Yanmar 1GM10 Shop Manual
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Yanmar 1GM10 Shop Manual

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YANMAR
DIESEL INBOARD SHOP MANUAL
ONE, TWO 8. THREE CYLINDER ENGINES

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Summary of Contents for Yanmar 1GM10

  • Page 1 YANMAR DIESEL INBOARD SHOP MANUAL ONE, TWO 8. THREE CYLINDER ENGINES...
  • Page 2 General Information Troubleshooting Operation, Lubrication, Maintenance and Tune-up Lay-up and Fitting Out Single-Cylinder Engines Cooling System Index Wiring Diagrams...

  • Page 3: Table Of Contents

    Contents QUICKREFERENCEDATA CHAPTER ONE Manual organization Lubricants Notes. cautions and warnings RTV gasket sealant Safety first Threadlock Service hints Basic hand tools Parts replacement Precision measuring tools Torque specifications Mechanic's tips Fasteners Bearing replacement Seals CHAPTER TWO Starting system Engine exhaust smoke Charging system Engine noises Charging system tests...
  • Page 4 CHAPTER THREE OPERATION. LUBRICATION. MAINTENANCE AND TUNE-UP Fuel requirements Engine maintenance and lubrication Preoperational checks Cooling system Starting checklist Battery ......Stopping the engine Engine tune-up Emergency engine stopping...
  • Page 5 CHAPTER EIGHT 1 5 9 Cooling systems Seawater pump Thermostat Freshwater pump Hose replacement Freshwater cooling system maintenance Drivebelts Seawater cooling system maintenance CHAPTER NINE ELECTRICALSYSTEM 1 8 3 Senders Battery Electrical protection Warning lamps Charging system Alarm buzzer Starting system Tachometer Switches CHAPTER TEN...

  • Page 8: Manual Organization

    Tables 1-4 are located at the end of the chapter. Each Yanmar marine diesel can be identified by its indi- vidual model number. The model numbers for all Yanmar marine diesel engines covered in this manual are listed in MANUAL ORGANIZATION Table 1.

  • Page 14: General Information

    GENERAL INFORMATION Common nut Self-locking nut Correct installation of cotter pin Flat washers are often used between a lockwasher and a fastener to provide a smooth bearing surface. This allows the fastener to be turned easily with a tool. NOTE Plain Folding As much care should be given to the selec-...
  • Page 15 CHAPTER ONE to make alignment. Insert a new cotter pin through the nut and hole, then tap the head lightly to seat it. Bend one arm over the flat on the nut and the other against the top of the stud or bolt (Figure 13).
  • Page 28 GENERAL INFORMATION Bearing Blocks Press Shaft Bearing Spacer...
  • Page 29 CHAPTER ONE Shaft and rewash the housing as required to re- move all traces of oil and other chemical de- posits. a. The housing must be heated to a temperature of ap- proximately 212" F (100" C) in an oven or on a hot Socket plate.
  • Page 30 GENERAL INFORMATION e. While the housing is still hot, install the new bear- i n g ( ~ ) into the housing. Install the bearings by hand, if possible. If necessary, lightly tap the bearing(s) into the housing with a socket placed on the outer bearing race.
  • Page 31 CHAPTER ONE Table I YANMAR MODELS Number of Horsepower Transmission ratio Model cylinders , Displacement Transmission (forward gear) 293 cc (17.9 cu. in.) 6.5 hpI3400 rpm 318 cc (19.4 cu. in.) 8 hpI3400 rpm 586 cc (35.7 cu. in.) 13 hpI3400 rpm 586 cc (35.7 cu.

  • Page 32: Parts Replacement

    Chapter Troubleshooting Every internal combustion engine requires an uninter- once, what color smoke (if any) came from the exhaust, rupted supply of fuel, air, ignition and adequate compres- etc. sion. If any of these are lacking, the engine will not run. After defining the symptoms, test and analyze those ar- eas that could cause the problem(s).

