Yanmar 3YM30 Operations Manual (January 2009)

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Yanmar 3YM30 Operations Manual (January 2009) | Manualzz

YM series

MANUAL

2YM15

3YM20

3YM30

P/N: 0AYMM-G00200

MARINE

ENGINES

Disclaimers:

All information, illustrations and specifications in this manual are based on the latest information available at the time of publishing. The illustrations used in this manual are intended as representative reference views only. Moreover, because of our continuous product improvement policy, we may modify information, illustrations and / or specifications to explain and / or exemplify a product, service or maintenance improvement. We reserve the right to make any change at any time without notice.

Yanmar and are registered trademarks of Yanmar Co., Ltd. in Japan, the

United States and / or other countries.

All Rights Reserved:

No part of this publication may be reproduced or used in any form by any means - graphic, electronic, or mechanical, including photocopying, recording, taping, or information storage and retrieval systems - without the written permission of Yanmar Marine

International.

© 2009 Yanmar Marine International

0109 ii YM Series Operation Manual

© 2009 Yanmar Marine International

TABLE OF

CONTENTS

Page

Introduction ..................................................................... 1

Record of Ownership ................................................. 2

Safety ............................................................................... 3

Safety Precautions ..................................................... 4

General Information ............................................. 4

Before You Operate............................................. 4

During Operation and Maintenance..................... 5

Location of Safety Decals .......................................... 8

Product Overview ........................................................... 9

Yanmar YM Features and Applications...................... 9

New Engine Break-In......................................... 10

Component Identification ......................................... 11

Right Side (from Flywheel) - 2YM15.................. 11

Left Side (from Flywheel) - 2YM15 .................... 11

Right Side (from Flywheel) - 3YM20.................. 12

Left Side (from Flywheel) - 3YM20 .................... 12

Right Side (from Flywheel) - 3YM30.................. 13

Left Side (from Flywheel) - 3YM30 .................... 13

Location of Nameplates ........................................... 14

Function of Major Components ................................ 15

Control Equipment ................................................... 16

Instrument Panel (Optional)............................... 16

Single-Lever Remote Control Handle ................ 20

Before You Operate ...................................................... 21

Safety Precautions ................................................... 21

Introduction .............................................................. 21

Diesel Fuel ............................................................... 22

Diesel Fuel Specifications ................................. 22

Filling the Fuel Tank .......................................... 25

Bleeding the Fuel System.................................. 26

YM Series Operation Manual

© 2008 Yanmar Marine International iii

TABLE OF CONTENTS iv

Engine Oil ................................................................. 27

Engine Oil Specifications .................................. 27

Engine Oil Viscosity ........................................... 28

Checking the Engine Oil..................................... 28

Adding Engine Oil .............................................. 29

Marine Gear or Sail Drive Oil.................................... 29

Marine Gear Oil Specifications........................... 29

Sail Drive Oil Specifications - SD20 ................... 29

Checking Marine Gear Oil.................................. 30

Adding Marine Gear Oil...................................... 30

Checking and Adding Sail Drive Oil ................... 30

Engine Coolant ......................................................... 31

Engine Coolant Specifications ........................... 31

Checking and Adding Coolant............................ 31

Cranking the Engine ................................................. 34

Engine Operation .......................................................... 35

Safety Precautions ................................................... 35

Introduction ............................................................... 36

Starting the Engine ................................................... 37

Restarting After Starting Failure......................... 37

Starting at Low Temperatures............................ 38

After the Engine has Started .............................. 38

Remote Control Handle Operation ........................... 39

Acceleration and Deceleration ........................... 39

Shifting the Engine ............................................. 40

Shutting Down the Engine ........................................ 40

Emergency Shutdown ........................................ 41

Checking the Engine After Operation ....................... 42

Periodic Maintenance ................................................... 43

Safety Precautions ................................................... 43

Introduction ............................................................... 45

Precautions............................................................... 45

The Importance of Periodic Maintenance .......... 45

Performing Periodic Maintenance ...................... 45

The Importance of Daily Checks ........................ 45

Keep a Log of Engine Hours and Daily Checks . 46

Yanmar Replacement Parts ............................... 46

Tools Required................................................... 46

Ask Your Authorized Yanmar Marine Dealer or

Distributor for Help ............................................. 46

Tightening Fasteners ......................................... 47

EPA Maintenance Requirements ............................. 48

EPA Requirements for USA and Other

Applicable Countries .......................................... 48

Conditions to Ensure Compliance with EPA

Emission Standards ........................................... 48

YM Series Operation Manual

© 2008 Yanmar Marine International

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TABLE OF CONTENTS

Inspection and Maintenance.............................. 48

Installing Sample Port........................................ 48

Periodic Maintenance Schedule............................... 50

Inspection and Maintenance of EPA

Emission-Related Parts ..................................... 54

Periodic Maintenance Procedures ........................... 55

Daily Checks...................................................... 55

After Initial 50 Hours of Operation ..................... 56

Every 50 Hours of Operation ............................. 60

Every 100 Hours of Operation ........................... 62

Every 150 Hours of Operation ........................... 63

Every 250 Hours of Operation ........................... 63

Every 1000 Hours of Operation ......................... 66

Troubleshooting .......................................................... 69

Safety Precautions ................................................... 69

Troubleshooting After Starting ................................. 69

Troubleshooting Information .............................. 70

Troubleshooting Chart.............................................. 71

Long-Term Storage ...................................................... 75

Safety Precautions ................................................... 75

Introduction .............................................................. 75

Prepare Engine for Long-Term Storage................... 76

Draining the Cooling System.................................... 76

Specifications ............................................................... 79

Principal Engine Specifications ................................ 79

2YM15 Engine Specifications ............................ 79

3YM20 Engine Specifications ............................ 81

3YM30 Engine Specifications ............................ 83

Marine Gear and Sail Drive Specifications ........ 85

System Diagrams ......................................................... 87

Piping Diagrams....................................................... 87

Wiring Diagrams....................................................... 93

EPA Warranty USA Only .............................................. 99

Yanmar Co., Ltd. Limited Emission Control

System Warranty - USA Only................................... 99

Your Warranty Rights and Obligations: ........... 100

Warranty Period:.............................................. 100

Warranty Coverage: ........................................ 101

Exclusions: ...................................................... 101

Owner’s Responsibility: ................................... 101

Customer Assistance:...................................... 102

Emission System Warranty ....................................... 103

Non-Road Emission System Warranty................... 103

Yanmar Co., Ltd. Limited Emission Control

System Warranty - USA Only .......................... 103

YM Series Operation Manual

© 2008 Yanmar Marine International v

TABLE OF CONTENTS

Maintenance Log.............................................. 106 vi YM Series Operation Manual

© 2008 Yanmar Marine International

YM Series Operation Manual

INTRODUCTION

Welcome to the world of Yanmar Marine!

Yanmar Marine offers engines, drive systems and accessories for all types of boats, from runabouts to sailboats, and from cruisers to mega yachts. In marine leisure boating, the worldwide reputation of

Yanmar Marine is second to none. We design our engines to respect nature. This means quieter engines, with minimal vibrations, cleaner than ever. All of our engines meet applicable regulations, including emissions, at the time of manufacture.

To help you enjoy your Yanmar YM series engine for many years to come, please follow these recommendations:

• Read and understand this Operation

Manual before you operate the engine to ensure that you follow safe operating practices and maintenance procedures.

• Keep this Operation Manual in a convenient place for easy access.

• If this Operation Manual is lost or damaged, order a new one from your authorized Yanmar Marine dealer or distributor.

• Make sure this manual is transferred to subsequent owners. This manual should be considered a permanent part of the engine and remain with it.

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

Marine dealer or distributor.

• The specifications and components

(instrument panel, fuel tank, etc.) described in this manual may differ from ones installed on your vessel. Please refer to the manual provided by the manufacturer of these components.

• Refer to the Yanmar Limited Warranty

Handbook for a complete warranty description.

YM Series Operation Manual

© 2009 Yanmar Marine International

1

INTRODUCTION

RECORD OF OWNERSHIP

Take a few moments to record the information you need when you contact Yanmar for service, parts or literature.

Engine Model: __________________________________________________________

Engine Serial No.: _______________________________________________________

Date Purchased: ________________________________________________________

Dealer: _________________________________________________________________

Dealer Phone: ___________________________________________________________

2 YM Series Operation Manual

© 2009 Yanmar Marine International

YM Series Operation Manual

SAFETY

Yanmar considers safety of great importance and recommends that anyone who comes in close contact with its products, such as those who install, operate, maintain or service Yanmar products, exercise care, common sense and comply with the safety information in this manual and on the engine’s safety decals. Keep the decals from becoming dirty or torn and replace them if they are lost or damaged. Also, if you need to replace a part that has a decal attached to it, make sure you order the new part and decal at the same time.

A

This safety alert symbol appears with most safety statements. It means attention, become alert, your safety is involved! Please read and abide by the message that follows the safety alert symbol.

Indicates a hazardous situation which, if not avoided, will result in death or serious injury.

Indicates a hazardous situation which, if not avoided, could result in death or serious injury.

Indicates a hazardous situation which, if not avoided, could result in minor or moderate injury.

Indicates a situation which can cause damage to the engine, personal property and / or the environment or cause the equipment to operate improperly.

YM Series Operation Manual

© 2009 Yanmar Marine International

3

SAFETY

SAFETY PRECAUTIONS

General Information

There is no substitute for common sense and careful practices. Improper practices or carelessness can cause burns, cuts, mutilation, asphyxiation, other bodily injury or death. This information contains general safety precautions and guidelines that must be followed to reduce risk to personal safety. Special safety precautions are listed in specific procedures. Read and understand all of the safety precautions before operation or performing repairs or maintenance.

Before You Operate

The safety messages that follow have

DANGER level hazards.

NEVER permit anyone to install or operate the engine without proper training.

• Read and understand this Operation

Manual before you operate or service the engine to ensure that you follow safe operating practices and maintenance procedures.

• Safety signs and decals are additional reminders for safe operating and maintenance techniques.

• See your authorized Yanmar Marine dealer or distributor for additional training.

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During Operation and

Maintenance

The safety messages that follow have

WARNING level hazards.

Explosion Hazard

While the engine is running or the battery is charging, hydrogen gas is being produced and can be easily ignited. Keep the area around the battery well-ventilated and keep sparks, open flames and any other form of ignition out of the area.

Fire and Explosion Hazard

Diesel fuel is flammable and explosive under certain conditions.

NEVER use a shop rag to catch the fuel.

Wipe up all spills immediately.

NEVER refuel with the engine running.

Store any containers containing fuel in a well-ventilated area, away from any combustibles or sources of ignition.

Fire Hazard

Undersized wiring systems can cause an electrical fire.

SAFETY

Sever Hazard

NEVER wear jewelry, unbuttoned cuffs, ties or loose-fitting clothing and

ALWAYS tie back long hair when working near moving / rotating parts such as the flywheel or PTO shaft. Keep hands, feet and tools away from all moving parts.

The propeller may rotate during towing or ifthe engine is running at idle speed.

NEVERservice the engine while being towed orwhen the engine is running.

If the vessel has more than one engine,NEVER service an engine if either of theengines is running. In multi-engineconfigurations the propeller for an enginethat is shut down may rotate if any of theother engines are running.

NEVER operate the engine without theguards in place.

Alcohol and Drug Hazard

NEVER operate the engine while under the influence of alcohol or drugs or if you are feeling ill.

Ensure that appropriate fire detection and extinguishing equipment are installed and checked periodically for proper operation.

Exposure Hazard

ALWAYS wear personal protective equipment including appropriate clothing, gloves, work shoes, eye and hearing protection as required by the task at hand.

Coolant may be flammable under certain conditions. NEVER allow coolant to come into contact with hot surfaces or insulation material.

YM Series Operation Manual

© 2009 Yanmar Marine International

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SAFETY

Burn Hazard

Some of the engine surfaces become very hot during operation and shortly after shutdown. Keep hands and other body parts away from hot engine surfaces.

Exhaust Hazard

NEVER block windows, vents or other means of ventilation if the engine is operating in an enclosed area. All internal combustion engines create carbon monoxide gas during operation and special precautions are required to avoid carbon monoxide poisoning.

Sudden Movement Hazard

NEVER operate the engine while wearing a headset to listen to music or radio because it will be difficult to hear the warning signals.

The safety messages that follow have

CAUTION level hazards.

Poor Lighting Hazard

Ensure that the work area is adequately illuminated. ALWAYS install wire cages on portable safety lamps.

Tool Hazard

ALWAYS use tools appropriate for the task at hand and use the correct size tool for loosening or tightening engine parts.

Flying Object Hazard

ALWAYS wear eye protection when servicing the engine or when using compressed air or high-pressure water.

Dust, flying debris, compressed air, pressurized water or steam may injure your eyes.

Coolant Hazard

Wear eye protection and rubber gloves when you handle Long Life engine coolant. If contact with the eyes or skin should occur, flush eyes and wash immediately with clean water.

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The safety messages that follow have

NOTICE level hazards.

It is important to perform daily checks as listed in the Operation Manual.

Periodic maintenance prevents unexpected downtime, reduces the number of accidents due to poor engine performance and helps extend the life of the engine.

See your authorized Yanmar Marine dealer or distributor if you need to operate the engine at high altitudes. At high altitudes the engine will lose power, run rough and produce exhaust gases that exceed the design specifications.

ALWAYS be environmentally responsible.

Follow the guidelines of the

EPA or other governmental agencies for the proper disposal of hazardous materials such as engine oil, diesel fuel and engine coolant. Consult the local authorities or reclamation facility.

NEVER dispose of hazardous materials by dumping them into a sewer, on the ground or into ground water or waterways.

If a Yanmar Marine Engine is installed at an angle that exceeds the specifications stated in the Yanmar Marine Installation

Manuals, engine oil may enter the combustion chamber causing excessive engine speed, white exhaust smoke and serious engine damage. This applies to engines that run continuously or those that run for short periods of time.

SAFETY

If you have an installation with two or three engines and only one engine is operating, the seacock of the non-running engine(s) should be closed. This will prevent water from being forced past the seawater pump and entering the engine. The result of water entering the engine could cause engine seizure or other serious problems.

If you have an installation with two or three engines, and only one engine is operating, please note that if the propeller shaft thru-hull (stuffing box) is lubricated by engine water pressure and the engines are interconnected, care must be taken that water from the running engine does not enter the exhaust of the non-running engine(s). This water could cause seizure of the non-running engine(s). See your authorized Yanmar Marine dealer or distributor for a complete explanation of this condition.

If you have an installation with two or three engines, and only one engine is operating, it is important to limit the amount of throttle applied to the running engine. If you observe black smoke or movement of the throttle does not increase engine rpm, you are overloading the engine that is running.

Immediately throttle back to approximately two-thirds throttle or to a setting where the engine performs normally. Failure to do so may cause the running engine to overheat or cause excess carbon buildup which may shorten the engine's life.

NEVER turn off the battery switch (if equipped) or short the battery cables during operation. Damage to the electrical system will result.

YM Series Operation Manual

© 2009 Yanmar Marine International

7

SAFETY

LOCATION OF SAFETY DECALS

Figure 1 shows the location of safety decals on Yanmar YM series marine engines.

Figure 1 YM Engines

(2) (1)

WARNING

8

(3)

196630-12980

1 – Part Number: 128377–07260

2 – Part Number: 128377–07350

X 0 0 1 4 4 6 2 0

Figure 1

3 – Part Number: 196630–12980

YM Series Operation Manual

© 2009 Yanmar Marine International

YM Series Operation Manual

PRODUCT OVERVIEW

YANMAR YM FEATURES

AND APPLICATIONS

The YM series are four-stroke direct injection diesel engines equipped with liquid coolant systems.

The 2YM15 is a 2-cylinder engine and is naturally aspirated.

The 3YM20 is a 3-cylinder engine and is naturally aspirated.

The 3YM30 is a 3-cylinder engine and is naturally aspirated.

These engines are equipped with a marine gear or sail drive unit.

These engines are designed for pleasure craft use and complied with EPA regulation

Tier3 marine from 2009 year.

It is recommended that new vessels be propped so the engines can operate at 100 to 200 rpm above the Maximum Rated

Power Output rpm (3700 to 3800) to allow for some added weight and hull resistance.

The engine must be able to reach the

Maximum Rated Power rpm (3600) under full load at all times.

Failure to do so can lead to reduced vessel performance, increased smoke levels and can cause permanent damage to your engine, which is not covered by warranty.

The engine must be installed correctly with coolant lines, exhaust gas lines and electrical wiring. Any auxiliary equipment attached to the engine should be easy to use and accessible for service. To handle the drive equipment, propulsion systems

(including the propeller) and other onboard equipment, always observe the instructions and cautions given in the operation manuals supplied by the shipyard and equipment manufacturers.

The YM series engines are designed to be operated at maximum throttle (3600 rpm) for less than 5% of total engine time (30 minutes out of every 10 hours) and cruising speed (3400 rpm or less) for less than 90% of total engine time (9 hours out of every 10 hours).

The laws of some countries may require hull and engine inspections, depending on the use, size and cruising area of the boat.

