3Ym30 Service Manual

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Model 3YM30 has been used for the illustrations in this service manual, but they apply to other models in the 3YM series engines. For accident prevention, it is important to avoid such causes before development to accidents. Please read this manual carefully before starting repair or maintenance to fully understand safety precautions and appropriate inspection and maintenance procedures. Damage to the engine, shortened engine life and or personal injury may result. Check the customer ledger file for the history of the engine. General rules are described here.: User-maintenance: Parts replacement: Shop-inspection. Unit: liter (quart) Engine oil capacity Model at rake angle 8 degree 3YM30 with KM2P-1 Full:2.8 (3.0) -0.2 3YM20 with KM2P-1 Full:2.7 (2.9) -0.2. Usually do not open the filler cap to check or replenish. Standard Cooling water volume Unit: liter (quart) Model Engine Coolant recovery tank 3YM30 4.9 (5.2) 0.8 (0.8) 3YM20 4.1 (4.3) 0.8 (0.8) Increase in the water level of the coolant recovery tank during operation is not abnormal. Remove the V-belt. After replacing with a new V-belt and adjusting the tension, run the engine for 5 minutes and readjust the Belt adjuster deflection to the value in the table above. (3YM30) Tighten the adjusting bolt. Standard valve clearance (mm) 0.15-0.25 c) Apply oil to the contact surface between adjusting screw and push rod. Failure to do so could cause short-circuiting and fires. GREASE When the amount of fluid nears the lower limit, fill with battery fluid (available in the market) to the upper limit. If operation continues with insufficient battery fluid, the battery life is shortened, and the battery may overheat and explode. Otherwise, it results in engine damage, (Fuel filter) uneven engine performance and shorten engine life. Be sure to replace the fresh water every year. When the long life coolant is used of the specified type, the replacement period of two years can be obtained.
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Use clean soft water and be sure to add the Long Life Coolant Antifreeze (LLC) to the cooling water in order to prevent rust built up and freezing. There are two types of mixing elbows, the L-type and the U-type. The mixing elbow is attached to the exhaust manifold. The exhaust gas is mixed with seawater in the mixing elbow. U-type Mixing elbow Seawater. Check whether each connection part doesn't have looseness. STOP B-type panel Glow connector GLOW START Neutral safety switch Glow plug (Fitting to marine gear) Glow relay Magnet relay Safety Extension relay wire harness Alternator To lube switch and. Never approach the injection nozzle portion with a hand. The oil jetting out from the nozzle is at a high pressure to cause loss of sight or injury if coming into careless contact with it. Place the heat Air hose Filler cap exchanger in a water tank, feed in compressed air from the overflow pipe and check for any (water) leakage, (air bubbles). Remote High speed control limiting bolt Fuel 2) If the no-load maximum speed is out of the cable injection standard, adjust it by turning the high idle limiting. The thermostat is functioning normally if it starts to open between 75-78 deg C, and opens until 8 mm or more at 90 deg C. When the signs of a trouble appear in the engine or a trouble occurs, grasp the trouble conditions fully by the next point and find out the cause of sincerity according to the troubleshooting. When problems arise, it is important to carefully observe and analyze the indications of trouble in order to save time in determining their cause. TROUBLE AND TROUBLESHOOTING (I-1) Add fuel oil and prime. (II-1) Replace. (I-2) Bleed air. (II-2) Clean carefully to insure good working order. (I-3) Remove water from drain and fuel oil system and prime. (I-4) Check and make necessary repairs. (I-5) Clean. Please use them as instructed. 4.2.1 General hand tools Name of tool Illustration Remarks Wrench Size: 10 x 13 Wrench Size: 12 x 14 Wrench.