  • Page 33: Troubleshooting

    TROUBLESHOOTING STARTING CIRCUIT (TYPICAL) Starter solenoid Key switch STARTING SYSTEM service, as well as to provide a measure of safety that is not required of automotive service. For example, a marine The starting system consists of the battery, starter mo- starter is flashproofed to prevent possible ignition of fuel tor, starter solenoid, starter switch, key switch, fuse and vapor in the bilge.
  • Page 34 CHAPTER TWO Ohmmeter Ohmmeter (S) terminal Starter motor the engine. Once the engine has started and the start switch is released, the slave solenoid is de-energized. Without current to hold the solenoid in position, the 3. Repeat Step 1. If the starter running speed is still too starter motor overrunning clutch disengages the starter slow, replace the starter.
  • Page 35 TROUBLESHOOTING Loud grinding noises when starter runs This can be caused by improper meshing of the starter Ammeter Voltmeter pinion and flywheel ring gear or by a broken overrunning clutch mechanism. 1. Remove the starter. See Chapter Nine. 2. Check the starter pinion gear. If the teeth are chipped or worn, inspect the flywheel ring gear for the same prob- lem.
  • Page 36 CHAPTER TWO CHARGING SYSTEM (TYPICAL) Battery switch...
  • Page 37 TROUBLESHOOTING 3. Charging system warning lamp jlashes on and 3. Hold a vibration-type tachometer against the starter usually indicates that the charging system is frame. working intermittently. Check drive belt tension first, then 4. To operate the starter motor, connect a wire between check all electrical connections in the charging circuit.
  • Page 38 CHAPTER TWO VOLTAGE OUTPUT TEST 55A ALTERNATOR If the reading varies or if no reading is obtained, check for 9. Connect a tachometer to the engine. Connect a carbon poor connections or damaged wiring. pile load device to the battery terminals. 6.
  • Page 40 CHAPTER TWO FUEL INJECTION SYSTEM High pressure fuel pipe described in Chapter Seven to remove air in fuel. Check 6 . Engine knocks-<heck the fuel injection pump timing for a clogged or defective fuel injection pump or fuel in- as described in Chapter Seven. Check for a defective fuel jector.
  • Page 41 TROUBLESHOOTING 1. Loose pump drive belt (except 1 GM models)- A loose Black Smoke drive belt prevents the circulating pump from operating at Black exhaust smoke results from excess fuel (rich) that the proper speed. forms soot when burned. Either excess fuel or insufficient 2.
  • Page 42 CHAPTER TWO main bearing, the noise is worse during acceleration. It Chapter Seven to repair the governor. If a fuel system may increase in transition from acceleration to coasting. problem is suspected, refer to troubleshooting in the Fuel System section of this chapter. Disabling the fuel injectors will help isolate this knock as well.
  • Page 43 TROUBLESHOOTING LUBRICATION SYSTEM (1 GM AND 1 GM1O MODELS) Valve rocker arm support Lubricating oil suction pipe...
  • Page 44 CHAPTER TWO LUBRICATION SYSTEM...
  • Page 45 TROUBLESHOOTING LUBRICATION SYSTEM 3HM AND 3HM35 MODELS Filter...
  • Page 47 Table 1 ENGINE TROUBLESHOOTING (continued) Trouble Probable cause Correction Governor malfunction Repair governor Engine stops suddenly (continued) Engine seized lnspect and repair Locate cause for overload and rectify Engine slows unexpectedly Overload Fuel filter or fuel lines clogged lnspect and unclog or replace Air in fuel system Bleed air in fuel system Remove water...
  • Page 48 Chapter Three Operation, Lubrication, Maintenance and Tune-up A diesel engine must have clean air, fuel, and oil. Regu- NOTE Poor fuel is one of the leading causes of lar preventive maintenance and proper lubrication will rough engine operation orfailure to start. pay dividends in longer engine and transmission life, as well as safer boat operation.
  • Page 49 OPERATION, LUBRICATION, MAINTENANCE AND TUNE-UP CA UTION 4. Check the condition of all drive belts. If a belt is in If the alarm buzzer or lamps remain on after doubtful condition, replace it. 5. Check all water hoses for leaks, loose connections and mine the cause.
  • Page 51 CA, CB, CC or CD. The classification the rocker arm cover. system ranges from CA for light diesel engine service to CD for severe diesel engine service. Yanmar specifies en- gine oils with classification CB or CC for use in the Engine Oil and Filter Change Yanmar diesel engines covered in this manual.
  • Page 53 OPERATION. LUBRICATION. MAINTENANCE AND TUNE-UP Air that enters the fuel system due to a damaged fuel line or loose connection may cause the engine to missfire. Bleed the fuel system as described in this chapter. Using clean fuel and maintaining the fuel system are extremely important when operating a diesel engine.
  • Page 56 CHAPTER THREE Intake port Alternator drive belt replacement (all models) 1. Loosen the alternator retaining nuts (B, Figure 12). 2. Move the alternator inward sufficiently to allow re- moval of the belt from the pulleys and remove the belt. 3. Clean the pulley grooves so they are dry and free of rust or other corrosion.
  • Page 59 OPERATION, LUBRICATION, MAINTENANCE AND TUNE-UP ANODE MOUNTINGS Mounting plug Mounting plug Gasket Anode Gasket Gasket Anode CYLINDER BLOCK may be used for most engines, but modification of the pro- (closed) cooling system requires additional maintenance cedure may be necessary for some installations. due to the freshwater portion of the system, which in- cludes a freshwater pump and may include an antifreeze 1.
