2YM15 3YM20 YM 3YM30 series OPERATION MANUAL P/N ... - …€¦ · INTRODUCTION Welcome to the world of Yanmar Marine! Yanmar Marine offers engines, drive systems and accessories

YMseries

OPERATION MANUAL2YM153YM203YM30

P/N: 0AYMM-G00100

MARINEENGINES

Disclaimers:All information, illustrations and specifications in this manual are based on the latestinformation available at the time of publishing. The illustrations used in this manual areintended as representative reference views only. Moreover, because of our continuousproduct improvement policy, we may modify information, illustrations and / or specificationsto explain and / or exemplify a product, service or maintenance improvement. We reservethe right to make any change at any time without notice. Yanmar and areregistered trademarks of Yanmar Co., Ltd. in Japan, the United States and / or othercountries.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 storageand retrieval systems - without the written permission of Yanmar Marine International.© 2007 Yanmar Marine International

0907

ii YM Series Operation Manual© 2007 Yanmar Marine International

TABLE OFCONTENTS

PageIntroduction .............................................................. 1

Record of Ownership . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2Safety ....................................................................... 3

Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4Before You Operate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4During Operation and Maintenance . . . . . . . . . . . . . . . . . . . . . 4

Location of Safety Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Product Overview ...................................................... 9

Yanmar YM Features and Applications . . . . . . . . . . . . . . . . . . . . . . . 9New Engine Break-In . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Component Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11Service Side - 2YM15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11Non-Service Side - 2YM15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11Service Side - 3YM20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12Non-Service Side - 3YM20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12Service Side - 3YM30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13Non-Service Side - 3YM30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Location of Nameplates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14Function of Major Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15Control Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Instrument Panel (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16Single-Lever Remote Control Handle . . . . . . . . . . . . . . . . . . 19

Before You Operate .................................................. 21Diesel Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Diesel Fuel Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21Filling the Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24Bleeding the Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

YM Series Operation Manual iii© 2007 Yanmar Marine International

Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26Engine Oil Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26Engine Oil Viscosity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26Checking the Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27Adding Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Marine Gear or Sail Drive Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28Marine Gear Oil Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . 28Sail Drive Oil Specifications - SD20 . . . . . . . . . . . . . . . . . . . . 28Checking Marine Gear Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28Adding Marine Gear Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29Checking and Adding Sail Drive Oil . . . . . . . . . . . . . . . . . . . . 29

Engine Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29Engine Coolant Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . 29Checking and Adding Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Cranking the Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32Daily Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Visual Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33Checking Diesel Fuel, Engine Oil and EngineCoolant Levels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34Checking and Refilling Marine Gear Oil . . . . . . . . . . . . . . . 34Checking the Battery Electrolyte Level . . . . . . . . . . . . . . . . 34Checking the Alternator Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34Checking the Remote Control Handle . . . . . . . . . . . . . . . . . 34Checking the Alarm Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . 34Preparing Fuel, Oil and Coolant in Reserve . . . . . . . . . . 34

Engine Operation ...................................................... 35Starting the Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Restarting After Starting Failure . . . . . . . . . . . . . . . . . . . . . . . . . 37Starting at Low Temperatures . . . . . . . . . . . . . . . . . . . . . . . . . . . 37After the Engine Has Started . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Remote Control Handle Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39Acceleration and Deceleration . . . . . . . . . . . . . . . . . . . . . . . . . . 39Shifting the Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Shutting Down the Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40Emergency Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Checking the Engine After Operation . . . . . . . . . . . . . . . . . . . . . . . . . 41Periodic Maintenance ................................................ 43

Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

The Importance of Periodic Maintenance . . . . . . . . . . . . . 45Performing Periodic Maintenance . . . . . . . . . . . . . . . . . . . . . . 45The Importance of Daily Checks . . . . . . . . . . . . . . . . . . . . . . . . 45

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iv YM Series Operation Manual© 2007 Yanmar Marine International

Keep a Log of Engine Hours and Daily Checks . . . . . 45Yanmar Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45Tools Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45Ask Your Authorized Yanmar Marine Dealer orDistributor For Help . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45Tightening Fasteners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

EPA Maintenance Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47EPA Requirements for USA and Other ApplicableCountries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47Conditions to Ensure Compliance with EPAEmission Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47Inspection and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

Periodic Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48Inspection and Maintenance of EPA Emission-Related Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

Periodic Maintenance Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52After Initial 50 Hours of Operation . . . . . . . . . . . . . . . . . . . . . . 52Every 50 Hours of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56Every 100 Hours of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . 58Every 150 Hours of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . 59Every 250 Hours of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . 59Every 1000 Hours of Operation . . . . . . . . . . . . . . . . . . . . . . . . . 62

Troubleshooting ....................................................... 65Troubleshooting After Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

Troubleshooting Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

Long-Term Storage ................................................... 71Prepare Engine for Long-Term Storage . . . . . . . . . . . . . . . . . . . . . . 71Draining the Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

Specifications .......................................................... 75Principal Engine Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

2YM15 Engine Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . 753YM20 Engine Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . 773YM30 Engine Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . 79Marine Gear and Sail Drive Specifications . . . . . . . . . . . 81

System Diagrams ..................................................... 83Piping Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88

Emission System Warranty ........................................ 91Non-Road Emission System Warranty . . . . . . . . . . . . . . . . . . . . . . . 91

TABLE OF CONTENTS

YM Series Operation Manual v© 2007 Yanmar Marine International

Yanmar Co., Ltd. Limited Emission ControlSystem Warranty - USA Only . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91Maintenance Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94

TABLE OF CONTENTS

vi YM Series Operation Manual© 2007 Yanmar Marine International

INTRODUCTIONWelcome to the world of Yanmar Marine!Yanmar Marine offers engines, drivesystems and accessories for all types ofboats, from runabouts to sailboats, and fromcruisers to mega yachts. In marine leisureboating, the worldwide reputation of YanmarMarine is second to none. We design ourengines to respect nature. This meansquieter engines, with minimal vibrations,cleaner than ever. All of our engines meetapplicable regulations, including emissions,at the time of manufacture.To help you enjoy your Yanmar YM seriesengine for many years to come, pleasefollow these recommendations:

• Read and understand this OperationManual before you operate the engine toensure that you follow safe operatingpractices and maintenance procedures.

• Keep this Operation Manual in aconvenient place for easy access.

• If this Operation Manual is lost ordamaged, order a new one from yourauthorized Yanmar Marine dealer ordistributor.

• Make sure this manual is transferred tosubsequent owners. This manual shouldbe considered a permanent part of theengine and remain with it.

• Constant efforts are made to improve thequality and performance of Yanmarproducts, so some details included in thisOperation Manual may differ slightly fromyour engine. If you have any questionsabout these differences, please contactyour authorized Yanmar Marine dealer ordistributor.

• The specifications and components(instrument panel, fuel tank, etc.)described in this manual may differ fromones installed on your vessel. Please referto the manual provided by themanufacturer of these components.

• Refer to the Yanmar Limited WarrantyHandbook for a complete warrantydescription.

YM Series Operation Manual 1© 2007 Yanmar Marine International

RECORD OF OWNERSHIPTake a few moments to record the information you need when you contact Yanmar forservice, parts or literature.

Engine Model:

Engine Serial No.:

Date Purchased:

Dealer:

Dealer Phone:

INTRODUCTION

2 YM Series Operation Manual© 2007 Yanmar Marine International

SAFETYYanmar considers safety of greatimportance and recommends that anyonewho comes in close contact with itsproducts, such as those who install,operate, maintain or service Yanmarproducts, exercise care, common senseand comply with the safety information inthis manual and on the engine’s safetydecals. Keep the decals from becomingdirty or torn and replace them if they are lostor damaged. Also, if you need to replace apart that has a decal attached to it, makesure you order the new part and decal at thesame time.

!

This safety alert symbol appearswith most safety statements. Itmeans attention, become alert,your safety is involved! Pleaseread and abide by the messagethat follows the safety alertsymbol.

! DANGERIndicates a hazardous situation which, ifnot avoided, will result in death orserious injury.

! WARNINGIndicates a hazardous situation which, ifnot avoided, could result in death orserious injury.

! CAUTIONIndicates a hazardous situation which, ifnot avoided, could result in minor ormoderate injury.

NOTICEIndicates a situation which can causedamage to the engine, personal propertyand / or the environment or cause theequipment to operate improperly.


SAFETY PRECAUTIONSGeneral InformationThere is no substitute for common senseand careful practices. Improper practices orcarelessness can cause burns, cuts,mutilation, asphyxiation, other bodily injuryor death. This information contains generalsafety precautions and guidelines that mustbe followed to reduce risk to personal safety.Special safety precautions are listed inspecific procedures. Read and understandall of the safety precautions before operationor performing repairs or maintenance.Before You Operate

! DANGERThe safety messages that follow haveWARNING level hazards.