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Test indicator Measures narrow and deep places, which cannot be measured with dial gauge. Magnetic stand Keeps the dial gauge firmly in position, thereby permitting it to be used at various angles. Torque wrench Used to tighten bolts and nuts to standard torque. Thickness gauge Measures the distance between the ring and ring groove, and between the shaft and shaft joint at time of assembling. Compression gauge Measures the pressure of the compression. Yanmar code No. TOL-97190080. Three Bond 200g Non-drying liquid gasket;. Intake pipe 2) Remove the intake silencer from cylinder head. Cylinder head Intake silencer (6) Removing the mixing elbow 1) Remove the seawater rubber hose connecting to a heat exchanger- a mixing elbow. 2) Remove the mixing elbow from the exhaust manifold. Gear case Spacer bolt V-belt. Washer 2) Remove the engine mounting feet. Crankshaft V-pully (22)Removing the crankshaft V-pulley Loosen the bolt tightening the crankshaft V-pulley and Oil pan remove the crankshaft V-pulley with a pulley puller. Outer rotor Control Inner rotor valve Gear case cover (27)Removing the idle gear Bolt Loosen the three bolts holding the idle gear and pull out the idle gear and shaft. NOTE 1) When mounting the gear case, match up the two knock pins for cylinder block. NOTE: The thrust metal (lower) is mounted to the base main bearing cap. (35)Removing the crankshaft 1) Remove the crankshaft NOTE: Cylinder block. NOTE: 1) If the dust remain with the parts, engine may cause the seizing or damage. 2) The cleaning agent removes even carbon adhering to disassembled parts. Lower NOTE: Thrust metal 1) The lower main bearing metal does not have an oil hole. Flywheel housing (8) Mounting the gear case Apply the liquid gasket to the gear case and mount the gear case and lube oil line O-ring onto the cylinder block.
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NOTE: 1) Insert the piston so that the match mark on the large end of the connecting rod faces the fuel nozzle, and the manufacture’s embossed mark on the stem faces toward the flywheel. Damper disk Align the damper disk with the input shaft spline and insert. 2) Mount the marine gearbox to the flywheel housing. Flywheel (20) Mounting the cylinder head Assembly 1) Put the cylinder head gasket on the cylinder block,. Before mounting heat exchanger to the cylinder head, adjust the injection timing.). Cylinder head 2) Renew the O-ring for the connecting part of the pump, which is inserted in the cylinder block, and tighten the fresh water pump. Cylinder block Mount the lube oil filter with the tool of the filter case remover. Lube oil pressure switch Lube oil filter (27) Mounting the seawater pump 1) Tighten the spacer bolt to the gear case cover. 2) Mount the bracket and the seawater pump assembly to the gear case cover. Cylinder head Bracket Fuel pipe. Model Engine capacity L (quart) 3YM30 4.9 (5.2) 3YM20 4.1 (4.3) 2) Fill with water until the level in the coolant recovery tank is between the full and low marks. The side walls are save shaped to maximize rigidity for strength and low noise. 5.1.1 Inspection of parts Cap plug 45 mm Make a visual inspection to check for cracks on engines. Cylindricity is the maximum value between those difference values.Special alloy stellite with superior resistance to heat and wear is fitted on the seats, and the area between the valves is cooled by the water jet. Thoroughly remove all the carbon and dirt after disassembly and carefully inspect all parts. Measure the inside diameter of the valve guide and replace it if it exceeds the wear limit. Standard Limit Intake 6.000-6.012 6.08 Valve guide inside dia. When they are removed, be sure to replace them.The side with the smaller pitch (painted yellow) should face down (cylinder head). Model 3YM30 75.970 3YM20 69.
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975 (3) Removing the piston pin A floating type piston pin is used in this engine. The piston pin can be pressed into the piston pin hole at room temperature (Coat with oil to make it slide easily). Measure the thickness and width of the rings, and the ring-to-groove clearance after installation. Replace if wear exceed the limit. 3YM30 Standard Limit Groove width 1.550-1.570 Width Top ring Ring width 1.470-1.490. Joint of coil expander. The large end with the aluminium metal can be separated into two and the small end has a 2-layer copper alloy coil bushing. Standard Limit Connecting rod. Excessive piston pin bushing wear may result in damage to the piston pin or the piston itself. Measure the piston pin bushing inside diameter and the piston pin outside diameter. Crank shaft The crankshaft main veering is of the hanger type. Correct by grinding if unevenly wear, roundness exceeding the limit or insufficient outside diameter is found. The cams have a curve that minimized the repeated shocks on the valve seats and maximizes valve seat life. The oil clearance shall be calculated by Flywheel side subtracting the measured camshaft outside diameter Micrometer from the inside diameter of the camshaft bearing or bushing. Check the contact of each tappet and replace if excessively or unevenly worn.Tighten the nut. 2) Adjust the rack position to R0 (15mm) with the FO limiter, and measure the injection volume (A) at the rated speed. The cause of the trouble may not necessarily be in the pump itself, but may be in the engine or the fuel system. Clean immediately stops. (2) Fuel filter is clogged. Disassemble and clean, or replace the element Replace packing repair (3) Improper air- tightness of the fuel pipe pipe connection or pipe is broken and air is being sucked in. Adjust (2) Injection from nozzle is improper. Adjust Fuel drips after each injection. (3) Injection nozzle starting pressure is too high Adjust (4) Uneven injection.
