Yanmar | 3GM30 | Specifications | Yanmar 3GM30 Specifications

OPERATION MANUAL
MARINE ENGINES
2YM15
3YM20
3YM30E
3YM30
en
English
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 CO., LTD.
OPERATION MANUAL
MODEL
2YM15, 3YM20, 3YM30E, 3YM30
CODE
0AYMM-G00202
All Rights Reserved, Copyright
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TABLE OF
CONTENTS
INTRODUCTION .............................................................. 1
YM SERIES EMISSION CONTROL SYSTEM
WARRANTY-USA, THE ENVIRONMENTAL
PROTECTION AGENCY (EPA) ONLY ...................... 2
RECORD OF OWNERSHIP ...................................... 3
SAFETY ........................................................................... 5
SAFETY PRECAUTIONS ..........................................
General Information .............................................
Before You Operate.............................................
During Operation and Maintenance.....................
6
6
6
6
LOCATION OF SAFETY DECALS .......................... 10
PRODUCT OVERVIEW ................................................. 11
YANMAR YM SERIES FEATURES AND
APPLICATIONS ....................................................... 11
New Engine Break-In......................................... 12
COMPONENT IDENTIFICATION ............................
Right Side (Viewed from Flywheel) - 2YM15 .....
Left Side (Viewed from Flywheel) - 2YM15 .......
Right Side (Viewed from Flywheel) - 3YM20 .....
Left Side (Viewed from Flywheel) -3YM20 ........
Right Side (Viewed from Flywheel) - 3YM30(E)
Left Side (Viewed from Flywheel) - 3YM30(E)...
13
13
13
14
14
15
15
NAMEPLATES ......................................................... 16
FUNCTION OF MAJOR COMPONENTS ................ 17
CONTROL EQUIPMENT ......................................... 18
Instrument Panel ............................................... 18
Single-Handle Remote Control Head ................ 24
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TABLE OF CONTENTS
BEFORE YOU OPERATE .............................................. 25
INTRODUCTION ...................................................... 25
SAFETY PRECAUTIONS......................................... 25
DIESEL FUEL...........................................................
Diesel Fuel Specifications ..................................
Filling the Fuel Tank...........................................
Bleeding the Fuel System ..................................
26
26
29
30
ENGINE OIL .............................................................
Engine Oil Specifications ..................................
Engine Oil Viscosity ..........................................
Checking the Engine Oil.....................................
Adding Engine Oil ..............................................
31
31
31
32
32
MARINE GEAR OR SAIL DRIVE OIL ......................
Marine Gear Oil Specifications...........................
Sail Drive Oil Specifications- SD20 ....................
Checking Marine Gear Oil..................................
Adding Marine Gear Oil......................................
Checking and Adding Sail Drive Oil ...................
33
33
33
33
33
33
ENGINE COOLANT .................................................
Engine Coolant Specifications ...........................
Coolant (Closed Cooling System) ......................
Checking and Adding Coolant............................
34
34
34
35
CRANKING THE ENGINE........................................ 37
ENGINE OPERATION .................................................... 39
INTRODUCTION ...................................................... 39
SAFETY PRECAUTIONS......................................... 39
STARTING THE ENGINE ........................................
If the Engine Fails to Start..................................
Starting at Low Temperatures............................
After the Engine has Started ..............................
41
42
42
43
REMOTE CONTROL HANDLE OPERATION .......... 44
Acceleration and Deceleration ........................... 44
Shifting the Engine ............................................. 44
CAUTIONS DURING OPERATION.......................... 45
SHUTTING DOWN THE ENGINE ............................ 46
Normal Shutdown............................................... 46
Emergency Shutdown ........................................ 47
CHECKING THE ENGINE AFTER OPERATION..... 48
PERIODIC MAINTENANCE ........................................... 49
INTRODUCTION ...................................................... 49
SAFETY PRECAUTIONS......................................... 49
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TABLE OF CONTENTS
12/05
PRECAUTIONS .......................................................
The Importance of Periodic Maintenance ..........
Performing Periodic Maintenance .....................
The Importance of Daily Checks .......................
Keep a Log of Engine Hours and Daily Checks
Yanmar Replacement Parts ..............................
Tools Required ..................................................
Ask Your Authorized Yanmar Marine Dealer or
Distributor for Help.............................................
Tightening Fasteners .........................................
EPA MAINTENANCE REQUIREMENTS.................
EPA Requirements for USA and Other
Applicable Countries..........................................
Conditions to Ensure Compliance with
EPA Emission Standards ..................................
Inspection and Maintenance..............................
Installing Sample Port........................................
51
51
51
51
51
51
51
51
52
53
53
53
53
54
PERIODIC MAINTENANCE SCHEDULE ................ 55
Inspection and Maintenance of
EPA Emission-Related Parts ............................. 58
PERIODIC MAINTENANCE PROCEDURES ..........
Daily Checks......................................................
After Initial 50 Hours of Operation .....................
Every 50 Hours of Operation .............................
Every 100 Hours of Operation ...........................
Every 150 Hours of Operation ...........................
Every 250 Hours of Operation ...........................
Every 1000 Hours of Operation .........................
59
59
60
65
67
67
68
71
TROUBLESHOOTING ................................................... 75
SAFETY PRECAUTIONS ........................................ 75
TROUBLESHOOTING AFTER STARTING ............. 75
TROUBLESHOOTING INFORMATION................... 76
TROUBLESHOOTING CHART................................ 77
LONG-TERM STORAGE ............................................... 79
PREPARE ENGINE FOR LONG-TERM STORAGE 79
DRAIN SEAWATER COOLING SYSTEM ............... 80
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TABLE OF CONTENTS
SPECIFICATIONS .......................................................... 83
PRINCIPAL ENGINE SPECIFICATIONS .................
2YM15 Engine Specifications ............................
3YM20 Engine Specifications ............................
3YM30E Engine Specifications ..........................
3YM30 Engine Specifications ............................
Marine Gear and Sail Drive Specifications.........
83
84
85
86
87
88
SYSTEM DIAGRAMS..................................................... 89
PIPING DIAGRAMS ................................................. 89
WIRING DIAGRAMS ................................................ 94
EPA WARRANTY USA ONLY ....................................... 97
YANMAR CO., LTD. LIMITED EMISSION
CONTROL SYSTEM WARRANTY - USA ONLY .....
Your Warranty Rights and Obligations:..............
Warranty Period: ................................................
Warranty Coverage: ...........................................
Exclusions: .........................................................
Owner’s Responsibility:......................................
Customer Assistance: ........................................
97
98
98
99
99
99
99
EMISSION SYSTEM WARRANTY............................... 101
NON-ROAD EMISSION SYSTEM WARRANTY .... 101
Yanmar Co., Ltd. Limited Emission
Control System Warranty - USA Only .............. 101
Maintenance Log.............................................. 104
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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 machine
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
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INTRODUCTION
YM SERIES EMISSION CONTROL SYSTEM
WARRANTY-USA, THE ENVIRONMENTAL PROTECTION
AGENCY (EPA) ONLY
YM series engines come with an emission control system warranty. In all states, 2009 and
later 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 YM series engine for the periods of time listed below.
Emission Control Certification
Model Year
2011
2012
2013
2YM15
EPA marine CI Tier 3
3YM20
EPA marine CI Tier 3
3YM30E
3YM30
EPA marine CI Tier 3
intermediate (NTE)
EPA marine CI Tier 3 intermediate
Note: Since 2013, the 3YM30 does not comply with the EPA regulation.
2
2014
YM Series Operation Manual
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INTRODUCTION
12/05
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: __________________________________________________________
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INTRODUCTION
This Page Intentionally Left Blank
4
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SAFETY
Yanmar considers safety of great
importance and recommends that anyone
that comes into 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 machine’s safety
decals. Keep the labels 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 label attached to
it, make sure you order the new part and
label 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.
YM Series Operation Manual
DANGER
Indicates a hazardous situation which,
if not avoided, will result in death or
serious injury.
WARNING
Indicates a hazardous situation which,
if not avoided, could result in death or
serious injury.
CAUTION
Indicates a hazardous situation which,
if not avoided, could result in minor or
moderate injury.
NOTICE
Indicates a situation which can cause
damage to the machine, personal property
and / or the environment, or cause the
equipment to operate improperly.
5
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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
DANGER
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 labels are additional
reminders for safe operating and
maintenance techniques.
• Consult authorized Yanmar Marine
dealer or distributor for additional
training.
During Operation and
Maintenance
WARNING
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.
Fire Hazard
Undersized wiring systems
can cause an electrical fire.
Store any containers containing fuel or
other flammable products in a
well-ventilated area, away from any
combustibles or source of ignition.
Store any equipment in a designated
area away from moving parts.
Never use the engine compartment for
storage.
6
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SAFETY
12/05
WARNING
Sever Hazard
Rotating parts can cause
severe injury or death.
Never wear jewelry,
unbuttoned cuffs, ties or
loose-fitting clothing and
always tie long hair back when working
near moving / rotating parts such as the
flywheel or PTO shaft. Keep hands, feet
and tools away from all moving parts.
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.
Alcohol and Drug Hazard
Never operate the engine
while under the influence of
alcohol or drugs, or when
feeling ill.
Exposure Hazard
Always wear personal
protective equipment
including appropriate
clothing, gloves, work
shoes, and eye and hearing protection
as required by the task at hand.
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.
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.
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SAFETY
CAUTION
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
machine 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 engine coolant. If
contact with the eyes or skin should
occur, flush eyes and wash immediately
with clean water.
8
NOTICE
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.
Consult 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.
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SAFETY
12/05
NOTICE
If you have an installation with two or three
engines and only one engine is operating,
the water pickup (thru-hull) of the
non-running engine(s) should be closed.
This will prevent water from being forced
past the seawater pump and eventually
finding its way into the engine. The result
of water entering the engine could cause
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). Consult
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 speed,
you are overloading the engine that is
running. Immediately throttle back to
approximately 2/3 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.
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SAFETY
LOCATION OF SAFETY DECALS
Figure 1, show the location of safety decals on Yanmar YM series marine engines.
YM Engines
2
1
3
051101-00X00
Figure 1
1–Part Number: 128990-07270
2–Part Number: 128377-07350
3–Part Number: 196630-12980
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PRODUCT OVERVIEW
YANMAR YM SERIES
FEATURES AND
APPLICATIONS
Failure to do so can lead to reduced vessel
performance, lead to increased smoke
levels and cause permanent damage to
your engine.
The YM series are four-stroke swirl
pre-combustion chamber diesel engines
equipped with liquid coolant systems.
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 inboard
equipment, always observe the
instructions and cautions given in the
operation manuals supplied by the
shipyard and equipment manufacturers.
The 2YM15 is a 2-cylinder engine and is
naturally aspirated.
The 3YM20 is a 3-cylinder engine and is
naturally aspirated.
The 3YM30E, 3YM30 is a 3-cylinder
engine and is naturally aspirated.
The 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 min-1 above the Maximum Rated
output power engine speed (3700 to 3800)
to allow for some added weight and hull
resistance.
The engine must be able to reach the
Maximum Rated Power engine speed
(3600) under full load at all times.
YM Series Operation Manual
The YM series engines are designed to be
operated at maximum throttle (3600 min-1)
for less than 5% of total engine time (30
minutes out of every 10 hours) and
cruising speed (3400 min-1 or less).
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
Yanmars local subsidiary in your region or
your authorized Yanmar Marine dealer or
distributor.
