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3YM30 20.book

1. 152 152 153 9 2 1 Lube oil DUIMPSCOMSWUC HOM 153 9 2 2 Opecilicalions or IUDe ONl DUMP 153 8 2 3 Lube pump disassembly and 153 o 24 LUDE Ol DUMP INSDCCUOM nes ak icon 154 8 2 5 Pressure control valve construction ccccceeccceececeececeeeeceeeeseeeceeeseseeecseeessesessueensasensatensessenees 154 LUDE Ol TION c Pm 155 T UU E E 155 2 2 TT 155 o 4 Rotary Waste ol DUMP qua o ua pu ood 156 9 Waller 157 Cooling Water SVSTOITI ead oa Modes 157 9 2 SCAW ALE r PUMP
2. a 131 AGEA T 131 5 9 HOUSING sessio muta d ge ques 132 5 8 1 Position of top dead center and fuel injection 132 9 02 eain enda cus m 133 6 Fuelaniecaion SOGUIDIMENE en edi a ER 134 6 1 F el Injection p mp gOoVOeFPDOF 2 255 VIVE bv dean aude ac ecd Gua ut aes ou 134 6 1 1 Fuel systemdiagraM essre eher eui games due seu etii se vues ape edat eee di 134 6 1 2 Fuel injection pump service data and 135 6 1 3 Fuelinjection PUMP SUCIU G iid ee cm 139 6 1 4 REMOVING a tuelinjection pUttip s osuc ues se 140 Installing a Tuel Injlecdon pULTID buen a 140 6 1 6 Adjusting fuel 140 6 1 7 Troubleshooting of fuel injection 141 6 1 6 Major faults and troubleshooting deci A cu cde one cen en Pa met Peta du ceu tau ea ara ioni Fe Sae 141 6 2 Pel Teed PUMO
3. 172 mecnm 174 LLO TIOUDIESMOOUNG t rn 175 10 Reduction and reversing gear 176 ue d ERIT TEE 176 TTdSermote control ODUIOTDal 177 121 Remote control SV SCI gt 177 11 1 1 Construction of remote control system 177 11 1 2 Remote control device Comporienfis be ded id 177 11 2 Remote control instalation Cu eau dde 179 11 3 Remote control inspection acu unte deatur xo 181 a 182 12 Electrical SVSIGITI 183 12 1 Electroal SVSIOlTl 183 IZ VV INI COAG 184 USA REM 185 12 9 Staring TOOLDOE ouest sra 186 WZ ay Rd LE 186 1232 186 12 9 9 UC LUC aden
4. 187 12 3 4 Wiring diameter of a starting 188 T2 4 Alternator Standard 12 Vi GOA 189 a a a a 189 124 UIC quU 190 191 124 4 Standard output characteristics eer tese 191 HP 192 12 5 Allernator 12V 99A ODHODal be et antes 193 xu 193 129 AI Brei eere 194 T2559 VIDIT ML i LL des 195 12 5 4 Standard output aoi oe 195 IZS UMEN DaN E E a 196 12 6 1 B type instrument panel 196 197 2 197 12 7 2 Cooling water temperature
5. 113 5 2 6 Measuring top 114 5 2 EC EM 114 9 2 9 Adjustment or valve cleararice pedale REM UE duse UU NEUE 115 9 9 ht 116 sx we e 116 SP DAR cil roue nme terc E Tx 117 9 19 9 PISONI S te sema 118 S4 COMME ING TOO c 121 5 4 1 Inspecting the connection rod ads 2 genie e nun aono eva 121 OA ZC FAN ULT 122 ALS Piston 124 5 4 4 Assembling piston and connecting rod 124 9 5 Grankshattahg main tosta dy Fasc dese 125 I UU 125 MAN DONIN HMM MuR 127 a 128 2 128 0 2 raw 130 g TIMINI m 131
6. 159 9 2 1 Specifications of seawater 159 92 2 Seawater DUMP GISASSEMDIY sunk oases ce 159 2 35 tent De cao tetti 160 9 2 4 Seawater pump reassembly 161 Freshwater ertor 162 9 3 1 Fresh water pump 162 9 3 2 Specifications of fresh water 162 9 9 9 Fresh walter pu mp disasserbly MED E 163 9 9 4 Fresn water DUMP INSPOCIION ie tone dne ure op 163 9 4 TD Em 165 9 AA due 165 9 4 2 Disassembly reassembly of the heat exchanger 165 9 4 3 Heat exchanger inspection bad pecie oae qulbus a o seu ole odes 165 9 5 Pressure and coolant recovery tank 166 a e eiut ics doas 166 9 5 2 Pressure cap pressufe
7. S 2 Nozzle case nut o 39 2 Inspection and adjustment 2 Spray pattern inspection After adjustment to the specified valve opening pressure use a nozzle tester and check the spray pattern and seat oil tightness a Seat oil tightness check After injecting a few times increase the pressure gradually Hold the pressure for about 5 seconds at a little before the valve opening pressure of 1 96 MPa 20 kgf cm and check to see that oil does not drip from the tip end of the nozzle e f extreme oil leak from the overflow joint exists during injection by the nozzle tester check after retightening If much oil is leaking replace the nozzle assembly b Spray and injection states Operate the nozzle tester lever at a rate of once or twice a second and check no abnormal injection e f normal injection as shown below cannot be obtained replace the fuel injection valve e No extreme difference in angle Finely atomized spray Excellent spray departure Che Normal spray pattern Abnormal spray pattern 3 Nozzle valve sliding test Wash the nozzle valve in clean fuel oil Place the nozzle body vertically and insert the nozzle into the body to about 1 3 of its length The valve is normal if it smoothly falls by its own weight into the body In case of a new nozzle remove the seal peel and immerse it in clean diesel oil or the like to clean the inner and outer surfaces and to thor
8. u ive buta ELLA dnd OD APR ia ix etat au 144 624 Constr caon of THE TEGO minut lu dee 144 6 2 2 Fuel feed pump specifications eise ettet ota eoe iau eun tulimus 144 6 2 3 Disassembly and reassembly of fuel feed 2 22 145 6 2 4 Fuel feed pump IDnsDeGlobi cmeooee oma catu 145 ash 147 ae 147 AR UIN ilircidiacjer iejon met 147 GA CCNA MR len Saran iat aad T 148 149 TF Io Ec 149 7 1 1 Breather system A reductor to intake air system of blowby 149 7 1 2 Diaphragm assy InspeotlODis nas comis aca eens 150 TXMAS SY SUC IN 151 ONSE ML I E MM M c E 151 eod ons De Tub capa a 151
9. 198 12 9 GIOW DIG LR 199 12 9 Electic engine deVICG 200 S6mMce Standard cM mU m 201 ENGINE UDIN ee EE pm 201 NDZ ES INGIING OGY A 202 ENES E a sc on cetacean a tense EE COLS 202 12 2 2 usd 203 192 9 C VIII oeste acest 204 13 3 Lubricating oll system 207 14 Tightening torque for bolts and nuts 208 t4 t Main boland NUT 208 14 2 Standard bolts and nuts without lube 208 FOR SAFETY 1 SAFETY LABELS Most accidents are caused by negligence of basic safety rules and precautions 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 Attempting at a repair or maintenance job without sufficient knowledge may cause an unexpected accident It is impossible to cover every possible danger in repair or maintenance in the manual Sufficient consideration for
10. 2 Measure the outer diameter of the tappet and replace if worn beyond the limit mm Tappet outside 957 20 960 20 907 diameter Tappet guide hole inside dia 21 000 21 021 21 041 cylinder block 0 040 0 094 0 134 3 Measuring push rods Measure the bend of the push rods mm Push rod bend Less than 0 03 Thickness gage Push rod bend 130 5 Inspection and servicing of basic engine parts 5 7 Timing gear The timing gear is helical type for minimum noise and specially treated for high durability 5 7 1 Inspecting the gears 1 Inspect the gears and replace if the teeth are damaged or worn 2 Measure the backlash of all gears that mesh and replace the meshing gears as a set if wear exceeds the limit NOTE If backlash is excessive it will not only result in excessive noise and gear damage but also lead to bad valve and fuel injection timing and a decrease in engine performance mm Backlash 0 06 0 12 3 Idling gear The bushing is pressure fitted into the idling gear Measure the bushing inner diameter and the outer diameter of the shaft and replace the bushing or idling gear shaft if the oil clearance exceeds the wear limit A B and C are inscribed on the end of the idling gear When assembling these marks should align with those on the cylinder block mm Idle gear shaft 44 950 44 975 44 900 diameter Idle gear bushing 45 950 45 925 45 075 inside dia Idle gear Idl
11. Fuel system air bleeding procedures 1 Check the fuel level in the fuel tank Replenish if Insufficient 2 Loosen the air bleeding bolt at the top of the fuel filter by turning it 2 or 3 times 3 Feed fuel with the fuel feed pump by moving the lever on the left side of the feed pump up and down 4 Allow the fuel containing air bubbles to flow out from the air bleeding bolt hole When the fuel no longer contains bubbles tighten the air bleeding bolt This completes the air bleeding of the fuel system Retaining ring 5 After the engine start up the automatic air bleeding device works to purge the air in the fuel system No manual air venting is required for Fuel filter normal engine operation Filter element Filter cap 25 2 Inspection and adjustment Cylinder head Fuel pipe Fuel injection pump Fuel pipe 26 2 Inspection adjustment 2 Check the electrolyte level in the battery WARNING W Battery structure Fire due to electric short circuit Make sure to turn off the battery switch or disconnect the negative cable before inspecting the electrical system Failure to do so could cause short circuiting and fires e Always disconnect the Negative battery cable first before disconnecting the battery cables from battery An accidental Short circuit may cause damage fire and or personal injury And remember to connect the Negative battery cabl
12. 206 13 Service standards 13 3 Lubricating oil system Trochoid pump 1 Outside clearance of outer rotor mm Standard Reference page 0 12 0 21 8 2 4 1 2 Tip clearance between outer rotor and inner rotor mm Standard Reference page 82401 3 Side clearance of outer rotor mm Standard Reference page 0 02 0 07 8 2 4 2 4 Outside diameter clearance of inner rotor centering location part mm page Gear case cover 1 0 46 13 46 18 US Inner rotor O D 45 98 46 00 8 2 4 3 Rotor clearance 0 13 0 20 207 14 Tightening torque for bolts and nuts 14 Tightening torque for bolts and nuts 14 1 Main bolt and nut Thread diameter died e Torque thread portion and seat X pitch Nem kgfem surface Head bolt M9 x 1 25 Coat with lube oil 53 9 57 9 5 5 5 9 Rod bolt M7 x 1 0 Coat with lube oil 22 6 27 5 2 3 2 8 EX Flywheel retainer bolt M10 x 1 25 Coat with lube oil 80 4 86 4 8 2 8 8 4 Metal cap retainer bolt Metal cap retainer retainer bolt M 0x125 x 1 25 Coat with lube oil 5 5 81 5 7 7 8 3 Crankshaft pulley bolt B FC250 pulley M10 x 1 25 Coat with lube oil 83 3 93 3 8 5 9 5 E Fuel pump gear nut M12 x 1 75 Coat with lube oil 58 8 68 8 6 0 7 0 7 Nozzle Nozzle fastening nut nut M20x15 x 1 5 Nohbeol lube oil 4953 5 0 5 4 53 5 0 5 4 Z nore senno i injection pipe M12 x 1 25 No lube oil 29 4 34 4 3 0 3 5 joint nut
13. Lower limit Unit liter quart Engine oil capacity 3YM30 with KM2P 1 Full 2 8 9 5 3 0 3YM20 with KM2P 1 Full 2 7 9 5 2 9 b If the remaining engine oil level is low fill the oil pan with the specified engine oil to the specified level through the filler port NOTICE The engine oil should not be overfilled to exceed the upper limit line If engine oil is overfilled the engine may intake the engine oil in the combustion chamber during the operation and white smoke oil hummer or urgent rotation may occur because the blowby gas is reduced in the suction air flow 17 2 Inspection and adjustment 2 Checking marine gear lube oil level a Check the lube oil level of the marine gear with a dipstick Unit liter pint Marine gear oil capacity KM2P 1 Full 0 30 0 64 b When the level is low remove a oil filler cap at the top of the housing and fill it with marine gear clutch lube oil to the upper limit on the dipstick Tighten the oil filler cap securely by hand 4 Seawater outlet Check whether seawater comes out just after the engine has started If seawater doesn t come out shut down the engine immediately Check the leakage of seawater in the seawater pass and the damage of the seawater pump impeller 5 Check cooling water level Daily inspection of cooling water should be done only by coolant recovery tank A WARNING Never open the filler cap We the engine is still
14. Inner rotor O D 45 98 46 00 MEE Rotor clearance 0 13 0 20 8 2 5 Pressure control valve construction The pressure control valve controls the oil pressure from the time the lube oil leaves the filter When the pressure of lube oil entering the cylinder body main gallery exceeds the standard the control valve piston opens the bypass hole and lube oil flows back into the oil pan 0 29 0 44 MPa Standard oil pressure 2 3 0 4 5 kgf cm 154 8 Lubrication system 8 3 Lube oil filter 8 3 1 Lube oil filter construction The lube oil filter is a full flow paper element type mounted to the side of the cylinder block The cartridge type filter is easy to remove To prevent seizure in the event of the filter clogging up a bypass circuit is provided in the oil filter When the difference of the pressure in front and behind the paper element reaches 0 08 0 12 MPa 0 8 1 2 kgf cm the bypass valve inside the filter opens and the lube oil is sent to each part automatically as an emergency measure without passing through the filter Pell ow paper ele Filtration area 0 10 m2 Discharge volume 30 l min Lube oil pressure switch Lube oil filter 0 03 0 05 MPa Pressure loss 2 0 3 0 5 kgf cm By pass valve 0 08 0 12 MPa regulating pressure 0 8 1 2 kgf cm 8 3 2 Lube oil filter replacement Refer to 2 2 2 2 155 8 Lubrication system 8 4 Rotary waste oil pump Optional A rotary waste oil p
15. ani 166 SESS Pressure Cap INS DECOM erm 166 95 4 Replacing Tiller MOCK 167 9 5 5 Function of the coolant recovery 168 9 5 6 Specifications of coolant recovery 168 9 5 7 Mounting the coolant recovery 168 9 5 8 Precautions on usage of the coolant recovery tank 168 OO AMCNMOStAL T TCU IPC TEMP 169 S Rom gtiaredejagee NIM aae ci EET E 169 96 2 Thermostat CoFStEHO 2 aa 169 9 6 3 Characteristics Of INGIMOS 169 96 4 Thermostat Ins DECON 169 9 6 5 POSTING the thelmoestal x oc 169 9 7 Bilge pump and bilge strainer Optional 170 S Bes WV 010 0 Old Oe eee 170 9r O me 171 HM Tr 171 9 rA AsSemDIy
16. Glow plug M10 x 1 25 No lube oil 14 7 19 6 1 5 2 0 12 1 25 Coat with lube 68 7 73 7 7 0 7 5 support fastening nut 14 2 Standard bolts and nuts without lube oil Nem kgf m Hexagon bolt 7T and 9 8 11 8 1 0 1 2 Use 80 of the value at nut left when the tightening part is aluminum M10 x 1 5 44 54 4 5 5 5 Use 60 of the value at M12 x 1 75 78 2 98 2 8 0 10 0 left for bolts and lock nuts 1 0 Mg 243440538 _ 3314916959 _ wwe _ 208 YANMAR MARINE INTERNATIONAL P O BOX 30112 1303 AC ALMERE NL BRUGPLEIN 11 1332 BS ALMERE DE VAART THE NETHERLANDS TEL 31 36 5493211 FAX 31 36 5493549 YANMAR MARINE U S A CORPORATION 101 INTERNATIONAL PARKWAY ADAIRSVILLE GA 30103 U S A TEL 1 770 877 9894 FAX 1 770 877 7565 YANMAR ASIA SINGAPORE CORPORATION PTE LTD 4 TUAS LANE SINGAPORE 638613 TEL 65 6861 3855 FAX 65 6862 5195 YANMAR LTD MARINE FACTORY ENGINE PRODUCT OPERATIONS DIVISION 5 3 1 TSUKAGUCHI HONMACHI AMAGASAKI SHI HYOGO 661 JAPAN TEL 81 6 6428 3123 FAX 81 6 6421 5549 YANMAR CO LTD Printed in Japan
17. Mallet Local supply Eger qmi ca eS Offset wrench Local supply 1 set Box spanner Local supply 1 set 4 Disassembly and reassembly o i i Cid Rod spanner for Local supply hexagon socket Size 6mm head screws 8mm 10 mm Stariing pliers Hole type Shaft type Local supply S Hole type H Shaft type 67 4 Disassembly reassembly 4 2 2 Special hand tools Piston pin insertion extraction tool Piston pin extractor f Extraction of piston Connecting rod small end bushing insertion extraction tool 20 80 9 9 CN N N Locally manufactured Intake and exhaust valve insertion 20 extraction tool E LO Locally manufactured Crankshaft pulley insertion tool M12 x P1 25 4 Disassembly reassembly Lube oil filter case remover Piston ring replacer for removal installation of piston ring Valve lapping tool Rubber cap type Valve lapping powder 28210 000070 Feeler gauge Pulley puller Removing the coupling Local supply 4 Disassembly reassembly Press tool 1 for filler neck 89 ai T Tool 1 Stem seal insertion for inserting stem seal Press tool 2 for filler neck copper tube Chamfer is 70 4 Disassembly reassembly 4 2 3 Measuring instruments 1 Application of tools Vernier cali
18. e f the inside of the pump is dry or if the water is not being drawn up initially after a period of 10 seconds lift the strainer above the water surface and stop the pump Prime the pump before starting it up again 7 Fixing the strainer e After the test operation fix the strainer into place with screws Be careful not to damage the bottom of the boat with the screws 173 9 Cooling water system 9 7 5 Cautions for assembling Observe the following cautions for handling Do not use gasoline or solvents 1 gasoline 2 ester 3 benzol 4 battery fluid 5 liquids at 70 C or greater or engine oil Never run when there is no water in the bilge Check to be sure that the strainer is in the water before turning on the switch Keep the cord terminal away from the water Water inside the motor or switch may lead to damage When the insulation around the cord is damaged water can seep in to the wires thus care should be taken not to scratch or nick the cord When the pump has not been used for a long period of time the inside of the pump will be dry and it may not operate properly at first If after 10 seconds the pump is not working turn off the switch and prime the pump before trying again Never run the pump dry for period of greater than 10 seconds Replace the diesel engine oil only after the engine has been stopped for a period of 30 minutes oil temp 20 70 C Whenever possible refrain from operation when the oi
19. 1 Open a seawater drain cock to drain the seawater 2 Open a drain cock on the cylinder body to drain the fresh water from the cylinder head and cylinder body 3 Open a fresh water drain cock on the lower part of the coolant tank to drain the fresh water 4 Open a fresh water drain cock on the lower part of the fresh water pump to drain the fresh water Coolant tank PR C IP zi V c Y v e a Fresh water Drain cock for seawater Drain cock for coolant Drain cock for seawater 2 Drain lube oil 1 Remove the pipe coupling bolt which holds the lube oil dipstick guide and drain the lube oil from the engine 2 Remove the drain plug on the lower part of the crank case control side and drain the lube oil from the marine gearbox 77 4 Disassembly reassembly lube oil supply discharge pump is used for the engine the intake hose is placed in the dipstick guide and for the clutch side gearbox it is placed in the oil hole on top of the case Refer to 2 2 2 2 amp 3 3 Removing electrical wiring Remove the wiring from the engine Refer to 2 2 4 9 4 Removing the fuel filter amp fuel pipe 1 Remove the fuel pipes fuel filter fuel feed pump fuel filter fuel injection pump and fuel nozzle fuel pump 2 Remove the fuel filter Fuel pipe Fuel filter Fuel injection pump 29 d 2 27 5 2069 XE S 9 Fuel pipe 78 4 Disa
20. BLOCK 10 230 I 48 108311 ee 9 274 185 FRESH gt yo NE WATER 6 m DRAIN 8 LO FILTER PR i NOTE 1 DWG SHOWS MOUNTING BLOCKS ORIGINAL HEIGHT 2 ENGINE WEIGHT WILL COMPRESS BLOCKS BY 4 5 mm 3 MOUNTING BLOCKS ARE EQUIPPED FOR STANDARD ACCESSORY Mo d 4 4 amp SHOWS CENTER OF GRAVITY 1 5 Piping diagrams 1 3YM30 3YM20 with KM2P 1 marine gear X 7 8 x t4 5 rubber hose X 7 8 x 14 5 rubber hose X 7 8 14 5 rubber hose Fuel feed pump Marks of piping X 7 8 x t4 5 rubber hose Screw joint Union valve X 7 8 x t4 5 rubber hose Fuel oil filter 2 5 14 5 Fuel injection pump rubber hose Overflow Fuel oil inlet 4 76 x t0 7 steel pipe Insertion joint Drill hole Pressure control valve Cooling fresh water piping Cooling seawater piping m TE Lubricating oil pump Lubricating oil piping Fuel oil piping Lubricating oil filter cartridge type Fresh water temperature switch l Fuel high pressure pipe Fuel injection nozzle Hot water connection inlet R3 8 7 Q pressure switch Cooling water pump fresh water AR i Thermostat Y cylinder v M wi shaf U Hot water connection outlet R3 8 E 28 x t4 rubber hose 1 28 x t4 rubber hose Mixing elbow Cooling water pump s
21. Joint of coil expander 120 5 Inspection and servicing of basic engine parts 5 4 Connecting rod The connecting rod is made of high strength forged carbon steel The large end with the aluminium metal can be separated into two and the small end has a 2 layer copper alloy coil bushing Connecting rod Crank pin metal Connecting rod bid end cap 5 4 1 Inspecting the connection rod 1 Twist and parallelism of the large and small ends Insert the measuring tool into the large and small ends of the connecting rod Measure the extent of twist and parallelism and replace if they exceed the tolerance mm Connecting rod Less than 0 03 twist and parallelism per 100 mm Parallelism Twist and parallelism measurement Connecting rod aligner Twist measurement A a connecting rod aligner 121 5 Inspection and servicing of basic engine parts 2 Checking the side clearance of a connecting rod Fit the respective crank pins to the connecting rod and check to make sure that the side clearance in the crankshaft direction is correct Connecting rod 0 20 0 40 side clearance a Crankshaft Thickness gage Connecting rod side gap 5 4 2 Crank pin metal 1 Checking crank pin metal Check for flaking melting or seizure on the contact surface of the crank pin metal 2 Measuring crank pin oil clearance Measure the crankpin outside diameter and the crank pin metal inside
22. Main bearing metal intermediate Main bearin cap y V Main bearing bolt Main bearing cap intermediate Main bearing bolt Deflection Dial gage V block V block Crankshaft bend measurement 5 Inspection and servicing of basic engine parts 3 Measuring the crank pin and journal Measure the outside diameter roundness and taper at each crank pin and journal Correct by grinding if unevenly wear roundness exceeding the limit or insufficient outside diameter is found Replace if the defect is excessive ter Standard Limit Diameter Diameter Rounaness 0 01 or less 0 02 Taper To look for the oil clearance of crank pin measure the inside diameter of crank pin metal Refer to 5 4 2 2 mm Outside dia 41 952 41 962 41 902 Crank pin Oil 0 020 0 058 0 120 clearance Crankshaft journal Crank pin Measuring position of the crank Pin and crank journal Outside dia 46 952 46 962 46 902 pou journal 0 020 0 050 0 120 clearance Dimension and finishing precision of crankshaft journal and pin As for grinding processing of journal and pin machine it by using the grinding wheel of the dimension R of below table Surface finishing precision standard on journal and pin Ry 0 8S super polishing Crank Pin Crank Journal Surface finishing precision standard on the thrust side Crankshaft R machining 1 6 of crankshaft arm Finishing pre
23. tearance 0 Ring width 1 470 1 490 1 450 0 050 0 090 0 210 Ring width 2 970 3 010 2 950 Groove width 3 010 3 030 3 130 Oil ring 0 020 0 060 0 180 118 5 Inspection and servicing of basic engine parts 2 Measuring piston ring gap Press the piston ring onto a piston liner and measure YZ YA the piston ring gap with a gauge Press on the ring about 30mm from the bottom of the liner Head surface 3YM30 3YM20 mm Top ring gap 0 15 0 30 0 390 Cylinder block Zy 4 KOM Second ring gap 0 18 0 33 0 420 Oil ring gap 0 20 0 45 0 540 Piston ring AN Approx 30 mm 3 Removing the piston rings 1 Thoroughly clean the ring grooves when removing Make the punched manufacturer s piston rings mark face upward 2 The side with the manufacturer s mark should ap Piston ring 3 After fitting the piston ring make sure it moves easily and smoothly 4 Stagger the piston rings at 120 intervals making sure none of them line up with the piston 1st piston ring 1st piston ring 099 75 2st piston ring Direction of piston pin Oil ring Oil ring 1st piston ring aS ees 2nd piston ring Direction of side pressure 2st piston ring Oil ring 119 5 Inspection and servicing of basic engine parts 5 The oil ring is provided with a coil expander The coil expander joint should be opposite staggered 180 the oil ring gap
24. 15 C or less And store the battery in a warm place until the next use the unit to start the engine easily at low ambient temperature Electrolyte level 2 Battery charge Use a battery tester or hydrometer and check the battery condition If the battery is discharged recharge it a Measurement with a battery tester When checking the battery with the batter tester connect the red clip of the tester to the battery positive terminal and black clip to the battery negative terminal by pinching them securely and judge the battery charge level from the indicator position Green zone Normal Yellow zone Slightly discharged Red zone Defective or much discharged Battery charge measurement with battery tester 28 2 Inspection adjustment Measurement with hydrometer When using a hydrometer the measured specific gravity must be corrected according to the temperature at the time of measurement The specific gravity of battery electrolyte is defined with 20 C as the standard Since the specific gravity increases or decreases by 0 0007 when the temperature varies by 1 C correct the value according to the equation below 20 St 0 007 1 20 E Electrolyte temperature at measurement Specific gravity at measurement Converted specific gravity at 20 Battery charge measu rement with a hydrometer Specific gravity and remaining battery charge y 9 y 9 Rubber bulb Specific Dischar
25. 71 42A Eun tcr DEus 75 4 3 Disassembly arid reassembly 77 DISA SSEM yere awe 77 2 9 2 IRROOSSOITIDIV 89 5 Inspection and servicing of basic engine parts 104 T RERO ETT E P 104 Oe Mele 104 5 1 2 CICAMING or om hel S 104 e 104 Replacement ol Cap plugs s oo toe ete oU 105 5 1 5 Cylinder bore Trieds urerfIe DI 106 9 2 Cyllidel edd a 107 9 2 1 m 108 5 2 2 Valve seat correction 109 5 2 3 Intake exhaust valves valve guides ccccccecccecceneeseeteeeeneceeeceeceeeseeteeeseeseeteeeeeeseeseeeteeeseeeeaess 110 9 2 4 WAIVE SPNG S 112 5 2 5 Assembling the cylinder head
26. Adjust 1 Faulty fuel injection pump POOR EXHAUST COLOR 1 Il Il Il Faulty fuel injection valve 1 Clean 2 Check repair or replace 3 Adjust 4 Check repair or replace 5 Clean 1 Faulty plunger operation 1 Injection opening is clogged 2 Worn plunger 2 Sticking of valve needle 3 Faulty ejection valve 3 Low injection pressure 4 Uneven quantity of fuel injected 4 Faulty spry condition 5 Irregular fuel injection timing 5 Carbon deposit POOR EXHAUST COLOR 1 Clogged filter 1 Overloading 2 Too great a quantity of lube oil 3 Carbon deposit in suction valves 4 Dirty air cooler 5 Poor quality fuel oil 6 Clogging in exhaust system Cause Clogged intake air filter 11 1 Clean IV Miscellaneous IV 1 Reduce load IV 2 Adjust quantity of oil IV 3 Clean IV 4 Clean IV 5 Reduce with new oil IV 6 Clean buioouse qnoJ Chart 4 TROUBLE AND TROUBLESHOOTING TROUBLE WITH MARINE GEAR Disassemble and clean l 7 Replace Review 1 1 1 11 1 1 Replace Repair or replace 8 Reduce load 2 Replace Repair or replace 9 Adjust to correct position 3 Eliminate dangerous rotation 10 11 Reassemble Check oil level and adjust Check for oil leakage Check water level and adjust and replenish Change oil Review manual Countermeasure 1 Low clutch oil pre
27. Attach the oil drain pump to the dipstick guide and drain off the lube oil Notice For easier draining remove the oil filler cap yellow at the top of the rocker arm cover When lube oil is absorbed without removing a oil filler cap negative pressure grows big in the crankcase and it may cause the rubber of the diaphragm cracked 2 Turn the lube oil filter counter clockwise using a filter wrench to remove it 20 A 1 LU LRN y IA eu M 5 4 fum 2 Inspection adjustment 3 Moisten the new oil filter gasket with the lube oil and install a new lube oil filter manually turning it clockwise until it comes into contact with the mounting surface and tighten it further to 3 4 of a turn with the filter wrench Tightening torque 20 24Nem 177 212 Fill with new lube oil Perform a trial run of the engine and check the oil leakage 6 Approximately 10 minutes after stopping the engine check the oil level by using the oil dipstick Add oil if the level is too low Standard The level shall be between the upper and lower limit lines on the dipstick Unit liter quart Engine oil capacity 3YM30 with KM2P 1 Full 2 8 9 9 3 0 3YM20 with KM2P 1 Full 2 7 9 9 2 9 Notice When checking the lube oil level right after the engine running the oil level in the dipstick guide decreases drastically and the accurate oil measurement c
28. Cooling water volume Unit liter quart 3YM30 4 9 5 2 0 8 0 8 1 4 3 18 2 Inspection adjustment IMPORTANT If the cooling water runs short quickly or when the coolant tank runs short of water with the coolant recovery tank level unchanged water may be leaking or the air tightness may be lost Increase in the water level of the coolant recovery tank during operation is not abnormal The increased water in the coolant recovery tank returns to the coolant tank when the engine is cooled down If the water level is normal in the coolant recovery tank but low in the coolant tank check loosened clamping of the rubber hose between the coolant tank and coolant recovery tank or tear in the hose 6 Check the alarm lamps amp devices Before and after starting the engine check to see that the alarm functions normally Failure of alarm cannot warn the lack of the engine oil or the cooling water Make it a rule to check the alarm operation before and after starting engine every day When the sensor detects a problem during operation the lamp comes on and the buzzer goes off Alarm lamps are located on the panel buzzer is located on the back of panel Under normal conditions the monitors are off When there is a problem the monitors light up Battery low When the alternator output is too low the lamp will come on charge alarm When charge begins the lamp will turn off The alarm buzzer will not sound when the lamp comes
29. E 6 7 5 MOUNTING BLOCKS ID 100 DIRECTION OF ROTATION DL 185 185 DETAIL OF PULLEY B 80A ALTERNATOR U MIXING ELBOW OPTIONAL OPTIONAL _ FUEL OVERFLOW Ps 8 0 FUEL INLET 08 3 Yi N y PU NA ERE SEAWATER INLET zdel p psc ie AR 173 O J oy E T Eo j hf EE 2 CRANKSHAFT CENTER TE 7 Q dE i 175 SEAWATER DRAIN PLUG NOTE 48 1 DWG SHOWS MOUNTING BLOCKS AT ORIGINAL HEIGHT 6 693 5 2 ENGINE WEIGHT WILL COMPRESS BLOCKS BY 4 5 mm APPROX 3 MOUNTING BLOCKS ARE EQUIPPED FOR STANDARD ACCESSORY 4 4 SHOWS CENTER OF GRAVITY 1 General 4 3YM20 with SD20 sail drive MOUNTING BLOCKS ID 100 463 248 215 80A ALTERNATOR U MIXING ELBOW OPTIONAL OPTIONAL FUEL OVERFLOW 8 0 PIPE _ i Bir m WV Wiese Yn Tha as 2227 35 X FUEL INLET at em 8 3 x 5 j HOLT CF LA SEAWATER INLET Z Y 2 N H D 17 3 2 A TRH 2 5 Seat ee r Eram CE CRANKSHAFT CENTER ys CECI ORT EE nazis PES doce
