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YM

seriesYM Series Operation ManualOPERATION

MANUAL2YM15

3YM203YM30

P/N: 0AYMM-G00200

MARINE

ENGINES

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ii YM Series Operation Manual 2009 Yanmar Marine International

Disclaimers:

All information, illustrations and specifications in this manual are based on the latestinformation available at the time of publishing. The illustrations used in this manual areintended as representative reference views only. Moreover, because of our continuousproduct improvement policy, we may modify information, illustrations and / orspecifications to explain and / or exemplify a product, service or maintenanceimprovement. We reserve the right to make any change at any time without notice.Yanmar and are registered trademarks of Yanmar Co., Ltd. in Japan, theUnited States and / or other countries.

All Rights Reserved:

No part of this publication may be reproduced or used in any form by any means - graphic,electronic, or mechanical, including photocopying, recording, taping, or informationstorage and retrieval systems - without the written permission of Yanmar MarineInternational.

2009 Yanmar Marine International

0109

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YM Series Operation Manual iii 2008 Yanmar Marine International

TABLE OF

CONTENTS

Page

Introduction..................................................................... 1

Record of Ownership ................................................. 2

Safety ............................................................................... 3

Safety Precautions..................................................... 4General Information............................................. 4Before You Operate............................................. 4During Operation and Maintenance..................... 5

Location of Safety Decals .......................................... 8

Product Overview ........................................................... 9Yanmar YM Features and Applications...................... 9

New Engine Break-In......................................... 10

Component Identification ......................................... 11Right Side (from Flywheel) - 2YM15.................. 11Left Side (from Flywheel) - 2YM15 .................... 11Right Side (from Flywheel) - 3YM20.................. 12Left Side (from Flywheel) - 3YM20 .................... 12Right Side (from Flywheel) - 3YM30.................. 13

Left Side (from Flywheel) - 3YM30 .................... 13Location of Nameplates ........................................... 14

Function of Major Components................................ 15

Control Equipment ................................................... 16Instrument Panel (Optional)............................... 16Single-Lever Remote Control Handle................ 20

Before You Operate ...................................................... 21

Safety Precautions................................................... 21

Introduction .............................................................. 21Diesel Fuel ............................................................... 22

Diesel Fuel Specifications ................................. 22Filling the Fuel Tank .......................................... 25Bleeding the Fuel System.................................. 26

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iv YM Series Operation Manual 2008 Yanmar Marine International

Engine Oil ................................................................. 27Engine Oil Specifications .................................. 27Engine Oil Viscosity ........................................... 28Checking the Engine Oil..................................... 28Adding Engine Oil .............................................. 29

Marine Gear or Sail Drive Oil.................................... 29

Marine Gear Oil Specifications........................... 29Sail Drive Oil Specifications - SD20................... 29Checking Marine Gear Oil.................................. 30Adding Marine Gear Oil...................................... 30Checking and Adding Sail Drive Oil ................... 30

Engine Coolant ......................................................... 31Engine Coolant Specifications ........................... 31Checking and Adding Coolant............................ 31

Cranking the Engine................................................. 34

Engine Operation .......................................................... 35

Safety Precautions ................................................... 35

Introduction............................................................... 36

Starting the Engine................................................... 37Restarting After Starting Failure......................... 37Starting at Low Temperatures............................ 38After the Engine has Started .............................. 38

Remote Control Handle Operation ........................... 39Acceleration and Deceleration ........................... 39Shifting the Engine............................................. 40

Shutting Down the Engine ........................................ 40Emergency Shutdown........................................ 41

Checking the Engine After Operation ....................... 42

Periodic Maintenance ................................................... 43

Safety Precautions ................................................... 43

Introduction............................................................... 45

Precautions............................................................... 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 orDistributor for Help ............................................. 46Tightening Fasteners ......................................... 47

EPA Maintenance Requirements ............................. 48EPA Requirements for USA and OtherApplicable Countries .......................................... 48Conditions to Ensure Compliance with EPAEmission Standards ........................................... 48

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Inspection and Maintenance.............................. 48Installing Sample Port........................................ 48

Periodic Maintenance Schedule............................... 50Inspection and Maintenance of EPAEmission-Related Parts ..................................... 54

Periodic Maintenance Procedures ........................... 55

Daily 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 .......................................................... 69


Troubleshooting After Starting ................................. 69Troubleshooting Information.............................. 70

Troubleshooting Chart.............................................. 71

Long-Term Storage ...................................................... 75


Introduction .............................................................. 75

Prepare Engine for Long-Term Storage................... 76

Draining the Cooling System.................................... 76

Specifications ............................................................... 79

Principal Engine Specifications................................ 792YM15 Engine Specifications............................ 793YM20 Engine Specifications............................ 813YM30 Engine Specifications............................ 83Marine Gear and Sail Drive Specifications ........ 85

System Diagrams ......................................................... 87

Piping Diagrams....................................................... 87

Wiring Diagrams....................................................... 93EPA Warranty USA Only .............................................. 99

Yanmar Co., Ltd. Limited Emission ControlSystem Warranty - USA Only................................... 99

Your Warranty Rights and Obligations: ........... 100Warranty Period:.............................................. 100Warranty Coverage: ........................................ 101Exclusions: ...................................................... 101Owners Responsibility: ................................... 101Customer Assistance:...................................... 102

Emission System Warranty ....................................... 103

Non-Road Emission System Warranty................... 103Yanmar Co., Ltd. Limited Emission ControlSystem Warranty - USA Only .......................... 103

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Maintenance Log.............................................. 106

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YM Series Operation Manual 1 2009 Yanmar Marine International

YM Series Operation Manual

INTRODUCTION

Welcome to the world of Yanmar Marine!

Yanmar Marine offers engines, drivesystems and accessories for all types ofboats, from runabouts to sailboats, andfrom cruisers to mega yachts. In marineleisure boating, the worldwide reputation ofYanmar Marine is second to none. Wedesign our engines to respect nature. Thismeans quieter engines, with minimalvibrations, cleaner than ever. All of ourengines meet applicable regulations,

including emissions, at the time ofmanufacture.

To help you enjoy your Yanmar YM seriesengine for many years to come, pleasefollow these recommendations:

Read and understand this Operation

Manualbefore you operate the engine toensure that you follow safe operatingpractices and maintenance procedures.

Keep this Operation Manualin aconvenient place for easy access.

If this Operation Manualis lost ordamaged, order a new one from yourauthorized Yanmar Marine dealer ordistributor.

Make sure this manual is transferred tosubsequent owners. This manual shouldbe considered a permanent part of theengine and remain with it.

Constant efforts are made to improve thequality and performance of Yanmarproducts, so some details included inthis Operation Manualmay differ slightlyfrom your engine. If you have any

questions about these differences,please contact your authorized YanmarMarine dealer or distributor.

The specifications and components(instrument panel, fuel tank, etc.)described in this manual may differ fromones installed on your vessel. Pleaserefer to the manual provided by themanufacturer of these components.

Refer to the Yanmar Limited WarrantyHandbook for a complete warrantydescription.

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INTRODUCTION

2 YM Series Operation Manual 2009 Yanmar Marine International

RECORD OF OWNERSHIP

Take a few moments to record the information you need when you contact Yanmar forservice, parts or literature.

Engine Model: __________________________________________________________

Engine Serial No.: _______________________________________________________

Date Purchased: ________________________________________________________

Dealer:_________________________________________________________________

Dealer Phone:___________________________________________________________

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SAFETY

Yanmar considers safety of great

importance and recommends that anyonewho comes in close contact with itsproducts, such as those who install,operate, maintain or service Yanmarproducts, exercise care, common senseand comply with the safety information inthis manual and on the engines safetydecals. Keep the decals from becomingdirty or torn and replace them if they arelost or damaged. Also, if you need to

replace a part that has a decal attached toit, make sure you order the new part anddecal at the same time.

Indicates a hazardous situation which,if not avoided, willresult in death orserious injury.

Indicates a hazardous situation which,if not avoided, couldresult in death orserious injury.

Indicates a hazardous situation which,if not avoided, couldresult in minor ormoderate injury.

Indicates a situation which can cause

damage to the engine, personal propertyand / or the environment or cause theequipment to operate improperly.

A

This safety alert symbol appearswith most safety statements. Itmeans attention, become alert,your safety is involved! Pleaseread and abide by the messagethat follows the safety alert

symbol.

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SAFETY


SAFETY PRECAUTIONS

General Information

There is no substitute for common senseand careful practices. Improper practices

or carelessness can cause burns, cuts,mutilation, asphyxiation, other bodily injuryor death. This information contains generalsafety precautions and guidelines thatmust be followed to reduce risk to personalsafety. Special safety precautions arelisted in specific procedures. Read andunderstand all of the safety precautionsbefore operation or performing repairs ormaintenance.