The installation, fitting and surveying of this engine all require specialized knowledge and engineering skills. See

Yanmar’s local subsidiary in your region or your authorized Yanmar Marine dealer or distributor.

9 YM Series Operation Manual

© 2009 Yanmar Marine International

PRODUCT OVERVIEW

New Engine Break-In

As with all reciprocating engines, the way the engine is operated during its first 50 hours of operation plays a significant role in determining how long it will last and how well the engine will perform over its lifetime.

A new Yanmar diesel engine must be operated at suitable speeds and power settings during the break-in period to allow the sliding parts, such as piston rings, to break in properly and to stabilize engine combustion.

During the break-in period, the engine coolant temperature gauge should be monitored. The temperature should be between 71° and 87°C (160° and 190°F).

During the first 10 hours of operation, the engine should be operated at maximum rpm minus 400 to 500 rpm (approximately

60 to 70% of load) most of the time. This will ensure the sliding parts break in properly.

NOTICE: During this period, avoid operating at maximum engine speed and load to avoid damaging or scoring sliding parts.

Do not operate the engine at low idle or at low speed and light load for more than

30 minutes at a time. Since unburned fuel and engine oil will adhere to the piston rings when operating at low speeds for long periods, this will interfere with proper movement of the rings and the diesel fuel consumption may increase. Low idle speed does not allow break-in of sliding parts.

If operating the engine at low speed and light load, you must race the engine to clean the carbon from the cylinders and the fuel injection valve.

Perform this procedure in open waters:

• With the clutch in NEUTRAL, accelerate from the low-speed position to the high-speed position briefly.

• Repeat this process five times.

Once past the initial 10 hours until 50 hours, the engine should be used over its full operating range, with special emphasis on running at relatively high power settings. This is not the time for an extended cruise at idle or low speed. The boat should be operated at maximum speed minus 400 rpm most of the time

(approximately 70% load), with a 10 minute run at maximum minus 200 rpm

(approximately 80% load) every

30 minutes and a 4 to 5 minute period of operation at WOT (wide open throttle) once every 30 minutes. During this period, be sure not to operate the engine at low speed and light load for more than

30 minutes. If operating engine at low speed and light load is necessary, race the engine after low idle operation.

To complete engine break-in, perform

After Initial 50 Hours maintenance procedures on page 56.

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COMPONENT

IDENTIFICATION

Figure 1

Right Side (from Flywheel) -

2YM15

Figure 1 and Figure 2 illustrate a typical version of a 2YM15 engine. Your engine may have different equipment from that illustrated.

(2)

(1) (3)

(4)

(5)

PRODUCT OVERVIEW

Figure 2

Left Side (from Flywheel) -

2YM15

(3)

(2) (4)

(5)

(7)

(6)

(7)

(8)

(9)

0004781

Figure 1

1 – Intake Silencer (air cleaner)

2 – Intake Manifold

3 – Fuel Filter

4 – Fuel Injection Pump

5 – Engine Oil Dipstick

6 – Engine Oil Filler Cap

7 – Fuel Feed Pump

8 – Engine Oil Filter

9 – Marine Gear

(1)

(8)

(6)

0004782

Figure 2

1 – Seawater Pump

2 – Coolant Filler Cap

3 – Engine Nameplate (on rocker arm cover)

4 – Coolant Tank / Heat Exchanger

5 – Exhaust Manifold

6 – Starter Motor

7 – Shift Lever

8 – Alternator

YM Series Operation Manual

© 2009 Yanmar Marine International

11

PRODUCT OVERVIEW

Figure 3

Right Side (from Flywheel) -

3YM20

Figure 3 and Figure 4 illustrate a typical version of a 3YM20 engine. Your engine may have different equipment from that illustrated.

(1) (2)

(3)

(4)

(5)

(6)

(7)

Figure 4

Left Side (from Flywheel) -

3YM20

(2) (3)

(4)

(8)

(9)

0004783

Figure 3

1 – Intake Silencer (air cleaner)

2 – Intake Manifold

3 – Fuel Filter

4 – Fuel Injection Pump

5 – Engine Oil Dipstick

6 – Engine Oil Filler Cap

7 – Fuel Feed Pump

8 – Engine Oil Filter

9 – Marine Gear

(5)

(6)

(1)

(8) (7)

0004784

Figure 4

1 – Seawater Pump

2 – Coolant Filler Cap

3 – Engine Nameplate (on rocker arm cover)

4 – Coolant Tank / Heat Exchanger

5 – Exhaust Manifold

6 – Starter Motor

7 – Shift Lever

8 – Alternator

12 YM Series Operation Manual

© 2009 Yanmar Marine International

Figure 5

12/05

Right Side (from Flywheel) -

3YM30

Figure 5 and Figure 6 illustrate a typical version of a 3YM30 engine. Your engine may have different equipment from that illustrated.

(1) (2)

(3)

(4)

(5)

(6)

(7)

PRODUCT OVERVIEW

Figure 6

Left Side (from Flywheel) -

3YM30

(2) (3)

(4)

(1)

(8)

(5)

(6)

(7)

0004786

(8)

(9)

0004785

Figure 5

1 – Intake Silencer (air cleaner)

2 – Intake Manifold

3 – Fuel Filter

4 – Fuel Injection Pump

5 – Engine Oil Dipstick

6 – Engine Oil Filler Cap

7 – Fuel Feed Pump

8 – Engine Oil Filter

9 – Marine Gear

Figure 6

1 – Seawater Pump

2 – Coolant Filler Cap

3 – Engine Nameplate (on rocker arm cover)

4 – Coolant Tank / Heat Exchanger

5 – Exhaust Manifold

6 – Starter Motor

7 – Shift Lever

8 – Alternator

YM Series Operation Manual

© 2009 Yanmar Marine International

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PRODUCT OVERVIEW

LOCATION OF

NAMEPLATES

Figure 7

The nameplate of the Yanmar YM series engine is shown in Figure 7 . Check the engine’s model, output, rpm and serial number on the nameplate. Replace it if it is damaged or lost.

The engine nameplate is attached to the engine rocker arm cover.

Model

G e a r M o d e l

Continuous power kW

Speed of prop. shaft

Fuel stop power kW

ENG.No.

MFG. DATE

/

/

/ min

-1 min -1 min -1

Figure 8

The marine gear nameplate (Figure 8) is attached to the marine gear. Check the marine gear’s model, gear ratio, oil used, oil quantity and serial number.

MODE L KM

GEAR R ATIO

OI L SAE 20 /

30

HD

OI L QT Y. LTR.

NO.

Figure 8

0004529

Figure 7

0 0 2 7 0 0 7 6 9 2 1

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FUNCTION OF MAJOR COMPONENTS

PRODUCT OVERVIEW

Name of Component

Fuel Filter

Fuel Feed Pump

Fuel Feed Lever

Engine Oil Filler Port

Engine Oil Filter

Function

Removes dirt and water from the fuel. Drain the filter periodically. The filter element should be replaced periodically. The water separator (if equipped) should be drained periodically. See Draining Fuel Filter / Water Separator on

page 60.

Pumps fuel from the tank to the fuel injection system. Pushing the manual lever on the side of the feed pump supplies fuel to the engine when fuel priming is needed.

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

Filler port for the engine oil.

Filters fine metal fragments and carbon from the engine oil. Filtered engine oil is distributed to the engine’s moving parts. The filter is a spin-on type and the element should be replaced periodically. See Replacing the Engine Oil Filter

Element on page 64.

Filler port for marine gear oil; located on top of the marine gear case.

Marine Gear Filler Port

Cooling System

Closed Cooling Circulation

Pump

Seawater Pump

There are two cooling systems: closed cooling with coolant (fresh water) and seawater. The engine is cooled by the closed cooling circuit. The closed circuit is cooled by seawater using a heat exchanger. The seawater also cools the engine / marine gear oil.

The centrifugal water pump circulates coolant inside the engine. The circulating pump is driven by a V-belt.

Pumps seawater from outside vessel to the engine. The seawater pump has a replaceable rubber impeller.

Coolant Filler Cap

Coolant Recovery Tank

The filler cap on the heat exchanger / coolant tank covers the water supply port.

The cap has a pressure regulating valve. When the cooling water temperature rises, the pressure rises inside the coolant system.

The pressure valve in the filler cap releases vapor and hot water overflow to the coolant recovery tank. When the engine stops and the coolant cools, the pressure in the coolant tank drops. The filler cap vacuum valve then opens to send coolant back from the coolant recovery tank. This minimizes coolant consumption. The closed cooling system coolant level can easily be checked and refilled in this tank.

Engine Oil Cooler

Nameplates

A heat exchanger that cools high temperature engine oil using coolant.

Intake Silencer (Air Cleaner) The intake silencer guards against dirt in the air and reduces the noise of air intake.

Nameplates are provided on the engine and the marine gear and have the model, serial number and other data. See Location of Nameplates on page 14.

Starter

Alternator

Engine Oil Dipstick

Starter motor for the engine; powered by the battery.

Driven by a belt and generates electricity and charges the battery.

Gauge stick for checking the engine oil level.

YM Series Operation Manual

© 2009 Yanmar Marine International

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PRODUCT OVERVIEW

CONTROL EQUIPMENT

The control equipment at the helm makes remote control operation possible. It consists of the instrument panel, which is connected to the engine by a wire harness, and the remote control handle, which is connected by control cables to the engine control lever and marine gear.

Instrument Panel (Optional)

Equipment and Functions

The instrument panel is located at the helm. The following instruments enable you to start or stop the engine and to monitor its condition during operation. A typical instrument panel is shown in Figure 9 .

Figure 9 B-Type

(9)

(8)

(7)

(6)

(1)

(5)

(2)

(4)

0004486

(3)

Figure 9

1 – Tachometer

2 – Hourmeter

3 – Moisture Cap for Key Switch

4 – Key Switch

5 – STOP Button

6 – Battery Low Charge Indicator

7 – Water in Sail Drive Seal

Indicator

8 – Engine Oil Low Pressure

Indicator

9 – Coolant High Temperature

Indicator

Gauges

B-Type panels use analog electric gauges with needle indicators.

16

Instrument

Tachometer

Hourmeter

Instrument Panel Lights

Function

Shows the engine rotation speed.

Shows the number of operating hours; can be used as a guide for periodic maintenance checks. The hourmeter is located at the bottom of the tachometer.

When turning the key switch to ON, the gauges will illuminate for easier viewing.

YM Series Operation Manual

© 2009 Yanmar Marine International

Figure 10

12/05

Key Switch

(1)

(2)

(3)

(4)

0003622

Figure 10

1 – GLOW

2 – OFF

3 – ON

4 – START

The GLOW position (Figure 10, (1)) is the start aid position. Electric current to the glow plug is turned on. When the key is released, the switch will automatically move to the ON position.

The START position (Figure 10, (4)) allows current to the starting motor. When starting the engine, move the key to the

START position and release. The key will automatically move to the ON position.

When the key is in the OFF position

(Figure 10, (2)) , the electric current is off.

The key can be inserted or removed in this position.

The ON position (Figure 10, (3)) allows electrical current to the controls and equipment and allows the engine to keep running. To stop the engine, keep the key switch in the ON position and push the

STOP button. After stopping the engine, turn the key to the OFF position.

PRODUCT OVERVIEW

YM Series Operation Manual

© 2009 Yanmar Marine International

17

PRODUCT OVERVIEW

Figure 11 B (Keyless) - Type (Optional)

(1) (2) (3) (4)

10

0

20 30

40

50

(8)

1 – Coolant High Temperature

Indicator

2 – Engine Oil Low Pressure

Indicator

3 – Water in Sail Drive Seal

Indicator

4 – Battery Low Charge Indicator

(7) (6)

X 0 0 2 0 1 6 2 0

(5)

Figure 11

5 – OFF / ON / START Switch

6 – STOP / GLOW Switch

7 – Hourmeter

8 – Tachometer

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PRODUCT OVERVIEW

Figure 12

12/05

Indicators and Alarms (Optional)

When a sensor detects a problem during operation, the indicator on the instrument panel will light and an alarm will sound.

Indicators are located on the instrument panel. The alarm is located on the back of the panel. Under normal operating conditions, the indicators are off.

Figure 13

Figure 12

Battery Low Charge Indicator

(Figure 12) - When the alternator output is too low, the indicator will light. When charging begins, the indicator will turn off.

No alarm will sound for low battery charge.

Figure 14

Figure 14

Figure 15

Engine Oil Low Pressure Indicator and

Alarm (Figure 14) - When the engine oil pressure falls below normal, the oil pressure sensor will send a signal to the indicator, causing it to light and the alarm to sound. Stop operation immediately to avoid damage to the engine. Check the oil level and troubleshoot the lubrication system.

Figure 13

Coolant High Temperature Indicator and

Alarm (Figure 13) - When coolant temperature reaches the maximum allowable temperature (95°C [203°F] or higher), the indicator will light and the alarm will sound. Continuing operation at temperatures exceeding the maximum limit will result in damage and seizure.

Check the load and troubleshoot the cooling system.

Figure 15

Water in Sail Drive Seal Indicator and

Alarm (Figure 15) - When seawater is detected between the seals of the sail drive, the indicator will light and the alarm will sound.

Figure 16

STOP Button

0005439

Figure 16

Push the STOP button switch to stop the engine. The key switch must be in the ON position for the STOP button to operate.

After the engine has come to a complete stop, you can turn the key to the OFF position.

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PRODUCT OVERVIEW

Alarms

Check that indicators and alarms are working normally when the key is turned to ON.

Key Switch

Engine

Alarm

Indicators

OFF

ON

Before start

Battery Low Charge Indicator

Sound

ON

Coolant High Temperature Indicator OFF

Engine Oil Low Pressure Indicator

Water In Sail Drive Indicator

ON

OFF

START

ON

Running

No sound

OFF

OFF

OFF

OFF

Figure 17

Single-Lever Remote Control

Handle

(4)

(1)

(3)

(2)

(5)

0004504

Figure 17

1 – Low Speed - FWD or REV

2 – Low Speed - FWD or REV

3 – NEUTRAL - Power to the propeller shaft is cut off and the engine idles

4 – Maximum Engine Speed - FWD or REV

5 – Maximum Engine Speed - FWD or REV

A single-lever handle type (Figure 17) should be used to operate the marine gear clutch (NEUTRAL, FORWARD, and

REVERSE) and to control the engine speed.

Figure 18

The lever controls the direction of the boat

(ahead or astern) and also acts as an accelerator by increasing engine speed as the lever is pushed further in the

FORWARD or REVERSE directions.

When the lever is pulled out

(Figure 18, (1)) , the engine speed can be controlled without engaging the clutch. The clutch remains in the NEUTRAL, no load position. Turn the knob (Figure 18, (2)) counterclockwise to move the lever or clockwise to lock the lever.

(2)

(1)

0004511

Figure 18

Note: Yanmar recommends the use of a single-lever type for the remote control system. If only a two-lever type is available in the market, reduce engine rpm to

1000 or less before engaging and disengaging the marine gear clutch.

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BEFORE YOU OPERATE

SAFETY PRECAUTIONS

Before performing any operations within this section, review the Safety section on page 3.

INTRODUCTION

This section of the Operation Manual describes the diesel fuel, engine oil and engine coolant specifications and how to replenish them.

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BEFORE YOU OPERATE

DIESEL FUEL

Diesel Fuel Specifications

WARNING! Fire and Explosion Hazard.

Diesel fuel is flammable and explosive under certain conditions.

NOTICE: Only use diesel fuels recommended by Yanmar for the best engine performance, to prevent engine damage and to comply with EPA warranty requirements. Only use clean diesel fuel.

Diesel fuel should comply with the following specifications. The table lists several worldwide specifications for diesel fuels.

DIESEL

FUELSPECIFICATION

No. 2-D, No. 1-D, ASTM

D975

LOCATION

USA

EN590:96

ISO 8217 DMX

European Union

International

BS 2869-A1 or A2 United Kingdom

JIS K2204 Grade No. 2 Japan

Biodiesel Fuels

Yanmar approves the use of biodiesel fuels that do not exceed a blend of 5% non-mineral oil based fuel with 95% standard diesel fuel. Such biodiesel fuels are known in the marketplace as B5 biodiesel fuels. B5 biodiesel fuel can reduce particulate matter and the emission of “greenhouse” gases compared to standard diesel fuel.

NOTICE: If the B5 biodiesel fuel used does not meet the approved specifications, it will cause abnormal wear of injectors, reduce the life of the engine and it may affect the warranty coverage of your engine.

B5 diesel fuels must meet certain specifications.

The biodiesel fuels must meet the minimum specifications for the country in which they are used:

• In Europe, biodiesel fuels must comply with the European Standard EN14214.

• In the United States, biodiesel fuels must comply with the American Standard

ASTM D-6751.

Biodiesel should be purchased only from recognized and authorized diesel fuel suppliers.

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Precautions and concerns regarding the use of biofuels:

• Biodiesel fuels have a higher content of methyl-esters, which may deteriorate certain metal, rubber and plastic components of the fuel system. The customer and / or boat builder are responsible to verify the usage of biodiesel compatible components on the vessel fuel supply and return systems.

• Free water in biodiesel may result in plugging of fuel filters and increased bacterial growth.

• High viscosity at low temperatures may result in fuel delivery problems, injection pump seizures, and poor injection nozzle spray atomization.

