MARINE ENGINES2YM153YM203YM30E3YM30OPERATION MANUALenEnglish

INTRODUCTION4 YM Series Operation ManualThis Page Intentionally Left BlankYM OPM_EN.book 4 ページ ２０１３年６月７日　金曜日　午前１１時１１分

SYSTEM DIAGRAMS94 YM Series Operation ManualWIRING DIAGRAMSColor CodingRRedBBlackWWhiteLBlueRB Red / BlackLB Blue / BlackYW Yellow / WhiteYG Yellow /

SYSTEM DIAGRAMSYM Series Operation Manual 9512/05 Figure 32YM15, 3YM20, 3YM30(E) - B20 Type Instrument PanelFigure 3 Power SWGlow SWStop SWS

SYSTEM DIAGRAMS96 YM Series Operation Manual1 – Instrument panel B202 – Alarm lamps (3 to 7)3 – Engine oil low pressure indicator4 – Coolant high temp

YM Series Operation Manual 97EPA WARRANTY USA ONLYYANMAR CO., LTD. LIMITED EMISSION CONTROL SYSTEM WARRANTY - USA ONLY2YM15 EPA and CARBNameplate For

EPA WARRANTY USA ONLY98 YM Series Operation ManualTHIS EMISSION WARRANTY APPLIES TO THE ENGINES CERTIFIED TO UNITED STATES EPA 40 CFR Part 1042.135 AN

EPA WARRANTY USA ONLYYM Series Operation Manual 9912/05Warranty Coverage:Repair or replacement of any warranted parts will be performed at an authoriz

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YM Series Operation Manual 101EMISSION SYSTEM WARRANTYNON-ROAD EMISSION SYSTEM WARRANTYYanmar Co., Ltd. Limited Emission Control System Warranty - USA

EMISSION SYSTEM WARRANTY102 YM Series Operation ManualWarranty Coverage:This warranty is transferable to each subsequent purchaser for the duration of

EMISSION SYSTEM WARRANTYYM Series Operation Manual 10312/05Owners Warranty Responsibilities:As the engine owner, you are responsible for the performan

YM Series Operation Manual 5 SAFETYYanmar considers safety of great importance and recommends that anyone that comes into close contact with its produ

EMISSION SYSTEM WARRANTY104 YM Series Operation ManualMaintenance LogDate Operating Hours Maintenance Performed Dealer NameStamp or SignatureYM OPM_EN

EMISSION SYSTEM WARRANTYYM Series Operation Manual 10512/05Date Operating Hours Maintenance Performed Dealer NameStamp or SignatureYM OPM_EN.book 105

EMISSION SYSTEM WARRANTY106 YM Series Operation Manual YM OPM_EN.book 106 ページ ２０１３年６月７日　金曜日　午前１１時１１分

1st edition: November 20072nd edition 1st rev.: March 20122nd edition 2nd rev.: July 20123rd edition: February 20133rd edition 1st rev.: June 20132YM1

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SAFETY6 YM Series Operation ManualSAFETY PRECAUTIONSGeneral InformationThere is no substitute for common sense and careful practices. Improper practic

SAFETYYM Series Operation Manual 712/05WARNINGSever HazardRotating parts can cause severe injury or death. Never wear jewelry, unbuttoned cuffs, ties

SAFETY8 YM Series Operation ManualCAUTIONThe safety messages that follow have CAUTION level hazards.Poor Lighting HazardEnsure that the work area is a

SAFETYYM Series Operation Manual 912/05NOTICEIf you have an installation with two or three engines and only one engine is operating, the water pickup

SAFETY10 YM Series Operation ManualLOCATION OF SAFETY DECALSFigure 1, show the location of safety decals on Yanmar YM series marine engines.YM Engines

YM Series Operation Manual 11 PRODUCT OVERVIEWYANMAR YM SERIES FEATURES AND APPLICATIONSThe YM series are four-stroke swirl pre-combustion chamber die

PRODUCT OVERVIEW12 YM Series Operation ManualNew Engine Break-InAs with all reciprocating engines, the way your engine is operated during its first 50

PRODUCT OVERVIEWYM Series Operation Manual 1312/05COMPONENT IDENTIFICATIONRight Side (Viewed from Flywheel) - 2YM15Figure 1 and Figure 2 illustrate a

Disclaimers:All information, illustrations and specifications in this manual are based on the latest information available at the time of publishing.

