Yanmar Ym Series Operations Manual V2 21jan09
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4AAAAAAAAAAAAAIIAPAAdvOYQnE0p6YqC Aa HmPA8WDjE H9v5LpRTa1PdEPdD0B82PdD0B2B ELXqPbDE0E0E0L0B2N4mDSELA02yDPdLTPdDtFT0BxHa1aELCHQA0aBJyA02yA02J1T1R 20EDr 1RTJR HQA0AN4lEDXrx A02J HQAPq02J0HQA0APbydFHQAPaa0aBaPa2ELA02HQAPa1PbDAV1lAV1eJ3bAV1c1eJ HQA0AH0BTHPbDHQAD HQAPqH0E0JaPbDxRJaByAPbDxTJa2HQAAPbDELAPbDELAPbDHQAAPbDHQA0ELa1aHQAELa1PbDHQAELa1PdEE0J pitqPcyD0BGN4m4PELa1Pcpj DPbDHQA1MFDq x0B8dFHQAT0BH1b2lPbDELa1PbDHQAz0fffh33D3h8UUUUX3D33DDDDHfffff3ffhFfhfffhf4EUUf333ffffh4HHDUUXfhfh5UUff5ff3ff3UDff3U3U3UUUffh3333333U4DDDUH6fhDfffffhfhffDff3ffD5VffU3DD33DUU33ff33UUffh3334Efffffh33335fUUUffhffff336ffhX6ffhdvOYQnE0p6YqYMseriesYM Series Operation ManualOPERATION MANUAL2YM153YM203YM30PN 0AYMMG00200 MARINEENGINESiiYM Series Operation Manual 2009 Yanmar Marine InternationalDisclaimersAll information illustrations and specifications in this manual are based on the latest information available at the time of publishing The illustrations used in this manual are intended as representative reference views only Moreover because of our continuous product improvement policy we may modify information illustrations andor specifications to explain andor exemplify a product service or maintenance improvement We reserve the right to make any change at any time without notice Yanmar and are registered trademarks of Yanmar Co Ltd in Japan the United States andor other countriesAll Rights ReservedNo part of this publication may be reproduced or used in any form by any means graphic electronic or mechanical including photocopying recording taping or information storage and retrieval systems without the written permission of Yanmar Marine International 2009 Yanmar Marine International0109 2008 Yanmar Marine InternationalIntroduction 1Record of Ownership 2Safety 3Safety Precautions 4General Information 4Before You Operate 4During Operation and Maintenance 5Location of Safety Decals 8Product Overview 9Yanmar YM Features and Applications 9New Engine BreakIn 10Component Identification 11Right Side from Flywheel 11Left Side from Flywheel2YM15 11Right Side from Flywheel 12Left Side from Flywheel3YM20 12Right Side from Flywheel 13Left Side from Flywheel3YM30 13Location of Nameplates 14Function of Major Components 15Control Equipment 16Instrument Panel Optional 16SingleLever Remote Control Handle 20Before You Operate 21Safety Precautions 21Introduction 21Diesel Fuel 22Diesel Fuel Specifications 22Filling the Fuel Tank 25Bleeding the Fuel System 26YM Series Operation Manual 2008 Yanmar Marine InternationalEngine Oil 27Engine Oil Specifications 27Engine Oil Viscosity 28Checking the Engine Oil 28Adding Engine Oil 29Marine Gear or Sail Drive Oil 29Marine Gear Oil Specifications 29Sail Drive Oil Specifications SD20 29Checking Marine Gear Oil 30Adding Marine Gear Oil 30Checking and Adding Sail Drive Oil 30Engine Coolant 31Engine Coolant Specifications 31Checking and Adding Coolant 31Cranking the Engine 34Engine Operation 35Safety Precautions 35Introduction 36Starting the Engine 37Restarting After Starting Failure 37Starting at Low Temperatures 38After the Engine has Started 38Remote Control Handle Operation 39Acceleration and Deceleration 39Shifting the Engine 40Shutting Down the Engine 40Emergency Shutdown 41Checking the Engine After Operation 42Periodic Maintenance 43Safety Precautions 43Introduction 45Precautions 45The Importance of Periodic Maintenance 45Performing Periodic Maintenance 45The Importance of Daily Checks 45Keep a Log of Engine Hours and Daily Checks 46Yanmar Replacement Parts 46Tools Required 46Ask Your Authorized Yanmar Marine Dealer or Distributor for Help 46Tightening Fasteners 47EPA Maintenance Requirements 48EPA Requirements foApplicable Countries 48re Compliance with EPA Emission Standards 48TABLE OF CONTENTS1205 2008 Yanmar Marine InternationalInspection and Maintenance 48Installing Sample Port 48Periodic Maintenance Schedule 50Inspection and Maintenance of EPA EmissionRelated Parts 54Periodic Maintenance Procedures 55Daily Checks 55After Initial 50 Hours of Operation 56Every 50 Hours of Operation 60Every 100 Hours of Operation 62Every 150 Hours of Operation 63Every 250 Hours of Operation 63Every 1000 Hours of Operation 66 Troubleshooting 69Safety Precautions 69Troubleshooting After Starting 69Troubleshooting Information 70Troubleshooting Chart 71LongTerm Storage 75Safety Precautions 75Introduction 75Prepare Engine for LongTerm Storage 76Draining the Cooling System 76 79Principal Engine Specifications 792YM15 Engine Specifications 793YM20 Engine Specifications 813YM30 Engine Specifications 83Marine Gear and Sail Drive Specifications 85System Diagrams 87Piping Diagrams 87Wiring Diagrams 93EPA Warranty USA Only 99Yanmar Co Ltd Limited Emission Control System Warranty USA Only 99Your Warranty Rights and Obligations 100Warranty Period 100Warranty Coverage 101Exclusions 101Owners Responsibility 101Customer Assistance 102Emission System Warranty 103NonRoad Emission System Warranty 103Yanmar Co Ltd Limited Emission Control System Warranty USA Only 103YM Series Operation Manual 2008 Yanmar Marine InternationalMaintenance Log 106 2009 Yanmar Marine InternationalYM Series Operation ManualWelcome to the world of Yanmar Marine Yanmar Marine offers engines drive systems and accessories for all types of boats from runabouts to sailboats and from cruisers to mega yachts In marine leisure boating the worldwide reputation of Yanmar Marine is second to none We design our engines to respect nature This means quieter engines with minimal vibrations cleaner than ever All of our engines meet applicable regulations including emissions at the time of manufactureTo help you enjoy your Yanmar YM series engine for many years to come please follow these recommendationsRead and understand this Operation Manual before you operate the engine to ensure that you follow safe operating practices and maintenance proceduresKeep this Operation Manualconvenient place for easy accessIf this Operation Manual is lost or damaged order a new one from your authorized Yanmar Marine dealer or distributorMake sure this manual is transferred to subsequent owners This manual should be considered a permanent part of the engine and remain with itConstant efforts are made to improve the quality and performance of Yanmar products so some details included in Operation Manual may differ slightly from your engine If you have any questions about these differences please contact your authorized Yanmar Marine dealer or distributorThe specifications and components instrument panel fuel tank etcdescribed in this manual may differ from ones installed on your vessel Please refer to the manual provided by the manufacturer of these componentsRefer to the Yanmar Limited Warranty Handbook for a complete warranty descriptionYM Series Operation Manual 2009 Yanmar Marine InternationalTake a few moments to record the information you need when you contact Yanmar for service parts or literatureEngine ModelEngine Serial NoDate PurchasedDealerDealer PhoneYM Series Operation Manual3 2009 Yanmar Marine InternationalYM Series Operation ManualSAFETYYanmar considers safety of great importance and recommends that anyone who comes in close contact with its products such as those who install operate maintain or service Yanmar products exercise care common sense and comply with the safety information in this manual and on the engines safety decals Keep the decals from becoming dirty or torn and replace them if they are lost or damaged Also if you need to replace a part that has a decal attached to it make sure you order the new part and decal at the same timeIndicates a hazardous situation which if not avoided will result in death or serious injuryIndicates a hazardous situation which if not avoided could result in death or serious injuryIndicates a hazardous situation which if not avoided could result in minor or moderate injuryIndicates a situation which can cause damage to the engine personal property andor the environment or cause the equipment to operate improperlyAThis safety alert symbol appears with most safety statements It means attention become alert your safety is involved Please read and abide by the message that follows the safety alert symbolSAFETY4YM Series Operation Manual 2009 Yanmar Marine InternationalSAFETY PRECAUTIONSGeneral InformationThere is no substitute for common sense and careful practices Improper practices or carelessness can cause burns cuts mutilation asphyxiation other bodily injury or death This information contains general safety precautions and guidelines that must be followed to reduce risk to personal safety Special safety precautions are listed in specific procedures Read and understand all of the safety precautions before operation or performing repairs or maintenanceBefore You OperateThe safety messages that follow have DANGER level hazardsNEVER permit anyone to install or operate the engine without proper trainingRead and understand this Operation Manual before you operate or service the engine to ensure that you follow safe operating practices and maintenance proceduresSafety signs and decals are additional reminders for safe operating and maintenance techniquesSee your authorized Yanmar Marine dealer or distributor for additional trainingSAFETYYM Series Operation Manual51205 2009 Yanmar Marine InternationalDuring Operation and MaintenanceThe safety messages that follow have WARNING level hazardsExplosion HazardWhile the engine is running or the battery is charging hydrogen gas is being produced and can be easily ignited Keep the area around the battery wellventilated and keep sparks open flames and any other form of ignition out of the areaFire and Explosion HazardDiesel fuel is flammable and explosive under certain conditions NEVER use a shop rag to catch the fuelWipe up all spills immediatelyNEVER refuel with the engine runningStore any containers containing fuel in a wellventilated area away from any combustibles or sources of ignitionFire HazardUndersized wiring systems can cause an electrical fireEnsure that appropriate fire detection and extinguishing equipment are installed and checked periodically for proper operationCoolant may be flammable under certain conditions NEVER allow coolant to come into contact with hot surfaces or insulation materialSever HazardNEVER wear jewelry unbuttoned cuffs ties or loosefitting clothing and ALWAYS tie back long hair when working near moving rotating parts such as the flywheel or PTO shaft Keep hands feet and tools away from all moving partsThe propeller may rotate during towing or ifthe engine is running at idle speed NEVERservice the engine while being towed orwhen the engine is runningIf the vessel has more than one engineNEVER service an engine if either of theengines is running In multiengineconfigurations the propeller for an enginethat is shut down may rotate if any of theother engines are runningNEVER operate the engine without theguards in placeAlcohol and Drug HazardNEVER operate the engine while under the influence of alcohol or drugs or if you are feeling ill Exposure HazardALWAYS wear personal protective equipment including appropriate clothing gloves work shoes eye and hearing protection as required by the task at handSAFETY6YM Series Operation Manual 2009 Yanmar Marine InternationalBurn HazardSome of the engine surfaces become very hot during operation and shortly after shutdown Keep hands and other body parts away from hot engine surfacesExhaust HazardNEVER block windows vents or other means of ventilation if the engine is operating in an enclosed area All internal combustion engines create carbon monoxide gas during operation and special precautions are required to avoid carbon monoxide poisoningSudden Movement HazardNEVER operate the engine while wearing a headset to listen to music or radio because it will be difficult to hear the warning signalsThe safety messages that follow have CAUTION level hazardsPoor Lighting HazardEnsure that the work area is adequately illuminated ALWAYS install wire cages on portable safety lampsTool HazardALWAYS use tools appropriate for the task at hand and use the correct size tool for loosening or tightening engine partsFlying Object HazardALWAYS wear eye protection when servicing the engine or when using compressed air or highpressure water Dust flying debris compressed air pressurized water or steam may injure your eyesCoolant HazardWear eye protection and rubber gloves when you handle Long Life engine coolant If contact with the eyes or skin should occur flush eyes and wash immediately with clean waterSAFETYYM Series Operation Manual71205 2009 Yanmar Marine InternationalThe safety messages that follow have NOTICE level hazards It is important to perform daily checks as listed in the Operation Manual Periodic maintenance prevents unexpected downtime reduces the number of accidents due to poor engine performance and helps extend the life of the engineSee your authorized Yanmar Marine dealer or distributor if you need to operate the engine at high altitudes At high altitudes the engine will lose power run rough and produce exhaust gases that exceed the design specificationsALWAYS be environmentally responsibleFollow the guidelines of the EPA or other governmental agencies for the proper disposal of hazardous materials such as engine oil diesel fuel and engine coolant Consult the local authorities or reclamation facilityNEVER dispose of hazardous materials by dumping them into a sewer on the ground or into ground water or waterwaysIf a Yanmar Marine Engine is installed at an angle that exceeds the specifications stated in the Yanmar Marine Installation Manuals engine oil may enter the combustion chamber causing excessive engine speed white exhaust smoke and serious engine damage This applies to engines that run continuously or those that run for short periods of time If you have an installation with two or three engines and only one engine is operating the seacock of the nonrunning enginesshould be closed This will prevent water from being forced past the seawater pump and entering the engine The result of water entering the engine could cause engine seizure or other serious problemsIf you have an installation with two or three engines and only one engine is operating please note that if the propeller shaft thruhull stuffing box is lubricated by engine water pressure and the engines are interconnected care must be taken that water from the running engine does not enter the exhaust of the nonrunning engines This water could cause seizure of the nonrunning engines your authorized Yanmar Marine dealer or distributor for a complete explanation of this conditionIf you have an installation with two or three engines and only one engine is operating it is important to limit the amount of throttle applied to the running engine If you observe black smoke or movement of the throttle does not increase engine rpm you are overloading the engine that is running Immediately throttle back to approximately twothirds throttle or to a setting where the engine performs normally Failure to do so may cause the running engine to overheat or cause excess carbon buildup which may shorten the engines lifeNEVER turn off the battery switch if equipped short the battery cables during operation Damage to the electrical system will resultSAFETY8YM Series Operation Manual 2009 Yanmar Marine InternationalLOCATION OF SAFETY DECALSFigure 1 shows the location of safety decals on Yanmar YM series marine engines Figure 1YMEnginesFigure1 1Part Number 128377072602Part Number 128377073503Part Number 196630129801966301298023WARNING0000020030040040050060000000071 2009 Yanmar Marine InternationalYM Series Operation ManualThe YM series are fourstroke direct injection diesel engines equipped with liquid coolant systems The 2YM15 is a 2cylinder engine and is naturally aspiratedThe 3YM20 is a 3cylinder engine and is naturally aspiratedThe 3YM30 is a 3cylinder engine and is naturally aspiratedThese engines are equipped with a marine gear or sail drive unitThese engines are designed for pleasure craft use and complieTier3 marine from 2009 yearIt is recommended that new vessels be propped so the engines can operate at 100 to 200 rpm above the Maximum Rated Power Output rpm 3700 to 3800 to allow for some added weight and hull resistance The engine must be able to reach the Maximum Rated Power rpm 3600der Failure to do so can lead to reduced vessel performance increased