• Biodiesel may have adverse effects on some elastomers (seal materials) and may result in fuel leakage and dilution of the engine lubricating oil.

• Even biodiesel fuels that comply with a suitable standard as delivered will require additional care and attention to maintain the quality of the fuel in the equipment or other fuel tanks. It is important to maintain a supply of clean, fresh fuel. Regular flushing of the fuel system, and / or fuel storage containers, may be necessary.

• The use of biodiesel fuels that do not comply with the standards as agreed to by the diesel engine manufacturers and the diesel fuel injection equipment manufacturers, or biodiesel fuels that have degraded as per the precautions and concerns above, may affect the warranty coverage of your engine.

BEFORE YOU OPERATE

Additional Technical Fuel

Requirements

• The fuel cetane number should be 45 or higher.

• The sulfur content must not exceed 0.5% by volume. Less than 0.05% is preferred.

• NEVER mix kerosene, used engine oil or residual fuels with the diesel fuel.

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

• Keep the fuel tank and fuel-handling equipment clean at all times.

• Ash content should not exceed 0.01% by volume.

• Carbon residue content should not exceed 0.35% by volume. Less than

0.1% is preferred.

• Total aromatics content should not exceed 35% by volume. Less than 30% is preferred.

• PAH (polycyclic aromatic hydrocarbons) content should be below 10% by volume.

• NEVER use Biocide.

• NEVER use kerosene or residual fuels.

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BEFORE YOU OPERATE

Handling of Diesel Fuel

WARNING! Fire and Explosion Hazard.

Only fill the fuel tank with diesel fuel.

Filling the fuel tank with gasoline may result in a fire and will damage the engine. NEVER refuel with the engine running. Wipe up all spills immediately.

Keep sparks, open flames or any other form of ignition (match, cigarette, static electric source) well away when refueling.

WARNING! Fire and Explosion Hazard.

ALWAYS put the diesel fuel container on the ground when transferring the diesel fuel from the pump to the container. Hold the hose nozzle firmly against the side of the container while filling it. This prevents static electricity buildup which could cause sparks and ignite fuel vapors.

Figure 1

Fuel Tank (Optional)

NOTICE: Water and / or dust in the fuel may cause engine failure. When fuel is stored, check that the inside of the storage container is clean and dry, and that the fuel is stored away from dirt or rain.

(3)

(1)

(2)

0004542

Figure 1

1 – Sediment Bowl

2 – Drain Cock

3 – Fuel Line to Engine

Install a drain cock (Figure 1, (2)) at the bottom of the fuel tank to remove water and contaminants from the sediment bowl

(Figure 1, (1)) .

The fuel outlet should be positioned 20 to

30 mm (0.75 to 1.125 in.) above the bottom of the tank (Figure 2, (4)) so that only clean fuel is distributed to the engine.

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Figure 2

12/05

Fuel System

(1)

(9)

(8)

(2)

(3)

(10)

(5)

(4)

(7)

(6)

0004788

Figure 2

1 – Fuel Filter

2 – Fuel Feed Pump (priming lever)

3 – Fuel / Water Separator

(optional)

4 – Approximately 20 to 30 mm

(0.75 to 1.125 in.)

5 – Within 500 mm (20 in.)

6 – Drain Cock

7 – Fuel Cock

8 – Fuel Return Line

9 – To Fuel Injection Pump

10 – Fuel Tank

Install the fuel line from the fuel tank to the fuel injection pump as shown in Figure 2 .

The recommended fuel / water separator

(Figure 2, (3)) (optional) is installed at the center section of that line.

BEFORE YOU OPERATE

Filling the Fuel Tank

WARNING! Fire and Explosion Hazard.

NEVER refuel with the engine running.

Before filling fuel tank for the first time:

Rinse the fuel tank with kerosene or diesel fuel. Dispose of waste properly.

To fill the fuel tank:

WARNING! Fire and Explosion Hazard.

Operate bilge ventilation (blowers) for a minimum of 5 minutes to purge fumes from engine compartment after refueling. Never operate bilge blower while refueling. Doing so can pump explosive fumes into the engine compartment and result in an explosion.

1. Clean the area around the fuel cap.

2. Remove the fuel cap from the fuel tank.

3. Fill the tank with clean fuel free of oil and dirt. WARNING! Fire and

Explosion Hazard. Hold the hose nozzle firmly against the filler port while filling. This prevents static electricity buildup which could cause sparks and ignite fuel vapors.

4. Stop fueling when the gauge shows the fuel tank is full. WARNING! Fire and

Explosion Hazard. NEVER overfill the fuel tank.

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BEFORE YOU OPERATE

Figure 3

5. Replace the fuel cap and hand-tighten.

Over-tightening the fuel cap will damage it.

Bleeding the Fuel System

The fuel system has an automatic air bleeding device that purges air from the fuel system. No manual air bleeding is required for normal operation. Manual bleeding must be done if any fuel system maintenance has been performed

(replacement of fuel filter, etc.) or if the engine does not start after several attempts.

Figure 4

Bleeding the Fuel System

(1)

0004512

Figure 3

If filling the tank from a storage container

(Figure 3) , keep the fuel container stationary for several hours to allow any dirt or water to settle to the bottom of the container. Use a pump to extract the clear, filtered fuel from the top of the container.

(2)

(3)

(4)

(5)

Figure 4

1 – Air Bleed Screw

2 – Bracket

3 – O-Ring

4 – Fuel Filter Element

5 – Fuel Filter Housing

6 – Retaining Ring

(6)

0004801

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1. Check the fuel level in the fuel tank.

Refill if necessary.

2. Open the fuel cock of the fuel tank.

WARNING! Exposure Hazard.

Always wear safety glasses when bleeding the fuel system.

3. Loosen the air bleed screw

(Figure 4, (1)) 2 to 3 turns.

4. Push up and down on the manual priming lever located on the side of the fuel feed pump to release air out of the air bleed screw. Always use an approved container to catch the diesel fuel.

5. Continue pumping until a solid stream of fuel with no air bubbles begins to flow.

6. Tighten the air bleed screw.

Note: After engine start-up, the automatic air-bleeding device works to purge the air in the fuel system.

BEFORE YOU OPERATE

ENGINE OIL

Engine Oil Specifications

NOTICE: Only use the engine oil specified.

Other engine oils may affect warranty coverage, cause internal engine components to seize and / or shorten engine life. NEVER mix different types of engine oil. This may adversely affect the lubricating properties of the engine oil.

Use an engine oil that meets or exceeds the following guidelines and classifications:

• API Service Categories: CD or higher

TBN value: 9 or more

The oil must be changed when the Total

Base Number (TBN) has been reduced to 2.0.

TBN (mgKOH/g) test method: JIS

K-2501–5.2–2(HCI), ASTM D4739(HCI)

• Recommended SAE Viscosity: 10W30,

15W40. Engine oil 10W30 and 15W40 can be used throughout the year.

• NEVER use API Service Category CG-4 or CH-4 oils.

NOTICE:

1. Be sure the engine oil, engine oil storage containers and engine oil filling equipment are free of sediment or water.

2. Change the engine oil after the first 50 hours of operation and then at every

150 hours thereafter. See Changing the

Engine Oil on page 57.

3. Select the oil viscosity based on the ambient temperature where the engine is being operated. See the SAE Service

Grade Viscosity Chart (Figure 5).

4. Yanmar does not recommend the use of engine oil “additives.”

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BEFORE YOU OPERATE

Handling Engine Oil

1. When handling and storing engine oil, be careful not to allow dust and water to contaminate the oil. Clean around the filler port before filling.

2. Do not mix lube oils of different types or brands. Mixing may cause the chemical characteristics of the oil to change and lubricating performance to decrease, reducing the engine’s life.

3. Engine oil should be replaced at the specified intervals, regardless of the engine’s operation history. See

Periodic Maintenance Schedule on

page 50.

Figure 5

Engine Oil Viscosity

SAE 10W-30

SAE 15W-40

-4°F 14°F 32°F 50°F 68°F 86°F 104°F

(-20°C) (-10°C) (0°C) (10°C) (20°C) (30°C) (40°C)

0000005

Figure 5

Select the appropriate engine oil viscosity based on the ambient temperature shown in the SAE Service Grade Viscosity Chart

(Figure 5) .

NOTICE: If you intend to operate your equipment at temperatures outside the limits shown, you must consult your authorized Yanmar Marine dealer or distributor for special lubricants or starting aids.

Figure 6

Checking the Engine Oil

(2)

(1)

(3)

(4)

(5)

0004789

Figure 6

1 – Filler Port

2 – Rocker Arm Cover

3 – Dipstick

4 – Upper Limit

5 – Lower Limit

Note: 3YM30 shown. Other models are similar.

1. Make sure the engine is off. It is recommended that the engine be as level as possible before checking the oil.

2. NOTICE: Prevent dirt and debris from contaminating engine oil. Carefully clean the dipstick, filler port cap and the surrounding area before you remove

the cap. Remove the dipstick

(Figure 6, (3)) and wipe with a clean cloth.

3. Fully reinsert the dipstick.

4. Remove the dipstick. The oil level should be between upper

(Figure 6, (4)) and lower (Figure 6, (5)) lines on the dipstick.

5. Add oil if necessary. See Adding

Engine Oil on page 29.

6. Fully reinsert the dipstick.

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Adding Engine Oil

1. NOTICE: Prevent dirt and debris from contaminating engine oil. Carefully clean the dipstick, filler port cap and the surrounding area before you remove

the cap. Remove the yellow oil filler port cap from the filler port (Figure 6, (1)) on the rocker arm cover (Figure 6, (2)) and fill with engine oil.

2. Fill with engine oil to the upper limit

(Figure 6, (4)) on the dipstick

(Figure 6, (3)) . NOTICE: NEVER overfill the engine with engine oil.

3. Insert the dipstick fully to check the level. NOTICE: ALWAYS keep the oil level between the upper and lower lines on the oil cap / dipstick.

4. Hand-tighten the filler port cap securely.

BEFORE YOU OPERATE

MARINE GEAR OR SAIL

DRIVE OIL

Marine Gear Oil Specifications

Use marine gear oil that meets or exceeds the following guidelines and classifications:

KM2P-1 (S), (G) or (GG):

• API Service Categories: CD or higher

• SAE Viscosity: #20 or #30

Sail Drive Oil Specifications -

SD20

Refer to the Sail Drive Operation Manual for the procedure to fill or replace the sail drive oil.

SD20:

• API Service Category: GL4.5

• SAE Viscosity: 90 or 80W90

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Figure 7

BEFORE YOU OPERATE

Checking Marine Gear Oil

(3)

(4)

(1)

(2)

0004811

Figure 7

1 – Dipstick

2 – Marine Gear Filler Port

3 – Upper Limit

4 – Lower Limit

1. Make sure the engine is off. Make sure the engine is as level as possible and wipe area clean around the marine gear filler port (Figure 7, (2)) .

2. Remove the filler cap at the top of the housing.

3. Remove the dipstick (Figure 7, (1)) and wipe with a clean cloth.

4. Fully reinsert the dipstick.

5. Remove the dipstick. The oil level should be between the upper

(Figure 7, (3)) and lower (Figure 7, (4)) lines on the dipstick.

6. Fully reinsert the dipstick.

Adding Marine Gear Oil

1. Make sure the engine is as level as possible.

2. Remove the filler cap at the top of the housing.

3. Fill with oil to the upper limit on the dipstick (Figure 7, (3)) . See Marine

Gear Oil Specifications on page 29.

NOTICE: NEVER overfill the marine gear with oil.

4. Fully reinsert the dipstick.

5. Hand-tighten the filler port cap.

Checking and Adding Sail Drive

Oil

Refer to the Sail Drive Operation Manual for the procedure for checking and filling the sail drive oil.

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ENGINE COOLANT

Engine Coolant Specifications

• Texaco Long Life Coolant (LLC), both standard and premixed, product code

7997 and 7998

• Havoline Extended Life

Antifreeze / Coolant, product code 7994

Note: In the U.S., LLC is required for the warranty to be valid.

NOTICE: Following the manufacturer’s recommendations, use a proper LLC which will not have any adverse effects on the materials (cast iron, aluminum, copper, etc.) of the engine’s cooling system. See

Engine Coolant Specifications on page 31.

ALWAYS use the mixing ratios specified by the antifreeze manufacturer for the temperature range.

NOTICE: ALWAYS add LLC to soft water – especially when operating in cold weather.

NEVER use hard water. Water should be clean and free from sludge or particles.

Without LLC, cooling performance will decrease due to scale and rust in the coolant system. Water alone may freeze and form ice; it expands approximately 9% in volume. Use the proper amount of coolant concentrate for the ambient temperature as specified by the LLC manufacturer. LLC concentration should be a minimum of 30% to a maximum of

60%. Too much LLC will decrease the cooling efficiency. Excessive use of antifreeze also lowers the cooling efficiency of the engine. NEVER mix different types or brands of LLC, as a harmful sludge may form. Mixing different brands of antifreeze may cause chemical reactions, and may make the antifreeze useless or cause engine problems.

BEFORE YOU OPERATE

Replace the engine coolant periodically, according to the maintenance section in this Operation Manual.

Remove scale from the cooling system periodically by flushing the system.

Checking and Adding Coolant

Figure 8

Component identification

(1)

(4)

Figure 9

(5)

(3)

(2)

0004791

Figure 8

1 – Coolant Tank / Heat Exchanger

2 – Coolant Drain Plug

3 – Seawater Drain Plug

4 – Coolant Pump

5 – Seawater Pump

(1)

(2)

(3)

0005576

Figure 9

1 – Coolant Tank / Heat Exchanger

2 – Coolant Drain Plug

3 – Seawater Drain Cock

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Figure 10

BEFORE YOU OPERATE

(1)

(3)

(2)

Figure 10

1 – Stop Solenoid

2 – Seawater Drain Plug

3 – Flywheel Housing

0004793

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

Close all drain cocks before filling the system with coolant.

Figure 11

1. Allow the engine to cool.

2. Ensure all drain cocks are closed.

3. Loosen the coolant tank filler cap to relieve the pressure, then remove the filler cap. WARNING! Burn Hazard.

NEVER remove the coolant filler cap if the engine is hot. Steam and hot engine coolant will spray out and seriously burn you. Allow the engine to cool down before you attempt to remove the cap.

(2)

(1)

(3) (4) 0004492

1 – Filler Cap Tabs

2 – Coolant Filler Cap

3 – Filler Port Notches

4 – Coolant Tank / Heat Exchanger

Figure 11

4. NOTICE: NEVER pour cold coolant into a hot engine.

Pour coolant slowly into the coolant tank

/ heat exchanger (Figure 11, (4)) to avoid air bubbles. Fill until coolant overflows from the filler port.

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Figure 12

12/05

5. Align the filler cap tabs (Figure 11, (1)) with filler port notches (Figure 11, (3)) and tighten the filler cap

(Figure 11, (2)) .

(

(1)

(2)

FULL

(3)

LOW

0004493

1 – Rubber Hose to Coolant Tank

2 – FULL Mark

3 – LOW Mark

4 – Coolant Recovery Tank Cap

Figure 12

6. Check the coolant level in the coolant recovery tank. The level should be at the FULL mark (Figure 12, (2)) . Add coolant if necessary.

Note: The coolant level rises in the coolant recovery tank during operation. After stopping the engine, the coolant will cool down and the extra coolant will return to the coolant tank.

Note: NOTICE: NEVER pour cold coolant into a hot engine.

7. Remove coolant recovery tank cap

(Figure 12, (4)) to add coolant if necessary. NEVER add water.

8. Replace the filler cap and tighten it firmly. Failure to do so will cause coolant to leak.

BEFORE YOU OPERATE

WARNING! Burn Hazard. ALWAYS tighten the coolant tank cap securely after checking the coolant tank.

Steam can spray out during engine operation if the cap is loose.

Coolant Recovery Tank Capacity

0.8 L (0.95 qt)

9. Check the rubber hose (Figure 12, (1)) connecting the coolant recovery tank to the coolant tank / heat exchanger.

Replace if damaged.

NOTICE: If the coolant runs low too often or only the coolant level in the coolant tank

/ heat exchanger drops without any change in the level in the coolant recovery tank, there may be coolant or air leaks in the cooling system. See your authorized

Yanmar Marine dealer or distributor.

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BEFORE YOU OPERATE

CRANKING THE ENGINE

NOTICE: When performing engine break-in or if the engine has not been used for a long period of time, engine oil will not be distributed to all of the operating parts.

Using the engine in this condition will lead to seizure.

After a long period of non-use, distribute engine oil to each part by cranking the engine. Perform the following procedure before beginning operation:

Figure 13

1. Open the seacock.

2. Open the fuel cock.

3. Put the remote control shift lever in

NEUTRAL.

4. Turn the battery switch to ON (if equipped).

6. While pushing the STOP button on the control panel, turn the key to the

START position (Figure 13, (4)) .

NOTICE: NEVER hold the key in the

START position for longer than 15 seconds or the starter motor will overheat.

7. When the key is in the START position, the engine will begin cranking.

Continue cranking for about 5 seconds and listen for abnormal noise during that time.

NOTICE: If the STOP button is released during the cranking procedure, the engine will start. NEVER start the engine in this mode.