Before You Operate

The safety messages that follow haveDANGER level hazards.

NEVER permit anyone toinstall or operate theengine without propertraining.

Read and understand this OperationManual before you operate or servicethe engine to ensure that you follow safeoperating practices and maintenanceprocedures.

Safety signs and decals are additionalreminders for safe operating andmaintenance techniques.

See your authorized Yanmar Marinedealer or distributor for additionaltraining.

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SAFETY

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During Operation andMaintenance

The safety messages that follow have

WARNING level hazards.Explosion Hazard

While the engine is running orthe battery is charging,hydrogen gas is beingproduced and can be easilyignited. Keep the area around

the battery well-ventilated and keepsparks, open flames and any other form of

ignition out of the area.

Fire and Explosion Hazard

Diesel fuel is flammable and explosiveunder certain conditions.

NEVER use a shop rag to catch the fuel.

Wipe up all spills immediately.

NEVER refuel with the engine running.

Store any containers containing fuel in awell-ventilated area, away from anycombustibles or sources of ignition.

Fire Hazard

Undersized wiring systemscan cause an electrical fire.

Ensure that appropriate fire detection andextinguishing equipment are installed andchecked periodically for proper operation.

Coolant may be flammable under certainconditions. NEVER allow coolant to comeinto contact with hot surfaces or insulation

material.

Sever Hazard

NEVER wear jewelry,unbuttoned cuffs, ties orloose-fitting clothing andALWAYS tie back long hairwhen working near moving /

rotating parts such as the flywheel or PTOshaft. Keep hands, feet and tools awayfrom all moving parts.

The propeller may rotate during towing orifthe engine is running at idle speed.NEVERservice the engine while beingtowed orwhen the engine is running.

If the vessel has more than oneengine,NEVER service an engine if eitherof theengines is running. Inmulti-engineconfigurations the propeller foran enginethat is shut down may rotate ifany of theother engines are running.

NEVER operate the engine without

theguards in place.

Alcohol and Drug Hazard

NEVER operate the enginewhile under the influence ofalcohol or drugs or if you arefeeling ill.

Exposure Hazard

ALWAYS wear personalprotective equipmentincluding appropriateclothing, gloves, work shoes,eye and hearing protection

as required by the task at hand.

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SAFETY


Burn Hazard

Some of the engine surfacesbecome very hot during

operation and shortly aftershutdown. Keep hands andother body parts away from

hot engine surfaces.

Exhaust Hazard

NEVER block windows, ventsor other means of ventilation ifthe engine is operating in an

enclosed area. All internalcombustion engines createcarbon monoxide gas during operation andspecial precautions are required to avoidcarbon monoxide poisoning.

Sudden Movement Hazard

NEVER operate the engine while wearinga headset to listen to music or radiobecause it will be difficult to hear thewarning signals.

The safety messages that follow haveCAUTION level hazards.

Poor Lighting Hazard

Ensure that the work area is adequatelyilluminated. ALWAYS install wire cages onportable safety lamps.

Tool Hazard

ALWAYS use tools appropriate for the taskat hand and use the correct size tool forloosening or tightening engine parts.

Flying Object HazardALWAYS wear eye protection whenservicing the engine or when usingcompressed air or high-pressure water.Dust, flying debris, compressed air,pressurized water or steam may injureyour eyes.

Coolant Hazard

Wear eye protection andrubber gloves when youhandle Long Life enginecoolant. If contact with theeyes or skin should occur,

flush eyes and wash immediately withclean water.

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SAFETY


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The safety messages that follow haveNOTICE level hazards.

It is important to perform daily checks as

listed in the Operation Manual.Periodic maintenance preventsunexpected downtime, reduces thenumber of accidents due to poor engineperformance and helps extend the life ofthe engine.

See your authorized Yanmar Marinedealer or distributor if you need to operatethe engine at high altitudes. At highaltitudes the engine will lose power, runrough and produce exhaust gases thatexceed the design specifications.

ALWAYS be environmentallyresponsible.

Follow the guidelines of theEPA or other governmental

agencies for the proper disposal of

hazardous materials such as engine oil,diesel fuel and engine coolant. Consult thelocal authorities or reclamation facility.

NEVER dispose of hazardous materials bydumping them into a sewer, on the groundor into ground water or waterways.

If a Yanmar Marine Engine is installed at

an angle that exceeds the specificationsstated in the Yanmar Marine InstallationManuals, engine oil may enter thecombustion chamber causing excessiveengine speed, white exhaust smoke andserious engine damage. This applies toengines that run continuously or those thatrun for short periods of time.

If you have an installation with two or threeengines and only one engine is operating,the seacock of the non-running engine(s)should be closed. This will prevent waterfrom being forced past the seawater pumpand entering the engine. The result of

water entering the engine could causeengine seizure or other serious problems.

If you have an installation with two or threeengines, and only one engine is operating,please note that if the propeller shaftthru-hull (stuffing box) is lubricated byengine water pressure and the engines areinterconnected, care must be taken thatwater from the running engine does not

enter the exhaust of the non-runningengine(s). This water could cause seizureof the non-running engine(s). See yourauthorized Yanmar Marine dealer ordistributor for a complete explanation ofthis condition.

If you have an installation with two or threeengines, and only one engine is operating,it is important to limit the amount of throttle

applied to the running engine. If youobserve black smoke or movement of thethrottle does not increase engine rpm, youare overloading the engine that is running.Immediately throttle back to approximatelytwo-thirds throttle or to a setting where theengine performs normally. Failure to do somay cause the running engine to overheator cause excess carbon buildup which may

shorten the engine's life.

NEVER turn off the battery switch (ifequipped) or short the battery cablesduring operation. Damage to the electricalsystem will result.

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SAFETY


LOCATION OF SAFETY DECALS

Figure 1 shows the location of safety decals on Yanmar YM series marine engines.

Figure 1YM Engines

Figure 1

1 Part Number: 128377072602 Part Number: 12837707350

3 Part Number: 19663012980

196630-12980

(2)

(3)

WARNING

026441-00X

(1)

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PRODUCT OVERVIEW

YANMAR YM FEATURES

AND APPLICATIONS

The YM series are four-stroke directinjection diesel engines equipped withliquid coolant systems.

The 2YM15 is a 2-cylinder engine and isnaturally aspirated.



These engines are equipped with a marinegear or sail drive unit.

These engines are designed for pleasurecraft use and complied with EPA regulationTier3 marine from 2009 year.

It is recommended that new vessels bepropped so the engines can operate at 100to 200 rpm above the Maximum RatedPower Output rpm (3700 to 3800) to allowfor some added weight and hull resistance.The engine must be able to reach theMaximum Rated Power rpm (3600) underfull load at all times.

Failure to do so can lead to reduced vesselperformance, increased smoke levels andcan cause permanent damage to yourengine, which is not covered by warranty.

The engine must be installed correctly with

coolant lines, exhaust gas lines andelectrical wiring. Any auxiliary equipmentattached to the engine should be easy touse and accessible for service. To handlethe drive equipment, propulsion systems(including the propeller) and other onboardequipment, always observe theinstructions and cautions given in theoperation manuals supplied by theshipyard and equipment manufacturers.

The YM series engines are designed to beoperated at maximum throttle (3600 rpm)for less than 5% of total engine time (30minutes out of every 10 hours) andcruising speed (3400 rpm or less) for lessthan 90% of total engine time (9 hours outof every 10 hours).

The laws of some countries may requirehull and engine inspections, depending on

the use, size and cruising area of the boat.The installation, fitting and surveying ofthis engine all require specializedknowledge and engineering skills. SeeYanmars local subsidiary in your region oryour authorized Yanmar Marine dealer ordistributor.

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PRODUCT OVERVIEW


New Engine Break-In

As with all reciprocating engines, the waythe engine is operated during its first 50hours of operation plays a significant rolein determining how long it will last and how

well the engine will perform over itslifetime.

A new Yanmar diesel engine must beoperated at suitable speeds and powersettings during the break-in period to allowthe sliding parts, such as piston rings, tobreak in properly and to stabilize enginecombustion.

During the break-in period, the engine

coolant temperature gauge should bemonitored. The temperature should bebetween 71 and 87C (160 and 190F).

During the first 10 hours of operation, theengine should be operated at maximumrpm minus 400 to 500 rpm (approximately60 to 70% of load) most of the time. Thiswill ensure the sliding parts break inproperly.

NOTICE: During this period, avoidoperating at maximum engine speed andload to avoid damaging or scoring slidingparts.

