Yanmar 1GM10/2GM20/3GM30/3HM35 Marine Diesel Engine OEM Service & Repair Manual

fr i WINIWAfr? REzfjRVNI DIJELOW ERODSK'H IIOTORA WINIWAfrE Brtva poklopca ventrla r 1 9660-351 50 1 04500-557 1 0 128'170-77350 !28170-11310 1 021 03-55520 1 281 76-420701281 70-4209027210-200200 10421 1-49160 10421r-4S160 128270-1 13r0 11 9660-351 50 1 04500 557 1 0 1 021 03.55520 r0421.1 -42070 10421 1.42090272 1 0,200300 2s1 32-003000 1 0451 1 -78780 1 2321 0-0931 0 104211-49160 1 28270-1 1 31 0 119660-35150 1 04500.5 57 | 0 128296-42070 12 1 750-498001 29350-4gf, 1 1045r 1-78780 124223-42110 12827G.1 1310 1 19660-351s01 04500-557 1 0 l 02 1 03-55520 1042 11 -42070 10421 1-42090 I 23210-09310 10421 1 -491 60 128670-77J50 10451 1 -78780 119660-351501 04500-557 1 0 1 021 03-55520 128?9642070 104511-7878012827G11310 12422342110 119660-351501 04500-557 | 0 104511-7878012145G11310 121 750-49800 251 32-003700 119660-3s1s01 04500-557 1 0 1 021 03-55520 104511-78780121450-11310 '1042 1 1 {2070 104211-42090 272 1 0-200300 1 232I 0-093 1 0 104211-49160 119660-351501 04500-557 1 0 1 021 03-55520 128296-42070 I 0451 1 -78780 1 21 450-11 31 0 12422342110 1 21 75049800 1 293504954 1 121450-1 1310 1 04500-557 1 0 1 021 03-55520 104211-42070 27?1A-?O0300 r 2E670-7735010451-1-78780 12321 0-093r0 10421 1-49160 11 9660.351 50 1 04500,557 1 0 10451 I -78780 '121450-1 13r0 1 02 1 03,55520 1 28296-42070124223421 t0 1 2 1 750-49800 51 32-003700 1 1 9660-351 50 10451 1-78780 121450-1 1310 ,*':rii,,lti.lts-,.{ 121 750-49800 124085-351 11 128670-1 1310 12422342110 12r575-49160 1 28670-77350 10451 1.78780 1 24085-351 11 121450-1 ''|31 0 12422342110 1 2r 750-49800 1 2 9 3 5 0 . 4 9 5 4 1251 1 2-004600 1 710E7-42280 129150- r1310 1 19305-351 50 129470-55701 r2915$11310 | 29150-351 50 129470-42531 12S550-1 1310 12S150-351 50 129470-55701 1 29550- 1 131 0 251 32-004600 129"150-35150 129571-s5710 1 29550- I 1 31 0 12947V42531 2434 1 -000500 ; 1 1.;.:;,'1 129150-351 51 129470-55701 129550-1 1310 11977342570 r2947049801 1 291 50-351 51 1 29574-557 1 0 129550.1 131 0 1 2979549551 1 1 9005-351 00 1218s7-55710 1?761042200 't 19100-11320 1 21 850-4981 0 1 21 85049550 1 27695-351 50 12761042200 1 1 91 00-1 1 320 1218s0-49810 1 21 850-49550 121 850-42280 r 27695-351 5D 41650-502320 1 2 r 850-49550 119r00-11320 12761042200 2X't 7730 1 -5490C 121 850-4981 0 r 27695-35 1 50 119100-11320 1?761042200 11 917542570 121850-49810 HI.ADNJAK ZRAKAX 1 1 1 9574-1 8790 HLADNJAK ULJA 2X 1 1 9574-441 50 1 2769S35r 50 121857-55710 1 19100-1 1320 1233254202024 32 1 -000700 1 2 1 850-42280 x51 86 1 00664 1 1 9773-42600 119773-49570119773-77250 | 't 9770-90620 51861 00664 I 1 S771 -00040 119773426001 1 9773-42570 1 19773-4S550119773-4957011977U77250 | 1959135100 1 19593-1 1360 1 1 9574-42550 119593-4929'l 119563-11360 1 19574-42550 1 1959349550 11 9593-4929 I 11 9593-{2280 119593-35100 119593-11380 1 1 9574-42550 s D20/31/40 Cink anoda na izlazu rz pete 1 96420-02652 272 1 0-2005s0 7017 03 Kontakl k 1 2407G91 290 124070-S 1 290 I 24070-91290 1 24070-91 290 I 24070-91 290 1 24070-91 290 1 2407&9 1 290 | 24070-S 1 290 1 24070-9 1 290 1 24070-9 1 290 I 21070-9 1 29C 12407Q-9129C 124070-9 129C I 23482-91 2S 1 123482-91291 1 23482.91 291 1 23482-9 1 231 1 23482-9 1 291 1 23482-9 1 291 1 23482-9 1 291 123482-9'1 23 1 123482-91?91 '123482-91291 1?3482-51291 1 23482-91 2g 1 23482-91 29 1 23482-9 1 2E 1 23a62_9129 '=EfTE/HTE/DTE ""TE/HTE/DTE i .i/