smoke levels and can cause permanent damage to your engine which is not covered by warrantyThe engine must be installed correctly with coolant lines exhaust gas lines and electrical wiring Anattached to the engine should be easy to use and accessible for service To handle the drive equipment propulsion systems including the propeller and other onboard equipment always observe the instructions and cautions given in the operation manuals supplied by the shipyard and equipment manufacturersThe YM series engines are designed to be operated at maximum throttle 3600rpm for less than 5 of total engine time 30 minutes out of every 10 hoursd cruising speed 3400 rpm or less less than 90 of total engine time 9 hours out of every 10 hoursThe laws of some countries may require hull and engine inspections depending on the use size and cruising area of the boat The installation fitting and surveying of this engine all require specialized knowledge and engineering skills See Yanmars local subsidiary in your region or your authorized Yanmar Marine dealer or distributorYM Series Operation Manual 2009 Yanmar Marine InternationalAs with all reciprocating engines the way the engine is operated during its first 50 hours of operation plays a significant role in determining how long it will last and how well the engine will perform over its A new Yanmar diesel engine must be operated at suitable speeds and power settings during the breakin period to allow the sliding parts such as piston rings to d to stabilize engine combustionDuring the breakin period the engine coolant temperature gauge should be monitored The temperature should be between 71 and 87C 160 and 190FDuring the first 10 hours of operation the engine should be operated at maximum rpm minus 400 to 500 rpm approximately 60 to 70 of loadst of the time This will ensure the sliding parts break in properlyNOTICE During this period avoid operating at maximum engine speed and load to avoid damaging or scoring sliding parts Do not operate the engine at low idle or at low speed and light load for more than 30minutes at a time Since unburned fuel and engine oil will adhere to the piston rings when operating at low speeds for long periods this will interfere with proper movement of the rings and the diesel fuel consumption may increase Low idle speed does not allow breakin of sliding partsIf operating the engine at low speed and light load you must race the engine to clean the carbon from the cylinders and the fuel injection valvePerform this procedure in open watersWith the clutch in NEUTRAL accelerate from the lowspeed position to the highspeed position briefly Repeat this process five timesOnce past the initial 10 hours until 50 hours the engine should be used over its full operating range with special emphasis on running at relatively high power settings This is not the time for an extended cruise at idle or low speed The boat should be operated at maximum speed minus 400 rpm most of the time approximately 70 load with a 10 minute run at maximum minus 200 rpm approximately 80 load every 30minutes and a 4 to 5 minute period of operation at WOT wide open throttleonce every 30 minutes During this period be sure not to operate the engine at low speed and light load for more than 30minutes If operating engine at low speed and light load is necessary race the engine after low To complete engine breakin perform After Initial 50 Hours maintenance procedures on pagePRODUCT OVERVIEWYM Series Operation Manual111205 2009 Yanmar Marine InternationalCOMPONENT IDENTIFICATIONRight Side from Flywheel2YM15Figure 1 and Figure 2 illustrate a typical version of a 2YM15 engine Your engine may have different equipment from that illustrated Figure 1Figure1 1Intake Silencer air cleaner2Intake Manifold3Fuel Filter4Fuel Injection Pump5Engine Oil Dipstick6Engine Oil Filler Cap7Fuel Feed Pump8Engine Oil Filter9Marine GearLeft Side from Flywheel2YM15 Figure 2Figure2 1Seawater Pump2Coolant Filler Cap3Engine Nameplate on rocker arm cover4Coolant Tank Heat Exchanger5Exhaust Manifold6Starter Motor7Shift Lever8Alternator1234567890004781124576830004782PRODUCT OVERVIEW12YM Series Operation Manual 2009 Yanmar Marine InternationalRight Side from Flywheel3YM20Figure 3 and Figure 4 illustrate a typical version of a 3YM20 engine Your engine may have different equipment from that illustrated Figure 3Figure3 1Intake Silencer air cleaner2Intake Manifold3Fuel Filter4Fuel Injection Pump5Engine Oil Dipstick6Engine Oil Filler Cap7Fuel Feed Pump8Engine Oil Filter9Marine GearLeft Side from Flywheel3YM20 Figure 4Figure4 1Seawater Pump2Coolant Filler Cap3Engine Nameplate on rocker arm cover4Coolant Tank Heat Exchanger5Exhaust Manifold6Starter Motor7Shift Lever8Alternator1234567890004783123456780004784PRODUCT OVERVIEWYM Series Operation Manual131205 2009 Yanmar Marine InternationalRight Side from Flywheel3YM30Figure 5 and Figure 6 illustrate a typical version of a 3YM30 engine Your engine may have different equipment from that illustrated Figure 5Figure5 1Intake Silencer air cleaner2Intake Manifold3Fuel Filter4Fuel Injection Pump5Engine Oil Dipstick6Engine Oil Filler Cap7Fuel Feed Pump8Engine Oil Filter9Marine GearLeft Side from Flywheel3YM30 Figure 6Figure6 1Seawater Pump2Coolant Filler Cap3Engine Nameplate on rocker arm cover4Coolant TankHeat Exchanger5Exhaust Manifold6Starter Motor7Shift Lever8Alternator1245678930004785123456780004786PRODUCT OVERVIEW14YM Series Operation Manual 2009 Yanmar Marine InternationalLOCATION OF NAMEPLATESThe nameplate of the Yanmar YM series engine is shown in Figure 7 Check the engines model output rpm and serial number on the nameplate Replace it if it is damaged or lostThe engine nameplate is attached to the engine rocker arm cover Figure 7Figure7 The marine gear nameplate Figure 8 is attached to the marine gear Check the marine gears model gear ratio oil used oil quantity and serial number Figure 8Figure8 Gear ModelENGNoMFG DATEModelmin1min1min1Continuous power kW Speed of prop shaftFuel stop power kW000002003004005006007006005002006006MODEL KMGEAR RATIOOIL SAE2030HDOIL QTY LTRNO00045291205 2009 Yanmar Marine InternationalName of ComponentFunction Fuel FilterRemoves dirt and water from the fuel Drain the filter periodically The filter element should be replaced periodically The water separator if equipped should be drained periodically See Draining Fuel Filter Water Separator on page60Fuel Feed Pump Pumps fuel from the tank to the fuel injection system Pushing the manual lever on the side of the feed pump supplies fuel to the engine when fuel priming is Fuel Feed LeverMoving the fuel feed lever up and down feeds the fuel The lever is used to bleed air from the fuel system after running out of fuelEngine Oil Filler PortFiller port for the engine oil Engine Oil FilterFilters fine metal fragments and carbon from the engine oil Filtered engine oil is distributed to the engines moving parts The filter is a spinon type and the element should be replaced periodically See Replacing the Engine Oil Filter Element on page64Marine Gear Filler PortFiller port for marine gear oil located on top of the marine gear caseCooling System There are two cooling systems closed cooling with coolant fresh water and seawater The engine is cooled by the closed cooling circuit The closed circuit is cooled by seawater using a heat exchanger The seawater also cools the enginemarine gear oilClosed Cooling Circulation The centrifugal water pump circulates coolant inside the engine The circulating pump is driven by a Vbelt Seawater Pump Pumps seawater from outside vessel to the engine The seawater pump has a replaceable rubber impellerCoolant FillerCap The filler cap on the heat exchanger coolant tank covers the water supply port The cap has a pressure regulating valve When the cooling water temperature rises the pressure rises inside the coolant systemCoolant Recovery TankThe pressure valve in the filler cap releases vapor and hot water overflow to the coolant recovery tank When the engine stops and the coolant cools the pressure in the coolant tank drops The filler cap vacuum valve then opens to send coolant back from the coolant recovery tank This minimizes coolant consumption The an easily be checked and refilled in this Engine Oil CoolerA heat exchanger that cools high temperature engine oil using coolant Intake Silencer Air CleanerThe intake silencer guards against dirt in the air and reduces the noise of air intakeNameplatesNameplates are provided on the engine and the marine gear and have the model serial number and other data See Location of Nameplates on page14Starter Starter motor for the engine powered by the battery AlternatorDriven by a belt and generates electricity and charges the battery Engine Oil DipstickGauge stick for checking the engine oil levelPRODUCT OVERVIEW16YM Series Operation Manual 2009 Yanmar Marine InternationalCONTROL EQUIPMENTThe control equipment at the helm makes remote control operation possible It consists of the instrument panel which is connected to the engine by a wire harness and the remote control handle which is connected by control cables to the engine control lever and marine gearInstrument Panel OptionalEquipment and FunctionsThe instrument panel is located at the helm The following instruments enable you to start or stop the engine and to monitor its condition during operation A typical instrument panel is shown in Figure 9 Figure 9BTypeFigure9 1Tachometer2Hourmeter3Moisture Cap for Key Switch4Key Switch5STOP Button6Battery Low Charge Indicator7Water in Sail Drive Seal Indicator8Engine Oil Low Pressure Indicator9Coolant High Temperature IndicatorGaugesBType panels use analog electric gauges with needle indicators0004486123456789InstrumentFunctionTachometerShows the engine rotation speedHourmeterShows the number of operating hours can be used as a guide for periodic maintenance checks The hourmeter is located at the bottom of the tachometerInstrument Panel LightsWhen turning the key switch to ON the gauges will illuminate for easier viewingPRODUCT OVERVIEWYM Series Operation Manual171205 2009 Yanmar Marine InternationalKey Switch Figure 10Figure10 1GLOW2OFF3ON4STARTThe GLOW position Figure 101 is the start aid position Electric current to the glow plug is turned on When the key is released the switch will automatically move to the ON positionThe START position Figure 104 allows current to the starting motor When starting the engine move the key to the START position and release The key will automatically move to the ON positionWhen the key is in the OFF position Figure 102 the electric current is off The key can be inserted or removed in this positionThe ON position Figure 103 allows electrical current to the controls and equipment and allows the engine to keep running To stop the engine keep the key switch in the ON position and push the STOP button After stopping the engine turn the key to the OFF position00036221234PRODUCT OVERVIEW18YM Series Operation Manual 2009 Yanmar Marine International Figure 11B Keyless Type OptionalFigure11 1Coolant High Temperature Indicator2Engine Oil Low Pressure Indicator3Water in Sail Drive Seal Indicator4Battery Low Charge Indicator5OFF ON START Switch6STOP GLOW Switch7Hourmeter8Tachometer0102030405087561234000002003004000002005000000006PRODUCT OVERVIEWYM Series Operation Manual191205 2009 Yanmar Marine InternationalIndicators and Alarms OptionalWhen a sensor detects a problem during operation the indicator on the instrument panel will light and an alarm will sound Indicators are located on the instrument panel The alarm is located on the back of the panel Under normal operating conditions the indicators are off Figure 12Figure12 Battery Low Charge Indicator Figure 12 When the alternator output is too low the indicator will light When charging begins the indicator will turn off No alarm will sound for low battery charge Figure 13Figure13 Coolant High Temperature Indicator and Alarm Figure 13 When coolant temperature reaches the maximum allowable temperature 95C 203Fhigherthe indicator will light and the alarm will sound Continuing operation at temperatures exceeding the maximum limit will result in damage and seizure Check the load and troubleshoot the cooling system Figure 14Figure14 Engine Oil Low Pressure Indicator and Alarm Figure 14 When the engine oil pressure falls below normal the oil pressure sensor will send a signal to the indicator causing it to light and the alarm to sound Stop operation immediately to avoid damage to the engine Check the oil level and troubleshoot the lubrication system Figure 15Figure15 Water in Sail Drive Seal Indicator and Alarm Figure 15 When seawater is detected between the seals of the sail drive the indicator will light and the alarm will soundSTOP Button Figure 16Figure16 Push the STOP button switch to stop the engine The key switch must be in the ON position for the STOP button to operate After the engine has come to a complete stop you can turn the key to the OFF position0005439PRODUCT OVERVIEW20YM Series Operation Manual 2009 Yanmar Marine InternationalAlarmsCheck that indicators and alarms are working normally when the key is turned to ONSingleLever Remote Control Handle Figure 17Figure17 1Low Speed FWD or REV 2Low Speed FWD or REV 3NEUTRAL Power to the propeller shaft is cut off and the engine idles4Maximum Engine Speed FWD or REV5Maximum Engine Speed FWD or REVA singlelever handle type Figure 17 should be used to operate the marine gear clutch NEUTRAL FORWARD and REVERSEand to control the engine speedThe lever controls the direction of the boat ahead or asternd also acts as an accelerator by increasing engine speed as the lever is pushed further in the FORWARD or REVERSE directionsWhen the lever is pulled out Figure 181 the engine speed can be controlled without engaging the clutch The clutch remains in the NEUTRAL no load position Turn the knob Figure 182 counterclockwise to move the lever or clockwise to lock the lever Figure 18Figure18 Note Yanmar recommends the use of a singlelever type for the remote control system If only a twolever type is available in the market reduce engine rpm to 1000 or less before engaging and disengaging the marine gear clutchKey SwitchOFF 000 ONSTART 000 ONEngineBefore startRunningAlarmSoundNo soundIndicatorsBattery Low Charge IndicatorONOFFCoolant High Temperature IndicatorOFFOFFEngine Oil Low Pressure IndicatorONOFFWater In Sail Drive IndicatorOFFOFF143250004504210004511 EF HHEFa aHHEF a FHHEFa a aHHEFa fHHEFa aaHH E D ZQX DY QX MDY QX DY EhD EFvhEDCCeCCppEEDED EEadPQXEDYCcbB ECDCCe ia bddaXaYEDzEDCXEDzEi D QXDzzYYFFaHKS XYXY EDEDEeE j Bhja RyE TXYaDRy E TXYaDCCCCCCCCeCCeCCeKRXEDY I c RX8e8c8YKdQXEiCY a a CC5vAp AE PXaYddbQXdd bYQXddUbYddbEhEheKSKQZX EDYKTX EDYKSKQZX8YKTX8YCXYCXYKTCZX8YCXddadQX FH FHYYCXddadQX FH FHYYKSKQZXYKSKQZXYKSKQZCZX8YKTKTZCZX8YVtgadQG9HTdnd9JS bYLQ99dddXdVH3NLJs8G8dXd7YdiNGAPd4ydV60VCMFPNJTT50T42UV 2009 Yanmar Marine InternationalYM Series Operation ManualBefore performing any operations within this section review the Safety section on pageThis section of the Operation Manualdescribes the diesel fuel engine oil and engine coolant specifications and how to replenish themBEFORE YOU OPERATEYM Series Operation Manual 2009 Yanmar Marine InternationalDiesel Fuel SpecificationsFire and Explosion Hazard Diesel fuel is flammable and explosive under certain conditionsNOTICE Only use diesel fuels recommended by Yanmar for the best engine performance to prevent engine damage and to comply with EPA warranty requirements Only use clean diesel fuelDiesel fuel should comply with the following specifications The table lists e specifications for diesel fuelsBiodiesel FuelsYanmar approves the use of biodiesel fuels that do not exceed a blend of 5 nonmineral oil based fuel with 95 standard diesel fuel Such biodiesel fuels are known in the marketplace as B5 biodiesel fuels B5 biodiesel fuel can reduce particulate matter and the emission of greenhouse gases compared to standard diesel fuelNOTICE If the B5 biodiesel fuel used does not meet the approved specifications it will cause abnormal wear of injectors reduce the life of the engine and it may affect the warranty coverage of your engineB5 diesel fuels must meet certain specificationsThe biodiesel fuels must meet the minimum specifications for the country in which they are usedIn Europe biodiesel fuels must comply with the European Standard EN14214In the United States biodiesel fuels must comply with the American Standard Biodiesel should be purchased only