30. 1 Disassembly and reassembly precautions 1 Disassembly e Take sufficient time to accurately pin point the cause of the trouble and disassemble only those parts which are necessary Be careful to keep all disassembled parts in order Prepare disassembly tools e Prepare a cleaner and cleaning Clear an adequate area for parts and prepare a container s Drain cooling water seawater fresh water and lube oil e Close the seacock 2 Reassembly e Sufficiently clean and inspect all parts to be assembled Coat sliding and rotating parts with new engine oil when assembling Replace all gaskets and O rings Use a liquid packing agent as necessary to prevent oil water leaks e Check the oil and thrust clearances etc of parts when assembling Make sure you use the correct bolt nut washer e Tighten main bolts nuts to the specified torque Be especially careful not to over tighten the aluminum alloy part mounting bolts Align match marks if any when assembling Make sure that the correct sets of parts are used for bearings pistons and other parts where required 64 4 Disassembly reassembly 4 2 Disassembly and reassembly tools The following tools are required when disassembling and reassembling the engine Please use them as instructed 4 2 1 General hand tools Screwdriver e 2 B de i 65 4 Disassembly reassembly Copper hammer Local supply I
31. 21 33 Ib in If there are any leaks the pressure will not rise If there are no leaks the pressure will not fall 4 Pressure cap inspection Do not open the pressure cap while the engine is running or right after WARNING stopping because high temperature steam will be blown out Remove the cap only after the water cools down rn a Remove scale and rust and check the seat and seat valve etc for scratches or wear Check the spring for corrosion or settling Replace if necessary NOTE Clean the pressure cap with fresh water as it will not close completely if it is dirty b Fit the adopter on the tester to the pressure cap Pump until the pressure gauge is within the specified pressure range 0 074 0 103 MPa 0 75 1 05 kgf cm and note the gauge reading The cap is normal if the pressure holds for six seconds If the pressure does not rise or drop immediately inspect the cap and repair or replace as necessary 42 2 Inspection adjustment 5 Diaphragm assembly inspection Inspect the diaphragm assy on the rocker arm cover 1 Loosen screws and remove diaphragm Diaphragm cover 5 assembly and check whether oil and so on doesn t Spring amp enter between the diaphragm and the cover If oil Center plate and so on enters into the diaphragm assy the Diaphragm K diaphragm doesn t work well 2 Check the damages of the diaphragm rubber and Rocker arm cover the spring If neces
32. 3 Wiring diagram oe M lamp m 12V3 4W d Battery IC regulator b Lt Alternator NOTICE 1 Don t do mis connecting and short circuit of each terminal 2 Don t remove a battery terminal and a B terminal when rotating 3 Shut out a battery switch during the alternator stop 12 4 4 Standard output characteristics The standard output characteristics of this alternator are shown as the below figure A 7 qo 13 5V constant mM 6 12 Alternator speed 1 Output current Al i a i i BRENNEN 18 X 10 Standard characteristics 191 12 Electrical System 12 4 5 Inspection 1 V belt inspection 1 Inspect the matter whether there are not crack es pias stickiness and wear on the belt visually 2 Check that belt doesn t touch the bottom part of e the pulley groove If necessary replace the V belt set 2 V belt tension Clearance Refer to 2 2 2 4 in Chapter 2 2 Visual check of wiring and check of unusual sound 1 Confirm whether wiring is right or there is no looseness of the terminal part 2 Confirm that there is no unusual sound from the alternator during the engine operation Inspection of V pulley 3 Inspection of charge lamp circuit 1 Move a start switch to the position of on Confirm lighting of the charge lamp 2 Start an engine and confirm the lights out of the lamp Rep
33. 75 4 Disassembly reassembly Usual contents Features and application Scale solvent Scale solvent 1 box The scale solvent removes scale in a short time 4kg x 4 to 10 hours removers Prepare water Seawater is possible in an amount that is about 10 times the weight of the Neutralizer 1 box solvent Mix the solvent with water caustic soda 2kg x 4 Just dipping disassembled part into removes neutralizers scale To shorten removal time stir remover mixture BEPISSEDSDSE If cleaning performance drops replace remover mixture with new remover mixture Neutralize used mixture and then dispose of it To judge cleaning performance of mixture put pH test paper into mixture If test paper turns red remover mixture is still effective Antirust Add antirust to fresh water system Then operate engine for approximately 5 minutes Antirust will be effective for 6 months Anti freeze Add antirust to fresh water system at the cold area to engine operate Cleaning agent he cleaning agent removes even carbon adhering to disassembled parts e cleaning machine is used prepare 4 to 6 mixture of 60 to 80 to ensure more effective cleaning Notice It is recommended that the liquid gasket of Three Bond 1212 should be used for service work Before providing service observe the cautions below 1 Build up each gasket equally 2 For a bolt hole apply liquid gasket to the inside surface of the hole 3 Co
34. 7E 139 6 Fuel injection equipment 6 1 4 Removing a fuel injection pump The procedure to remove a fuel injection pump from the gear case is shown NOTICE Be sure to remove a flange and a fuel injection pump drive gear with a pair without loosening the flange bolts 1 9 Remove fuel injection pipes fuel pipes remote control wire Block the entrance with tape MN gt Fuel injection pump so that trash may not enter the fuel injection pipes Ts drive gear and the fuel injection pump Mark the position of the timing marks of fuel pump and a gear case Or put a mark on the gear case at the position to agree the timing mark of a fuel pump Remove a pump cover from the gear case Pump drive gear nut Give the marks on a fuel injection pump drive gear and a idle gear with paint or the like Loosen fuel injection pump installation nuts three nuts Loosen a installation nut of a fuel injection pump drive gear Pull a fuel injection pump drive gear and a flange with a pair to your side by gear puller Remove a pump drive gear nut and a washer Remove a fuel injection pump Leave the pump drive gear in the gear case 6 1 5 Installing a fuel injection pump NOTICE Use a new O ring on the fuel pump flange and apply grease Confirm whether the marks of the pump drive gear and the idle gear is correct Turn a
35. Borexstoke Output at KW HPY MU HP 20 1 27 3 3489 14 7 20 0 3489 Continuous power Engine speed at Fuel temp 25 C at Fuel temp 25 C 22 1 30 3600 16 2 22 3600 KW HP at Fuel temp 25 at Fuel temp 25 crankshaft Engine speed min 21 3 29 0 3600 15 3 20 8 3600 at Fuel temp 40 C at Fuel temp 40 21 4 29 1 3600 15 7 21 3 3600 at Fuel temp 25 C at Fuel temp 25 C 20 7 28 1 3600 14 9 20 2 3600 at Fuel temp 40 C at Fuel temp 40 C Output at propeller shaft Engine speed Installation Flexible mounting Fuel injection timing deg b T D C FID 16 1 FIC Air 18 1 FID 22 1 FIC Air 24 1 POLI ORO DM jd 11 8 0 98 120 10 4 12 3 098 125 19 pressure kgf cm Main power take off At Flywheel side Counter clockwise viewed from stern EP Crankshaft Direction of Clockwise viewed from stern Propeller shaft Fresh water cooling with heat exchanger Ahead Engine 4 9 5 2 Engine 4 1 4 3 Lubrication system Cooling water capacity Coolant recovery tank 0 8 0 8 Coolant recovery tank 0 8 0 8 at rake angle 8 deg at rake angle 0 deg at rake angle 8 deg at rake angle 0 deg L quart fresh water Rake angle Lubricating oil capacity Total Note 4 engine L quart Effective Note 5 1 4 1 5 Vi 1 5 1 6 DC 12V 1 4 kW genera
36. Coat the bolts with engine oil and gradually tighten them alternately to the specified torque If a torque wrench is not available make match marks on the bolt heads and large end cap before disassembling to indicate the proper torque position and retighten the bolts to those positions 4 Make sure there is no sand metal cuttings or other foreign matter in the lube oil and that the crankshaft is not scratched Take special care in cleaning the oil holes 123 5 Inspection and servicing of basic engine parts 5 4 3 Piston pin bushing 1 Measuring piston pin clearance 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 Calculate the oil clearance from the measured values Refer to 5 3 2 for the piston pin mm a pin metal 59 925 22 038 22 068 Pin PinOD D 21 21 991 22 000 22 000 21 21963 ELI 0 047 m x NOTE Since the rod small end is tapered bush insertion is extremely difficult Any minor mistake will cause abnormalities such as twist and bite Do not insert the bush on site No piston pin bush spare part is available It is included in the connecting rod assembly supplied as a spare part Cylinder gage Connecting rod small end 5 4 4 Assembling piston and connecting rod Piston ID mark The piston and connecting rod should be assembled so that the mat
37. Measure the outer diameter of the shaft and the inner diameter of the veering and replace if wear exceeds the limit Outside dia of intake and 11 966 11 984 11 94 exhaust rocker arm shaft Intake and exhaust rocker 456500 45020 12 07 arm bushing inside dia Rocker arm shaft and bushing clearance at 0 016 0 054 0 13 assembly Rocker arm hole diameter Replace the rocker arm bushing if it moves and replace the entire rocker arm if there is no tightening clearance 2 Valve spring Check the rocker arm spring and replace it if it is corroded or worn 3 Rocker arm and valve top retainer wear 4 Inspect the contact surface of the rocker arm and replace it if there is abnormal wear or flaking 114 5 Inspection and servicing of basic engine parts 5 2 8 Adjustment of valve clearance 1 Make adjustments when the engine is cool Refer to 2 2 2 8 mm Intake and exhaust valve clearance 0 15 0 25 2 Be sure that the opening and closing angles for both the intake and the exhaust valves are checked when the timing gear is disassembled The gauge on the flywheel can be read deg 115 Exhaust 232 Intake 232 5 Inspection and servicing of basic engine parts 5 3 Piston and piston pins Pistons are made of a special light alloy with superior 1st compression ring thermal expansion characteristics and the top of the 2st compression ring piston forms a combustion chamber ID marks
38. Tighten l 2 Repair using sandpaper or replace Repair using sandpaper 3 Replace Replace Repair using sandpaper and Repair using sandpaper then grease Type 500 600 1 4 1 5 Adjust Replace 7 Countermeasure Replace Replace Pinion gears do not mesh E battery engage 1 Loose battery magnet terminal 5 Edges of gear starter terminal 2 Faulty connection V teeth misshapen 2 Faulty connection in in starting switch V 6 Faulty positioning of engage magnet switch 3 Cut battery engage pinion and ring gears TCU magnet coil 7 Seizure of starter metal 4 Commutator 4 Rough cap movement rough and dirty _ 1 Worn plunger 3 Plunger sticks 4 D O 4 v 2 O 2 Damaged plunger spring _ 4 Oil leakage from exhaust valve 5 Air inside pump 6 Damaged exhaust valve spring V Faulty fuel injection pump Replace plunger and barrel as a unit VI 1 Adjust Replace 2 Tighten firmly Disassemble and repair or replace 3 Lap valves 4 Bleed air Replace 1 2 3 4 Bleed air Countermeasure Adjust Undercut and repair or replace with thicker or shorter wire II Ring gears do not mesh 5 Cut starter coil 6 Worn commutator 7 Slippage of starter clutch 3 Worn brushes 8 Excessive resistance between battery and starter 9 Insufficient battery charge 1 8 Water in f
39. and repair Inspect and repair Replace Repair or replace 6 Fuel injection equipment 7 Loud knocking 1 Injection timing is too fast or too slow 2 Injection from nozzle is improper Fuel drips after each injection 3 Injection nozzle starting pressure is too high 4 Uneven injection 5 Engine overheats or insufficient compression 8 Engine When exhaust Injection timing is too fast Adjust exhausts smoke is Air volume intake is insufficient Inspect and repair too black The amount of injection is uneven Adjust 1 2 3 smoke 4 Injection from nozzle is improper Repair or replace 1 2 When exhaust smoke 15 Injection timing is too slow Adjust Water is mixed in fuel Inspect fuel system and white clean 3 Shortage or lube oil in the engine Repair 4 Engine is over cooled Inspect 143 6 Fuel injection equipment 6 2 Fuel feed pump Fuel injection pump The fuel feed pump feeds fuel from the fuel tank passes it through the fuel filter element and supplies it to the fuel injection pump The fuel feed pump is mounted on the side of this engine and is driven by the eccentric cam of the fuel pump camshaft It is provided with a manual priming lever so that fuel can be supplied when the engine is stopped Fuel feed pump 6 2 1 Construction of fuel feed pump 25 4 7 8 9 10 11 12 13 14 1 Bottom body 6 Pin 11 Top body assembly 2 Piston spring 7 Le
40. battery terminal and a B terminal when rotating 3 Shut out a battery switch during the alternator stop 12 5 4 Standard output characteristics The standard output characteristics of this alternator are shown as the below figure WA ass constant L LL LII LL tt Output current oT tT tt 0 2 4 6 8 10 103 Alternator speed 1 Standard characteristics 195 12 Electrical System 12 6 Instrument panel The new type instrument panels are applied for 3YM30 3YM20 series engines 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 The engine speed with new panel is activated by alternator B terminal pulse 12 6 1 B type instrument panel Optional Coolant high Water in sail temperature alarm drive seal alarm Lubricating oil low Battery low pressure alarm charge alarm Rubber seal Panel with Tachometer Key switch Stop button B panel cover foil switch Hour meter Moisture cap for key switch 196 12 Electrical System 12 7 Warning devices 12 7 1 Oil pressure alarm If the engine oil pressure is below 0 01 0 03 MPa 0 1 0 3 kgf cm 1 42 4 26 Ib in with the main switch in the ON position the contacts of the oil pressure are closed by a spring and the lamp is illuminated through the lamp gt oil pressure switch gt groun
41. be burnt 1 Apply lube oil to rotor outer inner insertion part 2 Fasten the pump cover by the standard torque Tightening torque oe en 9 oe 0 6 0 8 kgf m 3 When replacing the lube oil pump replace the whole assy 153 8 Lubrication system 8 2 4 Lube oil pump inspection 1 Outside diameter clearance and side clearance of outer rotor Gear case Outer rotor V f Ry Insert gap gauge between the outer rotor the gear case cover and measure outside diameter gap Put a ruler on the end face of the gear case cover and insert a gap gauge between rotor and measure a side ap Outside clearance mm Standard Limit 0 12 0 21 0 30 Inner rotor Outer diameter clearance 2 Tip clearance between outer rotor and inner rotor Insert a gap gage between an outer rotor and an inner rotor and measure the tip clearance Tip clearance mm Standard Limit 0 16 3 Side clearance When measuring a side clearance put a right angle gage to the pump body insert a gap gage and measure the clearance 7S oide clearance mm Ls otandard Limit 0 02 0 07 0 12 Outer rotor Side clearance 4 Outside diameter clearance of inner rotor centering location part Measure the outside diameter of inner rotor centering location part and the hole diameter of gear case cover Calculate the clearance from that difference Inspection item otandard Gear case cover I D 46 13 46 18
42. be used again e Parts to be used again shall be washed and cleaned sufficiently e Select especially clean locations and use clean tools for disassembly of hydraulic units such as the fuel injection pump 5 Precautions for Inspection and Measurement Inspect and measure parts to be used again as required to determine whether they are reusable or not 6 Precautions for Reassembly e Reassemble correct parts in correct order according to the specified standards tightening torques and adjustment standards Apply oil important bolts and nuts before tightening when specified Always use genuine parts for replacement e Always use new oil seals O rings packing and cotter pins Apply sealant to packing depending on the place where they are used Apply of grease to sliding contact portions and apply grease to oil seal lips 7 Precautions for Adjustment and Check Use measuring instruments for adjustment to the specified service standards 1 1 General 1 1 Exterior views Operating Side Intake silencer Intake manifold Oil filter 5 NL j Marine gear Non Operating Side Engine name plate on the rocker arm cover Fresh water filler cap Coolant tank Heat exchanger Exhaust manifold Starter motor Shift lever Alternator Sea water pump V belt Note This illustration shows the 3YM30 with Yanmar marine gear Model KM2P 1 1 1 2 Specifications
43. camshaft so that the key of the pump camshaft may almost agree in a position of the key groove of a pump drive gear Insert a fuel injection pump into the installation hole of the gear case straight to prevent the damage of the O ring Insert a fuel pump while confirming whether the key of a camshaft and the key groove of a drive gear agree Assemble a pump drive gear nut and a washer together temporarily Turn a fuel injection pump to the position where the marks of the fuel injection pump and the gear case agrees Fasten pump installation nuts three nuts on the fuel injection pump Tighten the pump installation nut by the specified standard torque Tightening torque of the pump drive gear nut without lube oil Tighteningtorque Nem kgfem 58 8 68 8 6 0 7 0 6 1 6 Adjusting fuel injection timing Refer to 2 2 6 1 in chapter 2 140 6 Fuel injection equipment 6 1 7 Troubleshooting of fuel injection pump Complete repair means not only replacing defective parts but finding and eliminating the cause of the trouble as well The cause of the trouble may not necessarily be in the pump itself but may be in the engine or the fuel system If the pump is removed prematurely the true cause of the trouble may never be known Before removing the pump from the engine at least go through the basic check points given here Basic checkpoints e Check for breaks or oil leaks throughout the fuel system from the fuel tank to the nozzl
44. concerns 1 Waste fluids such as lube oil fuel and coolant shall be carefully put into separate sealed containers and disposed of properly 2 Do NOT dispose of waste materials irresponsibly by dumping them into the sewer overland or into natural waterways 3 Waste materials such as oil fuel coolant solvents filter elements and batteries must be disposed of properly according to local ordinances Consult the local authorities or reclamation facility 8 FURTHER PRECAUTIONS Fueling Refueling Keep sparks open flames or any other form of ignition match cigarette etc away when fueling refueling the unit Fire and or an explosion may result A WARNING Hot Surfaces Do NOT touch the engine or any of its components during running or shortly after shutting it down Scalding serious burns may result Allow the engine to cool down before attempting to approach the unit WARNING e Rotating Parts Be careful around moving rotating parts Loose clothing jewelry ties or tools may become entangled causing damage to the engine and or severe personal injury Preventing burns from scalding 1 Never open the radiator filler cap shortly after shutting the engine down Steam and hot water will spurt out and seriously burn you Allow the engine to cool down before attempt to open the filler cap 2 Securely tighten the filler cap after checking the radiator Steam can spur
45. control has been designed so that operation of the clutch shift and governor throttle can be effected with one lever Two cables are required for the MT 2 single one for the clutch and the other for the governor When warming up the engine to freely control the MT 3 Type governor separately from the clutch put the lever in neutral the central position and pull the knob in the center of the control lever When the lever is returned to the neutral position the knob automatically returns to its original position and the clutch is free The governor can then be freely operated The MN type controller has been designed so that operation of the clutch and throttle can be effected with one lever When the button next to the control lever is pulled out with the lever in the central position it holds the clutch in the neutral position so that the throttle can be opened all the way and warm up the engine When the engine is warmed up return the handle to the central position and push the button back in Control of the clutch and throttle is thus effected with one handle 177 2 Remote control cable Use only Super Responsive Morse Control Cables 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 3 Engine stop cable 178 11 Remote contro Option
46. enters the outside of the element and passes through the element under its own pressure As it passes through the dirt and impurity in the fuel are filtered out allowing only clean fuel to enter the interior of the element Element The fuel exits from the outlet at the top center of the filter and is sent to the injection pump A cross headed hexagonal bolt is fitted to the fuel filter body Loosen the bolt with a cross headed screw driver before starting or after dismantling and reassembly to bleed the air in the fuel system to the fuel filter injection pump Filter cup 6 3 1 Fuel filter specifications Filtering area 333 cm 20 3 2 Retaining ring Material of element Cotton fiber Filter mesh 6 3 2 Fuel filter inspection The fuel filter must be periodically inspected If there is water and sediment in the filter remove all dirt rust etc by washing the filter with clean fuel The normal replacement interval for the element is 250 hours but the element should be replaced whenever it is dirty or damaged even if the 250 hour replacement period has not elapsed 147 6 Fuel injection equipment 6 4 Fuel tank A triangular 30 liter fuel tank with a 2000mm 78 7402 in rubber fuel hose to fit all models is available as an option 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 Fuel return connection Tank Level gau
47. first Gy Check the spray condition ofa uel maze _ Wy Clean amp checkthewater passages 2 4 6 Adjust the tension of the alternator driving belt 5 Retighten all major nuts and bolts Adjust intake exhaust valve clearance Check adjust the remote control operation 10 Adjust the propeller shaft alignment 1 Check the injection timing The fuel injection timing is adjusted so that engine housing performance may become the best condition As for the b inspection and adjustment of the fuel pump it is based CN on the service manual of the ML pump The fuel 9 NC Ke do injection timing is adjusted by the following procedure No 1 oylinder 17 1 ICs 1 Complete air bleeding from the fuel line and set the TDC A engine ready for starting MM 2 See that the timing marks fuel pump mounting flange and gear case are aligned 3 Set the speed control lever at the operating position 4 Disconnect the injection pipe on the fuel pump side for the No 1 cylinder Do not remove the delivery holder 5 Check the fuel discharge from the delivery holder while turning the crankshaft clockwise as seen from the radiator and stop turning it at the same time when the fuel comes out Wipe out the fuel of the delivery holder exit Next turn the crankshaft in the opposite direction counterclockwise and return it to about 20 degrees before top dead center 6 Check again the fuel discharge from the d
48. follows after the maintenance job 2 6 1 Preliminary precautions Before making a test run make sure of the following points 1 Warm the engine up 2 Remove any precipitation from the F O filter water separator and F O tank 3 Use only lube oil recommended by Yanmar 4 Be sure to add Long Life Coolant Antifreeze LLC to cooling fresh water 5 Provide good ventilation in the engine room 2 6 2 Adjusting operation procedure 1 Supply the fuel oil lubricating oil and cooling water Note Check the levels of the lube oil and cooling water again after test running for about 10 minutes and add as required 2 Start the engine and carry out idling at a low speed 700 to 900 min for a few minutes 3 Run in the engine for about five minutes at the rated speed no load Check any water fuel or lube oil leakage and existence of abnormal vibration or noise Also check the oil pressure cooling water temperature and exhaust gas color 4 Adjust the no load minimum and maximum speed Refer to 2 3 5 Perform loaded operation as required 46 2 Inspection adjustment 2 6 3 Check points and precautions running Checks before 1 Make sure that the sea cock is open 3 Lamp should go off operation 2 Make sure there is enough lube oil and fresh when engine is cooling water running 3 Operate the remote control handle and check if the device connected to the engine works property No load
49. in a safe manner For work in enclosed or dark areas a drop cord should be utilized The drop cord must have a wire cage to prevent bulb breakage and possible ignition of flammable substances e Safety Equipment Fire extinguisher s first aid kit and eye wash shower station should be close at hand or easily accessible in case of an emergency 2 WORK WEAR GARMENTS A CAUTION gs Well fitting OK 3 TOOLS A WARNING A WARNING e Safe Work Clothing Appropriate safety wear gloves special shoes boots eye ear protection head gear harness clothing etc should be used worn to match the task at hand Avoid wearing jewelry unbuttoned cuffs ties or loose fitting clothes around moving machinery A serious accident may occur if caught in moving rotating machinery e Appropriate Lifting Holding When lifting an engine use only a lifting device crane jack etc with sufficient lifting capacity Do not overload the device Use only a chain cable or lifting strap as an attaching device Do not use rope serious injury may result To hold or support an engine secure the engine to a support stand test bed or test cart designed to carry the weight of the engine Do not overload this device serious injury may result Never run an engine without being properly secured to an engine support stand test bed or test cart serious injury may result e Appropriate Tools Always use tools that are des
50. of clearance between piston and cylinder 2 Degree of clearance at intake exhaust valve seat 3 Gas leak from nozzle gasket or cylinder head gasket In other words the pressure drops due to increased parts wear and reduced durability resulting from long use of the engine A pressure drop may also be caused by scratched cylinder or piston by dust entrance from the dirty air cleaner element or worn or broken piston ring Measure the compression pressure to diagnose presence of any abnormality in the engine 1 Compression pressure measurement method 1 After warming up the engine remove the fuel injection pipe and valves from the cylinder to be measured 2 Crank the engine before installing the compression gage adapter a Perform cranking with the stop handle at the stop position no injection state b See 4 2 3 2 in Chapter 4 for the compression gage and compression gage adapter 3 Install the compression gage and compression Measurement of the compression pressure gage adapter at the cylinder to be measured a Never forget to install a gasket at the tip end of the adapter 4 With the engine set to the same state as in 2 a crank the engine by the starter motor until the compression gage reading Is stabilized Compression 2 Standard compression pressure Engine compression pressure list reference value Compression pressure at 250 Deviation among cylinders Model MPa kgf cm 2 3YM30 3
51. on Coolant high When the temperature reaches the maximum 95 203F or higher the temperature lamp will light alarm Continuing operation at temperatures exceeding the maximum limit will result in damage and seizure Check the load and the fresh water cooling system for any abnormalities Lubricating oil When the lube oil pressure falls below normal the oil pressure sensor will low pressure register this and the lamp will come on and alarm will sound alarm Continuing operation with insufficient oil pressure will result in damage and seizure Check the oil level Water in sail When seawater is detected between the seals of sail drive the lamp will drive seal come on and the alarm will sound alarm Normal action of alarm devices Alarm devices act as shown below Check that the alarm lamps and buzzer are working normally when the key is turned on Key switch OFF gt ON START gt Battery low alarm 2 Alarm lamps Lube oil low pressure alarm 7 Check the leakage of water lube oil and fuel Before and after starting the engine check the leakage of cooling water and seawater from cooling water system Also check the leakage of lube oil and fuel 8 Check adjust the remote control operation Make sure that the accelerator of a boat can be operated smoothly before starting the engine If it feels heavy to manipulate lubricate the accelerator cable joints and pivots Adjust the accelerator ca
52. operation 1 When the lube oil temperature is raised to allow 2 warm up operation the engine to start the pilot lamp goes off Fit leaks if any 2 When the engine is started check the following Check the intake There is no leakage of water fuel and lube oil exhaust valves fuel e Exhaust gas does not leak when the engine is injection nozzle and started cylinder head here is no abnormal indication on the instrument 3 Do not raise the panel engine speed There is no abnormality in cooling water discharge abruptly engine vibration or engine sound To warm up the engine operate at low speed for about 5 minutes then raise the speed to the rated speed and then to max speed Cruising load 1 Do not operate the engine at full load yet but raise operation the speed gradually for about 10 minutes until it reaches the rated speed 2 Make sure that exhaust gas color and temperature are normal 3 Check the instrument panel and see if the water temperature and oil pressure are normal Stopping the 1 Before stopping the engine operate it at 650 700 1 Stopping the engine engine for about 5 minutes suddenly during high speed operation increases the temperature of engine parts 2 This procedure prevents carbon from being deposited on the valve seats etc 2 Raise engine speed to 1 800 jut before stopping the engine and idle the engine for about 3 4 seconds 1 Check again for water and o