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PRODUCT OVERVIEW
New Engine Break-In
As with all reciprocating engines, the way
your engine is operated during its first 50
hours of operation plays a very 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 make
the sliding parts, such as piston rings,
break-in properly and to stabilize engine
combustion.
During the break-in period, the engine
coolant temperature gauge should be
monitored; temperature should be
between 71° and 87°C (160° and 190°F).
During the first 10 hours of operation, the
engine should be run at maximum engine
speed minus 400 to 500 min-1
(approximately 60 to 70% of load) most of
the time. This will ensure the sliding parts
break in properly. During this period, avoid
operating at maximum engine speed and
load to avoid damaging or scoring sliding
parts.
NOTICE
Do not operate at WOT (wide open
throttle) for more than a minute at a time
during the first 10 hours of operation.
If operating engine at low speed and light
load, you must race the engine to clean the
carbon from the cylinders and 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 run at maximum speed
minus 400 min-1 most of the time
(approximately 70% load), with a 10
minute run at maximum minus 200 min-1
(approximately 80% load) every
30 minutes and a 4 to 5 minute period of
operation at WOT (wide open throttle)
once each 30 minutes. During this period,
be sure not to operate your engine at low
speed and light load for more than
30 minutes. If operating engine at low
speed and light load by necessity, just
after the low idle operation, be sure to race
the engine.
To complete engine break-in, perform
After Initial 50 Hours of Operation
maintenance procedures. After Initial 50
Hours of Operation on page 60.
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 engine oil
consumption may increase. Low idle
speed does not allow break-in of sliding
parts.
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PRODUCT OVERVIEW
12/05
COMPONENT
IDENTIFICATION
Left Side (Viewed from Flywheel)
- 2YM15
3
Right Side (Viewed from
Flywheel) - 2YM15
4
5
Figure 1 and Figure 2 illustrate a typical
version of a 2YM15 engine. Your engine
may have different equipment from that
illustrated.
6
2
1
2
7
3
8
4
1
051098-00X00
5
6
7
8
9
0004781
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
Figure 1
1
2
3
4
5
6
7
8
9
– Intake Silencer (air cleaner)
– Intake Manifold
– Fuel Filter
– Fuel Injection Pump
– Engine Oil Dipstick
– Engine Oil Filler Cap
– Fuel Feed Pump
– Engine Oil Filter
– Marine Gear
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PRODUCT OVERVIEW
Right Side (Viewed from
Flywheel) - 3YM20
Left Side (Viewed 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.
2
3
4
5
2
6
1
3
4
5
6
7
8
9
0004783
Figure 3
1
2
3
4
5
6
7
8
9
14
– Intake Silencer (air cleaner)
– Intake Manifold
– Fuel Filter
– Fuel Injection Pump
– Engine Oil Dipstick
– Engine Oil Filler Cap
– Fuel Feed Pump
– Engine Oil Filter
– Marine Gear
7
1
8
051099-00X00
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
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PRODUCT OVERVIEW
12/05
Right Side (Viewed from
Flywheel) - 3YM30(E)
Left Side (Viewed from Flywheel)
- 3YM30(E)
Figure 5 and Figure 6 illustrate a typical
version of a 3YM30(E) engine. Your
engine may have different equipment from
that illustrated.
2
3
4
5
2
1
3
4
5
6
7
1
8
6
7
051100-00X00
Figure 6
8
9
0004785
Figure 5
1
2
3
4
5
6
7
8
9
– Intake Silencer (air cleaner)
– Intake Manifold
– Fuel Filter
– Fuel Injection Pump
– Engine Oil Dipstick
– Engine Oil Filler Cap
– Fuel Feed Pump
– Engine Oil Filter
– Marine Gear
YM Series Operation Manual
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
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PRODUCT OVERVIEW
NAMEPLATES
The nameplates of Yanmar YM series
engines are shown in Figure 7. Check the
engine’s model, output, min-1 and serial
number on the nameplate. Please replace
if damaged or lost.
The engine nameplate is attached to the
engine rocker arm cover.
The marine gear nameplate (Figure 8) is
attached to the marine gear. Check the
marine gears model, gear ratio, oil used,
oil quantity and serial number.
㻹㻻㻰㻱㻸
㻹㻲㻳㻚㻌㻺㻻㻚
㻳㻱㻭㻾㻌㻾㻭㼀㻵㻻
㻻㻵㻸㻌
Model
Gear Model
Continuous power kW
177524-02903
kW/
Speed of prop.shaft
mi
n-1
Figure 8
mi
n-1
/
Fuel stop power kW
mi
n-1
ENG.No.
/
MFG.DATE
The sail drive nameplate (Figure 9) is
attached to the sail drive. Check the sail
drive model and serial number.
㻹㻻㻰㻱㻸
129670-07201
Figure 7
㻼㻭㻿㻿㻱㻰
㻹㻭㻾㻷
㻹㻲㻳㻚㻺㼛㻚
196420-02124
Figure 9
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PRODUCT OVERVIEW
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FUNCTION OF MAJOR COMPONENTS
Name of Component
Function
Fuel Filter
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 65.
Fuel Feed Pump
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.
Fuel Feed Lever
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.
Engine Oil Filler Port
Filler port for engine oil.
Engine Oil Filter
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 cartridge type and the element should be replaced
periodically. See Changing the Engine Oil on page 61.
Marine Gear Filler Port
Filler port for marine gear lube oil. Located on top of the marine gear case.
Cooling System
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.
Closed Cooling Circulation
Pump
The centrifugal water pump circulates coolant inside the engine. The circulating pump is
driven by a V-ribbed belt.
Seawater Pump
Pumps seawater from outside vessel to the engine. The seawater pump is gear-driven and
has a replaceable rubber impeller. Do not operate it without seawater, as this will damage the
impeller.
Coolant Filler Cap
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.
Reservoir
The pressure valve in the filler cap releases vapor and hot water overflow to the reservoir.
When the engine stops and the coolant cools, the pressure in the coolant tank drops. The filler
cap vacuum valve then opens to send water back from the reservoir. This minimizes coolant
consumption. The closed cooling system coolant level can easily be checked and refilled in
this tank.
Engine Oil Cooler
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
Nameplates are provided on the engine and the marine gear and have the model, serial
number and other data. See Nameplates on page 16
Starter
Starter motor for the engine; powered by the battery.
Alternator
Driven by a belt and generates electricity and charges the battery.
Engine Oil Dipstick
Gauge stick for checking the engine oil level.
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PRODUCT OVERVIEW
CONTROL EQUIPMENT
The equipment in the control room 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
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.
B20-Type
1
2
3
4
042563-00X00
Figure 10
1 – Alarm lamps
2 – Tachometer
3 – LCD
4 – Switches (push-buttons)
Control panel switches
All switches are push-buttons.
Start switch
Glow switch
Pushing this switch operates
the starter and starts the
engine.
Pushing this switch for the
specified time heats the glow
plug in the combustion
chamber. It becomes red-hot,
facilitating fuel ignition. This
assists starting in cold weather.
042566-00X00
042564-00X00
Power switch
Stop switch
Pushing this switch turns on or
off the power.
Pushing this switch stops the
engine.
042567-00X00
042565-00X00
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Meters
Instrument
Function
Tachometer
Shows engine rotation speed.
Hourmeter
Shows number of operating hours. Can be used as a guide for periodic
maintenance checks. The hourmeter is located at the bottom of the
tachometer.
Panel Lights
When the power switch is pushed, the gauges will illuminate for easier viewing.
Note: The LCD on the instrument panel show hourmeter, display brightness and
battery voltage.
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 and the
alarms are located on the back of the panel. Under normal operating conditions, the
indicators are off.
Battery Low Charge Indicator
When the alternator output is too low, the indicator will light. When
charging begins, the indicator will turn off.
Coolant High Temperature Indicator and Alarm
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.
Engine Oil Low Pressure Indicator and Alarm
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 to avoid damage to the engine. Check the oil level
and troubleshoot the lubrication system.
Water in Sail Drive Seal Indicator and Alarm
When water is detected between the seals of the sail drive, the indicator
will light and the alarm will sound.
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PRODUCT OVERVIEW
LCD control (hourmeter, display brightness, battery voltage)
You can switch (scroll) between displays
by pressing the buttons on the bottom.
Figure 1
• Switching screens by pressing the
right button (Pressing the left button
switches the screens in the opposite
direction.)
Press the power switch.
• After 4 seconds, the LCD shows the
hourmeter.
Scroll
Engine hour ( >300 min-1)
Pressing the right button on the bottom of
the LCD shows the temperature display.
This feature is not available on this
engine.
Pressing the right button again shows the
LCD brightness settings.
To set the brightness of the backlight:
Coolant temperature
Backlighting Brightness
Press the left button continuously and
the digits of the LCD start flashing.
In this condition, press the right button
to decrease the brightness and the left
button to increase the brightness.
(The brightness changes in 6 steps of
20 %.)
1
2
Push and hold
(display will blink when
ready)
To set the desired brightness, do not
touch the buttons for 3 seconds.
Note: Continuously pressing means
holding the button for approx. 2
seconds.
Oil pressure
Next, press the right button to show the
pressure display.
Battery voltage
3
Scroll
100, 80, 60, 40, 20, 0
(value will be set after
3 seconds)
This feature is not available on this
engine.
Press again to show the battery voltage.
Pressing the button once more returns the
display to the initial hourmeter.
20
Return to hourmeter
Figure 11
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PRODUCT OVERVIEW
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Setup Screen Access and Control
(Setting the engine speed pulse value for B20/C30 type panel)
Use the buttons on the bottom of the LCD
display to set the instrument panel.
Press the left button to switch between
displays.
Figure 2
Press and hold both buttons until “SET
UP” appears.
Press the left button and go to the
screen “UNIT”.
1
2
Scroll
Press the left button and go to the next
screen “ENGINE”.
Confirm that the display says
“ENGINE”. Press the right button and
“P****” appears.
Note: The pre-set value of speed pulse
is indicated on the box of each
panel.
Next, press the left button and select
the speed pulse value for each engine
model.
Engine model
3
Select
Engine type select
Speed pulse value
YM with HITACHI
alternator
10.29
YM with VALEO
alternator
12.10
4
5
Scroll
After confirming the value is changed
correctly, press the right button to
return to the “ENGINE” screen.
Press the left button again to go from
the “ENGINE” screen to the “EXIT”
screen.
6
7
Select
Exit setup
After confirming the display, press the
right button to re-start the panel and
return to the hourmeter display.
8
Return to LCD control
043719-02EN03
Figure 12
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PRODUCT OVERVIEW
Alarms
Checking the Warning Devices
Before and after engine start, make sure that the instruments and warning devices
operate correctly.
If the engine runs out of coolant or lubricating oil and the instruments and warning devices
fail, they can not give you warning to prevent accidents. This can also lead to incorrect
operation and cause further malfunctions of the engine.
Before Engine Start
1. Turn on the battery switch.
2. Push the power switch on.
• All alarm lamps light up for 4 seconds.
• After 4 seconds, the charge lamp and the lubricating oil pressure alarm lamp light up,
and the hourmeter is displayed.
• The alarm buzzer sounds until the engine starts.
After Engine Start
After engine start, make sure that the warning devices operate correctly and according to
“After start” in the below table.
• All alarm lamps turn off. The above check tells you whether the electric circuit for the
warning lamps and alarm buzzer operate correctly. If they do not operate correctly,
inspection and repair are required. Consult your dealer or distributor for repairs.
Correct operation of the warning devices
Instrument panel (power switch)
Power ON
Immediately
After 2 seconds
After 4 seconds
Before start
After start
Starter switch
OFF
ON
Alarm buzzer
ON
OFF
Charge lamp
ON
ON
ON
OFF
Coolant temperature lamp
ON
ON
OFF
OFF
ON
ON
ON
Yanmar
Full display
Engine lubricating oil pressure lamp
LCD display
OFF
Hourmeter
NOTICE
When the warning devices are activated and normal operation is impossible, stop the
engine and do not use it until the problem has been solved.
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Accessory power output
The harness attached to the panel has a terminal where the signal that is synchronized to
the panel power supply can be taken off. (Figure 13) ( Refer to the Wiring Diagrams on
page 94.)
The maximum current of this output terminal is 3 A. Do not use a current higher than 3 A.
For the content of the output terminal, refer to the Wiring Diagrams on page 94.
Figure 3
Buzzer
F1A - 3 AMP Fuse
ACC Output
043801-00E00
Figure 13
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PRODUCT OVERVIEW
Single-Handle Remote Control
Head
2
Figure 4
3
2
5
1
1
4
0004511
Figure 15
0004504
Figure 14
Note: Direction of travel will vary
depending on installation
location.
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
Note: Yanmar recommends the use of
a single-handle type for the
remote control system. If only a
two-handle type is available in
the market, reduce engine
speed to 1000 min-1 or less
before engaging and
disengaging the marine gear
clutch.
A single handle-type (Figure 14) should
be used to operate the marine gear clutch
(NEUTRAL, FORWARD and REVERSE)
and to control the engine speed.
The handle controls the direction of the
boat (ahead or astern) and also acts as an
accelerator by increasing engine speed as
the control handle is pushed further in
FORWARD or REVERSE directions.
When the handle is pulled out
(Figure 15, (1)), the engine speed can be
controlled without engaging the marine
gear. The marine gear remains in
NEUTRAL, no load
position. Turn the knob (Figure 15, (2))
counterclockwise to move the handle or