  • Page 60 CHAPTER THREE Freshwater (Closed) Cooling Systems Inspection WARNING When performing any service work on the engine or cooling system, never remove the Heat pressure fill cap on the exhaust manifold exch (Figure 24), drain coolant or disconnect any hose while the engine is hot. Scalding fluid and steam may be blown out under pressure and cause serious injuly.
  • Page 61 OPERATION, LUBRICATION, MAINTENANCE AND TUNE-UP FRESHWATER HEAT EXCHANGER (TYPICAL) Seawater Freshwater Seawater WARNING Do not siphon coolant by mouth with a hose. The coolant mixture is poisonous and in- gesting even a very small amount may cause illness. Observe warning labels on anti- freeze containers.
  • Page 62 CHAPTER THREE ground. Put it in suitable containers and dispose of it according to local regulations. CA UTION Be careful not to spill antifreeze on painted surfaces, as it may damage the surface. Wash any spilled antifreeze immediately with soapy watel; then rinse the area thor- oughly with clean water: Flushing and refilling freshwater coolant system Use the following procedure to flush and refill the...
  • Page 63 OPERATION. LUBRICATION. MAINTENANCE AND TUNE-UP BATTERY CUTAWAY VIEW necessary to restore and maintain maximum power and performance. Perform an engine tune-up as needed at periodic inter- vals to maintain maximum engine performance. If the en- gine is used infrequently, perform a tune-up at least once a season.
  • Page 65 OPERATION, LUBRICATION, MAINTENANCE AND TUNE-UP CA UTION Always rotate the crankshaft in the normal VALVE CLEARANCE running direction (clockwise at crankshaft ADJUSTMENT (ALL MODELS) pulley); otherwise the water pump impeller will be damaged. Adjusting screw 4. Rotate the crankshaft nut clockwise so the 1T mark on the flywheel aligns with the reference pointer (B, Figure 31) on the clutch cover.
  • Page 67 OPERATION, LUBRICATION, MAINTENANCE AND TUNE-UP screw it in. Pull out the dipstick and read the oil level on Transmission Oil Level Check the dipstick. Check the transmission oil level on a weekly basis. 2. Add oil, if necessary, through the dipstick hole so the 1.
  • Page 68 CHAPTER THREE Table 4 FRESHWATER (CLOSED) COOLING SYSTEM CAPACITY Model Capacity 2.9 L (0.77 gal.) 3.4 L (0.9 gal.) 4.9 L (1.3 gal.) Table 5 TUNE-UP SPECIFICATIONS Full throttle rpm Fuel injection Valve clearance Model (no-load) (no-load) timing (0.008 in.) 15"...
  • Page 69 Chapter Four Lay-up and Fitting ber is specijied. For example, ifmodel 3GM LAY-UP is called out in a procedure, the procedure also applies to 3GMD and 3GMF. Boats that are stored for more than a month require careful preparation for the lay-up. This is necessary to 1.
  • Page 72 CHAPTER FOUR able containers and dispose of it according done, determine if the work is easier, and possibly more to local regulations. Make sure to wipe up economical, if performed before returning the engine to any spills and cover any containers of anti- service.
  • Page 73 LAY-UP AND FITTING OUT 12. Thoroughly inspect the engine. Check for leakage, 15. Operate all engine controls to be sure they operate rust or corrosion that will affect engine operation. Check properly and smoothly. all hoses for deterioration and clamps for tightness. 16.
  • Page 74 Chapter Five Single-Cylinder Engines pansion and exhaust cycle occur in the same sequence for This chapter covers the Yanmar 1 GM and lGM 10 sin- gle-cylinder, diesel engines. compression ignition engines as for spark ignition en- The engine consists of a cast-iron cylinder block, con- gines.
  • Page 75 SINGLE-CYLINDER ENGINES 4-STROKE DIESEL ENGINE PRINCIPLES As the piston travels downward, the exhaust When the crankshaft continues to rotate, the valve closes and the intake valve opens, piston moves upward, compressing the air. allowing air to be drawn into the cylinder. When the piston reaches the bottom of its travel (BDC), the intake valve closes and remains closed for the next 1 112 revolutions of the...
  • Page 76 Figure 2. The fuel and air are con- marine environment. fined to one area. Usually the piston crown is concave to Use only Yanmar parts or parts approved for use on ma- form the combustion chamber and provide turbulence re- rine engines.
  • Page 83 SINGLE-CYLINDER ENGINES 1. Wear cap 2. Keys 3. Valve spring retainer Valve spring 5. Valve seal 6. Valve guide 7. Valve VALVES AND VALVE SEATS Servicing the valves, guides and valve seats must be done by a dealer or machine shop, as special knowledge and expensive machine tools are required.
  • Page 84 CHAPTER FIVE Valve head thickness 5. Remove the valve keys (2, Figure 22) and release the spring tension. 6. Remove the valve spring retainer and valve spring. CA UTION Remove any burrs from the valve stem lock grooves (Figure 24) before removing the valve to prevent damage to the valve guide.
  • Page 85 SINGLE-CYLINDER ENGINES 8. Check each spring on a flat surface with a steel square. See Figure 27. Slowly revolve the spring 360" and note the space between the top of the coil and the square. If it exceeds 1.4 mm (0.055 in.) at any point, replace the spring.
  • Page 86 CHAPTER FIVE 3. Remove the cylinder head as described in this chapter. NOTE Note the location of the long screw when re- moving the oil pan retaining screws. 4. Remove the oil pan. 5. Rotate the crankshaft until the piston is at bottom dead center.
  • Page 87 SINGLE-CYLINDER ENGINES Piston rings Piston pin Bore Connecting Rod cap with a hair dryer. Separate the piston from the connecting rod. Bolts Unless precision measuring equipment is available, have this procedure done by a machine shop. 1. Measure the piston diameter with a micrometer (Fig- ure 34) at a right angle to the piston pin bore 9 mm (0.35 2.