Do not operate the engine at low idle or atlow speed and light load for more than30 minutes at a time. Since unburned fueland engine oil will adhere to the pistonrings when operating at low speeds for

long periods, this will interfere with propermovement of the rings and the diesel fuelconsumption may increase. Low idlespeed does not allow break-in of slidingparts.

If operating the engine at low speed andlight load, you must race the engine toclean the carbon from the cylinders andthe fuel injection valve.

Perform this procedure in open waters:

With the clutch in NEUTRAL, acceleratefrom the low-speed position to thehigh-speed position briefly.

Repeat this process five times.

Once past the initial 10 hours until 50hours, the engine should be used over itsfull operating range, with special emphasison running at relatively high powersettings. This is not the time for anextended cruise at idle or low speed. Theboat should be operated at maximumspeed minus 400 rpm most of the time(approximately 70% load), with a 10

minute run at maximum minus 200 rpm(approximately 80% load) every30 minutes and a 4 to 5 minute period ofoperation at WOT (wide open throttle)once every 30 minutes. During this period,be sure not to operate the engine at lowspeed and light load for more than30 minutes. If operating engine at lowspeed and light load is necessary, race theengine after low idle operation.

To complete engine break-in, performAfter Initial 50 Hoursmaintenanceprocedures on page 56.

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PRODUCT OVERVIEW


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COMPONENT

IDENTIFICATION

Right Side (from Flywheel) -2YM15

Figure 1 and Figure 2 illustrate a typicalversion of a 2YM15 engine. Your enginemay have different equipment from thatillustrated.

Figure1

Figure 1

1 Intake Silencer (air cleaner)2 Intake Manifold3 Fuel Filter4 Fuel Injection Pump5 Engine Oil Dipstick6 Engine Oil Filler Cap7 Fuel Feed Pump8 Engine Oil Filter9 Marine Gear

Left Side (from Flywheel) -2YM15

Figure2

Figure 2

1 Seawater Pump2 Coolant Filler Cap3 Engine Nameplate (on rocker

arm cover)4 Coolant Tank / Heat Exchanger5 Exhaust Manifold6 Starter Motor7 Shift Lever8 Alternator

(1)(2)

(3)

(4)

(5)

(6)

(7)

(8)(9)

0004781

(1)

(2) (4)

(5)

(7)

(6)(8)

(3)

0004782

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PRODUCT OVERVIEW



Figure 3 and Figure 4 illustrate a typicalversion of a 3YM20 engine. Your enginemay have different equipment from that

illustrated.Figure3

Figure 3

1 Intake Silencer (air cleaner)2 Intake Manifold

3 Fuel Filter4 Fuel Injection Pump5 Engine Oil Dipstick6 Engine Oil Filler Cap7 Fuel Feed Pump8 Engine Oil Filter9 Marine Gear


Figure4

Figure 4


arm cover)4 Coolant Tank / Heat Exchanger5 Exhaust Manifold6 Starter Motor7 Shift Lever8 Alternator

(1) (2)

(3)

(4)

(5)(6)

(7)

(8)

(9) 0004783

(1)

(2) (3)

(4)

(5)

(6)

(7)(8)

0004784

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Figure 5 and Figure 6 illustrate a typicalversion of a 3YM30 engine. Your enginemay have different equipment from that

illustrated.Figure5

Figure 5

1 Intake Silencer (air cleaner)2 Intake Manifold3 Fuel Filter4 Fuel Injection Pump5 Engine Oil Dipstick6 Engine Oil Filler Cap7 Fuel Feed Pump8 Engine Oil Filter9 Marine Gear


Figure6

Figure 6


arm cover)4 Coolant Tank / Heat Exchanger5 Exhaust Manifold

6 Starter Motor7 Shift Lever8 Alternator

(1) (2)

(4)

(5)

(6)

(7)

(8)

(9)

(3)

0004785

(1)

(2) (3)

(4)

(5)

(6)

(7)(8)0004786

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PRODUCT OVERVIEW


LOCATION OF

NAMEPLATES

The nameplate of the Yanmar YM seriesengine is shown in Figure 7. Check theengines model, output, rpm and serial

number on the nameplate. Replace it if it isdamaged or lost.

The engine nameplate is attached to theengine rocker arm cover.

Figure7

Figure 7

The marine gear nameplate (Figure 8) isattached to the marine gear. Check themarine gears model, gear ratio, oil used,oil quantity and serial number.

Figure8

Figure 8

/

/

Gear Model

ENG.No.

MFG. DATE

/

Model

min-1

min-1

min-1

Continuous power kW

Speed of prop. shaftFuel stop power kW

129670-07200

MODE L KMGEAR RATIOOIL SAE 20/30HDOIL QTY. LTR.NO.

0004529

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PRODUCT OVERVIEW


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FUNCTION OF MAJOR COMPONENTS

Name of Component Function

Fuel Filter Removes 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

page 60.

Fuel 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

needed.

Fuel Feed Lever Moving 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 fuel.

Engine Oil Filler Port Filler port for the engine oil.

Engine Oil Filter Filters fine metal fragments and carbon from the engine oil. Filtered engine oil is

distributed to the engines moving parts. The filter is a spin-on type and the

element should be replaced periodically. See Replacing the Engine Oil Filter

Element on page 64.Marine Gear Filler Port Filler port for marine gear oil; located on top of the marine gear case.

Cooling 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

engine / marine gear oil.

Closed Cooling Circulation

Pump

The centrifugal water pump circulates coolant inside the engine. The circulating

pump is driven by a V-belt.

Seawater Pump Pumps seawater from outside vessel to the engine. The seawater pump has a

replaceable rubber impeller.

Coolant Filler Cap 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 system.

Coolant Recovery Tank The 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

closed cooling system coolant level can easily be checked and refilled in this

tank.

Engine Oil Cooler A heat exchanger that cools high temperature engine oil using coolant.

Intake Silencer (Air Cleaner) The intake silencer guards against dirt in the air and reduces the noise of airintake.

Nameplates Nameplates are provided on the engine and the marine gear and have the model,

serial number and other data. See Location of Nameplates on page 14.

Starter Starter motor for the engine; powered by the battery.

Alternator Driven by a belt and generates electricity and charges the battery.

Engine Oil Dipstick Gauge stick for checking the engine oil level.

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PRODUCT OVERVIEW


CONTROL EQUIPMENT

The control equipment at the helm makes remote control operation possible. It consists ofthe instrument panel, which is connected to the engine by a wire harness, and the remotecontrol handle, which is connected by control cables to the engine control lever andmarine gear.

Instrument Panel (Optional)

Equipment and Functions

The instrument panel is located at the helm. The following instruments enable you to startor stop the engine and to monitor its condition during operation. A typical instrument panelis shown in Figure 9.

Figure 9B-Type

Figure 9

1 Tachometer2 Hourmeter3 Moisture Cap for Key Switch

4 Key Switch5 STOP Button

6 Battery Low Charge Indicator7 Water in Sail Drive Seal

Indicator

8 Engine Oil Low PressureIndicator9 Coolant High Temperature

Indicator

Gauges

B-Type panels use analog electric gauges with needle indicators.

0004486

(1)

(2)

(3)

(4)

(5)

(6)

(7)

(8)

(9)

Instrument Function

Tachometer Shows the engine rotation speed.

Hourmeter Shows the number of operating hours; can be used as

a guide for periodic maintenance checks. The

hourmeter is located at the bottom of the tachometer.

Instrument Panel Lights When turning the key switch to ON, the gauges will

illuminate for easier viewing.

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PRODUCT OVERVIEW


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Key SwitchFigure10

Figure 10

1 GLOW2 OFF3 ON4 START

The GLOW position (Figure 10, (1)) is thestart aid position. Electric current to theglow plug is turned on. When the key isreleased, the switch will automaticallymove to the ON position.

The START position (Figure 10, (4))allows current to the starting motor. Whenstarting the engine, move the key to theSTART position and release. The key willautomatically move to the ON position.

When the key is in the OFF position(Figure 10, (2)), the electric current is off.The key can be inserted or removed in thisposition.

The ON position (Figure 10, (3)) allowselectrical current to the controls andequipment and allows the engine to keeprunning. To stop the engine, keep the keyswitch in the ON position and push theSTOP button. After stopping the engine,turn the key to the OFF position.

