User Manuals: Yanmar 2GM20C Marine Diesel Engine

Manuals and User Guides for Yanmar 2GM20C Marine Diesel Engine. We have 3 Yanmar 2GM20C Marine Diesel Engine manuals available for free PDF download: Service Manual, Operation Manual

Yanmar 2GM20C Service Manual (464 pages)

Yanmar Marine Diesel enginesines Service manual

Brand: Yanmar | Category: Engine | Size: 14 MB

Contents
3
Engine Model Name
5
Engine Model Name Plate and Clutch Model Name Plate
5
Item Descriptions on the Model Name Plates and Information to be Forwarded to Us
5
Location of Engine Model Name Plate and Clutch Model Name Plate
6
Cylinder Number
7
Location of Stamped Engine Serial Number
7
General
8
Specifications
9
Principal Construction
12
Performance Curves
13
Features
17
Engine Cross-Sections
18
Dimensions
25
Piping Diagrams
32
Basic Engine
37
Cylinder Block Construction
38
Cylinder of Model 1GM10(C) Engine
38
Cylinder of Model 2GM20(F)(C) Engine
39
Cylinder of Model 3GM30(F)(C) Engine
39
Cylinder of Model 3HM35(F)(C) Engine
40
Cylinder Block Inspection
40
Inspecting each Part for Cracks
40
Inspecting the Water Jacket of the Cylinder for Corrosion
40
Cylinder Bore Measurement
41
Oil and Water Passages
41
Color Check Flaw Detection Procedure
41
Boring the Cylinder
43
Measurement of Distortion on the Upper Surface of the Cylinder
44
Purpose of Cup Plug
45
How to Drive in the Cup Plug
45
Cylinder Head Construction
46
Cylinder Head of Model 1GM10(C) Engine
46
Cylinder Head of Model 2GM20(F)(C) Engine
47
Cylinder Head of Models 3GM30(F)(C) and 3HM35(F)(C)
48
Cylinder Head Inspection and Measurement
49
Measurement of Carbon Build-Up at Combustion Surface and Intake and Exhaust Ports
49
Deposit Build-Up in Water Passages
49
Inspection of Corrosion in Water Passages and Anti-Corrosion Zinc
49
Measuring Valve Sinkage
50
Dismounting and Remounting the Cylinder Head
51
Rocker Arm Support Positioning Pin
51
Cylinder Head Assembly Sequence
51
Tightening the Cylinder Head Bolts and Nuts
52
Cylinder Head Nut Loosening Sequence
53
Intake and Exhaust Valves, Valve Guide and Valve Spring
54
Inspecting and Measuring the Intake and Exhaust Valves
54
Inspecting and Measuring Valve Guides
55
Valve Spring
56
Precombustion Chamber and Top Clearance
57
Valve Stem Seal
57
Spring Retainer and Spring Cotter Pin
57
Intake and Exhaust Valve Rocker Arm
58
Insulation Packing
58
Components of Valve Rocker Arm
58
Measuring the Valve Rocker Arm Shaft and Bushing Clearance
60
Valve Rocker Arm and Valve Top Retainer Contact and Wear
60
Valve Clearance Adjusting Screw
60
Classification of the Intake and Exhaust Valve Rocker Arms
60
Adjusting Intake and Exhaust Valve Head Clearance
61
Decompression Mechanism
62
Adjusting Without a Feeler Gauge
62
Disassembling and Reassembling Cylinder Head
63
Piston Assembly Construction
65
Piston Inspection
65
Replacing a Piston
66
Piston Pin
67
Piston Pin Bushing
67
Piston Ring Configuration
68
Piston Rings Inspection
68
Connecting Rod Ass'y Construction
71
Connecting Rod Inspection
71
Crank Pin Bushing
71
Crank Pin and Bushing Clearance (Oil Clearance)
72
Tightening the Connecting Rod Bolts
73
Connecting Rod Side Clearance
73
Crank Pin Bushing Replacement Precautions
73
Piston Bushing and Piston Pin
74
Replacing the Piston Pin Bushing
74
Crankshaft Ass'y and Bearing Construction
75
Constructions of Models 2GM20(F)(C), 3GM30(F)(C) and 3HM35(F)(C) Crankshaft Assembly
76
Crank Journal and Crank Pin