53. pump X 65 x t4 5 rubber hose Fuel injection pump 4 76 x t0 7 steel pipe Lubricating oil filter cartridge type Fuel high pressure pipe Fuel injection nozzle Oil pressure switch shaf Thermostat Y cylinder x l head Hot water connection outlet R3 8 Mixing elbow Fresh water cooler 17 x t4 rubber hose Lubricating oil inlet filter Main bearing 11 1 General Detail of part A Detail of part B Detail of part D 1 1 6 Exhaust gas emission regulation 3YM30 3YM20 series engines are applicable with Off road Compression Ignition engines regulations of the EPA and ARB California Air Resources Board in USA and BSO regulations in Europe 1 6 1 Engine identification EPA ARB With the regulations on exhaust gas emission worldwide it has become necessary to identify engines in a manner to determine which regulations they comply with hence 1 Emission control label EPA and ARB IMPORTANT ENGINE INFORMATION THIS ENGINE CONFORMS TO LG M Y CALIFORNIA AND U S EPA REGULATIONS FOR OFF ROAD C ENGINES THIS ENGINE IS CERTIFIED TO OPERATE ON TYPE2 D FUEL _A____ DISPLACEMENT B LITERS EMISSION CONTROL SYSTEM EM FUEL RATE CD MM STROKE Q LE kW L E RPM REFER TO OWNER S MANUAL FOR MAINTENANCE SPECIFICATIONS AND ADJUSTMENTS YANMAR CO LTD O and ARB label Note Emission Contr
54. pump seawater pump 1 Remove the seawater pump cover and take out the O ring impeller and wear plate 2 Inspect the rubber impeller checking for splitting around the outside damage or cracks and replace if necessary Depending on the use the inside parts of a seawater pump may deteriorate and the discharge performance may drop At the specified interval or when the discharge volume of seawater is Pump body reduced inspect the seawater pump in accordance with the following procedures Impeller a Loosen the seawater pump cover set bolts and remove the cover Seawater pump b Illuminate the inside of the seawater pump with a flashlight and inspect c If no damage is found reassemble the cover d If any of the following problems are found take out the O ring and impeller If necessary replace with new one and reassemble the cover e Impeller blades are cracked or nicked Edges or surfaces of the blades are marred or scratched Note The impeller must be replaced periodically every 1000 hrs or four years whichever comes first e If a large amount of water leaks continuously from the water drain pipe beneath the seawater pump during engine operation check the oil seal inside the seawater pump Notice The seawater pump turns in the counterclockwise direction but the impeller must be installed by turning in the clockwise direction If the impeller has been removed for any reason and must be reassembled be
55. pump is too little he injection pump is sucking air he regulating valve is stuck in the open position he plunger is sticking and does not travel its full stroke plunger spring is broken he control sleeve is not sliding smoothly he governor lever is not operating properly or is worn excessively 9 The delivery valve spring is broken 10 The delivery valve is not sliding properly 11 The nozzle or the nozzle holder is not functioning properly 12 The injection timing is incorrect The specified full load injection quantity is not delivered he control lever is not reaching the maximum speed position governor spring is weak and therefore the governed speed is too low he plunger is worn he delivery valve seating portions are damaged 60 Readjust the timing Inspect then repair or replace Readjust Clean or replace Inspect and repair Inspect and repair Replace Replace the distributor assembly Replace Repair or replace Repair or replace Replace Repair or replace Inspect and then repair or replace Readjust Readjust Readjust Replace Replace the distributor assembly Replace Readjust Readjust 3 Troubleshooting 4 The nozzle or the nozzle holder is not functioning properly The engine cannot reach its maximum speed The engine s maximum speed is too high Idling is unstable The governor spring is too weak or is improperly a
56. rubber of the diaphragm cracked Dipstick Oil filler cap Lube oil filler 2 Fill with new lube oil 3 Perform a trial run of the engine and check the oil leakage 4 Approximately 10 minutes after stopping the engine check the oil level by using the oil dipstick Add oil if the level is too low Standard The level shall be between the upper and lower limit lines on the dipstick 22 Unit liter quart 22 i Oil drain pump Engine oil capacity 3YM30 with KM2P 1 Full 2 89 9 3 0 3YM20 with KM2P 1 Full 2 7 9 4 2 9 Notice When checking the oil level right after the engine running the oil level in the dipstick guide decreases drastically and the accurate oil measurement can t be performed because the pressure in the cylinder block decreases with the function of the diaphragm in the rocker arm cover Therefore measure the lube oil level after removing the oil filler cap or about 10 minutes later after stopping the engine 2 Replace the lube oil in a sail drive Refer to the sail drive operation manual for the procedure of replacing the oil 30 2 Inspection adjustment 2 2 5 Inspection every 250 hours or one year Be sure to check the following points every 250 hours or one year operation whichever comes first Clean the element of the air intake silencer Clean the exhaust water mixing elbow 9 Adjust the tension of the alternator driving belt 10 Check the wir
57. run dora ea pa an ruv ven 13 1 6 3 Guarantee conditions for emission standard 13 2 Inspeciaon and e Med 15 2 1 Periodic maintenance schedule veu D ua Ea RN RED rA USER NEUE 15 2 2 Periodic inspection and maintenance procedure 17 2 2 4 Gheck belore do ra ee e exo a tenis 17 2 2 2 inspection after initial 50 hours or one month operation 20 2 2 3 Inspection every 50 hours or monthly ean eno dao Fen tos eae bete eu rto ctt boc coii due sed uus 25 2 2 4 Inspection every 100 hours or two months 30 2 2 5 Inspection every 250 hours or one 31 2 2 6 Inspection every 1 000 hours or four 37 2 3 Adjusting the no load maximum or minimum speed 44 24 SSNSOFrNS DSCHON Succ oca ducta 44 P RE 44 2 ee 44 45 2 6 Adjustng OPETAUON sxad
58. switch Glow connector Extension wire harness To lube switch and fresh water switch Starting motor 183 12 1 1 Wiring diagram For B type instrument panel Color coding Red Black J Red Black Orange White Brown l Sail Buzzer CFW drive loi press temp seal Charge fuse 3A 50 Q Q Q YW WL YG LB LOL hour meter Aemlmps 0 590 050 Tacho meter Wire 0 85WBr ll harnessi Wire harness Il Em Amplifier only for sail drive a ae ee Se eh ee ee fee ee gt en esi fey ee Se Ses Se eee eg ey EIER 184 Allowable Length by cross sectional area of battery cable Procured by customer 12V Stop Relay 119247 77100 Coupler View from A A Battery a Key switch 0 85YG 0 85 Y E Sail drive only for sail drive ee Earth bolt 12 Electrical System 12 Electrical System 12 2 Battery The new type instrument panels are applied for 3YM30 series engines 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 The engine speed with new panel is activated by alter
59. the FO limiter and screw the adjusting bolt to the bottom Tighten the nut Adjust the rack position to RO 15mm with the FO limiter and measure the injection volume A at the rated speed When the measured injection volume A is out of the standard readjust the injection volume by screwing the FO limiter Pull the control lever to high idle side at full rack position Adjust the position of the high idle set bolt at high idle speed as to get the specified injection volume B Loosen the nut of the FO limiter and loosen the adjusting bolt at 180 Fix the nut Screw the angleichi at the torque rise speed to get the specified injection volume C Confirm the injection volume D at the specified speed at starting Push the control lever to low idle side 10 Adjust the position of the low idle set bolt at low idle speed as to get the specified injection volume E High idle set bolt Low idle set bolt Adjustment procedure for 5 and 10 138 6 Fuel injection equipment Rack position mm 1 Loosen nut 3 Tighten nut 2 Loosen adjusting bolt 3YM30 360 3YM20 180 Adjustment procedure for item 1 and 6 1 Loosen nut 3 Tighten nut 2 Screw angleich Adjust injection volume to C by screwing Adjustment procedure for 7 6 Fuel injection equipment 6 1 3 Fuel injection pump structure Section of a fuel injection pump governor for 3YM30 sal LIS E SA pou
60. the connecting rod and pull out the piston amp S A connecting rod assembly SEK 8 5 Rod bolt N Large end cap Crankpin bearing Removing piston and connecting rod 86 4 Disassembly reassembly 30 Removing the gear case 1 Remove the gear case from the cylinder block 2 Remove the O rings from the lube oil passage NOTE 1 When mounting the gear case match up the two knock pins for cylinder block 2 Be sure to coat the O rings for the cylinder block lube oil passage with grease when assembling so that it does not get out of place Liquid gasket 31 Loosening the main bearing bolts Loosen the main bearing bolts Don t remove them 32 Turning the engine over Turn the engine over with the cylinder head mounting surface facing down NOTE Make sure that the cylinder head positioning pins on the cylinder block do not come in contact with the wood block 33 Removing the flywheel housing Remove the flywheel housing with the oil seal from the cylinder block lt gt 0 I 4 Flywheel housing i Liquid gasket Oil seal Cylinder block 87 34 Removing the main bearing 1 Remove the main bearing bolts 2 Remove the main bearing cap and lower main bearing metal NOTE The thrust metal lower is mounted to the base main bearing cap 35 Removing the crankshaft 1 Remove the crankshaft NOTE 1 The thrust metal upper i
61. the coolant Mounting plate recovery tank is not submerged in bilge If the overflow pipe is submerged in bilge water in the bilge will be siphoned into the fresh water Overflow tube tank when the wafer is being cooled Sub tank Qe 9 5 8 Precautions on usage of the coolant recovery tank 1 Check the coolant recovery tank when the engine is cool and refill with fresh water as necessary to bring the water level between the low and full marks 2 Check the overflow pipe and replace if bent or cracked Clean out the pipe if it 15 clogged up 168 9 Cooling water system 9 6 Thermostat 9 6 1 Functioning of thermostat The thermostat opens and closes a valve according to changes in the temperature of the fresh water inside the engine controlling the volume of water flowing to the heat exchanger from the cylinder head and in turn maintaining the temperature of the fresh water in the engine at a constant level The thermostat is bottom bypass type It is located in a position connected with the cylinder head outlet line at the top of the top of fresh water pump unit When the fresh water temperature exceeds the above temperature the thermostat opens and a portion of the water is sent to the heat exchanger and cooled by seawater the other portion going from the bypass line to the fresh water pump intake The bypass line is closed off as the thermostat valve opens and is completely closed when the fresh water temperature reaches 81
62. the lube oil inlet pipe on the bottom of the cylinder block using new gasket Tightening torque Nem kgfem Lube oil inlet pipe 26 2 6 94 4 Disassembly reassembly 15 Mounting the oil pan spacer and the oil pan 1 Apply the liquid gasket to the surfaces of the gear case cover gear case flange and flywheel housing that contact with the cylinder block 2 Apply the liquid gasket to the spacer Mount the spacer to the cylinder block and tighten the bolts 3 Apply the liquid gasket to the oil pan Mount the oil pan to the spacer and tighten the bolts 4 Mount the dipstick and dipstick guide Oil pan spacer Cylinder block 16 Mounting the crankshaft pulley 1 Coat the oil seal with oil Crankshaft pulley 2 Make sure to wipe off oil on the taper surfaces of the crankshaft and the pulley 3 Mount the pulley insertion tool to the crankshaft and install the pulley on the crankshaft so that the oil seal may not be damaged 4 Tighten the pulley to the specified torque Tightening torque V pulley bolt Material casting iron Nem kgfem 83 3 93 3 8 5 9 5 UE 7 Pulley hi JA insertion i tool ES 0 TERT 77 Crankshaft 17 Mounting the engine mounting feet and turning the engine upright 1 Mount the engine mounting feet 2 Turn the engine upright Oil pan is the bottom side 18 Mounting the flywheel 1 C
63. time it will become clogged and this decreases the amount of intake air and may also be a cause of decreased output 2 Washing the intake silencer element Wash the air intake silencer element with a neutral detergent 34 2 Inspection adjustment 8 Clean the exhaust water mixing elbow There are two types of mixing elbows the L type and the U type The mixing elbow is attached to the exhaust manifold The exhaust gas is mixed with seawater in the mixing elbow U type Mixing elbow Lp Seawater N L type Mixing elbow Exhaust elbow Optional L type mixing elbow L type mixing elbow 1 Clean dirt and scale out of the air pass and seawater pass of the mixing elbow 2 Repair the crack or damage of the mixing elbow by welding or replace if necessary 3 Inspect the gasket and replace if necessary 9 Adjust the tension of the alternator driving belt Refer to 2 2 2 4 35 2 Inspection and adjustment 10 Check the wiring connectors Check whether each connection part doesn t have looseness B type panel _ Glow connector Neutral safety switch Fitting to marine gear Safet Extension rela wire harness y Alternator To lube switch and fresh water switch Battery switch 36 2 Inspection adjustment 2 2 6 Inspection every 1 000 hours or four years Be sure to check the following points every 1 000 hours or four years operation whichever comes
64. very careful not to make a mistake and turn it in the wrong direction Additionally if the engine is being turned manually be careful to turn it in the correct direction Incorrect turning will twist the impeller blades and damage it Seawater pump Impeller Impeller rotating direction Direction of impeller 32 2 Inspection adjustment 6 Replace the fresh water coolant 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 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 Cooling performance drops when cooling water is contaminated with rust and scale Even if antifreeze or antirust is added the cooling water must be replaced periodically because the properties of the agent will degenerate 1 Open the two cocks for fresh water and extract the fresh water Note One drain cock is behind the belt cover Remove the belt cover and open the cock 2 Close the two cocks for fresh water Fresh water line Seawater line Coolant tank Drain cock for seawater o C p c zi LL A t 4 A f Yk 497 941 Fresh water A A Seawater pump Drain cock for co
65. wash when the cooling water temperature reaches 85 b Check the joints at both ends of the tubes for looseness or damage and repair if loose Replace if damaged or corroded Check tubes and replace if leaking d Clean any scale or rust off the outside of the tubes 2 Heat exchanger body water leakage test a Check heat exchanger body and side cover for dirt and corrosion Replace if excessively corroded or cracked b Inspect seawater and fresh water inlets and outlets retighten any joints as necessary and clean the insides of the pipes c Check the exhaust gas intake flange and line and replace if corroded or cracked 41 2 Inspection and adjustment 3 Heat exchanger body water leakage test a Compressed air water tank test Fit rubber covers on the fresh water and Pressure gauge seawater inlets and outlets Place the heat H ir hose Filler cap exchanger in a water tank feed in compressed 2 air from the overflow pipe check for water leakage air bubbles 14 Br bee est pressure 0 20 MPa 2 kgf cm T 9 9 9 9 L Tast tank O O O O Rubber cap Heat exchanger b Use of the tester Fit the fresh and seawater inlets and outlets with m di Pressure tester rubber covers and fill the fresh water tank with fresh water Fit a pressure cap tester in place of the pressure cap operate the pump for one minute and set the pressure at 0 15 Mpa 1 5 kgf cm
66. with a pulley puller YC X 4 i d 7 4 ii rms ea md 4 NO lt 9 9 ur X WW e D VP OR Aij N SX TN 2 d 2 M XN mm A NY S Em e gt wi A 7 NN Ie Flywheel housing 23 Removing the oil pan Remove the oil pan and spacer Oil pan spacer A 7 y y Wid Wd WD Cylinder block 5 ANS 27 z Ny S BS GG NS Ww e XN S di Sy S AN 24 Removing the lube oil inlet pipe Remove the lube oil inlet pipe and O ring 25 Removing the gear case Loosen the gear case cover bolts and remove the gear case cover from the gear case S A VS 85 4 Disassembly reassembly 26 Removing the lube pump Remove the lube oil pump from the gear case cover 27 Removing the idle gear Loosen the three bolts holding the idle gear and pull out the idle gear and shaft 28 Removing the camshaft 1 Push up tappet by turning a camshaft to remove it from the cylinder block easily 2 Loosen the thrust metal bolts through the holes of the camshaft gear and remove 3 Pull out the camshaft gear and camshaft assembly from the cylinder block NOTE The camshaft gear and camshaft are shrunk fit They must be heated to 180 200 C to disassemble cap lt 2 Push
67. 1 Overloading 3 Sticking of governor sleeve 2 Seizure of moving parts 3 Clutch slippage IV Miscellaneous IV 1 Reduce load IV 2 Disassemble check and repair IV 3 Check and adjust buioouse qnoJ GG TROUBLE AND TROUBLESHOOTING 1 1 Increase injection pressure 2 Replace 1 3 Disassemble and lap 4 Disassemble and repair Countermeasure 1 Faulty fuel injection valve 1 Low injection pressure Chart 6 KNOCKING 11 1 Delay injection timing 11 2 Adjust standard injection pressure Faulty fuel injected 1 Early fuel injection 3 Sticking of valve needle 2 Damaged fuel valve spring 1 Excessive quantity of fuel is ejected from fuel pump 4 LLI O 4 o gt 1 Excessive quantity of fuel injected each time 1 Adjust pump adjustment rack Countermeasure 2 Fuel pressure is too high KNOCKING 4 Faulty injection spray 1 Insufficient cooling water 4 Poor quality fuel oil 2 Excess piston clearance 5 Water mixed in fuel oil 3 Excess bearing clearance 6 Incorrect pressure IV Miscellaneous 1 Check cooling water pump lap valves IV 2 Replace IV 3 Replace IV 4 Replace with good fuel oil IV 5 Replace with good fuel oil IV 6 Check and repair 9G TROUBLE AND TROUBLESHOOTING 1 1 Tighten
68. 1 4 Tighten adjustment valve l 4 Check teeth shaft and pushrod of gear for wear Replace where necessary 11 5 Tighten safety valve 11 6 Change lube oil 11 7 Add lube oil Replace Countermeasure us ss Nee Nee us See 11 8 1 Abnormal noise Low fuel oil pressure Low lube oil pressure 1 Cl il fil 1 Loose flywheel installment bolt 1 Loose pressure adjustment Wee ele 5 Oil leakage from pump safety valve 2 Lube oil temperature is too high NE 2 Loose crank bearing bolt 2 Damaged supply pump 6 Inadequate viscosity of lube oil 3 Trouble with lube oil pump 7 Insufficient amount of lube oil 3 Cl d filt 3 Worn crank pin meta 3 Clogged filter 4 Loose pressure adjustment valve 4 Faulty gear meshing 4 Leaky pipe 8 Faulty pressure gauge MISCELLANEOUS 1 Cooling water temperature 1 Insufficient amount of cooling water 1 Clogging in cooling water system TROUBLE 5 Air in cooling water 5 Engine outlet not constricted 2 Trouble with cooling water pump O 2 Trouble with cooling water pump 6 Water leakage from Amount of water returning 6 Overloading cooling water joints 3 Faulty lube oil puo de 3 Cooling water lift is too great temperature 4 Clogging in cooling adjustment valve water system 4 Air in cooling water IV Lube oil temperature is too high V C
69. 13 1 Engine tuning E Inspection item otandard page Intake exhaust valve clearance Num EN x V belt tension tween alternator Used part ICH ae at 98N 10kgf 2 2 2 4 11 8 12 8 3YM30 Fuel injection pressure 120 130 NEN 2 2 6 2 MPa kgf cm 12 3 13 28 PM 125 135 3YM30 3 43 0 1 2 75 0 1 Compression pressure at 250 3541 28 1 MPa kgf cm 3 23 0 1 2 55 0 1 33 1 26 1 m o Cooling water Capacity Engine 4143 2218 Coolant recovery tank 0 8 0 8 3YM30 Liter quart 280 at rake angle 8 degree 0 2 3YM20 Liter quart at rake angle 8 degree Marine gear KM2P 1 0 30 0 64 Liter pint 29 0 at low idle speed 5 2 above Lube oil capacity full 2 2 1 Lubricating oil pressure MPa kgf cm 12 7 1 Oil pressure switch operating pressure 0 05 0 01 MPa kgf cm 0 5 0 1 valve opening temperature 69 5 72 5 Thermostat deg Full opening lift mm 8 or above temperature 85 deg C Thermo switch temperature 93 97 12 7 2 201 13 Service standards 13 2 Engine body 13 2 1 Cylinder head 1 Cylinder head page Combustion surface distortion 0 05 or less E E E Valve sink Intake 0 4 0 6 5 2 3 3 Exhaust Seat angle Intake Valve seat 2 Intake exhaust valve and guide mm n TE Reference Inspection item Standard Limit page Intake Guide insi
70. 43 0 1 35 1 2 75 0 1 28 1 0 2 0 3 2 3 3YM20 3 23 0 1 33 1 2 55 0 1 26 1 0 2 0 3 2 3 62 3 Troubleshooting 3 Engine speed and compression pressure for reference 4 D uc O 3 o D O 300 350 Engine speed min 4 Measured value and troubleshooting When the measured compression pressure is below the limit value inspect each part by referring to the table below LS Item Cause Corrective action Air cleaner element Clogged element Clean the element Broken element Replace the element Defect at element seal portion 2 e Valve clearance e Excessive or no clearance Adjust the valve clearance See 3 5 in Chapter 3 Valve timing Incorrect valve clearance Adjust the valve clearance See 3 5 in Chapter 3 Cylinder head e Gas leak from gasket Replace the gasket gasket Retighten the cylinder head bolts to the specified torque See 4 2 2 12 in Chapter 4 trapping Replace the intake exhaust valve e Sticking valve Piston Gasleak due to scratching Perform honing and use an oversized Piston ring or wear part Cylinder See 4 4 5 5 1 5 4 and 6 in Chapter 4 Intake exhaust vale Gasleak due to worn valve Lap the valve seat Valve seat seat or foreign matter See 4 2 6 in Chapter 4 63 4 Disassembly reassembly 4 Disassembly and reassembly 4
71. 5 C valve lifts 4 mm 0 1575 in sending all of the water to the heat exchanger 9 6 2 Thermostat construction The thermostat used in this engine is of the wax pellet type with a solid wax pellet located in a small chamber When the temperature of the cooling water rises the wax melts and increases in volume This expansion and construction is used to open and close the valve Thermostat cover amp Thermostat 9 6 3 Characteristics of thermostat Opening temperature 69 5 72 5 C Full open temperature Fresh water pump body Valve lift at full open 8 mm or more 9 6 4 Thermostat inspection Remove the thermostat cover on top of the fresh water pump and take out the thermostat Clean off scale and rust and inspect and replace if the characteristics performance have changed or if the spring is broken deformed ar corroded 9 6 5 Testing the thermostat Refer to 2 5 in chapter 2 169 9 Cooling water system 9 7 Bilge pump and bilge strainer Optional 9 7 1 Introduction 1 General Introduction Rotation direction Right viewed from the impeller side Weight Pump 1 4 kg Negative pressure detector Diaphragm type Temperature 30 C 80 C 2 Exterior Motor assy Outlet Strainer nlet Pump dimensions Yoke diameter 261 Assembly hole diameter Assembly pitch 50 x 90 mm 170 9 Cooling water system 9 7 2 Description 1 Characteristics 1 Discharge at lift 0 di
72. 9961 03E100 YANMAR SERVICE MANUAL MAHINE DIESEL ENGINE YANMAR CO LTD Publication No M9961 03E100 History of Revision service Manual for Marine Diesel Engine Engine Model 3YM30 3YM20 Number Date of Reason for Correction item Corrected of Outline of correction revision correction No page by New edition March 2004 Printed in Japan M9961 03E100 FOREWORD This service manual has been complied for engineers engaged in sales service inspection and maintenance Accordingly descriptions of the construction and functions of the engine are emphasized in this manual while items which should already be common knowledge are omitted One characteristic of a marine diesel engine is that its performance in a vessel is governed by the applicability of the vessel s hull construction and its steering system Engine installation fitting out and propeller selection have a substantial effect on the performance of the engine and the vessel Moreover when the engine runs unevenly or when trouble occurs it is essential to check a wide range of operating conditions such as installation to the full and suitability of the ship s piping and propeller and not just the engine itself To get maximum performance from this engine you should completely understand its functions construction and capabilities as well as proper use and servicing Use this manual as a handy reference in da
73. Ben steam d water will spurt out and seriously burn you Wait until the engine is cooled down after the engine stopped wrap the filler cap with a rag 9 piece and turn the cap slowly to gently release the pressure inside the T flesh water tank gt e Securely tighten the filler cap after checking the flesh water tank If the cap is tightened loosely steam can spurt out during operation 1 Checking cooling water volume Check the cooling water level in the coolant To fresh water f I cooler recovery tank If the water level is close to the E LOW mark open the coolant recovery tank cap and replenish the coolant recovery tank with clean soft water to the FULL mark Standard Lower limit gt The water level of the coolant recovery tank shall be between the upper and lower limit lines Upper limit Coolant recovery tank lt 2 Replenishing engine with water If the cooling water leveling the coolant recovery tank is lower than the LOW mark open the filler cap and check the cooling water level in the coolant tank Replenish the engine with the cooling water if the level is low Check the cooling water level when the engine is cool Checking when the engine is hot is dangerous And the water volume is expanded due to the temperature Daily cooling water level check and replenishing shall be done only at the coolant recovery tank Usually do not open the filler cap to check or replenish Standard
74. E SUDDENLY STOPS 1 Seizure of moving parts 2 Overloading due to insufficient cooling water 5 Relay operation triggered by low lube IV Miscellaneous IV 1 Remove and repair or replace IV 2 Disassemble and clean cooling water pump and check cooling water system CG TROUBLE AND TROUBLESHOOTING Countermeasure 4 D dq LLI O c o 2 O Countermeasure 1 1 Bleed air 7 Disassemble and clean 2 Disassemble and clean and repair replace 3 Replace 4 Repair or replace 5 Replace 6 Tighten firmly 1 Uneven quantity of fuel oil injected 1 Air in the fuel injecti njecton PUMP 5 Damaged exhaust union packing 2 Faulty operation of plunger 0 7 6 Loose pinion Screw 7 Faulty fuel 3 Damaged plunger spring pump tappe 4 Faulty fuel oil ejection valve CYLINDER OUTPUT 1 Oil leakage in injection ee system 2 Damaged valve 4 Irregular injection timing spring 3 Insufficient injection 5 Sticking of injection valves pressure in injection valves Faulty fuel injection valve 1 1 Check and repair 1 2 Replace 11 3 Adjust 1 4 Adjust 1 5 Clean CYLINDER OUTPUT IS UNEVEN COUNTERMEASURE Trouble and Troubleshooting Cause and Effect Countermeasure Countermeasure 1 Check repair or replace 2 Replace 3 Check repair or replace 4 Adjust 5
75. R INLET 017 3 Crankshaft center NOTE 1 DWG SHOWS MOUNTING BLOCKS AT ORIGINAL HEIGHT 1 General 2 ENGINE WEIGHT WILL COMPRESS BLOCKS BY 4 5 mm APPROX 3 MOUNTING BLOCKS ARE EQUIPPED FOR STANDARD ACCESSORY 4 4 amp SHOWS CENTER OF GRAVITY 2 3YM30C with 020 drive 463 248 215 80 ALTERNATOR 262 OPTIONAL P ew T e 9 ni 5 JAN 23 4 HHO EY B 9 C L x A LE 962 na NIEH kar 2 1 T lb xz jen gt gt 362 eem d P4 l N A PA ee MOUNTING BLOCKS 10 100 185 185 185 468 5 U MIXING ELBOW OPTIONAL DIRECTION OF ROTATION DETAIL OF PULLEY A FUEL OVERFLOW 8 0 Jed A2 Ti oS 2 A 5 Lu K 0683 DESIT Arum 112 311 IE 017 3 Le LE SS ru UBI e 5 M CS 18 TELS 1 A V 597 FRESH WATER DRAIN 8 48 288 FUEL INLET SEAWATER INLET Crankshaft center NOTE 1 DWG SHOWS MOUNTING BLOCKS AT ORIGINAL HEIGHT 2 ENGINE WEIGHT WILL COMPRESS BLOCKS BY 4 5 mm APPROX 3 MOUNTING BLOCKS ARE EQUIPPED FOR STANDARD ACCESSORY 4 SHOWS CENTER OF GRAVITY 1 General 1 General 3 3YM20 with KM2P 1 marine gear MOUNTING BLOCKS ID 75 4 17
76. agm cover and not reduced in the intake manifold Therefore be careful of the diaphragm trouble 2 At lubricating oil replacement or lube oil supply The amount of lubricating oil isn t to be beyond the standard upper limit in the engine horizontality the upper limit mark of the dipstick Since the blowby gas reductor is adopted be careful that the amount of oil mist may be inducted in the combustion chamber and the oil hammer sometimes may occur when the lubricating oil quantity is beyond the upper limit or an engine is operated beyond the allowable maximum angle of an engine Reassembly Replace the diaphragm with new one when it is damaged 7 1 2 Diaphragm assy inspection Refer to 2 2 6 5 for the inspection procedure 150 Intake and exhaust system 7 2 Exhaust system 7 2 1 Construction There are two types of mixing elbows the L type and the U type The mixing elbow is attached to the exhaust manifold U type Mixing elbow Lp Seawater N L type Mixing elbow Exhaust elbow Heat exchanger Optional L type mixing elbow L type mixing elbow 7 2 2 Mixing elbow inspection 1 Clean dirt and scale out of the gas and cooling water lines 2 Repair crack or damage to welds or replace 3 Inspect the gasket packing and replace as necessary 151 8 Lubrication system 8 Lubrication system 8 1 Lubrication system The lube oil in the oil pan is pumped up through the intake filter and int
