminium, copper, etc.) of the engine's fresh water cooling system.

(2) Replace the cooling water periodi-

cally, according to the maintenance schedule given in this operation manual.

(3) Remove the scale from the cooling

water system periodically, according to the instructions in this operation manual.

Cooling performance will decrease due to scale and rust in the cooling water system.

This causes serious damage in the cooling system.

• Be sure to use the proper amount of coolant concentrate specified by the LLC manufacturer depending on the

NOTICE

Excessive use of LLC also lowers the cooling efficiency of the engine. Be sure to use the mixing ratios specified by the antifreeze maker for your temperature range.

Page 25

3. OPERATION

3.2 Before Initial Operation

Perform the following before using the engine for the first time:

3.2.1 Supply Fuel Oil

DANGER

(1) Before filling with fuel, wash out the

fuel tank and fuel system with clean kerosene or light oil.

(2) Fill the tank with clean fuel oil, free

of dirt and water.

3.2.2 Supply Engine Lubricating Oil

(1) Remove the filler port cap (yellow)

at the top of the rocker arm cover, and fill with engine oil.

(2) Fill with oil to the upper limit on the

dipstick. Insert the dipstick fully to check the level.

(3) Tighten the filler port cap securely

by hand.

Engine Oil Capacity

3YM30 with KM2P-1 Full: 2.8 L (3.0 quarts)

3YM30 with SD20 Full: 2.5 L (2.6 quarts)

3YM20 with KM2P-1 Full: 2.7 L (2.9 quarts)

3YM20 with SD20 Full: 2.4 L (2.5 quarts)

2YM15 with KM2P-1 Full: 2.0 L (2.1 quarts)

2YM15 with SD20 Full: 1.8 L (1.9 quarts)

Using gasoline, etc. may cause a fire.

To avoid mistakes, be sure to double-check the kind of fuel before filling. Wipe off any spilled fuel carefully.

NOTICE

Do not overfill.

Overfilling will cause oil to be sprayed into the cylinder and lead to engine problems.

A Filler port D Upper limit B Rocker arm cover E Lower limit C Dipstick

D E

3.2.3 Supply Marine Gear Lubricating Oil

(1) Remove the filler port cap at the top

of the housing, and fill with marine gear lubricating oil.

(2) Fill with oil to the upper limit on the

dipstick, insert the dipstick fully to check the level.

(3) Tighten the filler port cap securely

by hand.

Marine gear oil capacity

KM2P-1 Full 0.30 L (0.64 pints)

Page 26

3. OPERATION

A Oil filler cap B Dipstick

3.2.4 Supply Cooling Water

Supply cooling water according to the following procedures. Be sure to add antifreeze to the cooling water.

(1) Be sure to close the 4 water drain

cocks/plugs.

Fresh water line Seawater line

A Coolant tank C Drain cock for seawater B Drain plug for coolant

Note: The water drain cocks are opened before shipping from the plant.

A Coolant tank D Fresh water pump B Drain plug for coolant E Seawater pump C Drain plug for seawater

A Stop solenoid C Flywheel housing B Drain cock for fresh water

(2) Remove the filler cap of the fresh

water cooler by turning the cap counterclockwise 1/3 of a turn.

A Filler cap C Tabs B Fresh water cooler D Notches

Page 27

3. OPERATION

(3) Pour cooling water slowly into the

fresh water/coolant tank so that air bubbles do not develop. Pour until the water overflows from the filler port.

DANGER

If the filler cap is loose, hot steam and water will spout out which may cause burns.

(4) After supplying cooling water, re-

place the filler cap and tighten it firmly. Failure to do so will cause water leakage. To replace the cap, align the tabs on the bottom of the cap with the notches on the filler port and turn clockwise 1/3 of a turn.

(5) Remove the coolant recovery tank

cap and fill with coolant mix to the lower limit.

Replace the cap. Coolant recovery tank capacity:

0.8 L(1.7 pints)

(6) Check the rubber hose connecting

the coolant recovery tank to the fresh water cooler. Be sure the hose is securely connected and there is no looseness or damage.

When the hose is not watertight, an excessive amount of cooling water will be used.

A To fresh water cooler C Lower limit B Upper limit D Cap

3.2.5 Cranking

When the engine has not been used for a long period of time, lubricating oil will not be distributed to all of the operating parts. Using the engine in this condition will lead to seizure.

After a long period of disuse, distribute lubricating 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 lever in NEU-

TRAL

A Forward C Reverse B Neutral

(4) Turn on the battery switch and in-

sert the key into key switch. Turn the key to the ON position.

(5) Electric stop device

Push the stop button on the instrument panel continuously while cranking.

Page 28

3. OPERATION

(6) When the key switch is turned, the

engine will begin cranking. Continue cranking for about 5 seconds, and check for abnormal noise during that time. (If you remove your hand from the stop knob or stop button while cranking, the engine will start.)

3.2.6 Check and Re-supply Lubricating Oil and Cooling Water

When engine oil, clutch oil, or cooling water is supplied for the first time or when they must be replaced, conduct a trial operation of the engine for about 5 minutes and check the quantity of lubricating oil and cooling water. The trial engine operation will send the lubricating oil and cooling water to the passages, so the lubricating

oil and cooling water levels will drop. Check and re-supply as necessary.

(1) Supplying engine lubricating oil

(See 3.2.2). Approximately 10 minutes after stopping the engine, remove the oil dipstick and check the oil level. Add oil if the level is too low.

(2) Supplying marine gear lubricating

oil (See 3.2.3).

(3) Supplying cooling water (See

3.2.4).

DANGER

Never open the cap of the coolant tank while the engine is still hot. Steam and hot water will spurt out and burn you seriously. Wait until the temperature of the coolant tank has dropped, wrap a cloth around the filler cap and loosen the cap slowly. After inspection, refasten the cap firmly.

3.3 Operating your engine

WARNING

To prevent exhaust gas poisoning, ensure good ventilation during operation. Install ventilation windows, ports or ventilators in the engine room. Never touch or allow your clothes to touch the moving parts of the engine during operation. If the front drive shaft, V-belt, propeller shaft, etc. catches your body or clothes, serious injury may result. Check that no tools, cloth, etc. are left on or around the engine.

CAUTION

The engine is very hot during operation and immediately after stopping, especially the exhaust manifold and the exhaust pipe. Avoid burns! Never touch or allow your clothes to touch any part of the engine.