77
Crankshaft Side Gap
79
Disassembly of the Crankshaft
80
Side Gap Maintenance Standard and Wear Limit
80
Main Bearing Construction
82
Inspecting the Crank Bearing
82
Inspecting the Thrust Metal
83
Inspecting the Intermediate Main Bearing
83
Replacing the Crank Bearing
84
Crankshaft Oil Seal
85
Oil Seal Insertion Precautions
85
Oil Seal Type and Size
85
Flywheel and Housing
86
Specifications of Flywheel
86
Dimensions of Flywheel and Flywheel Housing
87
Ring Gear
89
Position of Top Dead Center
89
Construction of the Camshaft
90
Camshaft of Engine Model 1Gm10(C)
90
Camshaft of Engine Model 2GM20(F)(C)
91
Camshaft of Engine Models 3GM30(F)(C) and 3HM35(F)(C)
91
Valve Timing Diagram
92
Camshaft Inspection
92
Camshaft Height
92
Journals of Camshaft
92
Camshaft Ball Bearing
93
Tappets
93
Camshaft Deflection
93
Push Rods
94
Fuel Cam Check
94
Fuel Cam Assembly Precautions
94
Timing Gear Train Construction
96
Timing Gear of Model 1GM10(C)
96
Timing Gear of Models 2GM20(F)(C), 3GM30(F)(C) and 3HM35(F)(C)
97
Disassembly and Reassembly of the Timing Gear
98
Backlash Inspection
99
Inspecting the Gear Tooth Surface
100
Inspecting the Gear Boss
100
Fuel System
101
Fuel Injection System
102
Fuel Injection System Construction
103
Fuel Injection System Specifications
103
Injection Pump Construction
104
Specifications and Performance of Fuel Injection Pump
109
Injection Volume Characteristics of Fuel Injection Pump
109
Operation of Fuel Injection Pump
111
Fuel Control
112
Action of the Delivery Valve and the Sucking-Back of Fuel
112
Disassembly of Fuel Injection Pump
113
Dismantling of Fuel Pump of Model 2GM20(F)(C), 3GM30(F)(C) and 3HM35(F)(C)
114
Inspecting Injection Pump Parts
115
Plunger
116
Delivery Valve
116
Assembling the Fuel Injection Pump
117
Plunger Spring and Delivery Valve Spring
117
Plunger Guide
117
Inspection after Reassembly
121
Control Rack Resistance Test
121
Fuel Injection Timing
121
Injection Pump Adjustment
123
Setting Pump on Tester
123
Measuring the Sliding Resistance of the Fuel Control Rack
123
Adjusting the Plunger Top Clearance
123
Checking the Cylinder Injection Interval
124
Delivery Valve Oil-Tight Test
124
Plunger Pressure Test
124
Measuring the Fuel Injection Volume
124
Adjustment of Injection Volume for each Cylinder
125
Injection Nozzle Construction
126
Specifications for Nozzle Valve
126
Yanmar Throttle Nozzle
127
Nozzle Operation
127
Injection Nozzle Disassembly and Reassembly
127
Injection Nozzle Inspection and Adjustment
128
Carbon and Corrosion on the Nozzle Body
128
Checking Nozzle Action
128
Adjusting the Nozzle Injection Pressure
129
Nozzle Seat Oil Tightness Check
129
Checking the Spray Condition
129
Inspecting the Nozzle Spring
129
Fuel Filter Construction
130
Fuel Filter Specifications
130
Fuel Filter Inspection
130
Fuel Feed Pump Construction
131
Fuel Feed Pump Specifications
131
Fuel Feed Pump Disassembly and Reassembly
132
Inspecting and Adjusting the Fuel Feed Pump
132
Checking the Pump for Fuel Oil Leaks
132
Checking the Pump for Engine Oil Leaks
132
Aging, Breakdown and Cracking of the Diaphragm
133
The Contact Area and Mounting Condition of Valve
133
Diaphragm Spring and Rocker Arm Spring
133
Fuel Tank (Option)
134
Fuel Tank Dimension
135
Governor
136
Governor Construction
137
Governor Operation
141
Governor Performance
141
Governor Disassembly
142
Governor Parts Inspection and Replacement
142
Regulator Spring
142
Sleeve
143