(1)

(2)

(3)

(4)

0003622

1 – GLOW

2 – OFF

3 – ON

4 – START

Figure 13

Note: If the engine has not been operated for a long period of time, check that the key moves smoothly from the START to ON positions.

5. Turn the key to ON (Figure 13, (3)) .

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YM Series Operation Manual

ENGINE OPERATION

SAFETY PRECAUTIONS

Before performing any operations within this section, read the following safety information and review the Safety section on page 3.

Fire and Explosion

Hazard

NEVER jump-start the engine. Sparks caused by shorting the battery to the starter terminals may cause a fire or explosion.

ONLY use the key switch to start the engine.

Sudden Movement Hazard

Be sure the boat is in open water away from other boats, docks or other obstructions before increasing rpm.

Avoid unexpected equipment movement. Shift the marine gear into the NEUTRAL position any time the engine is at idle.

To prevent accidental equipment movement, NEVER start the engine in gear.

Sever Hazard

Keep children and pets away while the engine is operating.

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ENGINE OPERATION

If any indicator illuminates during engine operation, stop the engine immediately.

Determine the cause and repair the problem before continuing to operate the engine. If the alarm window with audible alarm fails to display and go out about 3 seconds later when the ignition switch is in the ON position, see your authorized

Yanmar Marine dealer or distributor for service before operating the engine.

Observe the following environmental operating conditions to maintain engine performance and avoid premature engine wear:

• Avoid operating in extremely dusty conditions.

• Avoid operating in the presence of chemical gases or fumes.

• NEVER run the engine if the ambient temperature is above +40°C

(+104°F) or below -16°C (+5°F).

• If the ambient temperature exceeds +40°C (+104°F), the engine may overheat and cause the engine oil to break down.

• If the ambient temperature is below -16°C (+5°F), rubber components such as gaskets and seals will harden, causing premature engine wear and damage.

• Contact your authorized Yanmar

Marine engine dealer or distributor if the engine will be operated outside of this standard temperature range.

NEVER engage the starter motor while the engine is running. Damage to the starter motor pinion and / or ring gear will result.

INTRODUCTION

This section of the Operation Manual describes the procedures for starting the engine, checking engine performance during operation and shutting down the engine.

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STARTING THE ENGINE

Figure 1

NOTICE: If the vessel is equipped with a water lift (water lock) muffler, excessive cranking could cause seawater to enter the cylinders and damage the engine. If the engine does not start after cranking for 10 seconds, close the seacock to avoid filling the muffler with water. Crank for 10 seconds or until the engine starts. When the engine does start, stop the engine immediately and turn the switch to the OFF position.

1. Open the seacock (if equipped).

2. Open the fuel cock.

3. Put the remote control handle in

NEUTRAL.

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

NEUTRAL.

(1)

(2)

(3)

(4)

0003622

1 – GLOW

2 – OFF

3 – ON

4 – START

Figure 1

4. Turn the battery master switch (if equipped) to ON.

5. Turn key switch to ON (Figure 1, (3)) .

Ensure that the instrument panel indicators light and the alarm sounds.

This indicates that indicators and alarm are working correctly.

ENGINE OPERATION

Note: The coolant high temperature alarm indicator and water in sail drive seal indicator should not come on during start-up.

6. Turn key switch to START

(Figure 1, (4)) . Release the key switch when the engine has started. NOTICE:

NEVER hold the key in the START position for longer than 15 seconds or the starter motor will overheat.

7. The alarm should stop and the indicators should go out. NOTICE: If any indicator fails to illuminate when the key switch is in the ON position, see your authorized Yanmar Marine dealer or distributor for service before operating the engine.

Note: When the engine has not been used for a long period of time, check that the key moves smoothly from the START position to the ON position.

Restarting After Starting Failure

Before turning the key switch again, be sure the engine has stopped completely.

NEVER attempt to restart the engine while the engine is running. The pinion gear on the starter motor will be damaged.

NOTICE: NEVER hold the key in the

START position for longer than 15 seconds or the starter motor will overheat.

NOTICE: NEVER attempt to restart the engine if the engine has not stopped completely. Pinion gear and starter motor damage will occur.

Air Bleeding the Fuel System After

Starting Failure

If the engine does not start after several attempts, there may be air in the fuel system. If air is in the fuel system, fuel cannot reach the fuel injection pump.

Bleed the air out of the system. See

Bleeding the Fuel System on page 26.

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ENGINE OPERATION

Starting at Low Temperatures

Comply with local environmental requirements. Use engine heaters to avoid starting problems and white smoke.

NOTICE: NEVER use an engine starting aid such as ether. Engine damage will result. Using a starting aid may void the warranty.

To limit white smoke, run the engine at low speed and under moderate load until the engine reaches normal operating temperature. A light load on a cold engine provides better combustion and faster engine warm-up than no load.

Avoid running the engine at idling speed any longer than necessary.

Starting with Air Heater (If

Equipped)

1. Open the seacock (if equipped).

2. Open the fuel tank cock.

3. Put remote control handle in

NEUTRAL.

4. Turn the battery master switch (if equipped) to ON.

5. Turn key switch to GLOW for 15 seconds.

6. Turn key switch to ON. Ensure that the instrument panel indicators light and the alarm sounds. This shows that indicators and alarm are working correctly.

Note: The coolant high temperature alarm indicator and water in sail drive seal indicator should not come on during start-up.

7. Turn key switch to START. Release the key switch when the engine has started. The alarm should stop and the indicators should go out. NOTICE:

NEVER hold the key in the START position for longer than 15 seconds or the starter motor will overheat.

After the Engine has Started

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

1. Check that the gauges, indicators and alarm are normal.

2. Check for any water, fuel, engine coolant or engine oil leaks. If any leaks are found, shut down the engine and perform the necessary repairs.

WARNING! Piercing Hazard. NEVER check for a fuel leak with your hands.

ALWAYS use a piece of wood or cardboard. Have your authorized

Yanmar Marine dealer or distributor repair the damage. Avoid skin contact with the high-pressure diesel fuel spray caused by a fuel system leak such as a broken fuel injection line.

High-pressure fuel can penetrate your skin and result in serious injury.

If you are exposed to high-pressure fuel spray, obtain prompt medical treatment.

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

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

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Check that water is being discharged from the seawater outlet pipe. Operation with inadequate seawater discharge will damage the impeller of the seawater pump. If seawater discharge is too low, stop the engine immediately. Identify the cause and repair. NOTICE: The engine will seize if it is operated when cooling seawater discharge is inadequate or if load is applied without any warm-up operation.

When operating the engine at low speed for long periods of time, race the engine once every 2 hours. Race the engine with the clutch in NEUTRAL, accelerate from the low-speed position to the high-speed position and repeat this process about five times. This cleans out carbon from the cylinders and the fuel injection valves.

NOTICE: Neglecting to race the engine will result in poor exhaust color and reduce engine performance.

Periodically operate the engine near maximum speed while underway. This will generate higher exhaust temperatures, which will help clean out hard carbon deposits, maintain engine performance and prolong the life of the engine.

For troubleshooting assistance, see

Troubleshooting After Starting on page 69 or see Troubleshooting Chart on page 71.

If necessary, see your authorized Yanmar

Marine dealer or distributor.

ENGINE OPERATION

REMOTE CONTROL

HANDLE OPERATION

Figure 2

Acceleration and Deceleration

(2)

(3)

(1)

(4)

0004513

Figure 2

1 – FORWARD or REVERSE

2 – NEUTRAL

3 – REVERSE or FORWARD

4 – Throttle Handle / Clutch Handle

Note: Direction of travel will vary depending on installation location.

Use the throttle handle (Figure 2, (4)) to control acceleration and deceleration.

Move the handle slowly.

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ENGINE OPERATION

Shifting the Engine

WARNING! Sudden Movement Hazard.

The boat will start to move when the marine gear is engaged:

• Ensure the boat is clear of all obstacles forward and aft.

• Quickly shift to the FORWARD position then back to the

NEUTRAL position.

• Observe whether the boat moves in the direction you expect.

NOTICE: Shifting the marine gear while operating at high speed or not pushing the handle fully into position (partial engagement) will result in damage to marine gear parts and abnormal wear.

• Before using the marine gear, be sure to move the throttle handle to a low idle position (less than 1000 rpm). Move the throttle handle slowly to a higher speed position after completing clutch engagement.

NOTICE: NEVER shift the marine gear at high engine speed. During normal operation, the marine gear should only

be shifted with the engine at idle. When moving the handle between FORWARD

(Figure 2, (1 or 3)) and REVERSE

(Figure 2, (1 or 3)) , bring the clutch to

NEUTRAL (Figure 2, (2)) and pause before slowly shifting to the desired position. Do not shift abruptly from

FORWARD to REVERSE or vice versa.

NOTICE: When sailing, set the remote control lever in NEUTRAL. Not doing so

WILL introduce slippage or any damage and void your warranty.

SHUTTING DOWN THE

ENGINE

NOTICE: NEVER stop engine abruptly during operation. Yanmar recommends that when shutting the engine down, allow the engine to run, without load, for 5 minutes. This will allow the engine components that operate at high temperatures, such as the exhaust system, to cool slightly before the engine is shut down.

1. Reduce engine speed to low idle and put remote control handle in

NEUTRAL.

2. Accelerate from low speed to high speed and repeat five times. This will clean out the carbon from the cylinders and the fuel injection nozzles.

3. Allow engine to run at low speed

(approximately 1000 rpm) without load for 5 minutes. NOTICE: Continue to hold the STOP button in until the engine is completely stopped. If the button is released before the engine has completely stopped, it may restart.

If the engine does not shut down, see

Emergency Shutdown on page 41 .

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4. With the key in the ON position, push and hold the STOP button

(Figure 3, (1)) . After the engine has stopped, turn the key switch to OFF.

Note: Continue to hold the STOP button in until the engine is completely stopped. If the button is released before the engine has completely stopped, it may restart. If the engine does not shut down, see Emergency

Shutdown on page 41 .

(1)

ENGINE OPERATION

Figure 4

Emergency Shutdown

NOTICE: NEVER use the emergency stop switch for a normal engine shutdown. Use this switch only when stopping the engine suddenly in an emergency.

If the engine cannot be shut down by the

STOP button on the panel, stop the engine by pushing the STOP button

(Figure 4, (1)) at the back of the stop solenoid (Figure 4, (2)) .

0004487

1 – STOP Button

Figure 3

5. Remove the key and cover the key switch with the moisture cap.

6. Turn off the battery master switch (if equipped).

7. Close the fuel cock.

8. Close the seacock (if equipped).

NOTICE: ALWAYS close the seacock.

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

(1)

(2)

Figure 4

1 – STOP Button

2 – Stop Solenoid

0004787

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ENGINE OPERATION

CHECKING THE ENGINE

AFTER OPERATION

• Check that the key switch is in the OFF position and that the battery master switch (if equipped) is turned to OFF.

• Fill the fuel tank. See Filling the Fuel

Tank on page 25.

• Close seacock(s).

• If there is a risk of freezing, check that the cooling system contains enough coolant. See Engine Coolant

Specifications on page 31.

• If there is a risk of freezing

(temperatures below 0°C [32°F]), drain the seawater system (see Draining the

Cooling System on page 76) and connect the engine heater (if equipped).

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PERIODIC

MAINTENANCE

SAFETY PRECAUTIONS

Before performing any maintenance procedures within this section, read the following safety information and review the

Safety section on page 3.

Explosion Hazard

ALWAYS turn off the battery switch (if equipped) or disconnect the negative (-) battery cable before servicing the equipment.

Crush Hazard

If the engine needs to be transported for repair, have a helper assist you in attaching it to a hoist and loading it on a truck.

Entanglement Hazard

NEVER leave the key in the key switch when you are servicing the engine.

Someone may accidentally start the engine and not realize you are servicing it.

Stop the engine before you begin to service it.

The engine lifting eyes are engineered to lift the weight of the marine engine only. ALWAYS use the engine lifting eyes when lifting the engine.

Additional equipment is necessary to lift the marine engine and marine gear together. ALWAYS use lifting equipment with sufficient capacity to lift the marine engine.

Piercing Hazard

Avoid skin contact with high-pressure diesel fuel spray caused by a fuel system leak such as a broken fuel injection line.

High-pressure fuel can penetrate your skin and result in serious injury. If you are exposed to high-pressure fuel spray, obtain prompt medical treatment.

NEVER check for a fuel leak with your hands. ALWAYS use a piece of wood or cardboard. Have your authorized

Yanmar Marine dealer or distributor repair the damage.

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PERIODIC MAINTENANCE

Tool Hazard

ALWAYS remove any tools or shop rags used during maintenance from the area before operation.

Shock Hazard

ALWAYS turn off the battery switch (if equipped) or disconnect the negative battery cable before servicing the equipment.

ALWAYS keep the electrical connectors and terminals clean. Check the electrical harnesses for cracks, abrasions, and damaged or corroded connectors.

Welding Hazard

Make welding repairs safely.

• ALWAYS turn off the battery switch

(if equipped) or disconnect the negative battery cable and the leads to the alternator when welding on the equipment.

• Remove the multi-pin connector to the engine control unit. Connect the weld clamp to the component to be welded and as close as possible to the welding point.

• NEVER connect the weld clamp to the engine or in a manner which would allow current to pass through a mounting bracket.

• When welding is completed, reconnect the leads to the alternator and engine control unit prior to reconnecting the batteries.

Any part which is found defective as a result of inspection, or any part whose measured value does not satisfy the standard or limit, must be replaced.

Modifications may impair the engine’s safety and performance characteristics and shorten the engine’s life. Any alterations to this engine may void its warranty. Always use Yanmar genuine replacement parts.

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INTRODUCTION

This section of the Operation Manual describes the procedures for proper care and maintenance of the engine.

PERIODIC MAINTENANCE

PRECAUTIONS

The Importance of Periodic

Maintenance

Engine deterioration and wear occur in proportion to the length of time the engine has been in service and the conditions the engine is subjected to during operation.

Periodic maintenance prevents unexpected downtime, reduces the number of accidents due to poor engine performance and helps extend the life of the engine.

Performing Periodic

Maintenance

WARNING! Exhaust Hazard. NEVER block windows, vents, or other means of ventilation if the engine is operating in an enclosed area. All internal combustion engines create carbon monoxide gas during operation.

Accumulation of this gas within an enclosure could cause illness or even death. Make sure that all connections are tightened to specifications after repair is made to the exhaust system.

Failure to comply could result in death or serious injury.

The Importance of Daily Checks

The Periodic Maintenance Schedule assumes that the daily checks are performed on a regular basis. Make a habit of performing daily checks before the start of each operating day. See Daily Checks

on page 55.

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PERIODIC MAINTENANCE

Keep a Log of Engine Hours and

Daily Checks

Keep a log of the number of hours the engine is operated each day and a log of the daily checks performed. Also note the date, type of repair (e.g., replaced alternator) and parts used for any service needed between the periodic maintenance intervals. Periodic maintenance intervals are every 50, 100, 150, 250 and 1000 engine hours. NOTICE: Failure to perform periodic maintenance will shorten the life of the engine and may void the warranty.

Yanmar Replacement Parts

Yanmar recommends that using genuine

Yanmar parts when replacement parts are needed. Genuine replacement parts help ensure long engine life.

Tools Required

Before starting any periodic maintenance procedure, make sure you have the tools needed to perform all of the required tasks.

Ask Your Authorized Yanmar

Marine Dealer or Distributor for

Help

Our professional service technicians have the expertise and skills to help with any maintenance or service related procedures.

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Tightening Fasteners

Use the correct amount of torque when you tighten fasteners on the engine. Applying excessive torque may damage the fastener or component and not enough torque may cause a leak or component failure.

NOTICE: The tightening torque in the Standard Torque Chart should be applied only to the bolts with a “7” head (JIS strength classification: 7T). Apply

60% torque to bolts that are not listed. Apply 80% torque when tightened to aluminum alloy.

Standard Torque Chart

Bolt Diameter x

Pitch (mm)

Tightening

Torque

N · m kgf·m lb-ft

M6x1.0

M8x1.25

11.0 ± 1.0

26.0 ± 3.0

1.1 ± 0.1

2.7 ± 0.3

8.0 ± 0.7

19.0 ± 2.1

M10x1.5

50.0 ± 5.0

5.1 ± 0.5

37 ± 3.6

M12x1.75

M14x1.5

M16x1.5

90.0 ± 10.0

140.0 ± 10.0

230.0 ± 10.0

9.2 ± 1.0

14.3 ± 1.0

23.5 ± 1.0

66.0 ± 7.2

103 ± 7.2

170 ± 7.2

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PERIODIC MAINTENANCE

EPA MAINTENANCE

REQUIREMENTS

To maintain optimum engine performance and compliance with the Environmental

Protection Agency (EPA) Regulations for

Engines, it is essential to follow the

Periodic Maintenance Schedule on page

50 and the Periodic Maintenance

Procedures on page 55.

EPA Requirements for USA and

Other Applicable Countries

The following are the requirements for the

EPA. Unless these requirements are met, the exhaust gas emissions will not be within the limits specified by the EPA.