0003622

(1)

(2)

(3)

(4)

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PRODUCT OVERVIEW


Figure 11B (Keyless) - Type (Optional)

Figure 11

1 Coolant High TemperatureIndicator

2 Engine Oil Low PressureIndicator

3 Water in Sail Drive SealIndicator

4 Battery Low Charge Indicator

5 OFF / ON / START Switch6 STOP / GLOW Switch7 Hourmeter8 Tachometer

0

10

20 30

40

50

(8) (7) (5)(6)

(1) (2) (3) (4)

026102-00X

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PRODUCT OVERVIEW


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Indicators and Alarms (Optional)

When a sensor detects a problem duringoperation, the indicator on the instrumentpanel will light and an alarm will sound.Indicators are located on the instrumentpanel. The alarm is located on the back ofthe panel. Under normal operatingconditions, the indicators are off.

Figure12

Figure 12

Battery Low Charge Indicator(Figure 12) - When the alternator output istoo low, the indicator will light. When

charging begins, the indicator will turn off.No alarm will sound for low battery charge.

Figure13

Figure 13

Coolant High Temperature Indicator andAlarm (Figure 13) - When coolanttemperature reaches the maximum

allowable temperature (95C [203F] orhigher), the indicator will light and thealarm will sound. Continuing operation attemperatures exceeding the maximumlimit will result in damage and seizure.Check the load and troubleshoot thecooling system.

Figure14

Figure 14

Engine Oil Low Pressure Indicator andAlarm (Figure 14) - When the engine oil

pressure falls below normal, the oilpressure sensor will send a signal to theindicator, causing it to light and the alarmto sound. Stop operation immediately toavoid damage to the engine. Check the oillevel and troubleshoot the lubricationsystem.

Figure15

Figure 15

Water in Sail Drive Seal Indicator andAlarm (Figure 15) - When seawater isdetected between the seals of the saildrive, the indicator will light and the alarmwill sound.

STOP ButtonFigure16

Figure 16

Push the STOP button switch to stop theengine. The key switch must be in the ONposition for the STOP button to operate.After the engine has come to a completestop, you can turn the key to the OFFposition.

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PRODUCT OVERVIEW


Alarms

Check that indicators and alarms are working normally when the key is turned to ON.

Single-Lever Remote ControlHandle

Figure17

Figure 17

1 Low Speed - FWD or REV2 Low Speed - FWD or REV3 NEUTRAL - Power to the

propeller shaft is cut off andthe engine idles

4 Maximum Engine Speed - FWDor REV

5 Maximum Engine Speed - FWD

or REVA single-lever handle type (Figure 17)should be used to operate the marine gearclutch (NEUTRAL, FORWARD, andREVERSE) and to control the enginespeed.

The lever controls the direction of the boat(ahead or astern) and also acts as anaccelerator by increasing engine speed as

the lever is pushed further in theFORWARD or REVERSE directions.

When the lever is pulled out(Figure 18, (1)), the engine speed can becontrolled without engaging the clutch. Theclutch remains in the NEUTRAL, no loadposition. Turn the knob (Figure 18, (2))counterclockwise to move the lever orclockwise to lock the lever.

Figure18

Figure 18

Note: Yanmar recommends the use ofa single-lever type for theremote control system. If only atwo-lever type is available in themarket, reduce engine rpm to1000 or less before engagingand disengaging the marine

gear clutch.

Key Switch OFF ON START ON

Engine Before start Running

Alarm Sound No sound

Indicators Battery Low Charge Indicator ON OFF

Coolant High Temperature Indicator OFF OFF

Engine Oil Low Pressure Indicator ON OFF

Water In Sail Drive Indicator OFF OFF

(1)

(4)

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(5)

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BEFORE YOU OPERATE

SAFETY PRECAUTIONS

Before performing any operations withinthis section, review the Safetysection onpage 3.

INTRODUCTION

This section of the Operation Manualdescribes the diesel fuel, engine oil andengine coolant specifications and how toreplenish them.

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BEFORE YOU OPERATE


DIESEL FUEL

Diesel Fuel Specifications

WARNING! Fire and Explosion Hazard.Diesel fuel is flammable and explosive

under certain conditions.NOTICE: Only use diesel fuelsrecommended by Yanmar for the bestengine performance, to prevent enginedamage and to comply with EPA warrantyrequirements. Only use clean diesel fuel.

Diesel fuel should comply with thefollowing specifications. The table listsseveral worldwide specifications for diesel

fuels.

Biodiesel Fuels

Yanmar approves the use of biodieselfuels that do not exceed a blend of 5%non-mineral oil based fuel with 95%standard diesel fuel. Such biodiesel fuelsare known in the marketplace as B5biodiesel fuels. B5 biodiesel fuel canreduce particulate matter and the emissionof greenhouse gases compared tostandard diesel fuel.

NOTICE: If the B5 biodiesel fuel used doesnot meet the approved specifications, it willcause abnormal wear of injectors, reducethe life of the engine and it may affect thewarranty coverage of your engine.

B5 diesel fuels must meet certainspecifications.

The biodiesel fuels must meet theminimum specifications for the country inwhich they are used:

In Europe, biodiesel fuels must complywith the European Standard EN14214.

In the United States, biodiesel fuels mustcomply with the American StandardASTM D-6751.

Biodiesel should be purchased only fromrecognized and authorized diesel fuelsuppliers.

DIESEL

FUELSPECIFICATIONLOCATION

No. 2-D, No. 1-D, ASTM

D975

USA

EN590:96 European Union

ISO 8217 DMX International

BS 2869-A1 or A2 United Kingdom

JIS K2204 Grade No. 2 Japan

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Precautions and concerns regardingthe use of biofuels:

Biodiesel fuels have a higher content ofmethyl-esters, which may deterioratecertain metal, rubber and plasticcomponents of the fuel system. The

customer and / or boat builder areresponsible to verify the usage ofbiodiesel compatible components on thevessel fuel supply and return systems.

Free water in biodiesel may result inplugging of fuel filters and increasedbacterial growth.

High viscosity at low temperatures mayresult in fuel delivery problems, injectionpump seizures, and poor injection nozzlespray atomization.

Biodiesel may have adverse effects onsome elastomers (seal materials) andmay result in fuel leakage and dilution ofthe engine lubricating oil.

Even biodiesel fuels that comply with asuitable standard as delivered will

require additional care and attention tomaintain the quality of the fuel in theequipment or other fuel tanks. It isimportant to maintain a supply of clean,fresh fuel. Regular flushing of the fuelsystem, and / or fuel storage containers,may be necessary.

The use of biodiesel fuels that do notcomply with the standards as agreed toby the diesel engine manufacturers andthe diesel fuel injection equipmentmanufacturers, or biodiesel fuels thathave degraded as per the precautionsand concerns above, may affect thewarranty coverage of your engine.

Additional Technical FuelRequirements

The fuel cetane number should be 45 orhigher.

The sulfur content must not exceed 0.5%

by volume. Less than 0.05% is preferred.

NEVER mix kerosene, used engine oil orresidual fuels with the diesel fuel.

Water and sediment in the fuel shouldnot exceed 0.05% by volume.

Keep the fuel tank and fuel-handlingequipment clean at all times.

Ash content should not exceed 0.01% byvolume.

Carbon residue content should notexceed 0.35% by volume. Less than0.1% is preferred.

Total aromatics content should notexceed 35% by volume. Less than 30%is preferred.

PAH (polycyclic aromatic hydrocarbons)

content should be below 10% by volume.

NEVER use Biocide.

NEVER use kerosene or residual fuels.

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BEFORE YOU OPERATE


Handling of Diesel Fuel

WARNING! Fire and Explosion Hazard.Only fill the fuel tank with diesel fuel.Filling the fuel tank with gasoline mayresult in a fire and will damage theengine. NEVER refuel with the enginerunning. Wipe up all spills immediately.Keep sparks, open flames or any otherform of ignition (match, cigarette, staticelectric source) well away whenrefueling.

WARNING! Fire and Explosion Hazard.ALWAYS put the diesel fuel containeron the ground when transferring thediesel fuel from the pump to the

container. Hold the hose nozzle firmlyagainst the side of the container whilefilling it. This prevents static electricitybuildup which could cause sparks andignite fuel vapors.

Fuel Tank (Optional)

NOTICE: Water and / or dust in the fuelmay cause engine failure. When fuel isstored, check that the inside of the storagecontainer is clean and dry, and that the fuelis stored away from dirt or rain.

Figure1

Figure 1

1 Sediment Bowl2 Drain Cock3 Fuel Line to Engine

Install a drain cock (Figure 1, (2)) at the

bottom of the fuel tank to remove waterand contaminants from the sediment bowl(Figure 1, (1)).

The fuel outlet should be positioned 20 to30 mm (0.75 to 1.125 in.) above thebottom of the tank (Figure 2, (4)) so thatonly clean fuel is distributed to the engine.

