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Shop manual
Table Of Contents - Yanmar 1GM Shop Manual
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:
Operation manual
(56 pages)
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Shop manual
(241 pages)
,
User manual
(240 pages)
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Table Of Contents
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Contents
Table of Contents
Troubleshooting
Bookmarks
Table of Contents
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Table of Contents
Contents
3
Quick Reference Data
6
Tune-Up Specifications
6
Freshwater (Closed) Cooling System Capacity
6
Engine Models
6
General Torque Specifications
7
General Information
8
Manual Organization
8
Notes, Cautions And Warnings
9
Safety First
9
Service Hints
10
Parts Replacement
11
Torque Specifications
11
Fasteners
11
Iso Metric Screw Threads
12
Machine Screws
12
Bolts
12
Openings For Tools
13
Nuts
13
Self-Locking Fasteners
13
Washers
14
Cotter Pins
14
Lubricants
15
Circlips
15
Engine Oil
15
Rtv Gasket Sealant
16
Threadlock
16
Basic Hand Tools
16
Grease
16
Screwdrivers
17
Pliers
18
Locking Pliers
18
Circlip Pliers
18
Box-End, Open-End And Combination Wrenches
19
Adjustable Wrenches
19
Socket Wrenches
19
Torque Wrenches
19
Precision Measuring Tools
20
Feeler Gauge
20
Hammers
20
Vernier Caliper
21
Outside Micrometers
21
Dial Indicator
21
Cylinder Bore Gauge
21
Compression Gauge
22
Multimeter Or Vom
22
Battery Hydrometer
22
Screw Pitch Gauge
22
Mechanic's Tips
23
Surface Plate
23
Expendable Supplies
23
Removing Frozen Nuts And Screws
23
Remedying Stripped Threads
24
Removing Broken Or Damaged Studs
24
Bearing Replacement
25
Removing Broken Screws And Bolts
25
Bearing Removal
25
Bearing Installation
26
Shrink Fit
27
Parts View
28
Seals
30
Yanmar Models
31
Decimal And Metric Equivalents
31
Troubleshooting
32
Starting System
33
Starting System Operation
33
Starting Circuit (Typical)
33
On-Boat Testing
34
Slow Running Starter
34
Starter Solenoid Clicks, Starter Does Not Run
34
Starter Solenoid Chatters (No Click), Starter Does Not Run
34
Starter Solenoid Resistance Tests
35
Starter Motor No-Load Current Draw Test
35
Starter Spins But Does Not Rotate Flywheel
35
Starter Will Not Disengage When Start Switch Is Released
35
Charging System (Typical)
36
Charging System
37
Charging System Tests
37
Alternator Regulated Voltage Test
37
Fuel System
38
Alternator Current Output Test
38
Voltage Output Test
38
Current Output Test
39
Cooling System
40
Engine Overheating
40
Fuel Injection System
40
Engine Exhaust Smoke
41
Engine Noises
41
Clicking Or Tapping Noises
41
Knocking Noises
41
Engine Troubleshooting
42
Lubrication System
42
Engine Will Not Start
42
Engine Misses
42
Lubrication System (1 Gm And 1 Gm 10 Models)
43
Lubrication System (2 Gm And 2 Gm 20 Models)
44
Lubrication System (3Gm, 3Gm30, 3Hm And 3Hm35 Models)
45
Oil Pressure Test
46
Starter Motor No-Load Specifications
47
Oil Pressure
47
Operation, Lubrication, Maintenance And Tune-Up
48
Fuel Requirements
48
Preoperational Checks
48
Starting Checklist
49
Engines Without Remote Control
49
Engines Equipped With Remote Control
49
Warm Engine
49
Stopping The Engine
50
Emergency Engine Stopping
50
Post-Operational Checks
50
Engine Maintenance And Lubrication
50
Engine Oil Level Check
51
Engine Oil And Filter Change
51
Fuel System Service
52
Fuel Lines
53
Fuel Filter
53
Air Filter
54
Drive Belts
54
Bleeding Air From The Fuel System
54
Alternator Drive Belt Adjustment (Models Equipped With Seawater Cooling)
55