Models A- Engine N4odel Name B. Engine Model Name Plate and Clutch Model Name Plate. C. Cylinder Number CHAPTER 1 GENERAL 1- Sp6itications 2. Principal Construction . 3. Performance Cures. . . . 4. F€tur6 5. Engine Cr6-S€1ions 6. Oimensions 7. Piping Diagrams. CHAPTER 2 BASIC ENGINE 1. CylinderBl@k ......... 2. Cylinder H@d . 3. Piston. . 4. ConnstingRod. ..... ... 5. Cranksha{t. 6. Flywh€l and Housing . . . . 7. Camshaft. 8. Timiog G€r . CHAPTER 3 FUEL SYSTEM '1. Fuel ini*lion Systm . . . . 2. Inietion Pump 3. Ini€lion Nozzle. 4. Fuel Filter 5. Fuel F@d Pump. 6- FuelTank (Oprion). . CHAPTER 4 GOVERNOR 1. Gowrnor. 2. Inietion Limiter.. 3- No-Load Maximum Speed Limiter 4. ldling Adjuster 5. Engine Stop Lffr . . . CHAPTER 5 INTAKE AND EXHAUST SYSTEM 1. Inbke and Exhaust Sys€m CHAPTER 8 FRESH WATER COOLING SYSTEM 1. Coolingsystem ... . 8-1 2. SeiwaterPump. ..-.- ..... 83 3. Fr6hwaterPump .... , .... 8{ 4. H€tExchaoger . ... - ...... 8-7 5.Filtercapandsubtank.... ... 8-1'l 6'Them*tat ""' 8-13 ?. CoolingwaterTemperatu.eswitch. ...... 8-16 g'Pr*autions ""' 8-17 CHAPTER 9 MODIFYING THE COOLING SYSTEM 1. General ?. Disasmbly ol S@ Water-C@led e"gi"" . . . . 3. A$embling modified pars to the Fr6h Water-Cooled Engine 4. CautioN whs the Engire is Install€d Inb@rd . ^/4-S' n- --n!p 9-1 9-2 9-7 9-12 o-1 0-1 0-3 '| "1 14 1-5 1-9 1-10 1-17 t-24 . 2-1 . 2-9 . 2-24 . 2-U . 234 . 249 . 2-53 5-1 5-3 s4 56 6-r 6-5 6,9 6-12 6-14 CHAPTER IO REDUCTION AND REVERSING GEAR lAl For Engine Models 1GMl0,2GM2O(F) and 3GM3O(FI l.Co6truction. ..... 10-1 3-29 4-9 4-11 4-12 4-13 2. Shifiing Dwice 3- Insprction and S€ryicing. 4. Disasmblv 5. P€smbly Drive Gear . 8- Disasembly 9. R€ssmbly .10-7 . 10-14 10-24 . lo-50 . 1056 . 10€1 . 1068 .10-73 lBl ForModel3GM35(F| l.construction ""'1G29 2. lnsbll€tion .""'10-33 3- OrrationandMainrenane ... - 1034 4. l6Btionandsewicing. -. ...1G35 5. oisa$emblv """1040 6. ReawblY ""-'10.44 [Cl Marire Ger Models KM2P. KN'!3Psnd KM3V tor Engine Models lGMlO,2GM2O(F} and 3GM3O(F) 2. Intake Silencg 3. Exhaust Svstm. 4. Br€ther CHAPTER 6 LUBRICATION SYSTEM 1. Lublication System. 2. Oil Pume. 3. Oil Filrer. 4. Oil Pr6uie RegulatorValve. 5. Oil Pr6ure M€suremqi CHAPTER 7 DIRECT SEA.WATER COOLING SYSTEM 'L Coctruction. .. 2- ShiftingDwice..... 3. Insp€ction and Sedicing 4. Dis$mbly 5. Rea$emblv IDl Vdrive G€r, Model KM3V l. Construction. 2. Speifications 3. P@er Transmission System . ...-1C77 .-..10€o .... 10€1 4. Anticorr6ionzink. . . . . . . . . 5. King6tonc@k(Optionl ...... 6- Bilge Pump and Bilge Srrairer (Optionl 7-^ 7 -11 ...... 7-14 ...... 7_16 4. Coolingsystem{S€-watercoolingEnginet. . . . . . . . . 1O€2 5. Piping Diagrams. " 1O€5 6. InsFtionandsedicing.. ." 1G9O 7. Shim Adjusrmfft for Vdriw Gear Shaft, and gacklashAdiustment for Vdrive G€r Shaft and .... 1G92 .... 10-94 . .. . 10€7 1- Cooling System . 2. water Pump . 3. Therm6tat ... Pintcd in Jw 0000404136r

