Yanmar 3YM30 | 3YM20 | 2YM15 Service Workshop Manual

Workshop service and repair manual for the Yanmar 3YM and 2YM units this full workshop manual set covers every component, service and repair procedure in full Yanmar factory specification with clear concise step by step photographs and technical drawings for the YM series with torque setting values throughout where required for fasteners and reassembly, below is an exhaustive list of the items covered within this set. This is the most comprehensive service manual available as used by Marine Engineers and Boatyards the world over.

General
Exterior Views
Specifications
Fuel Oil
Lubricating Oil
Cooling Water
Engine Outline
Piping Diagrams
Exhaust Gas Emission Regulation
Engine Identification (Epa/Arb)
Exhaust Gas Emission Standard (Epa/Arb)
Guarantee Conditions For Emission Standard (Epa/Arb)

Inspection And Adjustment
Periodic Maintenance Schedule
Periodic Inspection And Maintenance Procedure
1 Check Before Starting
2 Inspection After Initial 50 Hours Or One Month Operation
3 Inspection Every 50 Hours Or Monthly
4 Inspection Every 100 Hours Six Months
5 Inspection Every 150 Hours Or One Year
6 Inspection Every 250 Hours Or One Year
7 Inspection Every 1,000 Hours Or Four Years
Adjusting The No-load Maximum Or Minimum Speed
Sensor Inspection
Oil Pressure Switch
Thermo Switch
Thermostat Inspection
Adjusting Operation
Preliminary Precautions
Adjusting Operation Procedure
Check Points And Precautions During Running
Long Storage

Troubleshooting
Preparation Before Troubleshooting
Quick Reference Chart For Troubleshooting
Troubleshooting (Concerning Engine And Fuel Injection Equipment)
Troubleshooting By Measuring Compression Pressure

Disassembly And Reassembly
Disassembly And Reassembly Precautions
Disassembly And Reassembly Tools
General Hand Tools
Special Hand Tools
Measuring Instruments
Other Material
Disassembly
Reassembly

Inspection And Servicing Of Basic Engine Parts
1.Cylinder Block
Inspection Of Parts
Cleaning Of Oil Holes
Colour Check Procedure
Replacement Of Cap Plugs
Cylinder Bore Measurement

2.Cylinder Head
Inspecting The Cylinder Head
Valve Seat Correction Procedure
Intake/Exhaust Valves, Valve Guides
Valve Springs
Assembling The Cylinder Head
Measuring Top Clearance
Intake And Exhaust Rocker Arms
Adjustment Of Valve Clearance

3.Piston And Piston Pins
Piston
Piston Pin
Piston Rings

4.Connecting Rod
Inspecting The Connection Rod
Crank Pin Metal
Piston Pin Bushing
Assembling Piston And Connecting Rod

5.Crankshaft And Main Bearing
Crankshaft
Main Bearing
Camshaft
Tappets

6.Timing Gear
Inspecting The Gears
Gear Timing Marks

7.Flywheel And Housing
Position Of Top Dead Center And Fuel Injection Timing
Damper Disc

Fuel Injection Equipment
Fuel Injection Pump/Governor
Fuel System Diagram
Fuel Injection Pump Service Data And Adjustment
Fuel Injection Pump Structure
Removing Fuel Injection Pump
Installing Fuel Injection Pump
Adjusting Fuel Injection Timing
Troubleshooting Of Fuel Injection Pump
Major Faults And Troubleshooting

Fuel Feed Pump
Construction Of Fuel Feed Pump
Fuel Feed Pump Specifications
Disassembly And Reassembly Of Fuel Feed Pump
Fuel Feed Pump Inspection
Fuel Filter
Fuel Filter Specifications
Fuel Filter Inspection
Fuel Tank

Intake And Exhaust System
Intake System
Breather System (A Reductor To Intake Air System Of Blowby Gas)
Diaphragm Assy Inspection
Exhaust System
Construction
Mixing Elbow Inspection

Lubrication System
Lube Oil Pump
Lube Oil Pump Construction
Specifications Of Lube Oil Pump
Lube Oil Pump Disassembly And Reassembly
Lube Oil Pump Inspection
Pressure Control Valve Construction
Lube Oil Filter
Lube Oil Filter Construction
Lube Oil Filter Replacement
Rotary Waste Oil Pump (Optional)

Cooling Water System
Seawater Pump
Specifications Of Seawater Pump
Seawater Pump Disassembly
Seawater Pump Inspection
Seawater Pump Reassembly

Fresh Water Pump
Fresh Water Pump Construction
Specifications Of Fresh Water Pump
Fresh Water Pump Disassembly
Fresh Water Pump Inspection

Heat Exchanger
Heat Exchanger Construction
Disassembly And Reassembly Of The Heat Exchanger
Heat Exchanger Inspection

Pressure Cap And Coolant Recovery Tank
Pressure Cap Construction
Pressure Cap Pressure Control
Pressure Cap Inspection
Replacing Filler Neck
Function Of The Coolant Recovery Tank
Specifications Of Coolant Recovery Tank
Mounting The Coolant Recovery Tank
Precautions On Usage Of The Coolant Recovery Tank

Thermostat
Functioning Of Thermostat
Thermostat Construction
Characteristics Of Thermostat
Thermostat Inspection
Testing The Thermostat

Bilge Pump And Bilge Strainer
Introduction
Description
Cautions
Assembly Procedure
Cautions For Assembling
Troubleshooting

Reduction And Reversing Gear Specifications
Remote Control System
Construction Of Remote Control System
Remote Control Device Components
Remote Control Installation
Remote Control Inspection
Remote Control Adjustment

Electrical System
Wiring Diagram
Battery
Starting Motor – Specifications, Characteristics, Structure
Wiring Diameter Of Starting Motor
12.4 Alternator 12V/60A – 12V/80A – Specifications, Structure, Wiring Diagram
Standard Output Characteristics
Inspection
Instrument Panel
B-type Instrument Panel (Optional)

Warning Devices
Oil Pressure Alarm
Cooling Water Temperature Alarm
Glow Plug
Electric Engine Stopping Device

Service Standards
Engine Tuning
Engine Body
Cylinder Head
Camshaft And Gear Train
Cylinder Block
Lubricating Oil System (Trochoid Pump)

Tightening Torque For Bolts And Nuts
Main Bolt And Nut
Standard Bolts And Nuts (Without Lube Oil)