from recognized and authorized diesel fuel LOCATIONNo 2D No 1D ASTM EN59096European UnionBS 2869A1 or A2United KingdomJIS K2204 Grade No 2BEFORE YOU OPERATE1205 2009 Yanmar Marine InternationalPrecautions and concerns regarding the use of biofuelsBiodiesel fuels have a higher content of methylesters which may deteriorate certain metal rubber and plastic components of the fuel system The customer and or boat builder are responsible to verify the usage of biodiesel compatible components on the vessel fuel supply and return systemsFree water in biodiesel may result in plugging of fuel filters and increased bacterial growthHigh viscosity at low temperatures may result in fuel delivery problems injection pump seizures and poor injection nozzle spray atomizationBiodiesel may have adverse effects on some elastomers seal materialsd may result in fuel leakage and dilution of the engine lubricating oilEven biodiesel fuels that comply with a suitable standard as delivered will require additional care and attention to maintain the quality of the fuel in the equipment or other fuel tanks It is important to maintain a supply of clean fresh fuel Regular flushing of the fuel system and or fuel storage containers may be necessaryThe use of biodiesel fuels that do not comply with the standards as agreed to by the diesel engine manufacturers and the diesel fuel injection equipment manufacturers or biodiesel fuels that have degraded as per the precautions and concerns above may affect the warranty coverage of your engineAdditional Technical Fuel RequirementsThe fuel cetane number should be 45 or higherThe sulfur content must not exceed 05 by volume Less than 005 is preferredNEVER mix kerosene used engine oil or residual fuels with the diesel fuelWater and sediment in the fuel should not exceed 005 by volumeKeep the fuel tank and fuelhandling equipment clean at all timesAsh content should not exceed 001 by Carbon residue content should not exceed 035 by 01 is preferredTotal aromatics content should not exceed 35 by volume Less than 30 is preferredPAH polycyclic aromatic hydrocarbonscontent should be below 10 by volumeNEVER use BiocideNEVER use kerosene or residual fuelsBEFORE YOU OPERATE24YM Series Operation Manual 2009 Yanmar Marine InternationalHandling of Diesel FuelWARNING Fire and Explosion Hazard Only fill the fuel tank with diesel fuel Filling the fuel tank with gasoline may result in a fire and will damage the engine NEVER refuel with the engine running Wipe up all spills immediately Keep sparks open flames or any other form of ignition match cigarette static electric sourcell away when refuelingWARNING Fire and Explosion Hazard ALWAYS put the diesel fuel container on the ground when transferring the diesel fuel from the pump to the container Hold the hose nozzle firmly against the side of the container while filling it This prevents static electricity buildup which could cause sparks and ignite fuel vaporsFuel Tank OptionalNOTICE Water and or dust in the fuel may cause engine failure When fuel is stored check that the inside of the storage container is clean and dry and that the fuel is stored away from dirt or rain Figure 1Figure1 1Sediment Bowl2Drain Cock3Fuel Line to EngineInstall a drain cock Figure 12 at the bottom of the fuel tank to remove water and contaminants from the sediment bowl Figure 11The fuel outlet should be positioned 20 to 30 mm 075 to 1125 inve the bottom of the tank Figure 24 so that only clean fuel is distributed to the engine0004542312BEFORE YOU OPERATEYM Series Operation Manual251205 2009 Yanmar Marine InternationalFuel System Figure 2Figure2 1Fuel Filter2Fuel Feed Pump priming lever3Fuel Water Separator optional4Approximately 20 to 30 mm 075 to 1125 in5Within 500 mm 20 in6Drain Cock7Fuel Cock8Fuel Return Line9To Fuel Injection Pump10Fuel TankInstall the fuel line from the fuel tank to the fuel injection pump as shown in Figure 2 The recommended fuelwater separator Figure 23 optionalinstalled at the center section of that lineFilling the Fuel TankWARNING Fire and Explosion Hazard NEVER refuel with the engine runningBefore filling fuel tank for the first timeRinse the fuel tank with kerosene or diesel fuel Dispose of waste properlyTo fill the fuel tankWARNING Fire and Explosion Hazard Operate bilge ventilation blowersor a minimum of 5 minutes to purge fumes from engine compartment after refueling Never operate bilge blower while refueling Doing so can pump explosive fumes into the engine compartment and result in an explosion1Clean the area around the fuel cap2Remove the fuel cap from the fuel tank3Fill the tank with clean fuel free of oil and dirt WARNING Fire and Explosion Hazard Hold the hose nozzle firmly against the filler port while filling This prevents static electricity buildup which could cause sparks and ignite fuel vapors4Stop fueling when the gauge shows the fuel tank is full WARNING Fire and Explosion Hazard NEVER overfill the fuel tank123810467950004788BEFORE YOU OPERATE26YM Series Operation Manual 2009 Yanmar Marine International5Replace the fuel cap and handtighten Overtightening the fuel cap will damage it Figure 3Figure3 If filling the tank from a storage container Figure 3 keep the fuel container stationary for several hours to allow any dirt or water to settle to the bottom of the container Use a pump to extract the clear filtered fuel from the top of the containerBleeding the Fuel SystemThe fuel system has an automatic air bleeding device that purges air from the fuel system No manual air bleeding is required for normal operation Manual bleeding must be done if any fuel system maintenance has been performed replacement of fuel filter etc if the engine does not start after several attemptsBleeding the Fuel System Figure 4Figure4 1Air Bleed Screw2Bracket3ORing4Fuel Filter Element5Fuel Filter Housing6Retaining Ring00045121000480123456BEFORE YOU OPERATE1205 2009 Yanmar Marine International1Check the fuel level in the fuel tank Refill if necessary2Open the fuel cock of the fuel tank Exposure Hazard Always wear safety glasses when bleeding the fuel system3Loosen the air bleed screw Figure 41 2to3 turns4Push up and down on the manual priming lever located on the side of the fuel feed pump to release air out of the air bleed screw Always use an approved container to catch the diesel 5Continue pumping until a solid stream of fuel with no air bubbles begins to 6Tighten the air bleed screwNote After engine startup the automatic airbleeding device works to purge the air in the fuel systemEngine Oil Specifications NOTICE Only use the engine oil specified Other engine oils may affect warranty coverage cause internal engine components to seize and or shorten engine life NEVER mix different types of engine oil This may adversely affect the lubricating properties of the engine oilUse an engine oil that meets or exceeds the following guidelines and classifications API Service Categories CD or higherTBN value 9 or moreThe oil must be changed when the Total Base Number TBN has been reduced to 20TBN mgKOHg test method JIS K2501522HCI ASTM D4739HCIRecommended SAE Viscosity 10W30 15W40 Engine oil 10W30 and 15W40 can be used throughout the yearNEVER use API Service Category CG4 or CH4 oilsNOTICE 1Be sure the engine oil engine oil storage containers and engine oil filling equipment are free of sediment or water2Change the engine oil after the first 50 hours of operation and then at every 150 hours thereafter See Changing the Engine Oil on page573Select the oil viscosity based on the ambient temperature where the engine is being operated See the SAE Service Grade Viscosity Chart Figure 54Yanmar does not recommend the use of engine oil additivesBEFORE YOU OPERATE28YM Series Operation Manual 2009 Yanmar Marine InternationalHandling Engine Oil1When handling and storing engine oil be careful not to allow dust and water to contaminate the oil Clean around the filler port before filling2Do not mix lube oils of different types or brands Mixing may cause the chemical characteristics of the oil to change and lubricating performance to decrease reducing the engines life3Engine oil should be replaced at the specified intervals regardless of the engines operation history See Periodic Maintenance Schedule on page50Engine Oil Viscosity Figure 5Figure5 Select the appropriate engine oil viscosity based on the ambient temperature shown in the SAE Service Grade Viscosity Chart Figure 5NOTICE If you intend to operate your equipment at temperatures outside the limits shown you must consult your authorized Yanmar Marine dealer or distributor for special lubricants or starting aidsChecking the Engine Oil Figure 6Figure6 1Filler Port2Rocker Arm Cover3Dipstick4Upper Limit5Lower LimitNote 3YM30 shown Other models are similar1Make sure the engine is off It is recommended that the engine be as level as possible before checking the oil2NOTICE Prevent dirt and debris from contaminating engine oil Carefully clean the dipstick filler port cap and the surrounding area before you remove the cap Remove the dipstick Figure 63 and wipe with a clean cloth3Fully reinsert the dipstick4Remove the dipstick The oil level should be between upper Figure 64 and lower Figure 65 lines on the dipstick5Add oil if necessary See Adding Engine Oil on page296Fully reinsert the dipstick 4F 14F 32F 50F 68F 86F 104F 20C 10C 0C 10C 20C 30C 40CSAE 10W30SAE 15W400000005134520004789BEFORE YOU OPERATE1205 2009 Yanmar Marine InternationalNOTICE Prevent dirt and debris from contaminating engine oil Carefully clean the dipstick filler port cap and the surrounding area before you remove the cap Remove the yellow oil filler port cap from the filler port Figure 61on the rocker arm cover Figure 62and fill with engine oil2Fill with engine oil to the upper limit Figure 64 on the dipstick Figure 63NOTICE NEVER overfill the engine with engine oil3Insert the dipstick fully to check the level NOTICE ALWAYS keep the oil level between the upper and lower lines on the oil capdipstick4Handtighten the filler port cap Marine Gear Oil SpecificationsUse marine gear oil that meets or exceeds the following guidelines and classificationsKM2P1 SGGGAPI Service Categories CD or higherSAE Viscosity 20 or 30Sail Drive Oil Specifications Refer to the Sail Drive Operation Manualfor the procedure to fill or replace the sail drive oil API Service Category GL45SAE Viscosity 90 or 80W90BEFORE YOU OPERATE30YM Series Operation Manual 2009 Yanmar Marine InternationalChecking Marine Gear Oil Figure 7Figure7 1Dipstick2Marine Gear Filler Port3Upper Limit4Lower Limit1Make sure the engine is off Make sure the engine is as level as possible and wipe area clean around the marine gear filler port Figure 722Remove the filler cap at the top of the housing3Remove the dipstick Figure 71 and wipe with a clean cloth4Fully reinsert the dipstick5Remove the dipstick The oil level should be between the upper Figure 73 and lower Figure 74 lines on the dipstick6Fully reinsert the dipstickAdding Marine Gear Oil1Make sure the engine is as level as possible2Remove the filler cap at the top of the housing3Fill with oil to the upper limit on the dipstick Figure 73 See Marine Gear Oil Specifications on page29 NOTICE NEVER overfill the marine gear with oil4Fully reinsert the dipstick5Handtighten the filler port capChecking and Adding Sail Drive OilRefer to the Sail Drive Operation Manual for the procedure for checking and filling the sail drive oil12000481134BEFORE YOU OPERATEYM Series Operation Manual311205 2009 Yanmar Marine InternationalENGINE COOLANTEngine Coolant SpecificationsTexaco Long Life Coolant LLCstandard and premixed product code 7997 and 7998Havoline Extended Life AntifreezeCoolant product code 7994Note In the US LLC is required for the warranty to be validNOTICE Following the manufacturers recommendations use a proper LLC which will not have any adverse effects on the materials cast iron aluminum copper etche engines cooling system See Engine Coolant Specifications on page31 ALWAYS use the mixing ratios specified by the antifreeze manufacturer for the temperature range NOTICE ALWAYS add LLC to soft water especially when operating in cold weather NEVER use hard water Water should be clean and free from sludge or particles Without LLC cooling performance will decrease due to scale and rust in the coolant system Water alone may freeze and form ice it expands approximately 9 in volume Use the proper amount of coolant concentrate for the ambient temperature as specified by the LLC manufacturer LLC concentration should be a minimum of 30 to a maximum of 60 Too much LLC will decrease the cooling efficiency Excessive use of antifreeze also lowers the cooling efficiency of the engine NEVER mix different types or brands of LLC as a harmful sludge may form Mixing different brands of antifreeze may cause chemical reactions and may make the antifreeze useless or cause engine problems Replace the engine coolant periodically according to the maintenance section in this Operation Manual Remove scale from the cooling system periodically by flushing the systemChecking and Adding CoolantComponent identification Figure 8Figure8 1Coolant Tank Heat Exchanger2Coolant Drain Plug3Seawater Drain Plug4Coolant Pump5Seawater Pump Figure 9Figure9 1Coolant Tank Heat Exchanger2Coolant Drain Plug3Seawater Drain Cock1235400047911230005576BEFORE YOU OPERATE32YM Series Operation Manual 2009 Yanmar Marine International Figure 10Figure10 1Stop Solenoid2Seawater Drain Plug3Flywheel HousingNote The drain cocks are opened before shipping from the factory Close all drain cocks before filling the system with coolant1Allow the engine to cool2Ensure all drain cocks are closed3Loosen the coolant tank filler cap to relieve the pressure then remove the filler cap WARNING Burn Hazard NEVER remove the coolant filler cap if the engine is hot Steam and hot engine coolant will spray out and seriously burn you Allow the engine to cool down before you attempt to remove the cap Figure 111Filler Cap Tabs2Coolant Filler Cap3Filler Port Notches4Coolant Tank Heat ExchangerFigure11 4NOTICE NEVER pour cold coolant into a hot enginePour coolant slowly into the coolant tank heat exchanger Figure 114 to avoid air bubbles Fill until coolant overflows from the filler port123000479321430004492BEFORE YOU OPERATEYM Series Operation Manual331205 2009 Yanmar Marine International5Align the filler cap tabs Figure 111 with filler port notches Figure 113 and tighten the filler cap Figure 112 Figure 121Rubber Hose to Coolant Tank2FULL Mark3LOW Mark4Coolant Recovery Tank CapFigure12 6 Check the coolant level in the coolant recovery tank The level should be at the FULL mark Figure 122 Add coolant if necessary Note The coolant level rises in the coolant recovery tank during operation After stopping the engine the coolant will cool down and the extra coolant will return to the coolant tankNote NOTICE NEVER pour cold coolant into a hot engine7Remove coolant recovery tank cap Figure 124 to add coolant if necessary NEVER add water8Replace the filler cap and tighten it firmly Failure to do so will cause coolant to leakWARNING Burn Hazard ALWAYS tighten the coolant tank cap securely after checking the coolant tank Steam can spray out during engine operation if the cap is loose9Check the rubber hose Figure 121 connecting the coolant recovery tank to the coolant tankheat exchanger Replace if damagedNOTICE If the coolant runs low too often or only the coolant level in the coolant tank heat exchanger drops without any change in the level in the coolant recovery tank there may be coolant or air leaks in the cooling system See your authorized Yanmar Marine dealer or distributorLOWFULL1230004493Coolant Recovery Tank Capacity08 L 095 qtBEFORE YOU OPERATE34YM Series Operation Manual 2009 Yanmar Marine InternationalCRANKING THE ENGINENOTICE When performing engine breakin or if the engine has not been used for a long period of time engine oil will not be distributed to all of the operating parts Using the engine in this condition will lead to seizureAfter a long period of nonuse distribute engine oil to each part by cranking the engine Perform the following procedure before beginning operation1Open the seacock2Open the fuel cock3Put the remote control shift lever in NEUTRAL4Turn the battery switch to ON if equipped Figure 131GLOW2OFF3ON4STARTFigure13 Note If the engine has not been operated for a long period of time check that the key moves smoothly from the START to ON positions5Turn the key to ON Figure 1336While pushing the STOP button on the