ヤンマー YM シリーズエンジンの特徴と利点
ヤンマー YM シリーズエンジンは、農業、建設、産業アプリケーションに最適な、堅牢で信頼性の高いディーゼルエンジンです。
パワーと効率
YM シリーズエンジンは、30～60馬力のパワーレンジを備えています。高度な燃料噴射システムと燃焼室設計により、比類のないパワーと効率を実現しています。
信頼性と耐久性
YM シリーズエンジンは、厳しい条件でも長寿命で信頼性の高い動作を確保するために設計されています。高品質のコンポーネント、堅牢なブロック、精密加工部品を使用しています。
汎用性と適合性
YM シリーズエンジンは、さまざまな用途に柔軟に対応できます。農業機械、建設機械、産業機器に搭載できるよう設計されています。
主な特徴
* 強力で効率的なディーゼルエンジン
* 30～60馬力の出力範囲
* 信頼性と耐久性が高く、長寿命
* 汎用性が高く、さまざまな用途に対応
* 農業、建設、産業アプリケーション向け
* 先進的な燃料噴射システムと燃焼室設計
* 高品質のコンポーネントと精密加工部品
YM シリーズエンジンの利点
* 優れたパワーとトルクにより、重い負荷にも対応
* 優れた燃料効率により、運用コストを削減
* 信頼性の高い動作で、ダウンタイムを最小限に抑える
* 汎用性が高く、幅広い用途に対応
* 厳しい条件での耐久性と信頼性
結論
ヤンマー YM シリーズエンジンは、パワー、効率、信頼性、汎用性に優れたディーゼルエンジンです。農業、建設、産業アプリケーションに最適な、比類のないソリューションを提供します。
このマニュアルは英語または説明に記載されている言語で作成されることにご注意ください
This Complete Factory Yanmar YM Series - 3YM30, 3YM20 and 2YM15 Marine Diesel Engines workshop service manual includes needed instructions to maintain, repair and service your engine using detailed diagrams and manufacturers specifications.
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Comprehensive illustrations, exploded diagrams, drawings and photos guide you through the service repair procedures.
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CONTENTS:
1. General ............................................................................................................................ 1
1.1 Exterior views ...........................................................................................................................1
1.2 Specifications ...........................................................................................................................2
1.3 Fuel oil, lubricating oil and cooling water .................................................................................4
1.3.1 Fuel oil ............................................................................................................................................. 4
1.3.2 Lubricating oil................................................................................................................................... 4
1.3.3 Cooling water ................................................................................................................................... 5
1.4 Engine outline ..........................................................................................................................6
1.5 Piping diagrams .....................................................................................................................10
1.6 Exhaust gas emission regulation ...........................................................................................12
1.6.1 Engine identification (EPA/ARB)..................................................................................................... 12
1.6.2 Exhaust gas emission standard (EPA/ARB) ................................................................................... 13
1.6.3 Guarantee conditions for emission standard (EPA/ARB) ............................................................... 13
2. Inspection and adjustment ............................................................................................. 15
2.1 Periodic maintenance schedule .............................................................................................15
2.2 Periodic inspection and maintenance procedure ...................................................................17
2.2.1 Check before starting...................................................................................................................... 17
2.2.2 inspection after initial 50 hours or one month operation ................................................................. 20
2.2.3 Inspection every 50 hours or monthly ............................................................................................. 25
2.2.4 Inspection every 100 hours six months........................................................................................... 30
2.2.5 Inspection every 150 hours or one year.......................................................................................... 30
2.2.6 Inspection every 250 hours or one year.......................................................................................... 31
2.2.7 Inspection every 1,000 hours or four years..................................................................................... 37
2.3 Adjusting the no-load maximum or minimum speed ..............................................................44
2.4 Sensor Inspection ..................................................................................................................44
2.4.1 Oil pressure switch......................................................................................................................... 44
2.4.2 Thermo switch................................................................................................................................ 44
2.5 Thermostat inspection ............................................................................................................45
2.6 Adjusting operation ................................................................................................................46
2.6.1 Preliminary precautions .................................................................................................................. 46
2.6.2 Adjusting operation procedure ........................................................................................................ 46
2.6.3 Check points and precautions during running................................................................................. 47
2.7 Long storage ..........................................................................................................................48
3. Troubleshooting ............................................................................................................. 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. Disassembly and reassembly ........................................................................................ 64
4.1 Disassembly and reassembly precautions .............................................................................64
4.2 Disassembly and reassembly tools ........................................................................................65
4.2.1 General hand tools.......................................................................................................................... 65
4.2.2 Special hand tools.......................................................................................................................... 68
4.2.3 Measuring instruments.................................................................................................................... 71
4.2.4 Other material ................................................................................................................................ 75
4.3 Disassembly and reassembly ................................................................................................77
4.3.1 Disassembly................................................................................................................................... 77
4.3.2 Reassembly ................................................................................................................................... 89
5. Inspection and servicing of basic engine parts ............................................................ 104
5.1 Cylinder block .......................................................................................................................104
5.1.1 Inspection of parts......................................................................................................................... 104
5.1.2 Cleaning of oil holes...................................................................................................................... 104
5.1.3 Color check procedure.................................................................................................................. 104
5.1.4 Replacement of cap plugs ............................................................................................................ 105
5.1.5 Cylinder bore measurement.......................................................................................................... 106
5.2 Cylinder head .......................................................................................................................107
5.2.1 Inspecting the cylinder head ......................................................................................................... 108
5.2.2 Valve seat correction procedure ................................................................................................... 109
5.2.3 Intake/exhaust valves, valve guides ............................................................................................. 110
5.2.4 Valve springs ............................................................................................................................... 112
5.2.5 Assembling the cylinder head ....................................................................................................... 113
5.2.6 Measuring top clearance............................................................................................................... 114
5.2.7 Intake and exhaust rocker arms.................................................................................................... 114
5.2.8 Adjustment of valve clearance ...................................................................................................... 115
5.3 Piston and piston pins ..........................................................................................................116
5.3.1 Piston........................................................................................................................................... 116
5.3.2 Piston pin ..................................................................................................................................... 117