PRODUCT OVERVIEW14 YM Series Operation ManualRight Side (Viewed from Flywheel) - 3YM20Figure 3 and Figure 4 illustrate a typical version of a 3YM20 en

PRODUCT OVERVIEWYM Series Operation Manual 1512/05Right Side (Viewed from Flywheel) - 3YM30(E)Figure 5 and Figure 6 illustrate a typical version of a

PRODUCT OVERVIEW16 YM Series Operation ManualNAMEPLATESThe nameplates of Yanmar YM series engines are shown in Figure 7. Check the engine’s model, out

PRODUCT OVERVIEWYM Series Operation Manual 1712/05FUNCTION OF MAJOR COMPONENTSName of Component Function Fuel Filter Removes dirt and water from the

PRODUCT OVERVIEW18 YM Series Operation ManualCONTROL EQUIPMENTThe equipment in the control room makes remote control operation possible. It consists o

PRODUCT OVERVIEWYM Series Operation Manual 1912/05MetersNote: The LCD on the instrument panel show hourmeter, display brightness and battery voltage.I

PRODUCT OVERVIEW20 YM Series Operation ManualLCD control (hourmeter, display brightness, battery voltage)You can switch (scroll) between displays by p

PRODUCT OVERVIEWYM Series Operation Manual 2112/05Setup Screen Access and Control (Setting the engine speed pulse value for B20/C30 type panel)Use the

PRODUCT OVERVIEW22 YM Series Operation ManualAlarmsChecking the Warning DevicesBefore and after engine start, make sure that the instruments and warni

PRODUCT OVERVIEWYM Series Operation Manual 2312/05Accessory power outputThe harness attached to the panel has a terminal where the signal that is sync

YM Series Operation ManualTABLE OFCONTENTSINTRODUCTION ... 1YM SERIES EMISSION CONTROL SYS

PRODUCT OVERVIEW24 YM Series Operation ManualSingle-Handle Remote Control Head Figure 4Figure 14 Note: Direction of travel will vary depending on inst

YM Series Operation Manual 25 BEFORE YOU OPERATEINTRODUCTIONThis section of the Operation Manual describes the diesel fuel, engine oil and engine cool

BEFORE YOU OPERATE26 YM Series Operation ManualDIESEL FUELDiesel Fuel SpecificationsWARNINGFire and Explosion Hazard. Diesel fuel is flammable and exp

BEFORE YOU OPERATEYM Series Operation Manual 2712/05• Even biodiesel fuels that comply with a suitable standard as delivered will require additional c

BEFORE YOU OPERATE28 YM Series Operation ManualFigure 1 2. Keep the fuel container stationary for several hours to allow any dirt or water to settle t

BEFORE YOU OPERATEYM Series Operation Manual 2912/05Filling the Fuel TankBefore filling fuel tank for the first time:WARNINGFire and Explosion Hazard.

BEFORE YOU OPERATE30 YM Series Operation ManualBleeding the Fuel SystemThe fuel system has an automatic air bleeding device that purges air from the f

BEFORE YOU OPERATEYM Series Operation Manual 3112/05ENGINE OILEngine Oil Specifications NOTICEOnly use the engine oil specified. Other engine oils may

BEFORE YOU OPERATE32 YM Series Operation ManualNOTICEIf you intend to operate your equipment at temperatures outside the limits shown, you must consul

BEFORE YOU OPERATEYM Series Operation Manual 3312/05MARINE GEAR OR SAIL DRIVE OILMarine Gear Oil SpecificationsUse marine gear oil that meets or excee

TABLE OF CONTENTSYM Series Operation ManualBEFORE YOU OPERATE ... 25INTRODUCTION ...

