Yanmar 2GM20F Manuals

Manuals and User Guides for Yanmar 2GM20F. We have 5 Yanmar 2GM20F manuals available for free PDF download: Service Manual, Shop Manual, User Manual, Operation Manual

Yanmar 2GM20F Service Manual (464 pages)

Yanmar Marine Diesel enginesines Service manual

Brand: Yanmar | Category: Engine | Size: 14.15 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

Yanmar 2GM20F Shop Manual (241 pages)

Brand: Yanmar | Category: Engine | Size: 63.39 MB

Table of Contents
3
Freshwater (Closed) Cooling System Capacity
6
Quick Reference Data
6
Tune-Up Specifications
6
Approximate Engine Oil Capacities
6
General Torque Specifications
7
Chapter One

8
- General Information
  8
- Manual Organization
  8
  - Service Hints
    10
  - Fasteners
    11
  - Parts Replacement
    11
  - Torque Specifications Info
    11
  - Bolts
    12
  - ISO Metric Screw Threads
    12
  - Machine Screws
    12
  - Machine Screws View
    13
  - Nuts
    13
  - Openings for Tools View
    13
  - Self-Locking Fasteners
    13
  - Cotter Pins
    14
  - General Information
    14
  - Washers
    14
  - Circlips
    15
  - Engine Oil
    15
  - Lubricants
    15
  - Basic Hand Tools
    16
  - Grease
    16
  - RTV Gasket Sealant
    16
  - Threadlock
    16
  - Screwdrivers
    17
  - Circlip Pliers
    18
  - Locking Pliers
    18
  - Pliers
    18
  - Adjustable Wrenches
    19
  - Box-End, Open-End and Combination Wrenches
    19
  - Socket Wrenches
    19
  - Torque Wrench, Impact Driver
    19
  - Feeler Gauge
    20
  - Hammers
    20
  - Precision Measuring Tools
    20
  - Cylinder Bore Gauge
    21
  - Dial Indicator
    21
  - Outside Micrometers
    21
  - Telescoping Gauges
    21
  - Battery Hydrometer
    22
  - Compression Gauge
    22
  - Multimeter or vom
    22
  - Screw Pitch Gauge
    22
  - Expendable Supplies
    23
  - Mechanic's Tips
    23
  - Removing Broken Screws or Bolts
    23
  - Removing Frozen Nuts and Screws
    23
  - Remedying Stripped Threads
    24
  - Removing Broken or Damaged Studs
    24
  - Bearing Removal
    25
  - Bearing Replacement
    25
  - Bearing Installation
    26
  - Shrink Fit
    27
  - Seals
    30
  - Decimal and Metric Equivalents Table
    31
Chapter Two

32
- Parts Replacement
  32
- Charging System Tests
  37
  - Charging System Troubleshooting
    37
  - Alternator Current Output Test
    38
  - Fuel System Troubleshooting
    38
  - Voltage Output Test
    38
  - Engine Speed Decreases Unexpectedly
    39
  - Engine Stops Suddenly
    39
  - Engine will Not Run under Full Load
    39
  - Engine will Not Start
    39
  - Cooling System Troubleshooting
    40
  - Engine Overheating
    40
  - Fuel Injection System Diagram
    40
  - Black Smoke
    41
  - Blue Smoke
    41
- Engine Noises
  41
- White Smoke
  41
- Cooling System
  42
- Engine Misses
  42
- Engine Troubleshooting
  42
Chapter Three

48
- Starting Checklist
  49
  - Operation, Lubrication, Maintenance and Tune-Up
    48
  - Preoperational Checks
    48
    
    Ruel Requirements
    48
    
    Engines Equipped with Remote Control
    49
    
    Engines Without Remote Control
    49
    
    Emeregency Engine Stopping
    50
    
    Engine Maintenance and Lubrication
    50
    
    Post-Operatinal Checks
    50
    
    Stopping the Engine
    50
    
    Engine Oil and Filter Change
    51
    
    Engine Oil Level Check
    51
    
    Fuel System Service
    52
    
    Fuel Filter
    53
    
    Fuel Lines
    53
    
    Air Filter
    54
    
    Bleeding Air from Fuel System
    54
    
    Drive Belts
    54
    
    Alternator Drive Belt Adjustment (Models Equipped with Freshwater Cooling)
    55
    
