M9961-03E101 3YM30/3YM20/2YM15
Publication No. M9961-03E101 History of Revision Manual Name Service Manual for Marine Diesel Engine Engine Model: 3YM30/3YM20/2YM15 Number Date of of revision revision New edition R1 April 25, 2005 Reason for correction Outline of correction Correction item No (page) Corrected by March 2004 Quality Control Dept. Marine Factory Add : Eug. 1. Specifications table added. Model 2YM15 2. Engine outline added. 3. Piping diagram added. 4. Other data added. Corrected data. (3YM30, 3YM20) 1.
FOREWORD This service manual has been complied for engineers engaged in sales, service, inspection and maintenance. Accordingly, descriptions of the construction and functions of the engine are emphasized in this manual, while items, which should already be common knowledge, are omitted. One characteristic of a marine diesel engine is that its performance in a vessel is governed by the applicability of the vessel's hull construction and its steering system.
CONTENTS 1. General ............................................................................................................................ 1 1.1 Exterior views ...........................................................................................................................1 1.2 Specifications ...........................................................................................................................2 1.3 Fuel oil, lubricating oil and cooling water .............................
3.4 Troubleshooting by measuring compression pressure ..........................................................62 4. Disassembly and reassembly ........................................................................................ 64 4.1 Disassembly and reassembly precautions .............................................................................64 4.2 Disassembly and reassembly tools ........................................................................................65 4.2.
5.6 Camshaft and tappets ..........................................................................................................128 5.6.1 Camshaft....................................................................................................................................... 128 5.6.2 Tappets ......................................................................................................................................... 130 5.7 Timing gear ..................................................
8.2.2 Specifications of lube oil pump ..................................................................................................... 153 8.2.3 Lube oil pump disassembly and reassembly ................................................................................ 153 8.2.4 Lube oil pump inspection .............................................................................................................. 154 8.2.5 Pressure control valve construction ................................................
9.7 Bilge pump and bilge strainer (Optional) ..............................................................................170 9.7.1 Introduction ................................................................................................................................... 170 9.7.2 Description .................................................................................................................................... 171 9.7.3 Cautions.............................................................
12.7.1 Oil pressure alarm....................................................................................................................... 197 12.7.2 Cooling water temperature alarm................................................................................................ 198 12.8 Glow plug ...........................................................................................................................199 12.9 Electric engine stopping device ............................................
FOR SAFETY 1. SAFETY LABELS • Most accidents are caused by negligence of basic safety rules and precautions. For accident prevention, it is important to avoid such causes before development to accidents. Please read this manual carefully before starting repair or maintenance to fully understand safety precautions and appropriate inspection and maintenance procedures. Attempting at a repair or maintenance job without sufficient knowledge may cause an unexpected accident.
2. Safety Precautions (1) SERVICE AREA • Sufficient Ventilation Inhalation of exhaust fumes and dust particles may be hazardous to ones health. Running engines welding, sanding, painting, and polishing tasks should be only done in well ventilated areas. • Safe / Adequate Work Area The service area should be clean, spacious, level and free from holes in the floor, to prevent "slip" or "trip and fall" type accidents.
(2) WORK - WEAR (GARMENTS) • Safe Work Clothing Well fitting !! Appropriate safety wear (gloves, special shoes/boots, eye/ear protection, head gear, harness', clothing, etc.) should be used/worn to match the task at hand. Avoid wearing jewelry, unbuttoned cuffs, ties or loose fitting clothes around moving machinery. A serious accident may occur if caught in moving/rotating machinery. (3) TOOLS • Appropriate Lifting / Holding When lifting an engine, use only a lifting device (crane, jack, etc.
(5) FASTENER TORQUE • Torquing Fasteners Always follow the torque values and procedures as designated in the service manual. Incorrect values, procedures and or tools may cause damage to the engine and or personal injury. (6) Electrical • Short Circuits Always disconnect the (-) Negative battery cable before working on the electrical system. An accidental "short circuit" may cause damage, fire and or personal injury.
(8) FURTHER PRECAUTIONS • Fueling / Refueling Keep sparks, open flames or any other form of ignition (match, cigarette, etc.) away when fueling/refueling the unit. Fire and or an explosion may result. • Hot Surfaces. Do NOT touch the engine (or any of its components) during running or shortly after shutting it down. Scalding / serious burns may result. Allow the engine to cool down before attempting to approach the unit. • Rotating Parts Be careful around moving/rotating parts.
3. Precautions for Service Work (1) Precautions for Safety Read the safety precautions given at the beginning of this manual carefully and always mind safety in work. (2) Preparation for Service Work Preparation is necessary for accurate, efficient service work. Check the customer ledger file for the history of the engine.
1. General 1. General 1.1 Exterior views Operating Side Intake silencer Intake manifold Oil filler cap Fuel filter Fuel injection pump Dipstick Oil filler cap Fuel feed pump Lubricating oil filter Marine gear Non-Operating Side Engine name plate (on the rocker arm cover) Fresh water filler cap Coolant tank / Heat exchanger Cover Exhaust manifold Starter motor Shift lever Sea water pump V-belt Alternator This illustration shows the 3YM30 with Yanmar marine gear (Model:KM2P-1).
1. General 1.2 Specifications Official engine model name unit 3YM30 3YM20 Company internal model name - 3YM30 3YM30C 3YM20 3YM20C Marine gear model - KM2P-1 SD20 KM2P-1 SD20 Use - Pleasure use Type - Vertical water cooled 4 cycle diesel engine Combustion system - Indirect injection Air charging - Naturally aspirated Number of cylinders - 3 Bore x stroke mm(inch) 76 x 82 (2.99 x 3.23) 70 x 74 (2.76 x 2.91) Displacement L 1.115 0.
1. General Official engine model name unit 2YM15 Company internal model name - 2YM15 2YM15C Marine gear model - KM2P-1 SD20 Use - Pleasure use Type - Vertical water cooled 4 cycle diesel engine Combustion system - Indirect injection Air charging - Naturally aspirated Number of cylinders - 2 Bore x stroke mm(inch) 70 x 74 (2.76 x 2.91) Displacement L 0.570 Output at crankshaft / Engine speed kW(HP)/ min-1 9.4(12.8) / 3489 (at Fuel temp.
1. General (Note) 1. Rating condition : ISO 3046-1, 8665 2. 1HP (metric horse power) ≒ 0.7355 kW 3. Fuel condition : Density at 15°C = 0.842 * Fuel temperature 25°C at the inlet of the fuel injection pump. (ISO 3046-1) ** Fuel temperature 40°C at the inlet of the fuel injection pump. (ISO 8665) 4. The "Total" oil quantity includes: oil in oil pan and oil in channels, coolers and filter. 5. The effective amount of oil shows the difference in maximum scale of the dipstick and minimum scale.
1. General 1.3 Fuel oil, lubricating oil and cooling water 1.3.1 Fuel oil IMPORTANT: Only use the recommended fuel to obtain the best engine performance and prevent damage of parts, also prevent air pollution. (1) Selection of fuel oil Use the following diesel fuels for best engine performance: BS 2869 A1 or A2 Fuels equivalent to Japanese Industrial Standard, JIS. No. K2204-2 Fuel cetane number should be 45 or greater (2) Fuel handling • Water and dust in the fuel oil can cause operation failure.
1. General (2) Selection of marine gear lube oil Use the following engine oil • API classification ......... CD or better (Standards of America Petroleum Institute) • SAE viscosity ......... #20 or #30 (Standard of Society of Automotive Engineering) (3) Selection of lube oil for sail drive unit API service grade ......... GL4, 5 SAE viscosity ......... #90 or 80W-90 or QuickSilver High Performance Gear Lube QuickSilver® is registered trademark of Brunswick Corporation.
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1.General (4) 3YM20C (with SD20 sail drive) NOTE 1. DWG. SHOWS MOUNTING BLOCKS AT ORIGINAL HEIGHT. 2. ENGINE WEIGHT WILL COMPRESS BLOCKS BY 4.5 mm (APPROX.). 3. MOUNTING BLOCKS ARE EQUIPPED FOR STANDARD ACCESSORY. 4. SHOWS CENTER OF GRAVITY.
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1.General 1.5 Piping diagrams (1) 3YM30/3YM20 (with KM2P-1 marine gear) 7.8 x t4.5 rubber hose Overflow 7.8 x t4.5 rubber hose Screw joint (Union) Check valve Flange joint 7.8 x t4.5 rubber hose Fuel oil filter Eye joint 5 x t4.5 rubber hose Fuel injection pump 17 4.76 x t0.7 steel pipe C Insertion joint Drill hole Fuel feed pump 18 Marks of piping Fuel oil inlet 7.8 x t4.5 rubber hose 7.8 x t4.
1.General (2) 3YM30C/3YM20C (with sale drive SD20) 7.8 x t4.5 rubber hose Overflow 7.8 x t4.5 rubber hose Screw joint (Union) Check valve Flange joint 7.8 x t4.5 rubber hose Fuel oil filter Eye joint 5 x t4.5 rubber hose Fuel injection pump 17 4.76 x t0.7 steel pipe C Insertion joint Drill hole Fuel feed pump 18 Marks of piping Fuel oil inlet 7.8 x t4.5 rubber hose 7.8 x t4.
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1.General 1.6 Exhaust gas emission regulation 3YM30/3YM20/2YM15 series engines are applicable with Off-road Compression Ignition engines regulations of the EPA and ARB (,California Air Resources Board) in USA and BSO regulations in Europe. 1.6.
1.General 1.6.2 Exhaust gas emission standard (EPA/ARB) Engine Power Tier Model Year NOx HC NMHC + NOx CO PM 8 <= kW < 19 (11 <= hp < 25) Tier 1 2000 - - 9.5 (7.1) 6.6 (4.9) 0.80 (0.60) Tier 2 2005 - - 7.5 (5.6) 6.6 (4.9) 0.80 (0.60) 19<= kW < 37 (25 <= hp < 50) Tier 1 1999 - - 9.5 (7.1) 5.5 (4.1) 0.80 (0.60) Tier 2 2004 - - 7.5 (5.6) 5.5 (4.1) 0.60 (0.45) Note 1. 2. 3. 4. The transit smoke (ACC/LUG/PEAK) is not applicable. The EPA recommended fuel is used.
1.General (5) Quality guarantee period for exhaust emission related parts For exhaust emission related parts, follow the inspections outlined in the "List of Periodic Inspections", on the operation manual, and use the table below to carry out inspections based on operation hours or time in years. Whichever comes first is the guarantee period.
2. Inspection and adjustment 2. Inspection and adjustment 2.1 Periodic maintenance schedule The engine periodic inspection timing is hard to determine as it varies with the application, load status, qualities of the fuel and lubricating oils used and handling status. General rules are described here. { : User-maintenance System Whole Item *2 *2 *2 Every *2 Every Every *2 Every *2 Every Before Initial starting 50hrs. or 50hrs. or 100 hrs. or 150 hrs. or 250 hrs. or 1000 hrs.