3.3.1 Daily Start Up Inspection

Before starting the engine, make it a daily rule to conduct the following inspections:

(1) Visual Checks

Check for the following:

1. Lubricating oil leakage from the engine

2. Fuel oil leakage from the fuel system

3. Water leakage from the cooling water system

4. Damage to parts

5. Loosening or loss of bolts If any problem is found, do not operate

the engine before completing repairs.

Page 29

3. OPERATION

(2) Checking and Re-supplying Fuel

Oil

Check the fuel level inside the fuel tank and supply with the recommended fuel, if necessary. (See 3.2.1)

(3) Checking and Re-supplying Engine

Lubricating Oil.

1. After removing the oil filler cap, check the engine oil level with the oil dipstick.

2. If the oil level is low, supply with the recommended lubricating oil using the filler port. Supply oil up to the top mark on the oil dipstick. (See 3.2.2)

(4) Check and Re-supply Marine Gear

Lubricating Oil

1. Check the marine gear oil level with the oil dipstick.

2. If the oil level is low, supply with the recommended lubricating oil using the filler port. Fill oil up to the top mark on the oil dipstick. (See 3.2.3)

(5) Check and Re-supply Fresh Water

(For Fresh Water Cooling System)

Check the fresh water level before operation while the engine is cold.

Checking the water level while the engine is hot is dangerous, and the cooling water reading will be misleading due to thermal expansion.

Check and supply cooling water routinely at the coolant recovery tank only.

Do not remove the filler cap of the coolant tank during usual operation.

DANGER

Do not open the filler cap during operation or immediately after stopping the engine. Hot steam and

water will spout out. To remove the cap, wait until the engine has cooled down, wrap the cap with a cloth and loosen the cap slowly. After checking, replace the cap and tighten firmly.

1. Check that the coolant level is above the lower limit on the side of the coolant recovery tank.

2. If the coolant level is close to the lower limit, remove the filler cap and supply fresh coolant.

3. When the water in the coolant recovery tank runs out, remove the filler cap of the fresh water cooler and supply water until it overflows from the filler port. (See 3.2.4)

NOTICE

If the coolant runs out too often, or only the coolant in the fresh water tank drops without any change in the water level of the coolant recovery tank, there may be some leakage of water or air. In such cases, consult your Yanmar dealer or distributor without delay.

Note: The water rises in the coolant recovery tank during engine operation. This is not abnormal. After stopping the engine, the cooling water cools down and the extra water in the coolant recovery tank returns to the coolant tank.

(6) Check the Remote Control Handle

Be sure to check that the remote control handle lever moves smoothly before use. If it is hard to operate, lubricate the joints of the remote control cable and also the lever bearings.

If the lever comes out or there is play in the lever, adjust the remote control cable. (See 4.3.1 (5))

Page 30

3. OPERATION

(7) Check the Alarm Devices Electric

Operation

When operating the key switch, check that the alarm devices work normally. (See 2.5.1 (4))

(8) Prepare Fuel, Lubricating Oil, and

Cooling Fresh Water in Reserve

Always store lubricating oil and coolant water in reserve (for at least one refill) onboard, to be ready for emergencies.

3.3.2 How to Start the Engine

(1) Start the engine according to the

following procedures:

Electric Operation

1. Open the seacock.

2. Open the fuel cock.

3. Set the remote control lever in NEUTRAL.

NOTICE

Safety equipment should make it impossible to start the engine in any other position than NEUTRAL

6. Turn the key switch to start the engine. Release the key switch when the en-

gine has started. The alarm buzzer should stop and the alarm lamps go out.

OFF

GLOW

A OFF position C START position B ON position D GLOW position

START

(2) Starting at low ambient tempera-

ture

If the engine is hard to start in cold weather (approx. 0°C or below), use the glow plug for easier starting.

Follow steps 1 to 5 of the above procedure, and then follow the steps below.

Turn the key from the OFF to the GLOW and stay there for approx. 4 to 5 seconds until the glow plug is heated up.

Turn the key to the START position. After the engine starts, release the key.

ANEUTRAL

4. Turn on the battery switch.

5. Insert the key into the key switch and turn the key to ON. If the alarm buzzer sounds and alarm lamps come on, the alarm devices are normal.

Note: The coolant high temperature alarm lamp does not come on. (See 2.5.1.(4))

NOTICE

Limit the activation of the glow plug within 10 seconds to one attempt. Lengthy operation damages the plug.

(3) Re-starting After Starting Failure

Before turning the key switch again, be sure to confirm that the engine has stopped completely. If the engine is re-started while the engine still has not stopped, the pinion gear of the starter motor will be damaged.

Page 31

3. OPERATION

NOTICE

Turn the key for a maximum of 15 seconds in the start position. If the engine does not start the first time, wait for about 15 seconds before trying again. After the engine has started, do not turn the key off. (It should remain ON.)

Alarm devices will not work when the key is OFF.

CAUTION

If vessel is equipped with a water lift (water lock) muffler, excessive cranking could cause seawater to enter the cylinders and damage the engine.

(4) Air Venting of the Fuel System After

Starting Failure

If the engine only idles or won't 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. Vent the air in the system according to the following procedures.

Fuel System Air Venting Procedures

1. Check the fuel level in the fuel tank. Replenish if insufficient.

2. Loosen the air vent bolt at the top of the fuel/water separator by turning it 2 or 3 times. When fuel, which does not contain air bubbles comes out of the bolt hole, tighten the air vent bolt.

3. Loosen the air vent bolt of the fuel filter by turning it 2 or 3 turns.

4. Feed fuel with the fuel feed pump by moving the lever on the left side of the feed pump up and down.

5. Allow the fuel containing air bubbles to flow out from the air vent bolt holes. When the fuel coming out no longer contains bubbles, tighten the air vent bolt. This completes the air venting of the fuel system. Try starting the engine again.

6. In subsequent engine operation after the start-up, the automatic air-venting device works to purge the air in the fuel system. No manual air-venting is required for normal engine operation.

(5) After the engine has started

After the engine has started, check the following items at a low engine speed:

1. Check that the gauges and alarm devices on the instrument panel are normal.

2. Check for water or oil leakage from the engine.

3. Check that exhaust color, engine vibrations and sound are normal.

4. When there are no problems, keep the engine at low speed with the boat still stopped to send lubricating oil to all parts of the engine.