control panel turn the key to the START position Figure 134 NOTICE NEVER hold the key in the START position for longer than 15 seconds or the starter motor will overheat7When the key is in the START position the engine will begin cranking Continue cranking for about 5seconds and listen for abnormal noise during that timeNOTICE If the STOP button is released during the cranking procedure the engine will start NEVER start the engine in this mode00036221234YM Series Operation Manual35 2009 Yanmar Marine InternationalYM Series Operation Manual ENGINE OPERATIONSAFETY PRECAUTIONSBefore performing any operations within this section read the following safety information and review the Safety section on page3Fire and Explosion HazardNEVER jumpstart the engine Sparks caused by shorting the battery to the starter terminals may cause a fire or explosion ONLY use the key switch to start the engineSudden Movement HazardBe sure the boat is in open water away from other boats docks or other obstructions before increasing rpm Avoid unexpected equipment movement Shift the marine gear into the NEUTRAL position any time the engine is at idleTo prevent accidental equipment movement NEVER start the engine in gearSever HazardKeep children and pets away while the engine is operating ENGINE OPERATION36YM Series Operation Manual 2009 Yanmar Marine InternationalIf any indicator illuminates during engine operation stop the engine immediately Determine the cause and repair the problem before continuing to operate the engine If the alarm window with audible alarm fails to display and go out about 3 seconds later when the ignition switch is in the ON position see your authorized Yanmar Marine dealer or distributor for service before operating the engineObserve the following environmental operating conditions to maintain engine performance and avoid premature engine wear Avoid operating in extremelydusty conditionsAvoid operating in the presenceof chemical gases or fumesNEVER run the engine if the ambient temperature is above 40C104F or below 16C 5F If the ambient temperature exceeds 40C 104F the engine may overheat and cause theengine oil to break downIf the ambient temperature is below 16C 5F rubber components such as gaskets and sealswill harden causing prematureengine wear and damageContact your authorized YanmarMarine engine dealer or distributor if the engine will be operatedoutside of this standard temperature rangeNEVER engage the starter motor while the engine is running Damage to the starter motor pinion and or ring gear will resultINTRODUCTIONThis section of the Operation Manual describes the procedures for starting the engine checking engine performance during operation and shutting down the engineENGINE OPERATIONYM Series Operation Manual371205 2009 Yanmar Marine InternationalSTARTING THE ENGINENOTICE If the vessel is equipped with a water lift water lock muffler excessive cranking could cause seawater to enter the cylinders and damage the engine If the engine does not start after cranking for 10 seconds close the seacock to avoid filling the muffler with water Crank for 10 seconds or until the engine starts When the engine does start stop the engine immediately and turn the switch to the OFF position1Open the seacock if equipped2Open the fuel cock3Put the remote control handle in NEUTRALNote Safety equipment should make it impossible to start the engine in any position other than NEUTRAL Figure 11GLOW2OFF3ON4STARTFigure1 4Turn the battery master switch if equipped to ON5Turn key switch to ON Figure 13 Ensure that the instrument panel indicators light and the alarm sounds This indicates that indicators and alarm are working correctly Note The coolant high temperature alarm indicator and water in sail drive seal indicator should not come on during startup6Turn key switch to START Figure 14 Release the key switch when the engine has started NOTICE NEVER hold the key in the START position for longer than 15 seconds or the starter motor will overheat7The alarm should stop and the indicators should go out NOTICE If any indicator fails to illuminate when the key switch is in the ON position see your authorized Yanmar Marine dealer or distributor for service before operating the engineNote When the engine has not been used for a long period of time check that the key moves smoothly from the START position to the ON positionRestarting After Starting FailureBefore turning the key switch again be sure the engine has stopped completely NEVER attempt to restart the engine while the engine is running The pinion gear on the starter motor will be damaged NOTICE NEVER hold the key in the START position for longer than 15 seconds or the starter motor will overheatNOTICE NEVER attempt to restart the engine if the engine has not stopped completely Pinion gear and starter motor damage will occurAir Bleeding the Fuel System After Starting FailureIf the engine does not start after several attempts there may be air in the fuel system If air is in the fuel system fuel cannot reach the fuel injection pump Bleed the air out of the system See Bleeding the Fuel System on page2600036221234YM Series Operation Manual 2009 Yanmar Marine InternationalComply with local environmental requirements Use engine heaters to avoid starting problems and white smoke NOTICE NEVER use an engine starting aid such as ether Engine damage will result Using a starting aid may void the warrantyTo limit white smoke run the engine at low speed and under moderate load until the engine reaches normal operating temperature A light load on a cold engine provides better combustion and faster engine warmup than no loadAvoid running the engine at idling speed any longer than necessaryStarting with Air Heater If Equipped1Open the seacock if equipped2Open the fuel tank cock3Put remote control handle in NEUTRAL4Turn the battery master switch if equipped to ON5Turn key switch to GLOW for 15 6Turn key switch to ON Ensure that the instrument panel indicators light and the alarm sounds This shows that indicators and alarm are working correctlyNote The coolant high temperature alarm indicator and water in sail drive seal indicator should not come on during startup7Turn key switch to START Release the key switch when the engine has started The alarm should stop and the indicators should go out NOTICE NEVER hold the key in the START position for longer than 15 seconds or the starter motor will overheatAfter the EngineAfter the engine has started check the following items at a low engine speed1Check that the gauges indicators and alarm are normal2Check for any water fuel engine coolant or engine oil leaks If any leaks are found shut down the engine and perform the necessary repairsWARNING Piercing Hazard NEVER check for a fuel leak with your hands ALWAYS use a piece of wood or cardboard Have your authorized Yanmar Marine dealer or distributor repair the damage Avoid skin contact with the highpressure diesel fuel spray caused by a fuel system leak such as a broken fuel injection line Highpressure fuel can penetrate your skin and result in serious injury If you are exposed to highpressure fuel spray obtain prompt medical treatment3Check that the exhaust color engine vibration and sound are normal4When there are no problems keep the engine at low speed with the boat still stopped to distribute engine oil to all parts of the engineENGINE OPERATIONYM Series Operation Manual391205 2009 Yanmar Marine InternationalCheck that water is being discharged from the seawater outlet pipe Operation with inadequate seawater discharge will damage the impeller of the seawater pump If seawater discharge is too low stop the engine immediately Identify the cause and repair NOTICE The engine will seize if it is operated when cooling seawater discharge is inadequate or if load is applied without any warmup operationWhen operating the engine at low speed for long periods of time race the engine once every 2 hours Race the engine with the clutch in NEUTRAL accelerate from the lowspeed position to the highspeed position and repeat this process about five times This cleans out carbon from the cylinders and the fuel injection valves NOTICE Neglecting to race the engine will result in poor exhaust color and reduce engine performance Periodically operate the engine near maximum speed while underway This will generate higher exhaust temperatures which will help clean out hard carbon deposits maintain engine performance and prolong the life of the engine For troubleshooting assistance see Troubleshooting After Starting on page 69 or see Troubleshooting Chart on page 71If necessary see your authorized Yanmar Marine dealer or distributorREMOTE CONTROL HANDLE OPERATIONAcceleration and Deceleration Figure 2Figure2 1FORWARD or REVERSE2NEUTRAL3REVERSE or FORWARD4Throttle HandleClutch HandleNote Direction of travel will vary depending on installation locationUse the throttle handle Figure 24 to control acceleration and deceleration Move the handle slowly00045131243YM Series Operation Manual 2009 Yanmar Marine InternationalSudden Movement Hazard The boat will start to move when the marine gear is engagedEnsure the boat is clear of all obstacles forward and aftQuickly shift to the FORWARD position then back to the NEUTRAL positionObserve whether the boat moves in the direction you expectNOTICE Shifting the marine gear while operating at high speed or not pushing the handle fully into position partial engagementresultmarine gear parts and abnormal wearBefore using the marine gear be sure to move the throttle handle to a low idle position less than 1000 rpm Move the throttle handle slowly to a higher speed position after completing clutch engagementNOTICE NEVER shift the marine gear at high engine speed During normal operation the marine gear should only be shifted with the engine at idle moving the handle between FORWARD Figure 21 or 3 and REVERSE Figure 21 or 3 bring the clutch to NEUTRAL Figure 22 and pause before slowly shifting to the desired position Do not shift abruptly from FORWARD to REVERSE or vice versaNOTICE When sailing set the remote control lever in NEUTRAL Not doing so WILL introduce slippage or any damage and void your warrantyNOTICE NEVER stop engine abruptly during operation Yanmar recommends that when shutting the engine down allow the engine to run without load for 5 minutes This will allow the engine components that operate at high temperatures such as the exhaust system to cool slightly before the engine is shut down1Reduce engine speed to low idle and put remote control handle in NEUTRAL2Accelerate from low speed to high speed and repeat five times This will clean out the carbon from the cylinders and the fuel injection nozzles3Allow engine to run at low speed approximately 1000 rpmt load for 5minutes NOTICE Continue to hold the STOP button in until the engine is completely stopped If the button is released before the engine has completely stopped it may restart If the engine does not shut down see Emergency Shutdown on page 41 ENGINE OPERATIONYM Series Operation Manual411205 2009 Yanmar Marine International4With the key in the ON position push and hold the STOP button Figure 31 After the engine has stopped turn the key switch to OFF Note Continue to hold the STOP button in until the engine is completely stopped If the button is released before the engine has completely stopped it may restart If the engine does not shut down see Emergency Shutdown on page 41 Figure 31STOP ButtonFigure3 5Remove the key and cover the key switch with the moisture cap6Turn off the battery master switch if equipped7Close the fuel cock8Close the seacock if equipped NOTICE ALWAYS close the seacock Neglecting to close the seacock could allow water to leak into the boat and may cause it to sinkEmergency ShutdownNOTICE NEVER use the emergency stop switch for a normal engine shutdown Use this switch only when stopping the engine suddenly in an emergencyIf the engine cannot be shut down by the STOP button on the panel stop the engine by pushing the STOP button Figure 41 at the back of the stop solenoid Figure 42 Figure 4Figure4 1STOP Button2Stop Solenoid00044871120004787YM Series Operation Manual 2009 Yanmar Marine InternationalCheck that the key switch is in the OFF position and that the battery master switch if equippedturned to OFFFill the fuel tank See Filling the Fuel Tank on page25Close seacocksIf there is a risk of freezing check that the cooling system contains enough See Engine Coolant Specifications on page31If there is a risk of freezing temperatures below 0C 32the seawater system see Draining the Cooling System on page 76 and connect the engine heater if equippedYM Series Operation Manual43 2009 Yanmar Marine InternationalYM Series Operation ManualPERIODIC MAINTENANCESAFETY PRECAUTIONSBefore performing any maintenance procedures within this section read the following safety information and review the Safety section on page3Crush HazardIf the engine needs to be transported for repair have a helper assist you in attaching it to a hoist and loading it on a truckThe engine lifting eyes are engineered to lift the weight of the marine engine only ALWAYS use the engine lifting eyes when lifting the engineAdditional equipment is necessary to lift the marine engine and marine gear together ALWAYS use lifting equipment with sufficient capacity to lift the marine engine Explosion HazardALWAYS turn off the battery switch if equipped or disconnect the negative battery cable before servicing the equipmentEntanglement Hazard NEVER leave the key in the key switch when you are servicing the engine Someone may accidentally start the engine and not realize you are servicing itStop the engine before you begin to service it Piercing HazardAvoid skin contact with highpressure diesel fuel spray caused by a fuel system leak such as a broken fuel injection line Highpressure fuel can penetrate your skin and result in serious injury If you are exposed to highpressure fuel spray obtain prompt medical treatmentNEVER check for a fuel leak with your hands ALWAYS use a piece of wood or cardboard Have your authorized Yanmar Marine dealer or distributor repair the damagePERIODIC MAINTENANCE44YM Series Operation Manual 2009 Yanmar Marine InternationalTool HazardALWAYS remove any tools or shop rags used during maintenance from the area before operationShock HazardALWAYS turn off the battery switch if equipped or disconnect the negative battery cable before servicing the equipmentALWAYS keep the electrical connectors and terminals clean Check the electrical harnesses for cracks abrasions and damaged or corroded connectorsWelding HazardMake welding repairs safelyALWAYS turn off the battery switch if equipped or disconnect the negative battery cable and the leads to the alternator when welding on the equipmentRemove the multipin connector to the engine control unit Connect the weld clamp to the component to be welded and as close as possible to the welding pointNEVER connect the weld clamp to the engine or in a manner which would allow current to pass through a mounting bracketWhen welding is completed reconnect the leads to the alternator and engine control unit prior to reconnecting the batteriesAny part which is found defective as a result of inspection or any part whose measured value does not satisfy the standard or limit must be replaced Modifications may impair the engines safety and performance characteristics and shorten the engines life Any alterations to this engine may void its warranty Always use Yanmar genuine replacement partsPERIODIC MAINTENANCE1205 2009 Yanmar Marine InternationalThis section of the Operation Manualdescribes the procedures for proper care and maintenance of the engineEngine deterioration and wear occur in proportion to the length of time the engine has been in service and the conditions the engine is subjected to during operation Periodic maintenance prevents unexpected downtime reduces the number of accidents due to poor engine performance and helps extend the life of the engine WARNING Exhaust Hazard NEVER block windows vents or other means of ventilation if the engine is operating in an enclosed area All internal combustion engines create carbon monoxide gas during operation Accumulation of this gas within an enclosure could cause illness or even death Make sure that all connections are tightened to specifications after repair is made to the exhaust system Failure to comply could result in death or serious injuryThe Periodic Maintenance Schedule assumes that the daily checks