  • Page 88 CHAPTER FIVE Cylinder block surface 3. If the cylinder bore is damaged or excessively worn, piston is worn, but the cylinder bore is acceptable, install a Piston Ring FitIInstallation new piston. 1. Check the ring gap of each piston ring. To do this, posi- NOTE tion the ring at the bottom of the ring travel area and Provide the machine shop with the newpis-...
  • Page 103 SINGLE-CYLINDER ENGINES ing it out with an appropriate size drift or 4. Coat the inside diameter of the plug bore and the outer pin punch. When removing a large core diameter of the new plug with sealer. Use an oil-resistant plug, the use of a universal impact slide sealer if the plug is to be installed in an oil gallery or a wa- hammer is recommended.
  • Page 104 CHAPTER FIVE Table 1 ENGINE SPECIFICATIONS I1 GM. 1 OM1 01 (continued1 Camshaft Valve lobe lift 29.000 ( 1 .I417 in.) Fuel pump lobe lift in.) 22.000 (0.8661 Journal diameter in.) 20.000 (0.7874 mm max. in. max.) 0 . 0 2 (0.0008 Timing gear backlash 0.05-0.13...
  • Page 105 Chapter S i x Valve actuation is via mechanical lifters and pushrods This chapter covers the Yanmar 2GM, 2GM20, 3GM, acting on the rocker arms mounted in the cylinder head. engines. The cylinders on 2GM and 2GM20 engines are num- bered from rear (flywheel) to front (timing gearcase): 1-2.
  • Page 106 Automotive and marine engine parts may look similar; however, auto- motive parts may not be capable of operating in a harsh marine environment. Use only Yanmar parts or parts approved for use on ma- rine engines. ENGINE Precautions Some service procedures can be performed with the en- gine in the boat;...
  • Page 107 MULTICYLINDER ENGINES VALVE COVER 1. Valve cover 2. Gasket 3. O-ring 4. Decompression shaft 5. Decompression lever 6. Washer 8. Spring 9. Detent bail 10. Oil fill cap 11. O-ring 12. Nut 13. O-ring 14. Pin 15. Breather 16. Gasket 17.
  • Page 108 CHAPTER SIX VALVE COVER 3HM AND 3HM35 MODELS 1. Valve cover 2. Gasket 3. O-ring 4. Decompression shaft 5. Decompression lever 6. Washer 7. Nut 8. Spring 9. Detent ball 10. Oil fill cap 11. O-ring 12. Nut 13. O-ring 14.
  • Page 109 MULTICYLINDER ENGINES 2GM AND 2GM2O MODELS 2. Loosen the hose clamps and remove the water hose EXHAUST MANIFOLD from the exhaust elbow and thermostat housing. On 2GM models, the exhaust manifold is an elbow that 3. Remove the exhaust elbow from the cylinder head. is attached to the cylinder head (Figure 5).
  • Page 110 CHAPTER SIX EXHAUST MANIFOLD WITH CLOSED COOLING SYSTEM (TYPICAL) 1. Seawater pump 2. Hose 3. End cap 4. Gasket 5. O-ring 6. Pin 7. Heat exchanger 8. Cap 9. Filler neck 10. Gasket 11. Exhaust maniflold/reservoir 12. End cap 13. Elbow 14.
  • Page 111 MULTICYLINDER ENGINES cooling system with coolant as described in Chapter Three. CYLINDER HEAD Removal In some instances, the cylinder head may be removed for service without removing the engine. If engine re- moval is necessary, refer to the engine removal procedure. Refer to Figure 8 for an exploded view of the cylinder head assembly.
  • Page 112 CHAPTER SIX...
  • Page 113 MULTICYLINDER ENGINES Water temperature sensor CYLINDER HEAD 1. Snap ring 2. Washer 3. Bushing 4. Adjuster 5. Rocker arm 6. Nut 7. Rocker shaft stand 8. Nut 9. Washer 10. Spring 11. Washer 12. Rocker arm shaft 13. Pin 14. Locating screw 15.
  • Page 115 MULTICYLINDER ENGINES CYLINDER HEAD TIGHTENING SEQUENCE Screw Flywheel Gear 20. Adjust the valve clearance as described in Chapter Flywheel Three. 2 1. Reinstall the valve cover. ROCKER SHAFT ASSEMBLY Each valve is actuated by a rocker arm that rides on a shaft (Figure 8).
  • Page 116 CHAPTER SIX ROCKER ARMS INTAKE EXHAUST VALVE COMPONENTS 6. Inspect and measure the inside diameter of the rocker arm bushing and the outside diameter of the rocker arm shaft. Replace the rocker arm or rocker arm shaft if the measurements exceed the specifications listed in Tables NOTE The rocker arm and bushing are available 7.
  • Page 117 MULTICYLINDER ENGINES Valve Removal Refer to Figure 18 for this procedure. 1. Remove the cylinder head as described in this chapter. 2. Remove the rocker shaft assembly as described in this chapter. 3. Remove the wear cap Figure 18) on the valve stem. 4.
  • Page 118 CHAPTER SIX Exhaust valve guide Intake valve guide results with specifications in Tables 1-3. Worn guides must be replaced. 6. Test the valve springs under load on a spring tester (Figure 22). Replace any spring that does not meet the specification listed in Tables 1-3.
  • Page 119 MULTICYLINDER ENGINES OIL PICKUP 4. Reinstall the push rods by reversing the removal pro- cedure. Adjust valve clearance as described in Chapter Three. 1. Remove the engine as described in this chapter. 2. Place a suitable container under the oil pan and remove the drain plug.
  • Page 120 CHAPTER SIX Piston Pin RemovaUInstallation The steel piston pin rides directly in the piston and in a bushing in the connecting rod. Circlips at each end retain the piston pin in the piston. 1. Before removing the piston, place the crankshaft end of the connecting rod in a vise with soft jaws.
  • Page 121 MULTICYLINDER ENGINES block Bore gauge 2. Measure the cylinder bore diameter at several points with a bore gauge (Figure 32, typical). Figure 33 shows the points of normal cylinder wear. If dimension A ex- ceeds dimension B by more than 0.02 mm (0.0008 in.), 3.
  • Page 122 CHAPTER SIX 2. Measure the ring gap with a feeler gauge as shown in Figure 35. Compare the measurement with specifications in Tables 1-3. If the measurement is not within specifica- tion, the rings must be replaced as a set. Check the gap of new rings as well.
