Yanmar 2YM15 Service Manual Page 77
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- Table of contents
- TROUBLESHOOTING
- BOOKMARKS
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3. Troubleshooting
57
TROUBLE AND TROUBLESHOOTING
Cause and Effect
Countermeasure
(IV-1) Lap valves.
(IV-2) Adjust.
(IV-3) Replace.
(IV-4) Replace.
(IV-5) Disassemble and repair or replace.
(V-1) Adjust timing to
delay injection.
(V-2) Adjust timing to
speed injection.
(VI-1) Clean.
(VII-1) Replace with good fuel oil.
(VII-2) Clean.
(VII-3) Disassemble, check and repair.
(VII-4)
Lap cooling water pump suction/exhaust valves.
(VII-5)
Disassemble and clean lube oil pump and filter.
Countermeasure
INSUFFICIENT POWER OUTPUT
Chart 8
(I-1) Replace.
(I-2) Disassemble and repair or replace.
(I-3) Lap valves.
(I-4) Tighten firmly.
(I-5) (I-6) Adjust.
(I-7) (I-8) Clean.
(I-9) Replace.
(I-10) Repair.
(II-1) Clean nozzle hole or replace.
(II-2) Lap or replace.
(II-3) Lap or replace.
(II-4) Tighten firmly.
(II-5) Replace.
(II-6) lean.
(III-1) Replace.
(III-2) Repair.
(1) Leakage of gas from
suction/exhaust valves
(2) Inadequate tapper
clearance
(IV) Leakage of pressurized gas from inside cylinder
(3) Worn upper part
of cylinder liner
(4) Worn piston ring
(5) Sticking of piston ring
INSUFFICIENT
POWER OUTPUT
(I) Amount of oil supply from fuel injection pump inadequate
(1) Worn plunger
(6) Inaccurate positioning
of adjustment rack
(7) Clogging of fuel filter
(8) Clogging of fuel oil pipe
(9) Damaged valve spring
(10) Faulty supply pump
(2) Sticking of plunger
(3) Oil leakage from exhaust valve
(5) Faulty adjustment of fuel pump
(4) Oil leakage from joint of
high pressure pipe
(III) Faulty governor
(1) Damaged governor bearing
(2) Inaccurate length
of governor link
(II) Amount of fuel injection inadequate
(1) Clogging of nozzle hole
(2) Faulty valve seat
(3) Sticking of valve needle
(4) Loose high pressure pipe
(5) Worn valve needle
(6) Clogging of filter
(VII) Miscellaneous
(1) Poor quality fuel oil
(2) Clogging of exhaust line
(3) Seizure of moving parts
(5) Insufficient lube oil supplied
(4) Insufficient cooling water
(VI) Clogged intake air filter
(1) Clogging of air filter
(V) Irregular fuel injection timing
(1) Early injection
(2) Late injection
- 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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