BEFORE YOU OPERATE34 YM Series Operation ManualENGINE COOLANTEngine Coolant SpecificationsNote: In the U.S., LLC is required for the warranty to be va

BEFORE YOU OPERATEYM Series Operation Manual 3512/05Checking and Adding Coolant Figure 1Figure 8 1 – Coolant Tank / Heat Exchanger2 – Coolant Drain Pl

BEFORE YOU OPERATE36 YM Series Operation Manual Figure 3Figure 11 1 – Filler Cap Tabs2 – Coolant Filler Cap3 – Filler Port Notches4 – Coolant Tank / H

BEFORE YOU OPERATEYM Series Operation Manual 3712/059. Check the rubber hose (Figure 12, (1)) connecting the reservoir to the coolant tank / heat exch

BEFORE YOU OPERATE38 YM Series Operation Manual Figure 5Figure 13 6. Continue cranking the engine for about 5 seconds, checking for abnormal sounds. I

YM Series Operation Manual 39 ENGINE OPERATIONINTRODUCTIONThis section of the Operation Manual describes the diesel fuel, engine oil and engine coolan

ENGINE OPERATION40 YM Series Operation ManualWARNINGFire and Explosion HazardNever jump-start the engine. Sparks caused by shorting the battery to the

ENGINE OPERATIONYM Series Operation Manual 4112/05NOTICE• Contact your authorized Yanmar Marine engine dealer or distributor if the engine will be ope

ENGINE OPERATION42 YM Series Operation ManualIf the Engine Fails to StartBefore pushing the start switch again, be sure to confirm that the engine has

ENGINE OPERATIONYM Series Operation Manual 4312/05Starting with Glow plug (If Equipped)1. Open the seacock (if equipped).2. Open the fuel tank cock.3.

TABLE OF CONTENTSYM Series Operation Manual12/05PRECAUTIONS ... 51The Importance of Periodic Main

ENGINE OPERATION44 YM Series Operation ManualREMOTE CONTROL HANDLE OPERATIONAcceleration and DecelerationFigure 2 1 – FORWARD or REVERSE2 – NEUTRAL3 –

ENGINE OPERATIONYM Series Operation Manual 4512/05CAUTIONS DURING OPERATIONNOTICEEngine trouble can arise if the engine is operated for a long time un

ENGINE OPERATION46 YM Series Operation ManualNOTICERacing the engine: With the gear in NEUTRAL, accelerate from the low-speed position to the high-spe

ENGINE OPERATIONYM Series Operation Manual 4712/05NOTICEContinue to hold the stop switch in until the engine is completely stopped. If the switch is r

ENGINE OPERATION48 YM Series Operation ManualCHECKING THE ENGINE AFTER OPERATION• Check that the power switch is off and that the battery switch (if e

YM Series Operation Manual 49PERIODIC MAINTENANCEINTRODUCTIONThis section of the Operation Manual describes the procedures for proper care and mainten

PERIODIC MAINTENANCE50 YM Series Operation ManualWARNINGWelding Hazard• Always turn off the battery switch (if equipped) or disconnect the negative ba

PERIODIC MAINTENANCEYM Series Operation Manual 5112/05PRECAUTIONSThe Importance of Periodic MaintenanceEngine deterioration and wear occur in proporti

PERIODIC MAINTENANCE52 YM Series Operation ManualTightening FastenersUse the correct amount of torque when you tighten fasteners on the engine. Applyi

PERIODIC MAINTENANCEYM Series Operation Manual 5312/05EPA MAINTENANCE REQUIREMENTSTo maintain optimum engine performance and compliance with the Envir

TABLE OF CONTENTSYM Series Operation ManualSPECIFICATIONS ... 83PRINCIPAL ENGINE SPECIFICATIONS

