Yanmar 3GM Manuals

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Yanmar 3GM Shop Manual

Yanmar 3GM Shop Manual (241 pages)

Brand: Yanmar | Category: Engine | Size: 63 MB

Table of Contents

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
Fuel Injection and Governor Systems

144
- Fuel Injection Fundamentals
  144
- Fuel Injection System View
  145
- Fuel Injector
  146
  - Fuel and Fuel Filters
    146
  - Injection Pump View
    147
  - Fuel Injection System Bleeding
    148
  - Fuel Transfer Pump
    148
  - Fuel Injection Timing
    150
  - Adjust Fuel Injection Timing
    151
  - Fuel Injector Info
    152
  - Fuel Injector Removal and Installation
    153
  - Fuel Injection Pump Removal and Installation
    155
  - Fuel Pump Testing
    156
  - Fuel Pump Removal and Installation
    156
  - Fuel Lines Inspection
    157
  - Governor System Operation
    158
  - Governor System Diagrams
    159
  - Governor System Adjustments
    160
  - Governor Assembly View
    161
  - Governor Components Removal/Inspection/Installation
    161
  - Governor System Tightening Torques
    164
  - Governor Spring Free Length Table
    164
  - Governor Sleeve and Crankshaft Specifications
    164
  - Chapter 8: Cooling System
    165
  - Seawater (Standard) Cooling System
    165
Chapter Eight

166
- Seawater Cooling System Diagram (1GM and 1GM10)
  166
- Seawater Cooling System Diagram (2GM and 2GM20)
  167
- Seawater Cooling System Diagram (3GM and 3GM30)
  168
- Freshwater (Closed) Cooling System Diagram/Description
  169
- Closed Cooling System (Typical) Diagram
  170
- Heat Exchanger Diagram
  171
- Thermostat
  171
- Thermostat Removal/Installation
  172
- Cooling Systems
  173
  - Thermostat Testing (in Engine)
    173
  - Thermostat Testing (out of Engine)
    173
  - Hose Replacement
    174
  - Overheated Engine
    174
  - Slow Engine Warm-Up
    174
  - Alternator Belt Drive Replacement
    175
  - Drive Belt Routing Diagram
    175
  - Drive Belts Description
    175
  - Seawater Pump
    176
  - Seawater Pump Drive Belt Replacement (Except 1GM and 1GM10 Engines)
    176
  - Seawater Pump Precautions
    177
  - Seawater Pump Removal/Installation
    177
  - Water Pump Operating Mistakes
    177
  - Seawater Pump Disassembly/Assembly
    178
  - Seawater Pump Diagram (1GM and 1GM10 Models)
    179
  - Seawater Pump Diagram (2GM, 2GM20,3GM and 3GM30 Models)
    181
  - Seawater Pump Diagram (3HM and 3HM35 Models)
    182
  - Freshwater Cooling System Maintenance
    183
  - Freshwater Pump Removal/Installation
    183
  - Pressure Testing
    183
  - Cleaning the Seawater Section of the Heat Exchanger
    185
  - Closed Cooling System Diagram
    185
  - Freshwater Exhaust Manufold/Heat Exchanger Diagram
    186
  - Seawater Cooling System Maintenance
    187
  - Recommended Thermostat
    188
  - Seawater/Freshwater Pumps Tightening Torques
    188
  - Electrical System
    189
Chapter Nine