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Fuel SystemFigure2

Figure 2

1 Fuel Filter2 Fuel Feed Pump (priming lever)3 Fuel / Water Separator

(optional)4 Approximately 20 to 30 mm

(0.75 to 1.125 in.)5 Within 500 mm (20 in.)6 Drain Cock7 Fuel Cock8 Fuel Return Line9 To Fuel Injection Pump

10 Fuel TankInstall the fuel line from the fuel tank to thefuel injection pump as shown in Figure 2.The recommended fuel / water separator(Figure 2, (3)) (optional) is installed at thecenter section of that line.

Filling the Fuel Tank

WARNING! Fire and Explosion Hazard.NEVER refuel with the engine running.

Before filling fuel tank for the firsttime:

Rinse the fuel tank with kerosene or dieselfuel. Dispose of waste properly.

To fill the fuel tank:

WARNING! Fire and Explosion Hazard.Operate bilge ventilation (blowers) for aminimum of 5 minutes to purge fumesfrom engine compartment after

refueling. Never operate bilge blowerwhile refueling. Doing so can pumpexplosive fumes into the enginecompartment and result in anexplosion.

1. Clean the area around the fuel cap.

2. Remove the fuel cap from the fuel tank.

3. Fill the tank with clean fuel free of oiland dirt. WARNING! Fire and

Explosion Hazard. Hold the hosenozzle firmly against the filler portwhile filling. This prevents staticelectricity buildup which couldcause sparks and ignite fuel vapors.

4. Stop fueling when the gauge shows thefuel tank is full. WARNING! Fire andExplosion Hazard. NEVER overfillthe fuel tank.

(1)

(2)(3)

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(7)

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BEFORE YOU OPERATE


5. Replace the fuel cap and hand-tighten.Over-tightening the fuel cap willdamage it.

Figure3

Figure 3

If filling the tank from a storage container(Figure 3), keep the fuel containerstationary for several hours to allow anydirt or water to settle to the bottom of thecontainer. Use a pump to extract the clear,filtered fuel from the top of the container.

Bleeding the Fuel System

The fuel system has an automatic airbleeding device that purges air from thefuel system. No manual air bleeding isrequired for normal operation. Manual

bleeding must be done if any fuel systemmaintenance has been performed(replacement of fuel filter, etc.) or if theengine does not start after severalattempts.

Bleeding the Fuel SystemFigure4

Figure 4

1 Air Bleed Screw2 Bracket3 O-Ring4 Fuel Filter Element5 Fuel Filter Housing6 Retaining Ring

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1. Check the fuel level in the fuel tank.Refill if necessary.

2. Open the fuel cock of the fuel tank.WARNING! Exposure Hazard.Always wear safety glasses whenbleeding the fuel system.

3. Loosen the air bleed screw(Figure 4, (1)) 2 to 3 turns.

4. Push up and down on the manualpriming lever located on the side of thefuel feed pump to release air out of theair bleed screw. Always use anapproved container to catch the dieselfuel.

5. Continue pumping until a solid stream

of fuel with no air bubbles begins toflow.

6. Tighten the air bleed screw.

Note: After engine start-up, theautomatic air-bleeding deviceworks to purge the air in the fuelsystem.

ENGINE OIL

Engine Oil Specifications

NOTICE: Only use the engine oil specified.Other engine oils may affect warranty

coverage, cause internal enginecomponents to seize and / or shortenengine life. NEVER mix different types ofengine oil. This may adversely affect thelubricating properties of the engine oil.

Use an engine oil that meets or exceedsthe following guidelines and classifications:

API Service Categories: CD or higher

TBN value: 9 or more

The oil must be changed when the TotalBase Number (TBN) has been reducedto 2.0.

TBN (mgKOH/g) test method: JISK-25015.22(HCI), ASTM D4739(HCI)

Recommended SAE Viscosity: 10W30,15W40. Engine oil 10W30 and 15W40can be used throughout the year.

NEVER use API Service Category CG-4or CH-4 oils.

NOTICE:

1. Be sure the engine oil, engine oilstorage containers and engine oil fillingequipment are free of sediment orwater.

2. Change the engine oil after the first 50hours of operation and then at every150 hours thereafter. See Changing theEngine Oil on page 57.

3. Select the oil viscosity based on theambient temperature where the engineis being operated. See the SAE ServiceGrade Viscosity Chart(Figure 5).

4. Yanmar does not recommend the useof engine oil additives.

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BEFORE YOU OPERATE


Handling Engine Oil

1. When handling and storing engine oil,be careful not to allow dust and water tocontaminate the oil. Clean around thefiller port before filling.

2. Do not mix lube oils of different types orbrands. Mixing may cause the chemicalcharacteristics of the oil to change andlubricating performance to decrease,reducing the engines life.

3. Engine oil should be replaced at thespecified intervals, regardless of theengines operation history. SeePeriodic Maintenance Schedule onpage 50.

Engine Oil ViscosityFigure5

Figure 5

Select the appropriate engine oil viscositybased on the ambient temperature shownin the SAE Service Grade Viscosity Chart(Figure 5).

NOTICE: If you intend to operate yourequipment at temperatures outside thelimits shown, you must consult yourauthorized Yanmar Marine dealer ordistributor for special lubricants or startingaids.

Checking the Engine OilFigure6

Figure 6

1 Filler Port2 Rocker Arm Cover3 Dipstick4 Upper Limit

5 Lower Limit

Note: 3YM30 shown. Other modelsare similar.

1. Make sure the engine is off. It isrecommended that the engine be aslevel as possible before checking theoil.

2. NOTICE: Prevent dirt and debris fromcontaminating engine oil. Carefullyclean the dipstick, filler port cap and thesurrounding area before you removethe cap. Remove the dipstick(Figure 6, (3)) and wipe with a cleancloth.

3. Fully reinsert the dipstick.

4. Remove the dipstick. The oil levelshould be between upper(Figure 6, (4)) and lower (Figure 6, (5))

lines on the dipstick.

5. Add oil if necessary. See AddingEngine Oil on page 29.


-4F 14F 32F 50F 68F 86F 104F

(-20C) (-10C) (0C) (10C) (20C) (30C) (40C)

SAE 10W-30

SAE 15W-40

0000005

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(3)

(4)(5)

(2)

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Adding Engine Oil

1. NOTICE: Prevent dirt and debris fromcontaminating engine oil. Carefullyclean the dipstick, filler port cap and thesurrounding area before you remove

the cap. Remove the yellow oil filler portcap from the filler port (Figure 6, (1))on the rocker arm cover (Figure 6, (2))and fill with engine oil.

2. Fill with engine oil to the upper limit(Figure 6, (4)) on the dipstick(Figure 6, (3)). NOTICE: NEVERoverfill the engine with engine oil.

3. Insert the dipstick fully to check thelevel. NOTICE: ALWAYS keep the oillevel between the upper and lower lineson the oil cap / dipstick.

4. Hand-tighten the filler port capsecurely.

MARINE GEAR OR SAIL

DRIVE OIL

Marine Gear Oil Specifications

Use marine gear oil that meets or exceeds

the following guidelines and classifications:

KM2P-1 (S), (G) or (GG):

API Service Categories: CD or higher

SAE Viscosity: #20 or #30

Sail Drive Oil Specifications -SD20

Refer to the Sail Drive Operation Manual

for the procedure to fill or replace the saildrive oil.

SD20:

API Service Category: GL4.5

SAE Viscosity: 90 or 80W90

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Checking Marine Gear OilFigure7

Figure 7

1 Dipstick2 Marine Gear Filler Port3 Upper Limit4 Lower Limit

1. Make sure the engine is off. Make surethe engine is as level as possible and

wipe area clean around the marinegear filler port (Figure 7, (2)).

2. Remove the filler cap at the top of thehousing.

3. Remove the dipstick (Figure 7, (1)) andwipe with a clean cloth.


5. Remove the dipstick. The oil levelshould be between the upper

(Figure 7, (3)) and lower (Figure 7, (4))lines on the dipstick.


Adding Marine Gear Oil

1. Make sure the engine is as level aspossible.

2. Remove the filler cap at the top of thehousing.

3. Fill with oil to the upper limit on thedipstick (Figure 7, (3)). See MarineGear Oil Specifications on page 29.NOTICE: NEVER overfill the marinegear with oil.


5. Hand-tighten the filler port cap.

Checking and Adding Sail Drive

OilRefer to the Sail Drive Operation Manualfor the procedure for checking and fillingthe sail drive oil.

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ENGINE COOLANT

Engine Coolant Specifications

Texaco Long Life Coolant (LLC), bothstandard and premixed, product code

7997 and 7998 Havoline Extended Life

Antifreeze / Coolant, product code 7994

Note: In the U.S., LLC is required forthe warranty to be valid.