Seawater Pump Drive Belt Adjustment (2Gm, 2Gm20, 3Gm, 3Gm30, 3Hm And 3Hm35 Models)
55
Crankcase Breather
56
Alternator Drive Belt Replacement (All Models)
56
Seawater Pump Drive Belt Replacement (2Gm, 2Gm20, 3Gm, 3Gm30, 3Hm And 3Hm35 Models)
56
Alternator Maintenance
57
1Gm And 1Gm10 Models
57
2Gm, 2Gm20, 3Gm, 3Gm30, 3Hm And 3Hm35 Models
58
Sacrificial Anode Original Sizes
58
Seawater (Standard) Cooling System
59
Flushing The System
59
Anode Mountings
59
Freshwater (Closed) Cooling System
60
Inspection
60
Check/Fill Coolant (Not Equipped With Remote Reservoir)
60
Check/Fill Coolant (Equipped With A Remote Reservoir)
60
Freshwater Heat Exchanger (Typical)
61
Battery
62
Flushing And Refilling Freshwater Coolant System
62
Engine Tune-Up
63
Compression Test
63
Battery Cutaway View
63
Valve Clearance Adjustment
64
Idle Speed Adjustment
65
Valve Clearance Adjustment (All Models)
65
Idle Speed Adjustment (1Gm And 1Gm10 Models)
65
Transmission
66
Transmission Oil
66
Transmission Models Km2A, Km2C, Km2P, Km3A And Km3P
66
Transmission Models Kbw10D And Kbw10E
66
Transmission Oil Level Check
67
Maintenance Schedule
67
Engine Oil Viscosity
67
Engine Oil Crankcase Capacity
67
Freshwater (Closed) Cooing System Capacity
68
Compression Specifications
68
Lay-Up And Fitting Out
69
Cooling System Draining
70
Seawater Cooling System
70
Adding Antifreeze
71
Freshwater (Closed) Cooling Section
71
Fitting Out
72
Seawater Cooling Section
72
Single-Cylinder Engines
74
Diesel Engine Fundamentals
74
4-Stroke Diesel Engine Principles
75
Engine Serial Number And Code
76
Replacement Parts
76
Engine Removal Precautions
76
Valve Cover
77
Breather Assembly
77
Removal/Installation
77
Valve Cover Assembly
78
Decompression Mechanism
79
Cylinder Head
79
Removal
79
Installation
81
Rocker Shaft Assembly
82
Cylinder Head Tightening Sequence
82
Valves And Valve Seats
83
Valve Removal
83
Valve Components
83
Push Rods
85
Piston/Connecting Rod Assembly
85
Valve Guide Replacement
85
Piston/Connecting Rod Removal
85
Piston Pin Removal/Installation
86
Piston/Cylinder Bore Check
87
Piston Ring Fit/Installation
88
Connecting Rod Inspection
89
Connecting Rod Bearing Clearance Measurement
90
Piston/Connecting Rod Installation
90
Timing Gearcase
91
Oil Pump
92
Removal And Installation
93
Disassembly, Inspection And Reassembly
94
Flywheel
95
Pressure Relief Valve
95
Oil Pickup
95
Crankshaft Assembly
96
Drive Disc
97
Crankshaft
97
Main Bearings
99
Camshaft
99
Cylinder Block
101
Cleaning And Inspection
101
Core Plug Replacement
101
Engine Specifications (1Gm, 1Gm10)
103
Tightening Torques
104
Multicylinder Engines
105
Engine
106
Precautions
106
Valve Cover (2Gm, 2Gm20, 3Gm And 3Gm30 Models)
107
Valve Cover 3Hm And 3Hm35 Models
108
Exhaust Manifold
109
2Gm Models
109
3Gm, 3Gm30, 3Hm And 3Hm35 Models
109
Exhaust Manifold With Closed Cooling System (Typical)
110
2Gmf, 2Gm20F, 3Gmf, 3Gm30F, 3Hmf And 3Hm35F Models With Freshwater (Closed) Cooling System
111
Rocker Arms (3Gm, 3Gm30, 3Hm And 3Hm35 Models)
116
Oil Pickup (2Gm, 2Gm20, 3Gm And 3Gm30 Models)
119
Governor Assembly
126
Oil Pressure Regulator
128
Oil Pickup 2Gm, 1Gm10, 3Gm And 3Gm30 (Typical)
129
Intermediate Main Bearing
133
Camshaft Assembly
135
Cylinder Liners 2Gm, 3Gm And 3Hm (Including F And D Series) Models
135
Engine Specifications (2Gm And 2Gm20)
138
Engine Specifications (3Gm And 3Gm30)
139
Engine Specifications (3Hm And 3Hm35)
141
Fuel Injection And Governor Systems
144
Fuel Injection Fundamentals
144
Fuel Injection Pump
144
Fuel Injector
146
Fuel And Fuel Filters
146
Injection Pump
147
Fuel Injection System Bleeding