The EPA emission regulation is applicable only in the USA and other countries that have adopted the EPA requirements in part or in whole. Determine and follow the emission regulations in the country where your engine will be operating to assist you in specified compliance.

Conditions to Ensure

Compliance with EPA Emission

Standards

The 2YM15, 3YM20 and 3YM30 are

EPA-certified engines.

The following are the conditions that must be met in order to ensure that the emissions during operation meet the EPA standards:

• Ambient temperature: -20° to +40°C

(-4° to +104°F)

• Relative humidity: 80% or lower

The diesel fuel should be:

• ASTM D975 No. 1-D or No. 2-D, or equivalent (minimum of cetane No. 45)

The lubricating oil should be:

• Type API, Class CD or higher

Perform the inspections as outlined in

Periodic Maintenance Procedures on page

55 and keep a record of the results.

Pay particular attention to these important points:

• Replacing the engine oil

• Replacing the engine oil filter

• Replacing the fuel filter

• Cleaning the intake silencer (air cleaner)

Note: Inspections are divided into two sections in accordance with who is responsible for performing the inspection: the user or the manufacturer.

Inspection and Maintenance

See Inspection and Maintenance of EPA

Emission-Related Parts on page 54 for the

EPA emission-related parts. Inspection and maintenance procedures not shown in the Inspection and Maintenance of EPA

Emission-Related Parts section are covered in Periodic Maintenance Schedule

on page 50.

This maintenance must be performed to keep the emission values of the engine within the standard values during the warranty period. The warranty period is determined by the age of the engine or the number of hours of operation.

Installing Sample Port

All engines subject to emission standards shall be equipped with a connection in the engine exhaust system that is located downstream of the engine, and before any point at which the exhaust contacts water

(or any other cooling / scrubbing medium), for the temporary attachment of gaseous and / or particulate emissions sampling equipment.

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This connection shall be internally threaded with standard pipe threads of a size not larger than 12.7 mm (0.5 in.), and shall be closed by a pipe plug when not in use. Equivalent connections are allowed.

The instructions for the proper installation and location of the required sample port, in addition to those specified above in the quoted federal regulation, are as follows:

1. The connection should be located as far downstream as reasonably practicable from any sharp bend (of 30° or more) in the exhaust pipe to help ensure that a well-mixed exhaust flow sample may be taken;

2. The requirement that the connection be located before any point at which the exhaust contacts water (or any other cooling/scrubbing medium) does not include contact with water used to cool exhaust manifolds, unless the water is allowed to come into direct contact with the exhaust gases;

3. To allow ready access to the sample port, the connection should be located, if possible given the constraints of vessel design, approximately 0.6 to 1.8 m (2 to 6 ft) above a deck or walkway;

4. To facilitate insertion and withdrawal of an exhaust sample probe, there should be no obstructions for at least one and one-half exhaust pipe/stack diameters perpendicular, i.e., 90°, from the sample port; and

5. If a threaded connection is used, both the internal and external threads should be coated with a high-temperature, anti-seize compound before the initial installation and at every subsequent re-installation to facilitate removal of the connection for testing.

PERIODIC MAINTENANCE

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PERIODIC MAINTENANCE

PERIODIC MAINTENANCE SCHEDULE

Daily and periodic maintenance is important to keep the engine in good operating condition. The following is a summary of maintenance items by periodic maintenance intervals. Periodic maintenance intervals vary depending on engine application, loads, diesel fuel and engine oil used and are hard to establish definitively. The following should be treated only as a general guideline. NOTICE: Establish a periodic maintenance plan according to the engine application and make sure to perform the required periodic maintenance at the intervals indicated. Failure to follow these guidelines will impair the engine’s safety and performance characteristics, shorten the engine’s life and may affect the warranty coverage on your engine. See your authorized Yanmar Marine dealer or distributor for assistance when checking items marked with a

.

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: Check or Clean : Replace

: Contact your authorized Yanmar Marine dealer or distributor

Periodic Maintenance Interval

System Item

Before

Starting

See Daily

Checks on page 38 .

Initial

50

Hours

Every

50 hours or monthly which- ever comes first

Every

100 hours or six months which- ever comes first

Every

150 hours or one year which- ever comes first

Every

250 hours or one year which- ever comes first

Every

1000 hours or 4 years which- ever comes first

Whole

Fuel

System

Visual inspection of engine exterior

Check the fuel level and refill if necessary

Drain water and sediment from the fuel tank

Lubricating

System

Drain the fuel / water separator

Replace the fuel filter element

Check the fuel injection timing

Check the fuel injector spray pattern*

Engine Check the engine oil level

Marine

Gear

Replace the engine oil

Engine

Marine

Gear

Sail

Drive

Engine Replace the oil filter element

*

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PERIODIC MAINTENANCE

: Check or Clean : Replace

: Contact your authorized Yanmar Marine dealer or distributor

Periodic Maintenance Interval

System Item

Before

Starting

See Daily

Checks on page 38 .

Initial

50

Hours

Every

50 hours or monthly which- ever comes first

Every

100 hours or six months which- ever comes first

Every

150 hours or one year which- ever comes first

Every

250 hours or one year which- ever comes first

Every

1000 hours or 4 years which- ever comes first

Cooling

System

Seawater outlet

During

Operation

Check coolant level

Check or replace the seawater pump impeller

Replace coolant Every year. When Long Life Coolant (LLC) is used, replace every two years. See Engine Coolant Specifications on page 33.

Air Intake and

Exhaust

System

Clean and check the seawater passages

Clean the intake silencer (air cleaner) element

Clean or replace the exhaust / water mixing elbow

Clean the breather pipe

Check the exhaust gas condition During

Operation

Electrical

System

Check diaphragm assembly

Check the alarm and indicators

Check the electrolyte level in the battery

Adjust the tension of the alternator V-belt or replace V-belt

Check the wiring connectors

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: Check or Clean : Replace

: Contact your authorized Yanmar Marine dealer or distributor

Periodic Maintenance Interval

System Item

Before

Starting

See Daily

Checks on page 38 .

Initial

50

Hours

Every

50 hours or monthly which- ever comes first

Every

100 hours or six months which- ever comes first

Every

150 hours or one year which- ever comes first

Every

250 hours or one year which- ever comes first

Every

1000 hours or 4 years which- ever comes first

After

Starting

Engine

Cylinder

Head and

Block

Check for leakage of fuel, engine oil and engine coolant

Tighten all major nuts and bolts

Adjust intake / exhaust valve clearance

Miscellane- ous Items

Check the remote control cables

Adjust the propeller shaft alignment

* For EPA requirements, see Inspection and Maintenance of EPA

Emission-Related Parts on page 54.

Note: These procedures are considered normal maintenance and are performed at the owner’s expense.

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PERIODIC MAINTENANCE

Inspection and Maintenance of EPA Emission-Related Parts

• Marine diesel engines less than 37 kW (50 hp) are certified as EPA non-road engine

• Marine diesel engines greater than 37 kW (50 hp) are certified as EPA CI marine engines

Inspection and Maintenance of EPA Emission-Related Parts for Non-Road and CI Marine Engines

Parts

Clean the fuel injection nozzle.

Check the fuel injection nozzle pressure and spray pattern.

Check the fuel injection pump adjustment.

Check turbocharger adjustment (if equipped).

Check the electronic engine control unit and its associated sensors and actuators (if equipped).

Interval

1500 hours

3000 hours

Note: The inspection and maintenance items shown above should be performed at your Yanmar Marine dealer or distributor.

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PERIODIC MAINTENANCE

PROCEDURES

WARNING! Exposure Hazard. ALWAYS wear personal protective equipment when performing periodic maintenance procedures.

Daily Checks

Before you start for the day, make sure the engine is in good operating condition.

NOTICE: It is important to perform the daily checks as listed in this Operation

Manual. Periodic maintenance prevents unexpected downtime, reduces the number of accidents due to poor engine performance and helps extend the life of the engine.

Make sure to check the following items:

Visual Checks

1. Check for engine oil leaks.

2. Check for fuel leaks.

WARNING! Piercing Hazard. Avoid skin contact with the high-pressure diesel fuel spray caused by a fuel system leak such as a broken fuel injection line. High-pressure fuel can penetrate your skin and result in serious injury. If you are exposed to high-pressure fuel spray, obtain prompt medical treatment. NEVER check for a fuel leak with your hands.

ALWAYS use a piece of wood or cardboard. Have your authorized

Yanmar Marine dealer or distributor repair any damage.

3. Check for engine coolant leaks.

4. Check for damaged or missing parts.

5. Check for loose, missing or damaged fasteners.

6. Check the electrical harnesses for cracks, abrasions, and damaged or corroded connectors.

7. Check hoses for cracks, abrasions and damaged, loose or corroded clamps.

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PERIODIC MAINTENANCE

8. Check the fuel filter / water separator for presence of water and contaminants. If any water or contaminants are found, drain the fuel filter / water separator. See Draining

Fuel Filter / Water Separator on

page 60. If you have to drain the fuel filter / water separator frequently, drain the fuel tank and check for water in your fuel supply. See Draining the Fuel

Tank on page 63.

NOTICE: If any problem is noted during the visual check, the necessary corrective action should be taken before operating the engine.

Checking Diesel Fuel, Engine Oil and Engine Coolant Levels

Follow the procedures in Filling the Fuel

Tank on page 25, Checking the Engine Oil

on page 28 and Checking and Adding

Coolant on page 31 to check these levels.

Checking and Refilling Marine Gear

Oil

See Checking Marine Gear Oil on

page 30.

Checking the Battery Electrolyte

Level

Check the battery electrolyte level before use. See Checking the Battery Electrolyte

Level (Serviceable Batteries Only) on

page 61.

Checking the Alternator Belt

Check the belt tension before use. See

Checking and Adjusting the Alternator

V-Belt Tension on page 58.

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PERIODIC MAINTENANCE

Checking the Remote Control

Handle

Check the operation of the remote control handle and ensure it moves smoothly. If it is hard to operate, grease the joints of the remote control cable and lever bearings. If the lever is too loose, adjust the remote control cable. See Checking and Adjusting

the Remote Control Cables on page 59.

Checking the Alarm Indicators

Check the instruments and alarm indicators at regular intervals.

Preparing Fuel, Oil and Coolant in

Reserve

Prepare sufficient diesel fuel for the day’s operation. Always store engine oil and coolant in reserve (for at least one refill) onboard, to be ready for emergencies.

After Initial 50 Hours of

Operation

Perform the following maintenance after the initial 50 hours of operation.

• Draining the Fuel Tank

• Changing the Engine Oil

• Replacing the Engine Oil Filter

Element

• Changing the Marine Gear Oil

• Checking and Adjusting the

Alternator V-Belt Tension

• Inspecting and Adjusting

Intake / Exhaust Valve Clearance

• Checking and Adjusting the Remote

Control Cables

• Adjusting Propeller Shaft Alignment

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Draining the Fuel Tank

WARNING! Fire and Explosion Hazard.

When you are draining the fuel tank to perform maintenance, put an approved container under the opening to catch the fuel. NEVER use a shop rag to catch the fuel. Vapors from the rag are flammable and explosive. Wipe up any spills immediately.

WARNING! Exposure Hazard. Wear eye protection. The fuel system is under pressure and fuel could spray out when you remove any fuel system component.

(3)

(1)

(2)

0004542

Figure 1

1 – Sediment Bowl

2 – Drain Cock

3 – Fuel Line to Engine

Note: Optional fuel tank shown. Actual equipment may be different.

1. Put a pan under the drain cock

(Figure 1, (2)) to catch fuel.

2. Open the drain cock and drain water and sediment. Close the drain cock when the fuel is clean and free of air bubbles.

PERIODIC MAINTENANCE

Changing the Engine Oil

The engine oil on a new engine becomes contaminated from the initial break-in of internal parts. It is very important that the initial oil replacement is performed as scheduled.

It is easiest and most effective to drain the engine oil after operation while the engine is still warm. WARNING! Burn Hazard. If the engine oil must be drained while it is still hot, stay clear of the hot engine oil to avoid being burned. ALWAYS wear eye protection.

1. Turn the engine off.

2. NOTICE: Prevent dirt and debris from contaminating engine oil. Carefully clean the dipstick and the surrounding

area before removing the dipstick.

Remove the engine oil dipstick. Attach the oil drain pump (if equipped) and pump out the oil. For easier draining, remove the engine oil fill cap.

3. Fill with new engine oil. See Adding

Engine Oil on page 29. NOTICE:

NEVER mix different types of engine oil. This may adversely affect the lubricating properties of the engine oil.

NEVER overfill. Overfilling may result in white exhaust smoke, engine overspeed or internal damage.

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

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

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PERIODIC MAINTENANCE

Replacing the Engine Oil Filter

Element

Figure 2

1. Turn the engine off.

2. Turn the engine oil filter Figure 2 counterclockwise with a wrench.

3. Remove the engine oil filter.

Checking and Adjusting the

Alternator V-Belt Tension

Figure 3

NOTICE: NEVER get any oil on the belt(s).

Oil on the belt causes slipping and stretching. Replace the belt if it is damaged.

WARNING! Sever Hazard. Perform this check with engine off and key removed to avoid contact with moving parts.

(1)

(3)

0004797

Figure 2

Note: 3YM20 shown.

4. Install a new filter element and hand-tighten until the seal touches the housing.

5. Turn filter an additional 3/4 turn using a box wrench. Tighten to 20 to 24 N · m

(177 to 212 lb-in.).

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

(2)

Changing the Marine Gear Oil

Note: Refer to the Marine Gear

Operation Manual for procedure.

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

1. Remove cap from the filler port and attach an oil drain pump. Drain marine gear oil.

2. Fill marine gear with clean marine gear oil. See Marine Gear Oil Specifications

on page 29.

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

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

58

0004800

Figure 3

1 – Middle of V-Belt

2 – Alternator Bolt

3 – V-Pulley (coolant pump)

Note: 3YM20 shown.

1. Remove the belt cover.

2. Check the belt by pushing on the middle of the belt (Figure 3, (1)) with your finger.

With proper tension, the belt should deflect 8 to 10 mm (approximately

3/8 in.).

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3. Loosen the alternator bolt

(Figure 3, (2)) and move the alternator to adjust the V-belt tension.

4. Install the belt cover.

Note: If replacing the V-belt, loosen the V-pulley (Figure 3, (3)) of the coolant pump to remove the V-belt.

Inspecting and Adjusting

Intake / Exhaust Valve Clearance

Proper adjustment is necessary to maintain the correct timing for opening and closing the valves. Improper adjustment will cause the engine to run noisily, resulting in poor engine performance and engine damage. See your authorized

Yanmar Marine dealer or distributor to adjust the intake / exhaust valve clearance.

Checking and Adjusting the Remote

Control Cables

NOTICE: Never adjust the high-speed stop bolt (Figure 4, (4)) on the governor. This will void the engine warranty.

The various control levers on the engine side are connected to the remote control lever by remote control cables. The cables will become stretched and the attachments loose after long hours of operation. It is dangerous to control operation under these conditions, and the remote control cables must be checked and adjusted periodically.

PERIODIC MAINTENANCE

Figure 4

Adjusting the Throttle Remote Control

Cable

(6)

(1)

(3)

(4)

(2)

(5)

0004798

Figure 4

1 – Cable

2 – Fuel Injection Pump

3 – Adjustment

4 – High-Speed Stop Bolt

5 – Low-Speed Stop Bolt

6 – Control Lever

1. Check that the control lever on the engine side moves to the high-speed stop position and low-speed stop position when the remote control lever is moved to H (high speed) and L (low speed) respectively.

2. When there is deviation, loosen the bracket for the remote control cable on the engine side and adjust.

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

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PERIODIC MAINTENANCE

Figure 5

Adjusting Clutch Remote Control Cable

(4)

(2)

(1)

(3)

0004799

Figure 5

1 – Marine Gear

2 – Control Cable

3 – Control Lever

4 – Bracket (cable)

1. Check that the control lever

(Figure 5, (3)) moves to the correct position when the remote control cable handle is moved to the NEUTRAL,

FORWARD and REVERSE positions.

2. Use the NEUTRAL position as the standard for adjustment. When there is deviation, loosen the bracket

(Figure 5, (4)) for the remote control cable on the clutch side and adjust.

Adjusting Propeller Shaft Alignment

The flexible engine mounts are compressed slightly during initial engine operation and may cause misalignment between the engine and the propeller shaft.

After the first 50 hours of operation, the alignment should be checked and readjusted if necessary. This is considered normal maintenance and the adjustment requires specialized knowledge and techniques. Consult your authorized

Yanmar Marine dealer or distributor.

Every 50 Hours of Operation

When completing the initial 50 hour maintenance procedures, perform the following procedures every 50 hours thereafter or monthly, whichever comes first.

• Draining Fuel Filter / Water Separator

• Checking the Battery Electrolyte

Level

Draining Fuel Filter / Water

Separator

WARNING! Fire and Explosion Hazard.

When removing any fuel system component to perform maintenance

(such as changing the fuel filter), put an approved container under the opening to catch the fuel. NEVER use a shop rag to catch the fuel. Vapors from the rag are flammable and explosive. Wipe up any spills immediately.

WARNING! Exposure Hazard. Wear eye protection. The fuel system is under pressure and fuel could spray out when removing any fuel system component.