PERIODIC MAINTENANCE54 YM Series Operation ManualInstalling Sample PortAll engines subject to emission standards shall be equipped with a connection i

PERIODIC MAINTENANCEYM Series Operation Manual 5512/05PERIODIC MAINTENANCE SCHEDULEDaily and periodic maintenance is important to keep the engine in g

PERIODIC MAINTENANCE56 YM Series Operation Manual: Check or Clean : Replace ●: Contact your authorized Yanmar Marine dealer or distributorSystem Ite

PERIODIC MAINTENANCEYM Series Operation Manual 5712/05* For EPA requirements, see Inspection and Maintenance of EPA Emission-Related Parts on page 58

PERIODIC MAINTENANCE58 YM Series Operation ManualInspection and Maintenance of EPA Emission-Related Parts• Marine diesel engines less than 37 kW (50 h

PERIODIC MAINTENANCEYM Series Operation Manual 5912/05PERIODIC MAINTENANCE PROCEDURESWARNINGExposure Hazard. Always wear personal protective equipment

PERIODIC MAINTENANCE60 YM Series Operation ManualChecking and Refilling Marine Gear OilRefer to the Operation Manual for the marine gear.Checking the

PERIODIC MAINTENANCEYM Series Operation Manual 6112/05Draining the Fuel TankFigure 1 1–Sediment Bowl2 – Drain Cock3 – Fuel Line to EngineNote: Optiona

PERIODIC MAINTENANCE62 YM Series Operation ManualReplacing the Engine Oil Filter Element1. Turn the engine off.2. Turn the engine oil filter Figure 2

PERIODIC MAINTENANCEYM Series Operation Manual 6312/051. Remove the belt cover.2. Check the belt by pushing on the middle of the belt (Figure 3, (1))

YM Series Operation Manual 1INTRODUCTIONWelcome to the world of Yanmar Marine! Yanmar Marine offers engines, drive systems and accessories for all typ

PERIODIC MAINTENANCE64 YM Series Operation Manual1. Check that the control lever on the engine side moves to the high-speed stop position and low-spee

PERIODIC MAINTENANCEYM Series Operation Manual 6512/05When completing the initial 50 hour maintenance procedures, perform the following procedures eve

PERIODIC MAINTENANCE66 YM Series Operation Manual5. Be sure to bleed air from the fuel system. See Bleeding the Fuel System on page 30.Checking the Ba

PERIODIC MAINTENANCEYM Series Operation Manual 6712/05Perform the following maintenance every 100 hours or every 6 months of operation, whichever come

PERIODIC MAINTENANCE68 YM Series Operation ManualPerform the following maintenance every 250 hours or 1 year of operation, whichever comes first.• Dra

PERIODIC MAINTENANCEYM Series Operation Manual 6912/05When there is dirt in the fuel, the filter becomes clogged and the fuel will not flow easily. Ch

PERIODIC MAINTENANCE70 YM Series Operation ManualReplacing the CoolantCAUTIONCoolant Hazard. Wear eye protection and rubber gloves when you handle eng

PERIODIC MAINTENANCEYM Series Operation Manual 7112/05Adjusting the Alternator V-ribbed belt TensionSee Checking and Adjusting the Alternator V-ribbed

PERIODIC MAINTENANCE72 YM Series Operation ManualReplacing the Seawater Pump ImpellerThe seawater impeller must be replaced every 1000 hours or every

PERIODIC MAINTENANCEYM Series Operation Manual 7312/05Checking and Adjusting the Remote Control CablesSee Checking and Adjusting the Remote Control Ca

INTRODUCTION2 YM Series Operation ManualYM SERIES EMISSION CONTROL SYSTEM WARRANTY-USA, THE ENVIRONMENTAL PROTECTION AGENCY (EPA) ONLYYM series engine

PERIODIC MAINTENANCE74 YM Series Operation ManualThis Page Intentionally Left BlankYM OPM_EN.book 74 ページ ２０１３年６月７日　金曜日　午前１１時１１分

