Yanmar 3YM30/3YM20/2YM15 Marine Diesel Engine Repair Service Manual
Yanmar 3YM30/3YM20/2YM15 Marine Diesel Engine Repair Service Manual
- This Workshop Service Repair manual PDF download for the 3YM30, 3YM20, 2YM15 Yanmar Marine Diesel Engine has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to fully at every opportunity.
1. General 2. Inspection and adjustment 3. Troubleshooting 4. Disassembly and reassembly 5. Inspection and servicing of basic engine parts 6. Fuel injection equipment 7. Intake and exhaust system 8. Lubrication system 9. Cooling water system 10. Reduction and reversing gear 11. Remote control (Optional) 12. Electrical system 13. Service standards 14. Tightening torque for bolts and nuts
MANUAL SPECIFICATION :
File Format : PDF Language : English Printable : Yes Searchable : Yes Bookmarked : Yes Part Number : M9961-03E101 Total Pages : 231
This Service / Repair / Workshop Manual PDF Download contains specs, diagrams, actual real photo illustrations, and schemes. In addition to space savings, nice thing about having completly searcheble PDF files instead of a hard-printed manual is that you can use the Search feature in your PDF reader software (Adobe Acrobat) to find just what your looking for and just print out the exact pages you need or all manual easily. This is the same manual your local dealer will use when doing a repair. This is a must for the Do-It-Yourselfer! Saving Yourself $$$$$$ In Service Repair And Maintenance Costs !!!!
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Cover History of Revision FOREWORD CONTENTS FOR SAFETY 1. General 1.1 Exterior views 1.2 Specifications 1.3 Fuel oil, lubricating oil and cooling water 1.3.1 Fuel oil 1.3.2 Lubricating oil 1.3.3 Cooling water 1.4 Engine outline 1.5 Piping diagrams 1.6 Exhaust gas emission regulation 1.6.1 Engine identification (EPA/ARB) 1.6.2 Exhaust gas emission standard (EPA/ARB) 1.6.3 Guarantee conditions for emission standard (EPA/ARB) 2. Inspection and adjustment 2.1 Periodic maintenance schedule 2.2 Periodic inspection and maintenance procedure 2.2.1 Check before starting 2.2.2 inspection after initial 50 hours or one month operation 2.2.3 Inspection every 50 hours or monthly 2.2.4 Inspection every 100 hours six months 2.2.5 Inspection every 150 hours or one year 2.2.6 Inspection every 250 hours or one year 2.2.7 Inspection every 1,000 hours or four years 2.3 Adjusting the no-load maximum or minimum speed 2.4 Sensor Inspection 2.4.1 Oil pressure switch 2.4.2 Thermo switch 2.5 Thermostat inspection 2.6 Adjusting operation 2.6.1 Preliminary precautions 2.6.2 Adjusting operation procedure 2.6.3 Check points and precautions during running 2.7 Long storage 3. Troubleshooting 3.1 Preparation before troubleshooting 3.2 Quick reference chart for troubleshooting 3.3 Troubleshooting (Concerning engine and fuel injection equipment) 3.4 Troubleshooting by measuring compression pressure 4. Disassembly and reassembly 4.1 Disassembly and reassembly precautions 4.2 Disassembly and reassembly tools 4.2.1 General hand tools 4.2.2 Special hand tools 4.2.3 Measuring instruments 4.2.4 Other material 4.3 Disassembly and reassembly 4.3.1 Disassembly 4.3.2 Reassembly 5. Inspection and servicing of basic engine parts 5.1 Cylinder block 5.1.1 Inspection of parts 5.1.2 Cleaning of oil holes 5.1.3 Color check procedure 5.1.4 Replacement of cap plugs 5.1.5 Cylinder bore measurement 5.2 Cylinder head 5.2.1 Inspecting the cylinder head 5.2.2 Valve seat correction procedure 5.2.3 Intake/exhaust valves, valve guides 5.2.4 Valve springs 5.2.5 Assembling the cylinder head 5.2.6 Measuring top clearance 5.2.7 Intake and exhaust rocker arms 5.2.8 Adjustment of valve clearance 5.3 Piston and piston pins 5.3.1 Piston 5.3.2 Piston pin 5.3.3 Piston rings 5.4 Connecting rod 5.4.1 Inspecting the connection rod 5.4.2 Crank pin metal 5.4.3 Piston pin bushing 5.4.4 Assembling piston and connecting rod 5.5 Crankshaft and main bearing 5.5.1 Crankshaft 5.5.2 