5. Check that sufficient cooling water is discharged from the seawater outlet pipe. Operation with inadequate seawater discharge will damage the impeller of the seawater pump. If seawater discharge is too small, stop the engine immediately. Identify the cause and repair.

• Is the seacock open?

• Is the inlet strainer on the hull bottom clogged?

• Is the seawater suction hose broken, or does the hose suck in air due to a loose joint?

Page 32

3. OPERATION

NOTICE

The engine will seize if it is operated when cooling seawater discharge is too small or if load is applied without any warming up operation.

3.3.3 Operation

(1) Engine acceleration and decelera-

tion

Use the throttle handle to control acceleration and deceleration. Move the handle slowly.

(2) FORWARD- NEUTRAL (boat

stopped) - REVERSE Clutch

ANEUTRAL

Use the clutch handle to change from FORWARD to NEUTRAL (boat stopped) to REVERSE.

NOTICE

Shifting the marine gear while operating at high speed or not pushing the handle fully into position (partial engagement) will result in damage to the 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 rpm).

Move the throttle handle slowly to a higher speed position after completing clutch engagement.

2. When changing between FORWARD and REVERSE, bring the clutch to NEUTRAL and pause before slowly shifting to the desired position. Do not shift abruptly from FORWARD to REVERSE or vice versa.

3. Move the clutch handle accurately and fully into the FORWARD, NEUTRAL, and REVERSE positions.

3.3.4 Cautions During Operation

Always be on the lookout for problems during engine operation.

Pay particular attention to the following:

(1) Is sufficient water being discharged

from the seawater outlet pipe?

If the discharge is small, stop the engine immediately; identify the cause and repair.

(2) Is the exhaust color normal?

The continuous emission of black exhaust smoke indicates engine overloading. This shortens the engine's life and should be avoided.

(3) Are there abnormal vibrations or

noise?

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.

(4) Alarm buzzer sounds during opera-

tion.

If the alarm buzzer sounds during operation, lower the engine speed immediately, check the warning lamps, and stop the engine for repairs.

Page 33

3. OPERATION

(5) Is there water, oil, or gas leakage, or

are there any loose bolts?

Check the engine room periodically for any problems.

(6) Is there sufficient fuel oil in the fuel

oil tank?

Replenish fuel oil in advance to avoid running out of fuel during operation.

(7) When operating the engine at low

speed for long periods of time, race the engine once every 2 hours.

Note: Racing the Engine

With the clutch in NEUTRAL, accelerate from the low speed position to the high speed position and repeat this process about 5 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 exhaust color and reduce engine performance.

(8) If possible, periodically operate the

engine at near maximum rpm., 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.

(3) Cool down the engine at low speed

(approximately 1000 rpm) for about 5 minutes.

NOTICE

Always remember to allow engine to idle below 1000 rpm for five minutes prior to shut-down to remove heat from major components.

Shutting down the engine suddenly while operating at high speed will cause the engine temperature to rise quickly, causing deterioration of the oil and sticking of parts.

Electric stop device Push the stop button on the instru-

ment panel when the key is in the ON position.

Engine shut-down by stop button

NOTICE

Electric Operation

Never turn off the battery switch during operation. Damage to parts in the electric system will result.

3.3.5 Engine shut-down

Stop the engine in accordance with the following procedures:

(1) Put the remote control handle in

NEUTRAL

(2) Be sure to race the engine before

shut-down. (See 3.3.4 (7))

A Stop button on the instrument panel

(4) Close the fuel cock.

(5) Close the sea cock.

NOTICE

Neglecting to close the seacock could allow water to leak into the boat and may cause it to sink. Be sure to close the seacock.

Page 34

3. OPERATION

Emergency Stop

When you can’t stop the engine by the stop button on the panel, push the button at the back of the stop solenoid.(See 2.5.3)

3.4 Long Term Storage

(1) In cold temperatures or before long

term storage, be sure to drain the seawater from the seawater cooling system.

CAUTION

Drain seawater from the seawater cooling system after the engine has cooled down. Be careful to avoid burns.

NOTICE

If seawater is left inside, it may freeze and damage parts of the cooling system (fresh water cooler, seawater pump, etc.) when ambient temperature is below 0°C[32°F].

1. Loosen the drain cocks/plugs attached on the pipe and on the heat exchanger, and drain off the seawater inside.

If no liquid comes from the drain cocks/plugs, it may be necessary to use a stiff wire to remove any debris to allow drainage.

2. Loosen the 4 bolts attaching the side cover of the seawater pump, remove the cover and drain the water from inside.

Retighten the bolts when finished.

3. Close the drain cocks/plugs.

(2) Do not drain fresh water/coolant in

the cold season or before the long storage.

If LLC (Long Life Coolant) has not been added to the cooling fresh water, be sure to add LLC or drain off the fresh water from the fresh water cooling system daily after use

NOTICE

If the fresh water without LLC is not removed, it may freeze and damage parts of the cooling water system (fresh water cooler, cylinder block, cylinder head, etc.) when ambient temperature is below 0°C[32°F].

A Alternator C Drain plug for coolant B Coolant tank D Drain cock for seawater

1. Open the fresh water drain cocks/ plugs (2 positions as illustrated) and drain the fresh water from inside.

2. Close the drain cocks/plugs after draining the fresh water.

Page 35

3. OPERATION

A Coolant tank D Fresh water pump B Drain plug for seawater E Seawater pump C Drain plug for fresh water

A Stop solenoid C Flywheel housing B Drain cock for fresh water

(3) Carry out the following periodic in-

spection before placing the engine in storage. Clean the outside of the engine wiping off any dust or oil.

(4) To prevent condensation inside the

fuel tank, either drain off the fuel or fill the tank.

(5) Grease the exposed area and joints

of the remote control cable and the bearings of the remote control handle.

(6) Cover the intake silencer, exhaust

pipe, etc. with vinyl sheets and seal them to prevent moisture from entering.

(7) Drain bilge in the hull bottom com-

pletely.

Water may leak into the boat when it is moored, and whenever possible it should be hauled out, covered and blocked.

(8) Waterproof the engine room to pre-

vent rain and seawater from entering.

(9) During long-term storage, charge

the battery once a month to compensate for the battery's self-discharge.

(10)When storing an engine for long

time, run the engine periodically according to the following procedure because the rust occurrence inside the engine, the rack agglutination of the fuel pump, and so on are likely to occur (In case that the engine is equipped with a boat).