5.3.3 Piston rings .................................................................................................................................. 118
5.4 Connecting rod .....................................................................................................................121
5.4.1 Inspecting the connection rod ....................................................................................................... 121
5.4.2 Crank pin metal............................................................................................................................ 122
5.4.3 Piston pin bushing........................................................................................................................ 124
5.4.4 Assembling piston and connecting rod ......................................................................................... 124
5.5 Crankshaft and main bearing ...............................................................................................125
5.5.1 Crankshaft.................................................................................................................................... 125
5.5.2 Main bearing ................................................................................................................................ 127
5.6 Camshaft and tappets ..........................................................................................................128
5.6.1 Camshaft...................................................................................................................................... 128
5.6.2 Tappets ........................................................................................................................................ 130
5.7 Timing gear ..........................................................................................................................131
5.7.1 Inspecting the gears...................................................................................................................... 131
5.7.2 Gear timing marks......................................................................................................................... 131
5.8 Flywheel and housing ..........................................................................................................132
5.8.1 Position of top dead center and fuel injection timing..................................................................... 132
5.8.2 Damper disc................................................................................................................................. 133
6. Fuel injection equipment .............................................................................................. 134
6.1 Fuel Injection pump/governor ...............................................................................................134
6.1.1 Fuel system diagram..................................................................................................................... 134
6.1.2 Fuel injection pump service data and adjustment......................................................................... 135
6.1.3 Fuel injection pump structure........................................................................................................ 139
6.1.4 Removing a fuel injection pump.................................................................................................... 140
6.1.5 Installing a fuel injection pump...................................................................................................... 140
6.1.6 Adjusting fuel injection timing........................................................................................................ 140
6.1.7 Troubleshooting of fuel injection pump ......................................................................................... 141
6.1.8 Major faults and troubleshooting................................................................................................... 141
6.2 Fuel feed pump ....................................................................................................................144
6.2.1 Construction of fuel feed pump..................................................................................................... 144
6.2.2 Fuel feed pump specifications ...................................................................................................... 144
6.2.3 Disassembly and reassembly of fuel feed pump .......................................................................... 145
6.2.4 Fuel feed pump inspection............................................................................................................ 145
6.3 Fuel filter ..............................................................................................................................147
6.3.1 Fuel filter specifications................................................................................................................. 147
6.3.2 Fuel filter inspection ...................................................................................................................... 147
6.4 Fuel tank ..............................................................................................................................148
7. Intake and exhaust system .......................................................................................... 149
7.1 Intake system .......................................................................................................................149
7.1.1 Breather system (A reductor to intake air system of blowby gas)................................................. 149
7.1.2 Diaphragm assy inspection........................................................................................................... 150
7.2 Exhaust system ....................................................................................................................151
7.2.1 Construction................................................................................................................................. 151
7.2.2 Mixing elbow inspection ................................................................................................................ 151
8. Lubrication system ....................................................................................................... 152
8.1 Lubrication system ...............................................................................................................152
8.2 Lube oil pump .......................................................................................................................153
8.2.1 Lube oil pump construction ........................................................................................................... 153
8.2.2 Specifications of lube oil pump ..................................................................................................... 153
8.2.3 Lube oil pump disassembly and reassembly ................................................................................ 153
8.2.4 Lube oil pump inspection .............................................................................................................. 154
8.2.5 Pressure control valve construction .............................................................................................. 154
8.3 Lube oil filter .........................................................................................................................155
8.3.1 Lube oil filter construction ............................................................................................................. 155
8.3.2 Lube oil filter replacement............................................................................................................. 155
8.4 Rotary waste oil pump (Optional) .........................................................................................156
9. Cooling water system ................................................................................................. 157
9.1 Cooling water system ...........................................................................................................157
9.2 Seawater pump ....................................................................................................................159
9.2.1 Specifications of seawater pump .................................................................................................. 159
9.2.2 Seawater pump disassembly ........................................................................................................ 159
9.2.3 Seawater pump Inspection ........................................................................................................... 160
9.2.4 Seawater pump reassembly ......................................................................................................... 161
9.3 Fresh water pump ...............................................................................................................162
9.3.1 Fresh water pump construction..................................................................................................... 162
9.3.2 Specifications of fresh water pump ............................................................................................... 162
9.3.3 Fresh water pump disassembly .................................................................................................... 163
9.3.4 WFresh water pump inspection .................................................................................................... 163
9.4 Heat exchanger ....................................................................................................................165
9.4.1 Heat exchanger construction ........................................................................................................ 165
9.4.2 Disassembly and reassembly of the heat exchanger ................................................................... 165