Thrust Collar
143
Thrust Needle Bearing
143
Governor Weight
143
Regulator Lever and Handle
144
Injection Limiter Construction
145
Injection Limiter Inspection
145
Injection Limiter Adjustment
145
No-Load Maximum Speed Limiter Construction
147
No-Load Maximum Speed Limiter Handling Precautions
147
Idling Adjuster
148
Engine Stop Lever Construction
149
Engine Stop Lever Inspection
149
Intake and Exhaust System
150
Intake and Exhaust System of Model 1GM10(C)
151
Intake and Exhaust System of Model 2GM20(F)(C)
151
Intake and Exhaust System of Models 3GM30(F)(C) and 3HM35(F)(C)
152
Intake Silencer Construction
153
Inspection of the Intake Silencer
153
Washing the Intake Silencer Element
153
Exhaust System
154
Exhaust Manifold and Mixing Elbow
154
U Type Mixing Elbow
154
Exhaust Manifold Inspection
155
Mixing Elbow Inspection
155
Construction of Breather
156
Breather for Model 1GM10(C)
156
Breather for Models 2GM20(F)(C) and 3GM30(F)(C)
156
Breather for Model 3HM35(F)(C)
157
Lubrication System
158
Lubricating Oil Passage of Model 1GM10(C)
159
Lubrication Oil Passage of Model 2GM20(F)(C)
160
Lubrication Oil Passage of Model 3GM30(F)(C) and 3HM35(F)(C)
161
Table of Capacity for Lubricating Oil System
162
Oil Pump Construction
163
Lubricating Oil Pump on Model 1Gm10(C)
163
Lubricating Oil Pump on Models 2GM20(F)(C), 3GM30(F)(C) and 3HM35(F)(C)
164
Specifications of Lubrication Oil Pump
164
Oil Pump Disassembly
165
Oil Pump Inspection
166
Outer Rotor and Pump Body Clearance
166
Outer Rotor and Inner Rotor Clearance
166
Pump Body and Inner Rotor, Outer Rotor Side Clearance
166
Oil Filter Construction
167
Oil Filter Replacement
168
Replacing the Oil Filter
169
In Case of Oil Leakage
169
Oil Pressure Regulator Valve Construction
170
Oil Pressure Regulator Valve Specifications
171
Oil Pressure Measurement
172
Direct Sea-Water Cooling System
173
Cooling System Composition
174
Cooling Water Route
174
Piping
174
Cooling Water Passage of Engine Model 1GM10(C)
175
Cooling Water Passage of Engine Model 2GM20(C)
176
Cooling Water Passage of Engine Models 3GM30(C) and 3HM35(C)
177
Water Pump Construction and Operation
178
Cooling Water Pump of Engine Model 1GM10(C)
178
Cooling Water Pump of Engine Models 2GM20(C) and 3GM30(C)
179
Cooling Water Pump of Engine Model 3HM35(C)
180
Water Pump Disassembly
181
Water Pump Specifications
181
Water Pump Reassembly Precautions
182
Water Pump Handling Precautions
182
Water Pump Inspection
182
Thermostat Construction and Operation
184
Thermostat Inspection
185
Care Must be Taken When Assembling the Thermostat
186
Anticorrosion Zinc Principles
187
Anticorrosion Zinc Inspection
188
Kingston Cock Construction
189
Kingston Cock Handling Precautions
189
Kingston Cock Inspection
189
Bilge Strainer
190
Bilge Pump Specifications
190
Bilge Pump Performance
190
Fresh Water Cooling System
191
Cooling System Diagrams
192
Cooling System Configuration
193
Sea Water Pump
194
Fresh Water Pump Construction
195
Pump Capacity and Characteristic
196
Pump Disassembly
196
Pump Inspection and Measurement
196
Heat Exchanger Construction
198
Water Flow in Water Cooling Tube
200
Heat Exchanger Specifications
200
Heat Exchanger Disassembly
201
Heat Exchanger Inspection and Cleaning
201
Cooling Pipe
201
Heat Exchanger Body
201
Filler Cap Construction
202
Filler Cap Pressure Control
202
Filler Cap Inspection
202
Subtank Function
202
Installation of Subtank
203
Maintenance During Use
203