1. Replace the lube oil and the filter with new ones before the engine running.

2. If the fuel in the tank was removed, re-supply and bleed the fuel system.

3. Confirm that there is the coolant in the engine.

4. Operate the engine at the low idling speed for about five minutes. (If it can be done, once a month)

Page 36

4. MAINTENANCE AND INSPECTION

4.1 General Inspection Rules

(1) Conduct Periodic Inspection for

Your Safety.

The functions of engine components will degenerate and engine performance will drop according to the use of the engine. If countermeasures are not taken, you may encounter unexpected troubles while cruising at sea. Consumption of fuel or lubricating oil may become excessive and exhaust gas and engine noise may increase. These all shorten the life of the engine. Daily and periodic inspection and servicing increase your safety at sea.

(2) Inspect Before Starting.

Make it a daily rule to inspect before starting. (See 3.3.1)

(3) Periodic Inspections at Fixed Inter-

vals

Periodic inspections must be made after every 50, 100, 150, 250 and 1000 hours of use.

Conduct periodic inspections according to the procedures described in this Operation Manual.

(4) Use Genuine Yanmar Parts.

Be sure to use genuine Yanmar parts for consumable and replacement parts. Use of other parts will reduce engine performance and shorten the life of the engine.

(5) Consult Your YANMAR Dealer or

Distributor.

Specialized technicians are ready to assist you with periodic inspections and maintenance. Consult your YANMAR dealer or distributor in accordance with the service agreement.

(6) Servicing Tools

Prepare servicing tools onboard to be ready for inspecting and servicing the engine and other equipment.

(7) Tightening Torque of Bolts & Nuts

Over-tightening of bolts and nuts causes them to come off or their threads to be damaged. Insufficient tightening causes oil leakage from the installation face or troubles due to the loosening of bolts.

Bolts and nuts must be tightened to the appropriate tightening torque. Important parts must be tightened with a torque wrench to the correct tightening torque and in the right order. Consult with your dealer or distributor if the servicing requires the removal of such parts.

The standard tightening torque for standard bolts & nuts is listed below.

Page 37

4. MAINTENANCE AND INSPECTION

NOTICE

Apply the following tightening torque to bolts having "7" on the head. (JIS strength classification: 7T) Tighten

Bolt dia. x pitch (mm)

Tightening torque

(Nm) 11 ± 1 26 ± 3 50 ± 5 90 ± 10 140 ± 10 230 ± 10

(kgf-m) 1.1 ± 0.1 2.7 ± 0.3 5.1 ± 0.5 9.2 ± 1 14.3 ± 1 23.5 ± 1

(lb-ft) 8.0 ± 0.7 19 ± 2.1 37 ± 3.6 66 ± 7.2 103 ± 7.2 170 ± 7.2

M6x1.0 M8x1.25 M10x1.5 M12x1.75 M14x1.5 M16x1.5

4.2 List of Periodic Inspection Items

Daily and periodic inspections are important to keep the engine in its best condition. The following is a summary of inspection and servicing items by inspection interval. Periodic inspection intervals should vary depending on the uses, loads, fuels and lubricating oils used and handling conditions, and are hard to establish definitively. The following should be treated as a general standard only.

bolts with no "7" mark to 60% tightening torque. If the parts to be tightened are made from light alloy aluminium, tighten the bolts to 80% tightening torque.

NOTICE

Schedule your own periodic inspection plan according to the operational conditions of your engine and inspect every item. Neglect of periodic inspections may lead to engine troubles and shorten the life of the engine.

Inspection and servicing at 1000 hours and thereafter require special knowledge and techniques. Consult your Yanmar dealer or distributor.

Section 4.3 gives a detailed explanation of which parts must be inspected and the procedure for doing so for each interval.

Page 38

4. MAINTENANCE AND INSPECTION

: check : Replace z: Consult local dealer

System Item

Check the fuel level, and refill |

Drain the fuel tank ||

Fuel system

Lubricating system

Cooling system

Air intake and exhaust system

Electrical system

Cylinder head, etc.

Remote control system, etc.

Drain the fuel/water separator |

Replace the fuel filter 

Check the injection timing z

Check the injection spray condition

Check the lubricating oil level

Replace the lubricating oil

Replace the engine lubricating oil filter

Seawater outlet

Check cooling water level |

Check the impeller of the cooling water pump (seawater pump)

Replace the fresh water coolant

Clean & check the water passages z

Clean the element of the air intake silencer

Clean the exhaust/water mixing elbow

Clean the breather pipe |

Check the exhaust gas condition

Diaphragm assembly inspection z

Check the alarm lamps & devices |

Check the electrolyte level in the battery

Adjust the tension of the alternator driving belt

Check the wiring connectors |

Check for leakage of water and oil

Retighten all major nuts and bolts z

Adjust intake/exhaust valve clearance

Check/adjust the remote control operation

Adjust the propeller shaft alignment

Crankcase |

Marine gear |

Crankcase 

Marine gear 

Sail drive 

[1] Whichever comes first.

[2] For EPA requirements see also 4.4

Before start-

| During

Operation

When long life coolant is used of a specified type (see page 24), a

| During

Operation

| After starting

Initial

ing

50 hrs



replacement period of two years can be obtained.

||

|| z

First

Every 50

hrs or

monthly

Every 100

hrs or six

[1]

months [1]

Every year

Every 150 hrs or one

year [1]

Every 250 hrs or one

Every 1000

year [1]

hrs or 4

years [1]

[2]

|

Page 39

4. MAINTENANCE AND INSPECTION

4.3 Periodic Inspection Items

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

(1) Replace the Engine Lubricating Oil

and Lubricating Oil Filter (1st time)

During initial operation of the engine, the oil is quickly contaminated due to the initial wear of internal parts. The lubricating oil must therefore be replaced early. Replace the lubricating oil filter at the same time.

It is easiest and most effective to drain the engine lubricating oil after operation while the engine is still warm.

1. Remove the lubricating oil dipstick. Attach the oil drain pump and pump out the oil.

For easier draining, remove the oil filler cap (yellow) at the top of the rocker arm cover or gear case cover.