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Figure 6

(1)

(2)

(3)

(4)

(5)

(6)

0004801

Figure 6

1 – Air Bleed Screw

2 – Bracket

3 – O-Ring

4 – Fuel Filter Element

5 – Fuel Filter Housing

6 – Retaining Ring

1. Close the fuel cock of the fuel tank.

2. Put a pan under the fuel / water separator.

3. Loosen the retaining ring

(Figure 6, (6)) , remove the filter housing (Figure 6, (5)) and drain off any water or sediment collected inside.

4. After draining, tighten the air bleed screw (Figure 6, (1)) .

5. Be sure to bleed air from the fuel system. See Bleeding the Fuel System

on page 26.

PERIODIC MAINTENANCE

Checking the Battery Electrolyte

Level (Serviceable Batteries Only)

NEVER operate with insufficient battery electrolyte. Operating with insufficient electrolyte will destroy the battery.

WARNING! Exposure Hazard. Batteries contain sulfuric acid. NEVER allow battery fluid to come in contact with clothing, skin or eyes. Severe burns could result. ALWAYS wear safety goggles and protective clothing when servicing the battery. If battery fluid contacts the eyes and / or skin, immediately flush the affected area with a large amount of clean water and obtain prompt medical treatment.

NOTICE: NEVER turn off the battery switch (if equipped) or short the battery cables during operation. Damage to the electrical system will result.

NOTICE: Battery fluid tends to evaporate in high temperatures, especially in summer. In such conditions, inspect the battery earlier than specified.

1. Make sure the engine is off and the key is removed.

2. Turn the battery master switch to OFF

(if equipped) or disconnect the negative

(-) battery cable.

3. Remove the plugs and check the electrolyte level in all cells. NOTICE:

NEVER attempt to remove the covers or fill a maintenance-free battery.

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PERIODIC MAINTENANCE

Figure 7

4. If the electrolyte level is lower than the minimum fill level (Figure 7, (1)) , fill with distilled water (Figure 7, (2))

(available locally) up to the upper limit

(Figure 7, (3)) of the battery.

(2)

Every 100 Hours of Operation

Perform the following maintenance every

100 hours or every 6 months of operation, whichever comes first.

• Changing the Sail Drive Gear Oil

Changing the Sail Drive Gear Oil

Refer to the Sail Drive Operation Manual for the procedure for changing gear oil.

UPPER LE

VEL

LOWER LE

VEL

(3)

(1)

Figure 7

1 – Lower Level

2 – Distilled Water

3 – Upper Level

Note: The maximum fill level is approximately 10 to 15 mm

(3/8 to 9/16 in.) above the plates.

0004566

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Every 150 Hours of Operation

Perform the following maintenance every

150 hours or every year of operation, whichever comes first.

• Changing the Engine Oil

Changing the Engine Oil

See Changing the Engine Oil on page 57.

PERIODIC MAINTENANCE

Every 250 Hours of Operation

Perform the following maintenance every

250 hours or 1 year of operation, whichever comes first.

• Draining the Fuel Tank

• Replacing the Fuel Filter Element

• Replacing the Engine Oil Filter

Element

• Changing the Marine Gear Oil

• Checking or Replacing the Seawater

Pump Impeller

• Replacing the Coolant

• Cleaning the Intake Silencer (Air

Cleaner) Element

• Cleaning or Replacing the

Exhaust / Water Mixing Elbow

• Adjusting the Alternator V-Belt

Tension

• Cleaning the Breather Pipe

• Checking the Wiring Connectors

Draining the Fuel Tank

See Draining the Fuel Tank on page 57.

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PERIODIC MAINTENANCE

Figure 8

Replacing the Fuel Filter Element

WARNING! Fire and Explosion Hazard.

When removing any fuel system component to perform maintenance

(such as changing the fuel filter), put an approved container under the opening to catch the fuel. NEVER use a shop rag to catch the fuel. Vapors from the rag are flammable and explosive. Wipe up any spills immediately.

WARNING! Exposure Hazard. Wear eye protection. The fuel system is under pressure and fuel could spray out when removing any fuel system component.

(2)

(1)

0004804

Figure 8

1 – Housing

2 – Retaining Ring

When there is dirt in the fuel, the filter becomes clogged and the fuel will not flow easily. Check and replace the element.

1. Close the fuel cock of the fuel tank.

2. Place an approved container under the fuel filter.

3. Remove the filter case by loosening the retaining ring (Figure 8, (2)) . Turn the ring counterclockwise using a filter wrench.

4. Remove the housing (Figure 8, (1)) and remove the element. Replace the element with a new one.

5. Apply a thin film of clean diesel fuel to the sealing surface of the new filter gasket.

6. Clean the inside of the housing thoroughly, install the O-ring and hand-tighten the retainer ring. Use a filter wrench and tighten to 12 N·m

(106 in.-lb).

7. Air will enter the fuel system when the filter is disassembled. Bleed the fuel system to remove any air from the system. See Bleeding the Fuel System

on page 26.

8. Dispose of waste properly.

Replacing the Engine Oil Filter

Element

See Replacing the Engine Oil Filter

Element on page 58.

Changing the Marine Gear Oil

See Changing the Marine Gear Oil on

page 58.

Checking or Replacing the Seawater

Pump Impeller

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

2. Inspect the inside of the seawater pump with a flashlight. If any of the following are found, service the seawater pump:

• Impeller blades are cracked or nicked.

Edges or surfaces of the blades are marred or scratched.

• Wear plate is damaged.

3. If no damage is found when inspecting the inside of the pump, install the

O-ring and side cover.

4. If a large amount of water leaks continuously from the water drain line below the seawater pump during operation, replace the mechanical seal.

See your authorized Yanmar Marine dealer or distributor.

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

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The seawater pump turns in the direction as shown in Figure 9 . The impeller must be installed while considering the impeller direction.

Figure 9

4) (3)

(1)

(2)

0004806

Figure 9

1 – Impeller Vane Direction

2 – Impeller Rotating Direction

3 – Impeller

4 – Seawater Pump

PERIODIC MAINTENANCE

Replacing the Coolant

CAUTION! Coolant Hazard. Wear eye protection and rubber gloves when you handle engine coolant. If contact with the eyes or skin should occur, flush eyes and wash immediately with clean water.

Replace coolant every year.

Note: If Long Life Coolant (LLC) is used, replace coolant every 2 years.

Note: The drain cocks are opened before shipping from the factory. Close all drain cocks before filling the system with coolant.

1. Put a pan under the coolant drain cocks.

2. Open all coolant drain cocks.

3. Allow to drain completely. Dispose of waste properly.

4. Close all the drain cocks.

5. Fill coolant tank and coolant recovery tank with appropriate coolant. See

Engine Oil Specifications on page 27 and see Checking and Adding Coolant

on page 31.

Cleaning the Intake Silencer (Air

Cleaner) Element

Figure 10

1. Disassemble the intake silencer (air cleaner).

2. Remove element (Figure 10, (1)) .

Clean element and housing with a neutral detergent.

3. Dry completely and reassemble.

(1)

YM Series Operation Manual

© 2009 Yanmar Marine International

Figure 10

0004805

65

PERIODIC MAINTENANCE

Cleaning or Replacing the

Exhaust / Water Mixing Elbow

There are two types of mixing elbows, the

L-type and the U-type. The mixing elbow is attached to the exhaust manifold. The exhaust gas is mixed with seawater in the mixing elbow.

1. Remove the mixing elbow.

2. Clean dirt and scale out of the exhaust and seawater passages.

3. If the mixing elbow is damaged, repair or replace it. See your authorized

Yanmar Marine dealer or distributor.

4. Inspect the gasket and replace if necessary.

Replace the mixing elbow with a new one every 500 hours or 2 years, whichever comes first, even if no damage is found.

See your authorized Yanmar Marine dealer or distributor.

Adjusting the Alternator V-Belt

Tension

See Checking and Adjusting the Alternator

V-Belt Tension on page 58.

Cleaning the Breather Pipe

See your authorized Yanmar Marine dealer or distributor.

Checking the Wiring Connectors

See your authorized Yanmar Marine dealer or distributor.

Every 1000 Hours of Operation

Perform the following maintenance every

1000 hours or 4 years of operation, whichever comes first.

• Checking the Fuel Injection Timing

• Checking the Fuel Injector Spray

Pattern

• Replacing the Seawater Pump

Impeller

• Cleaning and Checking the Seawater

Passages

• Checking the Diaphragm Assembly

• Replacing the Alternator V-Belt

• Adjusting Intake / Exhaust Valve

Clearance

• Checking and Adjusting the Remote

Control Cables

• Adjusting the Propeller Shaft

Alignment

• Tightening All Major Nuts and Bolts

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PERIODIC MAINTENANCE

12/05

Checking the Fuel Injection Timing

See your authorized Yanmar Marine dealer or distributor.

Checking the Diaphragm Assembly

Inspect the diaphragm assembly on the rocker arm cover.

Checking the Fuel Injector Spray

Pattern

See Checking or Replacing the Seawater

Pump Impeller on page 64.

1. Loosen screws and remove diaphragm assembly.

See your authorized Yanmar Marine dealer or distributor.

2. Check for oil and contaminants between the diaphragm and cover.

NOTICE: If oil and contaminants enter the diaphragm assembly, the diaphragm will not operate properly.

Replacing the Seawater Pump

Impeller

The seawater impeller must be replaced every 1000 hours or every 4 years even if it is not damaged.

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

Figure 11 Breather System Components

(5)

Cleaning and Checking the

Seawater Passages

(1)

(2)

(3)

(4)

After prolonged use, clean the seawater passages to remove dirt, scale, rust and other contaminants that collect in the coolant passages. This can cause poor engine cooling. Inspect these items:

(6)

(7)

• Heat Exchanger

• Pressure Cap

(8)

Figure 11

0004807

See your authorized Yanmar Marine dealer or distributor.

1 – Diaphragm Cover

2 – Spring

3 – Center Plate

4 – Diaphragm

5 – Rocker Arm Cover

6 – Breather Baffle

7 – Baffle Plate

8 – Intake Silencer (air cleaner)

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PERIODIC MAINTENANCE

Replacing the Alternator V-Belt

1. Remove the V-belt cover.

2. Loosen the V-belt tension adjusting bolt of the alternator.

3. Remove the alternator V-belt.

4. Install a new alternator V-belt.

5. Adjust the alternator V-belt tension.

See Checking and Adjusting the

Alternator V-Belt Tension on page 58.

6. Replace the V-belt cover.

Adjusting Intake / Exhaust Valve

Clearance

See your authorized Yanmar Marine dealer or distributor.

Checking and Adjusting the Remote

Control Cables

See Checking and Adjusting the Remote

Control Cables on page 59.

Adjusting the Propeller Shaft

Alignment

See your authorized Yanmar Marine dealer or distributor.

Tightening All Major Nuts and Bolts

See Tightening Fasteners on page 47 or see your authorized Yanmar Marine dealer or distributor.

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YM Series Operation Manual

TROUBLESHOOTING

SAFETY PRECAUTIONS

Before performing any troubleshooting procedures within this section, review the

Safety section on page 3.

If a problem occurs, stop the engine immediately. Refer to the Symptom column in the Troubleshooting Chart to identify the problem.

TROUBLESHOOTING

AFTER STARTING

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

Is sufficient water being discharged from the seawater outlet pipe?

If the discharge is low, stop the engine immediately. Identify the cause and repair.

Is the exhaust color normal?

The continuous emission of black exhaust smoke indicates engine overloading. This shortens the engine’s life and should be avoided. When operating the engine at low speed for long periods of time, race the engine once every 2 hours. Racing the engine with the clutch in NEUTRAL, accelerate from the low-speed position to the high-speed position and repeat this process about five times. This is done to clean out carbon from the cylinders and the fuel injection valves. NOTICE:

Neglecting to race the engine will result in poor exhaust color and reduce engine performance.

Periodically operate the engine near maximum speed while underway. This will generate higher exhaust temperatures, which will help clean out hard carbon deposits, maintain engine performance and prolong the life of the engine.

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TROUBLESHOOTING

Are there abnormal vibrations or noise?

Depending on the hull structure, engine and hull resonance may suddenly increase at certain engine speed ranges, causing heavy vibrations. Avoid operation in this speed range. If any abnormal sounds are heard, stop the engine and inspect for cause.

Alarm sounds during operation.

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

Is there water, oil or fuel leakage? Are there any loose bolts or connections?

Check the engine room daily for any leaks or loose connections.

Is there sufficient fuel in the fuel tank?

Refill fuel in advance to avoid running out of fuel. If the tank runs out of fuel, bleed the fuel system. See Bleeding the Fuel

System on page 26.

Troubleshooting Information

If the engine does not operate properly, refer to the Troubleshooting Chart on page

71 or see your authorized Yanmar Marine dealer or distributor.

Supply your authorized Yanmar Marine dealer or distributor with the following information:

• Model name and serial number of your engine

• Boat model, hull material, size (tons)

• Use, type of boating, number of hours run

• Total number of operation hours (refer to hourmeter) and age of boat

• The operating conditions when the problem occurs:

• Engine rpm

• Color of exhaust smoke

• Type of diesel fuel

• Type of engine oil

• Any abnormal noises or vibration

• Operating environment such as high altitude or extreme ambient temperatures, etc.

• Engine maintenance history and previous problems

• Other factors that contribute to the problem

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TROUBLESHOOTING

12/05

TROUBLESHOOTING CHART

Symptom

Indicators light on the instrument panel and alarm sounds during operation

Engine oil low pressure alarm indicator lights

Probable Cause Measure Reference

Shift to low-speed operation immediately, and check which indicator has come on.

Stop the engine and inspect. If no abnormality is identified and there is no problem with operation, return to port at lowest speed and see your authorized Yanmar

Marine dealer or distributor.

Engine oil level is low.

Check engine oil level.

Add or replace as necessary.

See Checking the

Engine Oil on

page 28.

Engine oil filter is clogged. Replace engine oil filter.

Replace engine oil.

See Changing the

Engine Oil on

page 57.

Water in sail drive seal indicator lights

Coolant high temperature alarm lights

• Battery low charge indicator does not go out during operation

Rubber sail drive seal is broken. See your authorized

Yanmar Marine dealer or distributor.

Coolant in coolant tank / heat exchanger is low.

V-belt is loose or broken.

Check coolant level and refill.

See your authorized

Yanmar Marine dealer or distributor.

Replace V-belt or adjust tension.

-

See Checking and Adding

Coolant on

page 31.

Indicators Do Not Light:

When key is turned on

When any trouble occurs

(low oil pressure, etc.)

Insufficient seawater level causing temperature to rise.

Contamination inside cooling system.

No electrical current available.

Circuit broken or lamp burned out.

Check seawater system.

See your authorized

Yanmar Marine dealer or distributor.

See your authorized

Yanmar Marine dealer or distributor.

-

-

Faulty Warning Devices Do not operate the engine if alarm devices are not repaired. See you authorized

Yanmar Marine dealer or distributor. Serious accidents may result if abnormalities are not identified due to faulty indicators or alarm.

-

One of the indicators does not go out

Sensor switch is faulty.

-

Battery is defective.

Check battery fluid level, specific gravity or replace battery.

See Checking and Adjusting the

Alternator V-Belt

Tension on

page 58.

See Checking the

Battery

Electrolyte Level

(Serviceable

Batteries Only) on

page 61.

Alternator power generation failure.

See your authorized

Yanmar Marine dealer or distributor.

-

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TROUBLESHOOTING

Symptom

Starting Failures:

• Starter turns but engine does not start

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

• Engine cannot be turned manually

Probable Cause

No fuel.

Fuel filter is clogged.

Improper fuel.

Problem with fuel injection.

Compression leakage from intake / exhaust valve.

Faulty clutch position.

Insufficient battery charge.

Cable terminal contact failure.

Faulty safety switch device.

Faulty starter switch.

Power lacking due to accessory drive being engaged.

Internal parts seized.

Measure Reference

Add fuel. Bleed fuel system.

Replace filter element.

Replace with recommended fuel.

See your authorized

Yanmar Marine dealer or distributor.

See your authorized

Yanmar Marine dealer or distributor.

Shift to NEUTRAL and start.

Check fluid level.

Recharge or replace battery.

-

-

See Restarting

After Starting

Failure on

page 37.

See Checking the

Battery

Electrolyte Level

(Serviceable

Batteries Only) on

page 61.

Remove corrosion from terminals. Tighten battery cables.

See your authorized

Yanmar Marine dealer or distributor.

See your authorized

Yanmar Marine dealer or distributor.

See your authorized

Yanmar Marine dealer or distributor.

See your authorized

Yanmar Marine dealer or distributor.

See Filling the

Fuel Tank on

page 25 and see

Bleeding the Fuel

System on page

26.

See Replacing the Fuel Filter

Element on

page 64.

See Diesel Fuel

Specifications on

page 22.

-

-

-

-

-

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TROUBLESHOOTING

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Symptom Probable Cause Measure

Abnormal Exhaust Color:

• Black smoke Load increased.

Improper propeller matching.

See your authorized

Yanmar Marine dealer or distributor.

See your authorized

Yanmar Marine dealer or distributor.

Dirty intake silencer (air cleaner). Clean element.