  • Page 127 MULTICYLINDER ENGINES 3. Thoroughly clean all parts in solvent and blow them dry with compressed air. 4. Check the drive spindle and pump rotors for signs of wear, scoring or damage. Replace damaged parts. NOTE The oil pump shaft andgear are pressed to- gether;...
  • Page 128 CHAPTER SIX OIL PRESSURE REGULATOR 1. Plug 2. Shim 3. Oil pressure relief sprlng 4. Oil pressure relief ball 5. Plpe 8. 0 1 1 fllter FLYWHEEL Pressure relief valve An oil pressure relief valve is located in the oil filter mounting pipe (Figure 57).
  • Page 132 CHAPTER SIX d. Install a dial indicator as shown in Figure 63 and measure crankshaft end play. Compare the mea- surement with the specification in Tables 1-3. If end play is incorrect, refer to the Main Bearings section to determine the cause. e.
  • Page 137 MULTICYLINDER ENGINES Sealing edge before Installation Strike here Removal and Installation CA UTZON Do not drive core plugs into the engine cast- ing. It will be impossible to retrieve them and they can restrict coolant circulation, re- sulting in serious engine damage. 1.
  • Page 138 CHAPTER SIX Table I ENGINE SPECIFICATIONS ( X M AND 2GM20) Bore 72 mm (2.83 in.) 75 mm (2.95 in.) Stroke 72 mm (2.83 in.) Displacement 586 cc (35.7 cu. in.) 636 cc (38.8 cu. in.) Number of cylinders Firing order 1 -2 Cyiinder liner diameter (2GM) Cylinder liner protrusion (2GM)
  • Page 139 MULTICYLINDER ENGINES Timing gear backlash 0.3 mm (0.012 in.) 0.03 mm (0.0012 in.) Push rod runout-max. Valve lifter 10.000 mm (0.3937 in.) Outside diameter 9.95 mm (0.3917 in.) Outside diameter-min. 0.01 0-0.040 mm (0.0004-0.0016 in.) Clearance in block Max. clearance 0.10 mm (0.004 in.) Valve face angle Valve seat angle...
  • Page 140 CHAPTER SIX Table 2 ENGINE SPECIFICATIONS (3GM AND 3GM30) (continued) Cylinder block warpage-max. 0.05 mm (0.002 in.) Piston diameter Standard 71.91 3-71.943 mm (2.831 2-2.8324 in.) Wear limit 71.850 mm (2.8287 in.) Standard 74.910-74.940 mm (2.9492-2.9504 in.) Wear limit 74.850 mm (2.9468 in.) Piston top clearance Piston ring side clearance Top ring...
  • Page 141 MULTICYLINDER ENGINES Table 2 ENGINE SPECIFICATIONS (3GM AND 3GM30) (continued) 0.75-1.15 mm (0.030-0.045 in.) Seat width (int. and exh.) 1.77 mm (0.070 in.) Valve depth--max. 1.25 mm (0.049 in.) Valve stem ciearance intake 0.040-0.065 mm (0.0016-0.0026 in.) Exhaust 0.045-0.070 mm (0.0018-0.0028 in.) Max.
  • Page 142 CHAPTER SIX Piston ring side clearance (continued) Oil ring 0.020-0.055 mm (0.00064.0022 in.) Ring end gap Top ring Second ring Piston pin diameter 22.991-23.000 mm (0.9052-0.9055 in.) Piston pin hole diameter in piston in rod Piston pin clearance in rod in piston 0.005 mm tight-0.017 mm loose Piston ring width...
  • Page 143 MULTICYLINDER ENGINES Table 3 ENGINE SPECIFICATIONS (3HM AND 3HM35) (continued) Valve stem clearance (continued) Max. stem clearance 0.15 mm (0.006 In.) Valve stem diameter 7.000 mm (0.2756 In.) 6.900 mm (0.2717 In.) Valve stem wear limit Valve stem runout-max. 0.03 mm (0.0012 in.) 7.000 mm (0.2756 In.) Valve guide diameter Valve guide wear limit...
  • Page 144 Chapter Seven Fuel Injection and Governor Systems This chapter describes operation of the fuel injection The major components of the diesel fuel system are the and governor systems and service procedures. Refer to fuel tank, fuel filters, injection pump and injection noz- Chapter Two for troubleshooting procedures.
  • Page 145 FUEL INJECTION AND GOVERNOR SYSTEMS FUEL INJECTION SYSTEM Fuel tank hose fuel pipe...
  • Page 146 1D and 2D, with 1D the lighter Excess fuel is routed from the injectors back to the fuel fuel. The recommended fuel for the Yanmar engines cov- tank through a fuel return line. ered by this manual is 2-D diesel fuel.
  • Page 147 FUEL INJECTION AND GOVERNOR SYSTEMS INJECTION PUMP 1. Delivery valve holder 2. O-ring 3. Spring 4. Delivery valve 5. Gasket 6. Delivery valve seat 7. Barrel 8. Gasket 9. Pump body 10. Control rack 11. Shlms 12. Plunger 13. Control sleeve 14.
  • Page 159 FUEL INJECTION AND GOVERNOR SYSTEMS GOVERNOR SYSTEM OPERATION Speed control lever Speed control handle Fuel control rack No-load Governor lever 2 Crankshaft gear Governor spring Pivot point Fuel control lever Governor weight Governor sleeve Fuel injection limiter GOVERNOR SYSTEM No-load maximum speed limiter Control lever Governor lever 1...
  • Page 160 Engine stop lever Governor level 1 weight Adjustments Yanmar recommends that only idle speed adjustment should be performed by non-authorized service techni- cians. Refer to Chapter Three for the idle speed procedure. Other adjustments, such as no-load maximum governed speed and fuel limiter screw setting, are set by the manufacturer.
  • Page 161 FUEL INJECTION AND GOVERNOR SYSTEMS GOVERNOR ASSEMBLY 1. Nut 22. Roll pin 2. Washer 23. Shaft 3. Speed control lever 24. Start spring 25. Needle bearing 4. Bracket 26. Roll pin 5. Stop lever 27. Shaft support 6. O-ring 7. Spring 28.
  • Page 162 CHAPTER SEVEN GOVERNOR ASSEMBLY 1. Nut 23. Shaft 2. Washer 24 Start spring 3. Speed control lever 25. Needle bearing 4. Bracket 26. Roll pin 5. Stop lever 27. Shaft support 6. Taper pin 28. Lockwasher 7. Lock screw 29. Bolt 8.
  • Page 163 Figure 49. Replace either spring if its free length dimension is not as specified in Table 2. If either spring is questionable, take it to a Yanmar dealer- ship for testing. 9. Remove and inspect the thrust collar (32, Figure 47 or Figure 48).
  • Page 164 CHAPTER SEVEN Table 1 TIGHTENING TORQUES Fastener Injector fuel nut Injection pump retaining nuts Table 2 GOVERNOR SPRING FREE LENGTH Main governor spring 76 mm 78 mm 78 mm (2.99 in.) (3.07 in.) (3.07 in.) 18 mm 20 mm 20 mm (0.71 in.) (0.79 in.) (0.79 in.)
  • Page 166 CHAPTER EIGHT SEAWATER COOLING SYSTEM Mixing elbow Rubber hose Drain...