2. Inspection and adjustment { : User-maintenance System Item Å : Parts replacement z : Shop-inspection *2 *2 Every *2 Every *2 Every *2 Every *2 Every Before Initial starting 50hrs. or 50hrs. or 100 hrs. or 150 hrs. or 250 hrs. or 1000 hrs.
2. Inspection and adjustment 2.2 Periodic inspection and maintenance procedure 2.2.1 Check before starting Be sure to check the following points before starting an engine every day. No.
2. Inspection and adjustment 2) Checking marine gear lube oil level a) Check the lube oil level of the marine gear with a dipstick. Unit: liter (pint) Marine gear oil capacity KM2P-1 Dipstick Upper limit Lower limit Full : 0.30 (0.64) b) When the level is low, remove a oil filler cap at the top of the housing, and fill it with marine gearclutch- lube oil to the upper limit on the dipstick. c) Tighten the oil filler cap securely by hand.
2. Inspection and adjustment IMPORTANT: If the cooling water runs short quickly or when the coolant tank runs short of water with the coolant recovery tank level unchanged, water may be leaking or the air tightness may be lost. Increase in the water level of the coolant recovery tank during operation is not abnormal. The increased water in the coolant recovery tank returns to the coolant tank when the engine is cooled down.
2. Inspection and adjustment 2.2.2 inspection after initial 50 hours or one month operation Be sure to check the following points after initial 50 hours or one month operation, whichever comes first. No.
2. Inspection and adjustment 3) Moisten the new oil filter gasket with the lube oil and install a new lube oil filter manually turning it clockwise until it comes into contact with the mounting surface, and tighten it further to 3/4 of a turn with the filter wrench. Tightening torque: 20-24N•m (177-212 lb-in) Applicable oil filter Part No. 119305-35150 4) Fill with new lube oil. 5) Perform a trial run of the engine and check the oil leakage.
2. Inspection and adjustment (4) Adjust the tension of the alternator drive belt Push When there is not enough tension in the V-belt, it will slip and the cooling water pump will fail to supply cooling water. Engine over-heating and the seizure will occur. When there is too much tension in the V-belt, the belt will become damaged more quickly and the bearing of the cooling water pump may be damaged. Check and adjust the V-belt tension (deflection) in the following manner.
2. Inspection and adjustment (5) Adjusting the intake/exhaust valve clearance Make measurement and adjustment while the engine is cold. 1) Valve clearance measurement a) Remove the rocker arm cover above cylinder head. Injection timing marks b) Set the No.1 cylinder in the compression TDC Turn the crankshaft to bring the piston of the No.1 cylinder to its compression top dead center No.1 cylinder while watching the rocker arm motion, the timing T.D.C.
2. Inspection and adjustment b) Measure valve clearance Insert a 0.2 mm thickness gage between the rocker arm and valve cap, and adjust the valve clearance. Tighten the adjusting bolt. Standard valve clearance (mm) 0.15-0.25 c) Apply oil to the contact surface between adjusting screw and push rod. d) Adjusting other cylinders Turn the crankshaft 240° then and make adjustment for the No.3 cylinder. Then adjust the No.2 cylinder in this order.
2. Inspection and adjustment (7) Adjust the propeller shaft alignment The flexible engine mounts is compressed a little in the initial engine operation and it may cause the centering misalignment between the engine & the propeller shaft. 1) Check unusual noise and vibration of the engine / boat hull, while increasing the engine speed gradually and lowering it. 2) If there is unusual noise and/or vibration, adjust the propeller shaft alignment. (Refer to 6.4.
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2. Inspection and adjustment (2) Check the electrolyte level in the battery Fire due to electric short-circuit • Make sure to turn off the battery switch or disconnect the negative cable (-) before inspecting the electrical system. Failure to do so could cause short-circuiting and fires. • Always disconnect the (-) Negative battery cable first before disconnecting the battery cables from battery. An accidental "Short circuit" may cause damage, fire and or personal injury.
2. Inspection and adjustment (1) Electrolyte level • Check the level of fluid in the battery. When the amount of fluid nears the lower limit, fill with battery fluid (available in the market) to the upper limit. If operation continues with insufficient battery fluid, the battery life is shortened, and the battery may overheat and explode. • Battery fluid tends to evaporate more quickly in the summer, and the fluid level should be checked earlier than the specified times.
2. Inspection and adjustment (b) Measurement with hydrometer When using a hydrometer, the measured specific gravity must be corrected according to the temperature at the time of measurement. The specific gravity of battery electrolyte is defined with 20°C as the standard. Since the specific gravity increases or decreases by 0.0007 when the temperature varies by 1°C, correct the value according to the equation below. Float S20 = St + 0.
2. Inspection and adjustment 2.2.4 Inspection every 100 hours six months Be sure to check the following points every 100 hours or six months operation, whichever comes first. No. (1) Inspection Item Replace the lube oil in a sail drive. (1) Replace the lube oil in a sail drive. Refer to the sail drive operation manual for the procedure of replacing the oil. 2.2.5 Inspection every 150 hours or one year Be sure to check the following points every 150 hours or one year operation, whichever comes first. No.
2. Inspection and adjustment 2.2.6 Inspection every 250 hours or one year Be sure to check the following points every 250 hours or one year operation, whichever comes first. No.
2. Inspection and adjustment (3) Replace the marine gear lube oil. Refer to 2.2.2(3) for the procedure. (4) Replace the engine lube oil filter. Refer to 2.2.2(2) for the procedure. (5) Check the impeller of the cooling water pump (seawater pump). 1) Remove the seawater pump cover and take out the O-ring, impeller and wear plate. 2) Inspect the rubber impeller, checking for splitting O-ring around the outside, damage or cracks, and replace Cover if necessary.
2. Inspection and adjustment (6) Replace the fresh water coolant. Be sure to replace the fresh water every year. When the long life coolant is used of the specified type, the replacement period of two years can be obtained. Use clean soft water and be sure to add the Long Life Coolant Antifreeze (LLC) to the cooling water in order to prevent rust built up and freezing. Cooling performance drops when cooling water is contaminated with rust and scale.
2. Inspection and adjustment 5) After supplying cooling water, fit the filler cap and tighten it firmly. To reassemble 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. 6) Remove the coolant recovery tank cap and fill with coolant mix to the lower limit. Replace the cap to the coolant recovery tank. Coolant recovery tank capacity: 0.8 L (1.7 pints) 7) Check the rubber hose connecting the coolant recovery tank to the fresh water cooler.
2. Inspection and adjustment (8) Clean the exhaust/water mixing elbow. There are two types of mixing elbows, the L-type and the U-type. The mixing elbow is attached to the exhaust manifold. The exhaust gas is mixed with seawater in the mixing elbow. U-type Mixing elbow Seawater Joint L-type Mixing elbow Heat exchanger Seawater Exhaust elbow Heat exchanger Optional (U-type mixing elbow) (L-type mixing elbow) 1) Clean dirt and scale out of the air pass and seawater pass of the mixing elbow.
2. Inspection and adjustment (10) Check the wiring connectors. Check whether each connection part doesn't have loosened.
2. Inspection and adjustment 2.2.7 Inspection every 1,000 hours or four years Be sure to check the following points every 1,000 hours or four years operation, whichever comes first. No.
2. Inspection and adjustment (2) Check the injection spray condition of a fuel nozzle Wear protective glasses when testing injection from the fuel injection nozzle. Never approach the injection nozzle portion with a hand. The oil jetting out from the nozzle is at a high pressure to cause loss of sight or injury if coming into careless contact with it. 1) Injection pressure measurement Standard fuel injection pressure MPa (kgf/cm2) 12.3-13.
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2. Inspection and adjustment 2) Spray pattern inspection After adjustment to the specified valve opening pressure, use a nozzle tester and check the spray pattern and seat oil-tightness. a) Seat oil tightness check • After injecting a few times, increase the pressure gradually. Hold the pressure for about 5 seconds at a little before the valve opening pressure of 1.96 MPa (20 kgf/cm2), and check to see that oil does not drip from the tip end of the nozzle.
2. Inspection and adjustment 4) Nozzle punch mark NP - DN O P D N159 Design code Throttle type Size: size P Injection angle Type: pintle type NP- BOSCH D NOPD N 1 5 9 Identification number (3) Check the impeller of the cooling water pump (seawater pump) The impeller must be replaced with new one periodically (every 1000 hrs or four years whichever comes first). Refer to 2.2.5 (5) for the procedure.
2. Inspection and adjustment 3) Heat exchanger body water leakage test a) Compressed air/water tank test Fit rubber covers on the fresh water and seawater inlets and outlets. Place the heat exchanger in a water tank, feed in compressed air from the overflow pipe and check for any (water) leakage, (air bubbles). Test pressure Pressure gauge Air hose Filler cap Rubber cap Test tank 2 0.
2. Inspection and adjustment (5) Diaphragm assembly inspection Inspect the diaphragm assy on the rocker arm cover. 1) Loosen screws, and remove a diaphragm assembly, and check whether oil and so on doesn't enter between the diaphragm and the cover. If oil and so on enters into the diaphragm assy, the diaphragm doesn't work well. 2) Check the damages of the diaphragm rubber and the spring. If necessary, replace with new ones.
2. Inspection and adjustment 2.3 Adjusting the no-load maximum or minimum speed 1) After warming the engine up, gradually raise the speed and set it at the no-load maximum speed. 2) If the no-load maximum speed is out of the standard, adjust it by turning the high idle limiting bolt. 3) Then set the no-load minimum speed by adjusting the low idle limiting bolt.
2. Inspection and adjustment 2.5 Thermostat inspection (1) Put the thermostat in a beaker with fresh water, and heat it on an electric stove. The thermostat is functioning normally if it starts to open between 75-78 deg C, and opens until 8 mm or more at 90 deg C. Replace the thermostat if it not functioning normally. Thermometer Thermostat cover Thermostat Thermostat Fresh water pump body Valve opening Temperature (deg C)* 69.5-72.
2. Inspection and adjustment 2.6 Adjusting operation Perform the adjusting operation for an engine as follows after the maintenance job: 2.6.1 Preliminary precautions Before making a test run, make sure of the following points. (1) Warm the engine up. (2) Remove any precipitation from the F.O. filter. water separator, and F.O. tank. (3) Use only lube oil recommended by Yanmar. (4) Be sure to add Long Life Coolant Antifreeze (LLC) to cooling fresh water. (5) Provide good ventilation in the engine room.
2. Inspection and adjustment 2.6.3 Check points and precautions during running Step Item Instructions Precautions 3) Lamp should go off 1) Make sure that the sea cock is open. when engine is 2) Make sure there is enough lube oil and (fresh) running. cooling water. 3) Operate the remote control handle and check if the device connected to the engine works property. 1 Checks before operation 2 2) No load operation; 1) When the lube oil temperature is raised to allow • Fit leaks if any.
2. Inspection and adjustment 2.7 Long storage Observe the following instructions when the engine is to be stored for a long period without operation: 1) Do not drain cooling water in the cold season or before the long storage. [NOTICE] Negligence of adding anti-freeze will cause the cooling water remaining inside the engine to be frozen and expanded to damage the engine parts. 2) 3) 4) 5) 6) Remove the mud, dust and oil deposit and clean the outside.