NOTICE: Following the manufacturersrecommendations, use a proper LLC whichwill not have any adverse effects on thematerials (cast iron, aluminum, copper,etc.) of the engines cooling system. SeeEngine Coolant Specifications on page 31.

ALWAYS use the mixing ratios specifiedby the antifreeze manufacturer for thetemperature 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 willdecrease due to scale and rust in thecoolant system. Water alone may freezeand form ice; it expands approximately 9%in volume. Use the proper amount ofcoolant concentrate for the ambienttemperature as specified by the LLCmanufacturer. LLC concentration shouldbe a minimum of 30% to a maximum of

60%. Too much LLC will decrease thecooling efficiency. Excessive use ofantifreeze also lowers the coolingefficiency of the engine. NEVER mixdifferent types or brands of LLC, as aharmful sludge may form. Mixing differentbrands of antifreeze may cause chemicalreactions, and may make the antifreezeuseless or cause engine problems.

Replace the engine coolant periodically,according to the maintenance section inthis Operation Manual.

Remove scale from the cooling systemperiodically by flushing the system.

Checking and Adding Coolant

Component identificationFigure8

Figure 8

1 Coolant Tank / Heat Exchanger2 Coolant Drain Plug

3 Seawater Drain Plug4 Coolant Pump5 Seawater Pump

Figure9

Figure 9

1 Coolant Tank / Heat Exchanger2 Coolant Drain Plug3 Seawater Drain Cock

(1)

(2)(3)

(5)

(4)

0004791

(1)

(2)

(3)0005576

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Figure10

Figure 10

1 Stop Solenoid

2 Seawater Drain Plug3 Flywheel Housing

Note: The drain cocks are openedbefore shipping from the factory.Close all drain cocks beforefilling the system with coolant.

1. Allow the engine to cool.

2. Ensure all drain cocks are closed.3. Loosen the coolant tank filler cap to

relieve the pressure, then remove thefiller cap. WARNING! Burn Hazard.NEVER remove the coolant filler capif the engine is hot. Steam and hotengine coolant will spray out andseriously burn you. Allow the engineto cool down before you attempt toremove the cap.

Figure11

1 Filler Cap Tabs2 Coolant Filler Cap3 Filler Port Notches4 Coolant Tank / Heat Exchanger

Figure 11

4. NOTICE: NEVER pour cold coolant intoa hot engine.

Pour coolant slowly into the coolant tank/ heat exchanger (Figure 11, (4)) toavoid air bubbles. Fill until coolantoverflows from the filler port.

(1)

(2)(3)

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5. Align the filler cap tabs (Figure 11, (1))with filler port notches (Figure 11, (3))and tighten the filler cap(Figure 11, (2)).

Figure12

1 Rubber Hose to Coolant Tank2 FULL Mark3 LOW Mark4 Coolant Recovery Tank Cap

Figure 12

6. Check the coolant level in the coolantrecovery tank. The level should be atthe FULL mark (Figure 12, (2)). Addcoolant if necessary.

Note: The coolant level rises in thecoolant recovery tank duringoperation. After stopping theengine, the coolant will cooldown and the extra coolant willreturn to the coolant tank.

Note: NOTICE: NEVER pour coldcoolant into a hot engine.

7. Remove coolant recovery tank cap(Figure 12, (4)) to add coolant ifnecessary. NEVER add water.

8. Replace the filler cap and tighten itfirmly. Failure to do so will causecoolant to leak.

WARNING! Burn Hazard. ALWAYStighten the coolant tank cap securelyafter checking the coolant tank.Steam can spray out during engineoperation if the cap is loose.

9. Check the rubber hose (Figure 12, (1))connecting the coolant recovery tank tothe coolant tank / heat exchanger.Replace if damaged.

NOTICE: If the coolant runs low too oftenor only the coolant level in the coolant tank

/ heat exchanger drops without any changein the level in the coolant recovery tank,there may be coolant or air leaks in thecooling system. See your authorizedYanmar Marine dealer or distributor.

LOW

FULL

(

(1)

(2)

(3)

0004493

Coolant Recovery Tank Capacity

0.8 L (0.95 qt)

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BEFORE YOU OPERATE


CRANKING THE ENGINE

NOTICE: When performing enginebreak-in or if the engine has not been usedfor a long period of time, engine oil will notbe distributed to all of the operating parts.

Using the engine in this condition will leadto seizure.

After a long period of non-use, distributeengine oil to each part by cranking theengine. Perform the following procedurebefore beginning operation:

1. Open the seacock.

2. Open the fuel cock.

3. Put the remote control shift lever inNEUTRAL.

4. Turn the battery switch to ON (ifequipped).

Figure13

1 GLOW2 OFF

3 ON4 START

Figure 13

Note: If the engine has not beenoperated for a long period oftime, check that the key movessmoothly from the START to ONpositions.

5. Turn the key to ON (Figure 13, (3)).

6. While pushing the STOP button on thecontrol panel, turn the key to theSTART position (Figure 13, (4)).NOTICE: NEVER hold the key in theSTART position for longer than 15seconds or the starter motor will

overheat.7. When the key is in the START position,

the engine will begin cranking.Continue cranking for about 5 secondsand listen for abnormal noise duringthat time.

NOTICE: If the STOP button is releasedduring the cranking procedure, the enginewill start. NEVER start the engine in this

mode.

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ENGINE OPERATION

SAFETY PRECAUTIONS

Before performing any operations withinthis section, read the following safetyinformation and review the Safetysectionon page 3.

Fire and ExplosionHazard

NEVER jump-start theengine. Sparks caused byshorting the battery to thestarter terminals maycause a fire or explosion.ONLY use the key switch to

start the engine.

Sudden Movement Hazard

Be sure the boat is in open water awayfrom other boats, docks or otherobstructions before increasing rpm.Avoid unexpected equipmentmovement. Shift the marine gear intothe NEUTRAL position any time theengine is at idle.

To prevent accidental equipmentmovement, NEVER start the engine ingear.

Sever Hazard

Keep children and petsaway while the engine isoperating.

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ENGINE OPERATION


If any indicator illuminates during engineoperation, stop the engine immediately.Determine the cause and repair theproblem before continuing to operate the

engine. If the alarm window with audiblealarm fails to display and go out about 3seconds later when the ignition switch is inthe ON position, see your authorizedYanmar Marine dealer or distributor forservice before operating the engine.

Observe the following environmentaloperating conditions to maintain engineperformance and avoid premature enginewear:

Avoid operating in extremelydusty conditions.

Avoid operating in the presenceof chemical gases or fumes.

NEVER run the engine if the am-bient temperature is above +40C(+104F) or below -16C (+5F).

If the ambient temperature ex-ceeds +40C (+104F), the en-gine may overheat and cause theengine oil to break down.

If the ambient temperature is be-low -16C (+5F), rubber compo-nents such as gaskets and sealswill harden, causing prematureengine wear and damage.

Contact your authorized YanmarMarine engine dealer or distribu-tor if the engine will be operatedoutside of this standard tempera-ture range.

NEVER engage the starter motor while theengine is running. Damage to the startermotor pinion and / or ring gear will result.

INTRODUCTION

This section of the Operation Manualdescribes the procedures for starting theengine, checking engine performanceduring operation and shutting down the

engine.

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STARTING THE ENGINE

NOTICE: If the vessel is equipped with awater lift (water lock) muffler, excessivecranking could cause seawater to enter thecylinders and damage the engine. If the

engine does not start after cranking for 10seconds, close the seacock to avoid fillingthe muffler with water. Crank for 10seconds or until the engine starts. Whenthe engine does start, stop the engineimmediately and turn the switch to the OFFposition.

1. Open the seacock (if equipped).

2. Open the fuel cock.

3. Put the remote control handle inNEUTRAL.

Note: Safety equipment should make itimpossible to start the engine inany position other thanNEUTRAL.

Figure1

1 GLOW2 OFF3 ON4 START

Figure 1

4. Turn the battery master switch (ifequipped) to ON.

5. Turn key switch to ON (Figure 1, (3)).

Ensure that the instrument panelindicators light and the alarm sounds.This indicates that indicators and alarmare working correctly.

Note: The coolant high temperaturealarm indicator and water in saildrive seal indicator should notcome on during start-up.

6. Turn key switch to START(Figure 1, (4)). Release the key switchwhen the engine has started. NOTICE:NEVER hold the key in the STARTposition for longer than 15 seconds orthe starter motor will overheat.

7. The alarm should stop and theindicators should go out. NOTICE: Ifany indicator fails to illuminate when thekey switch is in the ON position, seeyour authorized Yanmar Marine dealer

or distributor for service beforeoperating the engine.