Thermostat Operation
204
Thermostat Construction
205
Cooling Water Temperature Switch
207
Precautions
208
Ventilator
208
Cooling Water
208
Antifreeze
208
Rust Inhibitor
209
Idling the Engine When Stopping
209
Cleaning the Heat Exchanger Tube
209
Modifying the Cooling System
210
Direct Sea Water-Cooled Engine and Fresh Water-Cooled Engine
211
Modification Method
211
Testing a Modified Engine
211
Kit for Modification into a Fresh Water-Cooled Engine
211
Disassembly of Sea Water-Cooled Engine
212
Drain the Cooling Sea Water
212
Remove the Cooling Water Pipe
212
Remove the Fuel Oil Pipe
212
Remove the Fuel Filter
213
Remove the Remote Control Bracket
213
Remove the Mixing Elbow
213
Remove the Exhaust Manifold
213
Remove the Thermostat Cover
214
Remove the Thermostat Bracket
214
Remove the Cooling Water By-Pass Connection
214
Remove the CSW Pump
214
Remove the Intake Silencer
215
Remove the Fuel High Pressure Pipe
215
Remove the Lifting Hook at the Front of the Engine
215
Remove the Lifting Hook at the Rear or the Engine Together with the Rear Cylinder Head Cover
215
Assembling Modified Parts to the Fresh Water-Cooled Engine
217
Assemble the Rear Cylinder Head Cover Together with the Rear Lifting Hook
217
Assemble the Front Lifting Hook
217
Assemble the Fuel Injection Tube
217
Assemble the CFW Joint to the Cylinder Block
218
Assemble the CFW Pump Assembly
218
Assemble the CFW Hose
218
Assemble the CSW Pump
218
Assemble the Heat Exchanger
219
Assemble the Fuel Filter
219
Assemble the Fuel Oil Pipe
219
Assemble the Mixing Elbow
220
Connect the CSW Hose between the Head Exchanger and Mixing Elbow and Tighten the Hose Clamp
220
Assemble the CFW Pump V-Belt Pulley
220
Assemble the Alternator
220
Assemble the Remote Control Bracket
221
Cautions When the Engine Is Installed Inboard
222
Reduction and Reversing Gear
223
Construction
224
Power Transmission System
226
Arrangement of Shafts and Gears
226
Reduction Ratio
226
Power Transmission Routine - Forward
227
Power Transmission Routine - Reverse
227
Drawing
228
Construction of Shifting Device
230
Action of the Shifting Device
231
Changing from Neutral to Forward
231
Engagement from Forward to Neutral
232
Clutch Shifting Force
233
Adjustment
233
Inspect for the Following Points
236
Inspection and Servicing
237
Clutch Case
237
Bearing
237
Gear
237
Oil Seal of Output Shaft
239
Input Shaft
239
Output Shaft
239
Intermediate Shaft
239
Notch Slot of Shift Lever Shaft
240
Notch
240
Notch Spring
240
Spring Joint
241
Damper Disc
241
Disassembly
242
Dismantling the Clutch
242
Removal of the Output Shaft
244
Removal of the Intermediate Shaft
245
Dismantling the Side Cover Assembly (Shifting Device)
246
Reassembly of Output Shaft
247
Reassembly of the Clutch
248
Reassembly of the Shifting Device
250
Reduction and Reversing Gear Installation
256
Remote Control Unit
256
Reduction and Reversing Gear Operation and Maintenance
257
Lube Oil
257
Side Cover
257
Friction Plate
259
Pressure Plate
259
Driving Plate
260
Retainer
260
Plate Spring
260
Shift Ring
261
Shift Fork and Shift Lever
261
Reassembling the Input Shaft
270
Reassembling the Intermediate Shaft
270
Installing the Input Shaft and Output Shaft
270
Reassembling and Installing the Operating System
271
Installing the Output Shaft Coupling
272
Marine Gear Models KM2P, KM3P and KM3V
273
Forward and Reverse Clutch Operation
280
Engagement and Disengagement of Clutch
280
Adjustment of Shifting Device