are performed on a regular basis Make a habit of performing daily checks before the start of each operating day See Daily Checks on page55PERIODIC MAINTENANCEYM Series Operation Manual 2009 Yanmar Marine InternationalDaily ChecksKeep a log of the number of hours the engine is operated each day and a log of the daily checks performed Also note the date type of repair eg replaced alternatord parts used for any service needed between the periodic maintenance intervals Periodic maintenance intervals are every 50 100 150 250 and 1000 engine hours NOTICE Failure to perform periodic maintenance will shorten the life of the engine and may void the warrantyYanmar recommends that using genuine Yanmar parts when replacement parts are needed Genuine replacement parts help ensure long engine lifeBefore starting any periodic maintenance procedure make sure you have the tools needed to perform all of the required tasksOur professional service technicians have the expertise and skills to help with any maintenance or service related proceduresPERIODIC MAINTENANCEYM Series Operation Manual471205 2009 Yanmar Marine InternationalTightening FastenersUse the correct amount of torque when you tighten fasteners on the engine Applying excessive torque may damage the fastener or component and not enough torque may cause a leak or component failureNOTICE The tightening torque in the Standard Torque Chart should be applied only to the bolts with a 7 head JIS strength classification 7Tly 60 torque to bolts that are not listed Apply 80 torque when tightened to aluminum alloyStandard Torque ChartBolt Diameter x Pitch mmM6x10M8x125M10x15M12x175M14x15M16x15Tightening TorqueNm110 10260 30500 50900 1001400 1002300 100kgfm11 0127 0351 0592 10143 10235 10lbft80 07190 2137 36660 72103 72170 72PERIODIC MAINTENANCEYM Series Operation Manual 2009 Yanmar Marine InternationalREQUIREMENTSTo maintain optimum engine performance and compliance with the Environmental Protection Agency EPA Regulations for Engines it is essential to follow the Periodic Maintenance Schedule on page and the Periodic Maintenance Procedures on page 55EPA Requirements for USA and Other Applicable CountriesThe following are the requirements for the EPA Unless these rthe exhaust gas emissions will not be within the limits specified by the EPAThe EPA emission regulation is applicable only in the USA and other countries that have adopted the EPA requirements in part or in whole Determine and follow the emission regulations in the country where your engine will be operating to assist you in specified complianceCompliance with EPA Emission The 2YM15 3YM20 and 3YM30 are The following are the conditions that must be met in order to ensure that the peration meet the EPA standardsAmbient temperature 20 to 40C 4to104FRelative humidity 80 or lowerThe diesel fuel should beASTM D975 No 1D or No 2D or equivalent minimum of cetane No 45The lubricating oil should beType API Class CD or higherPerform the inspections as outlined in Periodic Maintenance Procedures on page and keep a record of the resultsPay particular attention to these important pointsReplacing the engine oilReplacing the engine oil filterReplacing the fuel filter Cleaning the intake silencer air cleanerNote Inspections are divided into two sections in accordance with who is responsible for performing the inspection the user or the manufacturerInspection and MaintenanceSee Inspection and Maintenance of EPA EmissionRelated Parts on page54 for the and maintenance procedures not shown in Inspection and Maintenance of EPA EmissionRelated Partssection are Periodic Maintenance Schedule on page 50This maintenance must be performed to keep the emission values of the engine within the standard values during the warranty period The warranty period is determined by the age of the engine or the number of hours of operationInstalling Sample PortAll engines subject to emission standards shall be equipped with a connection in the engine exhaust system that is located downstream of the engine and before any point at which the exhaust contacts water or any other cooling scrubbing mediumfor the temporary attachment of gaseous and or particulate emissions sampling equipment PERIODIC MAINTENANCE1205 2009 Yanmar Marine InternationalThis connection shall be internally threaded with standard pipe threads of a size not larger than shall be closed by a pipe plug when not in use Equivalent connections are allowedThe instructions for the proper installation and location of the required sample port in addition to those specified above in the quoted federal regulation are as follows 1The connection should be located as far downstream as reasonably practicable from any sharp bend of 30 or more in the exhaust pipe to help ensure that a wellmixed exhaust flow sample may be taken 2The requirement that the connection be located before any point at which the exhaust contacts water or any other coolingscrubbing medium does not include contact with water used to cool exhaust manifolds unless the water is allowed to come into direct contact with the exhaust gases 3To allow ready access to the sample port the connection should be located if possible given the constraints of vessel design approximately 06 to 18 m 2 to 6 ftbove a deck or walkway 4To facilitate insertion and withdrawal of an exhaust sample probe there should be no obstructions for at least one and onehalf exhaust pipestack diameters perpendicular ie 90 from the sample port and 5If a threaded connection is used both the internal and external threads should be coated with a hightemperature antiseize compound before the initial installation and at every subsequent reinstallation to facilitate removal of the connection for testingPERIODIC MAINTENANCEYM Series Operation Manual 2009 Yanmar Marine InternationalDaily and periodic maintenance is important to keep the engine in good operating condition The following is a summary of maintenance items by periodic maintenance intervals Periodic maintenance intervals vary depending on engine application loads diesel fuel and engine oil used and are hard to establish definitively The following should be treated only as a general guideline NOTICE Establish a periodic maintenance plan according to the engine application and make sure to perform the required periodic maintenance at the intervals indicated Failure to follow these guidelines will impair the engines safety and performance characteristics shorten the engines life and may affect the warranty coverage on your engine See your authorized Yanmar Marine dealer or distributor for assistance when checking items marked with a PERIODIC MAINTENANCE1205 2009 Yanmar Marine International Check or Clean Replace Contact your authorized Yanmar Marine dealer or distributorSystemItemPeriodic Maintenance IntervalBefore See Daily Checks on page38Initial 50 HoursEvery hours monthly which comes firsthours or six months which comes hours or one year which ever comes firsthours or one year which ever comes firsthours which comes firstWholeVisual inspection of engine exteriorFuel Check the fuel level and refill if necessaryDrain water and sediment from the fuel tankDrain the fuelwater separatorReplace the fuel filter elementCheck the fuel injection Check the fuel injector spray patternLubricating Check the engine oil GearReplace the engine oilGearSail Replace the oil filter elementPERIODIC MAINTENANCEYM Series Operation Manual 2009 Yanmar Marine InternationalCooling Seawater outletDuring OperationCheck coolant level Check or replace the seawater pump Replace coolantEvery year When Long Life Coolant LLC is used replace every two years See Engine Coolant Specifications on page33Clean and check the seawater passagesAir Intake and Clean the intake silencer air cleanerelementClean or replace the exhaustwater mixing elbowClean the breather pipeCheck the exhaust gas During OperationCheck diaphragm assemblyCheck the alarm and indicatorsCheck the electrolyte level in the batterythe alternator Vbelt or replace VbeltCheck the wiring connectors Check or Clean Replace Contact your authorized Yanmar Marine dealer or distributorSystemItemPeriodic Maintenance IntervalBefore See Daily Checks on page38Initial HoursEvery hours monthly which comes hours or six months which comes hours or one year which ever comes firsthours or one year which ever comes firsthours which comes firstPERIODIC MAINTENANCE1205 2009 Yanmar Marine International For EPA requirements see Inspection and Maintenance of EPA EmissionRelated Parts on page 54Note These procedures are considered normal maintenance and are performed at the owners expenseEngine Cylinder Head and Check for leakage of fuel engine oil and engine coolantAfter Tighten all major nuts and boltsAdjust intakeexhaust ous ItemsCheck the remote control cablesAdjust the propeller Check or Clean Replace Contact your authorized Yanmar Marine dealer or distributorSystemItemPeriodic Maintenance IntervalBefore See Daily Checks on page38Initial 50 HoursEvery hours monthly which comes firsthours or six months which comes hours or one year which ever comes firsthours or one year which ever comes firsthours which comes firstPERIODIC MAINTENANCEYM Series Operation Manual 2009 Yanmar Marine International EPA EmissionRelated PartsMarine diesel engines less than 37 kW 50 hp are certified as EPA nonroad engineMarine diesel engines greater than 37 kW 50 hpe certified as EPA CI marine enginesInspection and Maintenance of EPA EmissionRelated Parts for NonRoad and CI Marine EnginesNote The inspection and maintenance items shown above should be performed at your Yanmar Marine dealer or distributorPartsIntervalClean the fuel injection nozzle1500 hoursCheck the fuel injection nozzle pressure and spray pattern3000 hoursCheck the fuel injection pump adjustmentCheck turbocharger adjustment if equippedCheck the electronic engine control unit and its associated sensors and actuators if equippedPERIODIC MAINTENANCE1205 2009 Yanmar Marine InternationalExposure Hazard ALWAYS wear personal protective equipment when performing periodic maintenance proceduresDaily ChecksBefore you start for the day make sure the engine is in good operating condition NOTICE It is important to perform the daily checks as listed in this Operation Manual Periodic maintenance prevents unexpected downtime reduces the number of accidents due to poor engine performance and helps extend the life of the engineMake sure to check the following itemsVisual Checks1Check for engine oil leaks2Check for fuel leaksPiercing Hazard Avoid skin contact with the highpressure diesel fuel spray caused by a fuel system leak such as a broken fuel injection line Highpressure fuel can penetrate your skin and result in serious injury If you are exposed to highpressure fuel spray obtain prompt medical treatment NEVER check for a fuel leak with your hands ALWAYS use a piece of wood or cardboard Have your authorized Yanmar Marine dealer or distributor repair any damage3Check for engine coolant leaks4Check for damaged or missing parts5Check for loose missing or damaged fasteners6Check the electrical harnesses for cracks abrasions and damaged or corroded connectors7Check hoses for cracks abrasions and damaged loose or corroded clamps8Check the fuel filter water separator for presence of water and contaminants If any water or contaminants are found drain the fuel filterwater separator See Draining Fuel Filter Water Separator on page60 If you have to drain the fuel filter water separator frequently drain the fuel tank and check for water in See Draining the Fuel Tank on page63NOTICE If any problem is noted during the visual check the necessary corrective action should be taken before operating the engineChecking Diesel Fuel Engine Oil and Engine Coolant LevelsFollow the procedures in Tank on page 25Checking the Engine Oil on page 28 and Checking and Adding Coolant on page 31 to check these levelsChecking and Refilling Marine Gear See Checking Marine Gear Oil on page30Checking the Battery Electrolyte LevelCheck the battery electrolyte level before use See Checking the Battery Electrolyte Level Serviceable Batteries Only on page61Checking the Alternator Belt Check the belt tension before use Checking and Adjusting the Alternator VBelt Tension on page58PERIODIC MAINTENANCEYM Series Operation Manual 2009 Yanmar Marine InternationalChecking the Remote Control HandleCheck the operation of the remote control handle and ensure it moves smoothly If it is hard to operate grease the joints of the remote control cable and lever bearings If the lever is too loose adjust the remote control cable See Checking and Adjusting the Remote Control Cables on page59Checking the Alarm IndicatorsCheck the instruments and alarm indicators at regular intervalsPreparing Fuel Oil and Coolant in ReservePrepare sufficient diesel fuel for the days operation Always store engine oil and coolant in reserve for at least one refillonboard to be ready for emergenciesPerform the following maintenance after the initial 50 hours of operationDraining the Fuel TankChanging the Engine OilReplacing the Engine Oil Filter ElementChanging the Marine Gear OilChecking and Adjusting the Alternator VBelt TensionInspecting and Adjusting IntakeExhaust Valve ClearanceChecking and Adjusting the Remote Control CablesAdjusting Propeller Shaft AlignmentAfter Initial 50 Hours of OperationPERIODIC MAINTENANCEYM Series Operation Manual571205 2009 Yanmar Marine InternationalDraining the Fuel TankWARNING Fire and Explosion Hazard When you are draining the fuel tank to perform maintenance put an approved container under the opening to catch the fuel NEVER use a shop rag to catch the fuel Vapors from the rag are flammable and explosive Wipe up any spills immediately WARNING Exposure Hazard Wear eye protection The fuel system is under pressure and fuel could spray out when you remove any fuel system component Figure 1Figure1 1Sediment Bowl2Drain Cock3Fuel Line to EngineNote Optional fuel tank shown Actual equipment may be different1Put a pan under the drain cock Figure 12 to catch fuel2Open the drain cock and drain water and sediment Close the drain cock when the fuel is clean and free of air bubblesChanging the Engine OilThe engine oil on a new engine becomes contaminated from the initial breakin of internal parts It is very important that the initial oil replacement is performed as scheduledIt is easiest and most effective to drain the engine oil after operation while the engine is still warm WARNING Burn Hazard If the engine oil must be drained while it is still hot stay clear of the hot engine oil to avoid being burned ALWAYS wear eye protection1Turn the engine off2NOTICE Prevent dirt and debris from contaminating engine oil Carefully clean the dipstick and the surrounding area before removing the dipstick Remove the engine oil dipstick Attach the oil drain pump if equipped and pump out the oil For easier draining remove the engine oil fill cap3Fill with new engine oil See Adding Engine Oil on page29 NOTICE NEVER mix different types of engine oil This may adversely affect the lubricating properties of the engine oil NEVER overfill Overfilling may result in white exhaust smoke engine overspeed or internal damage4Perform a trial run and check for oil leaks5Approximately 10 minutes after stopping the engine remove the oil dipstick and check the oil level Add oil if the level is too low0004542312PERIODIC MAINTENANCE58YM Series Operation Manual 2009 Yanmar Marine InternationalReplacing the Engine Oil Filter Element1Turn the engine off2Turn the engine oil filter Figure 2 counterclockwise with a wrench3Remove the engine oil filter Figure 2Figure2 Note 3YM20 shown4Install a new filter element and handtighten until the seal touches the housing5Turn filter an additional 34 turn using a box wrench Tighten to 20to24 Nm 177to212 lbin 6Perform a trial run and check for oil leaksChanging the Marine Gear OilNote Refer to the Marine Gear Operation Manual for procedureDuring initial operation the oil is quickly contaminated due to the initial wear of internal parts The marine gear oil must therefore be replaced early1Remove cap from the filler port and attach an oil drain pump Drain marine gear oil2Fill marine gear with clean marine gear oil See Marine Gear Oil Specifications on page293Perform a trial run and check for oil leaks4Approximately 10 minutes after stopping the engine remove the oil dipstick and check the oil level Add oil if the level is too lowChecking and Adjusting the Alternator VBelt TensionNOTICE NEVER get