77. air a charge lamp circuit when a lamp doesn t work 192 12 Electrical System 12 5 Alternator 12V 80A Optional 12 5 1 Specifications Yanmar code 119573 77201 Model of alternator LR180 03C HITACHI Model of IC regulator TR1Z 63 HITACHI Battery voltage Nominal output 12V 80A Earth polarity Negative earth Direction of rotation Clockwise viewed from pulley end Weight 5 4 kg Rated speed 5000 Operating speed 1 200 9 000 Speed for 13 5V at 20 1 200 or less Output current for 13 5V 75A or more 5000 Regulated voltage 14 5 0 3V at 20 C voltage gradient 0 01V C 193 12 Electrical System 12 5 2 Structure Disassembly drawing and Structure Brush regulator assy Rear cover assembly Stator assembly Rotor assembly Brush assembly Bearing retainer IC regulator assembly i i Through bolt nd Ball bearing E anti po Brush set 9 gt gt i E Pulley nut assembly A ER T Y Front cover assembly Ball beari am earing Rear cover Insulating bushing Pulley assembly Screw M5 x 0 8 X14 194 12 Electrical System 12 5 3 Wiring diagram d n Key Wu E Condenser Charge lamp 12V3 4W Battery switch T Ql Battery IC regulator Alternator NOTICE 1 Don t do mis connecting and short circuit of each terminal 2 Don t remove a
78. ake piping by the lube oil pump through the holes in the cylinder body and on to the lube oil pump through the holes in the cylinder body and on to the discharge filter The lube oil which flows from the holes in the cylinder body through the bracket to the oil element is filtered and sent to the oil cooler It returns from the oil cooler to the bracket the pressure is regulated and it is fed back to main gallery in the cylinder body The lube oil which flows in the main gallery goes to the crankshaft journal lubricates the crank pin from the crankshaft journal and a option of the oil is fed to the camshaft bearings Oil is sent from the gear case camshaft bearings through the holes in the cylinder body and cylinder head to the valve arm shaft to lubricate the valve arm and valves Oil is also sent from the main gallery to the piston cooling nozzle to cool the piston surface and is sent through the intermediate gear bearing oil holes to lubricate the intermediate gear bearings and respective gears Lube oil for the fuel injection pump is sent by pipe from the main gallery to the fuel injection pump Lube oil filter Bypass valve Fuel injection pump Oil pressure swich Cylinder block Main gallery valve Intermediate Camshaft Crank Lube oil pump gear shaft metal journal metal Rocker arm Crank Oil suction pipe metal pin metal strainer Rocker arm Tappet Cam face 152 8 Lubrication system 8 2 L
79. al 33C 11 Remote control Optional 11 2 Remote control installation 1 Speed control Optional Remote control handle MN Remote control handle MT 3 Governor Flywheel housing Cable joint 179 11 Remote contro Optional 2 Clutch control Neutral 52 Remote control head Spacer 0 Cable bracket 22 Note X Cable shift travel S1 More than 36 mm 1 42 S2 More than 36 mm 1 42 Clam 4 Clutch flange gt engine speed To marine gear ay Washer Lock nut M6 Shift lever Holder Connector Remote control cable clamp Bolt M8 x 25 KM2P 1 marine gear 3 Engine stop Usually when an engine is stopped the stop button of an instrument panel is pushed and the engine is stopped Moreover an emergency stop button after the stop solenoid is pushed and the engine is stopped 180 11 Remote control Optional 11 3 Remote control inspection 1 When the control lever movement does not coincide with operation of the engine check a Eon the cable end stop nut to see whither or not it V is loose and readjust retighten when ae necessary e re N EN N Free throttle 2 Too many bends turns in the cable or bends at too extreme and angle will make it difficult to turn the handle Reroute the cable to reduce the number of bends of enlarge the bending radius as much as possible to 200 mm or more 3 Check for loose cable brac
80. an t be performed because the pressure in the cylinder block decreases with the function of the diaphragm in the rocker arm cover Therefore measure the lube oil level about 10 minutes later after stopping the engine or after removing the oil filler cap Note The yellow label shown right is attached on the O L CHECK 10 MINUTES AFTER ENGINE STOP dipstick 10 MINUTES 3 Replace the marine gear lube oil During initial operation the oil is quickly contaminated due to the initial wear of internal parts The lube oil must therefore be replaced early Refer to the sail drive operation manual for the procedure of replacing the sail drive lube oil 1 Remove the cap from the filler port and attach the oil drain pump Drain off the oil 2 Fill with new lube oil Standard Unit liter pint Marine gear oil capacity KM2P 1 Full 0 30 0 64 3 Perform a trial run of the engine and check the oil leakage 21 4 Adjust the tension of the alternator drive belt When there is not enough tension in the V belt it will slip and the cooling water pump will fail to supply cooling water Engine over heating and the seizure will Occur When there is too much tension in the V belt the belt will become damaged more quickly and the bearing of the cooling water pump may be damaged Check and adjust the V belt tension deflection in the following manner Notice Be especially careful not to splash engine oil on the V belt bec
81. ase cover 2 Mount the bracket and the seawater pump assembly to the gear case cover Gear case Spacer bolt Bracket Seawater pump Seawater pump 28 Mounting the heal exchanger exhaust manifold fresh water tank unit Mount the gasket and heal exchanger exhaust manifold Note After adjusting injection timing and tightening the fuel injection pump mount the heat exchanger Because it is harder to tighten the fuel pump nuts after installing the heat exchanger 99 4 Disassembly reassembly 29 Mounting the mixing elbow 1 Mount the mixing elbow on the exhaust manifold outlet 2 Mount the cooing seawater pipe rubber hose with the hose clips heat exchanger mixing elbow 30 Mounting the cooling water pipes seawater fresh water 1 Mount the seawater pipes with the hose clips seawater pump heat exchanger 2 Mount the fresh water pipes with the hose clips exhaust manifold fresh water pump fresh water pump heat exchanger Mixing elbow Coolant tank Exhaust manifold From seacock Cooling water pipes 100 4 Disassembly reassembly 31 Mounting the alternator 1 Mount the bracket on the cylinder head and the adjuster on the gear case cover and then the alternator 2 Adjust V belt tension with the adjuster and tighten the set bolt Alternator Set bolt V belt Belt adjuster 3YM30 32 Mounting the starting motor Fit the starting motor
82. assembly and reassembly 10 1 Specifications Model KM2P 1 For engine models 3YM30 3YM20 Clutch Constant mesh gear with servo cone clutch wet type Reduction Forward 2 21 2 62 3 22 Propeller sh can ce Forward Reverse Counter clockwise viewed from stern Control head Single lever control Cable Morse 33 C cable travel 76 2 mm Clamp YANMAR made standard accessory Cable connector YANMAR made standard accessory coupling Pitch circle diameter 78 mm Connecting bolt holes 4 10 5 mm Position of shift lever viewed from stern 176 11 Remote control Optional 11 Remote control Optional 11 1 Remote control system 11 1 1 Construction of remote control system The remote control permits one handed control of the engine speed changing from forward to reverse and stopping Fittings which allow for easy connection of the remote control cables with the fuel injection pump and transmission are provided with the remote control set The use of Morse remote control cables clamps and a remote control head are also provided for the device to stop the engine is electric and will be explained under the section on electrical equipment 11 1 2 Remote control device components Remote control head Morse MT3 top mounting single lever Morse MN side mounting single lever Remote control cable Morse 33C x 4m Morse 33C x 7m Engine stop cable Yanmar 4m Yanmar 7m 1 Remote control handle The model MT 3 remote
83. assification CD or better Standards of America Petroleum Institute e SAE viscosity 20 or 30 Standard of Society of Automotive Engineering 3 Selection of lube oil for sail drive unit API service grade GL4 5 SAE viscosity 90 or 80W 90 or QuickSilver High Performance Gear Lube QuickSilvere is registered trademark of Brunswick Corporation 4 Handling of engine oil Carefully store and handle the oil so as to prevent dust or dirt entrance When supplying the oil pay attention and clean around the filler port Do not mix different types of oil as it may adversely affect the lubricating performance When touching engine oil by hand the skin of the hand may become CAUTION rough Be careful not to touch oil with your hands without protective gloves If touch wash your hands with soap and water thoroughly 1 3 3 Cooling water Use clean soft water and be sure to add the Long Life Coolant Antifreeze LLC in order to prevent rust built up and freezing If there is any doubt over the water quality distilled water or pre mixed coolant should be used The coolants antifreezes which are good performance for example are shown below e TEXACO LONG LIFE COOLANT ANTIFREEZE both standard and pre mixed Product codes 7997 7998 HAVOLINE EXTENDED LIFE ANTIFREEZE COOLANT Product code 7994 IMPORTANT Be sure to add Long Life Coolant Antifreeze LLC to soft water In co
84. ause it will cause slipping stretching and aging of the belt 1 Remove the belt cover Check the tension of the V belt by pressing down on the middle of the belt with your finger approx 98N 10kgf The specified deflection should be as follows For used V belt 8 10 mm 0 315 0 393 inches For new V belt 6 8 mm 0 236 0 315 inches New V belt refers to a V belt which has been used less than 5 minutes on a running engine Used V belt refers to a V belt which has been used on a running engine for 5 minutes or more 2 If necessary adjust the V belt tension deflection To adjust the V belt tension loosen the set bolt for the belt adjuster and move the alternator to tighten the V belt 3 Visually check the V belt for cracks oiliness or wear If any replace the V belt with new one Notice When the V belt will be replaced with new one loosen the set bolt move the alternator and also loosen the V pulley set bolts for the cooling water pump Remove the V belt After replacing with new V belt and adjusting the tension run the engine for 5 minutes and readjust the deflection to the value in the table above 22 2 Inspection and adjustment Qn Alternator di Set bolt V belt 3YM30 2 Inspection adjustment 5 Adjusting the intake exhaust valve clearance Make measurement and adjustment while the engine is cold 1 Valve clearance measurement a Remove the rocker arm
85. ave to be the No 1 cylinder Select and adjust the cylinder where the piston is the nearest to the top dead center after turning and make adjustment for other cylinders in the order of ignition by turning the crankshaft 240 each time 6 Check and adjust the remote control operation The various control levers on the engine side are connected to the remote control lever by the remote control cable The cable will become stretched and the attachments loose after long hours of use causing deviation It is dangerous to control operation under these conditions and the remote control cable must be checked and adjusted periodically 1 Adjusting the throttle remote control cable Check to see that the control lever on the engine Remote High speed control limiting bolt Fuel side moves to the high speed stop position and low injection speed stop position when the remote control lever RA pump is moved to H high speed and L low speed 6222222 respectively When there is deviation loosen the clamp for the aby Lei Low speed remote control cable on the engine side and ATA limiting bolt adjust 2 Adjust the high speed stop position first and then 2 EN La idli QU adjust the low speed idling by the adjustment bolt the remote control lever 2 Adjusting the clutch remote control cable Check that the shift lever moves to the correct position when the remote control handle i
86. between valve guide and stem seal Valve stem seal projection mm Stem seal insertion 10 9 11 2 5 2 4 Valve springs 1 Checking valve springs 1 Check the spring for scratches or corrosion 2 Measure the free length of the spring 3 Measure inclination Inclination Square gauge Valve spring 112 5 Inspection and servicing of basic engine parts 4 Measure spring tension 1 mm pressure 26 6 35 4 Smaller pitch 2 71 3 61 Larger pitch Spring tension tester 5 Assembling valve springs The side with the smaller pitch painted yellow should face down cylinder head TTT ATTN TTT TTT NOTE The pitch of the valve spring is not even The side with the smaller pitch yellow should face down cylinder head when assembled 6 Spring retainer and spring cotter Inspect the inside face of the spring retainer the outside surface of the spring cotter the contact area of the spring cotter inside surface and the notch in the head of the valve stem Replace the spring retainer and spring cotter when the contact area is less than 70 or when the spring cotter has been recessed because of wear 5 2 5 Assembling the cylinder head Disassembly Partially tighten the bolts in the specified order and then Camshait side tighten to the specified torque being careful that the head does not get distorted 1 Clean out the cylinder head bolt holes 2 Check for
87. ble if there is a dislocation or excessive play between the accelerator and the governor lever 19 2 Inspection and adjustment 2 2 2 inspection after initial 50 hours or one month operation Be sure to check the following points after initial 50 hours or one month operation whichever comes first Inspection Drain the fuel tank Replace the engine lube oil and the lube oil filter 3 Replace the marine gear amp sail drive lube oil Adjust the tension of the alternator driving belt Adjust the intake exhaust valve clearance 6 Check adjust the remote control operation 7 Adjust the propeller shaft alignment 1 Drain the fuel tank 1 Put a pan under the drain cock to catch the fuel 2 Open the drain cock and drain off any water or dirt collected 3 When the water and dirt are drained off and the fuel comes out close the drain cock 2 Replace the engine lube oil and the lube oil filter During the operation of an engine the oil is quickly contaminated due to the initial wear of internal parts The lube oil must therefore be replaced early It is easiest and most effective to drain the engine lube oil after operation while the engine is still warm Replace the lube oil filter at the same time To engine Sediment Beware of oil splashes if extracting the Lube oil while it is hot CAUTION 1 Remove the lube oil dipstick and also the oil filler cap at the top of the rocker arm cover
88. body and inserting a thickness gauge diagonally between the impeller and the body Measure the side clearance between the impeller and the plate by placing a straight edge against the end of the pump body and inserting a thickness gauge between the impeller and the straight edge Measuring outside clearance between impeller and pump body E i emn Outside clearance between 0 3 1 1 15 impeller and body Thickness gauge 163 9 Cooling water system Measuring side clearance between impeller and plate mm umb Side clearance between impeller and plate Thickness gauge 164 9 Cooling water system 9 4 Heat exchanger 9 4 1 Heat exchanger construction Side cover Gasket O ring G Cooler core S Pressure cap The heat exchanger cools the hot fresh water that has cooled the inside of the engine with seawater The cooler core consists of many small diameter tubes baffle plates and tube cover The seawater flows through the maze formed by the baffle plates There is a reservoir above the cooler core which serves as the fresh water tank There is an exhaust gas passageway in the reservoir which forms a water cooled exhaust manifold The pressure cap filer cap on top of the heat exchanger has a pressure valve which lets off steam through the overflow pipe when pressure in the fresh water system exceeds the specified value It also takes S Side cover in air from the overflow pip
89. ch mark on the connecting rod large en faced the fuel injection pump side and the combustion chamber above the piston is close to the fuel injection pump Camshaft side Nozzle side Cylinder size mark Flywheel side Piston ID mark Embossed mark Flywheel side Match mark Assembly direction of rod and piston 124 5 Inspection and servicing of basic engine parts 5 5 Crankshaft and main bearing The crank pin and crank journal have been induction hardened for superior durability and the crankshaft 15 provided with for balance weights for optional balance The crankshaft main veering is of the hanger type The upper metal cylinder block side is provided with an groove There is no oil groove on the lower metal bearing cap side The veering cap location cap of the flywheel side has a thrust metal which supports the thrust load 5 5 1 Crankshaft 1 Color check after cleaning the crankshaft and replace the crank shaft if there is any cracking or considerable damage 2 Bending of the crankshaft Support the crankshaft with V blocks at both ends of the journals Measure the deflection of the center journal with a dial gauge while rotating the crankshaft to check the extent of crankshaft bending The total indicating reading on the dial gauge is divided by two to obtain the crankshaft bend Crankshaft bend limit 0 01 mm 125 Main bearing metal basic EJ Thrust metal N
90. cision standard of dimension R mm 3 5 0 3 0 NOTICE 1 If the oil clearance is excessive though the thickness of the journal and crankpin metals are normal or if partial uneven wear is observed re grind the crankshaft and use an oversized metals 2 If rust or surface roughening exists on the rear side of the metals coat it with blue or minimum Then assemble the crankpin metal to the connecting rod and tighten the rod bolt to the specified torque to check the metal for contact If the contact surface occupies 75 or more the metal is normal If the contact surface is insufficient the metal interference is insufficient Replace the metal with a new one 126 5 Inspection and servicing of basic engine parts 4 Checking the side gap of a crankshaft After assembling the crankshaft tighten the main bearing cap to the specified toque and move the crankshaft to one side placing a dial gauge on one end of the shaft to measure thrust clearance Replace the thrust bearing if it is worn beyond the limit mm Crankshaft side gap 0 111 0 250 Other measurement method can also be effective Insert the thickness gauge directly into the clearance between the thrust metal and crankshaft thrust face Crankshaft Thrust metal Bearing cap Thickness gauge Side gap measurement 2 5 5 2 Main bearing Block side main bearing metals C VI A metal Dg 1 Inspecting the main bearing Check for flaking seiz
91. cover above cylinder head Flywheel ea b Set the No 1 cylinder in the compression TDC mE Turn the crankshaft to bring the piston of the njection ive i timing marks No 1 cylinder its compression top dead center EN We 4d M while watching the rocker arm motion the timing No 4 c i mark of the flywheel housing and the top mark of JS JaA INT TT the flywheel T D C T Position where both the intake and exhaust valves are closed Flywheel Notes he crankshaft shall be turned clockwise as seen from the gear case side he No 1 cylinder position is on the opposite side of the gear case e Since there is a clearance between the rocker arm and valve at the compression top dead center the position of TDC can be checked by hand Also see that the top mark on the flywheel aligns with the mark on the flywheel housing If there is no valve clearance disassemble and inspect around the valve seat since the valve seat may be worn abnormally 264 Valve clearance measurement Insert a thickness gage between the rocker arm Rocker arm an Screw Valve and valve cap and record the measured valve clearance Use it as the data for estimating the wear state d Adjusting other cylinders Turn the crankshaft 240 and make adjustment for the No 3 cylinder Then adjust the No 2 cylinder in this order The cylinder to be adjusted first does not have to Valve clearance b
92. d circuit system If the oil pressure is normal the contacts of the switch are opened by the lubricating oil pressure and the lamp remains off Een Main switch ON oO Battery Lube oil pressure pressure switch I switch Oil pressure alarm circuit Oil pressure Rated voltage 12V 0 04 0 06 MPa 0 4 0 6 kgf cm Operating pressure 2 N Oil pressure switch 197 12 Electrical System Inspection Inspection Item Inspection method Lamp not 1 Oil pressurelamp 1 Visual inspection Replace lamp illuminated when blown out 2 Lamp not illuminated even main switch set when main switch set to ON to ON position and terminals of oil pressure switch grounded 2 Operation of oil Lamp illuminated when checked as Replace oil pressure pressure switch described in 2 above switch Lamp not 1 Oil level low otop engine and check oil level with Add oil extinguished dipstick while engine 2 Oil pressure low Measure oil pressure Repair bearing wear and adjust regulator valve 3 Oil pressure Switch faulty if abnormal at 1 Replace oil pressure faulty 2 above switch 4 Wiring between Cut the wiring between the lamp Repair wiring harness lamp and oil and switch and wire with separate pressure switch wire faulty 12 7 2 Cooling water temperature alarm A water temperature lamp and a water temperature s
93. de diameter 6 000 6 012 Valve stem outside diameter 5 960 5 975 Clearance 000 0 025 0 052 0406 16 Va projection fom ofnderhead 98400 Valve guide driving in method Cold fited 3 Valve spring mm page 5 2 4 1 1 4 Rocker and shaft mm TE m Reference Inspection item Standard Limit page Arm shaft hole diameter 12 000 12 020 12 07 5 2 7 1 Shaft outside diameter 11 966 11 984 11 94 202 13 Service standards 5 Tappet and push rod page Tappet outside diameter 20 927 20 960 20 907 5 6 2 2 Tappet guide hole inside diameter cylinder block 21 000 21 021 21 041 Tappet oil clearance 0 040 0 094 0 134 Push rod bend Less than 0 03 13 2 2 Camshaft and gear train 1 Camshaft mm Shaft outside diameter Metal inside diameter Bushing inside diameter 40 000 40 075 40 150 Camshait outside 39 940 39 960 39 905 diameter Bushing inside diameter 40 000 40 025 40 100 Intermediate 39 910 39 935 39 875 5 6 1 3 diameter Bushing inside diameter 40 000 40 025 40 100 Flywheel side 39 940 39 960 39 905 diameter 2 Idle gear shaft and bushing mm page Shaft outside diameter 44 950 44 975 44 900 5 7 1 3 Bushing inside diameter 45 000 45 025 45 075 3 Backlash of each gear mm page Crank gear cam gear idle gear and fuel injection 0 06 0 12 57 100 pump gear 03 2 13 Serv
94. diameter Calculate the oil clearance from the measured values Refer to 5 5 1 3 for measuring the crank pin outside diameter Replace the crank pin metal if the oil clearance becomes about the limit dimension of the below table Correct by grinding if unevenly wear roundness exceeding the limit or insufficient outside diameter is found Also use an undersized metal if necessary NOTICE When measuring the inside diameter of the rod big end install the crank pin metal in the rod big end not to mistake the top and bottom of the metals and tighten the rod bolts by the standard torque Nem kgfem 22 6 27 5 Rod bolt tightening torque 2 3 2 8 Rod bushing I D measurement mm Mea 4984200 Metal thickness 1 503 1 509 0 020 0 058 0 120 122 5 Inspection and servicing of basic engine parts e Other procedure of measuring crank pin oil clearance 1 Use the press gauge Plastic gauge for measuring the oil clearance of the crank pin 2 Mount the connecting rod on the crank pin tighten to specified torque Plastic gauge 3 Remove the connecting rod and measure the broken plastic gauge with measuring paper 3 Precautions on replacement of crank pin metal 1 Wash the crank pin metal 2 Wash the large end cap mount the crank pin metal and make sure that it fits tightly on the large end cap 3 When assembling the connecting rod match up the large end and large end cap number
95. djusted The control lever is not reaching the maximum speed position The nozzle s injection operation iS poor The governor spring is too strong or is improperly adjust The governor flyweights or governor sleeve movement is not smooth The injection quantities are not uniform the delivery valve is not operating properly The governor s idling adjustment is improperly adjusted The plunger is worn The plunger spring is broken The rubber damper is worn The governor lever shaft pin is worn excessively The feed pump blades are not operating properly The regulating valve is stuck in the open position The fuel filter element is clogged and therefore fuel oil delivery is poor 10 The nozzle or the nozzle holder is not functioning properly 61 Inspect and then repair or replace Readjust or replace Readjust Repair or replace Readjust or replace Repair or replace Inspect or replace Readjust Replace the distributor assembly Replace Replace Replace Repair or replace Replace Clean or replace Inspect and then repair or replace 3 Troubleshooting 3 4 Troubleshooting by measuring compression pressure Compression pressure drop is one of major causes of increasing blowby gas lubricating oil contamination or increased lubricating oil consumption as a resultant phenomenon or starting failure The compression pres sure is affected by the following factors 1 Degree
96. dling e Water and dust in the fuel oil can cause operation failure Use containers which are clean inside to store fuel oil Store the containers away from rain 2 water and dust leave dregs near the bottom Before supplying fuel let the fuel container rest for several hours so that water and dust in the fuel are deposited on the bottom Pump up only the clean fuel 3 Fuel tank Be sure to attach a drain cock precipitation trap and primary strainer to the fuel tank as shown illustration Filler port right E uel return connection strainer Outlet to engine Drain cock 1 3 2 Lubricating oil Selection of viscosity IMPORTANT SAE Service grade Use of other than the specified engine oil may cause inner parts seizure or early wear leading to shorten the engine service life 20M gt 1 Selection of engine lube oil m _ a i E Use the following engine oil REM e 0 C API classification CD or better Standards of America Petroleum Institute y e SAE viscosity 10W 30 or 15W 40 AE ES d de Standard of Society of Automotive Engineering 20 10 0 10 20 30 40 50 Engine oil with 10W 30 be used throughout the year Refer to the right figure 10W 30 15W 40 be used almost throughout the year Atmospheric temperature 1 2 Selection of marine gear lube Use the following engine oil API cl
97. does not drain place side gap adjustment washers underneath the bottom plate to adjust Select the number of films used in accordance with the following When the pump is draining the electric current load is about 10A for 12V and 5A for 24V The pump operates efficiently at these electric current loads Steps for replacement 1 Remove the impeller plate by taking out the M4 screws 4 and opening the top of the diaphragm switch Screw lock has been applied to the screw and a dryer should be used to heat the screw before removing it 2 Clean the inside of the pump 3 Grease the plate impeller and film for side gap adjustment and then reassemble the pump by inserting first the film plate and then the impeller 174 9 Cooling water system 9 7 6 Troubleshooting Refer to the following countermeasures for difficulties that arise Problem Cause Countermeasure Faulty wiring Check the wiring between the motor and battery Check to see if the specific gravity of the battery fluid is greater than 1 Pump does not turn Faulty battery 1 25 Recharge or replace the battery Faulty starter switch Consult your local dealer Faulty pump Faulty pump Consult your local dealer Consult your local dealer local dealer 2 Pump turns but does not draw Draws up air Check hose connections up water Retighten pump screws Low voltage in battery Check to see if the specific gravity of the batter
98. e e Check the injection timings for all cylinders Are they correctly adjusted Are they too fast or too slow e Check the nozzle spray e Check the fuel delivery Is it in good condition Loosen the fuel pipe connection at the injection pump inlet and test operate the fuel feed pump 6 1 8 Major faults and troubleshooting 1 Engine Fuel not 1 No fuel in the fuel tank Re supply won t start delivered to 2 Fuel tank cock is closed Open Injection pump 3 Fuel pipe system is clogged Clean 4 Fuel filter element is clogged Disassemble and clean or replace element 5 Air is sucked into the fuel due to defective Repair connections in the piping from the fuel tank to the fuel pump 6 Defective valve contact of feed pump Repair or replace 7 Piston spring of feed pump is broken Replace 8 Inter spindle or tappets of feed pump are Repair or replace Fuel delivered 1 Defective connection of control lever and Repair or adjust to injection accel rod of injection pump pump Plunger is worn out or stuck Repair or replace Delivery valve is stuck Repair or replace Control rack doesn t move Repair or replace Injection pump coupling is damaged or the Replace key is broken Nozzle doesnt Nozzle valve doesn t open or close normally Repair or replace work Nozzle seat is defective Repair or replace Case nut is loose Inspect and tighten Injection nozzle starting pressure is too low Adjust Nozzle spring is broken Replace F
99. e back onto the battery LAST Proper ventilation of the battery area Keep the area around the battery well ventilated paying attention to keep away any fire source During operation or charging hydrogen gas is generated from the battery and can be easily ignited Do not come in contact with battery electrolyte Pay sufficient attention to avoid your eyes or skin from being in contact with the fluid The battery electrolyte is dilute sulfuric acid and causes burns Wash it off immediately with a large amount of fresh water if you get any on you Cathode plate Separator Glass mat Anode plate 27 2 Inspection and adjustment 1 Electrolyte level e Check the level of fluid the battery 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 Battery fluid tends to evaporate more quickly the ieee c summer and the fluid level should be checked earlier than the specified times If the engine cranking speed is so slow that the engine does not start up recharge the battery If the engine still will not start after charging replace the battery Remove the battery from the battery mounting of the machine unit after daily use if letting the machine unit leave in the place that the ambient temperature could drop at