clockwise to lock the handle.
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BEFORE YOU OPERATE
INTRODUCTION
SAFETY PRECAUTIONS
This section of the Operation Manual
describes the diesel fuel, engine oil and
engine coolant specifications and how to
replenish them.
Before performing any operations within
this section, review the Safety section on
page 5.
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BEFORE YOU OPERATE
DIESEL FUEL
B7 diesel fuels must meet certain
specifications.
Diesel Fuel Specifications
The biodiesel fuels must meet the
minimum specifications for the country in
which they are used:
WARNING
Fire and Explosion Hazard.
Diesel fuel is flammable and explosive
under certain conditions.
• In Europe, biodiesel fuels must comply
with the European Standard
EN590-2009, EN14214.
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.
• In the United States, biodiesel fuels must
comply with the American Standard
ASTM D6751 Grade-S15, D7467 Grade
B7-S15.
Diesel fuel should comply with the
following specifications. The table lists
several worldwide specifications for diesel
fuels.
DIESEL FUEL
SPECIFICATION
LOCATION
ASTM D975 No. 2-D S15,
No. 1-D S15
USA
EN590-2009
European Union
ISO 8217 DMX
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 7%
non-mineral oil based fuel with 93%
standard diesel fuel. Such biodiesel fuels
are known in the marketplace as B7
biodiesel fuels. B7 biodiesel fuel can
reduce particulate matter and the emission
of “greenhouse” gases compared to
standard diesel fuel.
Biodiesel should be purchased only from
recognized and authorized diesel fuel
suppliers.
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.
If the B7 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.
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BEFORE YOU OPERATE
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• 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.
Additional Technical Fuel
Requirements
• The fuel cetane number should be 40 or
higher.
• The sulfur content must not exceed 15
ppm by volume.
A higher sulfur content fuel may cause
sulfuric acid corrosion in the cylinders of
the engines.
Especially in U.S.A. and Canada, Ultra
Low Sulfur fuel must be used.
• 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.
• PAH (polycyclic aromatic hydrocarbons)
content should be below 10% by volume.
• Do not use Biocide.
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.
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.
1. Water and dust in the fuel may cause
engine failure. When fuel is stored, be
sure that the inside of the storage
container is clean and dry, and that the
fuel is stored away from dirt or rain.
• Ash content not to exceed 0.01% by
volume.
• Carbon residue content not to 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.
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BEFORE YOU OPERATE
The fuel outlet should be positioned 20 to
30 mm (0.75 to 1.125 in.) above the
bottom of the tank so that only clean fuel is
distributed to the engine.
Fuel System
1
8
2
3
9
10
0004512
5
Figure 1
2. 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.
Fuel Tank (Optional)
7
6
0004788
Figure 3
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
3
1
2
0004542
Figure 2
1 – Sediment Bowl
2 – Drain Cock
3 – Fuel Line to Engine
Install the fuel line from the fuel tank to the
fuel injection pump as shown in Figure 3.
The recommended fuel / water separator
(Figure 3, (3)) (optional) is installed at the
center section of that line.
Install a drain cock (Figure 2, (2)) at the
bottom of the fuel tank to remove water
and contaminants from the sediment bowl
(Figure 2, (1)).
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BEFORE YOU OPERATE
12/05
Filling the Fuel Tank
Before filling fuel tank for the first
time:
WARNING
Fire and Explosion Hazard.
Never overfill the fuel tank.
WARNING
Fire and Explosion Hazard.
Never refuel with the engine running.
5. Replace the fuel cap and hand-tighten.
Over-tightening the fuel cap will
damage it.
Rinse 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.
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BEFORE YOU OPERATE
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. 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.
1
2
3
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.
4
Note: After engine start-up, the
automatic air-bleeding device
works to purge the air in the fuel
system.
5
6
0004801
Figure 4
1
2
3
4
5
6
30
– Air Bleed Screw
– Bracket
– O-Ring
– Fuel Filter Element
– Fuel Filter Housing
– Retaining Ring
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BEFORE YOU OPERATE
12/05
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,CF, CF-4,
CI and CI-4.
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)
• Select the oil viscosity based on the
ambient temperature where the engine
is being operated. See Engine Oil
Viscosity Figure 5.
• Yanmar does not recommend the use of
engine oil "additives."
Handling Engine Oil
• 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.
• 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.
• Engine oil should be replaced at the
specified intervals, regardless of the
engine’s operation history. See Periodic
Maintenance Schedule on page 55.
Engine Oil Viscosity
• 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
• Be sure the engine oil, engine oil storage
containers and engine oil filling
equipment are free of sediment or water.
• 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 61.
YM Series Operation Manual
Figure 5
• Select the appropriate engine oil
viscosity based on the ambient
temperature shown in the SAE Service
Grade Viscosity Chart (Figure 5).
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BEFORE YOU OPERATE
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.
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 32.
6. Fully reinsert dipstick.
Adding Engine Oil
Checking the Engine Oil
1. Remove the yellow oil filler port cap
from the filler port (Figure 6, (1)) on the
rocker arm cover (Figure 6, (1)) and fill
with engine oil.
2
1
NOTICE
3
4
5
0004789
Figure 6
1
2
3
4
5
– Filler Port
– Rocker Arm Cover
– Dipstick
– Upper Limit
– 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.
Prevent dirt and debris from
contaminating engine oil. Carefully
clean the dipstick, filler port cap and the
surrounding area before you remove the
cap.
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
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.
Always keep the oil level between upper
and lower lines on the oil cap / dipstick.
4. Hand-tighten the filler port cap
securely.
2. Remove the dipstick(Figure 6, (3)) and
wipe with a clean cloth.
3. Fully reinsert dipstick.
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BEFORE YOU OPERATE
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MARINE GEAR OR SAIL
DRIVE OIL
Marine Gear Oil Specifications
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)).
Use marine gear oil that meets or exceeds
the following guidelines and classifications:
2. Remove the filler cap at the top of the
housing.
KM2P-1 (S), (G) or (GG):
3. Remove the dipstick (Figure 7, (1)) and
wipe with a clean cloth.
• API Service Categories: CD or higher
• SAE Viscosity: #20 or #30
Sail Drive Oil SpecificationsSD20
Refer to the Sail Drive Operation Manual
for the procedure to fill or replace the sail
drive oil.
4. Re- insert the dipstick without screw in,
please see illustration (Figure 7).
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. Screw in the dipstick.
SD20:
• API Service Category: GL4.5
Adding Marine Gear Oil
• SAE Viscosity: 90 or 80W90
1. Make sure the engine is as level as
possible.
Checking Marine Gear Oil
2. Remove the filler cap at the top of the
housing.
NOTICE
Never overfill the marine gear with oil.
1
3
3
4
3. Fill with oil to the upper limit on the
dipstick (Figure 7, (3)). See Marine
Gear Oil Specifications on page 29.
4
4. Screw in the dipstick.
5. Hand-tighten the filler port cap.
2
054316-00X00
Figure 7
1 – Dipstick
(Filler cap combined type)
2 – Marine Gear Filler Port
3 – Upper Limit
4 – Lower Limit (Dipstick end)
YM Series Operation Manual
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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BEFORE YOU OPERATE
ENGINE COOLANT
Engine Coolant Specifications
Note: In the U.S., LLC is required for
the warranty to be valid.
• Texaco Long Life Coolant (LLC), both
standard and premixed, product code
7997 and 7998
• Havoline Extended Life
Antifreeze / Coolant, product code 7994
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.
Always use the mixing ratios specified by
the antifreeze manufacturer for the
temperature range.
34
Coolant (Closed Cooling System)
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.
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BEFORE YOU OPERATE
12/05
Checking and Adding Coolant
Figure 1
Figure 2
1
1
5
3
4
2
0004793
Figure 10
3
2
051169-00X00
Figure 8
1
2
3
4
5
– Coolant Tank / Heat Exchanger
– Coolant Drain Plug
– Seawater Drain Plug
– Seawater Pump
– Coolant Pump
1
1 – Stop Solenoid
2 – Coolant Drain Cock
3 – Flywheel Housing
1. Allow the engine to cool.
Note: The drain cocks are opened
before shipping from the factory.
Close all drain cocks before
filling the system with coolant.
2. Ensure all drain cocks are closed.
3. Loosen the coolant tank filler cap to
relieve the pressure, then remove the
filler cap.
WARNING
2
3
051170-00X00
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.
Figure 9
1 – Coolant Tank / Heat Exchanger
2 – Seawater Drain Cock
3 – Coolant Drain Plug
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BEFORE YOU OPERATE
Figure 3
Figure 4
1
2
4
1
3
2
4
FULL
3
LOW
0004493
054720-00X00
Figure 11
1
2
3
4
– Filler Cap Tabs
– Coolant Filler Cap
– Filler Port Notches
– Coolant Tank / Heat Exchanger
4. Pour coolant slowly into the coolant
tank / heat exchanger (Figure 11, (4))
to avoid air bubbles. Fill until coolant
overflows from the filler port.
NOTICE
Never pour cold coolant into a hot
engine.
5. Align the filler cap tabs (Figure 11, (1))
with filler port notches (Figure 11, (3))
and tighten the filler cap
(Figure 11, (2)) .
Figure 12
1
2
3
4
– Rubber Hose to Coolant Tank
– FULL Mark
– LOW Mark
– Reservoir cap
6. Check the coolant level in the
reservooir. The level should be at the
FULL mark (Figure 12, (2)).
Note: The coolant level rises in the
reservooir during operation.
After stopping the engine, the
coolant will cool down and the
extra coolant will return to the
coolant tank.
NOTICE
Never pour cold coolant into a hot
engine.
7. Remove reservoir cap (Figure 12, (4))
to add coolant if necessary. Do not add
water.
8. Replace the filler cap and tighten it
firmly. Failure to do so will cause
coolant to leak.
Reservoir Capacity
0.8 L (0.8 qt)
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BEFORE YOU OPERATE
12/05
9. Check the rubber hose (Figure 12, (1))
connecting the reservoir to the coolant
tank / heat exchanger. Replace if
damaged.
CRANKING THE ENGINE
Note: If the coolant runs low too often
or the coolant level in the
coolant tank drops without any
change in the level in the
reservoir, there may be water or
air leaks in the cooling system.
Consult authorized Yanmar
dealer or distributor.
When 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 no use,
distribute engine oil to each part by
cranking. Perform in accordance with the
following procedures before beginning
operation.
NOTICE
1. Open seacock.
2. Open fuel cock.
3. Put remote control shift lever in
NEUTRAL. See Starting the Engine on
page 41.
4. Turn on the battery switch (if equipped).
5. Crank the engine.
1- Push the power switch on the
instrument panel and turn on the
power.
2- Operate the starter while pushing in
the emergency stop button
(Figure 13) on the back of the fuel
pump. This stops the fuel supply.
When you push the start switch on the
instrument panel while the emergency
button is pushed in, the starter operates
and the engine cranks.
Crank the engine 5 seconds.
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BEFORE YOU OPERATE
Figure 5
Stop solenoid
Push
(emergency stop)
006224-01E
Figure 13
6. Continue cranking the engine for about
5 seconds, checking for abnormal
sounds.
If you cannot find any abnormal
sounds, push the power switch and turn
off the engine.
Start switch
Power switch
042590-00E00
Figure 14
WARNING
Never touch or allow your
clothes to touch the moving
parts of the engine during
operation. If a part of your
body or clothing is caught in
the front drive shaft, V-ribbed belt, propeller
shaft, etc. serious injury may result.
Check to see that no tools, pieces of
cloth, etc. are left on or around the
engine.
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ENGINE OPERATION
INTRODUCTION
SAFETY PRECAUTIONS
This section of the Operation Manual
describes the diesel fuel, engine oil and
engine coolant specifications and how to
replenish them. It also describes the daily
engine checkout.
Before performing any operations within
this section, review the Safety section on
page 5.
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05-Engine Operation.fm
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ENGINE OPERATION
WARNING
FireandExplosionHazard
Never jump-start the
engine. Sparks caused by
shorting the battery to the
starter terminals may cause
a fire or explosion.
ONLY use the start switch
on the instrument panel 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 engine
speed. 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.
If the alarm indicater with audible alarm
fails to display and go out about 3 seconds
after the ignition switch is turned on,
consult authorized Yanmar Marine dealer
or distributor for service before operating
the engine
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 thru-hull water intake
valve to avoid filling the muffler with water.
Crank for 10 seconds at a time until the
engine starts. When the engine does start,
stop the engine immediately and turn off
the switch.
Be sure to re-open the seacock and restart
the engine. Operate the engine normally.
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.
NOTICE
If any indicator illuminates during engine
operation, stop the engine immediately.
Determine the cause and repair the
problem before you continue to operate
the engine.
• 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.
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ENGINE OPERATION
12/05
NOTICE
STARTING THE ENGINE
• Contact your authorized Yanmar Marine