281
Measurement and Adjustment of Clearance
282
Adjustment of the Remote Control Head
283
Marine Gearbox Control Side
283
V-Drive Gear, Model KM3V
300
KM3V Sectional View
301
Shim Adjustment for V-Drive Gear Shaft, and Backlash Adjustment for V-Drive Gear Shaft and Drive Gear
315
Backlash Adjustment for V-Drive Near Shaft and Drive Gear
316
Dismantling the V-Drive Assembly
317
Drain the Cooling Water from the Lube Oil Cooler
317
Remote Control System
323
Clutch and Speed Regulator Remote Control
326
One-Handle Remote Control Composition
326
Engine Side Installation
327
Movement of Lever for Model 1GM10(C)
327
Setting the Reduction and Reversing Gear Side
328
Movement of Lever for Models 2GM20(F)(C), 3GM30(F)(C) and 3HM35(F)(C)
328
Engine Stop Remote Control
330
Electrical System
331
Electrical System Diagram of Electric Parts
332
Wiring Diagram
333
Battery Construction
335
Battery Capacity and Battery Cables
335
Battery Inspection
335
Checking the Electrolyte
336
Voltage Test
336
Washing the Battery
336
Battery Charging
337
Battery Storage Precautions
337
Battery Charging Precautions
337
Starter Motor Specifications and Performance
338
Starter Motor Construction
338
Starter Motor Operation
340
Starter Motor Adjustment and Performance Test
340
L-Size Measurement (Gap between Pinion and Pinion Stopper)
340
Pinion Movement
340
Starter Motor Disassembly
341
Plunger Movement
341
Pinion Lock Torque Measurement
341
Mesh Clearance
341
Starter Motor Rear Cover
342
Starter Motor Brush Holder
342
Starter Motor Yoke
342
Starter Motor Armature
342
Starter Motor Inspection
343
Armature
343
Field Coil
344
Brush
344
Starter Motor Reassembly Precautions
346
Starter Motor no Load Test
347
Starter Motor Maintenance Standard
347
Various Problems and Their Remedies
348
Alternator Features
349
Alternator Specifications
349
Alternator Characteristics
349
Alternator Construction
350
Alternator Functioning
351
Alternator Handling Precautions
351
Alternator Disassembling the Alternator
352
Alternator Inspection and Adjustment
353
Alternator Reassembling the Alternator
355
Alternator Performance Test
356
Alternator Troubleshooting
357
Charging Failure
357
Overcharging
358
Charge Lamp Failure
358
Alternator, Option, 12V/35A
359
Alternator, Option, 12V/35A Wiring
361
Alternator, Option, 12V/35A Circuit Diagram
361
Alternator, Option, 12V/35A Principle of IC Regulator Function
361
Alternator, Option, 12V/35A Inspection and Adjustment
363
Alternator, Option, 12V/35A Diodes
363
Alternator, Option, 12V/35A Rotor
363
Alternator, Option, 12V/35A Stator Coil
364
Alternator, Option, 12V/35A Brush
364
Alternator, Option, 12V/35A Reassembly Precautions
365
Alternator, Option, 12V/35A Checking IC Regulator Unit
365
Alternator, Option, 12V/35A Performance Test
366
Alternator, Option, 12V/35A Standards of Adjustment
366
Alternator, Option, 12V/35A Troubleshooting and Repair
367
B-Type Instrument Panel
368
A-Type Instrument Panel
368
Key Switch
369
Push Button Switch
369
Warning Devices
370
Oil Pressure Alarm
370
Cooling Water Temperature Alarm
370
Alarm Buzzer
371
Buzzer for B-Type Instrument Board
371
Buzzer for A-Type Instrument Panel
372
Construction of Tachometer
374
Specifications and Dimensions of Tachometer
374
Measurement of Sensor Unit Characteristics
375
Operating Instructions
377
Fuel Oil and Lubricating Oil
378
Properties of Fuel
378
Recommended Fuels
378
Fuel Selection Precautions
378