3. Troubleshooting 3. Troubleshooting 3.1 Preparation before troubleshooting If the signs of a trouble appear, it is important to lecture on the countermeasure and treatment before becoming a big accident not to shorten the engine life. When the signs of a trouble appear in the engine or a trouble occurs, grasp the trouble conditions fully by the next point and find out the cause of sincerity according to the troubleshooting. Then repair the trouble, and prevent the recurrence of the trouble.
3. Troubleshooting 3.2 Quick reference chart for troubleshooting It is important to thoroughly under stand each system and the function of all of the parts of terse systems. A careful study of the engine mechanism will make this possible. When problems arise, it is important to carefully observe and analyze the indications of trouble in order to save time in determining their cause. Begin by checking the most easily identifiable causes of difficulty.
THE ENGINE SUDDENLY STOPS. Countermeasure TROUBLE AND TROUBLESHOOTING (I-1) Add fuel oil and prime. (I-2) Bleed air. (I-3) Remove water from drain and fuel oil system and prime. (I-4) Check and make necessary repairs. (I-5) Clean. (I-6) Replace. (I-7) Check and make necessary repairs. (II-1) Replace. (II-2) Clean carefully to insure good working order.
Chart 2 CYLINDER OUTPUT IS UNEVEN (1) Oil leakage in injection system (2) Damaged valve spring (4) Irregular injection timing Countermeasure Countermeasure (I -7) Disassemble and clean and repair replace.
TROUBLE WITH MARINE GEAR (I-1) Disassemble and clean. (I-2) Repair or replace. (I-3) Repair or replace. (I-4) Replace. (I-5) Repair. (I-6) Adjust. (I-7) Replace. (I-8) Replace. (I-9) Adjust to correct position. (I-10) Reassemble. (I-11) Check for oil leakage and replenish. (II-1) Review (I-1, I-11). (II-2) Reduce load. (II-3) Replace. (II-4) Check oil level and adjust. (II-5) Check water level and adjust. (II-6) Change oil. (II-7) Review manual. (III -1) Replace. (III -2) Replace.
Chart 5 ROTATION IS NOT SMOOTH Countermeasure TROUBLE AND TROUBLESHOOTING (I-1) Lap. (I-2) Replace. (II-1) Clean. (II-2) Replace. (II-3) Replace. (II-4) Correctly install pump. (II-5) Clean. (II-6) Replace.
KNOCKING Countermeasure TROUBLE AND TROUBLESHOOTING (II-1) Delay injection timing. (II-2) Adjust standard injection pressure. (I-1) Increase injection pressure. (I-2) Replace. (I-3) Disassemble and lap. (I-4) Disassemble and repair.
Chart 7 TROUBLE WITH STARTING (I-1) Tighten. (I-2) Repair using sandpaper or replace. (I-3) Replace. (I-4) Repair using sandpaper and then grease. (I-5) Adjust. (I-6) Adjust. (I-7) Replace. (II-1) Tighten. (II-2) Repair using sandpaper. (II-3) Replace. (II-4) Repair using sandpaper (Type 500 600). (II-5) Replace. (II-6) Undercut and repair or replace. (II-7) Replace. (II-8) Replace with thicker or shorter wire. (II-9) Charge. (III-1) Prime well. (III-2) Adjust. (III-3) Clean out matter causing clogging.
INSUFFICIENT POWER OUTPUT (I-1) Replace. (I-2) Disassemble and repair or replace. (I-3) Lap valves. (I-4) Tighten firmly. (I-5) (I-6) Adjust. (I-7) (I-8) Clean. (I-9) Replace. (I-10) Repair. (II-1) Clean nozzle hole or replace. (II-2) Lap or replace. (II-3) Lap or replace. (II-4) Tighten firmly. (II-5) Replace. (II-6) lean. (III-1) Replace. (III-2) Repair.
Chart 9 MISCELLANEOUS TROUBLE Countermeasure TROUBLE AND TROUBLESHOOTING (I-1) Tighten nuts. (I-2) Tighten nuts and insert pins. (I-3) Remove adjustment liner and adjust aperture, or replace. (I-4) Check teeth, shaft, and pushrod of gear for wear. Replace where necessary.
3. Troubleshooting 3.3 Troubleshooting (Concerning engine and fuel injection equipment) Malfunctions The engine does not operate 1. Fuel oil is not injected from the injection pump Causes Remedies 1. There is no fuel oil in the fuel tank 2. The fuel line from the fuel tank is blocked 3. The fuel is clogged 4. There is air in the fuel filter or the pump chamber 5. The accelerator linkage is not properly connected 6. The magnet valve wiring is broken or its armature is sticking 7.
3. Troubleshooting Malfunctions The engine exhaust contains smoke and the engine “knocks” The engine output is unstable Insufficient output 1. The injection quantity is insufficient Causes Remedies 1. The injection timing is incorrect 2. The nozzle or nozzle holder is functioning incorrectly 3. The injection quantity is excessive Readjust the timing Inspect, then repair or replace 1. The fuel filter element is clogged and fuel oil delivery is poor 2.
3. Troubleshooting Malfunctions Causes Inspect and then repair or replace 4. The nozzle or the nozzle holder is not functioning properly The engine cannot reach its maximum speed The engine’s maximum speed is too high Idling is unstable Remedies 1. The governor spring is too weak or is improperly adjusted 2. The control lever is not reaching the maximum-speed position 3. The nozzle’s injection operation is poor Readjust or replace 1. The governor spring is too strong or is improperly adjust 2.
3. Troubleshooting 3.4 Troubleshooting by measuring compression pressure Compression pressure drop is one of major causes of increasing blowby gas (lubricating oil contamination or increased lubricating oil consumption as a resultant phenomenon) or starting failure.
3. Troubleshooting Compression pressure (kgf/cm2) (3) Engine speed and compression pressure (for reference) 3YM30 40 3.92 35 3.43 30 2.94 3YM20/2YM15 25 2.45 20 1.96 (MPa) 200 250 300 350 400 Engine speed (min-1) (4) Measured value and troubleshooting When the measured compression pressure is below the limit value, inspect each part by referring to the table below. No.
4. Disassembly and reassembly 4. Disassembly and reassembly 4.1 Disassembly and reassembly precautions (1) Disassembly • Take sufficient time to accurately pin-point the cause of the trouble, and disassemble only those parts which are necessary. • Be careful to keep all disassembled parts in order. • Prepare disassembly tools. • Prepare a cleaner and cleaning can. • Clear an adequate area for parts and prepare a container(s) • Drain cooling water (seawater, fresh water) and lube oil.
4. Disassembly and reassembly 4.2 Disassembly and reassembly tools The following tools are required when disassembling and reassembling the engine. Please use them as instructed. 4.2.
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4. Disassembly and reassembly 4.2.2 Special hand tools Name of tool Illustration Piston pin insertion/ extraction tool 80 12 25 20 Remarks (Piston pin extractor) (Extraction of piston pin) (Insertion of piston pin) Connecting rod small end bushing insertion/extraction tool -0.3 24 -0.6 -0.3 80 22 -0.6 20 * Locally manufactured (Extraction) Intake and exhaust valve insertion/ extraction tool 75 9.5 5.5 20 * Locally manufactured Crankshaft pulley insertion tool 50 26 6 -0.
4. Disassembly and reassembly Name of tool Illustration Remarks Lube oil filter case remover Piston ring replacer (for removal / installation of piston ring) Valve lapping tool (Rubber cap type) Valve lapping powder Code No.
4. Disassembly and reassembly Name of tool Illustration Press tool 1 for filler neck Remarks - 105 89 2 40 25 27.5 35.5 1 (Tool 1) Press tool 2 for filler neck copper tube 170 30 30 24.2 28 30 Chamfer (Tool 2) Stem seal insertion (for inserting stem seal) mm d1 d2 d3 L1 L2 L3 15.0 21 12 11.
4. Disassembly and reassembly 4.2.3 Measuring instruments (1) Application of tools Name of tool Illustration Remarks Vernier calipers 0.05 mm 0-150 mm Micrometer 0.01 mm 0-25 mm 25-50 mm 50-75 mm 75-100 mm 100-125 mm 125-150 mm Cylinder gauge 0.01 mm 18-35 mm 35-60 mm 50-100 mm Thickness gauge 0.
4. Disassembly and reassembly (2) Use of tools No. Name of tool Use 1 Dial gauge Measures shaft bending, distortions of levelness, and gaps. 2 Test indicator Measures narrow and deep places, which cannot be measured with dial gauge. 3 Magnetic stand Keeps the dial gauge firmly in position, thereby permitting it to be used at various angles. 4 Micrometer Measures the outer diameter of the crank shaft, piston, piston pin, etc.
4. Disassembly and reassembly No. Name of tool Use 9 V Block Measures shaft distortion. 10 Torque wrench Used to tighten bolts and nuts to standard torque. 11 Thickness gauge Measures the distance between the ring and ring groove, and between the shaft and shaft joint at time of assembling. 12 Cap tester Check for leakage in the fresh water system. 13 Battery current tester Checks density of antifreeze and charging condition of battery fluid.
4. Disassembly and reassembly No. 16 Name of tool Rotation gauge Use Contact type Measures rotation speed by placing at the indentation hole of the revolving shaft. Photoelectric type Measures rotation speed by using a reflector seal which is placed on the exterior of the revolving shaft Illustration Revolving shaft Reflection mark High pressure fuel pipe clamp type Measures rotation speed without reference to revolving shaft center or the exterior of the revolving shaft.
4. Disassembly and reassembly 4.2.4 Other material Items Liquid gasket Usual contents Features and application Three Bond No.1 TB1101 200g (1 kg also available) Non-drying liquid gasket ; solvent less type, easy to remove, superior in seawater resistance, applicable to various mating surfaces. Three Bond No.2 TB1102 200g (1 kg also available) Non-drying liquid gasket ; easy to apply, superior in water resistance and oil resistance, especially superior in gasoline resistance. Three Bond No.
4. Disassembly and reassembly Items Scale solvent Usual contents Scale solvent 1 box (4 kg × 4 removers) Neutralizer (caustic soda) 1 box (2 kg × 4 neutralizers) pH test paper Features and application • The scale solvent removes scale in a short time. (1 to 10 hours) • Prepare water (seawater is possible) in an amount that is about 10 times the weight of the solvent. Mix the solvent with water. • Just dipping disassembled part into removes scale. To shorten removal time, stir remover mixture.
4. Disassembly and reassembly 4.3 Disassembly and reassembly 4.3.1 Disassembly • Preparation on a boat For engines mounted in an engine room of a ship, remove the piping and wiring connecting them to the ship. 1) Remove the remote control cable (from engine and marine gearbox). 2) Unplug the extension cord for the instrument panel from the engine. 3) Remove the wiring between the starting motor and the battery. 4) Remove the exhaust rubber hose from the mixing elbow.
4. Disassembly and reassembly [NOTE: ] If a lube oil supply/discharge pump is used for the engine, the intake hose is placed in the dipstick guide, and for the clutch side (gearbox) it is placed in the oil hole on top of the case. (Refer to 2.2.2(2) & (3) ) (3) Removing (electrical) wiring Remove the wiring from the engine. (Refer to 2.2.