• White smoke

Improper fuel.

Faulty spraying of fuel injector.

Incorrect intake / exhaust valve clearance.

Improper fuel.

Faulty spraying of fuel injector.

Reference

-

-

Replace with recommended fuel.

See Cleaning the

Intake Silencer

(Air Cleaner)

Element on

page 65.

See Diesel Fuel

Specifications on

page 22.

See your authorized

Yanmar Marine dealer or distributor.

See your authorized

Yanmar Marine dealer or distributor.

Replace with recommended fuel.

-

-

See Diesel Fuel

Specifications on

page 22.

See your authorized

Yanmar Marine dealer or distributor.

-

Excessive diesel fuel consumption.

Yanmar Marine dealer or distributor.

See your authorized

Yanmar Marine dealer or distributor.

-

-

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TROUBLESHOOTING

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YM Series Operation Manual

LONG-TERM STORAGE

SAFETY PRECAUTIONS

Before performing any storage procedures within this section, review the Safety section on page 3.

INTRODUCTION

If the engine will not be used for an extended period of time, special measures should be taken to protect the cooling system, fuel system and combustion chamber from corrosion and the exterior from rusting.

The engine can normally stand idle for up to 6 months. If it remains unused for longer than this, please contact your authorized

Yanmar Marine dealer or distributor.

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LONG-TERM STORAGE

PREPARE ENGINE FOR

LONG-TERM STORAGE

Note: If the engine is close to a periodic maintenance interval, perform those maintenance procedures before putting the engine into long-term storage.

1. Wipe off any dust or oil from the outside of engine.

2. Drain water from the fuel filters.

3. Drain the fuel tank completely or fill the tank to prevent condensation.

4. Drain the Cooling System (see Draining

the Cooling System on page 76).

5. Grease the exposed areas and joints of the remote control cables and the bearings of the remote control handle.

6. Seal the intake silencer, exhaust pipe, etc. to prevent moisture or contamination from entering engine.

7. Completely drain the bilge in hull bottom.

8. Waterproof the engine room to prevent rain or seawater from entering.

9. Charge the battery once a month to compensate for battery’s self-discharge.

10.Remove the key from key switch and cover the key switch with moisture cap.

Figure 1

DRAINING THE COOLING

SYSTEM

(2)

(1)

Figure 2

(3)

(4)

0004794

Figure 1

1 – Alternator

2 – Coolant Tank / Heat Exchanger

3 – Coolant Drain Cock

4 – Seawater Drain Cock

(4)

(1)

(5)

(2)

(3)

0004795

Figure 2

1 – Coolant Tank / Heat Exchanger

2 – Seawater Drain Cock

3 – Coolant Drain Cock

4 – Coolant Pump

5 – Seawater Pump

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Figure 3

(1)

(3)

(2)

0004793

Figure 3

1 – Stop Solenoid

2 – Coolant Drain Cock

3 – Flywheel Housing

Note: The drain cocks are opened before shipping from the factory. Close all drain cocks before filling the system with coolant.

NOTICE: If seawater is left inside, it may freeze and damage parts of the cooling system (heat exchanger, seawater pump, etc.) when ambient temperature is below

0°C (32°F).

1. Put a pan under the seawater drain cocks.

2. Open the seawater drain cocks on the pipe and on the heat exchanger. Allow to drain.

3. Remove the four bolts fastening the side cover of the seawater pump.

Remove the cover and drain the seawater.

4. Install the cover and tighten bolts.

5. Close all drain cocks.

LONG-TERM STORAGE

NOTICE: NEVER drain engine coolant in the cold season or before long storage. If

LLC (Long Life Coolant) has not been added to the cooling system, add LLC or drain the coolant from the coolant system after daily use. If the coolant without LLC is not removed, it may freeze and damage parts of the cooling system or engine when ambient temperature is below 0°C (32°F).

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LONG-TERM STORAGE

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YM Series Operation Manual

SPECIFICATIONS

PRINCIPAL ENGINE SPECIFICATIONS

2YM15 Engine Specifications

Specification

Marine Gear Model

Use

Type

Combustion System

Air Charging

Number of Cylinders

Bore x Stroke

Displacement

Continuous

Rated Output

Maximum

Rated Output

Output at

Crankshaft / Engine

Speed

Output at

Crankshaft / Engine

Speed

Output at

Propeller / Engine

Speed

Installation

Fuel Injection Timing

Fuel Injection Opening Pressure

Main Power Take Off

Direction of

Rotation

Crankshaft

Propeller Shaft

(Ahead)

Cooling System

Lubrication System

Coolant Capacity

2YM15

KM2P-1

Pleasure use

Vertical water cooled 4-cycle diesel engine

Swirl pre-combustion chamber

Natural aspiration

2

70 mm x 74 mm (2.76 in. x 2.92 in.)

0.570 L (35.0 cu in.)

SD-20

9.4 kW (12.8 hp metric) / 3489 rpm *

10.3 kW (14.0 hp metric) / 3600 rpm*

10.0 kW (13.6 hp metric) / 3600 rpm **

10.0 kW (13.6 hp metric) / 3600 rpm*

9.7 kW (13.2 hp metric) / 3600 rpm**

Flexible mounting

FID 21 ±1° BTDC

12.3 to 13.28 MPa (125 to 135 kgf/cm 2 )

At flywheel end

Counterclockwise viewed from stern

-

Clockwise viewed from stern -

Closed coolant system with heat exchanger

Complete enclosed forced lubrication system

Engine 3.0 L (3.17 qt), Coolant recovery tank: 0.8 L (0.95 qt)

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SPECIFICATIONS

Specification

Marine Gear Model

Lubricating

Oil Capacity

(Engine)

Rake Angle

Total ***

Starting

System

Effective ****

Type

Starting Motor

AC Alternator

Engine

Dimension

Overall Length

Overall Width

Overall Height

Engine Dry Mass (Including Marine

Gear)

KM2P-1

2YM15 at rake angle 8°

2.0 L (2.1 qt)

0.95 L (1.0 qt)

Electric

DC 12 V - 1.4 kW

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

613 mm (24.1 in.)

463 mm (18.2 in.)

528 mm (20.8 in.)

115 kg (253 lb)

* Rating Condition: Temperature of fuel; 25°C at fuel pump inlet; ISO 3046-1

** Rating Condition: Temperature of fuel; 40°C at fuel pump inlet; ISO 8665

SD-20 at rake angle 0°

1.8 L (1.9 qt)

0.9 L (0.95 qt)

-

134 kg (295 lb)

*** The “total” oil quantity includes oil in oil pan, channels, coolers and filter.

**** The effective amount of oil shows the difference in maximum scale of the dipstick and minimum scale.

Note: Density of fuel: 0.842 g/cm 3 at 15°C. Fuel temperature at the inlet of the fuel injection pump. 1hp metric = 0.7355 kW

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SPECIFICATIONS

12/05

3YM20 Engine Specifications

Specification

Marine Gear Model

Use

Type

Combustion System

Air Charging

Number of Cylinders

Bore x Stroke

Displacement

Continuous

Rated Output

Maximum

Rated Output

Output at

Crankshaft / Engine

Speed

Output at

Crankshaft / Engine

Speed

Output atPropeller / Engine

Speed

Installation

Fuel Injection Timing

Fuel Injection Opening Pressure

Main Power Take Off

Direction of

Rotation

Crankshaft

Propeller Shaft

(Ahead)

Cooling System

Lubrication System

Coolant Capacity

Lubricating

Oil Capacity

(Engine)

Rake Angle

Total ***

Effective ****

Starting

System

Type

Starting Motor

AC Alternator

3YM20

KM2P-1

Pleasure use

Vertical water cooled 4-cycle diesel engine

Swirl pre-combustion chamber

Natural aspiration

3

70 mm x 74 mm (2.76 in. x 2.92 in.)

0.854 L (52.0 cu in.)

SD-20

14.7 kW (20.0 hp metric) / 3489 rpm *

16.2 kW (22.0 hp metric) / 3600 rpm*

15.3 kW (20.8 hp metric) / 3600 rpm **

15.7 kW (21.3 hp metric) / 3600 rpm*

14.9 kW (20.2 hp metric) / 3600 rpm**

Flexible mounting

FID 22 ± 1° BTDC

12.3 to 13.28 MPa (125 to 135 kgf/cm 2 )

At flywheel end

Counterclockwise viewed from stern

-

Clockwise viewed from stern -

Closed coolant system with heat exchanger

Complete enclosed forced lubrication system

Engine 4.1 L (4.3 qt), Coolant recovery tank: 0.8 L (0.85 qt) at rake angle 8° at rake angle 0°

2.7 L (2.85 qt)

1.4 L (1.48 qt)

Electric

DC 12 V - 1.4 kW

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

2.4 L (2.54 qt)

1.5 L (1.59 qt)

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SPECIFICATIONS

Specification

Marine Gear Model

Engine

Dimension

Overall Length

Overall Width

Overall Height

Engine Dry Mass (Including Marine

Gear)

KM2P-1

3YM20

693 mm (27.3 in.)

463 mm (18.2 in.)

528 mm (20.8 in.)

130 kg (287 lb)

* Rating Condition: Temperature of fuel; 25°C at fuel pump inlet; ISO 3046-1

** Rating Condition: Temperature of fuel; 40°C at fuel pump inlet; ISO 8665

SD-20

-

151 kg (333 lb)

*** The “total” oil quantity includes oil in oil pan, channels, coolers and filter.

**** The effective amount of oil shows the difference in maximum scale of the dipstick and minimum scale.

Note: Density of fuel: 0.842 g/cm 3 at 15°C. Fuel temperature at the inlet of the fuel injection pump. 1hp metric = 0.7355 kW

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SPECIFICATIONS

12/05

3YM30 Engine Specifications

Specification

Marine Gear Model

Use

Type

Combustion System

Air Charging

Number of Cylinders

Bore x Stroke

Displacement

Continuous

Rated Output

Maximum

Rated Output

Output at

Crankshaft / Engine

Speed

Output at

Crankshaft / Engine

Speed

Output atPropeller / Engine

Speed

Installation

Fuel Injection Timing

Fuel Injection Opening Pressure

Main Power Take Off

Direction of

Rotation

Crankshaft

Propeller Shaft

(Ahead)

Cooling System

Lubrication System

Coolant Capacity

Lubricating

Oil Capacity

(Engine)

Rake Angle

Total ***

Effective ****

Starting

System

Type

Starting Motor

AC Alternator

3YM30

KM2P-1

Pleasure use

Vertical water cooled 4-cycle diesel engine

Swirl pre-combustion chamber

Natural aspiration

3

76 mm x 82 mm (2.99 in. x 3.23 in.)

1.115 L (68.04 cu in.)

SD-20

20.1 kW (30.0 hp metric) / 3600 rpm *

22.1 kW (30.0 hp metric) / 3600 rpm*

21.3 kW (29.0 hp metric) / 3600 rpm **

21.4 kW (29.1 hp metric) / 3600 rpm*

20.7 kW (28.1 hp metric) / 3600 rpm**

Flexible mounting

FID 16 ±1° BTDC

12.3 to 13.28 MPa (125 to 135 kgf/cm 2 )

At flywheel end

Counterclockwise viewed from stern

-

Clockwise viewed from stern -

Closed coolant system with heat exchanger

Complete enclosed forced lubrication system

Engine 4.9 L (5.2 qt), Coolant recovery tank: 0.8 L (0.85 qt) at rake angle 8° at rake angle 0°

2.8 L (2.96 qt)

1.4 L (1.48 qt)

Electric

DC 12 V - 1.4 kW

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

2.5 L (2.64 qt)

1.5 L (1.59 qt)

YM Series Operation Manual

© 2009 Yanmar Marine International

83

SPECIFICATIONS

Specification

Marine Gear Model

Engine

Dimension

Overall Length

Overall Width

Overall Height

Engine Dry Mass (Including Marine

Gear)

KM2P-1

3YM30

715 mm (28.1 in.)

463 mm (18.2 in.)

545 mm (21.5 in.)

133 kg (293 lb)

* Rating Condition: Temperature of fuel; 25°C at fuel pump inlet; ISO 3046-1

** Rating Condition: Temperature of fuel; 40°C at fuel pump inlet; ISO 8665

SD-20

-

154 kg (339 lb)

*** The “total” oil quantity includes oil in oil pan, channels, coolers and filter.

**** The effective amount of oil shows the difference in maximum scale of the dipstick and minimum scale.

Note: Density of fuel: 0.842 g/cm 3 at 15°C. Fuel temperature at the inlet of the fuel injection pump. 1hp metric = 0.7355 kW

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SPECIFICATIONS

12/05

Marine Gear and Sail Drive Specifications

Model

Type

Reduction Ratio (Forward /

Reverse)

Propeller Speed (Forward /

Reverse) *

Lubrication System

Lubricating Oil Capacity (Total)

KM2P-1(S)

2.21 / 3.06

1580 / 1140 rpm

KM2P-1(G)

2.62 / 3.06

1332 / 1140 rpm

Splash

0.3 L (0.32 qt)

KM2P-1(GG)

Mechanical cone clutch

3.22 / 3.06

SD20 (coupled at boat builder)

Dog Clutch

2.64 / 2.64

1083 / 1140 rpm 1322 rpm

Oil bath

2.2 L (2.3 qt)

Standard2.5 L (2.6 qt)

Long Reach

Lubricating Oil Capacity

(Effective)

Cooling System

0.05 L (0.05 qt) 0.15 L (0.16 qt)

Air cooling by fan on flywheel

Weight

* At continuous power engine speed 2907 rpm

10.3 kg (27.7 lb)

-

-

30 kg (66.1 lb)

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SPECIFICATIONS

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86 YM Series Operation Manual

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YM Series Operation Manual

SYSTEM DIAGRAMS

PIPING DIAGRAMS

Piping diagrams and wiring diagrams are provided for reference only. Contact your authorized Yanmar Marine dealer or distributor for the most current diagrams.

Notation Description

Screw Joint (Union)

Flange Joint

Eye Joint

Insertion Joint

Drilled Hole

Coolant Piping

Seawater Piping

Engine Oil Piping

Diesel Fuel Piping

Notes:

1. Steel pipe shows OD x wall thickness, rubber hose shows ID x wall thickness.

2. Rubber fuel lines meet EN/ISO7840.

3. Unit: mm

YM Series Operation Manual

© 2009 Yanmar Marine International

87

SYSTEM DIAGRAMS

Figure 1 2YM15 with KM2P-1 Marine Gear

(35)

(34)

D

(33)

(1)

(3)

(4)

(2)

(5) (6)

(7)

(8) (9)

C

P

(36)

(32)

(10)

(11)

(12)

(13)

(14)

(15)

(16)

(31)

(30)

P

P T

(38)

(37)

(29)

(28)

(27)

(26)

(25)

(24)

A

P

(23)

(22) (21) (20)

(17)

(19)

(18)

B

Figure 1

88 YM Series Operation Manual

© 2009 Yanmar Marine International

12/05

Unit: mm (in.)

Detail of part A Detail of part B

Ø17

(0.67)

X 0 0 0 3 5 6 2 0

Detail of part C

Ø9 (0.35)

Ø8 (0.31)

X 0 0 1 3 5 6 2 0

Detail of part D

Ø8.5 (0.33)

Ø8 (0.31)

X 0 0 2 3 5 6 2 0

X 0 0 3 3 5 6 2 0

SYSTEM DIAGRAMS

1 – 7.8 x t4.5 Rubber Hose

2 – Check Valve

3 – 7.8 x t4.5 Rubber Hose

4 – 7.8 x t4.5 Rubber Hose

5 – Overflow

6 – Fuel Inlet

7 – 7.8 x t4.5 Rubber Hose

8 – 5 x t4.5 Rubber Hose

9 – 7.8 x t4.5 Rubber Hose

10 – Fuel Feel Pump

11 – Fuel Injection Pump

12 – 4.76 x t0.7 Steel Pipe

13 – Engine Oil Filter (cartridge type)

14 – 4.76 x t0.7 Steel Pipe

15 – Fuel High-Pressure Pipe

16 – Fuel Injection Nozzle

17 – Oil Pressure Switch

18 – Mixing Elbow

19 – 17 x 14 Rubber Hose

20 – Heat Exchanger

21 – Engine Oil Inlet Filter

22 – Main Bearing

23 – Seawater Inlet

24 – 17 x t4 Rubber Hose

25 – Seawater Pump

26 – 28 x t4 Rubber Hose

27 – 28 x t4 Rubber Hose

28 – Hot Water Connection Outlet

(R3/8)

29 – Thermostat

30 – Coolant Pump

31 – Hot Water Connection Inlet

(R3/8)

32 – Coolant Temperature Switch

33 – Engine Oil Pump

34 – Pressure Control Valve

35 – Diesel Fuel

36 – To Oil Pan

37 – To Camshaft

38 – From Cylinder Head

YM Series Operation Manual

© 2009 Yanmar Marine International

89

SYSTEM DIAGRAMS

Figure 2 3YM20 and 3YM30 with KM2P-1 Marine Gear

(4)

(5)

(1) (2) (3)

C

(23)

(22)

(21)

(20)

D

P

(6)

(7)

(8)

(19)

(18)

P

P

T

(9)

(17)

(16)

P

B

(10)

(15)

A (14)

(11)

(12)

(13)

Figure 2

90 YM Series Operation Manual

© 2009 Yanmar Marine International

12/05

Unit: mm (in.)