NEVER permit anyone toinstall or operate theengine without propertraining.

• Read and understand this OperationManual before you operate or service theengine to ensure that you follow safeoperating practices and maintenanceprocedures.

• Safety signs and decals are additionalreminders for safe operating andmaintenance techniques.

• See your authorized Yanmar Marinedealer or distributor for additional training.

During Operation andMaintenance

! DANGERThe safety message that follows hasDANGER level hazards.

Crush HazardNEVER stand under a hoistedengine. If the hoist mechanismfails, the engine will fall on you.

Fire HazardEnsure that appropriate firedetection and extinguishingequipment are installed andchecked periodically forproper operation.

SAFETY


! WARNINGThe safety messages that follow haveWARNING level hazards.

Explosion HazardWhile the engine is running orthe battery is charging,hydrogen gas is beingproduced and can be easilyignited. Keep the area around

the battery well-ventilated and keep sparks,open flames and any other form of ignitionout of the area.

Fire and Explosion HazardDiesel fuel is flammable and explosiveunder certain conditions.

NEVER use a shop rag to catch the fuel.

Wipe up all spills immediately.

NEVER refuel with the engine running.

Store any containers containing fuel in awell-ventilated area, away from anycombustibles or sources of ignition.

Fire HazardUndersized wiring systemscan cause an electrical fire.

Sever HazardNEVER wear jewelry,unbuttoned cuffs, ties orloose-fitting clothing andALWAYS tie back long hairwhen working near moving /

rotating parts such as the flywheel or PTOshaft. Keep hands, feet and tools away fromall moving parts.

Alcohol and Drug HazardNEVER operate the enginewhile under the influence ofalcohol or drugs or if you arefeeling ill.

Exposure HazardALWAYS wear personalprotective equipmentincluding appropriateclothing, gloves, work shoes,eye and hearing protection as

required for the task at hand.

Sudden Movement HazardALWAYS stop the engine before beginningservice.

NEVER leave the key in the key switch whenyou are servicing the engine. Someone mayaccidentally start the engine and not realizeyou are servicing it.

NEVER operate the engine while wearing aheadset to listen to music or radio becauseit will be difficult to hear the warning signals.

Stop the engine before you begin to serviceit.

SAFETY


! WARNINGPiercing Hazard

Avoid skin contact with high-pressure diesel fuel spraycaused by a fuel system leaksuch as a broken fuel injectionline. High-pressure fuel can

penetrate your skin and result in seriousinjury. If you are exposed to high-pressurefuel spray, obtain prompt medical treatment.

NEVER check for a fuel leak with yourhands. ALWAYS use a piece of wood orcardboard. Have your authorized YanmarMarine dealer or distributor repair thedamage.

Burn HazardSome of the engine surfacesbecome very hot duringoperation and shortly aftershutdown. Keep hands andother body parts away fromhot engine surfaces.

Exhaust HazardNEVER block windows, ventsor other means of ventilation ifthe engine is operating in anenclosed area. All internalcombustion engines create

carbon monoxide gas during operation andspecial precautions are required to avoidcarbon monoxide poisoning.

! CAUTIONThe safety messages that follow haveCAUTION level hazards.

Poor Lighting HazardEnsure that the work area is adequatelyilluminated. ALWAYS install wire cages onportable safety lamps.

Tool HazardALWAYS use tools appropriate for the taskat hand and use the correct size tool forloosening or tightening engine parts.

Flying Object HazardALWAYS wear eye protection whenservicing the engine or when usingcompressed air or high-pressure water.Dust, flying debris, compressed air,pressurized water or steam may injure youreyes.

Coolant HazardWear eye protection andrubber gloves when youhandle Long Life enginecoolant. If contact with theeyes or skin should occur,

flush eyes and wash immediately with cleanwater.

SAFETY


NOTICEThe safety messages that follow haveNOTICE level hazards.It is important to perform daily checks aslisted in the Operation Manual.Periodic maintenance prevents unexpecteddowntime, reduces the number of accidentsdue to poor engine performance and helpsextend the life of the engine.

See your authorized Yanmar Marine dealeror distributor if you need to operate theengine at high altitudes. At high altitudes theengine will lose power, run rough andproduce exhaust gases that exceed thedesign specifications.

ALWAYS be environmentallyresponsible.

Follow the guidelines of the EPA or othergovernmental agencies for the properdisposal of hazardous materials such asengine oil, diesel fuel and engine coolant.Consult the local authorities or reclamationfacility.NEVER dispose of hazardous materials bydumping them into a sewer, on the groundor into ground water or waterways.

If a Yanmar Marine Engine is installed at anangle that exceeds the specifications statedin the Yanmar Marine Installation Manuals,engine oil may enter the combustionchamber causing excessive engine speed,white exhaust smoke and serious enginedamage. This applies to engines that runcontinuously or those that run for shortperiods of time.

If you have an installation with two or threeengines and only one engine is operating,the seacock of the non-running engine(s)should be closed. This will prevent waterfrom being forced past the seawater pumpand entering the engine. The result of waterentering the engine could cause engineseizure or other serious problems.

If you have an installation with two or threeengines, and only one engine is operating,please note that if the propeller shaftthru-hull (stuffing box) is lubricated byengine water pressure and the engines areinterconnected, care must be taken thatwater from the running engine does notenter the exhaust of the non-running engine(s). This water could cause seizure of thenon-running engine(s). See your authorizedYanmar Marine dealer or distributor for acomplete explanation of this condition.

If you have an installation with two or threeengines, and only one engine is operating,it is important to limit the amount of throttleapplied to the running engine. If you observeblack smoke or movement of the throttledoes not increase engine rpm, you areoverloading the engine that is running.Immediately throttle back to approximatelytwo-thirds throttle or to a setting where theengine performs normally. Failure to do somay cause the running engine to overheator cause excess carbon buildup which mayshorten the engine's life.

SAFETY


LOCATION OF SAFETY DECALSFigure 1 shows the location of safety decals on Yanmar YM series marine engines.

YM Engines

196630-12980

(1)(2)

(3)

0004780

WARNINGDANGER

Figure 11 – Part Number: 128377–072602 – Part Number: 128377–073503 – Part Number: 196630–12980

SAFETY


PRODUCT OVERVIEWYANMAR YM FEATURESAND APPLICATIONSThe YM series are four-stroke directinjection diesel engines equipped with liquidcoolant systems.The 2YM15 is a 2-cylinder engine and isnaturally aspirated.The 3YM20 is a 3-cylinder engine and isnaturally aspirated.The 3YM30 is a 3-cylinder engine and isnaturally aspirated.These engines are equipped with a marinegear or sail drive unit.These engines are designed for pleasurecraft use.It is recommended that new vessels bepropped so the engines can operate at100 - 200 rpm above the Maximum RatedPower Output rpm (3700 - 3800) to allow forsome added weight and hull resistance. Theengine must be able to reach the MaximumRated Power rpm (3600) under full load atall times.Failure to do so can lead to reduced vesselperformance, increased smoke levels andcan cause permanent damage to yourengine, which is not covered by warranty.

The engine must be installed correctly withcoolant lines, exhaust gas lines andelectrical wiring. Any auxiliary equipmentattached to the engine should be easy to useand accessible for service. To handle thedrive equipment, propulsion systems(including the propeller) and other onboardequipment, always observe the instructionsand cautions given in the operation manualssupplied by the shipyard and equipmentmanufacturers.The YM series engines are designed to beoperated at maximum throttle (3600 rpm) forless than 5% of total engine time (30 minutesout of every 10 hours) and cruising speed(3400 rpm or less) for less than 90% of totalengine time (9 hours out of every 10 hours).The laws of some countries may require hulland engine inspections, depending on theuse, size and cruising area of the boat. Theinstallation, fitting and surveying of thisengine all require specialized knowledgeand engineering skills. See Yanmar's localsubsidiary in your region or your authorizedYanmar Marine dealer or distributor.


New Engine Break-InAs with all reciprocating engines, the waythe engine is operated during its first 50hours of operation plays a significant role indetermining how long it will last and how wellthe engine will perform over its lifetime.A new Yanmar diesel engine must beoperated at suitable speeds and powersettings during the break-in period to allowthe sliding parts, such as piston rings, tobreak in properly and to stabilize enginecombustion.During the break-in period, the enginecoolant temperature gauge should bemonitored. The temperature should bebetween 71˚ and 87˚C (160˚ and 190˚F).During the first 10 hours of operation, theengine should be operated at maximum rpmminus 400 to 500 rpm (approximately 60 to70% of load) most of the time. This willensure the sliding parts break in properly.NOTICE: During this period, avoidoperating at maximum engine speedand load to avoid damaging or scoringsliding parts.NOTICE: NEVER operate at WOT (wideopen throttle) for more than a minute ata time during the first 10 hours ofoperation.Do not operate the engine at low idle or atlow speed and light load for more than30 minutes at a time. Since unburned fueland engine oil will adhere to the piston ringswhen operating at low speeds for longperiods, this will interfere with propermovement of the rings and the diesel fuelconsumption may increase. Low idle speeddoes not allow break-in of sliding parts.If operating the engine at low speed and lightload, you must race the engine to clean thecarbon from the cylinders and the fuelinjection valve.