  • Page 167: Cooling System

    COOLING SYSTEM SEAWATER COOLING SYSTEM (2GM AND 2GM20) U-type mixing elbow Rubber hose...
  • Page 168 CHAPTER EIGHT SEAWATER COOLING SYSTEM (3GM AND 3GM30 MODELS) 3HM AND 3HM35 Thermostat Exhaust manifold Thermostat switch cover Thermostat cover...
  • Page 169 COOLING SYSTEM CLOSED COOLING SYSTEM DIAGRAM Pressure fill cap Seawater line Freshwater line system operation is similar to the standard cooling system Freshwater (Closed) Cooling System previously described, except as follows: a. Coolant in the closed cooling system cools the en- gine block, cylinder head and exhaust manifold.
  • Page 170 CHAPTER EIGHT CLOSED COOLING SYSTEM (TYPICAL) elbow Joint...
  • Page 171 COOLING SYSTEM HEAT EXCHANGER Seawater Cooling tube outlet Freshwater inlet (from cylinder he cover THERMOSTAT coolant travels to the heat exchanger, where the heat ab- sorbed from engine operation passes through the parallel copper tubes to the water in the seawater system. The thermostat blocks coolant flow to the exhaust man- Engine cooling is thus accomplished without seawater ifold (standard cooling) or heat exchanger (closed cool-...
  • Page 173 COOLING SYSTEM Testing (Out of Engine) 1. Pour some tap water (not distilled water or coolant) into a container that can be heated. Submerge the thermo- stat in the water and suspend a thermometer as shown in Figure 13. NOTE not contact the pan.
  • Page 178 CHAPTER EIGHT equipped. Some engines are equipped with an O-ring that 3HM and 3HM35 seals between the pump and engine. 1. If the boat is in water, make sure the seacock is closed. 5. Reverse the removal steps to install the pump. Refer to 2.
  • Page 179 COOLING SYSTEM SEAWATER PUMP 1. Screw 9. Seal 2. Cover 10. Seal 3. Gasket 11. Bearing 4. Impeller 12. Shaft 5. Cam 13. Snap ring 6. Cam retaining 14. Bearing screw 15. Snap ring 7. Pump body 16. Bolt 8. O-ring 17.
  • Page 180 CHAPTER EIGHT 20. Install the cam (5, Figure 24) and the cam retaining screw (6). NOTE Replace the pump impeller anytime it is re- moved from the pump. Ifthe original impel- ler must be reused, make sure to install it in the same rotational direction as originally installed.
  • Page 181 COOLING SYSTEM SEAWATER PUMP 13. Cam retaining 2. Washer screw 3. Pulley 14. Elbow 4. Spacer 15. Elbow 5. Snap ring 16. Cam 6. Bearings 17. Impeller 7. Spacer 18. Gasket 8. Cover 19. Cover 9. Shaft 20. Screw 10. Seal ring 21.
  • Page 182 CHAPTER EIGHT SEAWATER PUMP (3HM AND 3HM35 MODELS) 1. Nut 11. Seal 2. Washer 12. Pump body 3. Pulley 13. Fitting 4. Snap ring 14. Cam retaining 5. Bearings screw 6. Snap ring 15. Cam 7. Shaft 16. Impeller 8. Key 17.
  • Page 183 COOLING SYSTEM ant or water may leak from behind the pump pulley. It is recommended that the pump be replaced as an assembly. Individual replacement parts are available. 1. Drain the freshwater cooling system. Refer to Chapter Four. NOTE proceed to Step 3. 2.
  • Page 185 COOLING SYSTEM CLOSED COOLING SYSTEM DIAGRAM Pressure fill car, Seawater line Seawater 10. Ifno signs of leakage can be found in Step 8 or Step 9, If extremely dirty or corroded, flush out the remaining yet the coolant level continues to require frequent topping deposits with a pressure flushing device.
  • Page 186 CHAPTER EIGHT FRESHWATER EXHAUST MANIFOLDIHEAT EXCHANGER 1. Pressure cap 13. Stud 2. Filler neck 14. Washer 3. Gasket 15. Nut 4. Overflow tube 16. Drain valve 5. Exhaust manifoldlheat 17. Plug exchanger 18. End cap 6. Heat exchanger core 19. Fitting 7.
  • Page 187 COOLING SYSTEM Hose Index 4. Remove the heat exchanger (Figure 38). NOTE Heat exchanger heavy scale deposits, take it to a marine dealership or automotive radiator repair shop for proper cleaning to avoid potential damage to the unit. 5. Clean all gasket residue from the end caps and heat exchanger sealing surfaces.
  • Page 188 CHAPTER EIGHT Table 1 TIGHTENING TORQUES Fastener Seawater pump All other models Freshwater pump 20-25 177-221 Table 2 RECOMMENDED THERMOSTAT Full open temperature Model Opening temperature All engines Seawater system Freshwater system...