4. Disassembly and reassembly (5) Removing the intake silencer 1) Remove the air intake hose attached to the intake manifold. 2) Remove the intake silencer from cylinder head. Intake pipe Cylinder head Intake silencer (6) Removing the mixing elbow 1) Remove the seawater rubber hose connecting to a heat exchanger- a mixing elbow. 2) Remove the mixing elbow from the exhaust manifold.
4. Disassembly and reassembly (7) Removing the alternator 1) Loosen the set bolt (belt adjuster bolt) and move the alternator downwards. Loosen the V-pulley set bolts for the cooling water pump and remove the Vbelt. 2) Remove the belt adjuster from the gear case and remove the alternator from the cylinder head (with bracket). Alternator Bracket Set bolt V-belt Belt adjuster (3YM30) (8) Removing the cooling water pipes (seawater/ fresh water) 1) Remove the seawater pipe (seawater pump-heat exchanger).
4. Disassembly and reassembly (9) Removing the heat exchanger (exhaust manifold, coolant tank unit) Remove the heat exchanger and gasket packing from cylinder head. (10)Removing the seawater pump Loosen the nut on the spacer bolt and remove the seawater pump. Gear case cover Spacer bolt V-belt Bracket Seawater pump (Seawater pump) (11)Removing the starting motor Remove the starting motor from the flywheel housing.
4. Disassembly and reassembly (13)Removing the fuel injection pipe 1) Remove the fuel injection pipe retainer. 2) Loosen the cap nuts on both ends of the fuel injection pipe and remove the fuel injection pipe. Note: When loosening the cap nut, loosen the nut with holding the return pipe by hand so that the fuel return pipe may not break. Fuel injection pipe retainer No. 3 No. 2 No.
4. Disassembly and reassembly (15)Removing the fuel injection nozzles Loosen the fuel nozzles and remove them from the cylinder head. Fuel injection nozzle Nozzle seat Nozzle protector Nozzle seat Cylinder head (16)Remove the fuel injection pump 1) Loosen the drive gear nut for fuel pump drive gear, and pull out the fuel pump drive gear /flange assembly with an extraction tool. Note: Don't disassemble the pump flange and the pump drive gear.
4. Disassembly and reassembly (17)Removing the rocker arm shaft assembly Don’t disassemble the cross-recessed-hand bolts. 1) Loosen the hexagon head bolts and remove the rocker arm cover. Note: Don't loosen the cross-recessed-head bolts on the rocker arm cover, when removing the rocker arm cover. 2) Remove the bolts(s) for the rocker arm shaft support, and remove the entire rocker arm shaft assembly. 3) Pull out the push rods.
4. Disassembly and reassembly (21)Turning the engine over Bolt 1) Place a wood block of appropriate size on the floor, and stand up the engine on the flywheel housing. 2) Remove the engine mounting feet. Washer Crankshaft V-pully (22)Removing the crankshaft V-pulley Loosen the bolt tightening the crankshaft V-pulley and remove the crankshaft V-pulley with a pulley puller. Oil pan Gear case cover Wood block Flywheel housing (23) Removing the oil pan Oil pan Remove the oil pan and spacer.
4. Disassembly and reassembly (26)Removing the lube oil pump Remove the lube oil pump from the gear case cover. Control valve Cover Outer rotor Inner rotor Gear case cover (27)Removing the idle gear Bolt Loosen the three bolts holding the idle gear and pull out the idle gear and shaft. Idle gear shaft (28) Removing the camshaft 1) Push up tappet by turning a camshaft to remove it from the cylinder block easily. 2) Loosen the thrust metal bolts through the holes of the camshaft gear, and remove.
4. Disassembly and reassembly (30) Removing the gear case Liquid gasket 1) Remove the gear case from the cylinder block. 2) Remove the O-rings from the lube oil passage. 70 77 12 9 70 1 2 - NOTE 1) When mounting the gear case, match up the two knock pins for cylinder block. 2) Be sure to coat the O-rings for the cylinder block lube oil passage with grease when assembling, so that it does not get out of place. Gear case (31)Loosening the main bearing bolts. Loosen the main bearing bolts.
4. Disassembly and reassembly (34)Removing the main bearing 1) Remove the main bearing bolts. 2) Remove the main bearing cap and lower main bearing metal. NOTE: The thrust metal (lower) is mounted to the base main bearing cap. (35)Removing the crankshaft 1) Remove the crankshaft NOTE: 1) The thrust metal (upper) is mounted to the standard main bearing of the cylinder block. 2) Remove the main bearing metal (upper) from the cylinder block.
4. Disassembly and reassembly 4.3.2 Reassembly (1) Clean all parts Clean all parts using by the cloth and diesel oil (or cleaning agent) before reassembly. NOTE: 1) If the dust remain with the parts, engine may cause the seizing or damage. 2) The cleaning agent removes even carbon adhering to disassembled parts. (2) Putting the cylinder block upside down Place a wood block on the floor and put the cylinder block upside down (with the cylinder head mounting surface facing down).
4. Disassembly and reassembly (5) Mounting the main bearing cap Coat the lower main bearing metal with engine oil, and mount it to the main bearing cap. NOTE: 1) The lower main bearing metal does not have an oil hole. 2) The base bearing thrust metal is fitted with the oil groove facing outwards. 1) Coat the flange and the thread of the main bearing bolts with engine oil, put them on the crankshaft journal, and tighten the main bearing bolts to the specified torque.
4. Disassembly and reassembly (7) Turning the engine over Cylinder block Stand up the engine on the flywheel housing. Flywheel housing (8) Mounting the gear case Apply the liquid gasket to the gear case and mount the gear case and lube oil line O-ring onto the cylinder block. NOTE: 1) When mounting the gear case, match up the two knock pins of the cylinder block. 2) Be sure to coat the O-ring for the cylinder block lube oil line with grease when assembling, so that it does not get out of place.
4. Disassembly and reassembly 2) Coat the outside of the piston and the inside of the connecting rod crank pin metal with engine oil and insert the piston with the piston insertion tool. Tightening torque Connecting rod bolt Nozzle side Camshaft side NOTE: 1) Insert the piston so that the match mark on the large end of the connecting rod faces the fuel nozzle, and the manufacture’s embossed mark on the stem faces toward the flywheel.
4. Disassembly and reassembly (11) Mounting the idling gear Upside 1) Mount the idling gear so that the mark of the idle gear shaft upward. Mark Oil hole (Idle gear shaft) 2) Align the "A" and "B" match marks of the idle gear with the match marks of the crankshaft gear and the camshaft gear. 3) Measure the idle gear, camshaft gear and crankshaft gear backlash. mm Backlash Standard Limit 0.07-0.15 0.
4. Disassembly and reassembly (13) Mounting the oil seal and gear case cover NOTE: Trim the liquid gasket if it protrudes onto the oil pan mounting surface. Crankshaft pulley 0 61.5 -1 Cylinder block Oil seal Gear case cover Gear case 9 -0777 12 70 12 1) Replace the used oil seal with a new one when the gear case cover is disassembled. 2) Insert a new oil seal by using the oil seal insertion tool on the position of the gear case cover end face (61.
4. Disassembly and reassembly (15) Mounting the oil pan spacer and the oil pan Oil pan Oil pan spacer 97 - 0 17 7 7 0 21 2 Cylinder block 977770 -01212 1) Apply the liquid gasket to the surfaces of the gear case cover, gear case and flywheel housing that contact with the cylinder block. 2) Apply the liquid gasket to the spacer. Mount the spacer to the cylinder block and tighten the bolts. 3) Apply the liquid gasket to the oil pan. Mount the oil pan to the spacer and tighten the bolts.
4. Disassembly and reassembly (19) Mounting the marine gearbox 1) Mount the damper disk to the flywheel. Align the damper disk with the input shaft spline and insert. 2) Mount the marine gearbox to the flywheel housing. Damper disk Flywheel 1st step Final 24-32 (2.5-3.3) 53.9-57.9 (5.5-5.
4. Disassembly and reassembly (22) Mounting the fuel injection pump Fuel injection pump drive gear 1) Lightly fit the fuel injection pump on the gear case. (After adjusting injection timing, tighten the fuel injection pump. Before mounting the heat exchanger to the cylinder head, adjust the injection timing.). NOTE: Be careful not to scratch the O-ring between the fuel injection pump and gear case. C Idle gear 2) Fit the fuel injection pump drive gear to the fuel pump camshaft.
4. Disassembly and reassembly (24) Mounting the fresh water pump 1) Thoroughly coat both sides of the gasket with adhesive. 2) Renew the O-ring for the connecting part of the pump, which is inserted in the cylinder block, and tighten the fresh water pump. Cylinder head Gasket Fresh water pump O-ring (25) Mounting the fuel injection pipe and fuel return pipe 1) Mount the fuel injection pipe and then assemble the fuel injection pipe retainer to prevent the pipe vibration.
4. Disassembly and reassembly (26) Mounting the lube oil filter. Cylinder block Mount the lube oil filter with the tool of the filter case remover. Lube oil pressure switch Lube oil filter (27) Mounting the seawater pump 1) Tighten the spacer bolt to the gear case cover. 2) Mount the bracket and the seawater pump assembly to the gear case cover. Gear case cover Spacer bolt V-belt Bracket Seawater pump (Seawater pump) (28) Mounting the heal exchanger (exhaust manifold, fresh water tank unit).
4. Disassembly and reassembly (29) Mounting the mixing elbow 1) Mount the mixing elbow on the exhaust manifold outlet. 2) Mount the cooing seawater pipe (rubber hose) with the hose clips (heat exchanger-mixing elbow). (30) Mounting the cooling water pipes (seawater / fresh water) 1) Mount the seawater pipes with the hose clips (seawater pump-heat exchanger). 2) Mount the fresh water pipes with the hose clips (exhaust manifold - fresh water pump, fresh water pump-heat exchanger).
4. Disassembly and reassembly (31) Mounting the alternator 1) Mount the bracket on the cylinder head and the adjuster on the gear case cover, and then the alternator. 2) Adjust V-belt tension with the adjuster, and tighten the set bolt. Alternator Bracket Set bolt V-belt Belt adjuster (3YM30) (32) Mounting the starting motor Fit the starting motor on the flywheel housing.
4. Disassembly and reassembly (34) Mounting the fuel filter and fuel pipe 1) Mount the fuel filter on the bracket, which is tightened to the cylinder head. 2) Mount the fuel pipe (fuel feed pump-fuel filter, fuel filter-fuel injection pump). Cylinder head Bracket Fuel pipe Fuel filter Fuel injection pump Clamp Fuel pipe (35) Electrical Wiring Connect the wiring to the proper terminals, observing the color coding to make sure the connections are correct.