engine dealer or distributor if the engine
will be operated outside of this standard
temperature range.
1. Open the seacock (if equipped).
Never engage the starter motor while the
engine is running. Damage to the starter
motor pinion and / or ring gear will result.
Note: Safety equipment should make it
impossible to start the engine in
any other position than
NEUTRAL.
2. Open the fuel tank cock.
3. Put remote control handle in
NEUTRAL.
Figure 1
Start switch
Glow switch
Power switch
042590-00E01
Figure 1
4. Turn on the battery switch (if equipped).
Do not turn off the battery switch during
engine operation. Also, turn it off when
the engine does not operate.
5. If the alarm buzzer and all warning
lamps operate when you turn on the
power switch on the instrument panel,
the warning devices operate correctly.
6. Pushing the start switch turns on the
engine. Release the switch after the
engine starts. If the warning lamps and
the alarm buzzer stops operating, the
warning devices operate correctly.
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ENGINE OPERATION
If the Engine Fails to Start
Before pushing the start switch again, be
sure to confirm that the engine has
stopped completely. If an attempt to restart
is made while the engine is running, the
pinion gear of the starter motor will be
damaged.
NOTICE
Never hold for longer than 15 seconds or
the starter motor will overheat.
Never attempt to restart the engine if the
engine has not stopped completely. Pinion
gear and starter motor damage will occur.
Note: Push and hold the start switch
for a maximum of 15 seconds. If
the engine does not start the first
time, wait for about 15 seconds
before trying again.
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 15
seconds, close the thru-hull water intake
valve to avoid filling the muffler with water.
Crank for 10 seconds at a time until the
engine starts. When the engine does start,
stop the engine immediately and turn off
the power switch. Be sure to re-open the
seacock and restart the engine. Operate
the engine normally.
42
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 30.
Starting at Low Temperatures
Comply with local environmental
requirements. Use engine heaters to avoid
starting problems and white smoke. Do not
use starting aids.
NOTICE
Never use an engine starting aid such as
ether. Engine damage will result.
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.
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ENGINE OPERATION
12/05
Starting with Glow plug
(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 switch on (if equipped).
5. Push the power switch 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 does not come
on during start-up.
6. Push and hold the glow switch for 10
seconds.
7. Push the start switch. Release the start
switch when the engine has started.
The alarm should stop and the
indicators should go out.
NOTICE
Never hold the start switch 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.
• Normal coolant operating temperature
is approximately 76° to 90°C (169° to
194°F).
• Normal oil pressure at 3000 min-1 is
0.28 to 0.54 MPa (41 to 78 psi).
2. Check for water, fuel or oil leakage
from the engine.
3. Check that the smoke 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.
5. Check that sufficient cooling water is
discharged from the seawater outlet.
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 seawater discharge is too small or
if load is applied without any warming up
operation.
For troubleshooting assistance, see
Troubleshooting After Starting on page
75 or Troubleshooting Chart on page 77
. If necessary, consult authorized
Yanmar dealer or distributor.
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ENGINE OPERATION
REMOTE CONTROL
HANDLE OPERATION
Acceleration and Deceleration
2
1
3
4
0004513
Figure 2
1
2
3
4
– FORWARD or REVERSE
– NEUTRAL
– REVERSE or FORWARD
– Throttle Handle / Shifting
Handle
Note: Direction of travel will vary
depending on installation
location.
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.
1. Before using the marine gear, be sure
to move the throttle handle to a low idle
position (less than 1000 min-1). Move
the throttle handle slowly to a higher
speed position after completing marine
gear engagement.
2. When moving the handle between
FORWARD (Figure 2, (1 or 3)) and
REVERSE (Figure 2, (3 or 1)), bring
the handle to NEUTRAL (Figure 2, (2))
and pause before slowly shifting to the
desired position. Never shift abruptly
from FORWARD to REVERSE or vice
versa.
NOTICE
Use the throttle handle (Figure 2, (4)) to
control acceleration and deceleration.
Move the handle slowly.
• Never shift the marine gear at high
engine speed. During normal
operation, the marine gear should only
be shifted with the engine at idle.
Shifting the Engine
• When sailing, set the remote control
handle in NEUTRAL. Not doing so
WILL introduce slippage or any
damage and void your warranty.
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.
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ENGINE OPERATION
12/05
CAUTIONS DURING
OPERATION
NOTICE
Engine trouble can arise if the engine is
operated for a long time under overloaded
conditions with the control handle in the full
throttle position (maximum engine speed
position), exceeding the continuous rated
output engine speed. Operate the engine
at about 100 min-1 lower than the full
throttle engine speed.
Note: If the engine is in the first 50
hours of operation, see New
Engine Break-In on page 12 .
Always be on the lookout for problems
during engine operation.
Pay particular attention to the following:
• Is sufficient seawater being discharged
from the exhaust and seawater outlet?
If the discharge is small, stop the engine
immediately; identify the cause and
repair.
• Is the smoke color normal?
The continuous emission of black smoke
indicates engine overloading. This
shortens the engines life and should be
avoided.
NOTICE
Excessive vibration may cause damage
to the engine, marine gear, hull and
onboard equipment. In addition, it
causes able passenger and crew
discomfort.
Depending on the hull structure, engine
and hull resonance may suddenly
become great at a certain engine speed
range, causing heavy vibrations. Avoid
operation in this speed range. If you hear
any abnormal sounds, stop the engine
and inspect.
• Alarm buzzer sounds during operation.
NOTICE
If any alarm indicator with audible alarm
sound appears on the display during
engine operation, stop the engine
immediately. Determine the cause and
repair the problem before you continue
to operate the engine.
• Is there water, oil or fuel leakage, or are
there any loose bolts?
Check the engine room periodically for
any problems.
• Is there sufficient diesel fuel in the diesel
fuel tank?
• Are there abnormal vibrations or noise?
Replenish diesel fuel before leaving the
dock to avoid running out of fuel during
operation.
• When operating the engine at low speed
for long periods of time, race the engine
once every 2 hours.
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ENGINE OPERATION
NOTICE
Racing the engine: With the gear 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 valve. Neglecting to race the
engine will result in poor smoke color
and reduce engine performance.
• If possible, periodically operate the
engine at near maximum engine speed
while underway. This will generate
higher exhaust temperatures, which will
help clean out hard carbon deposits,
maintaining engine performance and
prolonging the life of the engine.
NOTICE
Never turn off the battery switch (if
equipped) or short the battery cables
during operation. Damage to the electric
system will result.
SHUTTING DOWN THE
ENGINE
Normal Shutdown
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 min-1) without
load for 5 minutes.
NOTICE
For maximum engine life, Yanmar
recommends that when shutting the
engine down, you allow the engine to
idle, without load, for 5 minutes. This will
allow the engine components that
operate at high temperatures, such as
the turbocharger (if equipped) and
exhaust system, to cool slightly before
the engine itself is shut down.
Start switch
Stop switch
Power switch
042590-00E02
Figure 3
4. Push and hold the stop switch.
After the engine has stopped, push the
power switch off.
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ENGINE OPERATION
12/05
NOTICE
Figure 2
Continue to hold the stop switch in until
the engine is completely stopped. If the
switch is released before the engine
has completely stopped, it may restart.
If the engine does not shut down, see
Emergency Shutdown on page 47 .
5. Turn off the battery switch (if equipped).
6. Close the fuel cock.
7. Close the seacock (if equipped).
NOTICE
•Be sure to close the seacock.
Neglecting to close the seacock could
allow water to leak into the boat and
may cause it to sink.
•If seawater is left inside the engine, it
may freeze and damage parts of the
cooling system when the ambient
temperature is below 0°C (32°F).
1
2
0004787
Figure 4
1 – Stop button
2 – Stop solenoid
WARNING
Sever Hazard.
Always keep hands, body parts and
loose-fitting clothes away from moving /
rotating parts such as the flywheel or
PTO shaft.
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 switch on the panel, stop the engine
by pushing the button (Figure 4, (1)) at the
back of the stop solenoid (Figure 4, (2)).
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ENGINE OPERATION
CHECKING THE ENGINE
AFTER OPERATION
• Check that the power switch is off and
that the battery switch (if equipped) is
turned to off.
• Fill the fuel tank. See Filling the Fuel
Tank on page 29.
• Close seawater cock(s).
• If there is a risk of freezing, check that
the cooling system contains enough
coolant. See Engine Coolant
Specifications on page 34.
• If there is a risk of freezing, drain the
seawater system. See Drain Seawater
Cooling System on page 80.
• At temperatures below 0°C (32°F), drain
seawater system and connect the
engine heater (if equipped).
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PERIODIC
MAINTENANCE
INTRODUCTION
SAFETY PRECAUTIONS
This section of the Operation Manual
describes the procedures for proper care
and maintenance of the engine.
Before performing any maintenance
procedures within this section, read the
following safety information and review the
Safety section on page 5.
WARNING
Crush Hazard
If the engine needs to be
transported for repair, have a
helper assist you attach it to a
hoist and load it on a truck.
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.
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PERIODIC MAINTENANCE
WARNING
Never use undersized wiring for the
electrical system.
Welding Hazard
• 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 engine control unit
multi-pin connector. 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 alternator and engine
control unit prior to reconnecting the
batteries.
Tool Hazard
Always remove any tools or shop rags
used during maintenance from the area
before operation.
NOTICE
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. Be sure to use Yanmar genuine
replacement parts.
Entanglement Hazard
Never leave the power
switch on when you are
servicing the engine.
Someone may accidentally
start the engine and not
realize you are servicing it.
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.
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PERIODIC MAINTENANCE
12/05
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 machine
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 it a
habit to perform daily checks before the
start of each operating day. See Daily
Checks on page 59.
YM Series Operation Manual
Keep a Log of Engine Hours and
Daily Checks
Keep a log of the number of hours the
engine is run 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, 250, 500 and 1000 engine
hours. Failure to perform periodic
maintenance will shorten the life of the
engine.
NOTICE
Failure to perform periodic maintenance
will shorten the life of the engine and may
void the warranty.
Yanmar Replacement Parts
Yanmar recommends that you use
genuine Yanmar parts when replacement
parts are needed. Genuine replacement
parts help ensure long engine life.
Tools Required
Before you start any periodic maintenance
procedure, make sure you have the tools
you need 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 you with
any maintenance or service related
procedures you need help with.
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PERIODIC MAINTENANCE
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
he 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.
Bolt Diameter x
Pitch (mm)
Tightening
Torque
52
M6x1.0
M8x1.25
M10x1.5
M12x1.75
M14x1.5
M16x1.5
N·m
11.0 ± 1.0
26.0 ± 3.0
50.0 ± 5.0
90.0 ± 10.0
140.0 ± 10.0
230.0 ± 10.0
ft-lb
8.0 ± 0.7
19.0 ± 2.1
37.0 ± 3.6
66.0 ± 7.2
103 ± 7.2
170 ± 7.2
YM Series Operation Manual
PERIODIC MAINTENANCE
12/05
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
55 and the Periodic Maintenance
Procedures on page 59 .
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 3YM30E are
EPA-certified engines.
Note: Since 2013, the 3YM30 does not
comply with the EPA regulation.
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°C to +40°C
(-4°F to +104°F)
• Relative humidity: 80% or lower
YM Series Operation Manual
The diesel fuel should be:
• ASTM D975 No. 1-D S15 or No. 2-D S15
or equivalent (minimum of cetane No.
40)
The lubricating oil should be:
• Type API, Class CD, CF, CF-4, CI and
CI-4.
Perform the inspections as outlined in
Periodic Maintenance Procedures on page
59 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 58 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 55
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.
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PERIODIC MAINTENANCE
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.
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.
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 degrees, 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.
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
degrees 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;
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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.
Consult authorized Yanmar Marine dealer
or distributor for assistance when checking
items marked with a ●.
YM Series Operation Manual
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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 59.
Whole
Visual inspection of
engine exterior