any oil on the beltsOil on the belt causes slipping and stretching Replace the belt if it is damagedWARNING Sever Hazard Perform this check with engine off and key removed to avoid contact with moving parts Figure 3Figure3 1Middle of VBelt2Alternator Bolt3VPulley coolant pumpNote 3YM20 shown1Remove the belt cover2Check the belt by pushing on the middle of the belt Figure 31 with your fingerWith proper tension the belt should deflect 8to10 mm approximately 38in00047970004800123PERIODIC MAINTENANCEYM Series Operation Manual591205 2009 Yanmar Marine International3Loosen the alternator bolt Figure 32 and move the alternator to adjust the Vbelt tension4Install the belt coverNote If replacing the Vbelt loosen the Vpulley Figure 33 of the coolant pump to remove the VbeltInspecting and Adjusting IntakeExhaust Valve ClearanceProper adjustment is necessary to maintain the correct timing for opening and closing the valves Improper adjustment will cause the engine to run noisily resulting in poor engine performance and engine damage See your authorized Yanmar Marine dealer or distributor to adjust the intakeexhaust valve clearanceChecking and Adjusting the Remote Control CablesNOTICE Never adjust the highspeed stop bolt Figure 44 on the governor This will void the engine warrantyThe various control levers on the engine side are connected to the remote control lever by remote control cables The cables will become stretched and the attachments loose after long hours of operation It is dangerous to control operation under these conditions and the remote control cables must be checked and adjusted periodicallyAdjusting the Throttle Remote Control Cable Figure 4Figure4 1Cable2Fuel Injection Pump3Adjustment4HighSpeed Stop Bolt5LowSpeed Stop Bolt6Control Lever1Check that the control lever on the engine side moves to the highspeed stop position and lowspeed stop position when the remote control lever is moved to H high speed and L low speedively2When there is deviation loosen the bracket for the remote control cable on the engine side and adjust3Adjust the highspeed stop position first and then adjust the lowspeed idling using the adjustment bolt on the remote control lever1234560004798PERIODIC MAINTENANCE60YM Series Operation Manual 2009 Yanmar Marine InternationalAdjusting Clutch Remote Control Cable Figure 5Figure5 1Marine Gear2Control Cable3Control Lever4Bracket cable1Check that the control lever Figure 53 moves to the correct position when the remote control cable handle is moved to the NEUTRAL FORWARD and REVERSE positions 2Use the NEUTRAL position as the standard for adjustment When there is deviation loosen the bracket Figure 54 for the remote control cable on the clutch side and adjustAdjusting Propeller Shaft AlignmentThe flexible engine mounts are compressed slightly during initial engine operation and may cause misalignment between the engine and the propeller shaftAfter the first 50 hours of operation the alignment should be checked and readjusted if necessary This is considered normal maintenance and the adjustment requires specialized knowledge and techniques Consult your authorized Yanmar Marine dealer or distributorWhen completing the initial 50 hour maintenance procedures perform the following procedures every 50 hours thereafter or monthly whichever comes firstDraining Fuel FilterWater SeparatorChecking the Battery Electrolyte LevelDraining Fuel Filter Water SeparatorWARNING Fire and Explosion Hazard When removing any fuel system component to perform maintenance such as changing the fuel filter an approved container under the opening to catch the fuel NEVER use a shop rag to catch the fuel Vapors from the rag are flammable and explosive Wipe up any spills immediately WARNING Exposure Hazard Wear eye protection The fuel system is under pressure and fuel could spray out when removing any fuel system component13000479924Every 50 Hours of OperationPERIODIC MAINTENANCEYM Series Operation Manual611205 2009 Yanmar Marine International Figure 6Figure6 1Air Bleed Screw2Bracket3ORing4Fuel Filter Element5Fuel Filter Housing6Retaining Ring1Close the fuel cock of the fuel tank2Put a pan under the fuel water separator3Loosen the retaining ring Figure 66 remove the filter housing Figure 65 and drain off any water or sediment collected inside4After draining tighten the air bleed screw Figure 615Be sure to bleed air from the fuel system See Bleeding the Fuel System on page26Checking the Battery Electrolyte Level Serviceable Batteries OnlyNEVER operate with insufficient battery electrolyte Operating with insufficient electrolyte will destroy the batteryWARNING Exposure Hazard Batteries contain sulfuric acid NEVER allow battery fluid to come in contact with clothing skin or eyes Severe burns could result ALWAYS wear safety goggles and protective clothing when servicing the battery If battery fluid contacts the eyes and or skin immediately flush the affected area with a large amount of clean water and obtain prompt medical treatmentNOTICE NEVER turn off the battery switch if equipped short the battery cables during operation Damage to the electrical system will resultNOTICE Battery fluid tends to evaporate in high temperatures especially in summer In such conditions inspect the battery earlier than specified1Make sure the engine is off and the key is removed2Turn the battery master switch to OFF if equipped or disconnect the negative ttery cable 3Remove the plugs and check the electrolyte level in all cells NOTICE NEVER attempt to remove the covers or fill a maintenancefree battery1000480123456PERIODIC MAINTENANCE62YM Series Operation Manual 2009 Yanmar Marine International4If the electrolyte level is lower than the minimum fill level Figure 71 fill with distilled water Figure 72 available locally up to the upper limit Figure 73 of the battery Figure 7Figure7 1Lower Level2Distilled Water3Upper LevelNote The maximum fill level is approximately 10 to 15 mm 38to916 in above the platesPerform the following maintenance every 100 hours or every 6 months of operation whichever comes firstChanging the Sail Drive Gear OilChanging the Sail Drive Gear OilRefer to the Sail Drive Operation Manual for the procedure for changing gear oilUPPER LEVEL LOWER LEVEL 2310004566 Every 100 Hours of OperationPERIODIC MAINTENANCE1205 2009 Yanmar Marine InternationalPerform the following maintenance every 150 hours or every year of operation whichever comes firstChanging the Engine OilChanging the Engine OilSee Changing the Engine Oil on page57Perform the following maintenance every 250 hours or 1 year of operation whichever comes firstDraining the Fuel TankReplacing the Fuel Filter ElementReplacing the Engine Oil Filter ElementChanging the Marine Gear OilChecking or Replacing the Seawater Replacing the CoolantCleaning the Intake Silencer Air CleanermentCleaning or Replacing the ExhaustWater Mixing ElbowAdjusting the Alternator VBelt TensionCleaning the Breather PipeChecking the Wiring ConnectorsDraining the Fuel TankSee Draining the Fuel Tank on page57Every 250 Hours of OperationPERIODIC MAINTENANCE64YM Series Operation Manual 2009 Yanmar Marine InternationalReplacing the Fuel Filter ElementWARNING Fire and Explosion Hazard When removing any fuel system component to perform maintenance such as changing the fuel filter an approved container under the opening to catch the fuel NEVER use a shop rag to catch the fuel Vapors from the rag are flammable and explosive Wipe up any spills immediatelyWARNING Exposure Hazard Wear eye protection The fuel system is under pressure and fuel could spray out when removing any fuel system component Figure 8Figure8 1Housing2Retaining RingWhen there is dirt in the fuel the filter becomes clogged and the fuel will not flow easily Check and replace the element1Close the fuel cock of the fuel tank2Place an approved container under the fuel filter3Remove the filter case by loosening the retaining ring Figure 82 Turn the ring counterclockwise using a filter wrench 4Remove the housing Figure 81 and remove the element Replace the element with a new one5Apply a thin film of clean diesel fuel to the sealing surface of the new filter gasket 6Clean the inside of the housing thoroughly install the Oring and handtighten the retainer ring Use a filter wrench and tighten to 12 Nm 106 inlb7Air will enter the fuel system when the filter is disassembled Bleed the fuel system to remove any air from the system See Bleeding the Fuel System on page268Dispose of waste properlyReplacing the Engine Oil Filter ElementSee Replacing the Engine Oil Filter Element on page58Changing the Marine Gear OilSee Changing the Marine Gear Oil on page58Checking or Replacing the Seawater Pump Impeller1Loosen side cover bolts and remove the side cover2Inspect the inside of the seawater pump with a flashlight If any of the following are found service the seawater pumpImpeller blades are cracked or nicked Edges or surfaces of the blades are marred or scratchedWear plate is damaged3If no damage is found when inspecting the inside of the pump install the Oring and side cover4If a large amount of water leaks continuously from the water drain line below the seawater pump during operation replace the mechanical seal See your authorized Yanmar Marine dealer or distributorWhen disassembly and maintenance of the seawater pump are necessary consult your Yanmar Marine dealer or distributor100048042PERIODIC MAINTENANCEYM Series Operation Manual651205 2009 Yanmar Marine InternationalThe seawater pump turns in the direction as shown in Figure 9 The impeller must be installed while considering the impeller direction Figure 9Figure9 1Impeller Vane Direction2Impeller Rotating Direction3Impeller4Seawater PumpReplacing the CoolantCAUTION Coolant Hazard Wear eye protection and rubber gloves when you handle engine coolant If contact with the eyes or skin should occur flush eyes and wash immediately with clean waterReplace coolant every yearNote If Long Life Coolant LLCused replace coolant every 2 yearsNote The drain cocks are opened before shipping from the factory Close all drain cocks before filling the system with coolant1Put a pan under the coolant drain cocks2Open all coolant drain cocks3Allow to drain completely Dispose of waste properly4Close all the drain cocks5Fill coolant tank and coolant recovery tank with appropriate coolant See Engine Oil Specifications on page27 and see Checking and Adding Coolant on page 31Cleaning the Intake Silencer Air Cleanerment1Disassemble the intake silencer air cleaner2Remove element Figure 101 Clean element and housing with a neutral detergent3Dry completely and reassemble Figure 10Figure10 4312000480610004805PERIODIC MAINTENANCEYM Series Operation Manual 2009 Yanmar Marine InternationalCleaning or Replacing the ExhaustWater Mixing ElbowThere are two types of mixing elbows the Ltype and the Utype The mixing elbow is attached to the exhaust manifold The exhaust gas is mixed with seawater in the mixing elbow 1Remove the mixing elbow2Clean dirt and scale out of the exhaust and seawater passages3If the mixing elbow is damaged repair or replace it See your authorized Yanmar Marine dealer or distributor4Inspect the gasket and replace if necessaryReplace the mixing elbow with a new one every 500 hours or 2 years whichever comes first even if no damage is foundSee your authorized Yanmar Marine dealer or distributorAdjusting the Alternator VBelt TensionSee Checking and Adjusting the Alternator VBelt Tension on page58Cleaning the Breather PipeSee your authorized Yanmar Marine dealer or distributorChecking the Wiring ConnectorsSee your authorized Yanmar Marine dealer or distributorPerform the following maintenance every 1000 hours or 4 years of operation whichever comes firstChecking the Fuel Injection TimingChecking the Fuel Injector Spray Replacing the Seawater Pump Cleaning and Checking the Seawater PassagesChecking the Diaphragm AssemblyReplacing the Alternator VBeltAdjusting IntakeExhaust Valve ClearanceChecking and Adjusting the Remote Control CablesAdjusting the Propeller Shaft Tightening All Major Nuts and BoltsEvery 1000 Hours of OperationPERIODIC MAINTENANCEYM Series Operation Manual671205 2009 Yanmar Marine InternationalChecking the Fuel Injection TimingSee your authorized Yanmar Marine dealer or distributorChecking the Fuel Injector Spray PatternSee your authorized Yanmar Marine dealer or distributorReplacing the Seawater Pump ImpellerThe seawater impeller must be replaced every 1000 hours or every 4 years even if it is not damaged See Checking or Replacing the Seawater Pump Impeller on page64Cleaning and Checking the Seawater PassagesAfter prolonged use clean the seawater passages to remove dirt scale rust and other contaminants that collect in the coolant passages This can cause poor engine cooling Inspect these itemsHeat ExchangerPressure CapSee your authorized Yanmar Marine dealer or distributorChecking the Diaphragm Assembly Inspect the diaphragm assembly on the rocker arm cover1Loosen screws and remove diaphragm assembly2Check for oil and contaminants between the diaphragm and cover NOTICE If oil and contaminants enter the diaphragm assembly the diaphragm will not operate properly3Inspect the diaphragm rubber and spring for damage If necessary replace with new ones Figure 11Breather System ComponentsFigure11 1Diaphragm Cover2Spring3Center Plate4Diaphragm5Rocker Arm Cover6Breather Baffle7Baffle Plate8Intake Silencer air cleaner567800048071234PERIODIC MAINTENANCEYM Series Operation Manual 2009 Yanmar Marine InternationalReplacing the Alternator VBelt1Remove the Vbelt cover2Loosen the Vbelt tension adjusting bolt of the alternator3Remove the alternator Vbelt4Install a new alternator Vbelt5Adjust the alternator Vbelt tension See Checking and Adjusting the Alternator VBelt Tension on page586Replace the Vbelt coverAdjusting IntakeExhaust Valve ClearanceSee your authorized Yanmar Marine dealer or distributorChecking and Adjusting the Remote Control CablesSee Checking and Adjusting the Remote Control Cables on page59Adjusting the Propeller Shaft AlignmentSee your authorized Yanmar Marine dealer or distributorTightening All Major Nuts and BoltsSee Tightening Fasteners on page47 or see your authorized Yanmar Marine dealer or distributor 2009 Yanmar Marine InternationalYM Series Operation ManualBefore performing any troubleshooting procedures within this section review the Safety section on pageIf a problem occurs stop the engine immediately Refer to the Symptom column in the Troubleshooting Chart to identify the problemJust after the engine has started check the following items at a low engine speedIs sufficient water being discharged from the seawater outlet pipeIf the discharge is low stop the engine immediately Identify the cause and repairIs the exhaust color normalThe continuous emission of black exhaust smoke indicates engine overloading This shortens the engines life and should be avoided When operating the engine at low speed for long periods of time race the engine once every 2 hours Racing the engine with the clutch in NEUTRAL accelerate from the lowspeed position to the highspeed position and repeat this process about five times This is done to clean out carbon from the cylinders and the fuel injection valves NOTICE Neglecting to race the engine will result in poor exhaust color and reduce engine performance Periodically operate the engine near maximum speed while underway This will generate higher exhaust temperatures which will help clean out hard carbon deposits maintain engine performance and prolong the life of the engineYM Series Operation Manual 2009 Yanmar Marine InternationalAre there abnormal vibrations or noiseDepending on the hull structure engine and hull resonance may suddenly increase at certain engine speed ranges causing heavy vibrations Avoid operation in this speed range If any abnormal sounds are heard stop the engine and inspect for causeAlarm sounds during operationIf the alarm sounds during operation lower the engine speed immediately check the warning lamps and stop the engine for repairsIs there water oil or fuel leakage Are there any loose bolts or connectionsCheck the engine room daily for any leaks or loose connectionsIs there sufficient fuel in the fuel tankRefill fuel in advance to avoid running out of fuel If the tank runs out of fuel bleed the fuel system See Bleeding the Fuel System on page26If the engine does not operate properly refer to the Troubleshooting Chart on page or see your authorized Yanmar Marine dealer or distributorSupply your