A.Engine Model Name B. Engine Model Name Phle ond Clulch Model Name Plale SM/GM(F)(C).HM(F)(C) A. EngineModel Name The nomenclatureoJ the New GM(F)/HM(F) series lollows the order shown below. ".n.'2 I 2-cylinder I Marine engine seraes GM 20 F Discriminationof old GM(F) Model B. Engine ModelNamePlate To every engine model described in this manual, an engine model name plate and clutch model name plate are litted as shown in the following figures. In addition, the engine serial number is stampedon the cylinder body. Specificationsof the engine and clutch to be shipped are recorded and liled using the numbers marked on the engine model name plate and clulch model name plale. B-1 ltem descriptions on lhe model name plales and infomation lo be lorwarded to us fllem descriptions on Model name phlest The specilications or components of the engine or clutch may have been partiallyaltered to improve performance, and the components involved may not necessarily be inter- changeable. Therefore, when parts are ordered, please furnish the ilem description in the blank spacesshown in the ligures, using the descriptionsgiven on these plates. llnlomation to b€ lorwarded to usl and ClutchModelNamePlate Clulch model name olate GM-series HM-series Ptided it Jw 0000 A0 A l36l 0000A0A136r C'{APTER 11 REMOTE CONTROL SYSTEM t. Construction .... . . .. . .. . .. . .. ... . '11-1 2. Clutch andSp€ed Regulatq Rmote Control, . . .. -.. . ... 1 1-3 3. Eogire Stop Remote Control ... .. . .. .... . .. ... .. . -. . -. . 1 1-7 CflAPTER 12 ELECTRICAL SYSTEM '1. Electdelsystem ............ -.'..12-1 2 Battery.- ........ ...... -- ........ 12-4 3 startqMotor"'" '"""'"'"'"12-7 4. AttemtorStandard, 12Vl55A ... - ........... - - ......... '12-18 4A.Altermtor Opli6, 12VB5A -. .. . ..... -. -.. -. .. . .. -.. .. 12-m 5. l6trumtPaoef ....... --- ........ 12-37 6. Tachomets ...... .. - - ............ 12-43 CfIAPTER 13 OP€RATING INSTRUCTIONS t- Fuel Oil andLubd€ting Oil ........ - ................... 13-1 2. engire Opeating Instructions ........... - .... -., ....... 13-8 3 Troubleshobting and Fepair . . . - . . . . . . ,. . . . . . , . . . . . - . . - 1&13 CIIAPTER 14 DISASSEI,IBLY ANO REASSEMALY (Dlr€ct Seawattr Cooling Engln€) '1. Disasmbly and R@mbly Pr@utions . . - .... .. ... ... 1.1-1 2. Diwmbly a.rd R€sbly T@ls ....... ..... .. . .. . -. 1+2 3. Oihe6 .. .. . . .... . -. .. - -. .. . .. ... 1+13 a. Oisasmbly -. -. .. . .. ....... ... ... 1+14 5. R€smbly. . -. . - .. . .. . -. -. ... ... 1+28 iffi,rroP MARINE GEAR MOOEL KM 2 orL sAE 20i 30 H0 OIL OTY LTR. KANZAKI KOKYUKOKI MFG CO,. LTD MAffINE GEAfl MODEL KBW 10 6d';: :::: @;ioi, ^o , ,,, osaxa l!.Ll!!f!!J uenru Yourclutch gear ratio