Fuel
System
Check the fuel level and
refill if necessary

Drain water and sediment
from the fuel tank
Initial
50
Hours
Every
50
hours
or
monthly
whichever
comes
first
Every
100
hours
or six
months
whichever
comes
first
Every
150
hours
or one
year
whichever
comes
first

Drain the fuel / water
separator


Check the fuel injection
timing
●
Check the fuel injector
spray pattern*
●*
Check the
engine oil
level
Replace the
engine oil
Engine

Marine
Gear

Engine

Marine
Gear




Sail Drive
Replace the
oil filter
element
Cooling
System
Engine
Seawater outlet



During
Operatio
n
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 34.
Clean and check the
seawater passages
56
Every
1000
hours
or 4
years
whichever
comes
first

Replace the fuel filter
element
Lubricatin
g System
Every
250
hours
or one
year
whichever
comes
first
●
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12/05
: Check or Clean : Replace ●: Contact your authorized Yanmar Marine dealer or distributor
Periodic Maintenance Interval
Before
Starting
See
Daily
Checks
on
page 59.
Initial
50
Hours
Every
50
hours
or
monthly
whichever
comes
first
Every
100
hours
or six
months
whichever
comes
first
Every
150
hours
or one
year
whichever
comes
first
Every
250
hours
or one
year
whichever
comes
first
System
Item
Air Intake
and
Exhaust
System
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
Operatio
n
Check diaphragm
assembly
Electrical
System
Check the alarm and
indicators
●

Check the electrolyte level
in the battery

Adjust the tension of the
alternator V-ribbed belt or
replace V-ribbed belt

Check the wiring
connectors
Engine
Cylinder
Head and
Block
Check for leakage of fuel,
engine oil and engine
coolant


After
Starting
Tighten all major nuts and
bolts
Check the remote control
cables


●
Adjust intake / exhaust
valve clearance
Miscellan
e- ous
Items
Every
1000
hours
or 4
years
whichever
comes
first