authorized Yanmar Marine dealer or distributor with the following informationModel name and serial number of your engineBoat model hull material size tonsUse type of boating number of hours runTotal number of operation hours refer to hourmeter and age of boatThe operating conditions when the problem occursEngine rpmColor of exhaust smokeType of diesel fuelType of engine oilAny abnormal noises or vibrationOperating environment such as high altitude or extreme ambient temperatures etcEngine maintenance history and previous problemsOther factors that contribute to the problemTROUBLESHOOTING1205 2009 Yanmar Marine InternationalSymptomProbable CauseMeasureReferenceIndicators light on the instrument panel and alarm sounds during operationShift to lowspeed operation immediately and check which indicator has come on Stop the engine and inspect If no abnormality is identified and there is no problem with operation return to port at lowest speed and see your authorized Yanmar Marine dealer or distributor Engine oil low pressure alarm indicator lightsEngine oil level is lowCheck engine oil level Add or replace as necessary See Checking the Engine Oil on page28Engine oil filter is clogged Replace engine oil filter Replace engine oil See Changing the Engine Oil on page57Water in sail drive seal indicator lightsRubber sail drive seal is broken See your authorized Yanmar Marine dealer or distributor Coolant high temperature alarm lightsCoolant in coolant tank heat exchanger is lowCheck coolant level and refillSee Checking and Adding Coolant on page31Insufficient seawater level causing temperature to riseCheck seawater system system See your authorized Yanmar Marine dealer or distributorFaulty Warning DevicesDo not operate the engine if alarm devices are not repaired See you authorized Yanmar Marine dealer or distributor Serious accidents may result if abnormalities are not identified due to faulty indicators or alarm Indicators Do Not LightWhen key is turned onWhen any trouble occurs low oil pressure etcNo electrical current available Circuit broken or lamp burned outSee your authorized Yanmar Marine dealer or distributorOne of the indicators does not go outSensor switch is faultySee your authorized Yanmar Marine dealer or distributorBattery low charge indicator does not go out during operationVbelt is loose or brokenReplace Vbelt or adjust tensionSee Checking and Adjusting the Alternator VBelt Tension on page58Battery is defectiveCheck battery fluid level specific gravity or replace battery See Checking the Battery Electrolyte Level Batteries Onlypage61Alternator power generation failureSee your authorized Yanmar Marine dealer or distributorYM Series Operation Manual 2009 Yanmar Marine InternationalStarting FailuresStarter turns but engine does not startNo fuelAdd fuel Bleed fuel systemSee Filling the Fuel Tank on page25Bleeding the Fuel System on page Fuel filter is cloggedReplace filter elementSee Replacing the Fuel Filter Element on page64Improper fuelReplace with recommended fuelSee Diesel Fuel Specifications on page22Problem with fuel injectionSee your authorized Yanmar Marine dealer or Compression leakage from intakeexhaust valveSee your authorized Yanmar Marine dealer or Starter does not turn or turns slowly engine can be turned manuallyFaulty clutch positionShift to NEUTRAL and See Restarting After Starting Failure on page37Insufficient battery chargeCheck fluid level Recharge or replace batterySee Checking the Battery Electrolyte Level Batteries Onlypage61Cable terminal contact failureRemove corrosion from terminals Tighten battery Faulty safety switch deviceSee your authorized Yanmar Marine dealer or Faulty starter switchSee your authorized Yanmar Marine dealer or Power lacking due to accessory See your authorized Yanmar Marine dealer or Engine cannot be turned manuallyInternal parts seizedSee your authorized Yanmar Marine dealer or SymptomProbable CauseMeasureReferenceTROUBLESHOOTING1205 2009 Yanmar Marine International Abnormal Exhaust ColorBlack smokeLoad increasedSee your authorized Yanmar Marine dealer or distributorImproper propeller matchingSee your authorized Yanmar Marine dealer or distributorDirty intake silencer air cleanerClean elementSee Cleaning the Intake Silencer Element on page65Improper fuel Replace with recommended fuelSee Diesel Fuel Specifications on page22Faulty spraying of fuel injector See your authorized Yanmar Marine dealer or distributorIncorrect intakeexhaust valve clearance See your authorized Yanmar Marine dealer or distributorWhite smokeImproper fuelReplace with recommended fuelSee Diesel Fuel Specifications on page22Faulty spraying of fuel injector See your authorized Yanmar Marine dealer or distributorFuel injection timing off See your authorized Yanmar Marine dealer or distributorExcessive diesel fuel consumptionSee your authorized Yanmar Marine dealer or distributorSymptomProbable CauseMeasureReferenceYM Series Operation Manual 2009 Yanmar Marine International 2009 Yanmar Marine InternationalYM Series Operation ManualBefore performing any storage procedures within this section review the Safety section on pageIf the engine will not be used for an extended period of time special measures should be taken to protect the cooling system fuel system and combustion chamber from corrosion and the exterior from rustingThe engine can normally stand idle for up to 6 months If it remains unused for longer than this please contact your authorized Yanmar Marine dealer or distributorLONGTERM STORAGE76YM Series Operation Manual 2009 Yanmar Marine InternationalPREPARE ENGINE FOR LONGTERM STORAGENote If the engine is close to a periodic maintenance interval perform those maintenance procedures before putting the engine into longterm storage1Wipe off any dust or oil from the outside of engine2Drain water from the fuel filters3Drain the fuel tank completely or fill the tank to prevent condensation4Drain the Cooling System see Draining the Cooling System on page 765Grease the exposed areas and joints of the remote control cables and the bearings of the remote control handle6Seal the intake silencer exhaust pipe etc to prevent moisture or contamination from entering engine7Completely drain the bilge in hull bottom8Waterproof the engine room to prevent rain or seawater from entering9Charge the battery once a month to compensate for batterys selfdischarge10Remove the key from key switch and cover the key switch with moisture capDRAINING THE COOLING SYSTEM Figure 1Figure1 1Alternator2Coolant Tank Heat Exchanger3Coolant Drain Cock4Seawater Drain Cock Figure 2Figure2 1Coolant Tank Heat Exchanger2Seawater Drain Cock3Coolant Drain Cock4Coolant Pump5Seawater Pump12340004794123540004795LONGTERM STORAGEYM Series Operation Manual771205 2009 Yanmar Marine International Figure 3Figure3 1Stop Solenoid2Coolant Drain Cock3Flywheel HousingNote The drain cocks are opened before shipping from the factory Close all drain cocks before filling the system with coolantNOTICE If seawater is left inside it may freeze and damage parts of the cooling system heat exchanger seawater pump etc ambient temperature is below 0C 32F1Put a pan under the seawater drain cocks2Open the seawater drain cocks on the pipe and on the heat exchanger Allow to drain3Remove the four bolts fastening the side cover of the seawater pump Remove the cover and drain the seawater4Install the cover and tighten bolts5Close all drain cocksNOTICE NEVER drain engine coolant in the cold season or before long storage If LLC Long Life Coolant has not been added to the cooling system add LLC or drain the coolant from the coolant system after daily use If the coolant without LLC is not removed it may freeze and damage parts of the cooling system or engine when ambient temperature is below 0C 32F1230004793YM Series Operation Manual 2009 Yanmar Marine International 2009 Yanmar Marine InternationalYM Series Operation ManualPRINCIPAL ENGINE SPECIFICATIONSSpecification2YM15Marine Gear ModelKM2P1SD20UsePleasure useTypeVertical water cooled 4cycle diesel engineCombustion SystemSwirl precombustion chamberAir ChargingNatural aspirationNumber of Cylinders2Bore x Stroke70 mm x 74 mm 276 in x 292 inDisplacement0570 L 350 cu inContinuous Rated OutputOutput at CrankshaftEngine Speed 94 kW 128 hp metric rpmRated OutputOutput at CrankshaftEngine Speed103 kW 140 hp metric 3600 rpm100 kW 136 hp metric600 rpmOutput at PropellerEngine Speed 100 kW 136 hp metric0 rpm 97 kW 132 hp metric0 rpm InstallationFlexible mountingFuel Injection TimingFID 21 1 BTDCFuel Injection Opening Pressure123 to 1328 MPa 125 to 135 kgfcmMain Power Take OffAt flywheel endRotationCrankshaftCounterclockwise viewed from sternPropeller Shaft AheadClockwise viewed from stern Cooling SystemClosed coolanLubrication SystemComplete enclosed forced lubrication systemCoolant CapacityEngine 30 L 317 qtlant recovery tank 08 L 095 qtYM Series Operation Manual 2009 Yanmar Marine InternationalNote Density of fuel 0842 gcm at 15C Fuel temperature at the inlet of the fuel injection pump 1hp metric 07355 kWLubricating Oil Capacity EngineRake Angleat rake angle 8at rake angle 0Total20 L 21 qt18 L 19 qt095 L 10 qt09 L 095 qtStarting SystemTypeElectricStarting MotorDC 12 V 14 kWAC Alternator12 V 60 A 12 V 80 A optionalDimensionOverall Length613 mm 241 inOverall Width463 mm 182 inOverall Height528 mm 208 inEngine Dry Mass Including Marine 115 kg 253 lb134 kg 295 lb Rating Condition Temperature of fuel 25C at fuel pump inlet ISO 30461 Rating Condition Temperature of fuel 40C at fuel pump inlet ISO 8665 The total oil quantity includes oil in oil pan channels coolers and filter The effective amount of oil shows the difference in maximum scale of the dipstick and minimum Specification2YM15Marine Gear ModelKM2P1SD201205 2009 Yanmar Marine InternationalSpecification3YM20Marine Gear ModelKM2P1SD20UsePleasure useTypeVertical water cooled 4cycle diesel engineCombustion SystemSwirl precombustion chamberAir ChargingNatural aspirationNumber of Cylinders3Bore x Stroke70 mm x 74 mm 276 in x 292 inDisplacement0854 L 520 cu inContinuous Rated OutputCrankshaftEngine 147 kW 200 hp metricpmRated OutputCrankshaftEngine 162 kW 220 hp metric 3600 rpm153 kW 208 hp metric0 rpmatPropellerEngine 157 kW 213 hp metricpm 149 kW 202 hp metric rpm InstallationFlexible mountingFuel Injection TimingFID 22 1 BTDCFuel Injection Opening Pressure123 to 1328 MPa 125 to 135 kgfcmMain Power Take OffAt flywheel endRotationCrankshaftCounterclockwise viewed from sternAheadClockwise viewed from stern Cooling SystemClosed coolant system with heat exchangerLubrication SystemComplete enclosed forced lubrication systemCoolant CapacityEngine 41 L 43 qtecovery tank 08 L 085 qtLubricating Oil Capacity EngineRake Angleat rake angle 8at rake angle 0Total27 L 285 qt24 L 254 qt14 L 148 qt15 L 159 qtStarting SystemTypeElectricStarting MotorDC 12 V 14 kWAC Alternator12 V 60 A 12 V 80 A optionalYM Series Operation Manual 2009 Yanmar Marine InternationalNote Density of fuel 0842 gcm at 15C Fuel temperature at the inlet of the fuel injection pump 1hp metric 07355 kWDimensionOverall Length693 mm 273 inOverall Width463 mm 182 inOverall Height528 mm 208 inEngine Dry Mass Including Marine 130 kg 287 lb151 kg 333 lb Rating Condition Temperature of fuel 25C at fuel pump inlet ISO 30461 Rating Condition Temperature of fuel 40C at fuel pump inlet ISO 8665 The total oil quantity includes oil in oil pan channels coolers and filter The effective amount of oil shows the difference in maximum scale of the dipstick and minimum Specification3YM20Marine Gear ModelKM2P1SD201205 2009 Yanmar Marine InternationalSpecification3YM30Marine Gear ModelKM2P1SD20UsePleasure useTypeVertical water cooled 4cycle diesel engineCombustion SystemSwirl precombustion chamberAir ChargingNatural aspirationNumber of Cylinders3Bore x Stroke76 mm x 82 mm 299 in x 323 inDisplacement1115 L 6804 cu inContinuous Rated OutputOutput at CrankshaftEngine Speed 201 kW 300 hp metric600 rpmRated OutputOutput at CrankshaftEngine Speed 221 kW 300 hp metric0 rpm213 kW 290 hp metric 3600 rpmatPropellerEngine Speed 214 kW 291 hp metricpm 207 kW 281 hp metricrpm InstallationFlexible mountingFuel Injection TimingFID 16 1 BTDCFuel Injection Opening Pressure123 to 1328 MPa 125 to 135 kgfcmMain Power Take OffAt flywheel endRotationCrankshaftCounterclockwise viewed from sternPropeller Shaft AheadClockwise viewed from stern Cooling SystemClosed coolantLubrication SystemComplete enclosed forced lubrication systemCoolant CapacityEngine 49 L 52 qtoolant recovery tank 08 L 085 qtLubricating Oil Capacity EngineRake Angleat rake angle 8at rake angle 0Total28 L 296 qt25 L 264 qt14 L 148 qt15 L 159 qtStarting SystemTypeElectricStarting MotorDC 12 V 14 kWAC Alternator12 V 60 A 12 V 80 A optionalYM Series Operation Manual 2009 Yanmar Marine InternationalNote Density of fuel 0842 gcm at 15C Fuel temperature at the inlet of the fuel injection pump 1hp metric 07355 kWDimensionOverall Length715 mm 281 inOverall Width463 mm 182 inOverall Height545 mm 215 inEngine Dry Mass Including Marine 133 kg 293 lb154 kg 339 lb Rating Condition Temperature of fuel 25C at fuel pump inlet ISO 30461 Rating Condition Temperature of fuel 40C at fuel pump inlet ISO 8665 The total oil quantity includes oil in oil pan channels coolers and filter The effective amount of oil shows the difference in maximum scale of the dipstick and minimum Specification3YM30Marine Gear ModelKM2P1SD201205 2009 Yanmar Marine InternationalMarine Gear and Sail Drive SpecificationsModelKM2P1SKM2P1GKM2P1GGSD20 coupled at boat builderTypeMechanical cone clutchDog ClutchReduction Ratio Forward 221 306262 306322 306264 264Propeller Speed Forward 1580 1140 rpm 1332 1140 1083 1140 rpm 1322 rpm Lubrication SystemSplash Oil bathLubricating Oil Capacity Total03 L 032 qt22 L 23 qtStandard25 L 26 qtLong Reach Lubricating Oil Capacity 005 L 005 qt015 L 016 qtCooling SystemAir cooling by fan on flywheelWeight103 kg 277 lb30 kg 661 lb At continuous power engine speed 2907 rpm YM Series Operation Manual 2009 Yanmar Marine InternationalYM Series Operation Manual87 2009 Yanmar Marine InternationalYM Series Operation Manual SYSTEM DIAGRAMSPIPING DIAGRAMSPiping diagrams and wiring diagrams are provided for reference only Contact your authorized Yanmar Marine dealer or distributor for the most current diagramsNotes1Steel pipe shows OD x wall thickness rubber hose shows ID x wall thickness2Rubber fuel lines meet ENISO78403Unit mmNotationDescriptionScrew Joint UnionFlange JointEye JointInsertion JointDrilled HoleCoolant PipingSeawater PipingEngine Oil PipingDiesel Fuel PipingSYSTEM DIAGRAMS88YM Series Operation Manual 2009 Yanmar Marine International Figure 12YM15 with KM2P1 Marine GearFigure1 PPPPT1234567891011121315141617181920212224252623272829303132333436383735CD000002003004005006007000000010BASYSTEM DIAGRAMSYM Series Operation Manual891205 2009 Yanmar Marine InternationalUnit mm in178 x t45 Rubber Hose2Check Valve378 x t45 Rubber Hose478 x t45 Rubber Hose5Overflow6Fuel Inlet778 x t45 Rubber Hose85 x t45 Rubber Hose978 x t45 Rubber Hose10Fuel Feel Pump11Fuel Injection Pump12476 x t07 Steel Pipe13Engine Oil Filter cartridge type14476 x t07 Steel Pipe15Fuel HighPressure Pipe16Fuel Injection Nozzle17Oil Pressure Switch18Mixing Elbow1917 x 14 Rubber Hose20Heat Exchanger21Engine Oil Inlet Filter22Main Bearing23Seawater Inlet2417 x t4 Rubber Hose25Seawater Pump2628 x t4 Rubber Hose2728 x t4 Rubber Hose28Hot Water Connection Outlet R3829Thermostat30Coolant Pump31Hot Water Connection Inlet R3832Coolant Temperature Switch33Engine Oil Pump34Pressure Control Valve35Diesel Fuel36To Oil Pan37To Camshaft38From Cylinder HeadDetail of part ADetail of part BDetail of part CDetail of part D170671807100000200300400500000600000000750 1970000020030040050060070000000108 0319 03517 06700000200300400500200600000000785 0338 031165065000002003004005005006000000007SYSTEM DIAGRAMS90YM Series Operation Manual 2009 Yanmar Marine International Figure 23YM20 and 3YM30 with KM2P1 Marine GearFigure2 PPPTP0000020030040050030060000000071234567891110121314151617181920212223BACDSYSTEM DIAGRAMSYM Series Operation Manual911205 2009 Yanmar Marine InternationalUnit mm in1PCV2Overflow3Fuel Inlet4Fuel Feed Pump5Fuel Injection Pump6Engine Oil Filter cartridge type7Fuel HighPressure Pipe8Fuel Injection Nozzle9Oil Pressure Switch10Mixing Elbow11Heat Exchanger12Engine Oil Inlet Filter13Main Bearing14Seawater Inlet15Seawater Pump16Hot Water Connection Outlet17Thermostat18Coolant Pump19Hot Water Connection Inlet20Coolant