    Alternator Drive Belt Adjustment (Models Equipped with Seawater Cooling)
    55
    
    Seawater Pump Drive Belt Adjustment (2GM, 2GM20, 3GM, 3GM30, 3HM and 3HM35 Models)
    55
    
    Alternator Drive Belt Replacement (All Models)
    56
    
    Crankcase Breather
    56
    
    Seawater Pump Drive Belt Replacement
    56
    
    Anticorrosion Maintenance
    57
    
    Cooling System
    58
    
    Anode Mountings Diagram
    59
    
    Flushing the System
    59
    
    Seawater (Standard) Cooling Systems
    59
    
    Coolant
    60
    
    Freshwater (Closed) Cooling Systems
    60
    
    Remote Reservoir Checking/Filling
    60
    
    Fresh Water Heat Exchanger Diagram
    61
    
    Battery Maintenance
    62
    
    Flushing and Refilling Freshwater Coolant System
    62
    
    Battery Cutaway View
    63
    
    Compression Test
    63
    
    Engine Tune-Up
    63
    
    Valve Clearance Adjustment
    64
    
    Idle Speed Adjustment
    65
    
    Transmisson Oil
    66
    
    Engine Oil Crankcase Capacity
    67
    
    Engine Oil Viscosity
    67
    
    Maintenance Schedule Table
    67
    
    Transmission Oil Level Check
    67
    
    Compression Specifications
    68
    
    Freshwater (Closed) Cooling System Capacity Table
    68
    
    Tune-Up Specificationis Table
    68
    
    Lay-Up and Fitting out
    69
Chapter Four

69
Lay.upandfitt1Ngout

69
- Cooling System Draining
  70
- Seawater Cooling System
  70
- Adding Antifreeze
  71
- Freshwater (Closed) Cooling Section
  71
- Freshwater (Closed) Cooling System
  71
- Fitting out
  72
- Seawater Cooling Section
  72
Chapter Five

74
- Diesel Engine Fundamentals
  74
  - Single-Cylinder Engines
    74
  - 4-Stroke Diesel Engine Principles
    75
  - Engine Removal Precautions
    76
  - Engine Serial Number and Code
    76
    
    Replacement Parts (Engine)
    76
    
    Breather Assembly
    77
    
    Engine Removal/Installation
    77
    
    Valve Cover
    77
    
    Valve Cover Assembly Diagram
    78
    
    Cylinder Head Diagram
    79
    
    Cylinder Head Removal
    79
    
    Decompressoin Mechanism
    79
    
    Cylinder Head Inspection
    80
    
    Cylinder Head Installation
    81
    
    Rocker Shaft Assembly
    82
    
    Valve Components Diagram
    83
    
    Valve Removal
    83
    
    Valves and Valve Seats
    83
    
    Valve Inspection
    84
    
    Piston/Connecting
    85
    
    Valve Guide Replacement
    85
    
    Piston Pin Removal/Installation
    86
    
    Piston/Cylinder
    87
    
    Piston Ring Fit/Installation
    88
    
    Connecting Rod Inspection
    89
    
    Connecting Rod Bearing Clearance Measurement
    90
    
    Piston/Connecting Rod Installation
    90
    
    Timing Gearcase
    91
    
    Lubrication System Maintenance
    92
    
    Oil Pump
    92
    
    Oil Pump Removal and Installation
    93
    
    Oil Pump Disassembly, Inspection and Reassembly
    94
    
    Flywheel Removal/Installation
    95
    
    Oil Pickup
    95
    
    Pressure Relief Valve
    95
    
    Crankshaft Assembly Diagram
    96
    
    Crankshaft Removal and Installation
    97
    
    Camshaft Removal and Installation
    99
    
    Crankshaft Inspection
    99
    
    Main Bearings
    99
    
    Core Plug Replacement
    101
    
    Cylinder Block Cleaning and Inspection
    101
    
    Core Plug Removal and Installation
    102
    
    Engine Specifications Table (1GM, 1Gml0 )
    103
  - Cylinder Head
    104
- Engine Serial Number and Code (Multicylinder)
  105
Multicylinder Engines

105

Yanmar 2GM20F Shop Manual (241 pages)