Adjust the propeller shaft
alignment

●

●

●
* For EPA requirements, see Inspection and Maintenance of EPA
Emission-Related Parts on page 58 .
Note: These procedures are considered normal maintenance and are performed at
the owner’s expense.
YM Series Operation Manual
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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 CI marine engine
and CARB non-road engine
• Marine diesel engines greater than 37 kW (50hp) are certified as EPA CI marine
engines
Inspection and Maintenance of EPA Emission-Related Parts for Non-Road
and CI Marine Engines
Parts
Interval
Clean fuel injection nozzle
1500 hours
Check fuel injection nozzle pressure and spray pattern
3000 hours
Check fuel injection pump adjustment
Check turbocharger adjustment (if equipped)
Check electronic engine control unit and its associated sensors
and actuators (if equipped)
Note: The inspection and maintenance items shown above are to be performed at
your Yanmar Marine dealer or distributor.
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PERIODIC MAINTENANCE
12/05
PERIODIC MAINTENANCE
PROCEDURES
WARNING
Exposure Hazard.
Always wear personal protective
equipment when performing periodic
maintenance procedures.
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.
Daily Checks
5. Check for loose, missing or damaged
fasteners.
Before you head out for the day, make
sure the Yanmar engine is in good
operating condition.
6. Check the electrical harnesses for
cracks, abrasions, and damaged or
corroded connectors.
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 you 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.
YM Series Operation Manual
7. Check hoses for cracks, abrasions, and
damaged, loose or corroded clamps.
8. Check the fuel filter / water separator
for presence of water and
contaminants. If you find any water or
contaminants, drain the fuel filter /
water separator. See Draining Fuel
Filter / Water Separator on page 65. If
you have to drain the fuel filter / water
separator frequently, drain the fuel tank
and check for the presence of water in
your fuel supply. See Draining the Fuel
Tank on page 61.
NOTICE
If any problem is noted during the visual
check, the necessary corrective action
should be taken before operating the
engine.
Check Diesel Fuel, Engine Oil and
Engine Coolant Levels
Follow the procedures in Diesel Fuel on
page 26 , Engine Oil on page 31 and
Engine Coolant on page 34 to check these
levels.
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Checking and Refilling Marine Gear
Oil
Refer to the Operation Manual for the
marine gear.
Checking the Battery Electrolyte
Level
Check the battery electrolyte level before
use. See Checking the Battery Electrolyte
Level (Serviceable Batteries Only) on
page 66.
Checking the Alternator Belt
Check the belt tension before use. See
Checking and Adjusting the Alternator
V-ribbed belt Tension on page 62.
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 and
Replacing the Engine Oil Filter
Element
• Changing the Marine Gear Oil and
Replacing the Marine Gear Oil Filter (If
Equipped)
• Checking and Adjusting the
Alternator V-ribbed belt Tension
Checking the Remote Control
Handle
• Inspecting and Adjusting
Intake / Exhaust Valve Clearance
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 63.
• Checking and Adjusting the Remote
Control Cables
• Adjusting Propeller Shaft Alignment
Checking the Alarm Indicators
When operating the start switch on the
instrument panel, check that there is no
alarm message on the display and the
alarm indicators work normally. See
Control Equipment on page 18.
Preparing Fuel, Oil and Coolant in
Reserve
Prepare sufficient fuel for the days
operation. Always store engine oil and
coolant in reserve (for at least one refill)
onboard, to be ready for emergencies.
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Draining the Fuel Tank
WARNING
Burn Hazard.
If you must drain the engine oil while it
is still hot, stay clear of the hot engine
oil to avoid being burned. Always wear
eye protection.
3
1. Turn the engine off.
1
2
0004542
Figure 1
1 – Sediment Bowl
2 – Drain Cock
3 – Fuel Line to Engine
Note: Optional fuel tank shown. Actual
equipment may differ.
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.
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 arailable to drain the
engine oil after operation while the engine
is still warm.
2. 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. Dispose of used oil properly.
NOTICE
•Prevent dirt and debris from
contaminating engine oil. Carefully
clean the dipstick and the surrounding
area before removing the dipstick.
•Always be environmentally
responsible.
3. Fill with new engine oil. See Adding
Engine Oil on page 32.
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 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.
YM Series Operation Manual
61
PERIODIC MAINTENANCE
Replacing the Engine Oil Filter Element
1. Turn the engine off.
Checking and Adjusting the
Alternator V-ribbed belt Tension
WARNING
2. Turn the engine oil filter Figure 2
counterclockwise with a wrench.
Sever Hazard. Perform this check with
the power switch off and the battery
switch turned off to avoid contact with
moving parts.
3. Remove the engine oil filter.
Figure 1
NOTICE
0004797
Never get any oil on the belt(s). Oil on the
belt causes slipping and stretching.
Replace the belt if it is damaged.
Figure 2
Figure 2
3
Note: 3YM20 shown.
4. Install a new filter element and hand-tighten
until the seal touches the housing.
1
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.
Changing the Marine Gear Oil
4
2
4
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 33.
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.
62
051168-00X01
Figure 3
1
2
3
4
– Middle of V-ribbed Belt
– Alternator Bolt
– Alternator Bolt
– Alternator Adjusting Bolt
Note: 3YM30E shown.
YM Series Operation Manual
PERIODIC MAINTENANCE
12/05
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.).
3. Loosen the 3 bolts of alternator
(Figure 3, (2) (3) (4)).
4. Screw in the adjusting bolt
(Figure 3, (4)) and move the alternator
to adjust the belt tension properly.
5. Tighten the 3 bolts of the alternator.
6. Install the belt cover.
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. Consult 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.
Adjusting the Throttle Remote Control
Cable
Figure 3
4
2
1
5
6
3
0004798
Figure 4
1
2
3
4
5
6
YM Series Operation Manual
– Cable
– Fuel Injection Pump
– Adjustment
– High-Speed Stop Bolt
– Low-Speed Stop Bolt
– Control Lever
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PERIODIC MAINTENANCE
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.
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.
Adjusting Clutch Remote Control Cable
Figure 4
4
2
1
3
0004799
Figure 5
1
2
3
4
– Marine Gear
– Control Cable
– Control Lever
– 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.
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Figure 5
Every 50 Hours of Operation
1
When completing the initial 50 hour
maintenance procedures, perform the
following procedures every 50 hours
thereafter or monthly, whichever comes
first.
2
3
• Draining Fuel Filter / Water Separator
• Checking the Battery Electrolyte
Level
4
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.
Exposure Hazard.
Wear eye protection. The fuel system is
under pressure and fuel could spray
out when removing any fuel system
component.
5
6
000480
Figure 6
1
2
3
4
5
6
– Air Bleed Screw
– Bracket
– O-Ring
– Fuel Filter Element
– Fuel Filter Housing
– 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)).
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PERIODIC MAINTENANCE
5. Be sure to bleed air from the fuel
system. See Bleeding the Fuel System
on page 30.
Checking the Battery Electrolyte
Level (Serviceable Batteries Only)
Never operate with insufficient battery
electrolyte. Operating with insufficient
electrolyte will destroy the battery.
WARNING
NOTICE
Never attempt to remove the covers or fill a
maintenance-free battery.
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.
Figure 6
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.
2
UPPER
LEVEL
LOWER
LEVEL
3
1
NOTICE
Never turn off the battery switch (if
equipped) or short the battery cables
during operation. Damage to the electrical
system will result.
Battery fluid tends to evaporate in high
temperatures, especially in summer. In
such conditions, inspect the battery earlier
than specified.
0004566
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.
1. Make sure the engine is off.
2. Turn the battery switch to OFF (if
equipped) or disconnect the negative
(-) battery cable.
3. Remove the plugs and check the
electrolyte level in all cells.
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PERIODIC MAINTENANCE
12/05
Every 100 Hours of Operation
Every 150 Hours of Operation
Perform the following maintenance every
100 hours or every 6 months of operation,
whichever comes first.
Perform the following maintenance every
150 hours or every year of operation,
whichever comes first.
• Changing the Sail Drive Gear Oil
• Changing the Engine Oil
Changing the Sail Drive Gear Oil
Changing the Engine Oil
Refer to the Sail Drive Operation Manual
for the procedure for changing gear oil.
See Changing the Engine Oil on page 61.
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PERIODIC MAINTENANCE
Draining the Fuel Tank
Every 250 Hours of Operation
See Draining the Fuel Tank on page 61.
Perform the following maintenance every
250 hours or 1 year of operation,
whichever comes first.
Replacing the Fuel Filter Element
• Draining the Fuel Tank
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.
• 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-ribbed belt
Tension
• Cleaning the Breather Pipe
WARNING
Exposure Hazard.
Wear eye protection. The fuel system is
under pressure and fuel could spray
out when removing any fuel system
component.
Figure 7
• Checking the Wiring Connectors
2
1
0004804
Figure 8
1 – Housing
2 – Retaining Ring
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PERIODIC MAINTENANCE
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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 30.
8. Dispose of waste properly.
Replacing the Engine Oil Filter
Element
• 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.
Consult authorized Yanmar Marine
dealer or distributor.
When disassembly and maintenance of
the seawater pump are necessary, consult
your Yanmar Marine dealer or distributor.
The seawater pump turns in the direction
as shown in Figure 9. The impeller must
be installed while considering the impeller
direction.
Figure 8
2
1
See Replacing the Engine Oil Filter
Element on page 62.
Changing the Marine Gear Oil
See Changing the Marine Gear Oil on
page 62.
3
4
0004806
Figure 9
1
2
3
4
– Impeller Vane Direction
– Impeller Rotating Direction
– Impeller
– Seawater Pump
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:
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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.
Cleaning the Intake Silencer (Air
Cleaner) Element
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.
Figure 9
1
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 reservooir with
appropriate coolant. See Engine Oil
Specifications on page 31 and see
Checking and Adding Coolant on page
35 .
0004805
Figure 10
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. Consult 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.
Consult authorized Yanmar Marine dealer
or distributor.
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PERIODIC MAINTENANCE
12/05
Adjusting the Alternator V-ribbed
belt Tension
See Checking and Adjusting the Alternator
V-ribbed belt Tension on page 62.
Cleaning the Breather Pipe
Consult authorized Yanmar Marine dealer
or distributor.
Checking the Wiring Connectors
Consult 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-ribbed belt
• Adjusting Intake / Exhaust Valve
Clearance
• Checking and Adjusting the Remote
Control Cables
• Adjusting the Propeller Shaft
Alignment
• Tightening All Major Nuts and Bolts
Checking the Fuel Injection Timing
Consult authorized Yanmar Marine dealer
or distributor.
Checking the Fuel Injector Spray
Pattern
Consult authorized Yanmar Marine dealer
or distributor.
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PERIODIC MAINTENANCE
Replacing the Seawater Pump
Impeller
The seawater impeller must be replaced
every 1000 hours or every 4 years even if
it is not damaged.
See Checking or Replacing the Seawater
Pump Impeller on page 69.
Figure 10Breather System Components
1
2
3
4
5
6
Cleaning and Checking the
Seawater Passages
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:
• Heat Exchanger
• Pressure Cap
Consult authorized Yanmar Marine dealer
or distributor.
Checking the Diaphragm Assembly
Inspect the diaphragm assembly on the
rocker arm cover.
7
8
0004807
Figure 11
1
2
3
4
5
6
7
8
– Diaphragm Cover
– Spring
– Center Plate
– Diaphragm
– Rocker Arm Cover
– Breather Baffle
– Baffle Plate
– Intake Silencer (air cleaner)