Engine model 6ame Plate B. Engine Mdel Nane Plate md Cfulch Model Nme Phle 8.2 Location ol engine model name plate and clulch model name Plate B-2"1 1GM10(C) sM/GM(F)(cIHM(F)(c) mdel model nare Plate 2GM20(F)(C), 3GM3o(F)(C) nare plate 1GM10(C), 2GM20(F)(c), 3GM30(F)(C) B-23 3HU35(FXC) 00004041361 model name plal€ B. Engine Modet Nme Phte ond Cfulch Modcl Nune Plale C.Cylinder Numbet sM/GM(F)(C).HM(F)(C) 8.3 Location ol stamped engine serial number B-3.1 1GM10(c) C. Gylinder Number The cylinder numbers oI the 2 cylinder engine and 3 cylinder engine describ€d in lhis manual are designated as follows. (1) The sequence of cylinder numbers is given as No. 1, No. 2 and No. 3 starting lrom the flywheel side. (2) These cylinder numbers are consistently used lor devices and parts connected with the cylinder head and valve moving mechanism- However, please note that items related to the luel iniection pumP d0 not conespond to the numbering ot the cylinders. 0000404r361 s-3.2 2cM2o(FX c I, aru2uqpt$ sHMss(FXc)

o'T,k,",, CHAPTER 1 I Sllx{:r{rcatrons . .... -. 2 I)rirxirl)al C(tnslruclion 3 Pedolnrancc Curvos 4. Features - ..... .. 5. Engine Cross fuc|(xr:j 6- Dimensrons....... -. 7. Piping Diagrams..... GENERAL .1-l .15 .1-9 . 1-10 .1-17 .1-24 0000404r361

('hapter I Central l - Specifczlious 1. Specifications 1-1- Oirect Sea Water Cooling TYPe silt/G^t(F)(cltttt{c) 80 x 85 (3 15 x 3: 't.2€.2 l.74.231 22.413200(&1321 6.58 (93.57) 9.07 (29.76) 25.41W(U/U\ 7.02 (9!).82) I 63 (3r.sgl 24.8 b.Toc2lal 1@X5lU4-2! Combustid chadber Venial 4rycle water c@led diesel engire 75 x 72 (2.95 x 2.83) 0.99 (58 2r) 0.316 (19 40) 17 .1 /3&(24.1/34fnl 6.66 (94 71) 20.r /3mo(27.3/3600) kgf/cm2 (tb/in.2) broclsrllb.Toclsrllb.TDc18al M6hanical core clutch with single stage tor both ah€d aod astern Popeller sp€ed DIN.A ating (Ah€d/Astern) r1.0 (24.261 ?a5 €ar4) 455 (11r1) 4s5(r7.91) 410 (r6 14) r.6 (97.631 r3o (287) I I I t I ) I I I Numbe. of cylindeG Bore x slroke Oispl&ment Cdrian|ff6tng outplt (OlN6270Al O€ hor rafing outpd (OlN6270Bl Cofrpa6is (atro F@l iniectiq timing (FlO) F(Fl ini€lon pr6u@ Main @rer take off Frodt pwer take ofl f).redim ol ,obri6 C@ling system Lubra(5tion systs Sla.ting system cI|11sions Lubri@ling oil €pacity (rake angleS"l Engi@ reighr with cluth (dry) Printed in Japan a0At$tJc0l t, t at Flywhel side at Crankshaft V-pulley side Cdntsrl€tli* vi,ew€d tam stern Cl@kwis viered kom stc.rn Dir6l *a water c@liog (.ubber impeller water pump) Complete ercklsed forced lubri€tion E|ectric KBWl0€ multk i$ rehanl type rr2980 17.5 (3t1.58) 786 ($.94) 485 (19.0S) 617(24.29) i 2.7 116l.751 158 (348)