Perform this procedure in open waters:• With the clutch in NEUTRAL, accelerate

from the low speed position to the highspeed position briefly.

• Repeat this process five times.Once past the initial 10 hours until 50 hours,the engine should be used over its fulloperating range, with special emphasis onrunning at relatively high power settings.This is not the time for an extended cruise atidle or low speed. The boat should beoperated at maximum speed minus 400 rpmmost of the time (approximately 70% load),with a 10 minute run at maximum minus 200rpm (approximately 80% load) every30 minutes and a 4 to 5 minute period ofoperation at WOT (wide open throttle) onceevery 30 minutes. During this period, be surenot to operate the engine at low speed andlight load for more than 30 minutes. Ifoperating engine at low speed and light loadis necessary, race the engine after low idleoperation.To complete engine break-in, perform AfterInitial 50 Hours maintenance procedures.See After Initial 50 Hours of Operation onpage 52.

PRODUCT OVERVIEW


COMPONENTIDENTIFICATIONService Side - 2YM15Figure 1 and Figure 2 illustrate a typicalversion of a 2YM15 engine. Your enginemay have different equipment from thatillustrated.

(1)(2)

(3)

(4)

(5)

(6)

(7)(8)

(9) 0004781Figure 1

1 – Intake Silencer (Air Cleaner)2 – Intake Manifold3 – Fuel Filter4 – Fuel Injection Pump5 – Engine Oil Dipstick6 – Engine Oil Filler Cap7 – Fuel Feed Pump8 – Engine Oil Filter9 – Marine Gear

Non-Service Side - 2YM15

(1)

(2) (4)

(5)

(7)

(6)(8)

(3)

0004782

Figure 21 – Seawater Pump2 – Coolant Filler Cap3 – Engine Nameplate (On Rocker Arm

Cover)4 – Coolant Tank / Heat Exchanger5 – Exhaust Manifold6 – Starter Motor7 – Shift Lever8 – Alternator

PRODUCT OVERVIEW


Service Side - 3YM20Figure 3 and Figure 4 illustrate a typicalversion of a 3YM20 engine. Your enginemay have different equipment from thatillustrated.

(1) (2)(3)

(4)

(5)(6)

(7)

(8)

(9) 0004783

Figure 31 – Intake Silencer (Air Cleaner)2 – Intake Manifold3 – Fuel Filter4 – Fuel Injection Pump5 – Engine Oil Dipstick6 – Engine Oil Filler Cap7 – Fuel Feed Pump8 – Engine Oil Filter9 – Marine Gear


(1)

(2) (3)

(4)

(5)

(6)

(7)(8)0004784



PRODUCT OVERVIEW


Service Side - 3YM30Figure 5 and Figure 6 illustrate a typicalversion of a 3YM30 engine. Your enginemay have different equipment from thatillustrated.

(1) (2)

(4)(5)(6)

(7)

(8)

(9)

(3)

0004785

Figure 51 – Intake Silencer (Air Cleaner)2 – Intake Manifold3 – Fuel Filter4 – Fuel Injection Pump5 – Engine Oil Dipstick6 – Engine Oil Filler Cap7 – Fuel Feed Pump8 – Engine Oil Filter9 – Marine Gear


(1)

(2) (3)

(4)

(5)

(6)

(7)(8)0004786



PRODUCT OVERVIEW


LOCATION OFNAMEPLATESThe nameplate of the Yanmar YM seriesengine is shown in Figure 7. Check theengine's model, output, rpm and serialnumber on the nameplate. Replace it if it isdamaged or lost.The engine nameplate is attached to theengine rocker arm cover.

0005472

Figure 7

The marine gear nameplate (Figure 8) isattached to the marine gear. Check themarine gear's model, gear ratio, oil used, oilquantity and serial number

MODE L KMGEAR RATIOOIL SAE 20/30HDOIL QT Y. LTR.NO.

0004529

Figure 8

PRODUCT OVERVIEW


FUNCTION OF MAJOR COMPONENTSName of Component FunctionFuel 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 bedrained periodically. See Draining Fuel Filter / Water Separator on page 56.

Fuel Feed Pump Pumps fuel from the tank to the fuel injection system. Pushing the manual lever onthe 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 bleedair from the fuel system after running out of fuel.

Engine Oil Filler Port Filler port for the 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 spin-on type and the elementshould be replaced periodically. See Replacing the Engine Oil Filter Element onpage 53.

Marine Gear Filler Port Filler port for marine gear 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 iscooled by seawater using a heat exchanger. The seawater also cools theengine / marine gear oil.

Closed CoolingCirculation Pump

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

Seawater Pump Pumps seawater from outside vessel to the engine. The seawater pump has areplaceable rubber 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 temperaturerises, the pressure rises inside the coolant system.

Coolant Recovery Tank The pressure valve in the filler cap releases vapor and hot water overflow to thecoolant recovery tank. When the engine stops and the coolant cools, the pressurein the coolant tank drops. The filler cap vacuum valve then opens to send coolantback from the coolant recovery tank. This minimizes coolant consumption. Theclosed 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 (AirCleaner)

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 Location of Nameplates on page 14.

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.

PRODUCT OVERVIEW


CONTROL EQUIPMENTThe control equipment at the helm makes remote control operation possible. It consists ofthe instrument panel, which is connected to the engine by a wire harness, and the remotecontrol handle, which is connected by control cables to the engine control lever and marinegear.Instrument Panel (Optional)Equipment and FunctionsThe instrument panel is located at the helm. The following instruments enable you to start orstop the engine and to monitor its condition during operation. A typical instrument panel isshown in Figure 9.

B-Type

0004486

(1)

(2)

(3)

(4)

(5)

(6)

(7)(8)

(9)

Figure 91 – Tachometer2 – Hourmeter3 – Moisture Cap for Key Switch4 – Key Switch5 – Stop Button

6 – Battery Low Charge Indicator7 – Water in Sail Drive Seal Indicator8 – Engine Oil Low Pressure Indicator9 – Coolant High Temperature Indicator

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

Instrument FunctionTachometer Shows the engine rotation speed.Hourmeter Shows the number of operating hours; can be used as a guide

for periodic maintenance checks. The hourmeter is located atthe bottom of the tachometer.

Instrument Panel Lights When turning the key switch to ON, the gauges will illuminate foreasier viewing.

PRODUCT OVERVIEW


Key Switch

0003622

(1)(2)

(3)

(4)

Figure 101 – GLOW2 – OFF3 – ON4 – STARTThe GLOW position (Figure 10, (1)) is thestart aid position. Electric current to the glowplug is turned on. When the key is released,the switch will automatically move to the ONposition.The START position (Figure 10, (4)) allowscurrent to the starting motor. When startingthe engine, move the key to the STARTposition and release. The key willautomatically move to the ON position.When the key is in the OFF position(Figure 10, (2)) the electric current is off.The key can be inserted or removed in thisposition.The ON position (Figure 10, (3)) allowselectrical current to the controls andequipment and allows the engine to keeprunning. To stop the engine, keep the keyswitch in the ON position and push the stopbutton. After stopping the engine, turn thekey to the OFF position.

Indicators and Alarms (Optional)When a sensor detects a problem duringoperation, the indicator on the instrumentpanel will light and an alarm will sound.Indicators are located on the instrumentpanel. The alarm is located on the back ofthe panel. Under normal operatingconditions, the indicators are off.

Figure 11Battery Low Charge Indicator(Figure 11) - When the alternator output istoo low, the indicator will light. Whencharging begins, the indicator will turn off.No alarm will sound for low battery charge.

Figure 12Coolant High Temperature Indicator andAlarm (Figure 12) - When coolanttemperature reaches the maximumallowable temperature (95˚C [203˚F] orhigher), the indicator will light and the alarmwill sound. Continuing operation attemperatures exceeding the maximum limitwill result in damage and seizure. Check theload and troubleshoot the cooling system.

Figure 13Engine Oil Low Pressure Indicator andAlarm (Figure 13) - When the engine oilpressure falls below normal, the oil pressuresensor will send a signal to the indicatorcausing it to light and the alarm to sound.Stop operation immediately to avoiddamage to the engine. Check the oil leveland troubleshoot the lubrication system.

PRODUCT OVERVIEW


Figure 14Water in Sail Drive Seal Indicator and Alarm(Figure 14) - When seawater is detectedbetween the seals of the sail drive, theindicator will light and the alarm will sound.