  • Page 189: Electrical System

    Chapter Nine Electrical System Wiring diagrams are included at the end of this book. Ta- All engines covered in this manual are equipped with a ble 1 and Table 2 are located at the end of this chapter. 12-volt, negative-ground electrical system. Many electri- cal problems can be traced to a simple cause such as a NOTE blown fuse, a loose or corroded connection, a loose alter-...
  • Page 191 ELECTRICAL SYSTEM making or breaking any connection. Poor connections are a common cause of electrical arcs that cause explosions. Care and Inspection The following battery maintenance information applies to unsealed, wet-cell batteries. Although some of the pro- cedures also apply to other types of batteries, consult the battery manufacturer for specific recommendations.
  • Page 192 CHAPTER NINE BATTERY ELECTROLYTE LEVEL Float Electrolyte must be 3/16 in. above plates 10. Tighten the battery cable connections to 9 ft.-lb. (12 to the battery case. Coat the connections with petroleum jelly, or a light mineral grease. Aerosol anti-corrosion sprays can also be used.
  • Page 193 ELECTRICAL SYSTEM warm up to room temperature before charging. The bat- tery does not have to be removed from the boat before NEEDS FULLY charging, but it is a recommended procedure since a DEAD CHARGING CHARGED charging battery gives off highly explosive hydrogen gas. In many boats, the area around the battery is not well ven- tilated and the gas may remain in the area for several hours after the charging procedure has been completed.
  • Page 194 CHAPTER NINE to the alternator mounting bracket or an- other good engine ground and not the bat- tery itseg Make connections in numerical order (disconnect in reverse order 4-3-2-1) 2. Check that all jumper cables are out ofthe way of mov- ing parts on both engines.
  • Page 195 ELECTRICAL SYSTEM CHARGING SYSTEM (TYPICAL) Alternator Battery Battery or other electrical emergencies. Using the cutoff switch these basic rules could result in heat or fire damage to ma- jor parts or even the loss of the entire vessel. also prevents any electrical drain on the battery. All engines are equipped with a 30-amp fuse installed CHARGING SYSTEM in the wiring harness between the ignition switch and...
  • Page 198 CHAPTER NINE STARTER MOTOR (EXCEPT 3HM AND 3HM35 MODELS) 1. Bolt 17. Brush (pos.) 2. Lockwasher 18. Brush (neg.) 3. Drive end housing 19. Brush spring 4. Bushing 20. Brush plate 5. Dust cover 21. Commutator end cover 6. Yoke 22.
  • Page 199 ELECTRICAL SYSTEM STARTER MOTOR 18. Center plate 1. Bolt 19. Armature 2. Lockwasher 20. Washer 3. Drive end housing 21. Washer 4. Bushing 22. Frame assembly 5. Clip 23. Positive lead 6. Dust cover 24. Positive brush 7. Yoke 25. Brush plate 8.
  • Page 200 CHAPTER NINE Closed spring 11. To replace ground (negative) brushes, remove the brush lead attaching screws from the starter frame. Re- move the brushes and install new ones. 12. To replace field coil brushes, cut the insulated brush leads as close as possible to the field coils. Attach new brush leads and solder the connections together with rosin core solder and a 300-watt soldering iron.
  • Page 203 ELECTRICAL SYSTEM 3. To determine if a bulb is defective, substitute a good bulb. All warning lamps use the same type of bulb. Coolant temperature Charging System Warning Lamp sender The warning lamp for the charging circuit should illu- minate when the key switch is ON and the engine is not running, or when there is a malfunction in the charging circuit.
  • Page 206 CHAPTER TEN CONE CLUTCH flange Reverse Reverse idler gear gear SHIFTER (KM2A, KMPC AND KM3A MODELS) 1. Connector 2. Circllp 3. Spring retainer 4. Spring 5. Circllp 6. Holder 7. Cotter pin 8. Washer 9. Stud 10. Shift lever 11. Bolt 12.
  • Page 207 1. Shoulder bolt 2. Connector 3. Shift lever 4. Washer 5. Nut 6. Stop bolt 7. Shims 8. Bolt 9. Seal 10. Bolt 11. Shift body 12. O-ring 13. Shift shaft 14. Detent pin 15. Pin 16. Spring 17. Shifter forces the shifter to push the clutch cone into the gear.
  • Page 210 CHAPTER TEN Intermediate shaft 1. Remove and discard the O-ring (Figure at the end Intermediate shaft Reverse of the shaft. idler aear 2. Remove the thrust washer, gear and roller bearings. 3. Inspect the bearings, shaft and reverse idler gear inside diameter for excessive wear, grooves, metal transfer and discoloration from overheating.
  • Page 211 OUTPUT SHAFT 1. Shims 2. Nut (LH) 3. Washer 4. Roller bearing 5. Thrust washer 6. Retainer (KM2P and KM3P) 7. Spring cup (KM2P and KM3P) 8. Forward gear 9. Needle bearing 10. Inner bearing race 11. Thrust washer 12. Pin 13.
  • Page 212 CHAPTER TEN 1. Connector 12. Seal 2. Circlip 13. Setscrew 14. Spring 15. Detent pin 16. Body 6. Holder 17. Gasket 18. Plug 7. Cotter pin 8. Washer 19. O-ring 9. Stud 20. Bearing 10. Shift lever 21. Shift shaft 11.
  • Page 213 h. Tighten the nut (left-hand threads) to the torque Neutral hole specified in Table 2. i. Make sure the gears rotate freely. j. Stake the nut to lock the nut in place. Refer to Figure 20. 1. Ifnot previously removed, detach the cotter pin and re- move the actuator from the shift lever.
  • Page 214 CHAPTER TEN 14. Reassemble the shifter by reversing the disassembly procedure. Note the following during reassembly: a. Apply sealant to the detent setscrew threads. b. Install the shift lever-on the shift shaft while align- ing the marks made during disassembly. c.
  • Page 215 1. Shoulder bolt 2. Connector 3. Shift lever 4. Washer 5. Nut 6. Stop bolt 7. Shims 8. Bolt 9. Seal 10. Bolt 11. Shift body 12. O-ring 13. Shift shaft 14. Detent pin 15. Pin 16. Spring 17. Shifter...
  • Page 216 CHAPTER TEN bearings. After adjusting the bearings, continue to reas- semble the transmission as described in the following steps. If the preceding components have not been re- placed, bearing adjustment is not necessary and the orginal shims may be reused. Proceed to the following step.
  • Page 217 g. Apply sealer to the stop bolt threads, but not to the Input shaft threads at the end of the bolt (approximately 0.20 in.). Install the stop bolt into the shifter. Output shaft BEARING ADJUSTMENT Perform the following procedure if the following com- ponents have been replaced: input shaft, input shaft bear- ings, output shaft, thrust washers and output shaft bearings.
  • Page 218 CHAPTER TEN 1. Install the input shaft assembly in the transmission case. 2. Position the transmission case so the open end is up. 3. Install the outer bearing race on the input shaft tapered bearing. 4. Measure the distance (A, Figure 30) in millimeters from the mounting flange mating surface on the case to the top of the bearing race.
  • Page 220 CHAPTER TEN Table 1 ENGINEITRANSMISSION MODELS Transmission ratio Model Transmission (forward gear) KBWlOD KBWlOD KBWlOE KBWlOE Table 2 TIGHTENING TORQUES Fastener Transmission mounting flange Output shaft nut Output flange nut Drive disc Table 3 CLUTCH DEPTH Normal depth Wear limit 24.4-24.7 24.1 in.)
  • Page 221 Table 5 OUTPUT SHAFT (continued) Spring cup (KMSP, KM3P) 2.8-3.1 mm 2.6 mm (0.110-0.122 in.) (0.102 in.) Spring cup retainer (KM2P; KM3P) 2.92-3.08 mm 2.8 mm (0.1 15-0.121 in.) (0.110 in.) Table 6 SHIFTER (KMZA, KM2C AND KM3A) Shifter width 7.80-7.85 mm (0.3071 -0.3091 in.) Standard 7.7 mm (0.303 in.)
  • Page 222 Chapter Eleven Transmission-KBW Series This chapter covers the Kanzaki Hurth KBWlOD and 1 for a cross-reference of engine and transmission models. The identification plate (Figure 1) located on the trans- MARINE GEAR MOML mission case specifies the transmission model. The KBWlO series transmissions covered in this chap- ter are inline transmissions that provide forward and re- OIL OTY.
  • Page 223 Be careful not to damage special tools, which can be obtained from the case or the adjacent bearing race. Yanmar or fabricated. I f the special tools 19. If inspection indicates additional disassembly is nec- are not available, have a Yanmar dealership essary, refer to the following sections.
  • Page 224 CHAPTER ELEVEN...
  • Page 225 TRANSMISSION-KBW SERIES TRANSMISSION 36. Thrust washer 1. Mounting flange 37. Bearing 2. Shim 3. Output shaft 38. Seal 39. Shim 4. Key 40. Bearing 5. Bearing 6. Thrust washer 41. Input shaft 7. Bearing inner race 42. Bearing 43. intermediate shaft 8.
  • Page 226 10 O-ring on the shaft. Check that the idler rotates freely on the shaft. Place a pulling support plate (such as Yanmar special tool 17099-09030) between the collar of the output shaft Output shaft and bearing.
  • Page 227 TRANSMISSION-KBW SERIES 2. Inspect the output shaft bearings and seal surfaces for excessive wear, grooving, metal transfer and discolor- ation from overheating. 3. Inspect the key and output shaft keyway for damage. NOTE Shims behind the outer bearing race in the mounting flange determine bearing preload for the output shaft bearings.
  • Page 228 (12, Figure 3) over the Belleville springs and slide the snap ring onto the spline of the for- ward gear. Using Yanmar special tool 177095-09070, or a suitable equivalent tool, compress the forward gear as- sembly in a vise and engage the snap ring in the groove 4.
  • Page 229 11. Fit the key (4, Figure 3) into the slot on the output shaft so the fillet side of the key faces the threaded end of the output shaft. 12. Install the pressure plate, with the ball slots facing up, so the steel plate tangs fit into the three slots in the pres- Snap ring sure plate.
  • Page 230 CHAPTER ELEVEN 3. Push in the detent pin, remove the snap ring and re- move the pin and springs. 4. Use a screwdriver or suitable tool to pry out the seal. 5. Inspect the shift ring. Cfieck the detent notch for exces- sive wear that will allow poor clutch engagement.
  • Page 232 CHAPTER ELEVEN Table 1 ENGlNErrRANSMlSSlON MODELS Model Transmission Transmission ratio (forward gear) 2.14, 2.63 or 2.83 2.14 or 2.83 2.14 or 2.83 Table 2 TIGHTENING TORQUES Fastener Transmission mounting flange Output shaft nut Output flange nut Drive disc Table 3 CLUTCH SPECIFICATIONS 1.4-1.7 mm (0.055-0.067 in.) Steel plate warpage 11 .8-12.0 mm (0.464-0.472 in.)
  • Page 233 Index block ....... multicylinder 128- 13 1 Alarm buzzer ....single-cylinder 95-97 head...