Chapler I Oeneral l. Specifiealions SIVI / G IVI( FXC T IT M ( FXC ) 1-2. Fresh Waler Coollng Typ€ Model Type Cmbustion chamber Numbs ol cytindeG Bore x sl(oke Oisplacemenl Conlin!@s .ating output (DlN 62704) Lukicaring ol €prcity (rake angle 8P) Ore h@r Gt,ng outpul (OlN 62708) Coooa6sion aatio Fuel inieclion liming (FlO) F@l iniecti$ p.6su.e Maio porer lake ofl Frmt rcwe( take ofi Di.€tion ol otation C@lidg systm Lub.kFtir synm Starting system OiMsions Engine reighr with clutch (dry Printed in Japan A0At$t-Jc0l Veni@l 4qcle wats @led die$l 6gire Swid o.rcombustron chambcr 80 x 85 (3.15 x 3.35) |.242Fazil 22.4/32$(g/32co) 6.58 (93.s7) 9.07 (29.761 2s.u3m(ut3![o) 7.02 (99.82) 9,63 (31.59) b.TDC 2rar r6o!s (n4-zJ47l at Flywheel side at C€nkshaft V-pulley $de C@nte.-doc*wi* viewed t@ ste(n Ockwi$ viered trm stsn 75 x72 12. r2.&3) 'tl.7l?r'l(f,4rt1/34$l- kW/rpm(HP./rpm) ksf/cm'? (lb/in.'z) kW/rpm(HP/rpm) kgf/cm2 (tb/in.') b.Toc 15tl M€cl6nical core clutch with single stag€ tor both atEad md 6t6 Prcpelle. sp€€d OlN. A ating (Ahead/Aslem) 0.30 (18.31) 1r.0 (24.26) 'F.6h mt6 c@{ing with heat Comolete €ndo€ed forced lub.iqtio K8W10€ Wel multi{i$ reharicd type l12311uo o.fo(12721 17.5 (38.58) 791 (31.1,1) 475(18.701 dl8 (25.12) 5.4(329.5r) 2.7 (16..75' 167 (368)

(-hopter I Ceneral 3. I'erJornnnce Curves S trl / CtrI (F- )( C I H trl(F )( C ) Chapter I General 3. Performance Curves 3. Performance Curves 3-1.1GM1o(C) 92 2GM20(FXC) STl/GM(F)(CTHM(FXC) 240 g/HPh 220 2IJIJ kgf-m 4.0 3.0 HP 10 8 2 0 g/kw h 300 280 260 Nm 18 16 14 12 7 6 5 4 2 I 0 g/HP h 2.0 kgt'm 1.8 1.4 HP I I 7 6 5 4 3 2 g/kw.h 300 240 2ffi SPECIFICFUEL CONSUI\,'lPTlON (DlN6270B rating) ENGINE TOROUE (DlN6270B rating) 12@ 1600 2000 24tn 2800 3200 SPEED OF CRANKSHAFT: rpm THE ENGINE FLYWHEEL OUTPUT IS APPROX 3% HIGHER. NOfE: fhese curves show the avetage perlormance ol rcspective engine in test operation at our plant. 240 220 200 SPECIFIC FUEL CONSUMPTION {DlN6270B rating) ENGINE TOROUE (DlN6270B rating) 12co 1600 2oOO 24@ 2800 3200 3600 SPEED OF CRANKSHAFT: rpm THE€NGINE FLYWHEEL OUTPUT lS APPROX 3olo HIGHER NOTE: These curves show the average pertormance ot respective engine in test operalion at our plant. Nm 40 30 l8 14 1 0 0000.{0Ar36l 0000A041361 OUTPUT 7 ^s\ ^o' T2' (t ^o- e1" OUTPUT '/ i.F- - --o l.6N 1 o .'1 K -- 7, .tttt" 6l ,/o !.">