Stop Button

0005439

Figure 15Push the STOP button switch to stop theengine. The key switch must be in the ONposition for the stop button to operate. Afterthe engine has come to a complete stop, youcan turn the key to the OFF position.

PRODUCT OVERVIEW


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

Key Switch OFF ⇒ ON START ⇒ ONEngine Before start RunningAlarm Sound No soundIndicators Battery Low Charge Indicator ON OFF

Coolant High Temperature Indicator OFF OFFEngine Oil Low Pressure Indicator ON OFFWater In Sail Drive Indicator OFF OFF

Single-Lever Remote ControlHandle

(1)

(4)

(3) (2)

(5)

0004504

Figure 161 – Low Speed - FWD or REV2 – Low Speed - FWD or REV3 – NEUTRAL - Power to the propeller

shaft is cut off and the engine idles4 – Maximum Engine Speed - FWD or

REV5 – Maximum Engine Speed - FWD or

REVA single-lever handle type (Figure 16)should be used to operate the marine gearclutch (NEUTRAL, FORWARD, andREVERSE) and to control the engine speed.The lever controls the direction of the boat(ahead or astern) and also acts as anaccelerator by increasing engine speed asthe lever is pushed further in the FORWARDor REVERSE directions.

When the lever is pulled out(Figure 17, (1)), the engine speed can becontrolled without engaging the clutch. Theclutch remains in NEUTRAL, no loadposition. Turn the knob (Figure 17, (2))counterclockwise to move the lever orclockwise to lock the lever.

(2)

(1)

0004511

Figure 17Note: Yanmar recommends the use of asingle-lever type for the remote controlsystem. If only a two-lever type is availablein the market, reduce engine rpm to 1000rpm or less before engaging anddisengaging the marine gear clutch.

PRODUCT OVERVIEW


This Page Intentionally Left Blank

PRODUCT OVERVIEW


BEFORE YOU OPERATEThis section of the Operation Manualdescribes the diesel fuel, engine oil andengine coolant specifications and how toreplenish them. It also describes the dailyengine checks.Before performing any operations within thissection, review the Safety section on page3.

DIESEL FUELDiesel Fuel SpecificationsNOTICE: Only use diesel fuelsrecommended by Yanmar for the bestengine performance, to prevent enginedamage and to comply with EPAwarranty requirements. Only use cleandiesel fuel.Diesel fuel should comply with the followingspecifications. The table lists severalworldwide specifications for diesel fuels.

DIESEL FUELSPECIFICATION

LOCATION

ASTM D975 No. 2-D, No.1-D,

USA

EN590:96 European UnionISO 8217 DMX InternationalBS 2869-A1 or A2 United KingdomJIS K2204 Grade No. 2 Japan


Additional Technical FuelRequirements• The fuel cetane number should be 45 or

higher.• The sulfur content must not exceed 0.5%

by volume. Less than 0.05% is preferred.• NEVER mix kerosene, used engine oil or

residual fuels with the diesel fuel.• Water and sediment in the fuel should not

exceed 0.05% by volume.• Keep the fuel tank and fuel-handling

equipment clean at all times.• Ash content should not exceed 0.01% by

volume.• Carbon residue content should not

exceed 0.35% by volume. Less than 0.1%is preferred.

• Total aromatics content should notexceed 35% by volume. Less than 30% ispreferred.

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

• NEVER use Biocide.• NEVER use kerosene or residual fuels.

Handling of Diesel Fuel! DANGER

Only fill the fuel tank with diesel fuel. Fillingthe fuel tank with gasoline may result in a fireand will damage the engine. NEVER refuelwith the engine running. Wipe up all spillsimmediately. Keep sparks, open flames orany other form of ignition (match, cigarette,static electric source) well away whenrefueling.

ALWAYS store any containers containingfuel in a well-ventilated area, away from anycombustibles or sources of ignition.

ALWAYS put the diesel fuel container on theground when transferring the diesel fuelfrom the pump to the container. Hold thehose nozzle firmly against the side of thecontainer while filling it. This prevents staticelectricity buildup which could cause sparksand ignite fuel vapors.

BEFORE YOU OPERATE


Fuel Tank (Optional)NOTICE: Water and / or dust in the fuelmay cause engine failure. When fuel isstored, check that the inside of thestorage container is clean and dry, andthat the fuel is stored away from dirt orrain.

0004542

(3)

(1) (2)

Figure 11 – Sediment Bowl2 – Drain Cock3 – Fuel Line to EngineInstall a drain cock (Figure 1, (2)) at thebottom of the fuel tank to remove water andcontaminants from the sediment bowl(Figure 1, (1)).The fuel outlet should be positioned20 to 30 mm (0.75 to 1.125 in.) above thebottom of the tank (Figure 2, (4)) so thatonly clean fuel is distributed to the engine.

Fuel System(1)

(2)(3)

(8)

(10)

(4)

(6)

(7)

(9)

(5)

0004788

Figure 21 – Fuel Filter2 – Fuel Feed Pump (Priming Lever)3 – Fuel / Water Separator (Optional)4 – Approximately 20 - 30 mm (0.75 -

1.125 in.)5 – Within 500 mm (20 in.)6 – Drain Cock7 – Fuel Cock8 – Fuel Return Line9 – To Fuel Injection Pump10 – Fuel TankInstall the fuel line from the fuel tank to thefuel injection pump as shown in Figure 2.The recommended fuel / water separator(Figure 2, (3)) (optional) is installed at thecenter section of that line.

BEFORE YOU OPERATE


Filling the Fuel TankBefore filling fuel tank for the firsttime:Rinse the fuel tank with kerosene or dieselfuel. Dispose of waste properly.To fill the fuel tank:NOTICE: Operate bilge ventilation(blowers) for a minimum of 5 minutes topurge fumes from engine compartmentafter refueling. Never operate bilgeblower while refueling. Doing so canpump explosive fumes into the enginecompartment 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! Hold the hosenozzle firmly against the filler portwhile filling. This prevents staticelectricity buildup which couldcause sparks and ignite fuel vapors.

4. Stop fueling when the gauge shows thefuel tank is full. CAUTION! NEVERoverfill the fuel tank.

5. Replace the fuel cap and hand-tighten.Over-tightening the fuel cap willdamage it.

0004512

Figure 3If filling the tank from a storage container(Figure 3), keep the fuel containerstationary for several hours to allow any dirtor water to settle to the bottom of thecontainer. Use a pump to extract the clear,filtered fuel from the top of the container.

BEFORE YOU OPERATE


Bleeding the Fuel SystemThe fuel system has an automatic airbleeding device that purges air from the fuelsystem. No manual air bleeding is requiredfor normal operation. Manual bleeding mustbe done if any fuel system maintenance hasbeen performed (replacement of fuel filter,etc.) or if the engine does not start afterseveral attempts.Bleeding the Fuel System

(1)

0004801

(2)

(3)

(4)

(5)

(6)

Figure 41 – Air-Bleed Screw2 – Bracket3 – O-Ring4 – Fuel Filter Element5 – Fuel Filter Housing6 – Retaining Ring1. Check the fuel level in the fuel tank.

Refill if necessary.

2. Open the fuel cock of the fuel tank.WARNING! Always wear safetyglasses when bleeding the fuelsystem.

3. Loosen the air-bleed screw(Figure 4, (1)) 2 to 3 turns.

4. Push up and down on the manualpriming lever located on the side of thefuel feed pump to release air out of theair-bleed screw. Always use anapproved container to catch the dieselfuel.

5. Continue pumping until a solid streamof fuel with no air bubbles begins toflow.

6. Tighten the air-bleed screw.Note: After engine start-up, the automaticair-bleeding device works to purge the air inthe fuel system.

BEFORE YOU OPERATE


ENGINE OILEngine Oil SpecificationsNOTICE: Only use the engine oilspecified. Other engine oils may affectwarranty coverage, cause internalengine components to seize and / orshorten engine life. NEVER mix differenttypes of engine oil. This may adverselyaffect the lubricating properties of theengine oil.Use an engine oil that meets or exceeds thefollowing guidelines and classifications:• API Service Categories: CD or higher

TBN value: 9 or moreThe oil must be changed when the TotalBase Number (TBN) has been reduced to2.0.TBN (mgKOH/g) test method: JISK-2501–5.2–2(HCI), ASTM D4739(HCI)

• Recommended SAE Viscosity: 10W30,15W40. Engine oil 10W30 and 15W40can be used throughout the year.

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

NOTICE: 1. Be sure the engine oil, engine oil

storage containers and engine oilfilling equipment are free ofsediment or water.

2. Change the engine oil after the first50 hours of operation and then atevery 150 hours thereafter. SeeChanging the Engine Oil on page53.