2. Remove the lubricating oil filter with the filter detach/attach tool (Turn counterclockwise.)

3. Clean the filter installation face and attach the new filter, tightening by hand until the seal touches.

4. Turn an additional 3/4 of a turn with the attachment tool. (Turn clockwise. Tightening torque: 20 - 24 Nm (177-212 lb-in))

5. Fill with new lubricating oil. (See 3.2.2)

6. Perform a trial run and check for oil leaks.

7. Approximately 10 minutes after stopping the engine, remove the oil dipstick and check the oil level. Add oil if the level is too low.

CAUTION

Beware of oil splashes if extracting the lubricating oil while it is hot.

(2) Replace the Marine Gear Lubricat-

ing Oil (1st time)

During initial operation, the oil is quickly contaminated due to the initial wear of internal parts. The lubricating oil must therefore be replaced early.

1. Remove the cap from the filler port and attach the oil drain pump. Drain off oil.

2. Fill with new lubricating oil. (See 3.2.3)

3. Perform a trial run and check for oil leakage.

(3) Replace the Sail Drive Oil (1st time)

Refer to the operation manual of the sail drive for the procedure of the oil replacement.

(4) Draining the (optional) Fuel Tank

Put a pan under the drain to catch the fuel.

Open the drain cock and drain off any water or dirt collected.

Once the water and dirt has been drained off and the fuel coming out is clear, close the drain cock.

(5) Inspection and Adjustment of In-

take/ Exhaust Valve Head Clearance (1st time)

Settling of a new engine and individual engine use will cause changes in the intake/exhaust valve and rocker arm clearance, and adjustment is necessary. This adjustment requires specialized knowledge and techniques. Consult your Yanmar dealer or distributor.

Page 40

4. MAINTENANCE AND INSPECTION

(6) Adjusting the Remote Control Ca-

ble

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 use causing deviation. It is dangerous to control operation under these conditions, and the remote control cables must be checked and adjusted periodically.

1. Adjusting the Throttle Remote Control Cable

Check to see that the control lever on the engine side moves to the high speed stop position and low speed stop position when the remote control lever is moved to H (high speed) and

L (low speed) respectively. When there is deviation, loosen the

bracket for the remote control cable on the engine side and adjust.

Adjust the high-speed stop position first and then adjust the low speed idling by the adjustment bolt on the remote control lever.

A Cable D High speed stop bolt B Fuel injection pump E Low speed stop bolt C Adjustment F Control lever

2. Adjusting the Clutch Remote Control Cable

Check to see that the control lever moves to the correct position when the remote control handle is put in NEUTRAL, FORWARD, REVERSE.

Use the NEUTRAL position as the standard for adjustment. When there is deviation, loosen the bracket for the remote control cable on the clutch side and adjust.

CAUTION

Never adjust the high-speed stop bolt. This will render your warranty void.

A Marine gear C Adjustment B Cable

Page 41

4. MAINTENANCE AND INSPECTION

(7) Adjusting the Tension of Alternator

Driving Belt

When there is not enough tension in the V-belt, it will slip and the fresh water pump will fail to supply cooling water. Engine over-heating and seizure will result.

APush

4.3.2 Inspection Every 50 Hrs. (or Monthly)

(1) Drain the fuel/water separator.

1. Close the fuel cock of a fuel tank.

2. Loosen the retaining ring and remove the filter cup. Drain off any water and dirt collected inside.

3. After reassembly, be sure to vent air from the fuel system.

If air is in the fuel system, fuel cannot reach the fuel injection pump.

Vent the air in the system according to the following procedures.

When there is too much tension in the V-belt, the belt will become damaged more quickly and the bearing of the fresh water pump may be damaged.

1. Check the tension of the V-belt by pressing down on the middle of the belt with your finger (approx. 98N(10kgf)). With proper tension, the V-belt should deflect 8-10 mm (0.315-0.393 inches).

2. 2.If the V-belt deflection is out of the limit, adjust the V-belt tension. Loosen the set bolt and move the alternator to adjust the V-belt tension.

3. Be careful not to get any oil on the Vbelt. Oil on the belt causes slipping and stretching. Replace the belt if it is marred.

(Fuel filter) A Air bleeding bolt D Filter element BBracket EFilter cap C O-ring F Retaining ring

Fuel system air bleeding procedures

Page 42

4. MAINTENANCE AND INSPECTION

1. Check the fuel level in the fuel tank. Replenish if Insufficient

2. Loosen the air bleeding bolt at the top of the fuel filter by turning it 2 or 3 times.

3. Feed fuel with the fuel feed pump by moving the lever on the left side of the feed pump up and down.

4. Allow the fuel containing air bubbles to flow out from the air bleeding bolt hole. When the fuel no longer contains bubbles, tighten the air bleeding bolt. This completes the air bleeding of the fuel system.

5. After the engine start-up, the automatic air-bleeding device works to purge the air in the fuel system. No manual air-venting is required for normal engine operation.

2. 2.Loosen the drain plug and drain off any water and dirt collected inside.

Note: If no drain drips when the drain plug is

opened, loosen the air bleeding plug on the top of the fuel/water separator by turning counter-clockwise 2-3 times. (This may occur if the position of the fuel/water separator position is higher than the fuel oil level in the fuel tank).

3. After draining, be sure to tighten the air bleeding plug.

4. Be sure to bleed air in the fuel system.

(3) Check the Electrolyte Level in a

Battery

WARNING

Before inspecting the electrical system, be sure either to turn off the battery switch or to disconnect the (-) terminal of the ground cable. Otherwise, a short-circuit could cause a fire.

Ensure good ventilation when charging the battery. The use of open flames is strictly prohibited. Hydrogen gas may also catch fire.

A Cylinder head E Fuel injection pump BBracket FClamp C Fuel pipe G Fuel pipe D Fuel filter

(2) Drain the fuel/water separator (op-

tional).

1. Close the fuel cock of the fuel tank.

Battery fluid is dilute sulphuric acid. It can blind you or burn your eyes or skin. Wear goggles and gloves when handling battery fluid. Should the fluid be deposited on your skin, wash with a large quantity of fresh water and seek treatment from a doctor.

1. If operation continues with insufficient battery fluid, the battery will be destroyed.

Check the fluid level periodically. If the level is lower than specified, fill with distilled water (available in the market) up to the upper limit of the battery.

Page 43

4. MAINTENANCE AND INSPECTION

(Battery fluid tends to evaporate in high temperatures, especially in summer. In such cases, inspect the battery earlier than specified.)