100. e bellofrom IV 4 Repair link system Replace V 1 Replace VI 1 Check and repair Clean V 2 Replace VI 2 Disassemble and clean V 3 Adjust lube oil adjustment valve VI 3 Replace V 4 Change oil 4 Repair or replace Countermeasure VS TROUBLE AND TROUBLESHOOTING 1 1 Lap 2 Replace Countermeasure gt 1 Faulty operation of injection valve 1 Impediment to valve needle movement 2 Damaged valve spring 1 Damaged governor bearing D LLI O c o 2 Faulty operation of governor link 4 Faulty operation of fuel oil adjustment III Faulty operation of governor 11 1 Replace 11 2 Adjust 3 Clean 11 4 Disassemble wash and repair Countermeasure 4 Inaccurate assembly of fuel injection pump S T Chart 5 ROTATION IS NOT SMOOTH Clean Il 7 Bleed air and prime Replace Il 8 Adjust Replace 11 9 Adjust Correctly install pump Clean Replace 1 11 1 11 2 11 3 11 4 11 5 11 6 Uneven supply of fuel oil injected 1 Faulty operation of fuel pump plunger 2 Damaged fuel pump plunger 4 9 Clogging of fuel filter E tue pump punget 6 Damaged fuel cam dol 7 Air in fuel injection system m nger sprin 8 Faulty operation of adjustment rack 9 Uneven amount of fuel to cylinders ROTATION IS NOT SMOOTH
101. e gear bushing Idle gear shaft Oil clearance 0 025 0 075 0 175 5 7 2 Gear timing marks Fuel injection pump Match up the timing marks on each gear when drive gear assembling A Camshait gear Crankshaft gear Direction of rotation Gear train 131 5 Inspection and servicing of basic engine parts 5 8 Flywheel and housing The function of the flywheel is through inertia to rotate the crankshaft in a uniform and smooth manner by absorbing the turning force created during the combustion stroke of the engine and by compensating for the decrease in turning force during the other strokes The flywheel is mounted and secured by 6 bolts on the crankshaft end at the opposite end to the gear case it is covered by the mounting flange flywheel housing which is bolted to the cylinder block The fitting surface for the damper disc is on the crankshaft side of the flywheel The rotation of the crankshaft is transmitted through this disc to the input shaft of the reduction and reversing gear The reduction and reversing gear is fitted to the mounting flange The flywheel s unbalanced force on the shaft center must be kept below the specified value for the crankshaft as the flywheel rotates with the crankshaft at high speed To achieve this the valance is adjusted by drilling holes in the side of the flywheel and the unbalanced momentum is adjusted by drilling holes in the circumference The ring gear is shrin
102. e level in the coolant recovery tank is between the full and low marks 0 8L Coolant recovery tank capacity full 0 8 quart 39 Test running Refer to Adjusting operation of 2 6 in chapter 2 103 5 Inspection and servicing of basic engine parts 5 Inspection and servicing of basic engine parts 5 1 Cylinder block The cylinder block is a thin skinned low weight short skirt type with rationally placed ribs 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 Camshaft hole that have frozen up overturned or otherwise been subjected to undue stress Perform a color check on any portions that appear to be cracked and replace the cylinder block if the crack is not repairable Cap plug 30 mm Camshaft hole 5 1 2 Cleaning of oil holes Clean all oil holes making sure that none are clogged up and the cap plugs do not come off Color check kit Penetrant Cap plug 12 mm main gallery Developer Cleaner 5 1 3 Color check procedure 1 Clean the area to be inspected 2 Color check kit The color check test kit consists of an aerosol cleaner penetrant and developer 3 Clean the area to be inspected with the cleaner Either spray the cleaner on directly and wipe or wipe the area with a cloth moistened with cleaner 4 Spray on red penetrant After cleaning sp
103. e port with your finger move the Measuring cylinder priming lever and check for air bubbles _ Repair or replace any part which emits air m Air pressure kg cm bubbles Container filled with light oil 2 Attach a vinyl house to the fuel feed pump intake keep the pump at the specified depth from the fuel oil surface move the priming lever by hand and check for sudden spurts of fuel oil from the discharge port If oil is not spurted out inspect the diaphragm and diaphragm spring and repair replace as necessary 3 Diaphragm inspection Parts of the diaphragm that are repeatedly burned will become thinner or deteriorate over a long period of time Check the diaphragm and replace if necessary Diaphragm 145 4 Valve contact mounting Clean the valve seat and valve with air to remove any foreign matter Inlet valve 5 Inspect the diaphragm spring and piston spring for settling and the piston for wear and replace as necessary NOTE Replace parts as an assembly 146 6 Fuel injection equipment Outlet valve 6 Fuel injection equipment 6 3 Fuel filter amp 2 Air bleeding bolt The fuel filter is installed between the feed pump and From feed Nylon gasket injection pump and serves to remove dirt and impurity from the fuel fed from the fuel tank through the feed pump The fuel filter incorporates a replaceable filter paper element Fuel from the fuel tank
104. e reusing 8 Do not use the pump for showering If the pump outlet is deformed for showering the increase in water pressure will increase the load on the motor and cause motor seizure 9 Fix the strainer so that it well not turn upside down or on its side 10 When sludge has built up in the bilge to be drained position the strainer about 20 mm above the sludge When the pump is stopped be sure there is no sludge remaining inside the pump 11 The specific gravity for the battery fluid is 1 25 or more 9 7 4 Assembly procedure When bilge is being used assemble in accordance with the following 1 Assembling the bilge pump e Select a dry place above the bilge water level e Select the location for the bilge pump taking into consideration the length of the switch cable approx 3 m and its attachment point and the position of the battery Position at a 45 angle as shown in the illustration 907 70 cm with the nozzle facing up and 50 70 cm from the bottom of the boat Bige 2 Assembling the switch e Attach in a place to insure easy operation away from rainwater Connect the terminal to the battery When the cord will not reach the battery an extension of no greater than 3 m length suitable SIN 2mm AV2wire Red for AV3cm can be attached ILES H 65X12 screw Controller 2mm AV2wire White 3 Positioning the strainer e Attach at the place where the greatest amount of water i
105. e switch terminal and cylinder block while operating the engine It is abnormal if circuit is closed Tester probes Continuity test 2 4 2 Thermo switch Place the thermo switch in a container filled with antifreeze or oil Heat it while measuring the fluid NS temperature The switch is normal if the voltameter shows continuity when the fluid temperature is 93 97 deg C Tester probes Thermo switch Hot water 7 C 44 2 Inspection adjustment 2 5 Thermostat inspection 1 Put the thermostat in a beaker with fresh water and heat it on an electric stove 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 Replace the thermostat if it not functioning normally Thermometer Thermostat cover amp Thermostat Fresh water pump body Thermostat Valve opening Full open lift Temperature Temperature deg mm 69 5 72 5 8 or more 85 deg C Valve opening temperature is carved on the flange 2 Normally the thermostat should be inspected every 500 hours or operation but it should be inspected before this if the cooling temperature rises abnormally or white smoke is emitted for a long time after engine starting 3 Replace the thermostat every year or 2000 hours of operation whichever comes first 45 2 Inspection adjustment 2 6 Adjusting operation Perform the adjusting operation for an engine as
106. e the No 1 cylinder Select and adjust the cylinder where the piston is the nearest to the top dead center after turning and make adjustment for other cylinders in the order of ignition by turning the crankshaft 240 each time The adjustment method of reducing the flywheel turning numbers for reference Set No 1 cylinder to the compression T D C and adjust the clearance of the mark of the below table Next turn the flywheel once the suction exhaust valve of No 1 cylinder is in the position of the overlap T D C at this time and adjust the clearance of the O mark Ignition order of cylinder engines 1 gt 3 gt 2 No 1 compression 2 Valve clearance inspection and adjustment a Loosen adjusting bolts Loosen the lock nut and adjust the screw And check the valve for any inclination of valve cap N entrance of dirt wear Valve cap Normal Abnormal 23 2 Inspection and adjustment b Measure valve clearance Insert a 0 2 mm thickness gage between the rocker arm and valve cap and adjust the valve clearance 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 d Adjusting other cylinders Turn the crankshaft 240 then and make adjustment for the No 3 cylinder Then adjust the No 2 cylinder in this order Valve clearance adjustment The cylinder to be adjusted first does not h
107. e when pressure in the fresh water system drops below the normal value Filler neck 9 4 2 Disassembly and reassembly of the heat exchanger 1 Remove the side covers on both sides of the cooler core and take out the cooler core and O ring s NOTE Replace the O ring s when you have removed the cooler core 2 Remove the pressure cap 9 4 3 Heat exchanger inspection Refer to 2 2 6 4 165 9 Cooling water system 9 5 Pressure cap and coolant recovery tank 9 5 1 Pressure cap construction The pressure cap mounted on the filler neck incorporates a pressure control valve The cap is mounted on the filler neck cam by placing it on the rocking tab and rotating The top seal of the cap seals the top of the filler neck and the pressure valve seals the lock seat 9 5 2 Pressure cap pressure control The pressure valve and the vacuum valve seal both the valve seats when the pressure in the fresh water system is within the specified value of 88 kPa 0 9 kgf Pressure cap cm This seals the fresh water system When the pressure within the fresh water system exceeds the specified value the pressure valve opens and steam is discharged through the overflow pipe When the fresh water is cooled and the pressure within the fresh water system drops below the normal value atmospheric pressure opens the vacuum valve and air is drawn in through the overflow pipe The coolant recovery tank which sill be described later
108. eakage of gas from 5 Faulty adjustment of fuel pump 10 Faulty supply pump 6 Clogging of filter suction exhaust valves 3 Worn upper part Early injection 1 Clogging of air filter 1 Poor quality fuel oil 2 Late injection 2 Clogging of exhaust line 2 Inadequate tapper AYW clearance 4 Worn piston ring 3 Seizure of moving parts 5 Sticking of piston ring 4 Insufficient cooling water 5 Insufficient lube oil supplied IV Leakage of pressurized gas from inside cylinder V Irregular fuel injection timing Clogged intake air filter VII Miscellaneous gt ai a ai 1 Lap valves V 1 Adjust timing to VI 1 Clean VII 1 Replace with good fuel oil 2 Adjust delay injection VII 2 Clean IV 3 Replace V 2 Adjust timing to VII 3 Disassemble check and repair pran O dq LLI O 4 v IV 4 Replace speed injection VII 4 Lap cooling water pump suction exhaust valves IV 5 Disassemble and repair or replace VII 5 Disassemble and clean lube oil pump and filter Countermeasure 86 Chart 9 TROUBLE AND TROUBLESHOOTING MISCELLANEOUS TROUBLE 1 Tighten nuts Tighten adjustment valve 11 1 Clean 2 Tighten nuts and insert pins Check and repair 11 2 Add cooling water 1 3 Remove adjustment liner and adjust aperture 11 3 Disassemble and repair or replace or replace ir 1
109. eawater 17 x t4 rubber hose y Fresh water cooler 17 x t4 rubber hose Lubricating oil inlet filter Seawater inlet Main bearing Notes 1 Dimension of steel pipe outer dia x thickness Dimension of rubber pipe inner dia x thickness 2 Fuel rubber pipes marked X satisfy EN ISO7840 10 1 General Detail of part A Detail of part B Detail of part D 2 3YM30C 3YM20C with sale drive 5020 X 7 8 x t4 5 rubber hose n ae X 7 8 x t4 5 rubber hose 5 5 Check valve D Flange joint gt 5 X 7 8 x t4 5 rubber hose O r Eye joint Fuel oil filter cooing fresh water piping cooing seawater piping urea ret i pei Pressure control valve t Screw joint Union Lubricating oil pump Lubricating oil piping Fuel oil piping Fresh water temperature switch Hot water connection inlet R3 8 Cooling water pump fresh water SY l VIV From 28 x t4 rubber hose es a TRES 28 x t4 rubber hose 47 Cooling water pump seawater 17 x t4 rubber hose gt 17 x t4 rubber hose Notes 1 Dimension of steel pipe outer dia x thickness Dimension of rubber pipe inner dia x thickness 2 Fuel rubber pipes marked X satisfy EN ISO7840 Seawater inlet m p From drive X 7 8 x t4 5 rubber hose X 7 8 x t4 5 rubber hose Fuel feed
110. ecified injection volume C Confirm the injection volume D at the specified speed at starting Push the control lever to low idle side 10 Adjust the position of the low idle set bolt at low idle speed as to get the specified injection volume E High idle set bolt Low idle set bolt Adjustment procedure for 5 and 10 136 6 Fuel injection equipment Rack position mm 1 Loosen nut 3 Tighten nut 2 Loosen adjusting bolt 3YM30 360 3YM20 180 Adjustment procedure for item 1 and 6 1 Loosen nut 3 Tighten nut 2 Screw angleich Adjust injection volume to C by screwing Adjustment procedure for 7 6 Fuel injection equipment 3YM20 1 Service data for 3YM20 Part code Back No Adjustment SPEC SERVICE STD tem 170 Fuel injection pipe mm 22 x 600 Startin Pump speed R ti 1 BD o r Q on 0 in in iN NO C1 NA olume Q4 Variation Nc volume Qc Hi idle Pump speed i Injection volume LU Pump speed 4 i Injection Plungerdiameter Retracton voume of deivery vave Tepoearance fmm Governor spring Spring Free length mm 42 Note The value parentheses is a reference value lu ria t m lu m lu 3 N 1 C2 7 2 Fuel adjustment for 3YM20 1 2 3 4 5 9 Loosen the nut of
111. ection pump SN Fuel filter To fuel tank Feed pump From fuel tank 134 6 Fuel injection equipment 6 1 2 Fuel injection pump service data and adjustment 3YM30 1 Service data for 3YM30 Part code Back No Adjustment SPEC SERVICE STD tem 179 Fuel injection pipe mm 22 x 600 Startin Pump speed R ated load ump speed 1800 Injecti 2 min et 22 4 0 75 VO co NO Variation Nc me 7 Hi idle Pump speed 4 Np min Injection speed Injection MN Governor spring Spring N cm Free length mm 42 Note The value in parentheses is a reference value lu ria Injection m lu lu 1 C2 5 2 Fuel adjustment for 3YM30 1 2 3 4 5 9 Loosen the nut of the FO limiter and screw the adjusting bolt to the bottom Tighten the nut Adjust the rack position to RO 15mm with the FO limiter and measure the injection volume A at the rated speed When the measured injection volume A is out of the standard readjust the injection volume by screwing the FO limiter Pull the control lever to high idle side at full rack position Adjust the position of the high idle set bolt at high idle speed as to get the specified injection volume B Loosen the nut of the FO limiter and loosen the adjusting bolt at 360 Fix the nut Screw the angleich at the torque rise speed to get the sp
112. ection timing is hard to determine as it varies with the application load status qualities of the fuel and lubricating oils used and handling status General rules are described here O User maintenance Parts replacement Shop inspection x2 System Item dip 100 h y starting 5Ohrs or 1100 hrs or Fuel system Replace the fuel filter Check the injection timing Check the injection spray condition Check the lube oil 22 Lubricating Sail drive MEN Replace the engine lube oil filter Seawater outlet Check cooling water level ey Check the impeller of the cooling water pump seawater pump Every year Replace the fresh water coolant When long life coolant of a specified type is used replacement period of two years can be obtained Clean amp check the water passages Clean the element of the air intake silencer Air intake Clean the exhaust water mixing elbow Diaphragm assembiyhepeston _ 15 2 Inspection adjustment O User maintenance Parts replacement Shop inspection Every Item 5Ohrs or 100 hrs or Check the alarm lamps amp devices Check the electrolyte level in the Electrical battery system Adjust the tension of the alternator driving belt Check the wiring connectors Retighten all major nuts and bolts Check adjust the remote control control operation system etc Adjust the propel
113. elivery holder while turning the crankshaft clockwise and stop turning it at the same time when the fuel comes out 7 Read the timing scale on the flywheel from the hole on the flywheel housing It is standard fuel injection timing if the timing mark position meets the fuel injection timing of the below table Injection timing FID FIC Air 3YM30 16 1 18 1 22 1 24 1 Diaphragm assembly inspection Flywheel ZL i Flywheel 8 Repeat the step 5 to 7 a few times Note Injection timing check for one cylinder is generally sufficient If it is to be checked for all cylinders check each oylinder in the ignition order of 1 3 2 1 The cylinder to be checked is not limited to the No 1 cylinder and any cylinder may be checked 9 If the injection timing is out of the standard value loosen the fuel pump mounting nut and incline the fuel injection pump toward or away from the engine for adjustment Incline toward the engine to delay the timing and away from the engine to advance it 37 2 Inspection and adjustment 2 Check the injection spray condition of a fuel nozzle Wear protective glasses when testing injection from the fuel injection WARNING nozzle 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 1 Injection pressure measuremen
114. embling so that it does not get out of place 9 Mounting the piston and connecting rod 1 Reassemble the piston and connecting rod NOTE 1 When reassembling the piston and connecting rod make sure that the parts are assembled with the correct orientation 2 Install each piston ring on the piston with the punched manufacturer s mark facing upward 3 The piston ring joints shall be staggered at by 120 intervals Do not position the top ring joint vertical to the piston pin The coil expander joint shall be opposite to the oil ring joint 91 Cylinder block N 5 NW 99 A AS T Q UN 2 0 e a H Zope LA y Oy RS SG 2 Flywheel housing Make the punched manufacturer s mark face upward Piston ring 22 Oil ring joint ring joint Top ring joint Ring joints 2 Coat the outside of the piston and the inside of the connecting rod crank pin metal with engine oil and insert the piston with the piston insertion tool 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 2 After inserting the piston make sure the ID mark on the piston top is located at the fuel nozzle side looking from the top of the piston 3 Align the large end match mark mount the cap and tighten the connecting rod bolts Tighteni
115. ence inside the engine the rack agglutination of the fuel pump and so on are likely to occur In case that the engine is equipped with a boat a Replace the lube oil and the filter before the engine running b Supply fuel if the fuel in the fuel tank was removed and bleed the fuel system c Confirm that there is the coolant in the engine d Operate the engine at the low idling speed for about five minutes If it can be done once a month 7 lt 48 3 Troubleshooting 3 Troubleshooting 3 1 Preparation before troubleshooting If the signs of a trouble appear it is important to lecture on the countermeasure and treatment before becoming a big accident not to shorten the engine life 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 Then repair the trouble and prevent the recurrence of the trouble 1 What s the occurrence phenomenon or the trouble situation e g Poor exhaust color 2 Investigation of the past records of the engine Check a client control ledger and examine the history of the engine Investigate the engine model name and the engine number Mentioned in the engine label Examine the machine unit name and its number in the same way When was the engine maintained last time How much period and or time has it been used after it was maintai
116. eze and charging condition of battery fluid Nozzle tester Checks the shape and pressure of spray emitted from the fuel injection valve at the time of injection Digital thermostat Measures temperature of various parts Illustration 73 of tool Contact type Photoelectric type High pressure fuel pipe clamp type Circuit tester Compression gauge 4 Disassembly and reassembly Illustration Measures rotation speed by placing at the indentation hole of the revolving shaft Measures rotation speed by using a reflector seal which is placed on the exterior of the revolving shaft Measures rotation speed without reference to revolving shaft center or the exterior of the revolving shaft Measures the resistance voltage and continuity of the electric circuit Measures the pressure of the compression Yanmar code No TOL 97190080 74 4 Disassembly and reassembly 4 2 4 Other material WMems Usual contents Features and application Non drying liquid gasket solvent less type easy to remove superior in seawater resistance applicable to various mating surfaces gasket Three Bond 200g No 1 1 kg also TB1101 available Three Bond 200g No 2 1 kg also TB1102 available Non drying liquid gasket easy to apply superior in water resistance and oil resistance especially superior in gasoline resistance Three Bond No 3 TB1103 Drying film lo
117. f basic engine parts below 0 005 below 0 0 min 0 005 min LI below 0 010 0 min 3YM20 69 975 3 Removing the piston Piston outside diameter D2 0 030 max 0 020 min ener ad below 0 020 0 010 min D1 D2 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 5 3 2 Piston pin Measure at positions a and b Measure the outer diameter and replace the pin if it is in directions A and B e worn Standar hole 22000 22 009 22 039 inside dia pin 21 995 22 000 21 965 outside dia 0 000 0 014 0 074 Piston pin hole Measure at positions a b and c in directions A and B eL Piston pin outside diameter 117 5 Inspection and servicing of basic engine parts 5 3 3 Piston rings There are two compression rings and one oil ring Top ring The absence of an oil ring on the piston skirt prevents oil from being kept on the thrust surface and in turn provides good lubrication Second ring Oil ring 1 Measuring the rings Measure the thickness and width of the rings and the ring to groove clearance after installation Replace if wear exceed the limit mm p Sm T um Groove wian 7550 1570 00600100 3YM30 Thickness Measuring side clearance mm Sane T uw Groove with 18501570
118. filler neck Copper tube 167 9 Cooling water system 9 5 5 Function of the coolant recovery tank Coolant recovery tank Filler cap The pressure valve opens to discharge steam when the steam pressure in the fresh water tank exceeds 90 kPa 0 9 kgf cm This consumes water The coolant recovery tank maintains the water level by preventing this discharge of water The steam discharged into the coolant recovery tank condenses into watch and the water level in the tank rises When the pressure in the fresh water system drops below the normal value the water in the coolant recovery tank is sucked back into the fresh water tank to raise the water back to its original level The coolant recovery tank facilitates long hours of operation without water replacement and eliminates the possibility of burns when the steam is ejected from the filler neck because the pressure cap does not need to be removed 9 5 6 Specifications of coolant recovery tank Overall capacity Full scale position Low scale position 9 5 7 Mounting the coolant recovery tank Capacity of coolant recovery tank 1 The coolant recovery tank is mounted at approximately the same height as the heat exchanger fresh water tank allowable difference in height 300 mm 11 8110 in or less 2 The overflow pipe should be less than 1000 mm 39 3701 in long and mounted so that it P does not sag or bend p NOTE Make sure that the overflow pipe of
119. for piston size Oil ring MS I D mark IMPORTANT Piston shape differs among engine models If any Piston incorrect piston is installed combustion performance will drop Be sure to check the applicable engine model identification mark on the piston to insure use E of the correct part Circlip De Piston pin 3YM20 5 3 1 Piston 1 Piston head and combustion surface Remove the carbon that has accumulated on the piston head and combustion surface taking care not to scratch the piston Check the combustion surface for any damage 2 Measurement of piston outside diameter inspection 1 Replace the piston if the outsides of the piston or ring grooves are worn 2 Measure the outside diameter in the position of 22mm from the piston bottom in the right angle direction of the piston pin Piston outside diameter Model Standard Limit Clearance between piston and cylinder 75 965 3YM30 75 975 75 920 0 035 0 055 Piston outside diameter 69 970 69 980 69 925 0 030 0 050 If the piston outside diameter exceed the limit replace the piston with new one Selective pairing of cylinder and piston Piston must be paired with cylinder according to the below table The size mark of a piston is shown on the top surface of the piston and the size mark of a cylinder block is shown on the non operating side of the cylinder block The service parts of pistons are provided 116 5 Inspection and servicing o
120. foreign matter the cylinder boll head surface where it comes in contact with 3 cylinder head the block Assembly Camshaft side 3 Coat the head bolt threads and nut seats with lube oil 4 Use the positioning pins to line up the head gasket with the cylinder block Gear case side Head bolt tightening order 5 Match up the cylinder head with the head 3 cylinder head gasket and mount Nem kgfem Fiat Cylinder head bolt 27 0 33 0 53 9 57 9 tightening torque 2 8 3 4 5 5 5 9 113 5 Inspection and servicing of basic engine parts 5 2 6 Measuring top clearance 1 Place a high quality fuse 21 5 mm 10 mm long in three positions on the flat part of the piston head 2 Assemble the cylinder head gasket and the cylinder block and tighten the bolts in the specified order to the specified torque 3 Turn the crank in the direction of engine revolution and press the fuse against the piston until it breaks 4 Remove the head and take out the broke fuse 5 Measure the three positions where each fuse is broken and calculate the average Model Top clearance mm 3YM30 0 747 0 891 3YM20 0 697 0 841 5 2 Intake and exhaust rocker arms The wear of rocker arm and rocker arm bushing may change opening closing timing of the valve and may in turn affect the engine performance according to the extent of the change 1 Rocker arm shaft and rocker arm bushing
121. ge Pipe joint Clamp d Drain cock Rubber hose 148 Intake and exhaust system 7 Intake and exhaust system 7 1 Intake system Air enters in the intake silencer mounted at the end of the intake manifold rocker arm cover It is fed to the intake manifold and then on to each cylinder Exhaust gas goes into exhaust manifold in the fresh water tank mounted on the cylinder head outlet After cooling the exhaust gas enters the mixing elbow which is directly connected with the exhaust manifold and is discharged from the ship along with seawater When the inside of the intake manifold becomes dirty intake air resistance is increased and reduces engine power Periodically check the inside of the intake manifold In the same way the intake air silencer should be checked for dirt periodically and cleaned Care should also be taken to insure there is no air leakage Do not operate with the intake air silencer removed 7 1 1 Breather system A reductor to intake air system of blowby gas Emitting blowby gas is harmful to natural environment Therefore blowby gas reductor is adopted as breather system Some of the combustion gas passes through the clearance between cylinder and piston and flows to the crankcase This is said as blowby gas While it passes into cylinder head and rocker arm cover the blowby gas mixes with splash oil and becomes oil mist blowby gas The gas passes through the baffle plate i
122. ged quantity Remaining charge gravity of electricity Glass tube 3 Terminals Clean if corroded or soiled 4 Mounting bracket Repair or replace it if corroded Retighten if loosened 5 Battery appearance Replace the battery if cracked or deformed Clean with fresh water if contaminated How to read hydrometer 29 2 Inspection and adjustment 2 2 4 Inspection every 100 hours or two months Be sure to check the following points every 100 hours or two month operation whichever comes first Inspection Item Replace the engine lube oil Replace the lube oil in a sail drive 1 Replace the engine lube oil During the operation of an engine the oil deteriorates by the high temperature of the engine and is contaminated due to the wear of internal parts The lube oil must therefore be replaced periodically It is easiest and most effective to drain the engine lube oil after operation while the engine is still warm Beware of oil splashes if extracting the Lube oil while it is hot CAUTION 1 Remove the lube oil dipstick and also the oil filler cap at the top of the rocker arm cover Attach the Oil filler cap oil drain pump to the dipstick guide and drain off the lube oll Notice For easier draining remove the oil filler cap yellow at the top of the rocker arm cover When lube oil is absorbed without removing a oil filler cap negative pressure grows big in the crankcase and it may cause the
123. he cap plug so that the edge of the plug is 2 mm 0 0787 in below the cylinder surface ECC NNNM 105 5 Inspection and servicing of basic engine parts 5 1 5 Cylinder bore measurement Especially clean head surface cylinder bores and holes and check the below items after removing any carbon deposit and bonding agent a Appearance inspection Check if there is any discoloration or crack If crack is suspected perform color check Sufficiently clean the oil holes and check they are not clogged Cylinder bore and distortion Measure at 20 mm below the crest of the liner at 20 mm from the bottom end and at the center in two directions A and B as shown in the below figure Roundness Roundness is found as follows though it is the simple method Measure cylinder diameters of the A direction and the B direction on each section of a b and c Roundness is the maximum value among those difference values Cylindricity Cylindricity is found as follows though it is the simple method Measure cylinder diameters of a b and c sections in the direction calculate the difference P maximum value and minimum value of the measured diameters Cylinder bore measurement positions In the same way measure and calculate the difference in the B direction Cylindricity is the maximum value between those difference values mm Lii 1 x9 Cylinder roundness Inc