3. Select the oil viscosity based on theambient temperature where theengine is being operated. See theSAE Service Grade Viscosity Chart(Figure 5).

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

Handling Engine Oil1. When handling and storing engine oil,

be careful not to allow dust and water tocontaminate the oil. Clean around thefiller port before filling.

2. Do not mix lube oils of different types orbrands. Mixing may cause the chemicalcharacteristics of the oil to change andlubricating performance to decrease,reducing the engine's life.

3. Engine oil should be replaced at thespecified intervals, regardless of theengine's operation history. SeePeriodic Maintenance Schedule onpage 48.

Engine Oil Viscosity

-4°F 14°F 32°F 50°F 68°F 86°F 104°F (-20°C) (-10°C) (0°C) (10°C) (20°C) (30°C) (40°C)

SAE 10W-30

SAE 15W-40

0000005

Figure 5Select the appropriate engine oil viscositybased on the ambient temperature shown inthe SAE Service Grade Viscosity Chart inFigure 5.NOTICE: If you intend to operate yourequipment at temperatures outside thelimits shown, you must consult yourauthorized Yanmar Marine dealer ordistributor for special lubricants orstarting aids.

BEFORE YOU OPERATE


Checking the Engine Oil

(1)

(3)

(4)(5)

(2)

0004789

Figure 61 – Filler Port2 – Rocker Arm Cover3 – Dipstick4 – Upper Limit5 – Lower Limit

Note: 3YM30 shown. Other models aresimilar.1. Make sure the engine is off. It is

recommended that the engine be aslevel as possible before checking theoil.

2. NOTICE: Prevent dirt and debrisfrom contaminating engine oil.Carefully clean the dipstick, fillerport cap and the surrounding areabefore you remove the cap.Removethe dipstick (Figure 6, (3)) and wipewith a clean cloth.

3. Fully reinsert the dipstick.4. Remove the dipstick. The oil level

should be between upper(Figure 6, (4)) and lower(Figure 6, (5)) lines on the dipstick.

5. Add oil if necessary. See AddingEngine Oil on page 27.

6. Fully reinsert the dipstick.

Adding Engine Oil1. NOTICE: Prevent dirt and debris

from contaminating engine oil.Carefully clean the dipstick, fillerport cap and the surrounding areabefore you remove the cap.Removethe yellow oil filler port cap from the fillerport (Figure 6, (1)) on the rocker armcover (Figure 6, (2)) and fill with engineoil.

2. Fill with engine oil to the upper limit(Figure 6, (4)) on the dipstick(Figure 6, (3)). NOTICE: NEVERoverfill the engine with engine oil.

3. Insert the dipstick fully to check thelevel. NOTICE: ALWAYS keep the oillevel between the upper and lowerlines on the oil cap / dipstick.

4. Hand-tighten the filler port capsecurely.

BEFORE YOU OPERATE


MARINE GEAR OR SAILDRIVE OILMarine Gear Oil SpecificationsUse marine gear oil that meets or exceedsthe following guidelines and classifications:KM2P-1 (S), (G) or (GG):• API Service Categories: CD or higher• SAE Viscosity: #20 or #30Sail Drive Oil Specifications -SD20Refer to the Sail-Drive Operation Manual forthe procedure to fill or replace the sail driveoil.SD20:• API Service Category: GL4.5• SAE Viscosity: 90 or 80W90• QuickSilver® 1 High Performance Gear

Lube.

Checking Marine Gear Oil

(1)

(2)

0004811

(3)

(4)

Figure 71 – Dipstick2 – Marine Gear Filler Port3 – Upper Limit4 – Lower Limit1. Make sure the engine is off. Make sure

the engine is as level as possible andwipe area clean around the marine gearfiller port (Figure 7, (2)).

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

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

4. Fully reinsert the dipstick.5. Remove the dipstick. The oil level

should be between the upper(Figure 7, (3)) and lower(Figure 7, (4)) lines on the dipstick.

6. Fully reinsert the dipstick.

1 QuickSilver is a registered trademark of Brunswick Corporation.

BEFORE YOU OPERATE


Adding Marine Gear Oil1. Make sure the engine is as level as

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

housing.3. Fill with oil to the upper limit on the

dipstick (Figure 7, (3)). See MarineGear Oil Specifications on page 28.NOTICE: NEVER overfill the marinegear with oil.

4. Fully reinsert the dipstick.5. Hand-tighten the filler port cap.Checking and Adding Sail DriveOilRefer to the Sail-Drive Operation Manual forthe procedure for checking and filling the saildrive oil.

ENGINE COOLANTEngine Coolant Specifications• Texaco Long Life Coolant (LLC), both

standard and premixed, product code7997 and 7998.

• Havoline Extended LifeAntifreeze / Coolant, product code 7994.

Note: In the U.S., LLC is required for thewarranty to be valid.NOTICE: Following the manufacturer’srecommendations, use a proper LLCwhich will not have any adverse effectson the materials (cast iron, aluminum,copper, etc.) of the engine’s coolingsystem. See Engine CoolantSpecifications on page 33.ALWAYS use the mixing ratios specified bythe antifreeze manufacturer for thetemperature range.NOTICE: ALWAYS add LLC to soft water– especially when operating in coldweather. NEVER use hard water. Watershould be clean and free from sludge orparticles. Without LLC, coolingperformance will decrease due to scaleand rust in the coolant system. Wateralone may freeze and form ice; itexpands approximately 9% in volume.Use the proper amount of coolantconcentrate for the ambienttemperature as specified by the LLCmanufacturer. LLC concentrationshould be a minimum of 30% to amaximum of 60%. Too much LLC willdecrease the cooling efficiency.Excessive use of antifreeze also lowersthe cooling efficiency of the engine.NEVER mix different types or brands ofLLC, as a harmful sludge may form.Mixing different brands of antifreezemay cause chemical reactions, and maymake the antifreeze useless or causeengine problems.

BEFORE YOU OPERATE


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

Remove scale from the cooling systemperiodically by flushing the system.

Checking and Adding CoolantComponent Identification

(1)

(2)(3)

(5)

(4)

0004791

Figure 81 – Coolant Tank / Heat Exchanger2 – Coolant Drain Plug3 – Seawater Drain Plug4 – Coolant Pump5 – Seawater Pump

(1)

(2)(3)

0005576

Figure 91 – Coolant Tank / Heat Exchanger2 – Coolant Drain Plug3 – Seawater Drain Cock

(1)

(2)(3)0004793

Figure 101 – Stop Solenoid2 – Seawater Drain Plug3 – Flywheel Housing

BEFORE YOU OPERATE


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

1. Allow the engine to cool.2. Ensure all drain cocks are closed.3. Loosen the coolant tank filler cap to

relieve the pressure, then remove thefiller cap. WARNING! NEVER removethe coolant filler cap if the engine ishot. Steam and hot engine coolantwill spray out and seriously burnyou. Allow the engine to cool downbefore you attempt to remove thecap.

(2)

(1)

(4)(3) 0004492

Figure 111 – Filler Cap Tabs2 – Coolant Filler Cap3 – Filler Port Notches4 – Coolant Tank / Heat Exchanger

4. NOTICE: NEVER pour cold coolantinto a hot engine.Pour coolant slowly into the coolanttank / heat exchanger (Figure 11, (4))to avoid air bubbles. Fill until coolantoverflows from the filler port.

5. Align the filler cap tabs(Figure 11, (1)) with filler port notches(Figure 11, (3)) and tighten the fillercap (Figure 11, (2)).

LOW

FULL

(4)(1)

(2)

(3)

0004493

Figure 121 – Rubber Hose to Coolant Tank2 – FULL Mark3 – LOW Mark4 – Coolant Recovery Tank Cap

6. Check the coolant level in the coolantrecovery tank. The level should be atthe FULL mark (Figure 12, (2)). Addcoolant if necessary.

Note: The coolant level rises in thecoolant recovery tank duringoperation. After stopping theengine, the coolant will cool downand the extra coolant will return tothe coolant tank.

NOTICE: NEVER pour cold coolantinto a hot engine.

7. Remove coolant recovery tank cap(Figure 12, (4)) to add coolant ifnecessary. NEVER add water.

8. Replace the filler cap and tighten itfirmly. Failure to do so will causecoolant to leak.WARNING! ALWAYS tighten thecoolant tank cap securely afterchecking the coolant tank. Steamcan spray out during engineoperation if the cap is loose.

Coolant Recovery Tank Capacity0.8 L (0.95 qt)

BEFORE YOU OPERATE


9. Check the rubber hose(Figure 12, (1)) connecting the coolantrecovery tank to the coolant tank / heatexchanger. Replace if damaged.