  • Page 234: Torque Specifications

    INDEX Engine stopping the emergency stopping troubleshooting exhaust smoke tune-up 5 7-60 troubleshooting Exhaust manifold maintenance and lubrication 44-52 multicylinder 103-105 multicylinder 100- 10 1 breather assembly 10 1 . 102 camshaft 127- 128 Fasteners crankshaft 123-126 Fitting out 66-67 cylinder Flywheel 128-13 1...

  • Page 236: Battery

    INDEX Tune-up cover battery multicylinder engine tune-up 57-60 ....single-cylinder Valve and seats ....Warning lamps .

  • Page 237: Senders

    WIRING DIAGRAMS 23 1 EARLY MODELS WITH LARGE INSTRUMENT PANEL Coolant temp. warning i a r n p G Z G Oil pressure warning lamp Rubber seal lamp (Sail-drive) less than 6m. Tachometer Diagram Color Code Coolant Tachometer Black White temp.

  • Page 238: Wiring Diagrams

    WIRING DIAGRAMS EARLY MODELS WITH SMALL I N S TR U MENT P AN E L ( NO TACHOMETER ) Push button Coolant temp. warning lamp Color Code Black White Coolant Gmund temp. prwaura Blua Orange No connection...

  • Page 239: Instrument Panel

    WIRING DIAGRAMS LATE MODELS WITH LARGE INSTRUMENT PANEL Coolant temp. warning lamp Oil pressure warning lamp Rubber seal lamp (Sail-drive) less than 6m. Tachometer Buzzer Diagram Key Color Code Black Tachometer Connectors White temp. pressure sender switch switch Ground Blue Orange Frame ground No connectlon...
  • Page 240 WIRING DIAGRAMS LATE MODELS WITH SMALL INSTRUMENT PANEL (NO TACHOMETER) . . . Coolant temp. warning lamp warning lamp connector Color Code Black White Ground Blue Orange Coolant temp. pmssum No connection...

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