Brand: Yanmar | Category: Engine | Size: 67.6 MB

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

Yanmar 2GM20F User Manual (240 pages)

ONE, TWO & THREE CYLINDER ENGINES

Brand: Yanmar | Category: Engine | Size: 21.89 MB

Table of Contents
3
Quick Reference Data
6
Chapter One
8
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
Chapter Two
32
- Starting System
  33
- Charging System
  37
- Charging System Tests
  37
- Fuel System
  38
- Cooling System
  40
Engine Troubleshooting
42
Cooling System
42
Lubrication System
42
Chapter Three
48
Operation, Lubrication, Maintenance and Tune-Up
48
- Fuel Requirements
  48
- Preoperational Checks
  48
- Starting Checklist
  49
CHAPTER Four
69
- Lay-Up
  69
Single-Cylinder Engines
74
- Diesel Engine Fundamentals
  74
- Engine Serial Number and Code
  76
- Replacement Parts
  76
- Engine Removal Precautions
  76
- Valve Cover
  77
- Breather Assembly
  77
- Decompression Mechanism
  79
- Cylinder Head
  79
- Rocker Shaft Assembly
  82
Chapter Six
105
- Engine Serial Number and Code
  105
- Replacement Parts
  106
- Engine
  106
- Valve Cover
  107
- Breather Assembly
  107
- Decompression Mechanism
  108
- Exhaust Manifold
  109
Cooling System
111
Lubrication System
126
Drive Disc
129
Crankshaft
130
Crankshaft
133

Yanmar 2GM20F Operation Manual (64 pages)

Brand: Yanmar | Category: Engine | Size: 8.15 MB

Warning Symbols
3
Safety Precautions
3
Safety Precautions for Inspection
5
Product Explanation
7
Use, Driving System, Etc.
7
Detail of Name Plate
7
Engine Specifications
8
Direct Seawater Cooling Type, GM Series
8
Fresh Water Cooling Type, GMF Series
9
Direct Seawater Cooling Type, GMV Series
10
Fresh Water Cooling Type, GMFV Series
11
Direct Seawater Cooling Type, GMC Series
12
Fresh Water Cooling Type, GMFC Series
13
Names of Parts
14
Non Operation Side
14
Operation Side
14
Major Servicing Parts
15
Control Equipment
16
Control Panel
16
Controls and Equipment
17
Alarm Equipment
17
Alarm Devices
17
Single Lever Remote Control Handle (Morse Type)
18
Stopping Equipment
18
Decompression Equipment
18
Operation
19
Fuel Oil, Lube Oil, and Cooling Water
19
Selection of Fuel Oil
19
Handling of Fuel Oil
19
Lube Oil
20
Cooling Water
20
Selection of Engine Lube Oil
20
Handling the Lube Oil
20
Before Initial Operation
21
Supply Fuel Oil
21
Supply Engine Lube Oil
21
Handling of Cooling Water
21
Supply Clutch Lube Oil
22
Supply Cooling Water (for Fresh Water Cooling Type Only)
22
Marine Gear Oil Capacity
22
Cranking
23
Fresh Water Cooling Capacity
23
Manual Operation (Seawater Cooling Only)
23
Check and Resupply Lube Oil and Cooling Water
24
Operating Your Engine
24
Electric Operation
24
Inspection before Starting
25
Checking and Resupplying Fuel Oil
25
Checking and Resupplying Engine Lube Oil
25
Checking and Resupplying Clutch Lube Oil
25
How to Start the Engine
26
Checking the Remote Control Handle
26
Checking the Alarm Devices Electric Operation
26
Preparing Fuel, Lube Oil, and Cooling Fresh in Reserve
26
Restarting after Starting Failure
27
Air Venting of the Fuel System after Starting Failure
27
Fuel System Air Venting Procedures
28
After the Engine Has Started
28
Engine Acceleration and Deceleration
28
Forward-Neutral-Reverse Clutch
28
Cautions During Operation
29
Racing the Engine
29
Stopping the Engine
30
Long Term Storage
31
Fresh Water Cooling
31
Cooling Water Drain Cocks
32
Maintenance & Inspection
33
General Inspection Rules
33
List of Periodic Inspection Items
34
Inspection on Initial 50 Hrs. of Operation
36

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