NOTICE: If the coolant runs low toooften or only the coolant level in thecoolant tank / heat exchanger dropswithout any change in the level in thecoolant recovery tank, there may becoolant or air leaks in the coolingsystem. See your authorized YanmarMarine dealer or distributor.

CRANKING THE ENGINENOTICE: When performing enginebreak-in or if the engine has not beenused for a long period of time, engine oilwill not be distributed to all of theoperating parts. Using the engine in thiscondition will lead to seizure.After a long period of non-use, distributeengine oil to each part by cranking theengine. Perform the following procedurebefore beginning operation:1. Open the seacock.2. Open the fuel cock.3. Put the remote control shift lever in

NEUTRAL.4. Turn the battery switch to ON (if

equipped).

0003622

(1)(2)

(3)

(4)

Figure 131 – GLOW2 – OFF3 – ON4 – START

Note: If the engine has not beenoperated for a long period of time,check that the key moves smoothlyfrom the START to ON positions.

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

BEFORE YOU OPERATE


6. While pushing the STOP button on thecontrol panel, turn the key to the STARTposition (Figure 13, (4)). NOTICE:NEVER hold the key in the STARTposition for longer than 15 secondsor the starter motor will overheat.

7. When the key is in the START position,the engine will begin cranking.Continue cranking for about 5 secondsand listen for abnormal noise duringthat time.

NOTICE: If the STOP button is releasedduring the cranking procedure, theengine will start. NEVER start the enginein this mode.

DAILY CHECKSBefore you start for the day, make sure theengine is in good operating condition.CAUTION! It is important to perform thedaily checks as listed in this OperationManual. Periodic maintenance preventsunexpected downtime, reduces thenumber of accidents due to poor engineperformance and helps extend the life ofthe engine.Make sure to check the following items:Visual Checks1. Check for engine oil leaks.2. Check for fuel leaks.

WARNING! Avoid skin contact withthe high-pressure diesel fuel spraycaused by a fuel system leak, suchas a broken fuel injection line. High-pressure fuel can penetrate yourskin and result in serious injury. Ifyou are exposed to high-pressurefuel spray, obtain prompt medicaltreatment. NEVER check for a fuelleak with your hands. ALWAYS usea piece of wood or cardboard. Haveyour authorized Yanmar Marinedealer or distributor repair anydamage.

3. Check for engine coolant leaks.4. Check for damaged or missing parts.5. Check for loose, missing or damaged

fasteners.6. Check the electrical harnesses for

cracks, abrasions, and damaged orcorroded connectors.

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

BEFORE YOU OPERATE


8. Check the fuel filter / water separator forpresence of water and contaminants. Ifany water or contaminants are found,drain the fuel filter / water separator.See Draining Fuel Filter / WaterSeparator on page 56. If you have todrain the fuel filter / water separatorfrequently, drain the fuel tank and checkfor water in your fuel supply. SeeDraining the Fuel Tank on page 52.

CAUTION! If any problem is notedduring the visual check, the necessarycorrective action should be taken beforeoperating the engine.Checking Diesel Fuel, Engine Oiland Engine Coolant LevelsFollow the procedures in Filling the FuelTank on page 24, Checking the Engine Oilon page 27 and Checking and AddingCoolant on page 30 to check these levels.Checking and Refilling MarineGear OilSee Checking Marine Gear Oil on page 28.Checking the Battery ElectrolyteLevelCheck the battery electrolyte level beforeuse. See Checking the Battery ElectrolyteLevel (Serviceable Batteries Only) on page57.Checking the Alternator BeltCheck the belt tension before use.See Checking and Adjusting the AlternatorV-Belt Tension on page 54 .Checking the Remote ControlHandleCheck the operation of the remote controlhandle and ensure it moves smoothly. If it ishard to operate, grease the joints of theremote control cable and lever bearings. Ifthe lever is too loose, adjust the remotecontrol cable. See Checking and Adjustingthe Remote Control Cables on page 54.

Checking the Alarm IndicatorsCheck the instruments and alarm indicatorsat regular intervals.Preparing Fuel, Oil and Coolant inReservePrepare sufficient diesel fuel for the day’soperation. Always store engine oil andcoolant in reserve (for at least one refill)onboard, to be ready for emergencies.

BEFORE YOU OPERATE


ENGINE OPERATIONThis section of the Operation Manualdescribes the procedures for starting theengine, checking engine performanceduring operation and shutting down theengine.Before performing any operations within thissection, read the following safetyinformation and review the Safety section onpage 3.

! WARNINGFire and Explosion Hazard

NEVER jump-start the engine.Sparks caused by shorting thebattery to the starter terminalsmay cause a fire or explosion.ONLY use the key switch to

start the engine.

Sudden Movement HazardBe sure the boat is in open water away fromother boats, docks or other obstructionsbefore increasing rpm. Avoid unexpectedequipment movement. Shift the marine gearinto the NEUTRAL position any time theengine is at idle.

To prevent accidental equipmentmovement, NEVER start the engine in gear.

Sever HazardKeep children and pets awaywhile the engine is operating.

Exhaust HazardNEVER block windows, ventsor other means of ventilation ifthe engine is operating in anenclosed area. All internalcombustion engines create

carbon monoxide gas during operation andspecial precautions are required to avoidcarbon monoxide poisoning.


NOTICEIf any indicator illuminates during engineoperation, stop the engine immediately.Determine the cause and repair the problembefore continuing to operate the engine.If the alarm window with audible alarm failsto display and go out about 3 seconds laterwhen the ignition switch is in the ONposition, see your authorized YanmarMarine dealer or distributor for servicebefore operating the engine.

Observe the following environmentaloperating conditions to maintain engineperformance and avoid premature enginewear:• Avoid operating in extremely dusty

conditions.• Avoid operating in the presence of

chemical gases or fumes.• NEVER run the engine if the ambient

temperature is above +40˚C (+104˚F) orbelow -16˚C (+5˚F).

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

• If the ambient temperature is below -16˚C(+5˚F), rubber components such asgaskets and seals will harden causingpremature engine wear and damage.

• Contact your authorized Yanmar Marineengine dealer or distributor if the enginewill be operated outside of this standardtemperature range.

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

STARTING THE ENGINENOTICE: If the vessel is equipped with awater lift (water lock) muffler, excessivecranking could cause seawater to enterthe cylinders and damage the engine. Ifthe engine does not start after crankingfor 10 seconds, close the seacock toavoid filling the muffler with water.Crank for 10 seconds or until the enginestarts. When the engine does start, stopthe engine immediately and turn theswitch to the OFF position.1. Open the seacock (if equipped).2. Open the fuel cock.3. Put the remote control handle in

NEUTRAL.Note: Safety equipment shouldmake it impossible to start theengine in any position other thanNEUTRAL.

0003622

(1)(2)

(3)

(4)

Figure 11 – GLOW2 – OFF3 – ON4 – START

4. Turn the battery master switch (ifequipped) to ON.

ENGINE OPERATION


5. Turn key switch to ON (Figure 1, (3)).Ensure that the instrument panelindicators light and the alarm sounds.This indicates that indicators and alarmare working correctly.

Note: The coolant hightemperature alarm indicator andwater in Sail-Drive indicator shouldnot come on during start-up.

6. Turn key switch to START(Figure 1, (4)). Release the key switchwhen the engine has started. NOTICE:NEVER hold the key in the STARTposition for longer than 15 secondsor the starter motor will overheat.

7. The alarm should stop and theindicators should go out. NOTICE: Ifany indicator fails to illuminatewhen the key switch is in the ONposition, see your authorizedYanmar Marine dealer or distributorfor service before operating theengine.

Note: When the engine has not been usedfor a long period of time, check that the keymoves smoothly from the START position tothe ON position.Restarting After Starting FailureBefore turning the key switch again, be surethe engine has stopped completely. NEVERattempt to restart the engine while theengine is running. The pinion gear on thestarter motor will be damaged. NOTICE:NEVER hold the key in the STARTposition for longer than 15 seconds orthe starter motor will overheat.NOTICE: NEVER attempt to restart theengine if the engine has not stoppedcompletely. Pinion gear and startermotor damage will occur.

Air Bleeding the Fuel System AfterStarting FailureIf the engine does not start after severalattempts, there may be air in the fuel system.If air is in the fuel system, fuel cannot reachthe fuel injection pump. Bleed the air out ofthe system. See Bleeding the Fuel Systemon page 25.Starting at Low TemperaturesComply with local environmentalrequirements. Use engine heaters to avoidstarting problems and white smoke.NOTICE: NEVER use an engine startingaid such as ether. Engine damage willresult. Using a starting aid may void thewarranty.To limit white smoke, run the engine at lowspeed and under moderate load until theengine reaches normal operatingtemperature. A light load on a cold engineprovides better combustion and fasterengine warm-up than no-load.Avoid running the engine at idling speed anylonger than necessary.Starting with Air Heater (IfEquipped)1. Open the seacock (if equipped).2. Open the fuel tank cock.3. Put remote control handle in

NEUTRAL.4. Turn the battery master switch (if

equipped) ON.5. Turn key switch to GLOW for 15

seconds.6. Turn key switch to ON. Ensure that the

instrument panel indicators light andthe alarm sounds. This shows thatindicators and alarm are workingcorrectly.