148
Fuel Transfer Pump
148
Fuel Injection Timing
150
Adjust Fuel Injection Timing
151
Fuel Pump Testing
156
Overhaul
157
Governor System
158
Operation
158
Governor System Operation
159
Adjustments
160
Removal/Inspection/Installation
161
Governor Assembly (1Gm And 1Gm10 Models)
161
Governor Assembly (2Gm, 2Gm20, 3Gm, 3Gm30, 3Hm And 3Hm35 Models)
162
Main Governor Spring
163
Secondary Governor Spring
163
Governor Spring Free Length
164
Governor Sleeve And Crankshaft Specifications
164
Cooling Systems
165
Seawater Colling System (1Gm And 1Gm10)
166
Seawater Colling System (2Gm And 2Gm20)
167
Seawater Colling System (3Gm And 3Gm30 Models)
168
Closed Cooling System Diagram
169
Closed Cooling System (Typical)
170
Thermostat
171
Heat Exchanger
171
Seawater Cooling Systems
172
Freshwater Cooling Systems
172
Testing (Out Of Engine)
173
Testing (In Engine)
173
Hose Replacement
174
Overheated Engine
174
Slow Engine Warm-Up
174
Belt Adjustment
175
Belt Replacement
175
Alternator Drive Belt Replacement
175
Drive Belt Routing
175
Seawater Pump
176
Seawater Pump Drive Belt Replacement (Except 1Gm And 1Gm10 Engines)
176
Seawater Pump Precautions
177
Water Pump Operating Mistakes
177
1Gm And 1Gm10
177
Disassembly/Reassembly
178
2Gm, 2Gm20, 3Gm And 3Gm30
178
3Hm And 3Hm35
178
Seawater Pump (1Gm And 1Gm10 Models)
179
Seawater Pump (2Gm, 2Gm20, 3Gm And 3Gm30 Models)
181
Seawater Pump (3Hm And 3Hm35 Models)
182
Freshwater Pump
183
Freshwater Cooling System Maintenance
183
Pressure Testing
183
Cleaning
185
Cleaning The Seawater Section Of The Heat Exchanger
185
Freshwater Exhaust Manifold/Heat Exchanger
186
Sewater Cooling System Maintenance
187
Recommended Thermostat
188
Electrical System
189
Safety Precautions
190
Care And Inspection
191
Battery Testing
192
Battery Electrolyte Level
192
Charging
193
Jump Starting
193
Electrical Protection
194
Battery Cables
194
Preliminary Testing
195
Alternator Removal/Installation
196
Starter Removal/Installation
196
Solenoid Removal/Installation
197
Brush Replacement
197
1Gm, 1Gm10, 2Gm, 2Gm20, 3Gm And 3Gm30 Models
197
Starter Motor (Except 3Hm And 3Hm35 Models)
198
Starter Motor (3Hm And 3Hm35 Models)
199
3Hm And 3Hm35 Models
200
Switches
201
Senders
201
Key Switch
201
Start Switch
201
Coolant Temperature Sender
202
Warning Lamps
203
Alarm Buzzer
203
Tachometer
203
Coolant And Oil Pressure Warning Lamps
203
Tachometer Sender
204
Tachometer Gauge
204
Battery Capacity (Minimum)
204
Alternator And Starter Motor Tightening Torques
204
Transmission - Km Series
205
Cone Clutch
206
Shifter (Km2A, Km2C And Km3A Models)
206
Shifter (Km2P And Km3P Models)
207
Disassembly
208
Input Shaft
209
Intermediate Shaft
210
Output Shaft
210
Reassembly
214
Shifter Detents (Km2P And Km3P Models)
215
Bearing Adjustment
217
Km2A, Km2C And Km3A
217
Km2P And Km3P
217
Engine/Transmission Models
220
Clutch Depth
220
Clutch Groove Width
220
Transmission - Kwb Series
222
Shifter
229
Clutch Specifications
232
Index
233
Early Models With Large Instrument Panel
237
Early Models With Small Instrument Panel (No Tachometer)
238
Late Models With Large Instrument Panel
239
Late Models With Small Instrument Panel (No Tachometer)
240
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Table of Contents
Troubleshooting
Troubleshooting
32
Engine Troubleshooting
42
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This manual is also suitable for:
2gm
1gm10
2gm20
2gm20f
3gm
3gmf
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3gmd
3gm30
3gm30f
3hm
3hmf
3hm35
3hm3sf
2gmf
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