Temperature Switch21Engine Oil Pump22Pressure Control Valve23Fuel Filter24To Oil Pan25To Camshaft26From Cylinder HeadDetail of part ADetail of part BDetail of part CDetail of part D170671807100000200300400500000600000000750 1970000020030040050060070000000108 0319 03517 06700000200300400500200600000000785 0338 031165065000002003004005005006000000007SYSTEM DIAGRAMSYM Series Operation Manual 2009 Yanmar Marine InternationalSYSTEM DIAGRAMS1205 2009 Yanmar Marine InternationalColor CodingRRedBBlackWWhiteLBlueRBRed BlackLBBlue BlackYWYellow WhiteYGYellow GreenWLWhite BlueWGWhite GreenGRGreen RedOOrangeWBrWhite BrownAllowable Length by Cross Sectional Area of Battery CableSection of Cable inAllowable Length 15 0023 086 02620 0031 13 04030 0046 23 07040 0062 28 08550 0077 35 10760 0093 41 125SYSTEM DIAGRAMS94YM Series Operation Manual 2009 Yanmar Marine International Figure 32YM15 3YM20 3YM30 BType Instrument PanelFigure3 SBLE3R085LB085RB085YW085WL085 O085YGR2L12V13210R10B085B2B2RWBr2B5RWYB3BRBYBLYGRB2W17G1PG230WBrACRLLRWOBYWWLYGLB2B2B5R2W2B085B12899077910119247771001202707751111971777800085WBr2RAA3R3WYWWLWGBRBLBOYGGLOWOFFONSTART30ACG1G2173L000002003004005005006000000007987101213151416181721192022232425262728293011326541SYSTEM DIAGRAMS1205 2009 Yanmar Marine International1Alarm Lamps2Buzzer Oil Pressure3Coolant Temperature4Sail Drive Seal5Charge6Fuse 3A7Stop Switch8Diodes9Key Switch10Tachometer Hour Meter11Instrument Panel12Wire Harness Option L3M13Wire Harness Option L6M14Amplifier Only for Sail Drive15Procured by Customer16Battery17Battery Switch18Engine Stop Solenoid19Relay20Glow Plug21Stop Relay22Starter Relay23Starter24Coolant Temperature Switch25Engine Oil Pressure Switch26Alternator27Ground28Sail Drive only for sail drive29Key Switch30Coupler view from AASYSTEM DIAGRAMS96YM Series Operation Manual 2009 Yanmar Marine International Figure 42YM15 3YM20 3YM30 B Keylesspe Instrument Panel OptionalFigure4 000002003004005006007000000010181925263029313220282724171314151678654321910111212222123SBLE3R085LB085RB085YW085WL085 O085YGR2L12V13210R10B085B2B2RWBr2B5RWYB3BRBYBLYGRB2W2B2B5R2W2B085B11971711924777100120270775111289907791077800085WBr2RAA3R3WYWWLWGBRBLBOYG3LPO00470023W1N4007LWBrWRLYWRBYWWLYGLBRBRBRBBBRBIIIIIISYSTEM DIAGRAMS1205 2009 Yanmar Marine International1Optional2Diodes3Buzzer4Oil Pressure5Coolant Temperature6Sail Drive Seal7Charge8Fuse 3A9SWITCH GLOW I OFF 0 STOP II10SWITCH START IIN I OFF 011Diode12Switch13Tachometer Hour Meter14Instrument Panel main station option15Wire Harness16Wire Harness for Sub Panel17Amplifier only for sail drive18Procured by Customer19Battery20Battery Switch21Engine Stop Solenoid22Relay23Glow Plug24Stop Relay25Starter Relay26Starter27Coolant Temperature Switch28Engine Oil Pressure Switch29Alternator30Ground31Sail Drive only for sail drive32Coupler view from AASYSTEM DIAGRAMSYM Series Operation Manual 2009 Yanmar Marine InternationalYM Series Operation Manual99 2009 Yanmar Marine InternationalYM Series Operation ManualEPA WARRANTY USA ONLYYANMAR CO LTD LIMITED EMISSION CONTROL SYSTEM WARRANTY USA ONLY2YM15 3YM20 EPA and CARB NameplateFor Example 2YM15Figure1 3YM30 EPA and CARB NameplateFigure2 YANMAR CO LTD000002003004005006007006004004000006STANDARDS NOxHC 75gkWhr CO 66gkWhr PM 040gkWhrEMISSION CONTROL INFORMATIONTHIS ENGINE COMPLIES WITH US EPA MARINE AND CALIFORNIA OFFROADREGULATIONS FOR 2009 MY DIESEL ENGINESLOW SULFUR FUEL OR ULTRA LOW SULFUR FUEL ONLYENGINE FAMILY 9YDXN057P2N DISPLACEMENT 0569 LITERSENGINE MODEL 2YM15 EMISSION CONTROL SYSTEM EMFUEL RATE 174MM3STROKE 100kW 3600RPM 8003kW19APPLICATION VARIABLESPEED PROPULSION ENGINES USED WITH FIXEDPITCH PROPELLERSYANMAR CO LTD000002003004004005006005007007000005STANDARDS NOxHC 75gkWhr CO 55gkWhr PM 030gkWhrEMISSION CONTROL INFORMATIONTHIS ENGINE COMPLIES WITH US EPA MARINE AND CALIFORNIA OFFROADREGULATIONS FOR 2009 MY DIESEL ENGINESLOW SULFUR FUEL OR ULTRA LOW SULFUR FUEL ONLYENGINE FAMILY 9YDXN111P3N DISPLACEMENT 1116 LITERSENGINE MODEL 3YM30 EMISSION CONTROL SYSTEM EMFUEL RATE 232MM3STROKE 213kW 3600RPM 19003kW37APPLICATION VARIABLESPEED PROPULSION ENGINES USED WITH FIXEDPITCH PROPELLERSYM Series Operation Manual 2009 Yanmar Marine InternationalTHIS EMISSION WARRANTY APPLIES TO THE ENGINES CERTIFIED TO UNITED STATES EPA 40 CFR AND SOLD BY YANMAR THAT ARE INSTALLED IN VESSELS FLAGGED OR REGISTERED IN THE UNITED STATESObligationsYanmar warrants to the first user and each subsequent purchaser the emission control system on your engine for periods of time listed below provided the engine has been installed according to Yanmar installation requirements and there has been no abuse neglect or improper maintenance of your Yanmar Marine engineYanmar warrants that the engine is designed built and tested using genuine parts and equipped so as to conform to all applicable emission requirements of the US Environmental Protection Agency and is free from defects in material and workmanship which would cause this engine to fail to conform to the applicable emission regulations over its limited emission control system warranty periodWhere a warrantable emissions condition exists Yanmar will repair your engine at no charge to you for diagnosis parts and e or repair will be provided at authorized Yanmar Marine dealers or distributorsIt is recommended that any replacement parts used for maintenance repair or replacement of emission control systems are Yanmar parts The owner may elect to have maintenance replacement or repair of the emission control components and systems performed by any repair establishment or individual and may elect to use parts other than Yanmar parts for such maintenance replacement or repair However the cost of such service or parts and subsequent failures from such service or parts will not be covered under this emission control system warrantyThe warranty starts on either the date of delivery to the first enduser or the date the unit is first leased rented or loanedWhen a measurement device of use hours is not equipped warranties apply a period of use monthsEngine ModelWarranty Period kW 1930 months or 1500 hourswhichever comes first42 months or 2500 hourswhichever comes firstEPA WARRANTY USA ONLY1205 2009 Yanmar Marine InternationalWarranty CoverageRepair or replacement of any warranted parts will be performed at an authorized Yanmar dealer or distributor This limited emission control system warranty covers engine components that are a part of the emission control system of the engine as delivered by Yanmar to the original retail purchaser Such components may include Fuel Injection SystemTurbocharger SystemAftercoolerElectronic Engine Control Units and its associated Sensor and ActuatorsFailures other than those arising from defects in material andor workmanship are not covered by this limited emissions warranty This warranty does not extend to the following malfunction caused by abuse misuse improper adjustment modification alteration tampering disconnection improper or inadequate maintenance improper storage or use of nonrecommended fuels and lubricating oils accidentcaused damage and replacement of expendable andor consumable items made in connection with scheduled maintenance responsibility for incidental or consequential damages such as loss of time inconvenience loss of use of marine vessel engine or commercial lossAs the Yanmar Marine engine owner you are responsible for the performance of the required maintenance listed in your Operation Manual Yanmar recommends that you retain all documentation including receipts covering maintenance on your marine engine but Yanmar cannot deny warranty solely for the lack of receipts or for your failure to ensure the performance of all scheduled maintenanceYour engine is designed to operate on diesel fuel only Use of any other fuel may result in your engine no longer operating in compliance with applicable emission requirements You are responsible for initiating the warranty process You must present your marine engine to an authorized Yanmar dealer or distributor as soon as a problem existsYM Series Operation Manual 2009 Yanmar Marine InternationalIf you have any questions regarding your warranty rights and would like information on the nearest authorized Yanmar dealer or distributor you should contact Yanmar Marine USA Corporation for assistanceYanmar Marine USA Corporation101 International ParkwayAdairsville GA 30103 USA Telephone 7708779894Fax 7708777567 2009 Yanmar Marine InternationalYM Series Operation ManualSYSTEM WARRANTYEmission Control System Warranty USA OnlyYour Warranty Rights and ObligationsNote Please refer to Yanmars Limited Warranty Handbook for a description of the normal CaliforniaThe California Air Resources Board CARB the Environmental Protection Agency EPAanmar Co Ltd hereafter referred to as Yanmar are pleased to explain the emission control system warranty on your compressionignition engine In California model year 2000 or later offroad compressionignition engines must be designed built and equipped to meet the states stringent antismog standards In all states 1998 and later nonroad compressionignition engines must be designed built and equipped to meet the United States EPA emYanmar warrants the emission control system on your engine for the periods of time listed below provided there has been no abuse neglect or improper maintenance of your engineYour emission control system may include parts such as the fuel injection system and the air induction systemWhere a warrantable condition exists Yanmar will repaircompressionignition engine at no charge to you including diagnosis parts and laborManufacturers Warranty PeriodThe model year 1998 or later certified and labeled nonroad compressionignition engines are warranted for the periods listed below If any emissionrelated part on your engine is found to be defective during the applicable warranty period the part will be replaced by YanmarWhen a measurement device of use hours is not equipped warranties apply a period of use monthsEngine ModelWarranty Period 2YM15 3YM2030 months or 1500 hours of use whichever 19 kW 3742 months or 2500 hours of use whichever YM Series Operation Manual 2009 Yanmar Marine InternationalWarranty CoverageThis warranty is transferable to each subsequent purchaser for the duration of the warranty period Repair or replacement of any warranted part will be performed at an authorized Yanmar Marine engine dealer or distributorWarranted parts not scheduled for replacement as required maintenance in Operation Manual shall be warranted for the warranty period Warranted parts scheduled for replacement as required maintenance in the operation manual are warranted for the period of time prior to the first scheduled replacement Any part repaired or replaced under warranty shall be warranted for the remaining warranty periodDuring the warranty period Yanmar is liable for damages to other engine components caused by the failure of any warranted part during the warranty periodAny replacement part which is functionally identical to the original equipment part in all respects may be used in the maintenance or repair of your engine and shall not reduce Yanmars warranty obligations Addon or modified parts that are not exempted may not be used The use of any nonexempted addon or modified parts shall be grounds for disallowing a warrantyWarranted PartsThis warranty covers engine components that are a part of the emission control system of the engine as delivered by Yanmar to the original retail purchaser Such components may include the followingFuel Injection SystemCold Start Enrichment SystemPositive Crankcase Ventilation SystemSince emissionsrelated parts may vary slightly between models certain models may not contain all of these parts and other models may contain the functional equivalentsExclusionsFailures other than those arising from defects in material and or workmanship are not covered by this warranty The warranty does not extend to the following malfunctions caused by abuse misuse improper adjustment modification alteration tampering disconnection improper or inadequate maintenance or use of nonrecommended fuels and lubricating oils accidentcaused damage and replacement of expendable items made in connection with scheduled maintenance Yanmar disclaims any responsibility for incidental or consequential damages such as loss of time inconvenience loss of use of equipment engine or commercial lossOwners Warranty ResponsibilitiesAs the engine owner you are responsible for the performance of the required maintenance listed in your owners manual Yanmar recommends that you retain all documentation including receipts covering maintenance on your nonroad compressionignition engine but Yanmar cannot deny warranty solely for the lack of receipts or for your failure to ensure the performance of all scheduled maintenanceYanmar may deny your warranty coverage of your nonroad compressionignition engine if a part has failed due to abuse neglect improper maintenance or unapproved modificationsYour engine is designed to operate on diesel fuel only Use of any other fuel may result in your engine no longer operating in compliance with applicable emissions requirementsEMISSION SYSTEM WARRANTY1205 2009 Yanmar Marine InternationalYou are responsible for initiating the warranty process You must present your engine to a Yanmar dealer as soon as a problem exists The warranty repairs should be completed by the dealer as expeditiously as possibleCustomer AssistanceIf you have any questions regarding your warranty rights and would like information on the nearest authorized Yanmar dealer or distributor you should contact Yanmar Marine USA Corporation for assistanceYanmar Marine USA Corporation101 International ParkwayAdairsville GA 30103 USATelephone 7708779894Fax 7708777567YM Series Operation Manual 2009 Yanmar Marine InternationalDateOperatingHoursMaintenance Dealer NameStamp or SignatureEMISSION SYSTEM WARRANTY1205 2009 Yanmar Marine InternationalOperatingHoursMaintenance Dealer NameStamp or SignatureEMISSION SYSTEM WARRANTY108YM Series Operation Manual 2009 Yanmar Marine International F50T1UVcF90T1UVCMJGKKTT60T42UVF110T1UV9hvccOS9tLv10b N8KFpj70uPhbQM88AjxAtuaMKMB7kua1Hs5Lk7MXrsCcPbB7pMsNq8fpoNnNQoNwoSlDoQNp HxuYxfoxWxFx5yX wyEbnugfpVDFqt5wwqxWlykfzVygPtmuuvzdwCpxNVx9yfrxWtLytuRuvvhowUxd93xxtCMu iwwzwixWxDyzyyziWFzDfbTxJeJcDyShNVsCdjCBxGgtXUB5llzwWfSUBFFwDf9tTAAma8KNveTQAX9ubkwwNbmXZG2clZ5lYXF10kYF1YPXRQ7j5XFEm0hLjsl4cmRoIpJqlqqcHrQssctQueuuvz8uyuzrmzMbSzQjzYqnqyaP77h7vihkxXxlHnr65opZXp pguqGgrXsH0s6gtGutu1xhuxgxWyGTy6gyzgzBPtfNWNGi5wPxcAye0tzGgh9pkcybK4zGetMosX9wxaiJL43oOtzrwAdJh3l7vx9Iue3KX26 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The information on this web site has not been checked for accuracy. It is for entertainment purposes only and should be independently verified before using for any other reason. There are five sources. 1) Documents and manuals from a variety of sources. These have not been checked for accuracy and in many cases have not even been read by anyone associated with L-36.com. I have no idea of they are useful or accurate, I leave that to the reader. 2) Articles others have written and submitted. If you have questions on these, please contact the author. 3) Articles that represent my personal opinions. These are intended to promote thought and for entertainment. These are not intended to be fact, they are my opinions. 4) Small programs that generate result presented on a web page. Like any computer program, these may and in some cases do have errors. Almost all of these also make simplifying assumptions so they are not totally accurate even if there are no errors. Please verify all results. 5) Weather information is from numerious of sources and is presented automatically. It is not checked for accuracy either by anyone at L-36.com or by the source which is typically the US Government. See the NOAA web site for their disclaimer. Finally, tide and current data on this site is from 2007 and 2008 data bases, which may contain even older data. Changes in harbors due to building or dredging change tides and currents and for that reason many of the locations presented are no longer supported by newer data bases. For example, there is very little tidal current data in newer data bases so current data is likely wrong to some extent. This data is NOT FOR NAVIGATION. See the XTide disclaimer for details. In addition, tide and current are influenced by storms, river flow, and other factors beyond the ability of any predictive program.