Note: When the engine has not beenused for a long period of time,check that the key movessmoothly from the STARTposition to the ON position.

Restarting After Starting Failure

Before turning the key switch again, besure the engine has stopped completely.NEVER attempt to restart the engine whilethe engine is running. The pinion gear onthe starter motor will be damaged.NOTICE: NEVER hold the key in theSTART position for longer than 15 secondsor the starter motor will overheat.

NOTICE: NEVER attempt to restart the

engine if the engine has not stoppedcompletely. Pinion gear and starter motordamage will occur.

Air Bleeding the Fuel System AfterStarting Failure

If the engine does not start after severalattempts, there may be air in the fuelsystem. If air is in the fuel system, fuelcannot reach the fuel injection pump.Bleed the air out of the system. SeeBleeding the Fuel System on page 26.

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ENGINE OPERATION


Starting at Low Temperatures

Comply with local environmentalrequirements. Use engine heaters to avoidstarting problems and white smoke.NOTICE: NEVER use an engine starting

aid such as ether. Engine damage willresult. Using a starting aid may void thewarranty.

To limit white smoke, run the engine at lowspeed and under moderate load until theengine reaches normal operatingtemperature. A light load on a cold engineprovides better combustion and fasterengine warm-up than no load.

Avoid running the engine at idling speedany longer than necessary.

Starting with Air Heater (IfEquipped)

1. Open the seacock (if equipped).

2. Open the fuel tank cock.

3. Put remote control handle inNEUTRAL.

4. Turn the battery master switch (ifequipped) to ON.

5. Turn key switch to GLOW for 15seconds.

6. Turn key switch to ON. Ensure that theinstrument panel indicators light andthe alarm sounds. This shows thatindicators and alarm are workingcorrectly.

Note: The coolant high temperaturealarm indicator and water in saildrive seal indicator should notcome on during start-up.

7. Turn key switch to START. Release thekey switch when the engine hasstarted. The alarm should stop and theindicators should go out. NOTICE:NEVER hold the key in the START

position for longer than 15 seconds orthe starter motor will overheat.

After the Engine has Started

After the engine has started, check thefollowing items at a low engine speed:

1. Check that the gauges, indicators andalarm are normal.

2. Check for any water, fuel, enginecoolant or engine oil leaks. If any leaksare found, shut down the engine andperform the necessary repairs.

WARNING! Piercing Hazard. NEVERcheck for a fuel leak with your hands.ALWAYS use a piece of wood orcardboard. Have your authorizedYanmar Marine dealer or distributor

repair the damage. Avoid skin contactwith the high-pressure diesel fuelspray caused by a fuel system leaksuch as a broken fuel injection line.High-pressure fuel can penetrateyour skin and result in serious injury.If you are exposed to high-pressurefuel spray, obtain prompt medicaltreatment.

3. Check that the exhaust color, enginevibration and sound are normal.

4. When there are no problems, keep theengine at low speed with the boat stillstopped to distribute engine oil to allparts of the engine.

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Check that water is being discharged fromthe seawater outlet pipe. Operation withinadequate seawater discharge willdamage the impeller of the seawaterpump. If seawater discharge is too low,stop the engine immediately. Identify the

cause and repair. NOTICE: The engine willseize if it is operated when coolingseawater discharge is inadequate or if loadis applied without any warm-up operation.

When operating the engine at low speedfor long periods of time, race the engineonce every 2 hours. Race the engine withthe clutch in NEUTRAL, accelerate fromthe low-speed position to the high-speed

position and repeat this process about fivetimes. This cleans out carbon from thecylinders and the fuel injection valves.NOTICE: Neglecting to race the engine willresult in poor exhaust color and reduceengine performance.

Periodically operate the engine nearmaximum speed while underway. This willgenerate higher exhaust temperatures,

which will help clean out hard carbondeposits, maintain engine performanceand prolong the life of the engine.

For troubleshooting assistance, seeTroubleshooting After Starting on page 69or see Troubleshooting Chart on page 71.

If necessary, see your authorized YanmarMarine dealer or distributor.

REMOTE CONTROL

HANDLE OPERATION

Acceleration and DecelerationFigure2

Figure 2

1 FORWARD or REVERSE2 NEUTRAL3 REVERSE or FORWARD4 Throttle Handle / Clutch Handle

Note: Direction of travel will varydepending on installationlocation.

Use the throttle handle (Figure 2, (4)) tocontrol acceleration and deceleration.Move the handle slowly.

0004513

(1)

(2)

(4)

(3)

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ENGINE OPERATION


Shifting the Engine

WARNING! Sudden Movement Hazard.The boat will start to move when themarine gear is engaged:

Ensure the boat is clear of all

obstacles forward and aft. Quickly shift to the FORWARD

position then back to theNEUTRAL position.

Observe whether the boat movesin the direction you expect.

NOTICE: Shifting the marine gear whileoperating at high speed or not pushing thehandle fully into position (partial

engagement) will result in damage tomarine gear parts and abnormal wear.

Before using the marine gear, be sure tomove the throttle handle to a low idleposition (less than 1000 rpm). Move thethrottle handle slowly to a higher speedposition after completing clutchengagement.

NOTICE: NEVER shift the marine gear

at high engine speed. During normaloperation, the marine gear should onlybe shifted with the engine at idle. Whenmoving the handle between FORWARD(Figure 2, (1 or 3)) and REVERSE(Figure 2, (1 or 3)), bring the clutch toNEUTRAL (Figure 2, (2)) and pausebefore slowly shifting to the desiredposition. Do not shift abruptly fromFORWARD to REVERSE or vice versa.

NOTICE: When sailing, set the remotecontrol lever in NEUTRAL. Not doing soWILL introduce slippage or any damageand void your warranty.

SHUTTING DOWN THE

ENGINE

NOTICE: NEVER stop engine abruptlyduring operation. Yanmar recommendsthat when shutting the engine down, allow

the engine to run, without load, for 5minutes. This will allow the enginecomponents that operate at hightemperatures, such as the exhaust system,to cool slightly before the engine is shutdown.

1. Reduce engine speed to low idle andput remote control handle inNEUTRAL.

2. Accelerate from low speed to highspeed and repeat five times. This willclean out the carbon from the cylindersand the fuel injection nozzles.

3. Allow engine to run at low speed(approximately 1000 rpm) without loadfor 5 minutes. NOTICE: Continue tohold the STOP button in until theengine is completely stopped. If the

button is released before the enginehas completely stopped, it may restart.If the engine does not shut down, seeEmergency Shutdown on page 41 .

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4. With the key in the ON position, pushand hold the STOP button(Figure 3, (1)). After the engine hasstopped, turn the key switch to OFF.

Note: Continue to hold the STOPbutton in until the engine iscompletely stopped. If the buttonis released before the enginehas completely stopped, it mayrestart. If the engine does notshut down, see EmergencyShutdown on page 41 .

Figure3

1 STOP Button

Figure 3

5. Remove the key and cover the keyswitch with the moisture cap.

6. Turn off the battery master switch (ifequipped).

7. Close the fuel cock.

8. Close the seacock (if equipped).NOTICE: ALWAYS close the seacock.Neglecting to close the seacock could

allow water to leak into the boat andmay cause it to sink.

Emergency Shutdown

NOTICE: NEVER use the emergency stopswitch for a normal engine shutdown. Usethis switch only when stopping the enginesuddenly in an emergency.

If the engine cannot be shut down by theSTOP button on the panel, stop the engineby pushing the STOP button(Figure 4, (1)) at the back of the stopsolenoid (Figure 4, (2)).

Figure4

Figure 4

1 STOP Button2 Stop Solenoid

0004487

(1)

(1)

(2) 0004787

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ENGINE OPERATION


CHECKING THE ENGINE

AFTER OPERATION

Check that the key switch is in the OFFposition and that the battery masterswitch (if equipped) is turned to OFF.

Fill the fuel tank. See Filling the FuelTank on page 25.

Close seacock(s).

If there is a risk of freezing, check thatthe cooling system contains enoughcoolant. See Engine CoolantSpecifications on page 31.

If there is a risk of freezing(temperatures below 0C [32F]), drainthe seawater system (see Draining theCooling System on page 76) andconnect the engine heater (if equipped).

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YM Series Operation ManualPERIODIC

MAINTENANCE

SAFETY PRECAUTIONS

Before performing any maintenanceprocedures within this section, read thefollowing safety information and review theSafetysection on page 3.

Crush Hazard

If the engine needs to be

transported for repair, havea helper assist you inattaching it to a hoist andloading it on a truck.

