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Yanmar 2YM15 Service Manual Page 208
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TROUBLESHOOTING
BOOKMARKS
Rated
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12. Elec
trical Syst
em
187
12.3.3 Structure
(1)
Disassembly drawing
Magnetic switch
Internal gear
Bracket
Pinion
Gear housing
Armature
Yo
k
e
Rear cover
1
2
...
203
204
205
206
207
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3YM30/3YM20/2YM15
1
Printed in Japan
2
M9961-03E101
2
California
3
Proposition 65 Warning
3
CONTENTS
4
FOR SAFETY
10
Well fitting !!
12
1. General
16
1.2 Specifications
17
1.3.1 Fuel oil
20
1.3.2 Lubricating oil
20
1.3.3 Cooling water
21
1.4 Engine outline
22
1.General
23
007018-00E
25
1.5 Piping diagrams
28
5 YDX M 1.11 P 3 N
32
(b) Exhaust gas back pressure
33
(a) Fuel injection nozzle
34
(b) Fuel injection pump
34
2. Inspection and adjustment
35
2. Inspection and adjustment
36
2.2.1 Check before starting
37
(4) Seawater outlet
38
(5) Check cooling water level
38
Sediment
40
10 MINUTES
41
Alternator
42
Belt adjuster
42
Set bolt
42
(Valve clearance)
43
(Normal) (Abnormal)
43
(Valve clearance adjustment)
44
(Fuel filter)
45
Battery charge measurement
48
20 = St + 0.007 ( t - 20 )
49
(Hydrometer structure)
49
(How to read hydrometer)
49
(Oil drain pump)
50
Pressue cap
53
Fresh water
53
Coolant tankNotches
53
To fresh water
54
Rubber hose
54
(L-type mixing elbow)
55
Optional
55
(U-type mixing elbow)
55
Injection nozzle
58
Nozzle tester
58
(Abnormal spray pattern)
60
(Normal spray pattern)
60
NP - DN O P D N159
61
Test pressure
62
0.20 MPa (2 kgf/cm
62
(Breather system component)
63
2.4 Sensor Inspection
64
2.5 Thermostat inspection
65
2.6 Adjusting operation
66
2.7 Long storage
68
3. Troubleshooting
69
Cause and Effect
77
Countermeasure
77
3. Troubleshooting
79
Compression
82
4. Disassembly and reassembly
84
4.2.1 General hand tools
85
Local supply 1 set
86
H = Shaft type
87
S = Hole type
87
4.2.2 Special hand tools
88
(Local supply)
89
(Removing the coupling)
89
(Tool 1)
90
(Tool 2)
90
4.2.3 Measuring instruments
91
(2) Use of tools
92
Revolving shaft
94
Reflection mark
94
High pressure
94
4.2.4 Other material
95
[Notice]
96
4.3.1 Disassembly
97
(Cooling water pipes)
100
(Seawater pump)
101
(Removing flywheel)
104
(21)Turning the engine over
105
(23) Removing the oil pan
105
(25)Removing the gear case
105
(28) Removing the camshaft
106
(27)Removing the idle gear
106
(30) Removing the gear case
107
(32)Turning the engine over
107
(34)Removing the main bearing
108
(35)Removing the crankshaft
108
(36)Removing the tappets
108
4.3.2 Reassembly
109
(Journal bearing cap)
110
(Piston ring)
111
(Ring joints)
111
(Camshaft side gap)
112
(Idle gear shaft)
113
(Gear train)
113
Lube oil inlet pipe 26 (2.6)
114
(18) Mounting the flywheel
115
006757-00E
116
006758-00E
116
(31) Mounting the alternator
121
(35) Electrical Wiring
122
(37) Filling with lube oil
122
(39) Test running
123
5.1 Cylinder block
124
001494-00E
126
5.2 Cylinder head
127
Straight-edge
128
Thickness gage
128
(Valve lapping tool)
129
(Valve sink depth)
130
(Valve sink)
130
(4) Valve guide
131
(Stem seal insertion)
132
001509-00E
132
Free length
132
001511-00E
132
(3 cylinder head)
133
(2 cylinder head)
133
001515-00E
134
001516-00E
134
(Refer to 2.2.2(8).)
135
5.3 Piston and piston pins
136
5.3.2 Piston pin
137
(Ring components)
138
(Measuring side clearance)
138
180°) the oil ring gap
140
5.4 Connecting rod
141
(Connecting rod side gap)
142
Plastic gauge
143
Alignment mark (Punched mark)
143
Matching mark
143
(Connecting rod small end)
144
(Inspection by color check)
145
(Crankshaft bend measurement)
145
(Crankshaft R machining)
146
5.5.2 Main bearing
147
5.6 Camshaft and tappets
148
(Camshaft outside diameter)
149
(Camshaft bend)
149
5.6.2 Tappets
150
5.7 Timing gear
151
5.8 Flywheel and housing
152
5.8.2 Damper disc
153
6. Fuel injection equipment
154
(1) Service data
155
2) Service data for 3YM20
156
3) Service data for 2YM15
157
(2) Fuel adjustment procedure
158
(Adjustment procedure for 7))
159
6.2 Fuel feed pump
165
N•cm(kgf•cm)
166
001568-00E
167
Inlet valve Outlet valve
167
6.3 Fuel filter
168
6.4 Fuel tank
169
7. Intake and exhaust system
170
7.2 Exhaust system
172
8. Lubrication system
173
8.2 Lube oil pump
174
(Outer diameter clearance)
175
(Side clearance)
175
8.3 Lube oil filter
176
8. Lubrication system
177
9. Cooling water system
178
9.2 Seawater pump
180
(3) Mount the impeller
182
9.3 Fresh water pump
183
Thickness gauge
184
001582-00E
184
9. Cooling water system
185
9.4 Heat exchanger
186
9.5.3 Pressure cap inspection
187
9.5.4 Replacing filler neck
188
Filler cap
189
Coolant recovery tank
189
9.6 Thermostat
190
9.7.1 Introduction
191
9.7.2 Description
192
9.7.3 Cautions
192
9.7.4 Assembly procedure
193
Fixing hole
194
Delivery nozzle
194
9.7.5 Cautions for assembling
195
9.7.6 Troubleshooting
196
10.1 Specifications
197
11. Remote control (Optional)
198
(2) Remote control cable
199
(3) Engine stop cable
199
(1) Speed control
200
(Remote control cable clamp)
201
(KM2P-1 marine gear)
201
(1) Shift lever adjustment
203
(2) Throttle lever adjustment
203
12. Electrical system
204
12.1.1 Wiring diagram
205
12.2 Battery
206
12.3 Starting motor
207
12.3.3 Structure
208
(2) Structure
209
12.4.1 Specifications
210
Rotative direction
211
(Standard characteristics)
212
(Inspection of V pulley)
213
Clearance
213
12.5.1 Specifications
214
12.5.2 Structure
215
12. Electrical System
217
12.7 Warning devices
218
M16 x 1.5
219
12.8 Glow plug
220
Stop solenoid
221
Governor
221
Emergency stop button
221
13. Service standards
222
13.2 Engine body
223
(5) Tappet and push rod
224
(1) Camshaft
224
(3) Backlash of each gear
224
13.2.3 Cylinder block
225
(4) Piston and ring
226
(5) Connecting rod
227
13. Service standards
228
14.1 Main bolt and nut
229
SERVICE MANUAL
230
YANMAR CO,. LTD
231
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