189
- Switches
  189
  - Electrical System - Safety Precautions
    190
  - Electrical System - Care and Inspection
    191
  - Battery Testing
    192
  - Charging
    193
  - Jump Starting
    193
  - Electrical Protection
    194
  - Battery Cables
    194
  - Charging System
    195
  - Preliminary Testing
    195
  - Starting System
    196
  - Starter Removal/Installation
    196
  - Alternator Removal/Installation
    196
  - Solenoid Removal/Installation
    197
  - Brush Replacement
    197
  - Starter Motor Diagram (Except 3HM and 3HM35 Models)
    198
  - Starter Motor Diagram (3HM and 3HM35 Models)
    199
  - Switches
    201
  - Senders
    201
  - Oil Pressure Sender
    201
  - Battery Cutoff Switch
    201
  - Coolant Temperature Sender
    202
  - Coolant and Oil Pressure Warning Lamps
    203
  - Charging System Warning Lamp
    203
  - Alarm Buzzer
    203
  - Tachometer
    203
  - Tachometer Sender
    204
  - Tachometer Gauge
    204
  - Battery Capacity Table
    204
  - Alternator and Starter Motor Tightening Torques
    204
  - Transmission - KM Series
    205
  - Cone Clutch View
    206
  - Shifter View (KM2A, KM2C and KM3A Models)
    206
Chapter Ten

206
- Shifter View (KM2P, and KM3P Models)
  207
- Transmission (KM) Removal and Installation
  207
Transmission-Km Series

207
- Transmission (KM) Disassembly
  208
- Input Shaft Inspection
  209
- Transmission (KM) Inspection
  209
- Intermediate Shaft Inspection
  210
- Output Shaft Inspection
  210
- Output Shaft Diagram
  211
- Shifter Diagram (KM2A, KM2C and KM3A Models)
  212
- Transmission (KM) Reassembly
  214
- Shifter Detent (KM2P and KM3P Models)
  215
- Shifter Diagram (KM2P and KM3P Models)
  215
- Bearing Adjustment
  217
- Output Shaft
  218
- Drive Disc Inspection
  219
- Drive Disc Removal/Installation
  219
- Clutch Groove Width
  220
- Engine Transmission Models Table
  220
- Output Shart Table
  220
- Tightening Torques Table (Transmission KM Series)
  220
- Shifter Data Tables
  221
Chapter Eleven

222
- Operation
  222
  - Transmission (KBW Series) Removal/Installation
    223
  - Transmission (KBW Series) Overhaul
    223
  - Transmission (KBW Series) Disassembly
    223
  - Transmission (KBW Series) Diagram
    224
  - Input Shaft (KBW)
    226
  - Intermediate Shaft (KBW)
    226
  - Output Shaft (KBW)
    226
  - Transmission (KBW) Inspection
    227
  - Transmission (KBW) Reassembly
    228
  - Shifter (KBW)
    229
  - Bearing Adjustment (KBW)
    230
  - Drive Disc (KBW) Removal/Installation
    231
  - Drive Disc (KBW) Inspection
    231
  - Engine/Transmission (KBW) Data
    232
  - Tightening Torques (KBW)
    232
  - Clutch Specifications (KBW)
    232
  - Transmission - KBW Series
    222
- Drivedisc
  232

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Yanmar 3GM Shop Manual

Yanmar 3GM Shop Manual (241 pages)

Brand: Yanmar | Category: Engine | Size: 67 MB

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 Injection System
145
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
Fuel Lines
157
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 (Standard) Cooling System
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
Battery
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
Charging System (Typical)
195
Starting System
196
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
Transmission
225
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

Yanmar 3GM User Manual

Yanmar 3GM User Manual (240 pages)

ONE, TWO & THREE CYLINDER ENGINES

Brand: Yanmar | Category: Engine | Size: 21 MB

Table of Contents

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
Fuel Lines
157
Governor System
159
Chapter Eight
165
- Cooling Systems
  165
- Thermostat
  168
- Drive Belts
  175
Chapter Nine
189
Electrical System
189
- Battery
  189
- Electrical Protection
  194
- Charging System
  195
- Starting System
  196
- Removal/Installation
  196
Senders
201
Warning Lamps
203
Alarm Buzzer
203
Tachometer
203
Reassembly
214
Bearing Adjustment
217
Drive Disc
219
Bearing Adjustment
230
Drive Disc
231

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