Main bearing 5.6 Camshaft and tappets 5.6.1 Camshaft 5.6.2 Tappets 5.7 Timing gear 5.7.1 Inspecting the gears 5.7.2 Gear timing marks 5.8 Flywheel and housing 5.8.1 Position of top dead center and fuel injection timing 5.8.2 Damper disc 6. Fuel injection equipment 6.1 Fuel Injection pump/governor 6.1.1 Fuel system diagram 6.1.2 Fuel injection pump service data and adjustment 6.1.3 Fuel injection pump structure 6.1.4 Removing a fuel injection pump 6.1.5 Installing a fuel injection pump 6.1.6 Adjusting fuel injection timing 6.1.7 Troubleshooting of fuel injection pump 6.1.8 Major faults and troubleshooting 6.2 Fuel feed pump 6.2.1 Construction of fuel feed pump 6.2.2 Fuel feed pump specifications 6.2.3 Disassembly and reassembly of fuel feed pump 6.2.4 Fuel feed pump inspection 6.3 Fuel filter 6.3.1 Fuel filter specifications 6.3.2 Fuel filter inspection 6.4 Fuel tank 7. Intake and exhaust system 7.1 Intake system 7.1.1 Breather system (A reductor to intake air system of blowby gas) 7.1.2 Diaphragm assy inspection 7.2 Exhaust system 7.2.1 Construction 7.2.2 Mixing elbow inspection 8. Lubrication system 8.1 Lubrication system 8.2 Lube oil pump 8.2.1 Lube oil pump construction 8.2.2 Specifications of lube oil pump 8.2.3 Lube oil pump disassembly and reassembly 8.2.4 Lube oil pump inspection 8.2.5 Pressure control valve construction 8.3 Lube oil filter 8.3.1 Lube oil filter construction 8.3.2 Lube oil filter replacement 8.4 Rotary waste oil pump (Optional) 9. Cooling water system 9.1 Cooling water system 9.2 Seawater pump 9.2.1 Specifications of seawater pump 9.2.2 Seawater pump disassembly 9.2.3 Seawater pump Inspection 9.2.4 Seawater pump reassembly 9.3 Fresh water pump 9.3.1 Fresh water pump construction 9.3.2 Specifications of fresh water pump 9.3.3 Fresh water pump disassembly 9.3.4 WFresh water pump inspection 9.4 Heat exchanger 9.4.1 Heat exchanger construction 9.4.2 Disassembly and reassembly of the heat exchanger 9.4.3 Heat exchanger inspection 9.5 Pressure cap and coolant recovery tank 9.5.1 Pressure cap construction 9.5.2 Pressure cap pressure control 9.5.3 Pressure cap inspection 9.5.4 Replacing filler neck 9.5.5 Function of the coolant recovery tank 9.5.6 Specifications of coolant recovery tank 9.5.7 Mounting the coolant recovery tank 9.5.8 Precautions on usage of the coolant recovery tank 9.6 Thermostat 9.6.1 Functioning of thermostat 9.6.2 Thermostat construction 9.6.3 Characteristics of thermostat 9.6.4 Thermostat inspection 9.6.5 Testing the thermostat 9.7 Bilge pump and bilge strainer (Optional) 9.7.1 Introduction 9.7.2 Description 9.7.3 Cautions 9.7.4 Assembly procedure 9.7.5 Cautions for assembling 9.7.6 Troubleshooting 10. Reduction and reversing gear 10.1 Specifications 11. Remote control (Optional) 11.1 Remote control system 11.1.1 Construction of remote control system 11.1.2 Remote control device components 11.2 Remote control installation 11.3 Remote control inspection 11.4 Remote control adjustment 12. Electrical system 12.1 Electrical system 12.1.1 Wiring diagram 12.2 Battery 12.3 Starting motor 12.3.1 Specifications 12.3.2 Characteristics 12.3.3 Structure 12.3.4 Wiring diameter of a starting motor 12.4 Alternator standard, 12V/60A 12.4.1 Specifications 12.4.2 Structure 12.4.3 Wiring diagram 12.4.4 Standard output characteristics 12.4.5 Inspection 12.5 Alternator 12V/80A (Optional) 12.5.1 Specifications 12.5.2 Structure 12.5.3 Wiring diagram 12.5.4 Standard output characteristics 12.6 Instrument panel 12.6.1 B-type instrument panel (Optional) 12.7 Warning devices 12.7.1 Oil pressure alarm 12.7.2 Cooling water temperature alarm 12.8 Glow plug 12.9 Electric engine stopping device 13. Service standards 13.1 Engine tuning 13.2 Engine body 13.2.1 Cylinder head 13.2.2 Camshaft and gear train 13.2.3 Cylinder block 13.3 Lubricating oil system (Trochoid pump) 14. Tightening torque for bolts and nuts 14.1 Main bolt and nut 14.2 Standard bolts and nuts (without lube oil) Colophon Back cover