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The fuel feed pump is mounted on the side of this engine and is driven by the (eccentric) cam of the fuel pump camshaft. NOTE: Replace parts as an assembly. A fuel return connection is provided on top of the tank of which a rubber hose can be connected to return fuel from the fuel nozzles. It is fed to the intake manifold and then on to each cylinder. Intake pipe Exhaust gas goes into exhaust manifold (in the fresh water tank) mounted on the cylinder head outlet. When the internal pressure of the crankcase decreases too much due to the damage of a spring, much blowby gas containing oil is reduced in intake air system, and it may cause the combustion defect by the early dirt of the intake valve or the urgent rotation of the engine by the oil burning. The mixing elbow is attached to the exhaust manifold. U-type Mixing elbow Seawater Joint Heat exchanger L-type Mixing elbow Seawater Exhaust elbow Heat exchanger. Put a ruler on the end face of the gear case cover, and insert a gap gauge between rotor, and measure a side gap. The cartridge type filter is easy to remove. To prevent seizure in the event of the filter clogging up, Lube oil pressure a bypass circuit is provided in the oil filter. The cylinders, cylinder heads and exhaust manifold are cooled with fresh water, and fresh water cooler (heat exchanger) use seawater. V-pulley Shaft Retaining ring Ball bearing Spacer Retaining ring O-ring Ball bearing Plate Cover O-ring. NOTE: Coat the shaft with grease. (3) Mount the impeller. The fresh water pump consists of the pump body, impeller, pump shaft, bearing unit and mechanical seal. It is difficult to disassemble and, once disassembled, even more difficult to reassemble. Replace the pump as an assembly in the event of trouble. (2) When removing the fresh water pump, replace the O-ring (inlet to cylinder). Straightedge Standard Limit Side clearance between impeller and plate Thickness gauge.
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Cooler core The cooler core consists of many small diameter tubes, Pressure cap baffle plates and tube cover. The cap is mounted on the filler neck cam by placing it on the rocking tab and rotating. When the filler neck is removed, remove it with being careful not to damage the fresh water cooler, and scrap it. The coolant recovery tank maintains the water level by preventing this discharge of water. The pump can be run continuously for a period of 10 minutes. After this time it must shut off for a period of 2 hours before reusing. The hose attached at the nozzle should be 1.8 m or less and should reach without any strain, therefore care should be taken in deciding on the best position. Check to be sure that the strainer is in the water before turning on the switch. Problem Cause Countermeasure 1. Pump does not turn Faulty wiring Check the wiring between the motor and battery. Faulty battery Check to see if the specific gravity of the battery fluid is greater than 1.25. Reduction and reversing gear Marine gear KM2P-1 is applied to the 3YM30 and 3YM20 series engines. Refer to chapter 10 in the service manual of the GM series engines for inspection, disassembly and reassembly. These are designed specifically for use with Morse control heads. This engineered system of Worse cables, control head and engine connection kits ensures dependable, smooth operation with an absolute minimum of backlash. If they do not coincide, adjust the fittings as necessary (first engine side, then controller side). Electrical system 12.1 Electrical system STOP B-type panel Glow connector GLOW START Neutral safety switch Glow plug (Fitting to marine gear) Glow relay Magnet relay Safety Extension relay wire harness Alternator To lube switch and fresh water switch To earth bolt Stop solenoid Starting motor. The features are compactness, waterproof and independence from pulse by ring gear teeth number.
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The engine speed, indicated with the instrument panel is activated by the pulse from flywheel ring gear. The pinion engages with the ring gear of a engine, and the engine is started. Magnetic Switch Center Bracket (A) Torsion Spring Shift Lever Brush. It contains diodes that convert AC to DC, and an IC regulator that keeps the generated voltage constant even when the engine speed changes. 12.4.1 Specifications Yanmar code 128271-77200 Model of alternator LR160-741 (HITACHI) Check that a belt doesn't touch the bottom part of the pulley groove. If necessary, replace the V belt set. The features are compactness, waterproof and independence from pulse by ring gear teeth number. The engine speed, indicated with the instrument panel is activated by the pulse from flywheel ring gear. Replace lamp. illuminated when blown out. (2) Lamp not illuminated even main switch set when main switch set to ON to ON. The glow plug is M4 x 0.7 mounted to the cylinder head. The device is operated by the glow switch on the instrument panel. Rated current 8-10A Rated voltage. The device is operated by the stop switch on the Emergency stop button instrument panel. The emergency stop button is integrated with the solenoid. Can anyone please tell me where I can download a copy. Help is much appreciated: Best Regards: Sonny Soh Posts: 209No manuals are jumping out at me for download. Personally, unless you're really strapped for cash, buying the shop manual and parts manual package is a very good investment if you plan on doing any kind of work on the engine yourself. Good luck in your search.Boat: (Cruiser Living On Dirt). Posts: 38,198Anyone seeking a manual, is advised to look here. Boat: Catalac Catamaran. Posts: 2,462Boat: Knysna 480. Posts: 94I am about to acquire a boat with 2 and would like both service and shop manuals. I have looked at all of the above threads and their corresponding sites without success. Doesn't Yanmar offer them somewhere for sale ?Boat: Northstar 1500, 35'.