4. Disassembly and reassembly (38) Filling with cooling water 1) Open the coolant (fresh water) tank cap and fill with water. Model Engine capacity 3YM30(C) 4.9 (5.2) 3YM20(C) 4.1 (4.3) 2YM15(C) 3.0 (3.2) L (quart) 2) Fill with water until the level in the coolant recovery tank is between the full and low marks. Coolant recovery tank capacity (full) 0.8 L (0.8 quart) (39) Test running Refer to “Adjusting operation” of 2.6 in chapter 2.
5. Inspection and servicing of basic engine parts 5. Inspection and servicing of basic engine parts 5.1 Cylinder block The cylinder block is a thin-skinned, (low-weight), short skirt type with rationally placed ribs. The side walls are save shaped to maximize rigidity for strength and low noise. 5.1.1 Inspection of parts Make a visual inspection to check for cracks on engines that have frozen up, overturned or otherwise been subjected to undue stress.
5. Inspection and servicing of basic engine parts 5.1.4 Replacement of cap plugs Step No. 1 Description Procedure Tool of material used Screw driver or saw blade Thinner Clean and remove grease from the hole into which the cap plug is to be driven. (Remove scale and sealing material previously applied.) Remove foreign materials with a screw driver or saw blade. Remove grease from the cap plug. Visually check the nick around the plug. Thinner 3 Apply Threebond No.
5. Inspection and servicing of basic engine parts 5.1.5 Cylinder bore measurement Especially clean head surface, cylinder bores and oil holes, and check the below items after removing any carbon deposit and bonding agent. (a) Appearance inspection Check if there is any discoloration or crack. If crack is suspected, perform color check. Sufficiently clean the oil holes and check they are not clogged.
5. Inspection and servicing of basic engine parts 5.2 Cylinder head The cylinder head is of 3-cylinder integral construction, mounted with 14 bolts. Special alloy stellite with superior resistance to heat and wear is fitted on the seats, and the area between the valves is cooled by the water jet.
5. Inspection and servicing of basic engine parts 5.2.1 Inspecting the cylinder head The cylinder head is subjected to very severe operating conditions with repeated high pressure, high temperature and cooling. Thoroughly remove all the carbon and dirt after disassembly and carefully inspect all parts. (1) Distortion of the combustion surface Carefully check for cylinder head distortion as this leads to gasket damage and compression leaks. 1) Clean the cylinder head surface.
5. Inspection and servicing of basic engine parts 5.2.2 Valve seat correction procedure The most common method for correcting unevenness of the seat surface with a seat grinder is as follows: (1) Use a seat grinder to make the surface even. As the valve seat width will be enlarged, first use a 70° grinder, then grind the seat to the standard dimension with a 15° grinder. Seat grinder NOTE: When seat adjustment is necessary, be sure to check the valve and valve guide.
5. Inspection and servicing of basic engine parts 5.2.3 Intake/exhaust valves, valve guides Measurement point Measurement point (1) Wearing and corrosion of valve stem Replace the valve stem is excessively worn or corroded. mm Valve stem outside dia. Standard Limit Intake 5.960-5.975 5.90 Exhaust 5.945-5.960 5.90 30 mm 60 mm (2) Inspection of valve seat wear and contact surface Inspect for valve seat scratches and excessive wear. Check to make sure the contact surface is normal.
5. Inspection and servicing of basic engine parts (4) Valve guide 1) Measuring inside diameter of valve guide. Measure the inside diameter of the valve guide and replace it if it exceeds the wear limit. mm Valve guide inside dia. Clearance Standard Limit Intake 6.000-6.012 6.08 Exhaust 6.000-6.012 6.08 Intake 0.025-0.052 0.16 Exhaust 0.040-0.067 0.17 NOTE: The inside diameter standard dimensions assume a pressure fit.
5. Inspection and servicing of basic engine parts 4) Valve stem seals The valve stem seals in the intake/exhaust valve guides cannot be re-used. When they are removed, be sure to replace them. When assembling the intake/exhaust valves, apply an adequate quantity of engine oil on the valve stem before inserting them. Valve stem seal inserting tool Exhaust stem seal is marked by yellow. Intake stem seal is not marked. Stem seal a) Apply lube oil to the lip.
5. Inspection and servicing of basic engine parts 4) Measure spring tension. Valve spring Unit Standard Limit Free length A mm 37.8 36.3 Inclination B mm - 1.3 N/mm (kgf/mm) 26.6/35.4 (2.71/3.61) - Tension (1 mm pressure) (Smaller pitch/ Larger pitch) Spring tension tester 5) Assembling valve springs. Up side Smaller pitch side (yellow) Down side 007535-00E NOTE: The pitch of the valve spring is not even.
5. Inspection and servicing of basic engine parts 5.2.6 Measuring top clearance (1) Place a high quality fuse (Ø1.5 mm, 10 mm long) in three positions on the flat part of the piston head. (2) Assemble the cylinder head gasket and the cylinder head and tighten the bolts in the specified order to the specified torque. (3) Turn the crank, (in the direction of engine revolution), and press the fuse against the piston until it breaks. (4) Remove the head and take out the broke fuse.
5. Inspection and servicing of basic engine parts 5.2.8 Adjustment of valve clearance (1) Make adjustments when the engine is cool. (Refer to 2.2.2(8).) mm Intake and exhaust valve clearance 0.15-0.25 (2) Be sure that the opening and closing angles for both the intake and the exhaust valves are checked when the timing gear is disassembled (The gauge on the flywheel can be read.). T.D.C. 7-17 7-17 deg. Intake valve Open b.TDC. 7-17 Intake valve Closed a.BDC. 35-45 Exhaust valve Open b.BDC.
5. Inspection and servicing of basic engine parts 5.3 Piston and piston pins 1st compression ring Pistons are made of a special light alloy with superior thermal expansion characteristics, and the top of the piston forms a combustion chamber. 2st compression ring ID marks for piston size ML Oil ring MS IMPORTANT : Piston shape differs among engine models. If any incorrect piston is installed, combustion performance will drop.
5. Inspection and servicing of basic engine parts Piston outside diameter. D2 below + 0.005 0 min. Tolerance Size mark ML MS L { X M { { S X { +0.030 max. +0.020 min. Cylinder inside diameter D1 below +0.020 +0.010 min. below +0.010 0 min. Model below 0 -0.005 min. Cylinder inside diameter D1 Piston outside diameter. D2 3YM30 76 75.970 3YM20/2YM15 70 69.975 (3) Removing the piston pin A floating type piston pin is used in this engine.
5. Inspection and servicing of basic engine parts 5.3.3 Piston rings There are two compression rings and one oil ring. The absence of an oil ring on the piston skirt prevents oil from being kept on the thrust surface and in turn provides good lubrication. Top ring Second ring Oil ring (Ring components) (1) Measuring the rings. Measure the thickness and width of the rings, and the ring-to-groove clearance after installation. Replace if wear exceed the limit. 3YM30 mm Standard Groove width 1.550-1.
5. Inspection and servicing of basic engine parts (2) Measuring piston ring gap Press the piston ring onto a piston liner and measure the piston ring gap with a gauge. Press on the ring about 30mm from the bottom of the liner. 3YM30/3YM20/2YM15 mm Standard Limit Top ring gap 0.15-0.30 0.390 Second ring gap 0.18-0.33 0.420 3YM30 0.20-0.45 0.540 3YM20 2YM15 0.15-0.35 0.44 Oil ring gap Head surface Cylinder block Piston ring Approx.
5. Inspection and servicing of basic engine parts 5) The oil ring is provided with a coil expander. The coil expander joint should be opposite (staggered 180°) the oil ring gap.
5. Inspection and servicing of basic engine parts 5.4 Connecting rod Piston pin bushing The connecting rod is made of high-strength forged carbon steel. The large end with the aluminium metal can be separated into two and the small end has a 2-layer copper alloy coil bushing. Connecting rod Crank pin metal Connecting rod (bid end cap) Connecting rod bolt 5.4.1 Inspecting the connection rod Insert the measuring tool into the large and small ends of the connecting rod.
5. Inspection and servicing of basic engine parts (2) Checking the side clearance of a connecting rod Fit the respective crank pins to the connecting rod and check to make sure that the side clearance in the crankshaft direction is correct. Connecting rod side clearance Standard Limit 0.20-0.40 0.55 Crankshaft Thickness gage (Connecting rod side gap) 5.4.2 Crank pin metal (1) Checking crank pin metal Check for flaking, melting or seizure on the contact surface of the crank pin metal.
5. Inspection and servicing of basic engine parts • Other procedure of measuring crank pin oil clearance 1) Use the press gauge (Plastic gauge) for measuring the oil clearance of the crank pin. 2) Mount the connecting rod on the crank pin (tighten to specified torque). 3) Remove the connecting rod and measure the broken plastic gauge with measuring paper. Plastic gauge (3) Precautions on replacement of crank pin metal 1) Wash the crank pin metal.
5. Inspection and servicing of basic engine parts 5.4.3 Piston pin bushing (1) Measuring piston pin clearance. Excessive piston pin bushing wear may result in damage to the piston pin or the piston itself. Measure the piston pin bushing inside diameter and the piston pin outside diameter. Calculate the oil clearance from the measured values. (Refer to 5.3.2 for the piston pin.) mm Standard Limit Piston pin metal I.D. 22.025-22.038 22.068 Pin O.D. 21.991-22.000 21.963 0.025-0.047 0.
5. Inspection and servicing of basic engine parts 5.5 Crankshaft and main bearing The crank pin and crank journal have been induction hardened for superior durability, and the crankshaft is provided with four balance weights for optional balance. The crankshaft main bearing is of the hanger type. The upper metal (cylinder block side) is provided with an oil groove. There is no oil groove on the lower metal Main bearing (bearing cap side).
5. Inspection and servicing of basic engine parts (3) Measuring the crank pin and journal Measure the outside diameter, roundness and taper at each crank pin and journal. Correct by grinding if unevenly wear, roundness exceeding the limit or insufficient outside diameter is found. Replace if the defect is excessive. mm Item Standard (Diameter) Limit (Diameter) Roundness Taper 0.01 or less 0.02 To look for the oil clearance of crank pin, measure the inside diameter of crank pin metal. (Refer to 5.4.
5. Inspection and servicing of basic engine parts (4) Checking the side gap of a crankshaft After assembling the crankshaft, tighten the main bearing cap to the specified toque, and move the crankshaft to one side, placing a dial gauge on one end of the shaft to measure thrust clearance. Replace the thrust bearing if it is worn beyond the limit. mm Crankshaft side gap Standard Limit 0.111-0.250 0.30 (Side gap measurement 1) 001544-00E Other measurement method can also be effective.
5. Inspection and servicing of basic engine parts 5.6 Camshaft and tappets 5.6.1 Camshaft The camshaft is normalized and the cam and bearing surfaces are surface hardened and ground. The cams have a curve that minimized the repeated shocks on the valve seats and maximizes valve seat life. Push rod Tappet Camshaft Camshaft bushing Camshaft gear Thrust metal (1) Checking the camshaft side gap Measure the thrust gap before disassembly.
5. Inspection and servicing of basic engine parts (3) Camshaft and bearing hole measurement mm Cam height Intake Exhaust Standard Limit 34.135-34.265 33.89 Measure the camshaft outside diameter with a micrometer. The oil clearance shall be calculated by subtracting the measured camshaft outside diameter from the inside diameter of the camshaft bearing or bushing. The camshaft bushing at gear case side is measured with a cylinder gage after insertion to the cylinder.