Chapler I General 3- Pedormance Curves Chaptu I Gencral 3. PerJormance Curves SM/GM(FXC'HM(F)(C) g/HP.h 2n 2@ 180 8.0 kgf-m 6.0 SM/GM(FXCIHM(F)(C) zlo.qR.€.t{ 220 2@ 6.0 kgrf-m 5.0 4.0 HP H 3HM35(FXC) &3 3Gi|3{XFXC) g/kW.h 300 280 2& rfr. 50 & KW n 15 SPECIFIC'R EL CONSTJMPTION (D|N6270B rating) ENGINE TOfr€I{JE'DIN627OE I 2000 2400 g/kw.h 300 280 260 SPECIFIC FUEL CONSUMPTTON (DlN6270B rating) ENGINE TOROUE (OlN6270B rating) 1600 m6 2400 2800 3200 3600 SPEED OF CRANK SHAFT: rpm THE EI'IGINE FLYWHEEL OUTPUT IS APPROX 3%HIGHER NOTE: These cuftes show the average pedormance ol rcspective engine in test operation at ou plant' N.m 70 @ KW 25 27 24 21 18 15 12 9 6 J 0 36 HP 27 24 2'l 18 15 12 I '*nn^.Pl ll 0\T::i SPEED OF CRANKSHAFT: Cm THE ENGINE FLYWHEEL OUTPUT IS APPROX 3%HIGHER. NOTE: These curves show the avercge perlormance ot rcspective engine in tesl operation at our planl. 0000A04r35r 00004041361 OIJTP{JT 7 .ta$ V "4t"" v J OUTPUT 7 .+"", .a$ dt b4 ic

Chaplar I Cotrul l. Spet(i<'atiuns siv / G ivl (Fx(' ). Htvl (F)(c ) 1-3. Direct S€a Water Colling Type (Sail-drive) Model Type Cqnbustion chamber Nlmbe. ol cyliod€rs Sore r sttoke Displacemenl Conlinuous rathg output (DlN 6270A) Ore hM 6trng @tput (OlN 62709l Codp(sioo ratio F€l injecrion timing (FlO) F@l inieclion pres.e Main porer take off Front pows take ofl Cankshatt Oiretion of rotatioo C@liog systm Lubri@ti@ system Startiog system Sail-driw Lubri€taing oil €pacity (Engare side) Engire reight wilh Saildriw uoit (Ory) Printed in Japan A0At6tJC0l 7s x 72 (2.95x 2.a31 t7.1t340o(24.'il3dcol 1 1.8/34m( 16.0/3400) kgi/cmz (lb/in.') r3.4/3600( 18.2/3600) kW/rpm( HPlrpm ) 7.O7 (1o0.54l kgf/cm'(tb/in.2) Propellq sp€ed DlN. A aling Verli@|. 4{ycle mttr @hd diel engire Swi.l oregmbustaff chamber at FlywtEl sid€ at C€okshaft V?ui€Y sid€ C@nt6{lockwi$ vigred la@ Stem Countq{lckwis vGred ftm stm 80 x 85 (3.15 x 3.35) r.282 (78.23) 22.4/32fi(n/ncnl 5.58(93.57) 9.07 (29_76) 7.@ (99.82) g.dr (31.59) b.Toc 21tt r@filz?o4-?3471 Orect s €tq c@lirig (rubbe. impellet watd pump) Complele trl@d lorced lubrirttr C@stant Gh g@. with dog dulcil 2.64tZU 2.2(1 1212 2.1 llu.7sl 180(a)71 r-3

Yanmar 1GM10/2GM20/3GM30/3HM35 Marine Diesel Engine OEM Service & Repair Manual

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