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Posts: 318Boat: Knysna 480. Posts: 94Boat: Northstar 1500, 35'. Posts: 318Boat: (Cruiser Living On Dirt). Posts: 38,198Send me a short note and I?ll see what I can do for you. I guess a friend of mine still got some.pdf Manuals. Rgds Michael Can anyone please tell me where I can download a copy. Help is much appreciated: Best Regards: Sonny Soh Much appreciated. Best regards: sonnysohCheers: SonnySohI've also been looking around for a copyfor some time. Thank you. This manual contains maintenance and repair procedure for the Yanmar Marine Diesel Engine 3YM30 3YM20 2YM15. With this manual, you may maintain, service, diagnose and repair your own. All repair procedures are covered. Applicable Models Covers: Yanmar Marine Diesel Engine 3YM30 Yanmar Marine Diesel Engine 3YM20 Yanmar Marine Diesel Engine 2YM15 Service Repair Manual Covers: General Inspection And adjustment Troubleshooting Disassembly And Reassembly Inspection And Servicing Of Basic Engine Parts Fuel Injection Equipment Intake And Exhaust System Lubrication System Cooling Water System Reduction And Reversing Gear Remote Control Electrical System Service Standards Tightening Torque For Bolts And Nuts Instant Download means there is NO shipping costs or waiting for a CD or paper manual to arrive in the mail. You will receive this manual TODAY via Instant Download on completion of payment via our secure payment processor. All pages are printable.Thank you, for helping us keep this platform clean. The editors will have a look at it as soon as possible. Rated Output. Rated Speed Displacement Cylinder Bore x Stroke Combustion system. Indirect Injection, In-line Pump. Aspiration. Natural. Alternator Dimensions Controls. Mechanical. Certifications Downloads Contact us with inquiries, comments, and feedback. Copyright YANMAR Marine International. All rights reserved. Skip to content Learn more about how we use cookies by visiting our Cookie Policy Page.
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(5) When the camshaft timing gear comes to the most advanced position, take out the air pressure of the timing retard side path, and then, take out that of timing advance side path. CAUTION: Camshaft timing assembly gear occasionally shifts to the retard side abruptly, if the air compression of the advanced side path is released before retard side path. It often causes the breakage of the lock pin. (c) Check smooth revolution (1) Revolve the camshaft timing gear assembly within the movable range except for the most retarded position several times, and check the smooth revolution. CAUTION: Be sure to perform this check by hand, instead of air pressure. (d) Check the lock in the most retarded position. (1) Confirm that the camshaft timing gear assembly is locked at the most retarded position. 14--8 ENGINE MECHANICAL 19. CAUTION: Be careful not to damage the camshaft. (b) Cover 4 oil paths of cam journal with vinyl tape as shown in the illustration. Plug one of the path with a rubber piece. (c) Break through the tapes of the advance side path and the retard side path on the opposite side of the groove. A62191 Retard Side Path Advanced Side Path Decompress Hold Pressure A62192 3ZZ--FE,4ZZ--FE ENGINE REPAIR MANUAL (RM928E) (e) Confirm if the camshaft timing gear assembly revolves in the timing advance direction when weakening the air pressure of the timing retard path. HINT: The lock pin is released, and camshaft timing gear revolves in the advance direction. (f) When the camshaft timing gear comes to the most advanced position, take out the air pressure of the timing retard side path, and then, takeout that of timing advance side path. CAUTION: Camshaft timing gear assembly occasionally shifts to the retard side abruptly, if the air compression of the advanced side path is released before retard side paths. NOTICE: S Be sure not to remove the other 4 bolts. S In case of reusing the camshaft timing gear, release the strait pin locking first, and then install the gear.