5. Inspection and servicing of basic engine parts 5.6.2 Tappets (1) The tappets are offset to rotate during operation and thereby prevent uneven wearing. Check the contact of each tappet and replace if excessively or unevenly worn. NOTE: When removing tappets, be sure to keep them separate for each cylinder and intake/exhaust valve. Abnormal contact surface Normal contact surface (Tappet) 001552-00E (2) Measure the outer diameter of the tappet, and replace if worn beyond the limit.
5. Inspection and servicing of basic engine parts 5.7 Timing gear The timing gear is helical type for minimum noise and specially treated for high durability. 5.7.1 Inspecting the gears (1) Inspect the gears and replace if the teeth are damaged or worn. (2) Measure the backlash of all gears that mesh, and replace the meshing gears as a set if wear exceeds the limit.
5. Inspection and servicing of basic engine parts 5.8 Flywheel and housing The function of the flywheel is through inertia, to rotate the crankshaft in a uniform and smooth manner by absorbing the turning force created during the combustion stroke of the engine, and by compensating for the decrease in turning force during the other strokes.
5. Inspection and servicing of basic engine parts 5.8.2 Damper disc (1) Spline part Whenever uneven wear and/or scratches are found, replace with new one. (2) Spring Whenever uneven wear and/or scratches are found, replace with new one. Spline (3) Pin wear Whenever uneven wear and/or scratches are found, replace with new one. (4) Whenever a crack or damage to the spring slot is found, replace the defective part with new one.
6. Fuel injection equipment 6. Fuel injection equipment 6.1 Fuel Injection pump/governor Refer to the service manual of the YPES-ML fuel injection pump for the disassembly, assembly and adjustment procedure. 6.1.1 Fuel system diagram Fuel nozzle Fuel injection pipe Fuel return pipe Fuel injection pump Fuel filter To fuel tank Feed pump From fuel tank (3 cylinder eng.
6. Fuel injection equipment 6.1.2 Fuel injection pump service data and adjustment (1) Service data 1) Service data for 3YM30 Part code (Back No.) - Adjustment SPEC - ENGINE SPEC SERVICE STD Item Fuel valve (Valve pressure) - A (120) (170) Nozzle type (ID mark) - NP-DN0PDN158 DN-12SD12 mm Ø 2 x 320 Ø2 x 600 min-1 200 - mm3/st 38 ± 5 - min-1 1800 - mm3/st 22.4 ± 0.75 - % ±3 - min-1 1300 - mm3/st 25.9 ± 0.
6. Fuel injection equipment 2) Service data for 3YM20 Part code (Back No.) - Adjustment SPEC - ENGINE SPEC SERVICE STD Item Fuel valve (Valve pressure) - C (120) (170) Nozzle type (ID mark) - NP-DN0PDN159 DN-12SD12 mm Ø 2 x 300 Ø2 x 600 min-1 200 - mm3/st 30± 5 - min-1 1800 - mm3/st 17.4 ± 0.5 - % ±3 - min-1 1300 - mm3/st 19.6 ± 0.
6. Fuel injection equipment 3) Service data for 2YM15 Part code (Back No.) - Adjustment SPEC - ENGINE SPEC SERVICE STD Item Fuel valve (Valve pressure) - C (120) (170) Nozzle type (ID mark) - NP-DN0PDN159 DN-12SD12 mm Ø 2 x 300 Ø2 x 600 min-1 200 - mm3/st 30± 5 - min-1 1800 - mm3/st 17.9 ± 0.5 - % ±3 - min-1 1300 - mm3/st 20.6 ± 0.
6. Fuel injection equipment (2) Fuel adjustment procedure • Fuel adjustment for 3YM30 and 2YM15 19 Rack position (mm) 1) Loosen the nut of the FO limiter, and screw the adjusting bolt to the bottom. Tighten the nut. 2) Adjust the rack position to R0 (15mm) with the FO limiter, and measure the injection volume (A) at the rated speed. 3) When the measured injection volume (A) is out of the standard, readjust the injection volume by screwing the FO limiter.
6. Fuel injection equipment • Fuel adjustment for 3YM20 19 Rack position (mm) 1) Loosen the nut of the FO limiter, and screw the adjusting bolt to the bottom. Tighten the nut. 2) Adjust the rack position to R0 (15mm) with the FO limiter, and measure the injection volume (A) at the rated speed. 3) When the measured injection volume (A) is out of the standard, readjust the injection volume by screwing the FO limiter. 4) Pull the control lever to high idle side at full rack position.
6. Fuel injection equipment 6.1.3 Fuel injection pump structure Section of a fuel injection pump/ governor for 3YM30.
6. Fuel injection equipment 6.1.4 Removing a fuel injection pump The procedure to remove a fuel injection pump from the gear case is shown. [NOTICE] Be sure to remove a flange and a fuel injection pump drive gear with a pair without loosening the flange bolts. Fuel injection pump Flange 1) Remove fuel injection pipes, fuel pipes and a remote control wire.
6. Fuel injection equipment 6.1.7 Troubleshooting of fuel injection pump Complete repair means not only replacing defective parts, but finding and eliminating the cause of the trouble as well. The cause of the trouble may not necessarily be in the pump itself, but may be in the engine or the fuel system. If the pump is removed prematurely, the true cause of the trouble may never be known. Before removing the pump from the engine, at least go through the basic check points given here.
6. Fuel injection equipment Fault 2. Engine starts, but immediately stops. Cause (1) Fuel pipe is clogged. (2) Fuel filter is clogged. (3) Improper air- tightness of the fuel pipe connection or pipe is broken and air is being sucked in. (4) Insufficient fuel delivery from the feed pump 3. Engine’s (1) Knocking sounds caused by improper (too Defective output is fast) injection timing. injection timing (2) Engine overheats or emits large amount of insufficient.
6. Fuel injection equipment Fault Remedy (1) Injection timing is too fast or too slow. (2) Injection from nozzle is improper. Fuel drips after each injection. (3) Injection nozzle starting pressure is too high (4) Uneven injection. (5) Engine overheats, or insufficient compression. Adjust Adjust When exhaust smoke is black: (1) (2) (3) (4) Adjust Inspect and repair Adjust Repair or replace When exhaust smoke is white: (1) Injection timing is too slow. (2) Water is mixed in fuel. 7. Loud knocking.
6. Fuel injection equipment 6.2 Fuel feed pump Fuel injection pump The fuel feed pump feeds fuel from the fuel tank, passes it through the fuel filter element, and supplies it to the fuel injection pump. The fuel feed pump is mounted on the side of this engine and is driven by the (eccentric) cam of the fuel pump camshaft. It is provided with a manual priming lever so that fuel can be supplied when the engine is stopped. To fuel filter From fuel tank Packing Fuel feed pump 6.2.
6. Fuel injection equipment 6.2.3 Disassembly and reassembly of fuel feed pump (1) Disassembly 1) Remove the fuel feed pump mounting nut, and take the fuel feed pump off the fuel injection pump. 2) Clean the fuel feed pump assembly with fuel oil. 3) After checking the orientation of the arrow on the cover, make match marks on the upper body and cover, remove the small screw, and disassemble the cover, upper body and lower body.
6. Fuel injection equipment (4) Valve contact/mounting Clean the valve seat and valve with air to remove any foreign matter. Inlet valve Outlet valve (5) Inspect the diaphragm spring and piston spring for settling and the piston for wear, and replace as necessary. NOTE: Replace parts as an assembly.
6. Fuel injection equipment 6.3 Fuel filter Air bleeding bolt The fuel filter is installed between the feed pump and injection pump, and serves to remove dirt and impurity from the fuel fed from the fuel tank through the feed pump. The fuel filter incorporates a replaceable filter paper element. Fuel from the fuel tank enters the outside of the element and passes through the element under its own pressure.
6. Fuel injection equipment 6.4 Fuel tank A triangular 30 liter fuel tank with a 2000mm (78.7402 in.) rubber fuel hose to fit all models is available as an option. A fuel return connection is provided on top of the tank of which a rubber hose can be connected to return fuel from the fuel nozzles. Fuel return connection Tank Level gauge Pipe joint Clamp Cock Drain cock Rubber hose 82 0 47 Clamp 15 230 176 30 36 49 PF 1/2 362 477.4 94 87 190 22.
7. Intake and exhaust system 7. Intake and exhaust system 7.1 Intake system Air enters in the intake silencer mounted at the end of the intake manifold (rocker arm cover). It is fed to the intake manifold and then on to each cylinder. Exhaust gas goes into exhaust manifold (in the fresh water tank) mounted on the cylinder head outlet. After cooling, the exhaust gas enters the mixing elbow, which is directly connected with the exhaust manifold, and is discharged from the ship along with seawater.
7. Intake and exhaust system [NOTICE] 1) When a diaphragm is damaged, pressure control inside the crankcase becomes insufficient, and troubles occur. When the internal pressure of the crankcase decreases too much due to the damage of a spring, much blowby gas containing oil is reduced in intake air system, and it may cause the combustion defect by the early dirt of the intake valve or the urgent rotation of the engine by the oil burning.
7. Intake and exhaust system 7.2 Exhaust system 7.2.1 Construction There are two types of mixing elbows, the L-type and the U-type. The mixing elbow is attached to the exhaust manifold. U-type Mixing elbow Seawater Joint L-type Mixing elbow Heat exchanger Seawater Exhaust elbow Heat exchanger Optional (U-type mixing elbow) (L-type mixing elbow) 7.2.2 Mixing elbow inspection (1) Clean dirt and scale out of the gas and cooling water lines. (2) Repair crack or damage to welds, or replace.
8. Lubrication system 8. Lubrication system 8.1 Lubrication system The lube oil in the oil pan is pumped up through the intake filter and intake piping by the lube oil pump, through the holes in the cylinder body and on to the lube oil pump, through the holes in the cylinder body and on to the discharge filter. The lube oil, which flows from the holes in the cylinder body through the bracket to the oil element, is filtered.
8. Lubrication system 8.2 Lube oil pump 8.2.1 Lube oil pump construction The trochoid type lube oil pump is mounted in the gear case cover, and the inner rotor is driven by the crankshaft pulley. The lube oil flows from the intake filter mounted on the bottom of the cylinder body through the holes in the cylinder body and engine plate, and out from the holes in the engine plate and cylinder body to the discharge filter.
8. Lubrication system 8.2.4 Lube oil pump inspection (1) Outside diameter clearance and side clearance of outer rotor Insert a gap gauge between the outer rotor and the gear case cover, and measure outside diameter gap. Put a ruler on the end face of the gear case cover, and insert a gap gauge between rotor, and measure a side gap. Outside clearance Gear case Outer rotor mm Standard Limit 0.12-0.21 0.