9.4.3 Heat exchanger inspection ........................................................................................................... 165
9.5 Pressure cap and coolant recovery tank ..............................................................................166
9.5.1 Pressure cap construction ............................................................................................................ 166
9.5.2 Pressure cap pressure control ...................................................................................................... 166
9.5.3 Pressure cap inspection................................................................................................................ 166
9.5.4 Replacing filler neck...................................................................................................................... 167
9.5.5 Function of the coolant recovery tank ........................................................................................... 168
9.5.6 Specifications of coolant recovery tank......................................................................................... 168
9.5.7 Mounting the coolant recovery tank .............................................................................................. 168
9.5.8 Precautions on usage of the coolant recovery tank ...................................................................... 168
9.6 Thermostat ...........................................................................................................................169
9.6.1 Functioning of thermostat ............................................................................................................. 169
9.6.2 Thermostat construction ............................................................................................................... 169
9.6.3 Characteristics of thermostat ........................................................................................................ 169
9.6.4 Thermostat inspection................................................................................................................... 169
9.6.5 Testing the thermostat .................................................................................................................. 169
9.7 Bilge pump and bilge strainer (Optional) ..............................................................................170
9.7.1 Introduction .................................................................................................................................. 170
9.7.2 Description................................................................................................................................... 171
9.7.3 Cautions....................................................................................................................................... 171
9.7.4 Assembly procedure ..................................................................................................................... 172
9.7.5 Cautions for assembling ............................................................................................................... 174
9.7.6 Troubleshooting ............................................................................................................................ 175
10. Reduction and reversing gear ................................................................................... 176
10.1 Specifications .....................................................................................................................176
11. Remote control (Optional) ......................................................................................... 177
11.1 Remote control system ......................................................................................................177
11.1.1 Construction of remote control system ....................................................................................... 177
11.1.2 Remote control device components............................................................................................ 177
11.2 Remote control installation .................................................................................................179
11.3 Remote control inspection ..................................................................................................181
11.4 Remote control adjustment ................................................................................................182
12. Electrical system ........................................................................................................ 183
12.1 Electrical system ................................................................................................................183
12.1.1 Wiring diagram........................................................................................................................... 184
12.2 Battery ...............................................................................................................................185
12.3 Starting motor .....................................................................................................................186
12.3.1 Specifications............................................................................................................................. 186
12.3.2 Characteristics ............................................................................................................................ 186
12.3.3 Structure .................................................................................................................................... 187
12.3.4 Wiring diameter of a starting motor............................................................................................. 188
12.4 Alternator standard, 12V/60A .............................................................................................189
12.4.1 Specifications............................................................................................................................. 189
12.4.2 Structure .................................................................................................................................... 190
12.4.3 Wiring diagram........................................................................................................................... 191
12.4.4 Standard output characteristics .................................................................................................. 191
12.4.5 Inspection................................................................................................................................... 192
12.5 Alternator 12V/80A (Optional) ............................................................................................193
12.5.1 Specifications............................................................................................................................. 193
12.5.2 Structure .................................................................................................................................... 194
12.5.3 Wiring diagram........................................................................................................................... 195
12.5.4 Standard output characteristics .................................................................................................. 195
12.6 Instrument panel ................................................................................................................196
12.6.1 B-type instrument panel (Optional) ............................................................................................. 196
12.7 Warning devices .................................................................................................................197
12.7.1 Oil pressure alarm....................................................................................................................... 197
12.7.2 Cooling water temperature alarm................................................................................................ 198
12.8 Glow plug ...........................................................................................................................199
12.9 Electric engine stopping device ..........................................................................................200
13. Service standards ...................................................................................................... 201
13.1 Engine tuning .....................................................................................................................201
13.2 Engine body .......................................................................................................................202
13.2.1 Cylinder head............................................................................................................................. 202
13.2.2 Camshaft and gear train ............................................................................................................. 203
13.2.3 Cylinder block ............................................................................................................................. 204
13.3 Lubricating oil system (Trochoid pump) .............................................................................207
14. Tightening torque for bolts and nuts .......................................................................... 208
14.1 Main bolt and nut ................................................................................................................208
14.2 Standard bolts and nuts (without lube oil) ..........................................................................208
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This easy to follow manual is ideal for the Do-it-Yourself restorer or mechanic.
There are lots of pictures, diagrams, illustrations and charts.
Technical details and step-by-step instructions you will need are included.
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