124. he cooling pine The temperature of it flows through the cooling pine The temperature of the fresh water is thus kept within a constant range by the thermostat es Seawater circuit Fresh water circuit Coolant recovery tank Heat exchanger 7 Mixing Nm Thermostat Fresh water pump Seawater pump 157 Cooling water line Mixing elbow From seacock Cooling water pipes 158 9 Cooling water system 9 Cooling water system 9 2 Seawater pump The seawater pump is driven by a V belt Gear case Spacer bolt Seawater pump Seawater pump 9 2 1 Specifications of seawater pump Performance Flow Min 4000 L h at engine speed 3600 9 2 2 Seawater pump disassembly Refer to 2 2 5 5 1 Remove the rubber hose from the seawater pump outlet and then remove the seawater pump assembly from the gear case cover 2 Remove the seawater pump cover and take out the O ring impeller and wear plate 3 Remove the mechanical seal side stop ring 4 Insert pliers from the drive gear long hole and remove the stop ring that holds the bearings 5 Lightly tap the pump shaft from the impeller side and remove the pump shaft bearings and drive gear as a set 6 Remove the oil seal and mechanical seal if necessary 159 9 Cooling water system 9 2 3 Seawater pump Inspection Refer to 2 2 4 5 1 Inspect the rubber impeller checking for splitting around
125. he crankshaft gear have been disassembled they have to be shrink fitted heat the crank shaft gear to 180 200 deg C in the hot oil and press fit to the crankshaft 2 Coat the crank journal part of the cylinder block and the upper main bearing metal with oil and fit the upper main bearing metal onto the cylinder block NOTE 1 Be sure not to confuse the upper and lower main bearing metals The upper metal has an oil groove 2 When mounting the thrust metal fit it so that the surface with the oil groove slit faces outwards crankshaft side Y Crankshaft 3 Coat the crankpins and the crank journals of the crankshaft with engine oil and place it on the upper main bearing metals NOTE 1 Position so that the crankshaft gear is on the gear case side 2 Be careful not to let the thrust metal drop Main bearing Base Main bearing bolt Removing main bearing and cranksha 89 5 Mounting the main bearing Coat the lower main bearing metal with engine oil and mount it to the main bearing cap NOTE 1 The lower main bearing metal does not have an oil hole 2 The base bearing thrust metal is fitted with the oil groove facing outwards 1 Coat the flange and the thread of the main bearing bolts with engine oil put them on the crankshaft journal and tighten the main bearing bolts to the specified torque Tightening torque Nem kgfem Main bearing bolt 75 5 81 5 77 8 3 NOTE 1 The main beari
126. ice standards 13 2 3 Cylinder block 1 Cylinder block uu Reference Inspection item Standard Limit page 3YM30 76 000 76 030 76 200 Cylinder inside diameter 0 00 2 3YM20 70 000 70 030 70 200 Cylinder bore 0 01 or less 0 03 2 Crankshaft page Bending 1 2 the dial gauge reading o 07 00 5 5 1 2 Memitiomem 1894808 3 Thrust bearing page Crankshaft side gap 0 111 0 250 0 30 5 5 1 4 204 13 Service standards 4 Piston and ring 1 Piston mm page Piston outside diameter 3YM30 75 965 75 975 75 920 Measure the direction vertical to the piston pin 3YM20 69 970 69 980 69 925 5 3 1 1 Gowadtome atom Upward from the bottom end of the piston between piston and cylinder 3YM20 00300050 Piston pin outside diameter 0 3 2 2 Piston ring mm page Top ring Groove width 1 550 1 570 _ Ring width 1 470 1 490 1 450 Ring gap 0 15 0 30 0 390 5 3 3 1 3YM30 second ring Groove width 1 580 1 595 1 695 Ring width 1 430 1 450 1 410 0 013 0 165 0 285 205 13 Service standards 3YM20 mm page Side Gearence 098030 Ring width 2 970 3 010 2 950 0 020 0 060 0 180 Ring gap 0 20 0 45 0 540 5 Connecting rod 1 Rod big end page 2 Rod small end page Bushing inside diameter 22 025 22 038 22 068 Pin outside diameter 21 991 22 000 21 963 5 4 3 1 Clearance 0 025 0 047 0 105
127. igned for the task at hand Incorrect usage of tools may result in damage to the engine and or serious personal injury 4 GENUINE PARTS and MATERIALS A CAUTION Genuine Parts Always use genuine YANMAR parts or YANMAR recommended parts and goods Damage to the engine shortened engine life and or personal injury may result 5 FASTENER TORQUE A WARNING Torquing Fasteners Always follow the torque values and procedures as designated in the service manual Incorrect values procedures and or tools may cause Ce damage to the engine and or personal injury 6 Electrical e Short Circuits Always disconnect the Negative battery cable before working on the electrical system An accidental short circuit may cause damage fire A SF and or personal injury Remember to connect the Negative battery A WARNING cable back onto the battery LAST WARNING Charging Batteries Charging wet celled batteries produces hydrogen gas Hydrogen gas is extremely explosive Keep sparks open flame and any other form of ignition away Explosion may occur causing severe personal injury Battery Electrolyte Batteries contain sulfuric acid Do NOT allow it to come in contact with clothing skin and or eyes severe burns will result 7 WASTE MANAGEMENT Observe the following instructions with regard to hazardous waste A CAUTION disposal Negligence of these will have a serious impact on environmental pollution
128. il leaks 1 Check the oil seal 2 Make sure that no nuts and bolts are loose area 3 Close the sea cock and fuel cocks 2 Especially the engine 4 When the temperature is expected to fall below installation bolts freezing drain the seawater 4 Drain from the 5 Turn off the battery switch seawater pump Checks after stop ping the engine 47 2 Inspection adjustment 2 7 Long storage Observe the following instructions when the engine is to be stored for a long period without operation 1 Do not drain cooling water in the cold season or before the long storage NOTICE Negligence of adding anti freeze will cause the cooling water remaining inside the engine to be frozen and expanded to damage the engine parts 2 Remove the mud dust and oil deposit and clean the outside 3 Perform the nearest periodic inspection before the storage 4 Drain or fill the fuel oil fully to prevent condensation in the fuel tank 5 Disconnect the battery cable from the battery negative terminal 6 Cover the silencer air cleaner and electric parts with PVC Poly Vinyl Chloride cover to prevent water and dust from depositing or entrance 7 Select a well ventilated location without moisture and dust for storage 8 Perform recharging once a month during storage to compensate for self discharge 9 When storing an engine for long time run the engine periodically according to the following procedure because the rust occurr
129. ily inspection and maintenance and as a text for engineering guidance Model 3YM30 has been used for the illustrations in this service manual but they apply to other models in the 3YM series engines California California Proposition 65 Warning Proposition 65 Warning Diesel engine exhaust and some of its Battery posts terminals and related ac constituents are known to the State of cessories contain lead and lead com California to cause cancer birth de pounds chemicals known to the State fects and other reproductive harm of California to cause cancer and repro ductive harm Wash hands after handling The contents of this service manual may not be copied or reproduced without permission CONTENTS As SCC Val 1 TIE KEIO VIEWS 1 12 2 1 3 Fuel oil lubricating oil and cooling water 4 Bs x cdot cc 4 jm SPA ECO a RUE 4 jose TE 5 eee NECEM 6 To OlagPalTiS sicuti aser 10 1 6 Exhaust gas EMISSION FEGUIATION tte i eb e ct ar gated teu iw cd eu du 12 1 6 1 Engine identification EPAIARB eei ih odo a dec Eee m idea ee osse 12 1 6 2 Exhaust gas emission standard cria
130. in 2 700 8 4 Load Terminal voltage V Electric current A 250 Torque Nem 8 3 MIN Revolutions min 1 000 12 3 2 Characteristics Standard Performance 12V 1 4kW Voltage V NENNEN Nmf NE um NEN EN EE WE E NE __ NEN EDU Np NNL NL LN a a 2 m NN ENS END XQ LIN iin Current 186 12 Electrical System 12 3 3 Structure 1 Disassembly drawing BY NS Armature O 187 12 Electrical System 2 Structure When the starting switch is turned on a magnet switch takes a voltage and a pinion projects The pinion engages with the ring gear of a engine and the engine is started Magnetic Switch Center Bracket A Torsion Spring Shift Lever Gear Case Pinion Shaft Armature Planet Gear Center Bracket P Rear Cover Yoke Internal Gear 12 3 4 Wiring diameter of a starting motor 1 When a starting switch is turned on a magnet switch is charged and a moving core is absorbed Starting switch and a pinion clutch is moved forward through a lever and the pinion engages with a ring gear Magnetic switch 2 When the pinion engages the ring gear because a main contact point is closed and the main electric current flows and pull coil is short circuited by the main contact point a
131. ing connectors 1 Drain the fuel tank Refer to 2 2 2 1 for the procedure 2 Replace the fuel filter Replace the fuel filter with new one at the specified interval before it is clogged with dust to adversely affect SG Air bleeding the fuel flow Also replace the fuel filter after the engine has fully been cooled 1 Close the fuel cock of the fuel tank 2 Remove the fuel filter using a filter wrench customer procured When removing the fuel filter hold the bottom of the fuel filter with a piece of rag to prevent the fuel oil from dropping 3 Clean the filter mounting surface and slightly apply fuel oil to the gasket of the new fuel filter 4 Install the new fuel filter manually turning until it clement comes into contact with the mounting surface and tighten it further to one turn using a filter wrench Tightening torque 20 24Nem Applicable fuel filter element Part No Filter 104500 55710 24341 000440 5 Bleed the fuel system Refer to 2 2 3 1 IMPORTANT Retaining ring Be sure to use genuine Yanmar part Super fine mesh filter Otherwise it results in engine damage uneven engine performance and shorten engine life Fuel filter 31 2 Inspection and adjustment 3 Replace the marine gear lube oil Refer to 2 2 2 3 for the procedure 4 Replace the engine lube oil filter Refer to 2 2 2 2 for the procedure 5 Check the impeller of the cooling water
132. k fitted onto the circumference of the flywheel and this ring gear serves to start the engine by meshing with the starter motor pinion The stamped letter and line which show top dead center of each cylinder are positioned on the flywheel circumference and by matching these marks with the arrow mark at the hole of the flywheel housing the rotary position of the crankshaft can be ascertained in order to adjust tappet clearance or fuel injection timing 5 8 1 Position of top dead center and fuel injection timing 1 Marking Injection timing marks T No 1 cylinder 2 Matching mark The matching mark is made at the hole of the flywheel housing Matching rae y 132 5 Inspection and servicing of basic engine parts 5 8 2 Damper disc 1 Spline part Whenever uneven wear and or scratches are found replace with new one 2 Spring Whenever uneven wear and or scratches are found replace with new one 3 Pin wear Whenever uneven wear and or scratches are found replace with new one 4 Whenever a crack or damage to the spring slot is found replace the defective part with new one 133 6 Fuel injection equipment 6 Fuel injection equipment 6 1 Fuel Injection pump governor Refer to the service manual of the YPES ML fuel injection pump for the disassembly assembly and adjustment procedure 6 1 1 Fuel system diagram Fuel nozzle Fuel injection pipe Fuel return pipe Fuel inj
133. keeps the water level from dropping due to discharge of steam when the pressure valve opens Action of pressure control valve Open at 82 109 kPa Pressure valve 2 0 84 1 11 kgf cm 0 82 1 09 bar Fresh water cooler Copper tube Open at 8 kPa Vacuum valve 2 0 08 kgf cm below 9 5 3 Pressure cap inspection Refer to 2 2 6 4 166 9 Cooling water system 9 5 4 Replacing filler neck 1 Take out the copper pipe inside the filler neck with striking a circumference with a driver and so on When the filler neck is removed remove it with being careful not to damage the fresh water cooler and scrap it 2 Clean both new filler neck and the insertion part of fresh water cooler Apply T7471 type activator or equivalent on both the surfaces and let it evaporate 3 Apply Loctite 603 improved 601 glue or equivalent on filler neck outside contour and press the filler neck into the fresh water cooler with the special tool 7 Press the filler neck Filler neck Fresh water cooler Loctite 601 4 To fix the filler neck on the fresh water cooler press the small copper tube inside the filler neck with the special tool Note The top of this tube should be under the sealing surface of the filler neck for the pressure cap 5 Fit the pressure cap on the filler neck Filler neck Part No Copper tube Part No 129673 44110 129673 44150 Refer to 4 2 2 for tool 1 and tool 2 Press the copper tube in the
134. ket clamp bolts or nuts and retighten as necessary 4 Check cable connection screw heads cable sleeves and other metal parts for rust or corrosion Clean off minor rust and wax or grease the parts Replace if the parts are heavily rusted or corroded 181 11 Remote contro Optional 11 4 Remote control adjustment 1 Shift lever adjustment Move the lever several times the movement of the clutch lever on the engine from forward neutral and reverse must coincide with the forward neutral and reverse on the control lever If they do not coincide adjust the fittings as necessary first engine side then controller side 2 Throttle lever adjustment Move the control lever all the way to full throttle several times and then return The throttle lever on the engine must lightly push against the idle switch when it is returned If it is property adjusted the knob can be easily pulled out when the lever is in the neutral position and will automatically return when the control lever is brought back to the neutral position If the control lever presses too hard against the knob it may not return automatically in which case the cable end must be adjusted as explained for the clutch The knob cannot be pulled out when the lever is not in the neutral central position 182 12 Electrical system 12 Electrical system 12 1 Electrical system B type panel _ Neutral safety switch Fitting to marine gear Alternator Battery
135. l temperature is below 15 C or above 50 C Bilge water left in the hose or inside the pump can freeze and care should be taken to see that any excess bilge is completely discharged If bilge water should freeze and care should be taken to see that any excess bilge is completely discharged If bilge water should freeze inside the hose or pump it should be completely melted before starting up the pump When the temperature inside the pump is low it will take a longer time for the pump to operate 0 5 10 seconds Keep the pump in a dry place away from rain or other water Use the regulation hose do no use thin vinyl hose or hose which is not heat resistant The pump cannot be used to drain off rainwater or large quantities of flood water This pump can be operated continuously for a period of 10 minutes Do not use the pump for showering If the pump outlet is deformed for showering the increase in water pressure will increase the load on the motor and cause motor seizure When sludge has built up in the bilge to be drained position the strainer about 20 cm above the sludge When the pump is stopped be sure there is sludge remaining inside the pump housing The specific gravity for the battery fluid is 1 25 Refer to your local dealer for impeller replacement The local dealer will perform the following The impeller replacement kit includes one impeller and 3 films for adjusting the side gap If after replacing the impeller the pump
136. lash Crankshaft gear Direction of rotation Gear train 12 Mounting the lube oil pump Tighten the lube oil pump with bolts to the gear case Cover Lube oil applied Nem kgfem Ae Inner rotor Tightening torque 5 9 7 9 0 6 0 8 Gear case w NOTE e 1 Before installing the outer inner rotors coat them with lube oil 10W30 lube oil 2 Assemble the rotor so that the mark of the rotor may come to the cover side 3 Confirm that the rotor rotates smoothly 93 4 Disassembly reassembly 13 Mounting the oil seal and gear case cover 1 Replace the used oil seal with a new one when the Crankshaft gear case cover is disassembled pulley 2 Insert a new oil seal by using the oil seal insertion aia tool on the position of the gear case cover end face 65 0 1 mm distance from the end of the cylinder 61 5 2 block Refer to the right figure 3 Apply lithium grease to the oil seal lips V 4 When wear is found on the seal contact part of a crankshaft pulley replace the pulley with a new one Carefully install the pulley so as not to Ko damage the oil seal 5 Apply the liquid gasket to the gear case cover seal Gear case cover Gear case Position the two knock pins and tighten the bolts of the gear case cover NOTE Trim the liquid gasket if it protrudes onto the oil pan mounting surface Oil seal 14 Mounting the lube oil inlet pipe Mount
137. ld season the LLC is especially important Without LLC cooling performance will decrease due to scale and rust in the cooling water line Without LLC cooling water will freeze and expand to break the cooling line Be sure to use the mixing ratios specified by the LLC manufacturer for your temperature range e Do not mix different types brand of LLC chemical reactions may make the LLC useless and engine trouble could result e Replace the cooling water every once a year When handling Long Life Coolant Antifreeze wear protective rubber CAUTION gloves not to touch it If LLC gets eyes or skin wash with clean water at ONCE 1 4 Engine outline 1 3YM30 with KM2P 1 marine gear DETAIL OF COUPLING A 463 618 U MIXING ELBOW MOUNTING BLOCKS ID 75 ADJUSTABLE 185 c oe 12101 do 185 U MIXING ELBOW OPTIONAL N Z 7 CE O r e IM T b Bru D uui Yoo J Lele r D VTA L UPS A ey ERN 19702275 o 5 V lt e See qi med R4 Lom f _ Cf Lot gt JA 1 1 6 715 5 MOUNTING BLOCKS ID 100 DIRECTION OF ROTATION DETAIL OF PULLEY B FUEL OVERFLOW 8 0 FUEL INLET 08 3 SEAWATE
138. ler shaft alignment O Check for leakage of water and oil After starting Adjust intake exhaust valve clearance 7 For EPA requirements see also 1 5 in chapter 1 Whichever comes first 16 2 Inspection adjustment 2 2 Periodic inspection and maintenance procedure 2 2 1 Check before starting Be sure to check the following points before starting an engine every day Inspection 1 Visual inspection of engine outside Check the fuel level and refill 1 Visual inspection of engine outside If any problem is found do not use before the engine repairs have been completed Oil leak from the lubrication system Fuel leak from the fuel system Cooling water leak from the cooling water system e Damaged parts Loosened or lost bolts Fuel coolant tank rubber hoses V belt cracked loosened clamp 2 Check the fuel level and refill Check the remaining fuel oil level in the fuel tank and refill the recommended fuel if necessary 3 Check the lube oil level Crankcase Marine gear 1 Checking engine lube oil level Sy Filler port a Check the lube oil level of a engine with a dipstick Insert the dipstick fully and check the oil level The oil shall not be contaminated heavily and have appropriate viscosity No cooling water or diesel fuel shall be mixed Standard The level shall be between the upper and lower limit lines on the dipstick Dipstick Upper limit
139. lination 0 01 or less 106 superior resistance to heat and wear is fitted the seats and the area between the valves is cooled by The cylinder head is of 3 cylinder integral construction mounted with 14 bolts Special alloy stellite with the water jet 5 Inspection and servicing of basic engine parts 5 2 Cylinder head Rocker arm shaft alve guide Valve spring tem seal 9 gt oriek Qo Spring retainer AS E D a m gt on t 9 9 99 7 D aie SD gt Sw 8 Aam das D 153 Suction valve Exhaust valve 107 5 Inspection and servicing of basic engine parts 5 2 1 Inspecting the cylinder head The cylinder head is subjected to very severe operating conditions with repeated high pressure high temperature and cooling Thoroughly remove all the carbon and dirt after disassembly and carefully inspect all parts 1 Distortion of the combustion surface Carefully check for cylinder head distortion as this leads to gasket damage and compression leaks 1 Clean the cylinder head surface 2 Place a straight edge along each of the four sides and each diagonal Measure the clearance between the straight edge and combustion surface with a feeler gauge Straight edge Thickness gage Distortion at combustion surface Gylinder head 0 15 distortion 2 Checking for cracks in the combustion surface Remove the fuel i
140. ms careful study and understanding of the engine mechanism combined with good common sense will help you to rapidly become more expert at troubleshooting 50 LS TROUBLE AND TROUBLESHOOTING Countermeasure m 4 o 2 49 O Countermeasure 1 1 Add fuel oil and prime l 2 Bleed air 3 Remove water from drain and fuel oil system and prime 4 Check and make necessary repairs 5 6 Replace 7 Check and make necessary repairs 1 Fuel oil supply cut off 1 Insufficient oil in fuel oil tank TE 4 Fuel oil cock closed 2 Air in fuel oil system and fuel injection pump M 3 Water in fuel oil tank 5 Clogging of fuel oil filter Chart 1 THE ENGINE SUDDENLY STOPS 11 1 Replace 11 2 Clean carefully to insure good working order Governor trouble 1 Damage to governor spring AS gS SO o o 2 Sticking of governor sleeve 6 Damage fuel oil system 7 Problem with fuel feeding pump 8 1 Loose lube oil pressure adjustment valve 3 Leakage from lube oil safety valve 4 Trouble with lube oil pump 9 5 7 24 4 2 Clogging of lube oil filter oil pressure Emergency stoppage device in operation 1 Tighten adjustment valve 1 2 Clean 1 3 Tighten safety valve 1 4 Remove and repair or replace 5 Return to original condition THE ENGIN
141. n timing incorrectly installed on the engine he roller holder assembly s Replace the assembly roller or pin is worn excessively he plunger is worn excessively Replace the distributor assembly 3 The nozzle does not operate 1 The nozzle or nozzle holder is Inspect then repair or replace functioning incorrectly 4 The engine operates but only he pipe s to the injection Clean or replace the pipe s or fuel for short time pump is blocked or the fuel filter filter is clogged he fuel oil contains air or water Bleed of air or replace the fuel oil The feed pump s delivery Repair or replace quantity or pressure is insufficient 5 The engine knocks he injection timing is too Readjust the timing advanced The nozzle or nozzle holder is Inspect then repair or replace functioning incorrectly 59 3 Troubleshooting The engine exhaust contains smoke and the engine knocks The engine output is unstable Insufficient output 1 The injection quantity is insufficient 2 The injection timing is too advanced and the engine is knocking 3 The injection timing is too retarded and the engine is overheating or the exhaust contains smoke he injection timing is incorrect 2 nozzle or nozzle holder is functioning incorrectly he injection quantity is excessive The fuel filter element is clogged and fuel oil delivery is poor he amount of fuel or pressure delivered by the feed
142. nator B terminal pulse 1 Battery capacity Battery capacity 5 hours rating 12V 64 or more type 95D31L equivalent 2 Battery cable Wiring must be performed with the specified electric wire Thick short wiring should be used to connect the battery to the starter Using wire other than that specified may cause troubles The overall length of the wire between the battery terminal and the starter B terminal and between the battery terminal and the starter E terminal should be determined according to the following table Voltage system wiring voltage cross section Allowable overall length Upto25m 0 2 V or less 100A Up to 5 m Note Excessive resistance in the key switch circuit between the battery and start S terminals can cause improper pinion engagement To prevent this follow the wiring diagram carefully 185 12 Electrical System 12 3 Starting motor A starting motor turns the ring gear installed on a engine flywheel by the pinion while overcoming resistance such as the compression pressure and the friction loss of the engine and makes the engine start 12 3 1 Specifications YANMAR Part No 129608 77010 HITACHI Model No 5114 817 Nominal power kW Nominal voltage V Rating sec Direction of rotation Clockwise Looking from the pinion side Number of pinion teeth Weight kg 11 3 0 No load Terminal voltage V 11 Electric current 90 MAX Revolutions m
143. nctdczemdetdtecuedieset desde a 46 26 1 Preliminary precautlonS 46 2 0 2 ieee 46 2 6 3 Check points and precautions during 47 2 1 48 S zc dedans rin ie een oe ena ees One a ete eee roe 49 3 1 Preparation before troubleshooting 49 3 2 Quick reference chart for troubleshooting 50 3 3 Troubleshooting Concerning engine and fuel injection equipment 59 3 4 Troubleshooting by measuring compression pressure 62 4 DISASSEMDIY and reassermibly 64 4 1 Disassembly reassembly precautions 64 4 2 Disassembly and reassembly tools etin secu a De 65 42 Moro C 65 42 2PC NANa TOOS isin Lo 68 4 2 3 Measuring Ist ulTiellls S ti ee eher
144. nd it stops being charged with electricity the pinion is kept at the position by a holding coil during the start 3 When the starting switch is turned off the main contact point becomes open and the pinion clutch is returned to the stop position by a return spring Starting motor 188 12 Electrical System 12 4 Alternator standard 12V 60A The alternator serves to keep the battery constantly charged It is installed on the cylinder block by a bracket and is driven from the V pulley at the end of the crankshaft by a V belt The type of alternator used in this engine is ideal for high speed engines with a wide range of engine speeds It contains diodes that convert AC to DC and an regulator that keeps the generated voltage constant even when the engine speed changes 12 4 1 Specifications Yanmar code 128271 77200 2 Direction of rotation viewed from pulley end Rated speed Operating speed Speed for 13 5V at 20 C Output current for 13 5V 56A or more 5000 Regulated voltage 14 4 0 3V at 20 C voltage gradient 0 01V C 189 12 Electrical System 12 4 2 Structure 1 Disassembly drawing 12V60A alternator 2 Structure Bracket i I Stator Rotor Rectifier assembly assembly assembly Bracket Jl a d 4 EF Packing oaen Nut all bearing LEAL ME 190 12 Electrical System 12 4
145. nd lubricating oil a Fuel The diesel fuel oil BS 2869 A1 or A2 Cetane No 45 min b Lube oil API grade class CD 3 Do not remove the caps restricting injection quantity and engine speed 4 Perform maintenance without fail Note Inspections to be carried out by the user and by the maker are divided and set down in the List of Periodic Inspection on the operation manual and should be checked carefully EPA allows to apply the maintenance schedule for the emission related parts as follows Maintenance period Adjustment cleaning repairs for fuel Fuel nozzle cleaning nozzle fuel pump and electronic control Power Rating unit etc kW lt 19 Every 1500 hours Every 3000 hours 19 kW lt 37 Every 1500 hours Every 3000 hours 13 1 5 Quality guarantee period for exhaust emission related parts For exhaust emission related parts follow the inspections outlined in the List of Periodic Inspections on the operation manual and use the table below to carry out inspections based on operation hours or time in years Whichever comes first is the guarantee period Power Rating For fuel nozzle fuel pump kW lt 19 1500 hours or 2 years 19 S kW lt 37 3000 hours or 5 years The specific emissions related parts are a Fuel injection nozzle b Fuel injection pump 14 2 Inspection adjustment 2 Inspection and adjustment 2 1 Periodic maintenance schedule The engine periodic insp
146. nds when no water is being drawn up When the pump has not been used for a long period of time the inside of the pump will be dry and drawing ability will be lowered Before reusing clean the inside of the pump or prime it to insure that it is wet and check to be sure that the pump is then operating correctly When charging the diesel engine oil wait a period of 30 minutes or longer from the time of stopping oil temperature 20 70 C Refrain from operation when the temperature is below 15 C or above 50 C When the bilge inside the pump or hose freezes completely melt the water with a steaming towel before beginning operation When the temperature inside the pump is low it will take a longer amount of time for the pump to drain off the bilge The impeller replacement kit includes one impeller and 3 washers for adjusting the side gap If after replacing the impeller the pump does not drain place side gap adjustment washers underneath the bottom plate to adjust Select the number of washers used in accordance with the following When the pump is draining the electric current load is about 5A When there are too many washers the electric current value will be too great and will blow a fuse 171 9 Cooling water system 7 The pump cannot be used to drain off rain water or large amounts of flood 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 befor