The engine lifting eyes are engineeredto lift the weight of the marine engineonly. ALWAYS use the engine liftingeyes when lifting the engine.

Additional equipment is necessary tolift the marine engine and marine geartogether. ALWAYS use lifting equipmentwith sufficient capacity to lift the marineengine.

Explosion Hazard

ALWAYS turn off the battery switch (ifequipped) or disconnect the negative (-)battery cable before servicing theequipment.

Entanglement Hazard

NEVER leave the key in the key switch

when you are servicing the engine.Someone may accidentally start theengine and not realize you are servicingit.

Stop the engine before you begin toservice it.

Piercing Hazard

Avoid skin contact withhigh-pressure diesel fuelspray caused by a fuelsystem leak such as abroken fuel injection line.

High-pressure fuel can penetrate yourskin and result in serious injury. If youare exposed to high-pressure fuelspray, obtain prompt medical treatment.

NEVER check for a fuel leak with yourhands. ALWAYS use a piece of wood orcardboard. Have your authorizedYanmar Marine dealer or distributorrepair the damage.

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PERIODIC MAINTENANCE


Tool Hazard

ALWAYS remove any tools or shop ragsused during maintenance from the area

before operation.

Shock Hazard

ALWAYS turn off the batteryswitch (if equipped) ordisconnect the negativebattery cable beforeservicing the equipment.

ALWAYS keep the electrical connectors

and terminals clean. Check theelectrical harnesses for cracks,abrasions, and damaged or corrodedconnectors.

Welding Hazard

Make welding repairs safely.

ALWAYS turn off the battery switch(if equipped) or disconnect the

negative battery cable and theleads to the alternator whenwelding on the equipment.

Remove the multi-pin connector tothe engine control unit. Connectthe weld clamp to the componentto be welded and as close aspossible to the welding point.

NEVER connect the weld clamp tothe engine or in a manner whichwould allow current to passthrough a mounting bracket.

When welding is completed,reconnect the leads to thealternator and engine control unitprior to reconnecting the batteries.

Any part which is found defective as aresult of inspection, or any part whosemeasured value does not satisfy thestandard or limit, must be replaced.

Modifications may impair the enginessafety and performance characteristicsand shorten the engines life. Anyalterations to this engine may void itswarranty. Always use Yanmar genuinereplacement parts.

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INTRODUCTION

This section of the Operation Manualdescribes the procedures for proper careand maintenance of the engine.

PRECAUTIONS

The Importance of PeriodicMaintenance

Engine deterioration and wear occur in

proportion to the length of time the enginehas been in service and the conditions theengine is subjected to during operation.Periodic maintenance preventsunexpected downtime, reduces thenumber of accidents due to poor engineperformance and helps extend the life ofthe engine.

Performing Periodic

MaintenanceWARNING! Exhaust Hazard. NEVERblock windows, vents, or other meansof ventilation if the engine is operatingin an enclosed area. All internalcombustion engines create carbonmonoxide gas during operation.Accumulation of this gas within anenclosure could cause illness or even

death. Make sure that all connectionsare tightened to specifications afterrepair is made to the exhaust system.Failure to comply could result in deathor serious injury.

The Importance of Daily Checks

The Periodic Maintenance Scheduleassumes that the daily checks areperformed on a regular basis. Make a habit

of performing daily checks before the startof each operating day. See Daily Checkson page 55.

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Keep a Log of Engine Hours andDaily Checks

Keep a log of the number of hours theengine is operated each day and a log ofthe daily checks performed. Also note the

date, type of repair (e.g., replacedalternator) and parts used for any serviceneeded between the periodic maintenanceintervals. Periodic maintenance intervalsare every 50, 100, 150, 250 and 1000engine hours. NOTICE: Failure to performperiodic maintenance will shorten the lifeof the engine and may void the warranty.

Yanmar Replacement Parts

Yanmar recommends that using genuineYanmar parts when replacement parts areneeded. Genuine replacement parts helpensure long engine life.

Tools Required

Before starting any periodic maintenanceprocedure, make sure you have the toolsneeded to perform all of the required tasks.

Ask Your Authorized YanmarMarine Dealer or Distributor forHelp

Our professional service technicians havethe expertise and skills to help with anymaintenance or service relatedprocedures.

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Tightening Fasteners

Use the correct amount of torque when you tighten fasteners on the engine. Applyingexcessive torque may damage the fastener or component and not enough torque maycause a leak or component failure.

NOTICE: The tightening torque in the Standard Torque Chart should be

applied only to the bolts with a 7 head (JIS strength classification: 7T). Apply60% torque to bolts that are not listed. Apply 80% torque when tightened toaluminum alloy.

Standard Torque Chart

Bolt Diameter x

Pitch (mm)M6x1.0 M8x1.25 M10x1.5 M12x1.75 M14x1.5 M16x1.5

Tightening

Torque

Nm 11.0 1.0 26.0 3.0 50.0 5.0 90.0 10.0 140.0 10.0 230.0 10.0

kgfm 1.1 0.1 2.7 0.3 5.1 0.5 9.2 1.0 14.3 1.0 23.5 1.0

lb-ft 8.0 0.7 19.0 2.1 37 3.6 66.0 7.2 103 7.2 170 7.2

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EPA MAINTENANCE

REQUIREMENTS

To maintain optimum engine performanceand compliance with the EnvironmentalProtection Agency (EPA) Regulations for

Engines, it is essential to follow thePeriodic Maintenance Schedule on page50and the Periodic MaintenanceProcedures on page 55.

EPA Requirements for USA andOther Applicable Countries

The following are the requirements for theEPA. Unless these requirements are met,

the exhaust gas emissions will not bewithin the limits specified by the EPA.

The EPA emission regulation is applicableonly in the USA and other countries thathave adopted the EPA requirements inpart or in whole. Determine and follow theemission regulations in the country whereyour engine will be operating to assist youin specified compliance.

Conditions to EnsureCompliance with EPA EmissionStandards

The 2YM15, 3YM20 and 3YM30 areEPA-certified engines.

The following are the conditions that mustbe met in order to ensure that theemissions during operation meet the EPA

standards:

Ambient temperature: -20 to +40C(-4to +104F)

Relative humidity: 80% or lower

The diesel fuel should be:

ASTM D975 No. 1-D or No. 2-D, orequivalent (minimum of cetane No. 45)

The lubricating oil should be: Type API, Class CD or higher

Perform the inspections as outlined inPeriodic Maintenance Procedures on page55and keep a record of the results.

Pay particular attention to these importantpoints:

Replacing the engine oil

Replacing the engine oil filter

Replacing the fuel filter

Cleaning the intake silencer (air cleaner)

Note: Inspections are divided into twosections in accordance with who isresponsible for performing theinspection: the user or the

manufacturer.

Inspection and Maintenance

See Inspection and Maintenance of EPAEmission-Related Parts on page 54for theEPA emission-related parts. Inspectionand maintenance procedures not shown inthe Inspection and Maintenance of EPAEmission-Related Partssection are

covered in Periodic Maintenance Scheduleon page 50.

This maintenance must be performed tokeep the emission values of the enginewithin the standard values during thewarranty period. The warranty period isdetermined by the age of the engine or thenumber of hours of operation.

Installing Sample Port

All engines subject to emission standardsshall be equipped with a connection in theengine exhaust system that is locateddownstream of the engine, and before anypoint at which the exhaust contacts water(or any other cooling / scrubbing medium),for the temporary attachment of gaseousand / or particulate emissions samplingequipment.

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This connection shall be internallythreaded with standard pipe threads of asize not larger than 12.7 mm (0.5 in.), andshall be closed by a pipe plug when not inuse. Equivalent connections are allowed.

The instructions for the proper installationand location of the required sample port, inaddition to those specified above in thequoted federal regulation, are as follows:

1. The connection should be located asfar downstream as reasonablypracticable from any sharp bend (of 30or more) in the exhaust pipe to helpensure that a well-mixed exhaust flowsample may be taken;

2. The requirement that the connection belocated before any point at which theexhaust contacts water (or any othercooling/scrubbing medium) does notinclude contact with water used to coolexhaust manifolds, unless the water isallowed to come into direct contact withthe exhaust gases;

3. To allow ready access to the sample

port, the connection should be located,if possible given the constraints ofvessel design, approximately 0.6 to 1.8m (2 to 6 ft) above a deck or walkway;

4. To facilitate insertion and withdrawal ofan exhaust sample probe, there shouldbe no obstructions for at least one andone-half exhaust pipe/stack diametersperpendicular, i.e., 90, from thesample port; and

5. If a threaded connection is used, boththe internal and external threads shouldbe coated with a high-temperature,anti-seize compo

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