8. Lubrication system 8.3 Lube oil filter 8.3.1 Lube oil filter construction The lube oil filter is a full-flow paper element type mounted to the side of the cylinder block. The cartridge type filter is easy to remove. To prevent seizure in the event of the filter clogging up, a bypass circuit is provided in the oil filter. When the difference of the pressure in front and behind the paper element reaches 0.08-0.12 MPa (0.8-1.
8. Lubrication system 8.4 Rotary waste oil pump (Optional) A rotary waste oil pump to pump out waste oil is available as an option. Oil inlet pipe Outside dia. 16 mm Rotary waste oil pump Delivery capacity per one revolution Delivery pressure Suction head Part No. 0.057 L 0.15 MPa (1.
9. Cooling water system 9. Cooling water system 9.1 Cooling water system The cooling water system is of the indirect seawater cooled, fresh water circulation type. The cylinders, cylinder heads and exhaust manifold are cooled with fresh water, and fresh water cooler (heat exchanger) use seawater. Seawater pumped in from the sea by the seawater pump goes to the heat exchanger, where it cools the fresh water. Then it is sent to the mixing elbow and is discharged from the ship with the exhaust gas.
9.
9. Cooling water system 9.2 Seawater pump The seawater pump is driven by a V-belt. Gear case cover Spacer bolt V-belt Bracket Seawater pump (Seawater pump) 9.2.1 Specifications of seawater pump Performance Flow Min. 1650 L/h at engine speed 3600 min-1 9.2.2 Seawater pump disassembly Refer to 2.2.5.(5). (1) Remove the rubber hose from the seawater pump outlet and then remove the seawater pump assembly from the gear case cover. (2) Remove the seawater pump cover and take out the O-ring, and impeller.
9. Cooling water system 9.2.3 Seawater pump Inspection (Refer to 2.2.4(5).) (1) Inspect the rubber impeller, checking for splitting around the outside, damage or cracks, and replace if necessary. V-pulley Shaft Retaining ring Ball bearing Spacer Retaining ring Ball bearing O-ring Plate O-ring Oil seal Cover Pump body (Seawater pump) (2) Inspect the oil seal and replace if it is damaged. Also replace the oil seal if there is considerable water leakage during operation.
9. Cooling water system 9.2.4 Seawater pump reassembly (1) When replacing the oil seal, coat with grease and insert. (2) Mount the pump shaft, ball bearing and V-pulley to the pump unit and fit the bearing retaining ring. NOTE: Coat the shaft with grease. (3) Mount the impeller. (4) Mount the O-ring and the cover. NOTE: Replace the O-ring with new one.
9. Cooling water system 9.3 Fresh water pump 9.3.1 Fresh water pump construction The fresh water pump is of the centrifugal (volute) type, and circulates water from the fresh water tank to the cylinder block and the cylinder head. The fresh water pump consists of the pump body, impeller, pump shaft, bearing unit and mechanical seal. The V-pulley on the end of the pump shaft is driven by a V-belt. The bearing unit assembled in the pump shaft uses grease lubricated ball bearings and cannot be disassembled.
9. Cooling water system 9.3.3 Fresh water pump disassembly (1) Do not disassemble the fresh water pump. It is difficult to disassemble and, once disassembled, even more difficult to reassemble. Replace the pump as an assembly in the event of trouble. When the fresh water pump and the cover are disassembled, retighten to the specified torque. Tightening torque 9.3-11.3 N•m (0.95-1.2 kgf•m) (2) When removing the fresh water pump, replace the O-ring (inlet to cylinder). 9.3.
9. Cooling water system Measuring side clearance between impeller and plate. Straightedge mm Side clearance between impeller and plate Standard Limit 0.
9. Cooling water system 9.4 Heat exchanger 9.4.1 Heat exchanger construction The heat exchanger cools the hot fresh water, that has cooled the inside of the engine, with seawater. The cooler core consists of many small diameter tubes, baffle plates and tube cover. The seawater flows through the maze formed by the baffle plates. There is a reservoir above the cooler core, which serves as the fresh water tank. There is an exhaust gas passageway in the reservoir, which forms a water cooled exhaust manifold.
9. Cooling water system 9.5 Pressure cap and coolant recovery tank 9.5.1 Pressure cap construction The pressure cap mounted on the filler neck incorporates a pressure control valve. The cap is mounted on the filler neck cam by placing it on the rocking tab and rotating. The top seal of the cap seals the top of the filler neck, and the pressure valve seals the lock seat. 9.5.
9. Cooling water system 9.5.4 Replacing filler neck 1) Take out the copper pipe inside the filler neck with striking a circumference with a driver and so on. When the filler neck is removed, remove it with being careful not to damage the fresh water cooler, and scrap it. 2) Clean both new filler neck and the insertion part of fresh water cooler. Apply T7471 type activator or equivalent on both the surfaces and let it evaporate.
9. Cooling water system Coolant recovery tank mm 30 20.5 130 FULL 70 65 25 8 60 LOW 35 The pressure valve opens to discharge steam when the steam pressure in the fresh water tank exceeds 90 kPa (0.9 kgf/cm2). This consumes water. The coolant recovery tank maintains the water level by preventing this discharge of water. The steam discharged into the coolant recovery tank condenses into watch, and the water level in the tank rises.
9. Cooling water system 9.6 Thermostat 9.6.1 Functioning of thermostat The thermostat opens and closes a valve according to changes in the temperature of the fresh water inside the engine, controlling the volume of water flowing to the heat exchanger from the cylinder head, and in turn maintaining the temperature of the fresh water in the engine at a constant level. The thermostat is bottom bypass type.
9. Cooling water system 9.7 Bilge pump and bilge strainer (Optional) 9.7.1 Introduction (1) General Introduction Name Bilge pump Time 10 minutes Rotation direction Right (viewed from the impeller side) Weight Pump 1.4 kg Negative pressure detector Diaphragm type Temperature -30°C∼80°C (2) Exterior Motor assy Controller White Outlet Green Red Strainer Red (+) Inlet White (-) Pump dimensions Length 225 mm Yoke diameter Ø61 Assembly hole diameter Ø5.
9. Cooling water system 9.7.2 Description (1) Characteristics 1) Discharge at lift : 0 m discharge capacity : 20 liters/min. or greater. 2) Automatic feeding height : 1 m or greater (Limit for automatic feeding height: new pump with inside parts wet, approx. 2 m) 3) Automatic feeding time : 2-5 seconds. (Limit for automatic feeding time: new pump with inside parts wet, approx. 1 second.) 4) Automatic stopping : Air intake causes negative pressure triggering automatic stopping.
9. Cooling water system (7) The pump cannot be used to drain off rain water or large amounts of flood water. The pump can be run continuously for a period of 10 minutes. After this time it must shut off for a period of 2 hours before reusing. (8) Do not use the pump for showering. If the pump outlet is deformed for showering, the increase in water pressure will increase the load on the motor and cause motor seizure. (9) Fix the strainer so that it will not turn upside down or on its side.
9. Cooling water system (4) Attaching the delivery nozzle (outlet) • Make a fixing hole of Ø21 or less for attaching the nozzle. The hose attached at the nozzle should be 1.8 m or less and should reach without any strain, therefore care should be taken in deciding on the best position. • Fix the nozzle (outlet) in place and attach on the discharge side of the pump. Fixing hole 21 Hose Delivery nozzle (5) Attaching the hose • Attach the hose from the strainer to the pump inlet.
9. Cooling water system 9.7.5 Cautions for assembling Observe the following cautions for handling. • Do not use gasoline or solvents. 1) gasoline 2) ester 3) benzol 4) battery fluid 5) liquids at 70°C or greater or engine oil • Never run when there is no water in the bilge. Check to be sure that the strainer is in the water before turning on the switch. • Keep the cord terminal away from the water. Water inside the motor or switch may lead to damage.
9. Cooling water system 9.7.6 Troubleshooting Refer to the following countermeasures for difficulties that arise. Problem 1. Pump does not turn Cause Countermeasure Faulty wiring Check the wiring between the motor and battery. Faulty battery Check to see if the specific gravity of the battery fluid is greater than 1.25. Recharge or replace the battery. Faulty starter switch Consult your local dealer. Faulty pump Consult your local dealer. Draws up air. Check hose connections.
10. Reduction and reversing gear 10. Reduction and reversing gear Marine gear KM2P-1 is applied to the 3YM30, 3YM20 and 2YM15 series engines. Refer to chapter 10 in the service manual of the GM series engines for inspection, disassembly and reassembly. 10.1 Specifications Model KM2P-1 For engine models 3YM30, 3YM20, 2YM15 Clutch Reduction ratio Constant mesh gear with servo cone clutch (wet type) Forward 2.21 2.62 3.22 Reverse 3.06 3.06 3.
11. Remote control (Optional) 11. Remote control (Optional) 11.1 Remote control system 11.1.1 Construction of remote control system The remote control permits one handed control of the engine speed changing from forward to reverse, and stopping. Fittings which allow for easy connection of the remote control cables with the fuel injection pump and transmission are provided with the remote control set.
11. Remote control (Optional) (2) Remote control cable Use only Super Responsive Morse Control Cables. These are designed specifically for use with Morse control heads. This engineered system of Worse cables, control head and engine connection kits ensures dependable, smooth operation with an absolute minimum of backlash.
11. Remote control (Optional) 11.
11. Remote control (Optional) (2) Clutch control Neutral S1 Clamp S2 Reverse Forward Remote control head Retainer Spacer Cable bracket Note : ( ) Cable shift travel S1 = More than 36 mm (1.42") S2 = More than 36 mm (1.
11. Remote control (Optional) 11.3 Remote control inspection (1) When the control lever movement does not coincide with operation of the engine, check the cable end stop nut to see whether or not it is loose, and readjust/retighten when necessary. Reverse Neutral Shim in Forward Shim in Throttle Throttle Free throttle (2) Too many bends (turns) in the cable or bends at too extreme angle will make it difficult to turn the handle.
11. Remote control (Optional) 11.4 Remote control adjustment (1) Shift lever adjustment Move the lever several times-the movement of the clutch lever on the engine from forward, neutral and reverse must coincide with the forward, neutral and reverse on the control lever. If they do not coincide, adjust the fittings as necessary (first engine side, then controller side). (2) Throttle lever adjustment Move the control lever all the way to full throttle several times, and then return.
12. Electrical system 12. Electrical system 12.
12. Electrical System 12.1.1 Wiring diagram For B-type instrument panel (Color coding) R Red B Black W White L Blue RB Red / Black LB Blue / Black YW Yellow / White YG Yellow / Green WL White / Blue WG White / Green GR Green / Red O Orange WBr White / Brown 2 3 1 Allowable Length by Procured by customer cross sectional area of battery cable Section of cable Allowable Length 12V L=1+2+3(m) (mm2) 2 15(mm ) <0.86(m) Battery 20(mm2) <1.3(m) + 2 30(mm ) <2.3(m) 40(mm2) <2.8(m) 50(mm2) <3.5(m) 60(mm2) <4.
12. Electrical System 12.2 Battery The new type instrument panels are applied for 3YM30 series engines. The features are compactness, waterproof and independence from pulse by ring gear teeth number. The engine speed, indicated with the instrument panel is activated by the pulse from flywheel ring gear. The engine speed with new panel is activated by alternator B terminal pulse.