Properties and Compositions of Fuel of Various National Standards
379
Simple Methods of Identifying Fuel Properties
380
Troubles Caused by Bad Fuel
380
Relationship between Fuel Properties and Engine Performance
380
Fuel Handling Precautions
381
Action of the Lubricating Oil
381
Required Lubricating Oil Conditions
381
Classification by Viscosity
381
SAE Service Classification and API Service Classification
382
Recommended Lubricating Oils
383
Engine Oil Replacement and Handling
383
Adding Oil
383
Oil Capacity
384
Engine Operating Instructions
385
Preparations before Starting
385
Adding Lubricating Oil
385
Bleeding the Fuel System
385
Starting and Warm-Up
386
Checking for Abnormal Sounds by Cranking
386
Checking the Electrical System
386
Checking Appearance and Exterior
386
Starting with One-Handle Remote Control
387
After Starting
387
Operation
388
Stopping
388
Checks During Operation
388
Operating Precautions
388
Storage When Moored for an Extended Period
389
Emergency Stop
389
Troubleshooting and Repair
390
Troubles and Corrective Action at Starting
390
Troubles and Corrective Action During Operation
391
Disassembly and Reassembly (Direct Sea-Water Cooling Engine)
393
Disassembly and Reassembly Precautions
394
Disassembly and Reassembly Tools
395
Supplementary Packing Agent
406
Paint
406
Yanmar Cleaner
406
Neji Lock Super
406
Disassembly General Precautions
407
Dismantling Engine Model 1GM10(C)
407
Open the Cooling Water Drain Cock and Drain the Cooling Water
407
Drain the Lubricating Oil
407
Remove the Air Intake Silencer
408
Disconnect the Fuel Piping
408
Remove the Starter Motor
408
Remove the Alternator
408
Remove the Rocker Arm Chamber
409
Remove the Rocker Arms
409
Remove the Cylinder Head
409
Remove the Crankshaft Pulley
409
Remove the Timing Gear Case
410
Remove the Clutch Assembly
410
Remove the Flywheel
410
Remove the Flywheel Housing
410
Remove the Feed Pump
411
Remove the Governor Weight Assembly
411
Remove the Camshaft Gear
411
Remove the Crankshaft Gear and the Lubricating Oil Pump
411
Turn the Engine Onto Its Side
412
Remove the Oil Pan and the Oil Intake Pipe
412
Remove the Piston Connecting Rod Assembly
412
Remove the Main Bearing Housing
412
Dismantling Engine Models 2GM20(C) and 3GM30(C)
413
Remove the Camshaft
413
Remove the Tappets
413
Disconnect the Remote Control Cables
414
Disconnect the Electrical Wiring
414
Disconnect the Cooling Water Inlet Pipe and Bilge Pipe
414
Remove the Oil Filter
415
Install the Flywheel
431
Install the Clutch Assembly
431
Install the Lubricating Oil Pump
431
Assemble the Camshaft Gear and Fuel Cam
431
Assemble the Crankshaft Gears
432
Install the Governor Sleeve
432
Install the Timing Gear Case
432
Install the Crankshaft V-Pulley
433
Install the Water Pump
433
Install the Fuel Injection Pump
433
Install the Cylinder Head
433
Install the Rocker Arms
434
Install the Rocker Arm Cover
434
Install the Exhaust Manifold and the Mixing Elbow
435
Install the Fuel Pipe
435
Install the Starter Motor
435
Install the Intake Silencer
435
Connect the Electrical Wiring
436
Install the Remote Control Cables
436
Disassembly and Reassembly (Fresh Water Cooling Engine)
437
Disassembly of Fresh Water-Cooled Engine
438
Draining the Cooling Water
438
Reassembly of Fresh Water-Cooled Engine
448
Main Bolt and Nut Tightening Torque
458
Packing Supplement and Adhesive Application Points
461

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