Replacing the Alternator V-ribbed
belt
1. Remove the V-ribbed belt cover.
1. Loosen screws and remove diaphragm
assembly.
2. Loosen the V-ribbed belt tension
adjusting bolt of the alternator.
2. Check for oil and contaminants
between the diaphragm and cover.
3. Remove the alternator V-ribbed belt.
NOTICE
If oil and contaminants enter the
diaphragm assembly, the diaphragm will
not operate properly.
3. Inspect the diaphragm rubber and
spring for damage. If necessary,
replace with new ones.
72
4. Install a new alternator V-ribbed belt.
5. Adjust the alternator V-ribbed belt
tension. See Checking and Adjusting
the Alternator V-ribbed belt Tension on
page 62.
6. Replace the V-ribbed belt cover.
Adjusting Intake / Exhaust Valve
Clearance
Consult authorized Yanmar Marine dealer
or distributor.
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PERIODIC MAINTENANCE
12/05
Checking and Adjusting the Remote
Control Cables
See Checking and Adjusting the Remote
Control Cables on page 63.
Adjusting the Propeller Shaft
Alignment
Consult authorized Yanmar Marine dealer
or distributor.
Tightening All Major Nuts and Bolts
See Tightening Fasteners on page 52 or
consult authorized Yanmar Marine dealer
or distributor.
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PERIODIC MAINTENANCE
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TROUBLESHOOTING
SAFETY PRECAUTIONS
Before performing any troubleshooting
procedures within this section, review the
Safety section on page 5.
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 smoke color normal?
The continuous emission of black exhaust
smoke indicates engine overloading. This
shortens the engines life and should be
avoided.
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.
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TROUBLESHOOTING
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 30.
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 smoke color and reduce engine
performance.
TROUBLESHOOTING
INFORMATION
If the engine does not operate properly,
refer to the Troubleshooting Chart on page
77 or consult authorized Yanmar Marine
dealer or distributor.
Supply the 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), age of boat
• The operating conditions when the
problem occurs:
• Engine speed (min-1)
• Color of exhaust smoke
• Type of diesel fuel
• Type of engine oil
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.
• 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
Probable Cause
Measure
Reference
Indicators light on the
instrument panel and alarm
sounds during operation
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 consult authorized Yanmar Marine dealer or distributor.
Engine oil low pressure alarm
indicator lights
Engine oil level is low.
Check engine oil level. Add or
replace as necessary.
See Checking the
Engine Oil on
page 32.
Engine oil filter is clogged.
Replace engine oil filter.
Replace engine oil.
See Changing the
Engine Oil on
page 61.
Water in sail drive seal
indicator lights
Rubber sail drive seal is broken.
Consult authorized Yanmar
Marine dealer or distributor.
-
Coolant high temperature
alarm lights
Coolant in coolant tank / heat
exchanger is low.
Check coolant level and refill.
See Checking and
Adding Coolant on
page 35.
Insufficient seawater level causing
temperature to rise.
Check seawater system.
-
Contamination inside cooling system.
Consult 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.
Indicators Do Not Go On:
The tachometer does not turn
on, even though the power
switch is turned on
No electrical current available.
The battery switch is turned off, the
fuse (3 A) on the instrument panel is
burned out or the circuit is broken.
Consult authorized Yanmar
Marine dealer or distributor.
-
One of the indicators does
not go out
Sensor switch is faulty.
Consult authorized Yanmar
Marine dealer or distributor.
-
Battery low charge indicator
does not go out during
operation
V-ribbed belt is loose or broken.
Replace V-ribbed belt or
adjust tension.
See Checking and
Adjusting the
Alternator V-ribbed
belt Tension on
page 62.
Battery is defective.
Check battery fluid level,
specific gravity or replace
battery.
See Checking the
Battery Electrolyte
Level on page 60.
Alternator power generation failure.
Consult authorized Yanmar
Marine dealer or distributor.
-
No fuel.
Add fuel. Bleed fuel system.
Starting Failures:
Starter turns but engine does
not start
See Filling the Fuel
Tank on page 29
and see Bleeding
the Fuel System on
page 30 .
Fuel filter is clogged.
Replace filter element.
See Replacing the
Fuel Filter Element
on page 68.
Improper fuel.
Replace with recommended
fuel.
See Diesel Fuel
Specifications on
page 26.
Problem with fuel injection.
Consult authorized Yanmar
Marine dealer or distributor.
-
Compression leakage from
intake / exhaust valve.
Consult authorized Yanmar
Marine dealer or distributor.
-
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TROUBLESHOOTING
Symptom
Starter does not turn or turns
slowly (engine can be turned
manually)
Engine cannot be turned
manually
Probable Cause
Measure
Reference
Faulty clutch position.
Shift to NEUTRAL and start.
See If the Engine
Fails to Start on
page 42.
Insufficient battery charge.
Check fluid level. Recharge
or replace battery.
See Checking the
Battery Electrolyte
Level on page 60.
Cable terminal contact failure.
Remove corrosion from
terminals. Tighten battery
cables.
-
Faulty safety switch device.
Consult authorized Yanmar
Marine dealer or distributor.
-
Faulty starter switch.
Consult authorized Yanmar
Marine dealer or distributor.
-
Power lacking due to accessory drive
being engaged.
Consult authorized Yanmar
Marine dealer or distributor.
-
Internal parts seized.
Consult authorized Yanmar
Marine dealer or distributor.
-
Load increased.
Consult authorized Yanmar
Marine dealer or distributor.
-
Improper propeller matching.
Consult authorized Yanmar
Marine dealer or distributor.
-
Dirty intake silencer (air cleaner).
Clean element.
See Cleaning the
Intake Silencer (Air
Cleaner) Element
on page 70.
Improper fuel.
Replace with recommended
fuel.
See Diesel Fuel
Specifications on
page 26.
Faulty spraying of fuel injector.
Consult authorized Yanmar
Marine dealer or distributor.
-
Incorrect intake / exhaust valve
clearance.
Consult authorized Yanmar
Marine dealer or distributor.
-
Improper fuel.
Replace with recommended
fuel.
See Diesel Fuel
Specifications on
page 26.
Faulty spraying of fuel injector.
Consult authorized Yanmar
Marine dealer or distributor.
-
Fuel injection timing off.
Consult authorized Yanmar
Marine dealer or distributor.
-
Excessive diesel fuel consumption.
Consult authorized Yanmar
Marine dealer or distributor.
-
Abnormal Exhaust Color:
Black smoke
White smoke
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LONG-TERM STORAGE
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.
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.
Before performing any storage procedures
within this section, review the Safety
section on page 5.
2. Drain water from fuel filters.
In cold temperatures or before long-term
storage, be sure to drain the seawater
from the cooling system.
4. Grease the exposed areas and joints of
the remote control cables and the
bearings of the remote control handle.
NOTICE
Do not drain the coolant system. A full
coolant system will prevent corrosion and
frost damage.
If seawater is left inside of the engine, it
may freeze and damage parts of the
cooling system when the ambient
temperature is below 0°C (32°F).
YM Series Operation Manual
3. Drain fuel tank completely or fill the
tank to prevent condensation.
5. Seal the intake silencer, exhaust pipe,
etc. to prevent moisture or
contamination from entering engine.
6. Completely drain bilge in hull bottom.
7. Waterproof the engine room to prevent
rain or seawater from entering.
8. Charge the battery once a month to
compensate for battery’s
self-discharge.
9. Make sure the power switch is off.
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LONG-TERM STORAGE
DRAIN SEAWATER
COOLING SYSTEM
1
1
2
3
2
0004793
Figure 3
3
051170-00X00
1 – Stop Solenoid
2 – Coolant Drain Cock
3 – Flywheel Housing
Figure 1
1 – Coolant Tank / Heat Exchanger
2 – Seawater Drain Cock
3 – Coolant Drain Plug
1
Figure 4
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).
5
4
1. Put a pan under the seawater drain
cocks.
3
2
051169-00X00
Figure 2
1
2
3
4
5
80
– Coolant Tank / Heat Exchanger
– Coolant Drain Plug
– Seawater Drain Plug
– Seawater Pump
– Coolant Pump
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.
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LONG-TERM STORAGE
12/05
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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SPECIFICATIONS
PRINCIPAL ENGINE SPECIFICATIONS
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SPECIFICATIONS
2YM15 Engine Specifications
Specification
Marine Gear Model
2YM15
KM2P-1
SD-20
Use
Pleasure use
Type
Vertical water cooled 4-cycle diesel engine
Combustion System
Air Charging
Swirl pre-combustion chamber
Natural aspiration
Number of Cylinders
Bore x Stroke
2
70 mm x 74 mm (2.76 in. x 2.91 in.)
Displacement
0.570 L (34.8 cu in.)
Continuous
Power
Output at
Crankshaft / Engine Speed
9.1 kW (12.4 hp metric) / 3489 min-1
Fuel Stop
Power
Output at
Crankshaft / Engine Speed
10.0 kW (13.6 hp metric) / 3600 min-1*
Output at
Propeller / Engine Speed
Installation
9.7 kW (13.2 hp metric) / 3600 min-1**
Flexible mounting
Fuel Injection Timing
FID 21 ±1° BTDC
Fuel Injection Opening Pressure
12.3 to 13.28 MPa
Main Power Take Off
Direction of
Rotation
Crankshaft
Propeller Shaft (Ahead)
Cooling System
Lubrication System
Coolant Capacity
Lubricating
Oil Capacity
(Engine)
Starting
System
Rake Angle
At flywheel end
Counterclockwise viewed from stern
Clockwise viewed from stern
-
Coolant cooling with heat exchanger
Forced lubrication system
Engine 3.0 L (3.17 qt), Reservoir: 0.8 L (0.85 qt)
at rake angle 8°
at rake angle 0°
Total**
2.0 L (2.1 qt)
1.8 L (1.9 qt)
Effective***
0.95 L (1.0 qt)
0.9 L (0.95 qt)
Type
Starting Motor
AC Alternator
Engine
Dimension
-
Overall Length
Electric
DC 12 V - 1.4 kW
12 V - 120 A
613 mm (24.1 in.)
Overall Width
463 mm (18.2 in.)
Overall Height
528 mm (20.8 in.)
Engine Dry Mass (Including Marine Gear)
113 kg (249 lb)
-
134 kg (295 lb)
* Rating Condition: Temperature of fuel; 40°C at fuel pump inlet; ISO 8665
** 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/cm3 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
3YM20
Marine Gear Model
KM2P-1
SD-20
Use
Pleasure use
Type
Vertical water cooled 4-cycle diesel engine
Combustion System
Swirl pre-combustion chamber
Air Charging
Natural aspiration
Number of Cylinders
3
Bore x Stroke
70 mm x 74 mm (2.76 in. x 2.91 in.)
Displacement
0.854 L (52.1 cu in.)
Continuous
Power
Output at
Crankshaft / Engine Speed
13.9 kW (18.9 hp metric) / 3489 min-1
Fuel Stop
Power
Output at
Crankshaft / Engine Speed
15.3 kW (20.8 hp metric) / 3600 min-1*
Output at
Propeller / Engine Speed
14.9 kW (20.1 hp metric) / 3600 min-1**
Installation
Flexible mounting
Fuel Injection Timing
FID 22 ± 1° BTDC
Fuel Injection Opening Pressure
12.3 to 13.28 MPa
Main Power Take Off
Direction of
Rotation
At flywheel end
Crankshaft
Propeller Shaft (Ahead)
Cooling System
-
Engine 4.1 L (4.33 qt), Reservoir: 0.8 L (0.85 qt)
Rake Angle
at rake angle 8°
at rake angle 0°
Total**
2.7 L (2.85 qt)
2.4 L (2.54 qt)
Effective***
1.4 L (1.48 qt)
1.5 L (1.59 qt)
Type
Starting Motor
AC Alternator
Engine
Dimension
Clockwise viewed from stern
Forced lubrication system
Coolant Capacity
Starting System
Counterclockwise viewed from stern
Coolant cooling with heat exchanger
Lubrication System
Lubricating Oil
Capacity
(Engine)
-
Overall Length
Electric
DC 12 V - 1.4 kW
12 V - 120A
693 mm (27.3 in.)
Overall Width
463 mm (18.2 in.)
Overall Height
528 mm (20.8 in.)
Engine Dry Mass (Including Marine Gear)
130 kg (287 lb)
-
151 kg (333 lb)
* Rating Condition: Temperature of fuel; 40°C at fuel pump inlet; ISO 8665
** 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/cm3 at 15°C. Fuel temperature at the inlet of the fuel injection pump.
1hp metric = 0.7355 kW
YM Series Operation Manual
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SPECIFICATIONS
3YM30E Engine Specifications
Specification
Marine Gear Model
3YM30E
KM2P-1
SD-20
Use
Pleasure use
Type
Vertical water cooled 4-cycle diesel engine
Combustion System
Air Charging
Swirl pre-combustion chamber
Natural aspiration
Number of Cylinders
Bore x Stroke
3
76 mm x 82 mm (2.99 in. x 3.23 in.)
Displacement
1.115 L (68.04 cu in.)
Continuous
Power
Output at
Crankshaft / Engine Speed
19.4 kW (26.4 hp metric) / 3489 min-1
Fuel Stop
Power
Output at
Crankshaft / Engine Speed
21.3 kW (29.0 hp metric) / 3600 min-1*
Output at
Propeller / Engine Speed
Installation
20.7 kW (28.1 hp metric) / 3600 min-1**
Flexible mounting
Fuel Injection Timing
FID 18 ±1° BTDC
Fuel Injection Opening Pressure
12.3 to 13.28 MPa
Main Power Take Off
Direction of
Rotation
Crankshaft
Propeller Shaft (Ahead)
Cooling System
Lubrication System
Coolant Capacity
Lubricating
Oil Capacity
(Engine)