YM Series Operation Manual 75 TROUBLESHOOTINGSAFETY PRECAUTIONSBefore performing any troubleshooting procedures within this section, review the Safety

TROUBLESHOOTING76 YM Series Operation ManualIs there water, oil or fuel leakage? Are there any loose bolts or connections?Check the engine room daily

TROUBLESHOOTINGYM Series Operation Manual 7712/05TROUBLESHOOTING CHARTSymptom Probable Cause Measure ReferenceIndicators light on the instrument panel

TROUBLESHOOTING78 YM Series Operation ManualStarter does not turn or turns slowly (engine can be turned manually)Faulty clutch position. Shift to NEUT

YM Series Operation Manual 79 LONG-TERM STORAGEIf the engine will not be used for an extended period of time, special measures should be taken to prot

LONG-TERM STORAGE80 YM Series Operation ManualDRAIN SEAWATER COOLING SYSTEMFigure 1 1 – Coolant Tank / Heat Exchanger2 – Seawater Drain Cock

LONG-TERM STORAGEYM Series Operation Manual 8112/05NOTICENever drain engine coolant in the cold season or before long storage. If LLC (Long Life Coola

LONG-TERM STORAGE82 YM Series Operation ManualThis Page Intentionally Left BlankYM OPM_EN.book 82 ページ ２０１３年６月７日　金曜日　午前１１時１１分

YM Series Operation Manual 83 SPECIFICATIONSPRINCIPAL ENGINE SPECIFICATIONSYM OPM_EN.book 83 ページ ２０１３年６月７日　金曜日　午前１１時１１分

INTRODUCTIONYM Series Operation Manual 312/05RECORD OF OWNERSHIPTake a few moments to record the information you need when you contact Yanmar for serv

SPECIFICATIONS84 YM Series Operation Manual2YM15 Engine SpecificationsNote: Density of fuel: 0.842 g/cm3 at 15°C. Fuel temperature at the inlet of th

SPECIFICATIONSYM Series Operation Manual 8512/053YM20 Engine SpecificationsNote: Density of fuel: 0.842 g/cm3 at 15°C. Fuel temperature at the inlet o

SPECIFICATIONS86 YM Series Operation Manual3YM30E Engine SpecificationsNote: Density of fuel: 0.842 g/cm3 at 15°C. Fuel temperature at the inlet of th

SPECIFICATIONSYM Series Operation Manual 8712/053YM30 Engine SpecificationsNote: Density of fuel: 0.842 g/cm3 at 15°C. Fuel temperature at the inlet o

SPECIFICATIONS88 YM Series Operation ManualMarine Gear and Sail Drive SpecificationsModel KM2P-1(S) KM2P-1(G) KM2P-1(GG)SD20 (coupled at boat builder)

YM Series Operation Manual 89 SYSTEM DIAGRAMSPIPING DIAGRAMSPiping diagrams and wiring diagrams are provided for reference only. Contact your authoriz

SYSTEM DIAGRAMS90 YM Series Operation Manual Figure 12YM15 with KM2P-1 Marine GearFigure 1 PPPPT12345678910111213151416173029282726252434333

SYSTEM DIAGRAMSYM Series Operation Manual 9112/05Unit: mm (in.) 1 – 7.8 x t4.5 Rubber Hose2 – Check Valve3 – 7.8 x t4.5 Rubber Hose4 – 7.8 x t4.5 Rubb

SYSTEM DIAGRAMS92 YM Series Operation Manual Figure 23YM20 and 3YM30(E) with KM2P-1 Marine GearFigure 2 PPPTP026476-00X14562 397 81110121314

SYSTEM DIAGRAMSYM Series Operation Manual 9312/05Unit: mm (in.) 1–PCV2–Overflow3 – Fuel Inlet4 – Fuel Feed Pump5 – Fuel Injection Pump6 – Engine Oil F