12. Electrical System 12.3 Starting motor A starting motor turns the ring gear installed on a engine flywheel by the pinion while overcoming resistance such as the compression pressure and the friction loss of the engine and makes the engine start. 12.3.1 Specifications YANMAR Part No. 129608-77010 HITACHI Model No. S114-817A Nominal power (kW) Nominal voltage (V) Rating (sec) Direction of rotation (Looking from the pinion side) Number of pinion teeth Weight (kg) 1.4 12 30 Clockwise 11 3.
12. Electrical System 12.3.
12. Electrical System (2) Structure When the starting switch is turned on, a magnet switch takes a voltage, and a pinion projects. The pinion engages with the ring gear of a engine, and the engine is started. Magnetic Switch Center Bracket (A) Torsion Spring Shift Lever Brush Gear Case Pinion Shaft Pinion Armature Planet Gear Center Bracket (P) Rear Cover Yoke Internal Gear 12.3.
12. Electrical System 12.4 Alternator standard, 12V/60A The alternator serves to keep the battery constantly charged. It is installed on the cylinder block by a bracket, and is driven from the V-pulley at the end of the crankshaft by a V belt. The type of alternator used in this engine is ideal for high speed engines with a wide range of engine speeds. It contains diodes that convert AC to DC, and an IC regulator that keeps the generated voltage constant even when the engine speed changes. 12.4.
12. Electrical System 12.4.
12. Electrical System 12.4.3 Wiring diagram Condenser 2.2 BAT P F Rotor coil Diode Stator coil B S Key switch IG L 1 Charge lamp 12V3.4W L F P Battery E IC regulator E Alternator [NOTICE] 1) Don't do mis-connecting and short-circuit of each terminal. 2) Don't remove a battery terminal and a B terminal when rotating. 3) Shut out a battery switch during the alternator stop. 12.4.
12. Electrical System 12.4.5 Inspection (1) V belt inspection 1) Inspect the matter whether there are not crack, stickiness and wear on the belt visually. Check that a belt doesn't touch the bottom part of the pulley groove. If necessary, replace the V belt set. 2) V belt tension : (Refer to 2.2.2.(4) in Chapter 2.) (2) Visual check of wiring and check of unusual sound 1) Confirm whether wiring is right or there is no looseness of the terminal part.
12. Electrical System 12.5 Alternator 12V/80A (Optional) 12.5.1 Specifications Yanmar code 119573-77201 Model of alternator LR180-03C (HITACHI) Model of IC regulator TR1Z-63 (HITACHI) Battery voltage 12V Nominal output 12V/80A Earth polarity Negative earth Direction of rotation (viewed from pulley end) Clockwise Weight 5.4 kg 5000 min-1 Rated speed Operating speed 1,200-9,000 min-1 Speed for 13.5V at 20°C 1,200 min-1 or less Output current for 13.
12. Electrical System 12.5.
12. Electrical System 12.5.3 Wiring diagram P BAT Key switch R Diode Rotor coil SubDiode Condenser (3.2 F) R 50 L L Charge lamp 12V3.4W F E IC regulator Stator coil Battery E Alternator [NOTICE] 1) Don't do mis-connecting and short-circuit of each terminal. 2) Don't remove a battery terminal and a B terminal when rotating. 3) Shut out a battery switch during the alternator stop. 12.5.
12. Electrical System 12.6 Instrument panel The new type instrument panels are applied for 3YM30/3YM20/2YM15 series engines. The features are compactness, waterproof and independence from pulse by ring gear teeth number. The engine speed, indicated with the instrument panel is activated by the pulse from flywheel ring gear. The engine speed with new panel is activated by alternator B terminal pulse 12.6.
12. Electrical System 12.7 Warning devices 12.7.1 Oil pressure alarm If the engine oil pressure is below 0.01-0.03 MPa (0.1-0.3 kgf/cm2, 1.42-4.26 lb/in.2), with the main switch in the ON position, the contacts of the oil pressure are closed by a spring and the lamp is illuminated through the lamp J oil pressure switch J ground circuit system. If the oil pressure is normal, the contacts of the switch are opened by the lubricating oil pressure and the lamp remains off.
12. Electrical System Inspection Problem Inspection Item Inspection method Corrective action Lamp not illuminated when main switch set to ON. 1. Oil pressure lamp blown out. (1) Visual inspection. (2) Lamp not illuminated even when main switch set to ON position and terminals of oil pressure switch grounded. Replace lamp. 2. Operation of oil pressure switch. Lamp illuminated when checked as described in (2) above. Replace oil pressure switch. 1. Oil level low.
12. Electrical System 12.8 Glow plug A glow plug is available for warming intake air when starting in cold areas in winter. The glow plug is mounted to the cylinder head. The device is operated by the glow switch on the instrument panel. Rated current 8-10A Rated voltage DC11V 11 M4 x 0.7 Hexagon subtense 0 8.5 12 -0.3 mm M10 x 1.25 18.5 69 Glow connector 17.
12. Electrical System 12.9 Electric engine stopping device The electric engine stop device is fitted to the governor. The device is operated by the stop switch on the instrument panel. The emergency stop button is integrated with the solenoid. When pushing the stop button, the engine will shut down.
13. Service standards 13. Service standards 13.1 Engine tuning No. 1 2 3 4 5 Standard Limit Reference page 0.15-0.25 - 2.2.2(5) Used part 8-10 - New part 6-8 - 12.3-13.28 (125-135) - Inspection item Intake/exhaust valve clearance mm V-belt tension Between alternator at 98N (10kgf) and F.W. pump mm Fuel injection pressure MPa (kgf/cm2) 3YM30 Compression pressure (at 250 min-1) MPa (kgf/cm2) 3YM20 2YM15 3.43±0.1 (35±1) 2.75±0.1 (28±1) 3.23±0.1 (33±1) 2.55±0.1 (26±1) 3YM30 4.9 (5.
13. Service standards 13.2 Engine body 13.2.1 Cylinder head (1) Cylinder head Inspection item Combustion surface distortion Valve sink Valve seat mm Intake mm Exhaust Seat angle Intake deg. Exhaust Standard Limit Reference page 0.05 or less 0.15 5.2.1(1) 0.4-0.6 0.8 5.2.3(3) 120 - 90 - 5.2.1(3) (2) Intake/exhaust valve and guide mm Inspection item Intake Exhaust Standard Limit Guide inside diameter 6.000-6.012 6.08 Valve stem outside diameter 5.960-5.975 5.90 Clearance 0.
13. Service standards (5) Tappet and push rod mm Inspection item Standard Limit Tappet outside diameter 20.927-20.960 20.907 Tappet guide hole inside diameter (cylinder block) 21.000-21.021 21.041 0.040-0.094 0.134 Less than 0.03 0.03 Tappet oil clearance Push rod bend Reference page 5.6.2(2) 5.6.2(3) 13.2.2 Camshaft and gear train (1) Camshaft mm Standard Limit Reference page 0.05-0.15 0.25 5.6.1(1) 0.02 or less 0.05 5.6.1(4) 3YM30 34.135-34.265 33.89 3YM20/2YM15 34.535-34.
13. Service standards 13.2.3 Cylinder block (1) Cylinder block mm Inspection item Cylinder inside diameter Standard Limit 3YM30 76.000-76.030 76.200 3YM20/2YM15 70.000-70.030 70.200 5.1.5 Roundness Cylinder bore Reference page 0.01 or less Inclination 0.03 (2) Crankshaft mm Standard Limit Reference page - 0.01 5.5.1(2) Pin outside diameter 41.952-41.962 41.902 Metal inside diameter 41.982-42.010 - Metal thickness 1.503-1.509 - Clearance 0.020-0.058 0.
13. Service standards (4) Piston and ring 1) Piston mm Inspection item Standard Limit 3YM30 75.965-75.975 75.920 3YM20/2YM15 69.970-69.980 69.925 22 - 3YM30 0.035-0.055 - 3YM20/2YM15 0.030-0.050 - Piston pin hole inside diameter 22.000-22.009 22.039 Piston pin outside diameter 21.995-22.000 21.965 0.000-0.014 0.074 Piston outside diameter (Measure in the direction vertical to the piston pin.
13. Service standards 3YM20/2YM15 mm Inspection item Top ring Standard Limit Groove width 1.550-1.570 - Ring width 1.470-1.490 1.450 Side clearance 0.060-0.100 - 0.15-0.30 0.390 Groove width 1.540-1.560 1.660 Ring width 1.470-1.490 1.450 Side clearance 0.050-0.090 0.210 0.18-0.33 0.420 Groove width 3.010-3.030 3.130 Ring width 2.970-3.010 2.950 Side clearance 0.020-0.060 0.180 0.15-0.35 0.44 Ring gap Second ring Ring gap Oil ring Ring gap Reference page 5.3.
13. Service standards 13.3 Lubricating oil system (Trochoid pump) (1) Outside clearance of outer rotor mm Standard Limit Reference page 0.12-0.21 0.30 8.2.4(1) (2) Tip clearance between outer rotor and inner rotor mm Standard Limit Reference page - 0.16 8.2.4(1) (3) Side clearance of outer rotor mm Standard Limit Reference page 0.02-0.07 0.12 8.2.4(2) (4) Outside diameter clearance of inner rotor centering location part mm Inspection item Standard Limit Gear case cover I.D. 46.13-46.
14. Tightening torque for bolts and nuts 14. Tightening torque for bolts and nuts 14.1 Main bolt and nut No Name Thread diameter x pitch Lube oil application (thread portion and seat surface) Torque N•m(kgf•m) 1 Head bolt M9 x 1.25 Coat with lube oil 53.9-57.9 (5.5-5.9) 2 Rod bolt M7 x 1.0 Coat with lube oil 22.6-27.5 (2.3-2.8) 3 Flywheel retainer bolt M10 x 1.25 Coat with lube oil 80.4-86.4 (8.2-8.8) 4 Metal cap retainer bolt M10 x 1.25 Coat with lube oil 75.5-81.5 (7.7-8.
3YM30/3YM20/2YM15 SERVICE MANUAL Code No. M9961-03E101 First Edition : March 2004 2nd Edition : April 2005 Published by : Quality Control Dept. Marine Factory Large Power Products Operations Division. Edited by : YANMAR TECHNICAL SERVICE CO., LTD.
HEAD OFFICE 1-32, CHAYAMACHI, KITA-KU, OSAKA 530-8311, JAPAN YANMAR MARINE INTERNATIONAL B.V. P.O. BOX 30112,1303AC ALMERE, THE NETHERLANDS BRUGPLEIN 11, 1332 BS ALMERE-DE VAART, THE NETHERLANDS PHONE: 31 36-5493211 FAX: 31 36-5493549 URL: WWW.YANMARMARINE.COM YANMAR MARINE U.S.A CORPORATION 101 INTERNATIONAL PARKWAY, ADAIRSVILLE, GA 30103, USA PHONE: 1 770-877-9894 FAX: 1 770-877-7565 YANMAR ASIA (SINGAPORE) CORPORATION PTE LTD. 4 TUAS LANE.