Starting
System
Rake Angle
At flywheel end
Counterclockwise viewed from stern
Clockwise viewed from stern
-
Coolant cooling with heat exchanger
Forced lubrication system
Engine 4.9 L (5.2 qt), Reservoir: 0.8 L (0.85 qt)
at rake angle 8°
at rake angle 0°
Total**
2.8 L (2.96 qt)
2.5 L (2.64 qt)
Effective***
1.4 L (1.48 qt)
1.5 L (1.59 qt)
Type
Starting Motor
AC Alternator
Engine
Dimension
-
Overall Length
Electric
DC 12 V - 1.4 kW
12 V - 120 A
715 mm (28.1 in.)
Overall Width
463 mm (18.2 in.)
Overall Height
545 mm (21.5 in.)
Engine Dry Mass (Including Marine Gear)
133 kg (293 lb)
-
157 kg (346 lb)
* Rating Condition: Temperature of fuel; 40°C at fuel pump inlet; ISO 8665
** 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/cm3 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
3YM30
Marine Gear Model
KM2P-1
SD-20
Use
Pleasure use
Type
Vertical water cooled 4-cycle diesel engine
Combustion System
Swirl pre-combustion chamber
Air Charging
Natural aspiration
Number of Cylinders
3
Bore x Stroke
76 mm x 82 mm (2.99 in. x 3.23 in.)
Displacement
1.115 L (68.04 cu in.)
Continuous
Power
Output at
Crankshaft / Engine Speed
19.4 kW (26.4 hp metric) / 3489 min-1
Fuel Stop
Power
Output at
Crankshaft / Engine Speed
21.3 kW (29.0 hp metric) / 3600 min-1*
Output at
Propeller / Engine Speed
20.7 kW (28.1 hp metric) / 3600 min-1**
Installation
Flexible mounting
Fuel Injection Timing
FID 16 ±1° BTDC
Fuel Injection Opening Pressure
12.3 to 13.28 MPa
Main Power Take Off
Direction of
Rotation
At flywheel end
Crankshaft
Propeller Shaft (Ahead)
Cooling System
-
Engine 4.9 L (5.2 qt), Reservoir: 0.8 L (0.85 qt)
Rake Angle
at rake angle 8°
at rake angle 0°
Total**
2.8 L (2.96 qt)
2.5 L (2.64 qt)
Effective***
1.4 L (1.48 qt)
1.5 L (1.59 qt)
Type
Electric
Starting Motor
AC Alternator
Engine
Dimension
Clockwise viewed from stern
Forced lubrication system
Coolant Capacity
Starting
System
Counterclockwise viewed from stern
Coolant cooling with heat exchanger
Lubrication System
Lubricating
Oil Capacity
(Engine)
-
Overall Length
DC 12 V - 1.4 kW
12 V - 120 A
715 mm (28.1 in.)
Overall Width
463 mm (18.2 in.)
Overall Height
545 mm (21.5 in.)
Engine Dry Mass (Including Marine Gear)
133 kg (293 lb)
-
157 kg (346 lb)
* Rating Condition: Temperature of fuel; 40°C at fuel pump inlet; ISO 8665
** 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/cm3 at 15°C. Fuel temperature at the inlet of the fuel injection pump.
1hp metric = 0.7355 kW
YM Series Operation Manual
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SPECIFICATIONS
Marine Gear and Sail Drive
Specifications
Model
KM2P-1(S)
KM2P-1(G)
Type
KM2P-1(GG)
Mechanical cone clutch
SD20
(coupled at boat
builder)
Dog Clutch
Reduction Ratio
(Forward / Reverse)
2.21 / 3.06
2.62 / 3.06
3.22 / 3.06
2.64 / 2.64
Propeller Speed
(Forward / Reverse) *
1580 / 1140 min-1
1332 / 1140 min-1
1083 / 1140 min-1
1322 / 1322 min-1
Lubrication System
Lubricating Oil Capacity
(Total)
Lubricating Oil Capacity
(Effective)
Cooling System
Weight
Splash
Oil bath
0.3 L (0.32 qt)
2.2 L (2.3 qt)
Standard
2.5 L (2.6 qt)
Long Reach
0.05 L (0.05 qt)
0.15 L (0.16 qt)
Air cooling by fan on flywheel
-
10.3 kg (27.7 lb)
30 kg (66.1 lb)
* At continuous power engine speed 3489
88
min-1.
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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
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SYSTEM DIAGRAMS
Figure 12YM15 with KM2P-1 Marine Gear
1 2 3 4
5 6
78
C 9
10
35
11
12
D
13
14
P
34
15 16 17
33
(36)
32
31
30
29
28
P
P
T
(38)
(37)
B
27
26
25
24
A
P
22
21
20
19
18
23
026475-00X
Figure 1
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SYSTEM DIAGRAMS
12/05
Unit: mm (in.)
Ø50 (1.97)
Detail of part B
18
(0.71)
Detail of part A
X00-135620
Ø17
(0.67)
X00-035620
Detail of part C
Ø9 (0.35)
Detail of part D
Ø8.5 (0.33)
Ø8 (0.31)
17 (0.67)
16.5
(0.65)
Ø8 (0.31)
X00-235620
X00-335620
YM Series Operation Manual
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
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SYSTEM DIAGRAMS
Figure 23YM20 and 3YM30(E) with KM2P-1 Marine Gear
2 3
D
C
1
4
5
6
23
22
P
21
7 8
20
19
9
P
18
T
P
17
16
B
10
P
15
A
13 12
11
14
026476-00X
Figure 2
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SYSTEM DIAGRAMS
12/05
Unit: mm (in.)
Ø50 (1.97)
Detail of part B
18
(0.71)
Detail of part A
X00-135620
Ø17
(0.67)
X00-035620
Detail of part C
Ø9 (0.35)
Detail of part D
Ø8.5 (0.33)
Ø8 (0.31)
17 (0.67)
16.5
(0.65)
Ø8 (0.31)
X00-235620
X00-335620
YM Series Operation Manual
1
2
3
4
5
6
– PCV
– Overflow
– Fuel Inlet
– Fuel Feed Pump
– Fuel Injection Pump
– 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
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SYSTEM DIAGRAMS
WIRING DIAGRAMS
Color Coding
R
Red
B
Black
W
White
L
Blue
RB
Red / Black
LB
Blue / Black
YW
Yellow / White
YG
Yellow / Green
WL
White / Blue
V
Purple
BW
Blue / White
O
Orange
WBr
White / Brown
Allowable Length by Cross Sectional Area of
Battery Cable
94
Section of Cable
mm2 (in.2)
Allowable Length
L = 1 + 2 + 3 m (ft)
15 (0.023)
< 0.86 (0.26)
20 (0.031)
< 1.3 (0.40)
30 (0.046)
< 2.3 (0.70)
40 (0.062)
< 2.8 (0.85)
50 (0.077)
< 3.5 (1.07)
60 (0.093)
< 4.1 (1.25)
YM Series Operation Manual
1
3 4 5 6 7
2
9
8
10
12
11
14
15
18
16
17
B
V
19 20 21
BW
YM Series Operation Manual
13
G
WB
YB
22
YW
WL
WG
B
YG
O
LB
RB
YW
WL
Resistance
W
R
L
W
R
L
B
YG
O
LB
VW
WBr
WBr
A
A
2B
23
B
L
YG
RB
2L
5R
+
-
27
5R
WL
28
29
38
33
2B
WBr
2R
34
W
RB
LB
O
YG
L
YW
WL
WG
B
R
A-A
YW
30
W/Y
2W
31
B
26
+
1
RB
3R
12V
25
5R
*Self-holding
Power SW
Glow SW
Stop SW
Start SW
-
2W
2R
*
Output status table
Output Panel Power
ACC Power
Input
RB
3
24
LB
Glow Relay
20R
B
LB
L
W
O
S
B
YG
B
37
Starter Relay
36
051140-00EN00
Stop Relay
35
32
M
95 ページ
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12/05
SYSTEM DIAGRAMS
Figure 32YM15, 3YM20, 3YM30(E) - B20 Type Instrument Panel
Figure 3
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SYSTEM DIAGRAMS
1 – Instrument panel B20
2 – Alarm lamps (3 to 7)
3 – Engine oil low pressure
indicator
4 – Coolant high temperature
Indicator
5 – Water in sail drive seal
indicator
6 – Battery low charge indicator
7 – Water in fuel filter indicator
8 – Tachometer
9 – Segmented display
10 – Control unit (Tacho gauge)
11 – Fuse 3A
12 – Buzzer
13 – Switch module (14 to 18)
14 – Start switch
15 – Stop switch
16 – Glow switch
17 – Power switch
18 – Control unit (Switch module)
19 – Fuel tank level sensor input
20 – ACC power
21 – ACC GND
22 – Wire harness
23 – Water in sail drive seal sensor
amplifier (sail drive only)
24 – Procured by customer
25 – Battery
26 – Battery switch
27 – Relay (Glow plug)
28 – Glow plug
29 – Stop relay
30 – Engine stop solenoid
31 – Starter relay
32 – Starter
33 – Coolant temperature switch
34 – Engine oil pressure switch
35 – Alternator
36 – Ground
37 – Water in sail drive seal sensor
(Sail drive only)
38 – Details of coupler (Wire
harness, view from A-A)
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EPA WARRANTY USA
ONLY
YANMAR CO., LTD. LIMITED EMISSION CONTROL SYSTEM
WARRANTY - USA ONLY
2YM15 EPA and CARB
Nameplate For Example
3YM30E EPA and CARB Nameplate
EMISSION CONTROL INFORMATION
THIS ENGINE COMPLIES WITH U.S.EPA MARINE AND CALIFORNIA OFF-ROAD
REGULATIONS FOR 2013 M.Y. DIESEL ENGINES.
ULTRA LOW SULFUR DIESEL FUEL ONLY.
ENGINE FAMILY: DYDXN1.11P3N
DISPLACEMENT: 1.116 LITERS
ENGINE MODEL: 3YM30E E.C.S.: EM IFI
EMISSION CONTROL INFORMATION
THIS ENGINE COMPLIES WITH U.S.EPA MARINE AND CALIFORNIA OFF-ROAD
REGULATIONS FOR 2013 M.Y. DIESEL ENGINES.
ULTRA LOW SULFUR DIESEL FUEL ONLY.
ENGINE FAMILY: DYDXN0.57P2N
DISPLACEMENT: 0.570 LITERS
ENGINE MODEL: 2YM15 E.C.S.: EM IFI
FUEL RATE: 17.4MM3/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.
FUEL RATE: 21.9MM3/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.
YANMAR CO.,LTD.
128790-07712
128990-07712
Figure 3
Figure 1
3YM20 EPA and CARB
Nameplate For Example
EMISSION CONTROL INFORMATION
THIS ENGINE COMPLIES WITH U.S.EPA MARINE AND CALIFORNIA OFF-ROAD
REGULATIONS FOR 2013 M.Y. DIESEL ENGINES.
ULTRA LOW SULFUR DIESEL FUEL ONLY.
ENGINE FAMILY: DYDXN0.85P3N DISPLACEMENT: 0.854 LITERS
ENGINE MODEL: 3YM20
E.C.S.: EM IFI
FUEL RATE: 17.2MM3/STROKE @ 15.3kW / 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.
128890-07712
Figure 2
YM Series Operation Manual
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2013年6月7日 金曜日 午前11時11分
EPA WARRANTY USA ONLY
THIS EMISSION WARRANTY APPLIES
TO THE ENGINES CERTIFIED TO
UNITED STATES EPA 40 CFR Part
1042.135 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.
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
Warranty Period
2YM15, 3YM20
(kW < 19)
30 months or 1,500 hours of
use, whichever comes first.
3YM30E
(19 < kW < 37)
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.
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.
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EPA WARRANTY USA ONLY
12/05
Warranty Coverage:
Owner’s Responsibility:
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:
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.
• Fuel Injection System
• After cooler
• 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.
YM Series Operation Manual
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.
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 America
Corporation, Marine Engine Division for
assistance.
Yanmar America Corporation, Marine
Engine Division
101 International Parkway
Adairsville, GA 30103 USA
Telephone: 770-877-9894
Fax: 770-877-7567
Website: us.yanmar.com
E-mail: CS_support@yanmar.com
Toll Free Telephone Numbers:
1-855-416-7091
1-800-872-2867
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EPA WARRANTY USA ONLY
This Page Intentionally Left Blank
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EMISSION SYSTEM
WARRANTY
NON-ROAD EMISSION
SYSTEM WARRANTY
Yanmar Co., Ltd. Limited
Emission Control System
Warranty - USA Only
Your Warranty Rights and
Obligations:
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:
California
The Air Resources Board (ARB), 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
YM Series Operation Manual
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
Warranty Period
2YM15, 3YM20
(kW < 19)
30 months or 1,500 hours
of use, whichever comes first.
3YM30E
(19 < kW < 37)
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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EMISSION SYSTEM WARRANTY
Warranty Coverage:
Warranted Parts:
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.
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:
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.
• Fuel Injection System
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.
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.
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.
102
• 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:
YM Series Operation Manual
YM OPM_EN.book
103 ページ 2013年6月7日 金曜日 午前11時11分
EMISSION SYSTEM WARRANTY
12/05
Owners 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 America Corporation, Marine
Engine Division
101 International Parkway
Adairsville, GA 30103 USA
Telephone: 770-877-9894
Fax: 770-877-7567
Website: us.yanmar.com
E-mail: CS_support@yanmar.com
Toll Free Telephone Numbers:
1-855-416-7091
1-800-872-2867
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.
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 America
Corporation for assistance.
YM Series Operation Manual
103
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EMISSION SYSTEM WARRANTY
Maintenance Log
Date
104
Operating Hours
Maintenance Performed
Dealer Name
YM Series Operation Manual
Stamp or
Signature
YM OPM_EN.book
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EMISSION SYSTEM WARRANTY
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Date
Operating Hours
Maintenance Performed
YM Series Operation Manual
Dealer Name
Stamp or
Signature
105
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EMISSION SYSTEM WARRANTY
106
YM Series Operation Manual
‫ڦ‬Marine Operations Division
Quality Assurance Dept.
5-3-1, Tsukaguchi-honmachi, Amagasaki
Hyogo, 661-0001, Japan
Phone: +81-6-6428-3251 Fax: +81-6-6421-5549
Overseas Office
‫ڦ‬Yanmar Europe B.V. (YEU)
Brugplein 11, 1332 BS Almere-de Vaart, Netherlands
Phone: +31-36-5493200 Fax: +31-36-5493209
‫ڦ‬Yanmar Asia (Singapore) Corporation Pte Ltd. (YASC)
4 Tuas Lane, Singapore 638613
Phone: +65-6595-4200 Fax: +65-6862-5189
‫ڦ‬Yanmar America Corporation (YA)
101 International Parkway
Adairsville, GA 30103, U.S.A.
Phone: +1-770-877-9894 Fax: +1-770-877-9009
‫ڦ‬Yanmar Engine (Shanghai). Co., Ltd.
10F, E-Block POLY PLAZA, No.18 Dongfang Road
Pudong Shanghai, CHINA P.R.C. 200120
Phone: +86-21-6880-5090 Fax: +86-21-6880-8090
OPERATION MANUAL
2YM15, 2YM20, 3YM30E, 3YM30
1st edition: November 2007
2nd edition 1st rev.: March 2012
2nd edition 2nd rev.: July 2012
3rd edition: February 2013
3rd edition 1st rev.: June 2013
Issued by: YANMAR CO., LTD. Marine Operations Division
Edited by: YANMAR TECHNICAL SERVICE CO., LTD.
MARINE ENGINES
http://yanmar.com
0AYMM-G00202
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