147. ned last time What kind of problem was there on the engine last time and what kind of maintenance was dane Hear the occurrence phenomenon from the operator of the engine in detail SW1H of the occurrence phenomenon the investigation of when when where where who who what what why why and how how When did the trouble happen at what kind of time Was there anything changed before the trouble Did the trouble occur suddenly or was there what or a sign Was there any related phenomenon e g Poor exhaust color and starting failure at the same time 4 After presuming a probable cause based on the above investigation investigate a cause systematically by the next troubleshooting guide and find out the cause of sincerity 49 3 Troubleshooting 3 2 Quick reference chart for troubleshooting It is important to thoroughly under stand each system and the function of all of the parts of terse systems A careful study of the engine mechanism will make this possible When problems arise it is important to carefully observe and analyze the indications of trouble in order to save time in determining their cause Begin by checking the most easily identifiable causes of difficulty Where the cause of the difficulty is not readily apparent make a thorough examination of the system from the very beginning proceeding until the point of trouble can be determined While experience is an important factor in pinpointing engine proble
148. ng cap should be mounted with the arrow on the cap pointing towards the flywheel 2 Make sure to have the correct cylinder alignment number 2 Measure the crankshaft side clearance mm Standard Limit 0 133 0 233 0 28 3 Make sure that the crankshaft rotates smoothly and easily Crankshaft side clearance 6 Mounting the flywheel housing 1 Replace the used oil seal with new one Press fit the oil seal in the flywheel housing and coat the lip of the oil seal with engine oil 2 Apply the liquid gasket on the mounting surface of the flywheel housing and mount the flywheel housing to the cylinder block while matching up with the knock pins NOTE Be careful that the liquid gasket does not protrude onto the oil pan mounting surface 90 4 Disassembly and reassembly Upper main bearing metal Oil hole Groove Main bearing cap Wi Positioning number of reassembling x Journal bearing cap Flywheel housing Liquid gasket Oil seal Cylinder block 4 Disassembly and reassembly 7 Turning the engine over Stand up the engine on the 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 NOTE 1 When mounting the gear case match up the two knock pins of the cylinder block 2 Be sure to coat the O ring for the cylinder block lube oil line with grease when ass
149. ng torque Nem 1 Connecting rod bolt 22 6 27 5 2 3 2 8 NOTE If a torque wrench is not available match up with the mark made before disassembly 10 Mounting the camshaft gt 7 4 Disassembly reassembly Piston ID mark OO T OL Os Nozzle side Embossed mark Flywheel side 1 If the camshaft and the camshaft gear have been disassembled shrink fit the camshaft and the camshaft gear heat the camshaft gear to 180 220 deg C in the hot oil and press fit NOTE When mounting the camshaft and the camshaft gear be sure not to forget assembly of the thrust metal Also make sure they are assembled with the correct orientation 2 Coat the cylinder block camshaft bearings and camshaft with engine oil insert the camshaft in the cylinder block and tighten the thrust metal bolts 3 Measure the camshaft side gap mm Siamdam on 4 Make sure that the camshaft rotates smoothly 92 Camshaft side gap 4 Disassembly reassembly 11 Mounting the idling gear 1 Mount the idling gear so that the mark of the idle gear shaft upward Oil hole Idle gear shaft 2 Align the A and match marks of the idle gear with the match marks of the crankshaft gear and Fuel injection pump the camshaft gear drive gear Camshaft gear 3 Measure the idle gear camshaft gear and crankshaft gear backlash mm Back
150. njection nozzle intake and exhaust valve and clean the combustion surface Check for discoloration or distortion and conduct a color check test to check for any cracks 3 Checking the intake and exhaust valve seats Check the surface and width of the valve seats If they are too wide or if the surfaces are rough correct to the following standards Seat angle Eat Seat width Standard 108 5 Inspection and servicing of basic engine parts 5 2 2 Valve seat correction procedure The most common method for correcting unevenness of the seat surface with a seat grinder is as follows 1 Use a seat grinder to make the surface even As the valve seat width will be enlarged first use a 70 grinder then grind the seat to the standard dimension Seat grinder with a 15 grinder NOTE When seat adjustment is necessary be sure to check the valve and valve guide If the clearance exceeds the tolerance replace the valve or the valve guide and then grind the seat Seat width 2 Knead valve compound with oil and finish the valve seat with a lapping tool 3 Final finishing should be done with oil only Lapping tool Use a rubber cap type lapping tool for cylinders without a lapping tool groove with oil only NOTE Clean the valve and cylinder head with light oil or the Valve lapping tool equivalent after valve seat finishing is completed and make sure that there are no grindings remaining NOTE 1 Insert adj
151. nment 1 The rubber tension of the flexible engine mounts is lost after many hours use This leads to a drop in vibration absorption performance and also causes centering misalignment of the propeller shaft Refer to 5 Flexible Engine Mount in the installation manual for pleasure boat use Notice Be sure to replace the Yanmar flexible engine mounts every 1000 hours or 4 years whichever comes first 2 After replacing the flexible engine mounts check unusual noise and vibration of the engine and the boat hull with increasing the engine speed gradually and lowering it 3 If there is unusual noise and or vibration adjust the propeller shaft alignment Refer to 6 4 5 Centering the Engine in the installation manual for pleasure boat use 43 2 Inspection and adjustment 2 3 Adjusting the no load maximum or minimum speed 1 After warming the engine up gradually raise the speed and set it at the no load maximum speed Remote High speed 2 If the no load maximum speed is out of the 1 See standard adjust it by turning the high idle limiting Band bolt 3 Then set the no load minimum speed by adjusting Neg the low idle limiting bolt ASA Ji ez vire Standards min Cable 3850425 850425 jn 2 4 Sensor Inspection 2 4 1 Oil pressure switch Oil pressure switch Cylinder block X flywheel side Disconnect the connector from the oil pressure switch Keep the voltameter probes in contact with th
152. nside a rocker arm cover And it passes through a diaphragm assy and reaches a intake silencer The gas is reduced in the combustion chamber Pressure inside a crankcase is controlled by the function of the diaphragm assy and suitable amount of blowby gas is reduced in intake air system Disassemble When a rocker arm cover is taken off check whether oil or the like enter the diaphragm space from a small hole on the side of a diaphragm cover or not without disassembling the diaphragm 149 Intake pipe Intake silencer Diaphragm cover 5 Spring amp Center plate 2 Diaphragm Rocker arm cover Breather P d Baffle Intake manifold Breather system component Intake and exhaust system NOTICE 1 When a diaphragm is damaged pressure control inside the crankcase becomes insufficient and troubles occur 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 When pressure progresses in the crank case too much due to the wrong operation of the diaphragm and so on it is considered that oil leakage from the joint of a oil pan a oil seal and so on will occur When a diaphragm is damaged blowby is discharged from the breathing hole on the side of diaphr
153. nside diameter standard dimensions assume a pressure fit 2 Replacing the valve guide Use the insertion tool and tap in the guide with a Tool mallet The intake valve guide and exhaust valve guide are of different dimensions Valve guide 3 Valve guide projection Cylinder head a Put liquid nitrogen or ether or alcohol with dry ice added in a container and put the valve guide for replacement in it for cooling Then insert it in with a valve guide inserting tool CAUTION Do not touch the cooled valve guide with bare hands to avoid skin damage b Check the inside diameter and finish to the standard inside diameter as required with a reamer Check the projection from the seat surface of the valve spring Valve guide projection mm 9 8 10 0 Stem seal Clearance Valve guide Valve guide projection Stem seal projection 111 5 Inspection and servicing of basic engine parts 4 Valve stem seals The valve stem seals in the intake exhaust valve guides cannot be re used When they are removed be sure to replace them When assembling the intake exhaust valves apply an adequate quantity of engine oil on the valve stem before inserting them Valve stem seal inserting tool Exhaust stem seal is marked by yellow Intake stem seal is not marked a Apply lube oil to the lip b Push with the inserting tool for installation Measure and check the projection of valve stem seal to keep proper clearance
154. nuts for the fuel pump and remove the fuel injection pump and O ring from the gear case Fuel injection pump Pump flange ail Don t disassemble 1 Fuel pump drive gear Pump flange bolt Drive gear nut 83 4 Disassembly reassembly 17 Removing the rocker arm shaft assembly 1 Loosen the hexagon head bolts and remove the rocker arm cover Note Don t loosen the cross recessed head bolts on the rocker arm cover when removing the rocker arm cover Don t disassemble the cross recessed hand bolts 2 Remove the bolts s for the rocker arm shaft support and remove the entire rocker arm shaft assembly 3 Pull out the push rods 18 Removing the cylinder head 1 Loosen the cylinder head bolts with a torque wrench and remove the cylinder head 2 Remove the cylinder head gasket 19 Removing the marine gearbox Loosen the bolts for the clutch case flange and remove the gearbox assembly 20 Removing the flywheel Loosen the flywheel bolts and remove the flywheel Flywheel Note Flywheel housin Be careful not to scratch the ring gear e H Removing flywheel 84 4 Disassembly reassembly 21 Turning the engine over 1 Place a wood block of appropriate size on the floor and stand up the engine on the flywheel housing 2 Remove the engine mounting feet 22 Removing the crankshaft V pulley Loosen the bolt tightening the crankshaft V pulley and remove the crankshaft V pulley
155. nventionally Three Bond TB1104 gray or Three Bond TB1102 yellow is used for paper packing though single use of one of these bounds is not effective 4 If conventional packing is used do not use liquid packing Oil pan mating surface 6 uc on Buildup 1212 76 4 Disassembly and reassembly 4 3 Disassembly and reassembly 4 3 1 Disassembly Preparation on a boat For engines mounted in an engine room of a ship remove the piping and wiring connecting them to the ship 1 Remove the remote control cable from engine and marine gearbox 2 Unplug the extension cord for the instrument panel from the engine 3 Remove the wiring between the starting motor and the battery 4 Remove the exhaust rubber hose from the mixing elbow 5 Remove the rubber hose connecting the coolant recovery tank to the filler cap 6 Remove the seawater inlet hose for the seawater pump after making sure the seacock is closed 7 Remove the fuel oil inlet rubber hose from the fuel feed pump 8 Remove the body fit reamer bolts and disassemble the propeller shaft coupling and thrust shaft coupling 9 driven coupling is mounted to the front drive coupling disassemble 10 Remove the flexible mount nut lift the engine and remove it from the engine base Leave the flexible mount attached to the engine base Disassembling an engine a workshop 1 Drain cooling water Refer to 2 2 5 6
156. oat the flywheel bolts threads with engine oil 2 Align the positioning pins and tighten the flywheel bolts to the specified torque Tightening torque Nem kgfem Flywheel bolt 80 4 86 4 8 2 8 8 95 LTR y 7 m 73 C A z NS PD pet 2 S o NOW RX 4 Disassembly reassembly 19 Mounting the marine gearbox 1 Mount the damper disk to the flywheel Align the damper disk with the input shaft spline and insert 2 Mount the marine gearbox to the flywheel housing 20 Mounting the cylinder head 1 Put the cylinder head gasket on the cylinder block aligning it with the cylinder block positioning pins 2 Lift the cylinder head horizontally and mount it aligning with the cylinder head gasket 3 Coat the flange part and thread of the cylinder head bolt with engine oil and lightly tighten the bolts in the specified order first Then tighten completely in the same order Fuel pump side Head bolt tightening order Flywheel side Gear case side Tightening torque Nem kgfem Cylinder head 24 32 53 9 57 9 bolt 2 5 3 3 5 5 5 9 21 Mounting the rocker arm shaft assembly and pushrods Rocker arm Adjusting screw Valve 1 Fit the pushrod to the tappet clearance 7 XI Lock nut 2 Coat the top of the pushrod and the adjusting screw of the rocker arm with engine oil Apply lube oil to the screw and lock nut Mount the rocker arm shaft as
157. ol is accomplished through Engine Modification EM Design e The tamper resistance device is installed with EPA ARB certified 3YM30 series engines to prevent illegal change of fuel injection volume and high idling speed Fuel injection volume cap type High idling speed cap type Engine family name as assigned by EPA ARB identifying engine family group 4YDXM1 64D3N and this identifies YYDXM1 64D3N and this identifies 4 YDX M 1 11 P3 N 4 2004 Method of air aspiration 2005 Number of cylinders 6 2006 Combustion chamber design 7 2007 Displacement liter Marine engine Yanmar 2004 Model Year 2 Label location EPA ARB certification plate 1 General 1 6 2 Exhaust gas emission standard EPA ARB 8 kW 19 2000 9 6 6 19 lt kW 37 1999 Note 1 The transit smoke ACC LUG PEAK is not applicable 2 EPA recommended fuel is used 3 The ARB emission standard is the same as the EPA s 4 As for Model year the year which a regulation is applicable to is shown 1 6 3 Guarantee conditions for emission standard EPA ARB In addition to making sure that these conditions are met check for any deterioration that may occur before the required periodic maintenance times 1 Requirement on engine installation condition a Air intake negative pressure kPa mmAq Permissible 3 9 400 b Exhaust gas back pressure kPa mmAq Permissible 14 7 1500 2 Fuel oil a
158. olant Drain cock for coolant Drain cock for seawater 3 Remove the filler cap of the fresh water cooler by turning the cap counterclockwise 1 3 of a turn Filler cap Notches Coolant tank 4 Pour cooling water slowly into the coolant tank so that air bubbles do not develop Pour until the water overflows from the filler port If the filler is loose hot steam and water will spout out which A WARNING cause burns e rmn 33 2 Inspection adjustment 5 After supplying cooling water fit the filler cap and tighten it firmly To reassemble the cap align the tabs on the bottom of the cap with the notches on the filler port and turn clockwise 1 3 of a turn 6 Remove the coolant recovery tank cap and fill with coolant mix to the lower limit Replace the cap to the coolant recovery tank Coolant recovery tank capacity 0 8 L 1 7 pints 7 Check the rubber hose connecting the coolant recovery tank to the fresh water cooler Be sure the hose is securely connected and there is no looseness or damage When the hose is not watertight an excessive amount of cooling water will be used To fresh water 227 9 Cap cooler Rubber hose 7 Clean the element of the air intake silencer 1 Inspection of the intake silencer Occasionally disassemble the intake silencer remove the polyurethane element and inspect it Because the element filters the air if it is used over a long period of
159. on the flywheel housing 33 Mounting the intake silencer Mount the intake pipe on the intake manifold inlet coupling and tighten the intake silencer to the cylinder head Cylinder head Intake silencer 101 4 Disassembly reassembly 34 Mounting the fuel filter and fuel pipe 1 Mount the fuel filter on the bracket which is tightened to the cylinder head 2 Mount the fuel pipe fuel feed pump fuel filter fuel filter fuel injection pump Cylinder head Fuel pipe Bracket Fuel filter Fuel injection pump 35 Electrical Wiring Connect the wiring to the proper terminals observing the color coding to make sure the connections are correct 36 Installation in a boat and completion of the piping and wiring Mount the engine on the engine bed in the engine room of a boat after all engine assembly has been completed Connect the cooling water pipes fuel pipes other pipes on the boat and the exhaust hoses Connect the battery instrument panel remote control cable and other wiring 37 Filling with lube oil Fill the engine with lube oil from the filler port on top of the gear case or the rocker arm cover Fill the marine gearbox from the filler port on top of the clutch case 102 4 Disassembly and reassembly 38 Filling with cooling water 1 Open the coolant fresh water tank cap and fill with water Engine capacity L quart 3YM30 4 9 5 2 3YM20 4 1 4 3 2 Fill with water until th
160. ooling water temperature is too high VI Cooling water pressure is too low 1 Adjust the amount of returning water or Open closed parts Clean check the cooling water pump and lap valves Check pump and repair Check pump and repair 2 Reduce load Adjust amount of returning water Lessen lift or replace pump IV 3 Clean and adjust Clean Check suction opening Check suction opening Eliminate causes for high cooling water Reduction load temperature and constrict VI 6 Check and repair 4 LLI O 4 v 2 Overloading Countermeasure Bulooysajqnol 3 Troubleshooting 3 3 Troubleshooting Concerning engine and fuel injection equipment The engine does not operate 1 Fuel oil is not injected from the There is no fuel oil in the fuel Supply fuel and bleed the system injection pump tank The fuel line from the fuel tank Clean or replace is blocked The fuel is clogged Clean or replace There is air in the fuel filter or Bleed the system the pump chamber The accelerator linkage is not Repair properly connected The magnet valve wiring is Repair or replace broken or its armature is sticking The feed pump blades are Repair or replace sticking and therefore not operating The drive gear or woodruff key Replace is broken 2 Injection timing is incorrect The drive gear or belt Repair connections are incorrect he injection pump is Repair and adjust injectio
161. oughly remove rust preventive oil before using the nozzle Note that a new nozzle is coated with rust preventive oil and is pasted with the seal peel to shut off outer Nozzle valve sliding check by gravity air 40 2 Inspection adjustment 4 Nozzle punch mark NP DN O P D 159 D Design code Throttle type Size size P Injection angle Type pintle type BOSCH Identification number 3 Check the impeller of the cooling water pump seawater pump The impeller must be replaced with new one periodically every 1000 hrs or four years whichever comes first Refer to 2 2 5 5 for the procedure 4 Clean amp check the water passages When it is used for a long time cleaning of the cooling water passages is periodically necessary because trash scales rust and so on collect in the cooling water passages and the cooling performance declines a Cleaning and inspection of cooling water rubber hoses 1 Remove the cooling water rubber hoses for the fresh water line and the seawater line 2 Check the dust and trash inside the hoses If necessary clean it 3 Check the crack and the deterioration of the rubber hoses If necessary replace with new ones 4 Replace the used hose clips with new ones if necessary b Heat exchanger inspection 1 Cooler core inspection a Inspect the inside of the tubes for rust or scale buildup from seawater and clean with a wire brush if necessary NOTE Disassemble and
162. peed 3860 30 66 7 L min or more 162 9 Cooling water system 9 3 3 Fresh water pump disassembly 1 Do not disassemble the fresh water pump 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 3 When the fresh water pump and pump body and or fresh water pump and pump plate are disassembled retighten to the specified torque Tightening torque for pump 392 785 Necm setting bolts 40 80 kgfe cm 9 3 4 Fresh water pump inspection 1 Bearing unit inspection Rotate the impeller smoothly If the rotation is not smooth or abnormal noise is head due to excessive bearing play or contact with other parts replace the pump as an assembly 2 Impeller inspection Check the impeller blade and replace if damaged or corroded or if the impeller blade is worn due to contact with pump body 3 Check the holes in the cooling water and bypass lines clean out any dirt or other foreign matter and repair as necessary 4 Replace the pump as an assembly if there is excessive water leakage due to mechanical seal or impeller seal wear or damage 5 Inspect the fresh water pump body clean off scale and rust and replace if corroded 6 Measure the outside clearance between the impeller and the pump body by pushing the impeller all the way towards the
163. pers 0 05 mm 0 150 mm Micrometer 0 01 mm 0 25 mm 25 50 mm 50 75 mm 75 100 mm 100 125 mm 125 150 mm Cylinder gauge 0 01 mm 18 35 mm 35 60 mm 50 100 mm Thickness gauge 0 05 2 mm S G Torque wrench 128 Nem 0 13 kgf m Nozzle tester 0 49 Mpa 0 500 kgf cm 71 4 Disassembly reassembly 2 Use of tools No Name of tool Illustration 1 Dial gauge Measures shaft bending distortions of levelness and gaps lt gt SS 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 Micrometer Measures the outer diameter of the crank shaft piston piston pin etc cylinder liner and rod metal Vernier calipers Measures various outer diameters thicknesses and widths Depth micrometer Measures sinking of valves Measures distortion in position of springs and perpendicularity of parts r Cylinder gauge Measure the inner diameter of the 72 4 Disassembly and reassembly Name of tool V Block Measures shaft distortion 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 12 Cap tester Check for leakage in the fresh water system Battery current tester Checks density of antifre
164. r with a micrometer The oil clearance shall be calculated by subtracting the measured camshaft outside diameter from the inside diameter of the camshaft bearing or bushing The camshaft bushing at gear case side is measured with a cylinder gage after insertion to the cylinder Replace if they exceed the limit or are damaged Gear side Bushing I D 40 000 40 075 40 150 Camshaft 49 940 39 960 39 905 O D 0 040 0 135 0 245 clearance Intermediate Bushing 1 0 40 000 40 025 40 100 Camshaft outside diameter position d n 39 910 39 935 39 875 Oil 0 065 0 115 0 225 clearance Flywheel Bushing 1 0 40 000 40 025 40 100 side 39 940 39 960 39 905 O D 0 040 0 085 0 195 clearance 4 Bending of the camshaft Support both ends of the camshaft with V blocks place a dial gauge at the central bearing areas and measure bending Replace if excessive NOTE The reading on the dial gauge is divided by two to obtain the camshaft bend mm Camshaft bend 0 02 or less 0 05 Camshaft bend 129 5 Inspection and servicing of basic engine parts 5 6 2 Tappets 1 The tappets are offset to rotate during operation and thereby prevent uneven wearing Check the contact of each tappet and replace if excessively or unevenly worn NOTE When removing tappets be sure to keep them separate for each cylinder and intake exhaust valve Abnormal contact Normal contact surface surface Tappet
165. ray on the red penetrant and allow 5 10 minutes for penetration Spray on more red penetrant if it dries before it has been able to penetrate 5 Spray on developer Remove any residual penetrant on the surface after the penetrant has penetrated and spray on the surface after the penetrant has penetrated and spray on the developer If there are any cracks in the surface red dots or a red line will appear several minutes after the developer dries Hold the developer 300 400 mm away from the area the surface uniformly 6 Clean the surface with the cleaner NOTE Without fail read the instructions for the color check kit before use 104 5 Inspection and servicing of basic engine parts 5 1 4 Replacement of cap plugs Clean and remove grease from the hole into Screw driver or saw which the cap plug is to be driven blade Remove scale and sealing material previously Thinner applied Remove foreign materials with a screw driver or saw blade 2 Remove grease from the cap plug Visually check the Thinner around the plug Apply Threebond No 4 to the seat surface where Apply over the whole Threebond No 4 the plug is to be driven in outside of the plug Insert the plug into the hole Insert the plug so that it sits correctly Place a driving tool on the cap plug and drive it in Drive in the plug parallel e Driving tool using a hammer to the seating surface 2 3 Using the special tool drive t
166. rm Injection timings are not even The 1st and 2nd levers of the governor and the control rack or the injection pump are improperly lined up Delivery stopper is loose Delivery packing is defective Delivery valve seat is defective Delivery spring is broken Movement of control rack is defective Stiff plunger movement or sticking Rack and pinion fitting is defective Movement of governor is improper Delivery stopper is too tight Uneven injection volume Injection timing is defective Plunger is worn and fuel injection adjustment is difficult 5 Governor spring is too weak 6 Feed pump can t feed oil at low speeds 7 Fuel supply is insufficient at low speeds due to clogging of fuel filter 1 The wire or rod of the accel is caught 2 Control rack is caught and can t be moved 1 Governor spring is broken or excessively worn 2 Injection performance or nozzle is poor 142 Disassemble and clean or replace the element Replace packing repair pipe Repair or replace Inspect and adjust Inspect and adjust Repair or replace Inspect and retighten Repair or replace nozzle Replace Replace nozzle assembly Adjust Replace Adjust Adjust Repair Inspect and retighten Replace packing Repair or replace Replace Repair or replace Repair Repair Inspect and adjust adjust adjust Replace Replace Repair or replace Disassemble and clean or replace element Inspect
167. s collected when the boat is stopped e t is best to place the strainer as close to the bilge pump as possible Cut the 3 m hose to a length of 1 2 m 1 8 m and attach allowing plenty of give Check the strainer during a test operation before screwing firmly into place When the strainer is screwed in be especially careful not to damage the bottom of the boat he strainer contains a weight and can be used with the weight in place e Always keep the strainer clean 4X16 screw 1 each 172 9 Cooling water system 4 Attaching the delivery nozzle outlet Make a fixing hole of 21 or less for attaching the Fixing hole p21 nozzle The hose attached at the nozzle should be l m 1 8 m or less and should reach without any strain CE therefore care should be taken in deciding on the best position Delivery nozzle lt Fix the nozzle outlet in place and attach on the discharge side of the pump 5 Attaching the hose e Attach the hose from the strainer to the pump inlet e Attach the delivery nozzle hose to the pump outlet Make the hose as short as possible and avoid sharp bends 6 Test operation Collect water in the bottom of the boat and check for any problems with the hose or siring After doing this connect the battery e Turn on the pump switch and check to see that water is being taken in and discharged properly The pump will stop automatically when there is no water left
168. s mounted to the standard main bearing of the cylinder block 2 Remove the main bearing metal upper from the cylinder block 36 Removing the tappets Remove the tappets from the tappet holes in the cylinder black NOTE 1 Be careful to keep all disassembled parts in order 2 Prepare clear and adequate area for parts and a container s 3 Prepare a cleaner before disassembling 88 4 Disassembly and reassembly Crankshaft Main bearing Base Main bearing bolt Removing main bearing and cranksha 4 Disassembly reassembly 4 3 2 Reassembly 1 Clean all parts Clean all parts using by the cloth and diesel oil or cleaning agent before reassembly 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 2 Putting the cylinder block upside down Place a wood block on the floor and put the cylinder block upside down with the cylinder head mounting surface facing down 3 Inserting the tappets Coat the inside of the cylinder block tappet holes and the outside circumference of the tappets with engine oil and insert the tappets in the cylinder block NOTE Separate the tappets to make sure that they are reassembled in the same cylinder No and intake exhaust side as they came from 4 Mounting the crankshaft 1 The crankshaft and the crankshaft gear are shrink fitted If the crankshaft and t
169. s put in NEUTRAL FORWARD and REVERSE position Clutch remote Use the NEUTRAL position as the standard for control cable adjustment When there is deviation loosen the i clamp for the remote control cable and adjust the shift lever position 0 Shift lever 24 2 Inspection adjustment 7 Adjust the propeller shaft alignment The flexible engine mounts is compressed a little in the initial engine operation and it may cause the centering misalignment between the engine amp the propeller shaft 1 Check unusual noise and vibration of the engine boat hull while increasing the engine speed gradually and lowering it 2 If there is unusual noise and or vibration adjust the propeller shaft alignment Refer to 6 4 5 Centering the Engine in the installation manual for pleasure boat use 2 2 3 Inspection every 50 hours or monthly Be sure to check the following points every 50 hours or monthly whichever comes first Inspection Item Drain the fuel filter Check the electrolyte level in the battery 1 Drain the fuel filter 1 Close the fuel cock of a fuel tank amp 9 hir bleeding 2 Loosen the retaining ring and remove the filter cap Drain off any water and dirt collected inside 3 After reassembly be sure to vent air from the fuel system If air is in the fuel system fuel cannot reach the fuel injection pump Vent the air in the system according to the following procedures