Note: The coolant hightemperature alarm indicator andwater in Sail-Drive indicator shouldnot come on during start-up.

ENGINE OPERATION


7. Turn key switch to START. Release thekey switch when the engine has started.The alarm should stop and theindicators should go out. NOTICE:NEVER hold the key in the STARTposition for longer than 15 secondsor the starter motor will overheat.

After the Engine Has StartedAfter the engine has started, check thefollowing items at a low engine speed:1. Check that the gauges, indicators and

alarm are normal.2. Check for any water, fuel, engine

coolant or engine oil leaks. If any leaksare found, shut down the engine andperform the necessary repairs.WARNING! NEVER check for a fuelleak with your hands. ALWAYS usea piece of wood or cardboard. Haveyour authorized Yanmar Marinedealer or distributor repair thedamage. Avoid skin contact with thehigh-pressure diesel fuel spraycaused by a fuel system leak suchas a broken fuel injection line. High-pressure fuel can penetrate yourskin and result in serious injury. Ifyou are exposed to high-pressurefuel spray, obtain prompt medicaltreatment.

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

4. When there are no problems, keep theengine at low speed with the boat stillstopped to distribute engine oil to allparts of the engine.

Check that water is being discharged fromthe seawater outlet pipe. Operation withinadequate seawater discharge will damagethe impeller of the seawater pump. Ifseawater discharge is too low, stop theengine immediately. Identify the cause andrepair. NOTICE: The engine will seize if itis operated when cooling seawaterdischarge is inadequate or if load isapplied without any warm-up operation.When operating the engine at low speed forlong periods of time, race the engine onceevery two hours. Race the engine with theclutch in NEUTRAL, accelerate from the lowspeed position to the high speed positionand repeat this process about five times.This cleans out carbon from the cylindersand the fuel injection valves.NOTICE: Neglecting to race the enginewill result in poor exhaust color andreduce engine performance.Periodically operate the engine nearmaximum speed while underway. This willgenerate higher exhaust temperatures,which will help clean out hard carbondeposits, maintain engine performance andprolong the life of the engine.For troubleshooting assistance, seeTroubleshooting After Starting on page65 or Troubleshooting Chart on page67.If necessary, see your authorized YanmarMarine dealer or distributor.

ENGINE OPERATION


REMOTE CONTROLHANDLE OPERATIONAcceleration and Deceleration

0004513

(1)

(2)

(4)

(3)

Figure 21 – Forward or Reverse2 – Neutral3 – Reverse or Forward4 – Throttle Handle / Clutch Handle

Note: Direction of travel will vary dependingon installation location.Use the throttle handle (Figure 2, (4)) tocontrol acceleration and deceleration. Movethe handle slowly.

Shifting the EngineNOTICE: Shifting the marine gear whileoperating at high speed or not pushingthe handle fully into position (partialengagement) will result in damage tomarine gear parts and abnormal wear.1. Before using the marine gear, be sure

to move the throttle handle to a low idleposition (less than 1000 rpm). Move thethrottle handle slowly to a higher speedposition after completing clutchengagement.

2. NOTICE: NEVER shift the marinegear at high engine speed. Duringnormal operation, the marine gearshould only be shifted with theengine at idle. When moving thehandle between FORWARD(Figure 2, (1)) and REVERSE(Figure 2, (3)), bring the clutch toNEUTRAL (Figure 2, (2)) and pausebefore slowly shifting to the desiredposition. Do not shift abruptly fromFORWARD to REVERSE or vice versa.

ENGINE OPERATION


SHUTTING DOWN THEENGINENOTICE: NEVER stop engine abruptlyduring operation. Yanmar recommendsthat when shutting the engine down,allow the engine to run, without load, for5 minutes. This will allow the enginecomponents that operate at hightemperatures, such as the exhaustsystem, to cool slightly before theengine is shut down.1. Reduce engine speed to low idle and

put remote control handle inNEUTRAL.

2. Accelerate from low speed to highspeed and repeat five times. This willclean out the carbon from the cylindersand the fuel injection nozzles.

3. Allow engine to run at low speed(approximately 1000 rpm) without loadfor 5 minutes.

4. With the key in the ON position, pushand hold the stop button(Figure 3, (1)). After the engine hasstopped, turn the key switch to OFF.

Note: Continue to hold the stopbutton in until the engine iscompletely stopped. If the button isreleased before the engine hascompletely stopped, it may restart.If the engine does not shut down,see Emergency Shutdown onpage 40.

0004487

(1)

Figure 31 – STOP Button

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

6. Turn off the battery master switch (ifequipped).

7. Close the fuel cock.8. Close the seacock (if equipped).

NOTICE: ALWAYS close theseacock. Neglecting to close theseacock could allow water to leakinto the boat and may cause it tosink.

Emergency ShutdownNOTICE: NEVER use the emergencystop switch for a normal engineshutdown. Use this switch only whenstopping the engine suddenly in anemergency.

ENGINE OPERATION


If the engine cannot be shut down by theSTOP button on the panel, stop the engineby pushing the button (Figure 4, (1)) at theback of the stop solenoid (Figure 4, (2)).

(1)

(2) 0004787

Figure 41 – STOP Button2 – Stop Solenoid

CHECKING THE ENGINEAFTER OPERATION• Check that the key switch is in the OFF

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

• Fill the fuel tank. See Filling the FuelTank on page 24.

• Close seacock(s).• If there is a risk of freezing, check that the

cooling system contains enough coolant.See Engine Coolant Specifications onpage 29.

• If there is a risk of freezing (temperaturesbelow 0˚C [32˚F]), drain the seawatersystem. See Draining the CoolingSystem on page 72 and connect theengine heater (if equipped).

ENGINE OPERATION


This Page Intentionally Left Blank

ENGINE OPERATION


PERIODIC MAINTENANCEThis section of the Operation Manualdescribes the procedures for proper careand maintenance of the engine.Before performing any maintenanceprocedures within this section, read thefollowing safety information and review theSafety section on page 3.

SAFETY PRECAUTIONS ! WARNING

Crush HazardIf the engine needs to betransported for repair,have a helper assist youattach it to a hoist and loadit on a truck.

The engine lifting eyes are engineered to liftthe weight of the marine engine only.ALWAYS use the engine lifting eyes whenlifting the engine.

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


! WARNINGWelding Hazard

• ALWAYS turn off the battery switch (ifequipped) or disconnect the negativebattery cable and the leads to thealternator when welding on theequipment.

• Connect the weld clamp to thecomponent to be welded and as close aspossible to the welding point.

• NEVER connect the weld clamp to theengine or in a manner which would allowcurrent to pass through a mountingbracket.

• When welding is completed, reconnectthe leads to the alternator prior toreconnecting the batteries.

Exhaust HazardALWAYS ensure that allconnections are tightened tospecifications after repair ismade to the exhaust system.All internal combustion

engines create carbon monoxide gas duringoperation and special precautions arerequired to avoid carbon monoxidepoisoning.

Shock HazardALWAYS turn off thebattery switch (ifequipped) or disconnectthe negative battery cablebefore servicing the

equipment.

ALWAYS keep the electrical connectorsand terminals clean. Check the electricalharnesses for cracks, abrasions, anddamaged or corroded connectors.

NOTICEAny part which is found defective as a resultof inspection, or any part whose measuredvalue does not satisfy the standard or limit,must be replaced.

Modifications may impair the engine’ssafety and performance characteristics andshorten the engine’s life. Any alterations tothis engine may void its warranty. Alwaysuse Yanmar genuine replacement parts.

PERIODIC MAINTENANCE


PRECAUTIONSThe Importance of PeriodicMaintenanceEngine deterioration and wear occur inproportion to the length of time the enginehas been in service and the conditions theengine is subjected to during operation.Periodic maintenance prevents unexpecteddowntime, reduces the number of accidentsdue to poor engine performance and helpsextend the life of the engine.Performing PeriodicMaintenanceWARNING! NEVER block windows,vents, or other means of ventilation ifthe engine is operating in an enclosedarea. All internal combustion enginescreate carbon monoxide gas duringoperation. Accumulation of this gaswithin an enclosure could cause illnessor even death. Make sure that allconnections are tightened tospecifications after repair is made to theexhaust system. Failure to comply couldresult in death or serious injury.The Importance of Daily ChecksThe Periodic Maintenance Scheduleassumes that the daily checks areperformed on a regular basis. Make a habitof performing daily checks before the startof each operating day. See Daily Checks onpage 33.

