Yanmar 2YM15 manuals

Yanmar 2YM15 Service Manual (231 pages)

Brand: Yanmar | Category: Engine | Size: 16.79 MB |

English

Table of contents

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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