GREASE

UPPER LEVEL

LOWER LEVEL

A Electrolyte level D OK B Upper limit E Too low C Lower limit F Excessive

2. If the starter rpm is too low and the engine cannot be started, measure the specific gravity of the battery with a hydrometer.

When the specific gravity of the fluid is over 1.27(at 20°C)[68°F]), it is fully charged.

Fluid with a specific gravity of below

1.24 needs charging. If the specific gravity cannot be raised by charging, the battery must be replaced.

NOTICE

The capacities of the standard alternator and the recommended battery assume only the power necessary for regular operation.

If the power is also used for inboard lighting or other purposes, the generating and charging capacities

may be insufficient. In such cases, consult your Yanmar dealer or distributor.

4.3.3 Inspection Every 100 Hrs (or six months).

(1) Replace the Sail Drive Oil

Refer to the operation manual of the sail drive for the procedure of the oil replacement

4.3.4 Inspection Every 150 Hrs (or one year).

(1) Replace the Engine Oil

Refer to 4.3.1(1).

(2) Replace the Marine Gear oil

Refer to 4.3.1(2).

4.3.5 Inspection Every 250 Hrs (or one year).

(1) Replace the Fuel Tank

Refer to 4.3.1(4).

(2) Replace the Fuel Filter

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.

2. Remove the filter case by loosening the retainer ring (Turn counterclockwise) with the filter wrench.

3. Pull the element out from the bottom, and replace with a new one.

4. Clean the inside of the case thoroughly, put on the O-ring, and close with the retainer ring. (Turn clockwise: Tightening torque:12 Nm (106 lb-in)

5. Air will enter into the fuel system when the filter is disassembled, and should be vented. (See 3.3.2(4))

Page 44

4. MAINTENANCE AND INSPECTION

A Fuel filter

(3) Replace the Lubricating Oil Filter

(See 4.3.1 (1))

(4) Adjusting the Tension of the Alter-

nator Driving Belt (See 4.3.1 (7)).

(5) Clean the Intake Silencer

Disassemble the intake silencer and

clean the inside thoroughly. Remove the silencer by taking off the clamp. Clean the element with a neutral detergent. Reassemble after it is completely dry.

of seawater discharged is reduced, inspect the seawater pump in accordance with the following procedures:

1. Loosen the side cover bolts and remove the side cover.

2. Illuminate the inside of the seawater pump with a flashlight and inspect.

3. If any of the following problems are found, disassembly and maintenance are necessary:

1. Impeller blades are cracked or nicked. Edges or surfaces of the blades are marred or scratched.

Note: The impeller must be replaced periodically (every 1000 hrs.)

2. Wear plate is damaged.

3. If no damage is found when inspecting the inside of the pump, re-assemble the side cover.

Fit the O-ring to the groove of the joint face before replacing the side cover.

If a large amount of water leaks continuously from the water drain pipe beneath the seawater pump during operation, disassembly and maintenance (replacement of the lip seal) are necessary.

When disassembly and maintenance of the seawater pump are necessary, consult your Yanmar dealer or distributor.

A Element

(6) Inspect Inner Parts of the Seawater

Pump

Depending on the use, the inside parts of the seawater pump deteriorate and discharge performance drops. At the specified interval or when the volume

NOTICE

The seawater pump turns in the direction as shown in the below figure, and the impeller must be installed while considering the impeller direction.

If the impeller has been removed for any reason and must be re-assembled, be very careful not to make a mistake and turn it in the wrong direction. Additionally, if the engine is being turned manually, be

Page 45

4. MAINTENANCE AND INSPECTION

careful to turn it in the correct direction. Incorrect turning will twist the impeller and damage it

A Direction of Impeller B Impeller rotating direction C Impeller D Seawater pump

(7) Clean the Exhaust/Water Mixing El-

bow.

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. Clean dirt and scale out of the air pass and seawater pass of the mixing elbow.

2. Repair the crack or damage of the mixing elbow by welding, or replace if necessary.

3. Inspect the gasket and replace if necessary.

(8) Check the Wiring Connectors

Check that each electric connection part has not become loose.

4.3.6 Inspection Every 1000 Hrs (or 4 years).

Adjustment of the valve clearance is necessary and the adjustment requires specialized knowledge and techniques. Consult your Yanmar dealer or distributor.

(2) Inspect and Adjust the Fuel Injec-

tion Spray Condition.

Adjustment is necessary to obtain the optimal fuel injection to ensure the best possible engine performance. This inspection requires specialized knowledge and techniques.

Consult your Yanmar dealer or distributor.

(3) Adjusting the Remote Control Ca-

bles (See 4. 3. 1(6))

(4) Inspect and Adjust the Fuel Injec-

tion Timing

Fuel injection timing must be adjusted to ensure optimal engine performance.

Consult your Yanmar dealer or distributor.

(5) Diaphragm assembly inspection

Inspect the diaphragm assembly on the rocker arm cover.

1. Loosen screws, remove the diaphragm assembly, and check for oil and contaminants between the diaphragm and the cover. If oil and contaminants enter into the diaphragm assembly, the diaphragm will not operate as designed.

2. Inspect the diaphragm rubber and spring for damage. If necessary, replace with new ones.

(1) Inspection and Adjustment of In-

take/ Exhaust Valve Clearance.

When operating for long periods of time, the clearance between the intake/exhaust valve and the rocker arm will change and affect engine performance.

Page 46

4. MAINTENANCE AND INSPECTION

Breather system component

B C

A Diaphragm cover E Rocker arm cover B Spring F Breather baffle C Center plate G Baffle plate D Diaphragm H Intake manifold

NOTICE

1. When the diaphragm is damaged,

crankcase pressure control is affected. Excessive crankcase pressure will cause leaks at seals and mating part surfaces.

2. At lubricating oil replacement or lubricating oil fill, do not fill above the standard upper limit. If the lubricating oil quantity is above the upper limit, the amount of crankcase oil mist may increase resulting in oil hammer.

(6) Clean & Check the Water Passages

When it is used for a long time, cleaning of the cooling water passages such as cooling water rubber hoses and heat exchanger is periodically necessary. Because dirt, scale, rust, and so on collect in the cooling water passages and the cooling performance declines.

This maintenance requires specialized knowledge.Consult your Yanmar dealer or distributor.

(7) Adjust the Propeller Shaft Align-

ment

The rubber tension of the flexible engine mounts is lost after many hours' use. This leads to a drop in vibration absorption performance, and also causes centering misalignment of the propeller shaft.