170. safety is required in addition to the matters marked Especially for safety precautions in a repair or maintenance job not described in this manual receive instructions from a knowledgeable leader Safety marks used in this manual and their meanings are as follows DANGER indicates an imminent hazardous situation which if not avoided WILL result in death or serious injury WARNING indicates a potentially hazardous situation which if WARNING not avoided COULD result in death or serious injury DANGER CAUTION CAUTION indicates a potentially hazardous situation which if not avoided may result in minor or moderate injury NOTICE indicates that if not observed the product performance or quality may not be guaranteed 2 Safety Precautions 1 SERVICE AREA A WARNING A CAUTION A e Sufficient Ventilation Inhalation of exhaust fumes and dust particles may be hazardous to ones health Running engines welding sanding painting and polishing tasks should be only done in well ventilated areas Safe Adequate Work Area The service area should be clean spacious level and free from holes in the floor to prevent slip or trip and fall type accidents Clean orderly arranged place No dust mud oil or parts should be left on the floor surface Failure to Observe An unexpected accident may be caused e Bright Safely Illuminated Area The work area should be well lit or illuminated
171. sary replace with new ones Breather gt Nouga Baffle ES plate Intake manifold 1 When a diaphragm is damaged pressure control q inside the crankcase becomes insufficient and Breather system component troubles such as combustion defect and so on Occur 2 At lube oil replacement or lube oil supply the amount of lube oil isn t to be beyond the standard upper limit If the lube oil quantity is beyond the upper limit or an engine is operated beyond the allowable maximum angle of an engine the amount of oil mist may be inducted in the combustion chamber and the oil hammer sometimes may occur 6 Adjust the tension of the alternator driving belt Replace the alternator driving belt with new one every 1000 hours or four years whichever comes first even if there is no crack in the surface Refer to 2 2 2 4 for the procedure 7 Retighten all major nuts and bolts Retighten the major nuts and bolts bellow by the standard tightening torques See the table in 4 5 1 Cylinder head bolts 2 Crankshaft pulley bolts 3 Fuel injection nozzle set bolts 4 Fuel pump gear set bolts 5 Fuel injection line sleeve nut Retighten the following major bolts as requested 1 Rod bolts 2 Flywheel set bolts 3 Metal cap bolts 8 Adjust intake exhaust valve clearance Refer to 2 2 2 5 for the procedure 9 Check adjust the remote control operation Refer to 2 2 2 6 for the procedure 10 Adjust the propeller shaft alig
172. scharge capacity 20 liters min or greater 2 Automatic feeding height 1 m or greater Limit for automatic feeding height new pump with inside parts wet approx 2 m 3 Automatic feeding time 2 5 seconds Limit for automatic feeding time new pump with inside parts wet approx 1 second 4 Automatic stopping Air intake causes negative pressure triggering automatic stopping 2 Insulation 1 Insulation resistance 500V with a megatester when the difference between the continuity point and the body is 1M or greater 2 Insulation proof stress AC50 between the continuity point and the body or 60 2 500V for 1 minute when impressed current leakage is 10 mA or lower 3 Durability Rated voltage when there is 3 salt water 601 engine oil 3 and operation is at 1800 cycles and there are no difficulties 4 Vibration proof Amplitude 0 51 mm one side of the amplitude Vibration frequency 10 55 Hz Sweep time 90 seconds Direction of vibration each direction 4 hours No difficulties after test period 9 7 3 Cautions 1 2 3 5 Attach at a position higher than the bilge water away from rain or other water 50 70 cm above the bottom of the boat Never run the pump dry Be sure that the strainer is inserted in the drain water before pushing the switch If no water is being drawn up after a period of 10 seconds or more prime the pump Do not run the pump for longer than 10 seco
173. sembly to the cylinder head and tighten the bolts Engine oil 3 Adjust valve clearance mm Intake exhaust valve clearance 0 15 0 25 4 Coat the rocker arm and valve spring with engine oil and mount the rocker arm cover 96 4 Disassembly reassembly 22 Mounting the fuel injection pump 1 Lightly fit the fuel injection pump on the gear case After adjusting injection timing tighten the fuel injection pump Before mounting the heat exchanger to the cylinder head adjust the injection timing NOTE Be careful not to scratch the O ring between the fuel injection pump and gear case Camshaft gear 2 Fit the fuel injection pump drive gear to the fuel pump camshaft 3 Align the C match marks on the fuel injection pump drive gear and idle gear 4 Tighten the pump drive gear nut to the specified torque Do not apply lube oil to the nut Crankshaft gear Direction of rotation Gear train Tightening torque Nem kgfem Pump drive gear nut 58 9 68 7 6 0 7 0 5 Measure the backlash of the fuel injection pump drive gear Backlash mm Fuel injection pump drive gear 0 06 0 12 23 Mounting the fuel injection nozzle 1 Replace the used fuel nozzle protector and fuel nozzle seat with new ones Put the seat in the cylinder head and the protector to the nozzle tip Mount the fuel injection nozzle to the cylinder head 2 Tighten the fuel nozzle retainer bolt to the
174. specified torque Do not apply lube oil to the bolt Tightening torque Nem kgfem Fuel nozzle retainer bolt 49 0 53 0 5 0 5 4 97 4 Disassembly reassembly 24 Mounting the fresh water pump 1 Thoroughly coat both sides of the gasket with adhesive 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 Fresh water pump 25 Mounting the fuel injection pipe and fuel return pipe 1 Mount the fuel injection pipe and then assemble the fuel injection pipe retainer to prevent the pipe No 2 uration Fuel injection pipe No 1 NOTE Lightly tighten the pipe joint nuts both ends of the fuel injection pipe Completely tighten after adjusting the injection timing Standard tightening torque Nem kgfem fuel injection pipe joint nut 29 4 34 4 3 0 3 5 2 Mount the fuel return pipe with the clamp fuel injection nozzle fuel injection pump NOTE When tightening the fuel return pipe to fuel injection nozzle tighten the nut with holding the return pipe by hand so that the pipe may not break Refer to 4 3 1 13 Fuel injection nozzle X 236 98 4 Disassembly reassembly 26 Mounting the lube oil filter Mount the lube oil filter with the tool of the filter case remover Lube oil pressure switch 27 Mounting the seawater pump 1 Tighten the spacer bolt to the gear c
175. ssembly reassembly 5 Removing the intake silencer 1 Remove the air intake hose attached to the intake manifold 2 Remove the intake silencer from cylinder head Intake pipe 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 U type Mixing elbow Lp Seawater N L type Mixing elbow Exhaust elbow Optional L type mixing elbow L type mixing elbow 79 4 Disassembly reassembly 7 Removing the alternator 1 Loosen the set bolt belt adjuster bolt and move the alternator downwards Loosen the V pulley set bolts for the cooling water pump and remove the V belt 2 Remove the belt adjuster from the gear case and remove the alternator from the cylinder head with 3 7 bracket RA S Set bolt V belt Qn Alternator 3YM30 8 Removing the cooling water pipes seawater fresh water 1 Remove the seawater pipe seawater pump heat exchanger 2 Remove the fresh water pipe fresh water pump heat exchanger coolant tank fresh water pump Mixing elbow Coolant tank Exhaust manifold T From seacock Cooling water pipes 4 Disassembly reassembly 9 Removing the heat exchanger exhaust manifold coolant tank unit Remove the heat exchanger and gasket packing from cylinder head 10 Removing the seawater p
176. ssure clutch slips Overheating Abnormal noise P on Suction side 7 Mom sing pats of O Giona orosute forward reverse conversion valve 7 5 9 5 Problem with 1 Excessive backlash 2 Worn oil pump Y 8 Damaged O ring 2 rales 1 due oil cooler of gear 3 Sticking of oil pressure V ring in oil pressure pipe 6 Poor quality or adjustment valve T n inappropriate oil 4 ae A 3 Damaged bearing 2 Damaged bearing J pring 10 Poor assembly of low 7 Poor operation of 5 Damaged seal ring low speed valve 3 Abnormal vibration e Miss 6 Incorrect positioning of 411 Insufficient oil forward reverse conversion valve TROUBLE WITH 1 Damaged holding 1 Not enough warp 1 Oil leakage MINIME Eo 2 Foreian material teel plat 3 Lube oil pressure 3 Damaged or old lube oil spring pipe HE pipe system R is too high 2 Clogged lube valve spring n oil filter 3 Oil leakage where there 2 Damaged holding 4 Viscosity of lube 4 Sticking of lube oil i is remote control spring of pipe oil is too high adjustment valve 4 Too much oil oo _ O LLI O E 4 v O 4 Phase slippage IV Difficulty changing into forward neutral and reverse V Dragging VI Abnormal lube oil pressure 1 2 IV 3 Replenish oil and check Replac
177. t Standard fuel injection pressure MPa kgf cm 12 3 13 28 125 135 Notice As for the opening pressure of the brand new fuel nozzle about 0 5 MPa 5 kgf cm declines by the engine operation for about 5 hours because of the initial wear out of a spring etc Therefore adjust 0 5 MPa 5 kgf cm higher than the standard value of the above table when adjusting a new fuel nozzle of a spare part Injection pressure measurement with nozzle tester Remove carbon deposit at the nozzle hole thoroughly before measurement a Connect the fuel injection valve to the high pressure pipe of the nozzle tester b Operate the nozzle tester lever slowly and read the pressure at the moment when the fuel injection from the nozzle starts c If the measured injection pressure is lower than the standard level replace the pressure adjusting shim with a thicker one Thickness of pressure adjusting shims 1 Injection pressure adjustment The injection pressure is increased by approx 0 1 0 2 0 3 0 4 0 5 0 52 0 54 0 56 di 0 58 0 8 1 1 MPa 11 kof 2 when the adjusting shim thickness is increased by 01 mm 38 2 Inspection adjustment Informative Fuel injection valve structure Fuel return pipe Nozzle holder Pressure adjusting shim Nozzle spring y Sy Nozzle spring seat Coy 2 Valve stop spacer ig Nozzle valve Nozzle eos V Nozzle body
178. t out during engine running if tightening loose A WARNING e Safety Label Check Pay attention to the product safety label A safety label caution plate is affixed on the product for calling special attention to safety If it is missing or illegible always affix a new one A CAUTION 3 Precautions for Service Work 1 Precautions for Safety Read the safety precautions given at the beginning of this manual carefully and always mind safety in work 2 Preparation for Service Work Preparation is necessary for accurate efficient service work Check the customer ledger file for the history of the engine Preceding service date e Period operation hours after preceding service e Problems and actions in preceding service Replacement parts expected to be required for service e Recording form check sheet required for service 3 Preparation before Disassembly Prepare general tools special service tools measuring instruments oil grease non reusable parts and parts expected to be required for replacement e When disassembling complicated portions put match marks and other marks at places adversely affecting the function for easy reassembly 4 Precautions in Disassembly e Each time a parts is removed check the part installed state deformation damage roughening surface defect etc Arrange the removed parts orderly with clear distinction between those to be replaced and those to
179. the outside damage or cracks and replace if necessary V pulley Retaining ring Ball bearing Spacer Retaining ring Seawater pump 2 Inspect the oil seal and replace if it is damaged Also replace the oil seal if there is considerable water leakage during operation Cooling water leakage less than cm h 3 Make sure the ball bearings rotate smoothly Replace if there is excessive play 160 9 Cooling water system 9 2 4 Seawater pump reassembly 1 When replacing the oil seal coat with grease and insert 2 Mount the pump shaft ball bearing and V pulley to the pump unit and fit the bearing retaining ring NOTE Coat the shaft with grease 3 Mount the impeller 4 Mount the O ring and the cover NOTE Replace the O ring with new one 161 9 Cooling water system 9 3 Fresh water pump 9 3 1 Fresh water pump construction The fresh water pump is of the centrifugal volute type and circulates water from the fresh water tank to the cylinder block and the cylinder head The fresh water pump consists of the pump body impeller pump shaft bearing unit and mechanical seal The V pulley on the end of the pump shaft is driven by a V belt The bearing unit assembled in the pump shaft uses grease lubricated ball bearings and cannot be disassembled Cylinder head Cylinder block Gasket O ring To cylinder block Fresh water pump 9 3 2 Specifications of fresh water pump Pump shaft s
180. ton ring sticks 7 Insufficient tightening of head bolts 8 Damaged valve spring VII 1 valves VII 1 Replace 2 VII 2 Adjust VII 3 Vi 4 5 Replace VII 3 Move governor handle to acceleration position 6 Disassemble and 4 Check and repair repair or replace VII 5 Clean VII 7 Tighten tightening nuts uniformly 8 Replace 29 Chart 8 TROUBLE AND TROUBLESHOOTING INSUFFICIENT POWER OUTPUT 1 Replace Clean nozzle hole or replace 11 1 Replace l 2 Disassemble and repair or replace Lap or replace 11 2 Repair Lap valves Lap or replace Tighten firmly Tighten firmly 1 6 Adjust Replace 1 8 Clean lean 0 Countermeasure 1 3 1 4 1 5 1 7 1 9 1 1 1 Amount of oil supply from fuel injection pump inadequate Amount of fuel injection inadequate Faulty governor 1 Worn plunger 6 V cinese postoning 1 Clogging of nozzle hole 2 Sticking of plunger eee 2 Faulty valve seat 1 Damaged governor bearing 7 Clogging of fuel filter ee 3 Oil leakage from exhaust valve 3 Sticking of valve needle oie ae 8 Clogging of fuel oil pipe a J2 2 Inaccurate length 4 Oil leakage from joint of V 4 Loose high pressure pipe of governor lin __high pressure pipe 9 Damaged valve spring 5 Worn valve needle INSUFFICIENT POWER OUTPUT 1 L
181. tor V A 12V 60A 12V 80A optional Q o lt 02010 T 7 5 7 5 215 2 LAR SI amp Sy gt D 2 P Overall length 715 28 1 715 28 1 698 27 5 698 27 5 M Overall width mm inch 463 18 2 463 18 2 463 18 2 463 18 2 545 21 5 545 21 5 528 20 8 528 20 8 mass ko 133 157 with SD20 120 144 with SD20 include marine gear 2 1 Note 1 Rating condition ISO 3046 1 8665 2 1HP metric horse power 0 7355 kW 3 Fuel condition Density at 15 0 842 Fuel temperature 25 at the inlet of the fuel injection pump ISO 3046 1 Fuel temperature 40 at the inlet of the fuel injection pump ISO 8665 4 The Total oil quantity includes oil in oil pan and oil in channels coolers and filter 5 The effective amount of oil shows the difference in maximum scale of the dipstick and minimum scale 1 1 3 Fuel oil lubricating oil and cooling water 1 3 1 Fuel oil IMPORTANT Only use the recommended fuel to obtain the best engine performance and prevent damage of parts also prevent air pollution 1 Selection of fuel oil Use the following diesel fuels for best engine performance BS 2869 A1 or A2 Fuels equivalent to Japanese Industrial Standard JIS No K2204 2 Fuel cetane number should be 45 or greater 2 Fuel han
182. ube oil pump 8 2 1 Lube oil pump construction The trochoid type lube oil pump is mounted in the gear case and the inner rotor is driven by the crankshaft pulley The lube oil flows from the intake filter mounted on the bottom of the cylinder body through the holes in the cylinder body and engine plate and out from the holes in the engine plate and cylinder body to the discharge filter The lube oil pump is fitted with a control valve which controls the discharge oil pressure at the specified ressure Crankshaft pulley 8 2 2 Specifications of lube oil pump Lube oil pump specifications Engine speed 3600 min 800 Pump speed 3477 1 772 min Delivery quantity 719 0 min 78 0 I min Delivery pressure 0 43 MPa 4 4 kgf cm 70 049 MPa 0 5 kgf cm 8 2 3 Lube pump disassembly reassembly Disassembly 1 Remove the crankshaft pulley 2 Remove the gear case cover 3 Remove the lube oil pump cover from the gear case cover Do not disassemble the inner outer rotors and check that the pump rotates smoothly 4 Remove the pressure control valve from the lube oil pump cover Note Only wash the control valve Disassembly is unnecessary unless any abnormality in operation is detected Reassembly NOTICE Always check if the pump rotates smoothly after installation on the gear case Running the engine when the pump rotation is heavy may cause the pump to
183. uel oil filter is clogged Repair or replace Excessive oil leaks from the nozzle sliding Replace the nozzle area assembly Injection 1 Injection timing is retarded due to failure of Adjust timing is the coupling defective 2 Camshaft is excessively worn Replace camshaft 3 Roller guide incorrectly adjusted or Adjust or replace excessively worn 4 Plunger is excessively worn Replace plunger assembly 141 6 Fuel injection equipment 2 Engine starts but 1 Fuel pipe is clogged Clean 3 5 immediately stops Defective injection timing and other failures output is insufficient Nozzle movements is defective Injection pump is defective 4 Idling is rough 5 Engine runs at high speeds but cuts out at low speeds 6 Engine doesn t reach max speed 2 Fuel filter is clogged 3 Improper air tightness of the fuel pipe connection or pipe is broken and air is being sucked in 4 Insufficient fuel delivery from the feed pump 1 Knocking sounds caused by improper too fast injection timing 2 Engine overheats or emits large amount of 3 2 3 4 smoke due to improper to slow injection timing Insufficient fuel delivery from feed pump Case nut loose Defective injection nozzle performance Nozzle spring is broken Excessive oil leaks from nozzle Max delivery limit boll is screwed in too far Plunger is worn Injection amount is not unifo
184. uel oil tank 1 1 Fuel injection pump 2 No tappet clearance timing irregular 2 Loose high pressure fuel pipe 4 3 Damaged high pressure fuel pipe 4 Air in high pressure fuel pipe VI Faulty fuel injection system VII Leakage of pressurized air Chart 7 TROUBLE WITH STARTING Prime well 1 Lap 1 2 Adjust 2 Lap 1 3 Clean out matter causing clogging IV 3 Replace 4 Add fuel to fuel tank IV 4 Clean or replace 111 1 hike Open cock IV 5 Adjust Ill G Clean 1 7 Disassemble and repair or replace 1 8 Drain water from fuel system and prime IV Faulty fuel injection valve 1 Faulty valve seat 2 Sticking of valve needle 3 Worn valve needle 4 Clogged outlet 5 Low injection pressure STARTING TROUBLE 1 Incorrect thickness 3 Faulty gasket packing of gasket packing Upper part of cylinder liner worn 2 Faulty installation of governor ring and lever 3 Governor handle is in stop position 4 Faulty engine starter 5 Clogging of suction exhaust pipes VIII Miscellaneous III Fuel oil not injected 1 Imperfect priming of fuel oil system 2 Injection cut off due to faulty governor 3 Clogging of fuel inlet filter 4 Insufficient fuel oil in tank 9 Fuel oil tank cock closed 6 Clogging in fuel oil pipe 7 Damaged fuel oil supply pump Air leakage from suction exhaust valves 5 Worn piston ring 6 Pis
185. ump Loosen the nut on the spacer bolt and remove the seawater pump Gear case Spacer bolt Bracket Seawater pump Seawater pump 11 Removing the starting motor Remove the starting motor from the flywheel housing 12 Removing the lube oil filter Remove the lube oil filter from the cylinder block Lube oil pressure switch Lube oil filter 81 4 Disassembly reassembly 13 Removing the fuel injection pipe 1 Remove the fuel injection pipe retainer 2 Loosen the cap nuts on both ends of the fuel Fuel injection pipe retainer injection pipe and remove the fuel injection pipe i 2 0 Note Fuel injection pipe When loosening the cap nut loosen the nut with B holding the return pipe by hand so that the fuel return pipe may not break 3 Fuel injection pipe e A SL Fuel injection nozzle X wooo 3 Remove the fuel return pipe fuel nozzle fuel pump 14 Removing the fresh water pump Remove the fresh water pump and gasket Cylinder head 82 4 Disassembly and reassembly 15 Removing the fuel injection nozzles Loosen the fuel nozzles and remove them from the cylinder head Fuel injection nozzle 16 Remove the fuel injection pump 1 Loosen the drive gear nut for fuel pump drive gear and pull out the fuel pump drive gear flange assembly with an extraction tool Note Don t disassemble the pump flange and the pump drive gear 2 Loosen the three 3
186. ump to pump out waste oil is available as an option ATI m Rotary waste oil pump Delivery capacity per one revolution 0 057 L Delivery pressure 0 15 MPa 1 5 kg cm or below Suction head less than 1m Part No 124413 39100 156 9 Cooling water system 9 Cooling water system 9 1 Cooling water system The cooling water system is of the indirect seawater cooled fresh water circulation type The cylinders cylinder heads and exhaust manifold are cooled with fresh water and fresh water cooler heat exchanger use seawater Seawater pumped in from the sea by the seawater pump goes to the heat exchanger where it cools the fresh water Then it is sent to the mixing elbow and is discharged from the ship with the exhaust gas Fresh water is pumped by the fresh water to the cylinder jacket to cool the cylinders and the cylinder head The fresh water pump body also serves as a discharge passageway line at the cylinder head outlet and is fitted with a thermostat The thermostat is closed when the fresh water temperature is low immediately after the engine is started and during low load operation etc Then the fresh water flows to the fresh water pump inlet and is circulated inside the engine without passing through the heat exchanger When the temperature of the fresh water rises the thermostat opens fresh water flows to the heat exchanger and it is then cooled by the seawater in the tubes as it flows through t
187. ure or burning of the contact surface and replace if necessary Wheel side 2 Measuring the inner diameter of metal Tighten the cap to the specified torque and measure the inner diameter of the metal Thrust metals Nem kgfem 5 Main bearing bolt O Tightening torque 75 5 81 5 7 7 8 3 i NOTE Main bearing When assembling the bearing cap keep the following in mind 1 The lower metal cap side has no oil groove 2 The upper metal block side has an oil groove 3 Check the cylinder block alignment number 4 The FW on the cap lies on the flywheel side 127 5 Inspection and servicing of basic engine parts 5 6 Camshaft and tappets 5 6 1 Camshaft The camshaft is normalized and the cam and bearing Push rod surfaces are surface hardened and ground The cams have a curve that minimized the repeated shocks on the valve seats and maximizes valve seat life Tappet Camshaft Camshaft bushing Camshaft gear 1 Checking the camshaft side gap Measure the thrust gap before disassembly As the cam gear is shrink fitted to the cam be careful when replacing the thrust bearing mm Camshaft side gap 0 05 0 15 2 Measure the cam height and replace the cam if it is worn beyond the limit mm Standard Cam height Exhaust 35 34 265 33 89 Cam height 128 5 Inspection and servicing of basic engine parts 3 Camshaft and bearing hole measurement Measure the camshaft outside diamete
188. usting shims between the valve spring and cylinder head when seats have been refinishing with a seat grinder 2 Measure valve distortion after valve seat refinishing has been completed and replace the valve and valve seat if it exceeds the tolerance 109 5 Inspection and servicing of basic engine parts 5 2 3 Intake exhaust valves valve guides 1 Wearing and corrosion of valve stem Replace the valve stem is excessively worn or corroded stem Standard outside dia Exhaust 5 945 5 960 2 Inspection of valve seat wear and contact surface Inspect for valve seat scratches and excessive wear Check to make sure the contact surface is normal The seat angle must be checked and adjusted if the valve seat contact surface is much smaller than the width of the valve seat NOTE Keep in mind the fact that the intake and discharge valve have different diameters 3 Valve sink Over long periods of use and repeated lapping combustion efficiency may drop Measure the sinking distance and replace the valve and valve seat if the valve sink exceeds the tolerance Valve sinking depth mm Valve sink depth Depth micrometer Valve sink 110 5 Inspection and servicing of basic engine parts 4 Valve guide 1 Measuring inside diameter of valve guide Measure the inside diameter of the valve guide and replace it if it exceeds the wear limit mm po Sam Um _ Clearance NOTE The i
189. ver return spring 12 Packing 3 Piston 8 Lever assembly 13 Cover 4 Diaphragm spring 9 O ring 14 Small screw 5 Diaphragm assembly 10 Stop pin 15 Cap 6 2 2 Fuel feed pump specifications 230 cm min at 1500 cam discharge pressure of 0 020 MPa 0 2 kgf cm 0 029 MPa 0 3 kgf cm or more at 400 cam 144 6 Fuel injection equipment 6 2 3 Disassembly and reassembly of fuel feed pump 1 Disassembly 1 Remove the fuel feed pump mounting nut and take the fuel feed pump off the fuel injection pump 2 Clean the fuel feed pump assembly with fuel oil 3 After checking the orientation of the arrow on the cover make match marks on the upper body and cover remove the small screw and disassemble the cover upper body and lower body 2 Reassembly 1 Clean all parts with fuel oil inspect and replace any defective parts 2 Replace any packing on parts that have been disassembled 3 Make sure that the intake valve and discharge valve on upper body are mounted in the proper direction and that you don t forget the valve packing 4 Assemble the diaphragm into the body making sure the diaphragm mounting holes are lined up do not force 5 Align the match marks on the upper body of the pump and cover and tighten the small screws evenly Nem kgfem Tightening torque 147 245 15 25 6 2 4 Fuel feed pump inspection 1 Place the fuel feed pump in kerosene cover the discharg
190. w viscosity and forming of thin film appropriate for mating surface of precision parts Three Bond 200g No 4 1 kg also TB1104 do eng oemi drying viscoelastic material applicable to non flat surface having many indentations and protrusions superior in heat resistance water resistance and oil resistance Three Bond 100g oolvent less type silicone base sealant applicable to 10 high temperature areas 50 C to 250 C TB1211 Three Bond 100g oilicone base non fluid type thick application TB1212 possible Adhesive Three Bond 200g Prevention of loose bolts gas leakage and TB1401 corrosion Torque required to loosen bolt 10 to 20 larger than tightening torque Lock tight 50g Excellent adhesive strength locks bolt semi SUPER permanently TB1324 oeal tape 5m round tape Sealing material for threaded parts of various pipes Ambient temperature range 150 C to 200 C O ring kit 1 92 m dia 1 O ring of any size can be prepared whenever 2 2 42 m dia 1 required 3 12 m dia 1 Including adhesive release agent cutter and jig 3 52 m dia 5 72 m dia EP lubricant Brand name For assembly of engine cylinders pistons metals molybdenum LOWCOL shafts etc disulfate Spray type facilitates application work Brand name PASTE SPRAY Brand name Prevention of seizure of threaded parts at high MOLYPASTE temperature Applicable to intake and exhaust valves stem guide face
191. witch thermo switch backed up by an alarm in the instrument panel are used to monitor the temperature of the engine cooling water A high thermal expansion material is set on the end of the water temperature unit When the cooling water temperature reaches a specified high temperature the contacts are closed and an alarm lamp and buzzer are activated at the instrument panel Pilot lamp Fuse Main switch O Water temperature switch Alarm buzzer Water temperature unit Battery L Fresh water pump 93 97 deg temperature Electric capacity DC 12V 1A Tightening torque ree em 9 g torq 2 40 3 20 kgf m 198 12 8 Glow plug A glow plug is available for warming intake air when starting in cold areas in winter The glow plug is mounted to the cylinder head The device is operated by the glow switch on the instrument panel Rated current 8 10A Rated voltage DC11V Glow connector CE a CE Glow plug 9 199 12 Electrical System Hexagon subtense 0 12 0 3 mm M10 x 1 25 Glow plug 12 Electrical System 12 9 Electric engine stopping device The electric engine stop device is fitted to the governor The device is operated by the stop switch on the instrument panel The emergency stop button is integrated with the solenoid When pushing the stop button the engine will shut down 200 13 Service standards 13 Service standards
192. y fluid is greater than 1 25 Recharge or replace the battery The distance between the pump Lower the pump Position the and the surface of the water is too pump so that it is closer to the great surface of the water The pump is too high Lower the pump Position the pump so that it is 50 70 cm above the bottom of the boat If intake is still faulty after priming consult your local dealer Pump turns but the amount of Clogged strainer discharge IS low Hose is broken or damaged Check for damage and repair If incorrect hose has been used Pump intake is weak replace with the regulation type of hose 4 Water leakage from pump Water leakage from packing Retighten pump screws Faulty pump seal Consult your local dealer 5 Pump draws up bilge but motor Faulty diaphragm switch Check for loose wiring in stops when hand is removed diaphragm switch and correct from starter switch Damaged diaphragm switch Consult your local dealer 6 Motor does not stop when Clogged strainer or hose Clean strainer or hose Damaged diaphragm switch Check for continuity of diaphragm switch terminal there is no bilge water left Consult your local dealer if there is continuity 175 10 Reduction and reversing gear 10 Reduction and reversing gear Marine gear KM2P 1 is applied to the 3YM30 and 20 series engines Refer to chapter 10 in the service manual of the GM series engines for inspection dis

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