Keep a Log of Engine Hours andDaily ChecksKeep a log of the number of hours the engineis operated each day and a log of the dailychecks performed. Also note the date, typeof repair (e.g., replaced alternator), andparts used for any service needed betweenthe periodic maintenance intervals. Periodicmaintenance intervals are every 50, 100,150, 250 and 1000 engine hours. NOTICE:Failure to perform periodic maintenancewill shorten the life of the engine andmay void the warranty.Yanmar Replacement PartsYanmar recommends that using genuineYanmar parts when replacement parts areneeded. Genuine replacement parts helpensure long engine life.Tools RequiredBefore starting any periodic maintenanceprocedure, make sure you have the toolsneeded to perform all of the required tasks.Ask Your Authorized YanmarMarine Dealer or Distributor ForHelpOur professional service technicians havethe expertise and skills to help with anymaintenance or service related procedures.



Tightening FastenersUse the correct amount of torque when you tighten fasteners on the engine. Applyingexcessive torque may damage the fastener or component and not enough torque may causea leak or component failure.NOTICE: The tightening torque in the Standard Torque Chart should be applied only

to the bolts with a “7” head (JIS strength classification: 7T). Apply 60%torque to bolts that are not listed. Apply 80% torque when tightened toaluminum alloy.

Standard Torque ChartBolt diameter x pitch(mm) M6 x 1.0 M8 x 1.25 M10 x 1.5 M12 x 1.75 M14 x 1.5 M16 x 1.5

TighteningTorque

N·m 11.0 ± 1.0 26.0 ± 3.0 50.0 ± 5.0 90.0 ± 10.0 140.0 ± 10.0 230.0 ± 10.0kgf-m 1.1 ± 0.1 2.7 ± 0.3 5.1 ± 0.5 9.2 ± 1.0 14.3 ± 1.0 23.5 ± 1.0lb-ft 8.0 ± 0.7 19.0 ± 2.1 37 ± 3.6 66.0 ± 7.2 103 ± 7.2 170 ± 7.2



EPA MAINTENANCEREQUIREMENTSTo maintain optimum engine performanceand compliance with the EnvironmentalProtection Agency (EPA) Regulations forEngines, it is essential to follow the PeriodicMaintenance Schedule on page 48 andthe Periodic Maintenance Procedures onpage 52.EPA Requirements for USA andOther Applicable CountriesThe following are the requirements for theEPA. Unless these requirements are met,the exhaust gas emissions will not be withinthe limits specified by the EPA.The EPA emission regulation is applicableonly in the USA and other countries thathave adapted the EPA requirements in partor in whole. Determine and follow theemission regulations in the country whereyour engine will be operating to assist you inspecified compliance.Conditions to EnsureCompliance with EPA EmissionStandardsThe 2YM15, 3YM20 and 3YM30 are EPA-certified engines.The following are the conditions that must bemet in order to ensure that the emissionsduring operation meet the EPA standards:• Ambient temperature: -20˚ to +40˚C

(-4˚ to +104˚F)• Relative humidity: 80% or lowerThe diesel fuel should be:• ASTM D975 No. 1-D or No. 2-D, or

equivalent (minimum of cetane No. 45)The lubricating oil should be:• Type API, Class CD or higher

Perform the inspections as outlined inPeriodic Maintenance Procedures on page52 and keep a record of the results.Pay particular attention to these importantpoints:• Replacing the engine oil• Replacing the engine oil filter• Replacing the fuel filter• Cleaning the intake silencer (air cleaner)Note: Inspections are divided into twosections in accordance with who isresponsible for performing the inspection:the user or the manufacturer.Inspection and MaintenanceSee Inspection and Maintenance of EPAEmission-Related Parts on page 51 for theEPA emission-related parts. Inspection andmaintenance procedures not shown in theInspection and Maintenance of EPAEmission-Related Parts on page 51section are covered in PeriodicMaintenance Schedule on page 48.This maintenance must be performed tokeep the emission values of the enginewithin the standard values during thewarranty period. The warranty period isdetermined by the age of the engine or thenumber of hours of operation.



PERIODIC MAINTENANCE SCHEDULEDaily 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. Periodicmaintenance intervals vary depending on engine application, loads, diesel fuel and engineoil used and are hard to establish definitively. The following should be treated only as ageneral guideline. CAUTION! Establish a periodic maintenance plan according to theengine application and make sure to perform the required periodic maintenance atthe intervals indicated. Failure to follow these guidelines will impair the engine’ssafety and performance characteristics, shorten the engine’s life and may affect thewarranty coverage on your engine. See your authorized Yanmar Marine dealer ordistributor for assistance when checking items marked with a ●.



◯: Check or Clean ◊: Replace ●: Contact your authorized Yanmar Marine dealer or distributor

System Item

Periodic Maintenance Interval

BeforeStarting

See DailyChecks on

page 33

Initial 50Hours

Every 50hours ormonthlywhich-

evercomes

first

Every100

hours orsix

monthswhich-

evercomes

first

Every150

hours orone yearwhich-

evercomes

first

Every250


evercomes

first

Every1000

hours or4 yearswhich-

evercomes

first

Whole Visual inspectionof engine exterior ◯

Fuel System

Check the fuellevel and refill ifnecessary

◯

Drain water andsediment from thefuel tank

◯ ◯

Drain thefuel / waterseparator

◯

Replace the fuelfilter element ◊ Check the fuelinjection timing ●Check the fuelinjector spraypattern*

●*

LubricatingSystem

Checktheengineoil level

Engine ◯ MarineGear ◯

Replacetheengineoil

Engine ◊ ◊ MarineGear ◊ ◊ SailDrive ◊

Replacethe oilfilterelement

Engine ◊ ◊

CoolingSystem

Seawater outlet ◯ DuringOperation Check coolantlevel ◯ Check or replacethe seawater pumpimpeller

◯ ◊

Replace coolant Every year. When Long Life Coolant (LLC) is used, replace every two years.See Engine Coolant Specifications on page 29.Clean and checkthe seawaterpassages

●



◯: Check or Clean ◊: Replace ●: Contact your authorized Yanmar Marine dealer or distributor

System Item

Periodic Maintenance Interval

BeforeStarting

See DailyChecks on

page 33

Initial 50Hours

Every 50hours ormonthlywhich-

evercomes

first

Every100

hours orsix

monthswhich-

evercomes

first

Every150


evercomes

first

Every250


evercomes

first

Every1000

hours or4 yearswhich-

evercomes

first

Air Intakeand ExhaustSystem

Clean the intakesilencer (aircleaner) element

◯

Clean or replacethe exhaust / watermixing elbow

◯

Clean the breatherpipe ◯ Check the exhaustgas condition

◯ DuringOperation

Check diaphragmassembly ●

ElectricalSystem

Check the alarmand indicators ◯ Check theelectrolyte level inthe battery

◯

Adjust the tensionof the alternator V-belt or replace V-belt

◯ ◯ ◊

Check the wiringconnectors ◯

EngineCylinderHead andBlock

Check for leakageof fuel, engine oiland engine coolant

◯ AfterStarting

Tighten all majornuts and bolts ●Adjustintake / exhaustvalve clearance

◯ ●

Miscellane-ous Items

Check the remotecontrol cables ◯ ◯ ●Adjust thepropeller shaftalignment

◯ ●

* For EPA requirements, see Inspection and Maintenance of EPA Emission-Related Parts on page 51.Note: These procedures are considered normal maintenance and are performed at theowner’s expense.



Inspection and Maintenance of EPA Emission-Related Parts• Marine diesel engines less than 37 kW (50 hp) are certified as EPA non-road engine• Marine diesel engines greater than 37 kW (50 hp) are certified as EPA CI marine enginesInspection and Maintenance of EPA Emission-Related Parts for Non-Roadand CI Marine Engines

Parts IntervalClean the fuel injection nozzle 1500 hoursCheck the fuel injection nozzle pressure and spray pattern 3000 hoursCheck the fuel injection pump adjustmentCheck turbocharger adjustment (if equipped)Check the electronic engine control unit and its associated sensors andactuators (if equipped)

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



PERIODIC MAINTENANCEPROCEDURESAfter Initial 50 Hours ofOperation

Perform the following maintenance after theinitial 50 hours of operation.• Draining the Fuel Tank• Changing the Engine Oil• Replacing the Engine Oil Filter

Element• Changing the Marine Gear Oil• Checking and Adjusting the

Alternator V-Belt Tension• Inspecting and Ad

Documents

2YM15 3YM20 YM 3YM30 series OPERATION MANUAL P/N ... - …€¦ · INTRODUCTION Welcome to the world of Yanmar Marine! Yanmar Marine offers engines, drive systems and accessories