This maintenance requires specialized knowledge and techniques

Consult your Yanmar dealer or distributor.

Note: Be sure to replace the Yanmar flexible engine mounts every 1000 hours or 4 years, whichever comes first.

(8) Retighten all Major Nuts and Bolts.

After long time usage, the major nuts and bolts of the engine may loosen. Retighten the major nuts and bolts by the standard tightening torques. This inspection requires specialized knowledge and techniques. Consult your Yanmar dealer or distributor.

(9) Check the Impeller of a Seawater

Pump

The impeller must be replaced with new one periodically (every 1000 hrs or 4 years whichever comes first).

(See 4.3.5(6) for the procedure.)

(10)Adjust the Tension of an Alternator

Driving Belt

Replace the alternator driving belt with new one every 1000 hours or four years, whichever comes first, even if there is no crack or damage in the surface.

(See 4.3.5(7) for the procedure.)

4.3.7 Annually

(1) Replace Fresh Water Coolant

Cooling performance drops when cooling water is contaminated with rust and scale.

Page 47

4. MAINTENANCE AND INSPECTION

Even if LLC (Long Life Coolant) or antirust is added, the cooling water must be replaced periodically because the properties of the agent will degenerate.

To drain the fresh water/coolant, open the fresh water cocks/plugs (two places) as shown in 3.2.4 and 3.4(2).

(Refer to 3.2.4 for resupplying cooling water.)

4.4 EPA Requirements

4.4.1 EPA Certification Plate

This engine has the following EPA Certification Plate attached:

/;%#.+(140+##0&75'2#

4')7.#6+105(141((41#&%+'0)+0'5

4'('461190'45/#07#.(14/#+06'0#0%'52'%+(+%#6+105 #0&#&,756/'065

A Attachment Position for Certification Plate

(attached to the top of the rocker arm cover)

)

106;2'&(7'.

4.4.2 Conditions to Insure Compliance with Emission Standards

This product is an EPA approved engine.

The following are the conditions that must be met in order to insure that the emission during operation meets the EPA standards.

Be sure to follow these.

(1) The operating conditions should be

as follows:

1. Ambient temperature: -20 – 40°C

2. Relative humidity: 80% or lower

3. Permissible value for intake negative pressure: 3.9 kPa (400 mmAq) or lower

4. Permissible value for exhaust back pressure: 14.7 kPa (1500 mmAq) or lower

(2) The fuel and lubricating oil used

should be as follows:

1. Fuel: The diesel fuel oil ISO 8217 DMX, BS 2869 A1 or A2 (Cetane No. 45 minimally.)

2. Lubricating oil: Type API, class CD

(3) Do not remove the seals limiting

the amount of fuel injected and the engine speed.

(4) Be sure to carry out inspections.

Follow the basic guidelines outlined in

4.3 (Periodic Inspection Items) of this manual and keep a record of the results. Pay particular attention to these important points: replacing the lubricating oil, lubricating oil filter, the fuel filter and cleaning the intake silencer element.

Note: Inspections are divided into two sections in accordance with whom is in charge of carrying out the inspection: (the User) and (the Maker).

Page 48

4. MAINTENANCE AND INSPECTION

(5) Quality guarantee period for the emission related parts

If the schedule of periodic maintenance outlined in 4.4.3 (Inspection and Maintenance) is followed, the quality guarantee period is determined by the age of the engine or the number of hours of operation as indicated below.

Power rating Parts Quality guarantee period

kW<19 Fuel nozzle, fuel pump 1500 hrs. of operation or 2 years

19=<kW<37 Fuel nozzle, fuel pump 3000 hrs. of operation or 5 years

4.4.3 Inspection and Maintenance

Inspection and maintenance for EPA emission related parts are shown in the chart below.

(Inspection and maintenance not noted below are the same, see 4.2 and 4.3)

Parts Interval term

Check fuel valve nozzle (clean) 1500 hours

Check & adjustment of fuel injection pressure & atomizing condition 3000 hours

Check fuel pump (adjust) 3000 hours

Note: The inspection and maintenance shown above are to be performed at your Yanmar dealer or distributor

Page 49

5. TROUBLE AND TROUBLESHOOTING

Trouble Probable Cause Measure Reference

Alarm buzzer and alarm lamps on during operation

Lubricating oil low-pressure alarm. Warning lamp goes on

Water in sail drive seal alarm goes on.

Coolant temperature high alarm warning lamp goes on

Faulty warning devices

Warning lamps do not go onLubricating oil low pressure.

One of the warning lamps does not go out

Battery low charge lamp does not go out during operation

NOTICE

Shift to low speed operation immediately, and check which lamp has come on. Stop the engine for inspection. If no abnormality is identified and there is no problem with operation, return to port at your lowest speed and request repairs.

Engine Lubricating Oil level low. Check Lubricating Oil, Add

Lubricating oil filter clogged. Replace. 4.3.1(1)

Breakage of rubber seal on the sail drive

Insufficient water in coolant tank. Check coolant and replen-

Insufficient seawater causing temperature to rise.

Contamination inside cooling system.

or replace.

Check and change the rubber seal.

ish.

Check seawater system.

Ask for repairs.

3.2.3

3.2.4

NOTICE

Do not operate the engine if the alarm devices are not repaired. Serious accidents may result if difficulties are not spotted due to faulty alarm lamps. When the switch is turned ON: Alarm buzzer does not sound. Circuit broken or buzzer defective. Ask for repairs.

Ask for repairs. Water in sail drive seal alarm. No current available. Circuit broken or lamp burnt out.

Sensor switches faulty. Ask for repairs.

V-belt is loose or broken. Replace V-belt; adjust ten-

sion.

Battery defective. Check fluid level, specific

gravity. Replace.

Alternator failure. Ask for repairs.

4.3.1(6)

4.3.2(2)

Note: Other warning lamps do not light up when the switch is turned on. They only light up when there is an abnormality.

Page 50

5. TROUBLE AND TROUBLESHOOTING

Trouble Probable Cause Measure Reference

Starting Failures

Starter turns, but engine does not start

Starter does not turn or turns slowly (Engine can be turned manually)

Engine cannot be turned manually

Abnormal Exhaust Color Black smoke

White smoke Improper fuel. Ask for repairs. 3.1.1

No fuel. Replenish fuel; vent air. 3.3.2(3)

Fuel filter is clogged. Replace element. 4.3.5(1)

Improper fuel. Replace with recommended

fuel.