Detail of part A Detail of part B

Ø17

(0.67)

X 0 0 0 3 5 6 2 0

Detail of part C

Ø9 (0.35)

Ø8 (0.31)

X 0 0 1 3 5 6 2 0

Detail of part D

Ø8.5 (0.33)

Ø8 (0.31)

X 0 0 2 3 5 6 2 0

X 0 0 3 3 5 6 2 0

SYSTEM DIAGRAMS

1 – PCV

2 – Overflow

3 – Fuel Inlet

4 – Fuel Feed Pump

5 – Fuel Injection Pump

6 – Engine Oil Filter (cartridge type)

7 – Fuel High-Pressure Pipe

8 – Fuel Injection Nozzle

9 – Oil Pressure Switch

10 – Mixing Elbow

11 – Heat Exchanger

12 – Engine Oil Inlet Filter

13 – Main Bearing

14 – Seawater Inlet

15 – Seawater Pump

16 – Hot Water Connection Outlet

17 – Thermostat

18 – Coolant Pump

19 – Hot Water Connection Inlet

20 – Coolant Temperature Switch

21 – Engine Oil Pump

22 – Pressure Control Valve

23 – Fuel Filter

24 – To Oil Pan

25 – To Camshaft

26 – From Cylinder Head

YM Series Operation Manual

© 2009 Yanmar Marine International

91

SYSTEM DIAGRAMS

This Page Intentionally Left Blank

92 YM Series Operation Manual

© 2009 Yanmar Marine International

RB

LB

YW

YG

R

B

W

L

WL

WG

GR

O

WBr

12/05

WIRING DIAGRAMS

Color Coding

Red

Black

White

Blue

Red / Black

Blue / Black

Yellow / White

Yellow / Green

White / Blue

White / Green

Green / Red

Orange

White / Brown

Allowable Length by Cross Sectional Area of

Battery Cable

Section of Cable mm 2 (in.

2 )

Allowable Length

L = 1 + 2 + 3 m (ft)

15 (0.023)

20 (0.031)

30 (0.046)

40 (0.062)

50 (0.077)

60 (0.093)

< 0.86 (0.26)

< 1.3 (0.40)

< 2.3 (0.70)

< 2.8 (0.85)

< 3.5 (1.07)

< 4.1 (1.25)

SYSTEM DIAGRAMS

YM Series Operation Manual

© 2009 Yanmar Marine International

93

SYSTEM DIAGRAMS

Figure 3 2YM15, 3YM20, 3YM30 - B-Type Instrument Panel

1

3

2

+ -

0.85B

120270 -7751

0.85RB

0.85LB

0.85WBr

B L YG RB

94

Figure 3

X 0 0 7 7 4 6 2 0

YM Series Operation Manual

© 2009 Yanmar Marine International

12/05

1 – Alarm Lamps

2 – Buzzer Oil Pressure

3 – Coolant Temperature

4 – Sail Drive Seal

5 – Charge

6 – Fuse (3A)

7 – Stop Switch

8 – Diodes

9 – Key Switch

10 – Tachometer Hour Meter

11 – Instrument Panel

12 – Wire Harness Option L=3M

13 – Wire Harness Option L=6M

14 – Amplifier Only for Sail Drive

15 – Procured by Customer

SYSTEM DIAGRAMS

16 – Battery

17 – Battery Switch

18 – Engine Stop Solenoid

19 – Relay

20 – Glow Plug

21 – Stop Relay

22 – Starter Relay

23 – Starter

24 – Coolant Temperature Switch

25 – Engine Oil Pressure Switch

26 – Alternator

27 – Ground

28 – Sail Drive (only for sail drive)

29 – Key Switch

30 – Coupler (view from A-A)

YM Series Operation Manual

© 2009 Yanmar Marine International

95

SYSTEM DIAGRAMS

Figure 4 2YM15, 3YM20, 3YM30 - B (Keyless) - Type Instrument Panel (Optional)

1

3

2

120270 -77511

0.85RB

0.85LB

+ -

0.85B

0.85WBr

128990 -77910

B L YG RB

96

II I

0

I

0

II

Figure 4

(8)

RB

RB

YG

WL

YW

LB

X 0 0 5 7 3 6 2 0

YM Series Operation Manual

© 2009 Yanmar Marine International

12/05

1 – Optional

2 – Diodes

3 – Buzzer

4 – Oil Pressure

5 – Coolant Temperature

6 – Sail Drive Seal

7 – Charge

8 – Fuse 3A

9 – SWITCH GLOW (I) / OFF (0) /

STOP (II)

10 – SWITCH START (II) / ON (I) /

OFF (0)

11 – Diode

12 – Switch

13 – Tachometer Hour Meter

14 – Instrument Panel (main station)

(option)

15 – Wire Harness

16 – Wire Harness for Sub Panel

SYSTEM DIAGRAMS

17 – Amplifier (only for sail drive)

18 – Procured by Customer

19 – Battery

20 – Battery Switch

21 – Engine Stop Solenoid

22 – Relay

23 – Glow Plug

24 – Stop Relay

25 – Starter Relay

26 – Starter

27 – Coolant Temperature Switch

28 – Engine Oil Pressure Switch

29 – Alternator

30 – Ground

31 – Sail Drive (only for sail drive)

32 – Coupler (view from A-A)

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© 2009 Yanmar Marine International

97

SYSTEM DIAGRAMS

This Page Intentionally Left Blank

98 YM Series Operation Manual

© 2009 Yanmar Marine International

YM Series Operation Manual

EPA WARRANTY USA

ONLY

YANMAR CO., LTD. LIMITED

EMISSION CONTROL

SYSTEM WARRANTY - USA

ONLY

2YM15 / 3YM20 EPA and CARB

Nameplate

For Example (2YM15)

EMISSION CONTROL INFORMATION

THIS ENGINE COMPLIES WITH U.S. EPA MARINE AND CALIFORNIA OFF-ROAD

REGULATIONS FOR 2009 M.Y. DIESEL ENGINES.

LOW SULFUR FUEL OR ULTRA LOW SULFUR FUEL ONLY.

ENGINE FAMILY: 9YDXN0.57P2N DISPLACEMENT: 0.569 LITERS

ENGINE MODEL: 2YM15 EMISSION CONTROL SYSTEM: EM

FUEL RATE: 17.4MM

3 /STROKE @ 10.0kW / 3600RPM (8≤kW<19)

STANDARDS NOx+HC: 7.5g/kW-hr CO: 6.6g/kW-hr PM: 0.40g/kW-hr

APPLICATION: VARIABLE-SPEED PROPULSION ENGINES USED WITH

FIXED-PITCH PROPELLERS.

YANMAR CO., LTD.

0 1 7 7 0 0 9 7 8 2 1

Figure 1

3YM30 EPA and CARB Nameplate

EMISSION CONTROL INFORMATION

THIS ENGINE COMPLIES WITH U.S. EPA MARINE AND CALIFORNIA OFF-ROAD

REGULATIONS FOR 2009 M.Y. DIESEL ENGINES.

LOW SULFUR FUEL OR ULTRA LOW SULFUR FUEL ONLY.

ENGINE FAMILY: 9YDXN1.11P3N DISPLACEMENT: 1.116 LITERS

ENGINE MODEL: 3YM30 EMISSION CONTROL SYSTEM: EM

FUEL RATE: 23.2MM

3 /STROKE @ 21.3kW / 3600RPM (19≤kW<37)

STANDARDS NOx+HC: 7.5g/kW-hr CO: 5.5g/kW-hr PM: 0.30g/kW-hr

APPLICATION: VARIABLE-SPEED PROPULSION ENGINES USED WITH

FIXED-PITCH PROPELLERS.

YANMAR CO., LTD.

0 1 7 7 0 0 9 9 8 2 1

Figure 2

YM Series Operation Manual

© 2009 Yanmar Marine International

99

EPA WARRANTY USA ONLY

THIS EMISSION WARRANTY APPLIES

TO THE ENGINES CERTIFIED TO

UNITED STATES EPA 40 CFR AND

SOLD BY YANMAR THAT ARE

INSTALLED IN VESSELS FLAGGED OR

REGISTERED IN THE UNITED STATES.

Your Warranty Rights and

Obligations:

Yanmar warrants to the first user and each subsequent purchaser the emission control system on your engine for periods of time listed below provided the engine has been installed according to Yanmar installation requirements and there has been no abuse, neglect, or improper maintenance of your Yanmar Marine engine.

Yanmar warrants that the engine is designed, built and tested using genuine parts and equipped so as to conform to all applicable emission requirements of the

U.S. Environmental Protection Agency and is free from defects in material and workmanship which would cause this engine to fail to conform to the applicable emission regulations over its limited emission control system warranty period.

Where a warrantable emissions condition exists, Yanmar will repair your engine at no charge to you for diagnosis, parts, and labor. Warranty service or repair will be provided at authorized Yanmar Marine dealers or distributors.

It is recommended that any replacement parts used for maintenance, repair or replacement of emission control systems are Yanmar parts. The owner may elect to have maintenance, replacement or repair of the emission control components and systems performed by any repair establishment or individual and may elect to use parts other than Yanmar parts for such maintenance, replacement or repair.

However, the cost of such service or parts and subsequent failures from such service or parts will not be covered under this emission control system warranty:

Warranty Period:

The warranty starts on either the date of delivery to the first end-user, or the date the unit is first leased, rented, or loaned.

Engine Model

2YM15, 3YM20

(kW < 19)

3YM30

(19

kW < 37)

Warranty Period

30 months or 1,500 hours of use, whichever comes first.

42 months or 2,500 hours of use, whichever comes first.

When a measurement device of use hours is not equipped, warranties apply a period of use months.

100 YM Series Operation Manual

© 2009 Yanmar Marine International

12/05

Warranty Coverage:

Repair or replacement of any warranted parts will be performed at an authorized

Yanmar dealer or distributor. This limited emission control system warranty covers engine components that are a part of the emission control system of the engine as delivered by Yanmar to the original retail purchaser. Such components may include the following:

• Fuel Injection System

• Turbocharger System

• Aftercooler

• Electronic Engine Control Units and its associated Sensor and Actuators

Exclusions:

Failures other than those arising from defects in material and / or workmanship are not covered by this limited emissions warranty. This warranty does not extend to the following: malfunction caused by abuse, misuse, improper adjustment, modification, alteration, tampering, disconnection, improper or inadequate maintenance, improper storage or use of non-recommended fuels and lubricating oils, accident-caused damage, and replacement of expendable and / or consumable items made in connection with scheduled maintenance.

Yanmar disclaims any responsibility for incidental or consequential damages such as loss of time, inconvenience, loss of use of marine vessel / engine or commercial loss.

EPA WARRANTY USA ONLY

Owner’s Responsibility:

As the Yanmar Marine engine owner, you are responsible for the performance of the required maintenance listed in your

Operation Manual. Yanmar recommends that you retain all documentation, including receipts, covering maintenance on your marine engine, but Yanmar cannot deny warranty solely for the lack of receipts or for your failure to ensure the performance of all scheduled maintenance.

Your engine is designed to operate on diesel fuel only. Use of any other fuel may result in your engine no longer operating in compliance with applicable emission requirements. You are responsible for initiating the warranty process. You must present your marine engine to an authorized Yanmar dealer or distributor as soon as a problem exists.

YM Series Operation Manual

© 2009 Yanmar Marine International

101

EPA WARRANTY USA ONLY

Customer Assistance:

If you have any questions regarding your warranty rights and responsibilities or would like information on the nearest authorized Yanmar dealer or distributor, you should contact Yanmar Marine USA

Corporation for assistance.

Yanmar Marine USA Corporation

101 International Parkway

Adairsville, GA 30103 USA

Telephone: 770-877-9894

Fax: 770-877-7567

102 YM Series Operation Manual

© 2009 Yanmar Marine International

YM Series Operation Manual

EMISSION SYSTEM

WARRANTY

NON-ROAD EMISSION

SYSTEM WARRANTY

Yanmar Co., Ltd. Limited

Emission Control System

Warranty - USA Only

Your Warranty Rights and

Obligations:

Note: Please refer to Yanmar’s Limited

Warranty Handbook for a description of the normal

(non-EPA) warranty.

California

The California Air Resources Board

(CARB), the Environmental Protection

Agency (EPA) and Yanmar Co., Ltd. hereafter referred to as Yanmar, are pleased to explain the emission control system warranty on your compression-ignition engine. In California, model year 2000 or later off-road compression-ignition engines must be designed, built and equipped to meet the state’s stringent anti-smog standards. In all states, 1998 and later non-road compression-ignition engines must be designed, built and equipped to meet the

United States EPA emissions standards.

Yanmar warrants the emission control system on your engine for the periods of time listed below provided there has been no abuse, neglect or improper maintenance of your engine.

Your emission control system may include parts such as the fuel injection system and the air induction system.

Where a warrantable condition exists,

Yanmar will repair your non-road compression-ignition engine at no charge to you including diagnosis, parts and labor.

Manufacturer’s Warranty Period:

The model year 1998 or later certified and labeled non-road compression-ignition engines are warranted for the periods listed below. If any emission-related part on your engine is found to be defective during the applicable warranty period, the part will be replaced by Yanmar.

Engine Model

2YM15, 3YM20

(kW < 19)

3YM30

(19 ≤ kW < 37)

Warranty Period

30 months or 1,500 hours of use, whichever comes first.

42 months or 2,500 hours of use, whichever comes first.

When a measurement device of use hours is not equipped, warranties apply a period of use months.

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103

EMISSION SYSTEM WARRANTY

Warranty Coverage:

This warranty is transferable to each subsequent purchaser for the duration of the warranty period. Repair or replacement of any warranted part will be performed at an authorized Yanmar Marine engine dealer or distributor.

Warranted parts not scheduled for replacement as required maintenance in the Operation Manual shall be warranted for the warranty period. Warranted parts scheduled for replacement as required maintenance in the operation manual are warranted for the period of time prior to the first scheduled replacement. Any part repaired or replaced under warranty shall be warranted for the remaining warranty period.

During the warranty period, Yanmar is liable for damages to other engine components caused by the failure of any warranted part during the warranty period.

Any replacement part which is functionally identical to the original equipment part in all respects may be used in the maintenance or repair of your engine, and shall not reduce Yanmar’s warranty obligations. Add-on or modified parts that are not exempted may not be used. The use of any non-exempted add-on or modified parts shall be grounds for disallowing a warranty.

Warranted Parts:

This warranty covers engine components that are a part of the emission control system of the engine as delivered by

Yanmar to the original retail purchaser.

Such components may include the following:

• Fuel Injection System

• Cold Start Enrichment System

• Positive Crankcase Ventilation System

Since emissions-related parts may vary slightly between models, certain models may not contain all of these parts and other models may contain the functional equivalents.

Exclusions:

Failures other than those arising from defects in material and / or workmanship are not covered by this warranty. The warranty does not extend to the following: malfunctions caused by abuse, misuse, improper adjustment, modification, alteration, tampering, disconnection, improper or inadequate maintenance or use of non-recommended fuels and lubricating oils; accident-caused damage, and replacement of expendable items made in connection with scheduled maintenance. Yanmar disclaims any responsibility for incidental or consequential damages such as loss of time, inconvenience, loss of use of equipment / engine or commercial loss.

Owner’s Warranty Responsibilities:

As the engine owner, you are responsible for the performance of the required maintenance listed in your owner’s manual.

Yanmar recommends that you retain all documentation, including receipts, covering maintenance on your non-road compression-ignition engine, but

Yanmar cannot deny warranty solely for the lack of receipts, or for your failure to ensure the performance of all scheduled maintenance.

Yanmar may deny your warranty coverage of your non-road compression-ignition engine if a part has failed due to abuse, neglect, improper maintenance or unapproved modifications.

Your engine is designed to operate on diesel fuel only. Use of any other fuel may result in your engine no longer operating in compliance with applicable emissions requirements.

104 YM Series Operation Manual

© 2009 Yanmar Marine International

12/05

You are responsible for initiating the warranty process. You must present your engine to a Yanmar dealer as soon as a problem exists. The warranty repairs should be completed by the dealer as expeditiously as possible.

Customer Assistance

If you have any questions regarding your warranty rights and responsibilities or would like information on the nearest authorized Yanmar dealer or distributor, you should contact Yanmar Marine USA

Corporation for assistance.

Yanmar Marine USA Corporation

101 International Parkway

Adairsville, GA 30103 USA

Telephone: 770-877-9894

Fax: 770-877-7567

EMISSION SYSTEM WARRANTY

YM Series Operation Manual

© 2009 Yanmar Marine International

105

EMISSION SYSTEM WARRANTY

Maintenance Log

Date

Operating

Hours

Maintenance

Performed

Dealer Name Stamp or Signature

106 YM Series Operation Manual

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Date

Operating

Hours

Maintenance

Performed

EMISSION SYSTEM WARRANTY

Dealer Name Stamp or Signature

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© 2009 Yanmar Marine International

107

EMISSION SYSTEM WARRANTY

108 YM Series Operation Manual

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