Faulty fuel injection. Ask for repairs.

Compression leakage from intake/exhaust valve.

Faulty clutch position. Shift to NEUTRAL and start. 3.3.2.3

Insufficient battery charge. Check fluid level; recharge;

Cable terminal contact failure. Remove corrosion from termi-

Faulty safety switch device. Ask for repairs.

Faulty starter switch. Ask for repairs.

Power lacking due to accessory drive engaged.

Internal parts seized; broken. Ask for repairs.

Load increased.

Improper propeller matching

Contaminated intake silencer. Clean element. 4.3.5(4)

Improper fuel. Replace with recommended

Faulty spraying of fuel injector. Ask for repairs.

Incorrect intake/exhaust valve clearance.

Faulty spraying of fuel injector. Ask for repairs.

Fuel injection timing off. Ask for repairs.

Lubricating oil burns; excessive consumption.

Ask for repairs.

4.3.2(2)

replace.

nal; Retighten.

Consult your dealer.

fuel.

Ask for repairs.

Page 51

5. TROUBLE AND TROUBLESHOOTING

Consulting Your Yanmar Dealer or Distributor

Refer difficult problems and repairs to your Yanmar dealer or distributor. At the time of trouble, check and report the following:

(1) Engine model and number:

(2) Boat name, material of hull, size (tons):

(3) Use, type of boating done, no. of hours run:

(4) Total number of operation hours (refer to hour meter), age of boat:

(5) Condition before trouble (engine rpm, type of operation, load condition, etc.):

(6) Details of trouble:

(Exhaust color; sound of engine; does engine start; can engine be turned manually; type of fuel used; brand and viscosity of lubricating oil; etc.)

(7) Past problems and repairs: This should be a one-page report with the heading

SERVICE HISTORY

Date - Engine Hours - Service completed

WARRANTY SERVICE

Owner Satisfaction

Your satisfaction and goodwill are important to us and to your dealer.

Normally any problems concerning the product will be handled by our dealer's service department. If you have a warranty problem that has not been handled to your satisfaction, we suggest you take the following action:

• Discuss your problem with a member of dealership management.

Complaints can often quickly be resolved at this level. If the problem has already been reviewed with the Service Manager, contact the owner of the dealership or the General Manager.

• If your problem still has not been resolved to your satisfaction, contact your local Yanmar Subsidiary Company. (See the back of this manual for addresses)

We will need the following information in order to assist you:

• Your name, address and telephone number

• Product model and serial number

• Purchase date

• Dealer's name and address

• Nature of the problem

After reviewing all the facts involved, you will be advised of what action can be undertaken. Please remember that your problem will most likely be resolved at the dealership, using the dealer's facilities, equipment and personnel. It is therefore very important that your initial contact be with the dealer.

Page 52

6. PIPING DIAGRAMS

See Appendix A. at the back of this manual.

Notation

RH Rubber hose

SGP STS Steel Pipe

Screw joint (Union)

Flange Joint

Eye Joint

Insertion Joint

Drilled hole

Cooling fresh water piping

Cooling seawater piping

Lubricating oil piping

Fuel oil piping

1 Overflow

2 Fuel oil inlet

3 Fuel feed pump

4 Fuel injection pump

5 Lubricating oil filter (cartridge type)

6 Fuel high pressure lines

7 Fuel injection nozzle

8 Oil pressure switch

10 Mixing elbow

11 Coolant tank/Heat exchanger

12 Lubricating oil inlet filter

13 Main bearing

14 Seawater inlet

15 Cooling water pump (seawater)

16 Hot water connection outlet (to heater)

17 Thermostat

18 Cooling water pump (fresh water)

19 Hot water connection inlet (from heater)

20 Fresh water temperature switch

21 Lubricating oil pump

22 Pressure control valve

23 Fuel oil filter (cartridge type)

24 From cylinder head

25 To cam shaft

50 Detail of part A

51 Detail of part B

52 Detail of part C

53 Detail of part D

Page 53

7. WIRING DIAGRAMS

See Appendix B. at the back of this manual.

Color coding

R Red

B Black

W White

L Blue

RB Red/Black

LB Blue/Black

YW Yellow/White

YB Yellow/Black

YG Yellow/Green

WL White/Blue

WB White/Black

WG White/Green

GR Green/Red

O Orange

WBr White/Brown

1 Starter switch

2 Stop switch

3 Tachometer hour meter

4 Buzzer

5 Lubricating oil low pressure alarm

6 Coolant high temperature alarm

7 Water in sail drive seal alarm

8 Battery low charge alarm

9 Relay (for 2 station: Option)

10 Fuse (3A)

21 Glow plug

22 Engine stop solenoid

23 Stop relay

24 Starter relay

25 Starter

26 Coolant high temperature switch

27 Lubricating oil low pressure switch

29 Alternator

30 Water in sail drive seal sensor (on sail drive)

Water in sail drive seal sensor amplifier (Sail

drive only)

33 Battery

34 Procured by customer

35 Battery switch

36 Earth bolt

37 Key switch

38 Only for sail drive

39 Wire harness. Option.

40 Instrument panel

41 Diodes

42 Alarm lamps

Page 54

• MANUFACTURER’S DECLARATION FOR MACHINERY PARTS ACCORDING TO 94/25/EEC(ANNEX-15) & 89/336/EEC

• MANUFACTURER: YANMAR CO., LTD.

1-32, Chayamachi, Kita-ku, Osaka, Japan

• DESCRIPTION OF THE MACHINERY PARTS

• CATEGORY: Diesel engine

1. MAKE: YANMAR

2. THIS MACHINERY PART MUST NOT BE PUT INTO SERVICE UNTIL THE MACHINERY INTO WHICH IT IS TO BE INCORPORATED HAS BEEN DECLARED IN CONFORMITY WITH THE PROVISIONS OF THE DIRECTIVE.

• IMPORTER IN THE EU: YANMAR MARINE INTERNATIONAL B.V. Brugplein 11 1332 BS Almere-de Vaart, The Netherlands

Nagahama, Japan, Sept. 21, 1997 Place and date issued Y. Sugita Manager Quality Assurance Dept. Power System Operation Div.

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President, Yanmar Marine Int’l

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President, Yanmar Marine Int’l

Yanmar 3YM30, 3YM20, 2YM15 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual