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ERODSK'H WINIWAfrE Brtvapoklopca Kontakl
ventrla k
r 19660-35150 10 4 5 0 0 - 5 5 710 10 2 10 3 - 5 5 5 2 0 12 8 17 6 - 4 2 0 7 0 1281
70-4209027210-200200 1 0 4 2 1 - 4 9 1 6 0 10421r-4S 160 128' 170-77350 !28170-11310 12407G91
119660-35150 10450055710 102103.55520 r 0 4 2 1 .-14 2 0 7 0 1 0 4 2 1 . 4 2 0 9 0 27210,200300 123210-09310 0 32-003000104511-78780 128270-
1 0 4 2 1 1 - 4 9 1 6 2s1 13r
1 0 124070-S 1290
11 96 60 -35150104500.5
57| 0 128296-42070 124223-42110 121750-49800 129350-4gf,1 1045r 1- 78780128270-11310 I 24070-91290
119660-351s0104500-557 10 l 02103-55520 1 0 4 211- 4 2 0 7 0 1-42090
10421 I 23210-09310 10421 1-49160 128670-77J50 104511-78780 1 2 8 2 7 G.1 1 3 1 0 124070-91 290
119660-35150104500-557 10 102103-55520 128?9642070 12422342110 1 0 4 5 1 1 - 7 8 7 8 01 2 8 2 7 G1 1 3 1 0I 24070-91
11 96 60 -35150104500-557
|0 121750-49800 25132-0037001 0 4 5 1 1 - 7 8 7 8 01 2 1 4 5 G1 1 3 1 0124070-91290
119660-3s1s0104500-55710 102103-55520 '1042 0 7210-200300 1232I 0-093 10
11{2070 1 0 4 2 1 1 - 4 2 0 9 2 104211-49160 02407&91290
1 0 4 5 1 1 - 7 8 7 8 01 2 1 4 5 0 - 1 1 3 1 1
119660-35150104500-55710 102103- 5552 0 128296-42070 12422342110 12 17 5 0 4 9 8 0 0 1293504954 1 I 04511-78780 121450-11310 | 24070-S 1290
10 102103-55520 1 0 4 2 1 1 - 4 2 0 7 0 27?1A-?O030012321 0-093r0 1 0 4 2 1 - 4 9 1 6 0 r 2E670-7735010451-1-78780 1 2 1 4 5 0 -113 1 0 124070-91290
119660.35150 104500,557
10 102103, 55520 128296-42070124223421t0 12 1750-49800 5132-00370010451I -78780 '121450- 13r1 0 124070-91290
119660-35150 ,*':rii,,lti.lts-,.{
121750-49800 104511-78780 121450- 1310
1 I 21070-9129C
124085-35111 12422342110 1310 12407Q-9129C
128670-773501 0 4 5 1 .7 8 7 8 0 128670-1
12r 575- 49160
124085-35111 12422342110 12r 750-49800129350.4954125112-004600 ''|31
121450-1 129C
0 124070-9

1710E7-42280 129150-r 1310

119305-35150 129470-55701 r 2915$11310 2S1
I 23482-91
| 29150-351
50 129470-42531 12S550-1 1310 123482-91291
50 129470-55701
12S150-351 25132-004600 129550-11310 123482.91 291
129" 150 -3 5 1129571-s5710
50 12947V42531 24341-000500 ; 1 1.;.:;,'1 129550-I 1310 123482-91231
129150-35511 129470-55701 11977342570 r2947049801 1310
129550- 1291
1 123482-9
129150-35151 129574-55710 12979549551 1 3 10 123482-91291
1 2 9 5 5 0 .1
119005-35100 1218s7-55710 1?761042200 121850-4981
0 12185049550 't19100- 11320
127695-35150 12761042200 1218s0- 49810
121850-49550 121850-42280 231
119100-11320 123482-9'1
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r 27695-351 12761042200 2X't77301-5490C 121850-4981
0 12 r 850-49550 1 1 9 r 0 0 - 1 1 3 2 0123482-91?91
r 27695-35150 1?761042200 11917542570 HI.ADNJAK 1 2 1 85 0 - 4 9 8 1 0 1 1 9 1 0 0 - 1 1 3 2'123482-91291
12769S35r50 121857- 55710 1233254202024321-000700 ZRAKAX 1 12 1850-42280 1320 1?3482-51291
x5186100664 119773-42600 119 5 7 4 - 1
8790 119773-49570119773-77250
| 't9770-90620 5186100664 1 1 9 7 7 3 4 2 6 0 0 119773-42570 119773-4S550119773-4957011977U77250 I 1S771-00040 123482-91 2g
| 19 59 13 5100 11 9574-42550 HLADNJAK 119593-4929' l 119593-1 1360 123482-91 29
119574-42550 U L J A2 X I 119593-{2280
11959349550 119593-4929 023482-912E
1 1 9 5 6 3 - 1 1 3 61
119 59 3-3 5100 119574-42550 119 5 7 4 - 4 4510 123a62_9129
119593- 11380

s D20/31/40 Cink anoda na izlazu rz pete 196420-02652



^/4-S' --n!p

A- Engine N4odelName o-1

B. Engine Model Name Plate
and Clutch Model Name Plate. 0-1
C. Cylinder Number 0-3


'| "1 1. Coolingsystem ... . 8-1
1- Sp6itications
2. Principal Construction . 14 2. SeiwaterPump. ..-.-..... 83
3. Performance Cures. . . . 1-5 3. Fr6hwaterPump ....,.... 8{
4. F€tur6 1-9 4. H€tExchaoger. ...-...... 8-7
5. Engine Cr6-S€1ions 1-10 5.Filtercapandsubtank.... ... 8-1'l
6. Oimensions 1-17 6'Them*tat ""' 8-13
7. Piping Diagrams. t-24 ?. CoolingwaterTemperatu.eswitch. ...... 8-16
g'Pr*autions ""' 8-17
1. CylinderBl@k ......... . 2-1
3. Piston. . . 2-24 1. General 9-1
4. ConnstingRod. ..... ... . 2-U 9-2
?. Disasmbly ol S@ Water-C@led e"gi"" . . . .
5. Cranksha{t. . 234 3. A$embling modified pars
6. Flywh€l and Housing . . . . . 249 to the Fr6h Water-Cooled Engine 9-7
7. Camshaft. . 2-53 4. CautioN whs the Engire is Install€d Inb@rd . 9 -1 2
8. Timiog G€r .
lAl For EngineModels1GMl0,2GM2O(F)
'1. Fuel ini*lion Systm . . . . . . . . . 1 0 -1
l . C o 6 t ru c t i o n .
2. Inietion Pump 2. Shifiing Dwice . 1 0 -7
3. Ini€lion Nozzle. 3- Insprction and S€ryicing. . 1 0 -1 4
4. Fuel Filter 3-29 4. Disasmblv
5. Fuel F@d Pump. 5. P€smbly 10-24
6- FuelTank (Oprion). .
lBl ForModel3GM35(F|
CHAPTER 4 GOVERNOR l.construction ""'1G29
1. Gowrnor. 2. lnsbll€tion .""'10-33
2. Inietion Limiter.. 4-9
4-11 3- OrrationandMainrenane ... - 1034
3- No-Load Maximum Speed Limiter 4. l6Btionandsewicing. ...1G35
4-12 -.
4. ldling Adjuster 5. oisa$emblv """1040
5. Engine Stop Lffr . . . 4 -1 3
6. ReawblY ""-'10.44
1. Inbke and Exhaust Sys€m 5-1 tor Engine Models lGMlO,2GM2O(F} and 3GM3O(F)
2. Intake Silencg 5-3 'L Coctruction. .. . lo-50
3. Exhaust Svstm. s4 2- ShiftingDwice..... . 1056
4. Br€ther 56 3. Insp€ction and Sedicing . 10€1
4. Dis$mbly . 1068
CHAPTER 6 LUBRICATION SYSTEM 5. Rea$emblv . 1 0 -7 3
1. Lublication System. 6-r
6-5 IDl Vdrive G€r, Model KM3V
2. Oil Pume. . . . -1 C 7 7
6,9 l. Construction.
3. Oil Filrer. . -. . 1 0 € o
6-12 2. Speifications
4. Oil Pr6uie Regulator Valve. ....10€1
6-14 3. P@er Transmission System .
5. Oil Pr6ure M€suremqi
4. Coolingsystem{S€-watercoolingEnginet. . . . . . . . . 1O€2
1- Cooling System . 6. InsFtionandsedicing.. 1G9O
2. water Pump . 7-^ 7. Shim Adjusrmfft for Vdriw Gear Shaft,
3. Therm6tat ... 7 -11 and gacklashAdiustment for Vdrive G€r Shaft and
4. Anticorr6ionzink. . . . . . . . . ......7-14 Drive Gear . ....1G92
......7_16 8- Disasembly . . . . 1 0 -9 4
5. King6tonc@k(Optionl ......
9. R€ssmbly . .. . 10€7
6- Bilge Pump and Bilge Srrairer (Optionl

Pintcd in Jw
A.Engine Model Name
B. Engine Model Name Phle ond Clulch Model Name Plale

A. EngineModel Name
The nomenclatureoJ the New GM(F)/HM(F) series lollows
the order shown below.

".n.'2 GM 20 F
2-cylinder I
Discriminationof old GM(F) Model

B. EngineModelNamePlate
t. Cons tr u c t i o. .n. . . . .. . .. . .. . .. ... .' 11- 1
2. ClutchandSp€edRegulatqRmote Control,. . .. -.. . ... 11-3
and ClutchModelNamePlate
3. E o g ir eSt o pR e m ote Co n tro l ..... . .. .... . .. ... .. . - . . - . . 11- 7 The specilications or components of the engine or clutch
To every engine model described in this manual, an engine
CflAPTER 12 ELECTRICAL SYSTEM model name plate and clutch model name plate are litted may have been partiallyaltered to improve performance, and
' 1.E lec t d e l s y s t e m ............- .' ..12- 1 as shown in the following figures. In addition, the engine the components involved may not necessarily be inter-
2 Ba t t e r y . - . . . . . . . . ......- - ........12- 4 serial number is stampedon the cylinder body. changeable.
3 s t a rt q M o t o r "' " '" " " ' "' "' "12- 7 Specifications of the engine and clutch to be shipped are Therefore, when parts are ordered, please furnish the ilem
4. A t t e m t o r S t a n d ard 12
, Vl55A
... -........... - - .........' 12- 18
recorded and liled using the numbers marked on the engine description in the blank spaces shown in the ligures, using
4A.A lt er m t oO r pli6, 12VB5A -. .. . ..... -. -.. - . .. . .. - .. .. 12- m
5. l 6t rumt P a o e f .......- - - ........12- 37 model name plate and clulch model name plale. the descriptionsgiven on these plates.
6. T ac ho m e t s . . . . . . .. - -............12- 43


t- F uelO i l a n dL u b d €ti n gOi l ........ -...................13- 1 B-1 ltem descriptions on lhe model name plales and
2. e ngireO p e a t i n gI n stru cti o n s...........-.... - .,....... 13- 8 infomation lo be lorwarded to us
3 Troubleshobtingand Fepair . . . - . . . . . . ,. . . . . . , . . . . . - . . - 1&13
fllem descriptions on Model name phlest llnlomation to b€ lorwardedto usl
(Dlr€ct Seawattr Cooling Engln€)
'1.Disasmbly and R@mbly Pr@utions. . -.... .. ... ...1.1-1
2. D iwm b l y a . r dR€ sb l y T @l s ....... ..... .. . .. . - . 1+ 2
3. O ihe6 . . . . . . . . . . . -. .. - - . .. . .. ...1+13
a. Ois as m b l y -. -. .. . .. ....... ... ...1+14
5. R € s m b l y . . - . . - .. . .. . - . - . ... ...1+28

Clulch model name olate


orL sAE20i30 H0

Yourclutch gear ratio



6d';: ::::
^o, ,,,
Ptided it Jw osaxa l!.Ll!!f!!J uenru
0000 A0 A l36l

B. Engine Modet Nme Phte ond Cfulch Modcl Nune Plale
B. Engine Mdel Nane Plate md Cfulch Model Nme Phle C.Cylinder Numbet
sM/GM(F)(cIHM(F)(c) sM/GM(F)(C).HM(F)(C)

8.2 Location ol engine model name plate and clulch 8.3 Location ol stamped engine serial number
model name Plate
B-3.1 1GM10(c) c I, aru2uqpt$ sHMss(FXc)
Engine model 6ame Plate

C. GylinderNumber
The cylinder numbersoI the 2 cylinder engine and 3 cylinder
nare Plate engine describ€d in lhis manual are designated as follows.
2GM20(F)(C), mdel
3GM3o(F)(C) nare plate
1GM 10( C ) ,

B-23 3HU35(FXC)

model name plal€

(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.


I Sllx{:r{rcatrons . .... -. .1-l
2 I)rirxirl)alC(tnslruclion
3 Pedolnrancc Curvos .15
4. Features-..... .. .1-9
5. Engine Cross fuc|(xr:j . 1-10
6- Dimensrons....... -. .1-17
7. Piping Diagrams..... .1-24


('hapter I Central
l - Specifczlious silt/G^t(F)(cltttt{c)

1. Specifications
1-1- Oirect Sea Water Cooling TYPe

Venial 4rycle water c@led diesel engire

Combustid chadber

Numbe. of cylindeG
75 x 72 (2.95x 2.83) 80 x 85 (3 15 x 3:
Bore x slroke
0.316 (19 40) 0.99 (582r) 't.2€.2l.74.231
17.1/3&(24.1/34fnl 22.413200(&1321

Cdrian|ff6tng 6.66 (94 71) 6.58 (93.57)

outplt (OlN6270Al
9.07 (29.76)

20.r/3mo(27.3/3600) 25.41W(U/U\
O€ hor rafing 7.02 (9!).82)
kgf/cm2 (tb/in.2)
outpd (OlN6270Bl
I 63 (3r.sgl

Cofrpa6is (atro
br oc l s r l l b.T oc l s r l l b.T D c 18al b.Toc2lal
F@l iniectiq timing (FlO)

F(Fl ini€lon pr6u@

take off at Flywhel side

Main @rer

at Crankshaft V-pulley side
Frodt pwer take ofl
Cdntsrl€tli* vi,ew€d tam stern

f).redim ol ,obri6 Cl@kwis viered kom stc.rn

Dir6l *a water c@liog (.ubber impeller water pump)

C@ling system
Complete ercklsed forced lubri€tion
Lubra(5tion systs
Sla.ting system
M6hanical core clutch with single stage tor both ah€d aod astern multk i$ rehanl type

I Popeller sp€ed DIN.A ating (Ah€d/Astern)

r1.0(24.261 17.5(3t1.58)

?a5€ar4) 786 ($.94)

410( r 6 14) 4s5(r7.91) 455(11r1) 485 (19.0S)

617(24.29) i

Lubri@ling oil €pacity

r.6 (97.631 2.7 116l.751

(rake angleS"l
r3o (287) 158 (348)
Engi@ reighr with cluth (dry)

Printed in Japan
Chapler I Oeneral
l. Specifiealions

1-2. Fresh Waler Coollng Typ€

Type Veni@l 4qcle wats @led die$l 6gire
Cmbustion chamber Swid o.rcombustron chambcr
Numbs ol cytindeG

Bore x sl(oke 75 x72 12. r2.&3) 80 x 85 (3.15 x 3.35)

Oisplacemenl |.242 Fazil
k W /r pm ( H P./r pm ) 'tl.7l?r'l(f,4rt1/34$l- 22.4/32$(g/32co)
Conlin!@s .ating
output (DlN 62704) ksf/cm'? (lb/in.'z) 6.58(93.s7)
k W /r pm ( H P/r pm ) 2s.u3m(ut3![o)
Ore h@r Gt,ng
outpul (OlN 62708) k gf/c m 2 ( tb/i n.') 7.02(99.82)
Coooa6sion aatio

Fuel inieclion liming (FlO) b.Toc 15tl b.TDC2rar

F@l iniecti$ p.6su.e r6o!s (n4-zJ47l
Maio porer lake ofl at Flywheel side
Frmt rcwe( take ofi at C€nkshaft V-pulley $de

C@nte.-doc*wi* viewed t@ ste(n

Di.€tion ol otation
Ockwi$ viered trm stsn
C@lidg systm 'F.6h mt6 c@{ing with heat
Lub.kFtir synm Comolete €ndo€ed forced lub.iqtio
Starting system

M€cl6nical core clutch with single stag€ tor both atEad md 6t6 Wel multi{i$ reharicd type

Prcpelle. sp€€d OlN. A ating (Ahead/Aslem) l12311uo

0.30(18.31) o.fo(12721
1r.0 (24.26) 17.5 (38.58)
791 (31.1,1)
OiMsions 475(18.701
dl8 (25.12)

Lukicaring ol €prcity 5.4(329.5r)

(rake angle 8P)
2.7 (16..75'
Engine reighr with clutch (dry 167 (368)

Printed in Japan
(-hopter I Ceneral
Chapter I General
3. I'erJornnnce Curves 3. Performance Curves
Strl / C trI (F-)(CI H trl(F)(C) STl/GM(F)(CTHM(FXC)

3. PerformanceCurves 92 2GM20(FXC)
3-1. 1G M1o ( C )


g/kw h 240 g /H P h
g/kw.h 240 g/HPh

300 300
220 220
280 240
200 2IJIJ

ENGINE TOROUE (DlN6270B rating)

ENGINE TOROUE (DlN6270B rating)
Nm 2.0 kgt'm Nm kgf-m
18 1.8 40 4.0
14 1.4 30 3.0


I l8

6 I

7 7

^s\ 6
4 T2'

K -
o 1
. '1 7,
6l 10

,/o !."> 8


1 2

0 0 0
12@ 1600 2000 24tn 2800 3200 3200 3600
12co 1600 2oOO 24@ 2800



NOfE: fhese curves show the avetage perlormance ol NOTE: These curves show the average pertormance ot
rcspective engine in test operation at our plant. respective engine in test operalion at our plant.

Chapler I General
3- Pedormance Curves
Chaptu I Gencral SM/GM(FXC'HM(F)(C)
3. PerJormanceCurves SM/GM(FXCIHM(F)(C)

H 3HM35(FXC)
&3 3Gi|3{XFXC)

g/kw.h g/HP.h


g/kW.h zlo.qR.€.t{
300 220 260
N.m 8.0 kgf-m
rfr. 6.0 kgrf-m 70
50 5.0 @ 6.0

& 4.0
KW 36 HP
KW HP 25

n 27 7 27

24 24

7 21 2'l
.+"", .a$
18 18

.ta$ V 15 dt 15

12 b4 12

v 9

1600 m6 2400 2800 3200 3600




THE ENGINEFLYWHEEL NOTE: These cuftes show the average pedormance ol
rcspective engine in test operation at ou plant'
NOTE: These curves show the avercge perlormance ot
rcspective engine in tesl operation at our planl.

Chaplar I Cotrul
l. Spet(i<'atiuns s iv / Givl(Fx(' ).Htvl(F)(c)

1-3. Direct S€a Water Colling Type (Sail-drive)

Verli@|. 4{ycle mttr @hd diel engire
Swi.l oregmbustaff chamber
Cqnbustion chamber
Nlmbe. ol cyliod€rs
7s x 72 (2.95x 2.a31 80 x 85 (3.15x 3.35)
Sore r sttoke
11.8/34m(16.0/3400) t7.1t340o(24.'il3dcol 22.4/32fi(n/ncnl
Conlinuous rathg
kgi/cmz (lb/in.')
output (DlN 6270A) 9.07(29_76)

k W /r pm ( H Pl r pm ) 18.2/3600)
Ore hM 6trng 7.O7(1o0.54l 7.@ (99.82)
@tput (OlN 62709l g.dr (31.59)

Codp(sioo ratio
b.Toc 21tt
F€l injecrion timing (FlO)
F@l inieclion pres.e
at FlywtEl sid€
Main porer take off
at C€okshaft V?ui€Y sid€
Front pows take ofl
C@nt6{lockwi$ vigred la@ Stem
Oiretion of rotatioo Countq{lckwis vGred ftm stm

Orect s €tq c@lirig (rubbe. impellet watd pump)

C@liog systm
Complele trl@d lorced lubrirttr
Lubri@ti@ system

Startiog system

C@stant Gh g@. with dog dulcil

Sail-driw 1212
Propellq sp€ed DlN. A aling

Lubri€taing oil €pacity

(Engare side)
2.1 llu.7sl
Engire reight wilh Saildriw uoit (Ory)

Printed in Japan r-3

Chapler I General
2. Principal Condrudion sM/GM(FXCTHM(F)(C)

2. PrinciPalGonstruction
Integnlly€st wattr iacket and crankes

Engire bl@k M6talhousingtype
Oil pan
Integrated type cylinde6
Poppet type, eat angle So
Water@led type

Watd{@l€d mixing dbw ty(a

O€rh€ai, 6lve 96h rcd, rcks am systm

Fdfid polyuretham und abcquog tYPe

Attld|€d to cnnkshtft by flange' with ring 96r

llain mving eleMts Ov.l typo


frchoid pump

Lubricatis system Full-'flfl ertridg€ type, papers|€ment

Rubber lmpd|€r tYPe
fuling syslem Wil pslbt type

Fuel sastm fihafi&lcsltYPe
Fill€r Fpet

Go€mor ffi ltkFodmc(fiaricdtt"o


lillrrfrr{ltth bulltin lC
tldiel 94r @nstanl-m6h sryslem
Beductkr rewcing
Clutch sysrem Mhank:l tYPe

FEd|{ier doling.yttm (2dnoF Cq|ItF rd 3Hil35R

Chapler I General ChaPter I Ceneral
1. F-ealures 5. ingine C rossS ect

5-3 3GM30
4. Features
4-1 Superior combustion perlormance 4-6 Quiel operation
The unique Yanmar swirl precombustion chamber Intake and exhaust noises have be€n lowered by adopting
and new cooling system display superior combustion an intake silencer, water-cooled exhaust manifold and
perfomance in all typ€s of operation. Low-speed, low- water mixing elbow type exhaust system.
load combuslion performance, especially demanded for The precombustion chamber system and semi,throtile
marine applications, is also superb. and stable type iniection valve suppress combustion noise sub-
pertormance is maintained over a wide range oI speeds. stantially.
Since starting characteristics are also excellent and Moreover, gear noise has been reduced by the use of
warm-up is last, Iull engine performancecan be obtained helical gears around the gear train and clutch gear, and by
within a short lime- lhe bufferingelfect of a damper disc.
In addition, noise prevention measures have also been
+2 Low operating costs taken al the conlrol valve mechanism and other parts.
Excellent combustion and low friction reduce fuel costs,
while the optimized piston shape ring configuration and 4-7 Supedormatching to the huI
improved cooling system reduce oil consumption. continu- (1)Four-point supporl engine installation leet make
ous operaling time has been exlended and operating costs installationeasy.
reduced through improved durability. (2)Mist intake system prevents contamination of the
G3 Compact lightweight (3) Since the fuel pump is mounled on the engine, the fuel
The cylinder head is the integraily,cast typ€, and the tank can be installed anywhere.
crankshaft is the housing type. Minimum weighl has been (4) Waler-cooled manifold prevents a rise in the engine
pursued tor each engine part, and a reduclion reversing room temoerature.
gea employing a special new mechanism has b€en (5) Independent type instrument panel can be installed
incorporated to obtain revolutionary engine lightness. whereYer it is easiest to see.
(6) Speed, clutch forward and reverse, and engine stop can
rH Long lerm continuous operation all be remotely controlled.
(/) The use of rubberand vinyl hoses for ship interior piping
lmproved durability has been achieved by adopting special
not only facilitates piping work, bul atso eliminales
construction and materials for main moving parts and the
valve mechanism, which are the aaeas most subiect to brazing faulls caused by vibration.
(8) Eleclric type bilge pump is avaitabb as an oplion.
trouble in high-sp€ed engines. Moreover, a bypass system
wilh a thermostat mainlains lhe cooting water at a stable
tH Easy to operate
high lemperature, resulting in reduced cylinder liner and
piston ring wear, reduced themal load around the (1) Cooling water lemperature switch and lubricating oil
combustion chamber, and substantially improved pressure switch are provided, and alarm hmps and
durability. Long-term conlinuous op€ration is possible by buzzerare mounted on the instrument panel.
corect operation and proper altention to fuel and (2) Manual starting handle permits manualstarling.
lubricating oil. (Except model 3HM35(C) and tresh water cooling type)
(3) Posilive clutch engagement and disengagement;
ll-5 Low vibration propeller shaft does not rotate when clulch is Dlaced in
Vibralion has been reduced by minimizing the weights of neutral Dosition.
the pistons, connecting rods, and other sources of
vibration, slringent weighl managemenl at assembly, and
balancing of the flywheel, V-pultey, etc. VibEtion has also
been suppressed lhrough the adoption of a special cylinder
block rib construction and improved rigidity_Rubber shock 21. Connsting roo
11. Prsombusiion chamDer 22. Crankshaft
mounts are available when the engine is to be used under 1. Cylinder head 12- Oecompression lever 23. CGnkshaft oear
2. Cylinder body 13. Inlake sllencer . .
conditions which may lead to severe vibration.
3. Cvlinderhead gaskel 14. Exhaust manilolo
i ililX"'j.i[t"t ns
housi 15. Mixing elbow
16. Camshalt
26. Oil Pan
6. Exhaust 17. Camshalt gear oirinretpipe
?. lntake valve 18. TaPPet zlnc
8. VatYesPring 19. Push rod ^
ii. Fuel iniection PUmP cam
g- Vatse rocker arm suPPofi
20. Pislon
lO. ValYerocker am

t- tz

Il- 00004041361

Chapler I General
5. E ngine C ross-Sectiotts srr/cM(FXCIHM(F)(c)

5-3 3GM30

31. F@l inlectloo pump rl1. Revece laaoe geat

1- Cylinder hoad 1 1. P@ombuslion chamb€r 21. Conneling rod ,{2. Output shaft coupling
22. Cankshaft 32. Fuel inieclion nozle
2. Cylinder body 12. Decompaesglonlever
13. Intake silencer 23. C€nkshaft gear 33. Fuel f@d pump
3. Cylinder head gasket 34. C@lidg watd PumP
4. Maln bearing housing 1,1.Exhaust manllold 24. Flvwh@l
25. Crankshaft V-Pulley 35. Themostat
5. Inl€mediate main beadng housin0 15- Mixing elbow
16. Camshaft 26. Oil Pan 36. Slarter motd
6. Exhausl valve 37. Dampe( disc
7. lntak€ valve 17. Camshaft gear 27. Oloslick
28. Lubdcating oll inl€t PiPe 38. Inpul shaft
8. Valve spring 18. Tappet
19. Push rod 29. Anticorosion zinc 39. Outplt shatt
9. Valve r@ker arm supporl ilo. Foila.d large 9€.
.|0. Valve @ker am 20. Piston 3{1.Fu€l Injection PUmP cam


Chapler I General
5. Engine Cros-Sectiorc sw / c.r1(F)(cI HLI (F)(C)

5. EngineCross'Sections
s-'l 1GM10

11. lnlake silencer 21- Flywhel 31. Fuel fed pump

1, Cyllnde. head 32. C@ling water PUmP
'12.Mixing elbow 22. CGnkshalt V-Pulley
2. Cylinder body 3:}. Themostat
3- Maln b€adng housing 13. Camshalt 23. Oil pan
1ii. Camshatl gear 2,1.Dipstick 3rl. Starter motor
4. ExtEUst valYe 35. Damper disc
5. Intake valve 15. Tappet 25. Lubri€tinO oil PUmP
16. Push .od 26. Lubtlcaling oil iolet Pipe 36. Input shalt
6. Valve spring 37. Output shaft
7. valve rocker am supPort 17. Piston 27. Anticorosion zinc
18. Conn@ting tod 28. Fuel injection PumP cam 38. Fosard laroe g€r
8. Valve tocker aam 39. Reverse laagegear
9. Preomb{slion chamber 19. Craokshali 29- Fuel iniection PumP
20. C€nkshaft gear 30. Fuel iniectaoo nozle 40. output shalt caupling
l0- o@omprcssion leve(

Chapta I General
5. Engine Cros-S ecy'iotts


l. Cylindcr hoad 11. Pr€cmblgtlon chamb€. 21. Cnnklh8ft 31. Fusl Inloction nozls 41. Outout shatt couPling
2. Cy$ods body 12. D@mm$lon l€vet 22. CBnkEhaft 9er 3:L F@l f€ed pump
23. F wh€l gl. C@ling rds pump
3. Cy'inder h€ld g6k€t 13. lntskc all6n@,
'14. Exh&si |Mffold 24. CEnkhaft V.tulley 34. Thmrt t
Uain bodng hodng
5. Inl€dEdht€ main bedno houshg '15.Cqshaft 25. Oll pan 35. St|.w mtq
16. Cm3haft 9s 26. Dlpstick 36. Dirpd dae
6. Erhauat v.lve
7- Inlak€ valv€ 17. TepFt 27. Lub.lc.tlng oit inlel pip€ 3?. lopst thrft
18. Purh .od 2E. AntlcffGlon zinc 38. Oltpd lndt
E. valv€ apd.9 tiN(g6 g€r
19. Plston 29. Fu€l inietion pump €m 39. Fwad
9. Valve ,@kc. .m supPorl la.oe gear
t0. Valve .@k€r m 20. Coneling rod 30. Fuel ini€ction pump 40. Re@


Chapler I General
5. Engine CrosstS ectiorc

5-4 3HM35

': ,.: i':r:i!:;

. -ll.;:i.: ,:i.rjl :


l. Cylinder h€d
11. PJeombustlon chmbe,
2. Cylindq body '12.D@omprcsslon l€re. 31. FGt injection pump ,11.Output shaft couplinO
3. CYlinds head @sket rz. tuet ini4tion nozb
il. Maio bering ioustnO 13. Intake dlens
s. i@l fd oumo
14. Exhaust manlfold
B:frfmnf J"","o*rinohousine
15. Mlxlog elbow 3li. Stans moror
7. Intak€ valve 16. Cmshaft
17. Camshafl Oea !!. Dampnrrtisc
8. Valvo sp,ino rr. rnDutshaft
9. Valye ,@k€i am suD@d 18. T8oEt 3E. oqtout shaft
lo. valve aGker am -' 19- Puah rod
20. Pist@ 11. Fqi*ara large gear
w. ngve€e larog o@a

1- 13
(lhapler I Gen
6. Dimensiorc sM/cM(FXCIHM(F)(C)

6. Dimensions
& 1 1GM10

Fuelover{lowO8 3(O033)

4 ol o5tao4 1 t 7 t o2 8 )1 7 5 { o 3 0 ) _5:
/rcozatotot) LlL,rn 161

-11 ^,-e-ff"'"
\igl el u
Dsrrll ot 49llr|g (A} i-L: -=

Mrxingelbofl d45(d1.77) Water outlel 014(d0.55)



water inlel d14(d0.55)

ri@lion pump 41. Output shalt coupling

rta€lion nozle
s pump
{ disc
! rhdt
.d lrrge oear
c lrrge gear

Chaplcr I Oeneral
5. Engine Cross-Sections sM/GM(F'trc|HM(t-)(()

5-5 2GM20F

31. Fuel feed pump 41. Foruard laroe gear

11- P@ombuslion chamber 21. Crankshaft 42. Reverse large gear
1. Cylind€r h@d 32. lleat exchanger & exhaost manifold
12. D@ompression lever 22. Crankshafl gear 43. Output shatt coupling
2. Cylinder body 23. Flywheel 33. Pressure control valve
3. Cylinder head gaskel 13. Intake silencer
14. Mixing elbow 24. Crankshall V'PUlleY 34. Cooling lresh water PUmP
il. Main bearing housing 35. Cooling sea water PumP
15. Camshaft 25. Oil pan
5. Iniemediale maln b€aring housrng 26. Oipstick 36.lhemostat
6. Exhaust valve 16. Camshalt gear
27. Lubricatingoil inlet PiP€ 37. Starler motor
7. lnlake valve 17. Tappet
28. Fuel iniection PUmPcam 38. Damper disc
8. Valve spring 18. Push rod
29. Fuel inieclion PUmP 39. Input shalt
9. Valve tocker arm suPport 19. Pislon
30. Fuel iniection oozle 40.Output shafl
10. Valve .ocker a.m 20. Conf,ecling rod

Chopler I General
5. E ngine C ross-Sections

5-6 3GM30F

1. Cylioder head 11. Pr&ombusiion chamber 21. CGnkshafl 31. Fuel feed pump {1. Foryard large g@r
2. Cylinder body 12. O@ompression lever 22. Cnnkshaft gear 32. Heat exchanger & exhaust manifold 42. Reverse large Oear
3. Cylinderhead gasket 13. lnlake silencet 23. Flywheel 33. Pcssure @nlrol valve 43. Outpul shaft couplino
4. Main boaring houslno 1,1.Mixing elbow 24. C€nkshaft V.pulley 34. Cooling fresh water pump
5. Inlem€diate main beadnO housinO 15. Camshaft 25- Oil pan 35. C@ling s€ waler pump
6. Exhausl Yalve 16. Camshaft Oear 26, Dipstick 36. Themostat
7. Intake valve 17. Tappel 27. Lubricating oll inlet plpe 37. Starter motor
8. Valve sprlng 18. Push rod 28. Fuel inieclion pump cafr 38. Damper disc
9. Valve rocker arm support 19. Piston 29. Fuel injeclion pump 39. Input shatt
10. Valve r@ker arm m- Conn&tin9 rod 30. Fuel inieclion nozzle 40. OutDut shaft

1- 15
Chapter I Generul Chapler I Gencral
6. Dimcnsiorc 6. Dimensions

6-22GM20 G.33GM30

F uel overilow o8 3(o0 331

/ 51030) G) .

(A): 5

Delall ol cqJplir€ (A) (A)

Detailof @dirE

r72(6.77)=f-27s( r) ,r--l- 187\7

r84(725) +--355{13.98) 192\7

12x30(047x 1 18) 4+17(d0.67) 12x30(047x118) 4t17(d067)

Wareroullelo173(d0 68)

I -t,
& SJ

waler inlet d13 8(d0 54)

1- 18 l -1 9
0000A041361 0000.404136r
Chapler I General Chapler I Ceneral
6. Dimensions 6. Dimensions SM/GM(FXCIHM(FXC)

6-4 3HM35 6-5 2GM20F

F uel over{low d8 3(d0 33)


tHril ol cddi.|g (A)

Detail o{ d$liig (A}

t2x3O(047x1.18) 4 o17i6O671

FuelrnleloB 3(o0 33)

r U.Mixrngerw-..-..._

€xhaustoiF f€-r'F.:
I Exhausl PrF
cso.8(c2 ; d50 8(o2 m)


d1? 3(d0.68)


0000A0A1361 0000A0Ar361
Chapler I General
Chapter I General 6- Dimensions
6. Dimenions SM/GM(FXCIHM(F)(C)

6-7 3HM35F
6-6 3GM30F

n ori.5to0 41)
,,o ru, 7 5(0 30)
. rco78(d3 07'
4{0 16}

Ddril.'l ddhg G) D*ilolddi.E(A)

12x 30(047 x 1.18)

12x30(0.47x118) 4O17(O067)
Fuel inlet08.3(60.33)
water oullet d17 3(d0 68)
Fwr inbi oa.3fu&3)

U Mrxrng elbow \

€rffi*lipe Exhau$ fipe

6sO.8(o2.(n) d50 8(d2.m)


0000A0A1361 0000A0A136r
Chapler I Generol
7. Piping Diagroms
Chopler I Generol SM/GM(F)(CTHM(F)(C)
7. Piping Diagrarns SM/GM(F)(CTHM(F)(C)

7, PipingDiagrams I
7-1 1GM'10

t 8&
'da.9 E

lS E
aB. E
_sBt*$taE eis
*E Ep g - . 8 ==s B 3-- q=
3 -1
; '; 6 I c E i i E € E
a e

3 \A
;Y F qs E f l ; F . 3s s s
i/: 'i : 8 E F t 6 o a e ;
Et||ii llll
6 t t t ii
lll I
6 l i i i i I I d YH U =
q I | | | ii + + [ T b t * g
t rt .9
'l l a a
.l r
e o

o J o
'r) '
g e b
os 3

€E 'e
c ]
, t\ o
: s
t U
o .9

= g


Chapter I Gcneral
ChaPkr I General 7. Piping Diagrams
7. Piping Diagrams SM/CM(FXCIHM(FXC)
7-3 3GM30 and 3HM35

(-r-t i*

Y\ 3
t pt
U: " ,6E
.+dggoo- u" ,bg
EE i e *-
CJ) ;
i: E E E - ! pi \X
_i ;:;gi-09IeqE E E E
;:35.'36r i 6c ' 0I E
- el,
o:l ttrt!l
lll f
| I lt | | tA^
liiii l l A Y *r - E AE
aolli , ;
I I I ll + t U I aDcc>
"l I
o R I
E a riF
B! o

] z9

] 6

E xl

l--niir-' oo ?
I : I
= g
s q
-l I

o -ei ;

= "a
3: e
Ec E g
E d'ti E.':1 -al
t :3J$si3
6i? 5
) I

3! E
k trl
I !ittll
ii lll0P- o t r
I ti + u I

0000A0A1361 0000A041361
Chapler I General
7. Piping Diagrans

7-5 3GM30F and 3HM35F



a a




F -a

o at


is "'F;Ft55i sl
,3 g 5 5 s B;5 ri !
E lilililll{;*
Chapter 2 BasicEngine
I. Cylinder BIuk

1. CylinderBlock
1-l Construction
The cylinder block comprises a single unit casting tor the
cylinder body without the use of cylinder liners.

The cylinderblock is a high.qualitycast iron c€sting,wllh

integral cylinders and deep skirt crankcase construction.
As a result of stress analyses,the shapeand thickn€s of
each part has b€en optimized, and special ribs employed
which nol only increasethe strengthand rlgidity of the
block but alsoreducenoise.

1-1.1Cylinderof mod'el1GMl0(C)englne

water passage


Casl hole lor lubricatingoil

Chapler 2 Basic Engine
I. Cylinder Block Chapler 2 Buic Engine
I. Cylindo Block
1-1.2 Cylinder o, model 2cM20(FXC) engine
t-1.4 Cytinder ot model 3HM35(FXC) engine

D r i l l e d h o l e l o r co o ti n g w a te r


Camshaft hole

Screwed hole
lo. cooling wat €r ioint
Camshalt hole

(Gear case side)

Screwed hole
Crankshaft hote for c@ling watet loint
(Gea. cas side) ,.4
Cast hole for tubricatingoil

1-1.3 Cyllnd€r ol modet 3c[:fo(FXC) engine Cast hole for lubricating oil

hft for c@lino waler

1-2Cylinder block inspection
1.21 lnspectingeachparl lorcracks
It the enginehas b€enfrozenor dropp€d,visuallyinspectit 1GM10(C )
for cracksand othefabnormalitiesbeforedisassembling. lf Solt di€meter M10
there are any abnormalitiesor the dangerot any abnor'
malitiesoccuning,makea colorcheck.
Tighteningtorque 6.0k9f-m(43.4tLlb)

1.22 Insp€c{ingtho waterlackol of the cylinder tor

Insp€ct the cooling water passages for sea water cono-
sion, scale,and rust-Replacelhe cylinder body if cono'
sion.scaleor rust is severe.

1.23 Cyllnderheadstud bolts

Checktor loosecylinderheadbolts and for crackingcaus-
Camsha{t hole
ed by abnormallightening,eitherby visualinspectionor by
a colorcheck.
Replacethe cylinderblockil cracked.
Scewd hote
forc@lin O wale. ioinl

(Gear case side)

2GM20(F)( C )
Eolt diameter M12

Casl hole tor lubicatinO Tightonrngtorque 8.oksr-m(57.0fFlb)

000040A1361 0000404136r
Chapler 2 Basic Engine
Chapter 2 Basic Engine 1. Cylinder Block SM/GM(FXC}HM(FXC)
l. Cylinder Block
of the cylinder' the the crankshaft center lin€ due to the thrust ol the
Althouoh the greatest wear is at the top
at the topmost crankshafi and the angle ol the connecting rod.
1.2-5Colorcheck llaw delection procedure oi"ton iing does not slide with the cylinder Therefore, the amounl ol wear must be measured in the
'oosition. inerefore, a step-like paitem is formed between
(1)Clean lhe inspectionpoinl thoroughly- directions ol crankshaft rotation and the crankshaftcenter
(2) Procure the dye penetration flaw deteclion agent. This ihe wom part and the non-wom Part' line. When the difference ot these two values (i-e-circularity
iurttt"*bt", wear is liable to occur along the rotating
agent comes in spray cans, and consisls of a cleaner, pressure of the wear) is large, the cylinder must be repaired'
penelr:rnt, and developer in one set- direction of the crankshaft due to the lateral
direction of
ri"i.^. O" the other hand, wear occurs in the

-!!q$9t' o
-9% 4goJ
Top ring at T D.C.

if l r-l E

kf;, t=-% / top position


Middle Posation
(3)Pretreatthe insp€clionsurfacewith the cleaner.Spray
the cleanerdirectlyonto the inspectionsurface,or wipe
ihe insoectionsurfacewith a cloth moistenedwith the
\ Sottom Position
(4)Spray the red p€netrationliquid onto the inspection
surface.Aftercleaningthe inspectionsurface,spraythe
red penetrant(dyepenetrationflaw detectionagent)on-
to it andallowthe liquidto penelratefor5-'10minules.
lf the penetranttailsto penelratethe inspectionsurface at 8.D.C.
on account ol the ambient temperatureor for other
reasons,allow il to dry and respraythe insPection
(5)Spraythe developeronto the inspectionsurface.After
penetration processing,remove the residual penetrant
from the insoeclionsurfacewith the cleaner.and then
spray the der/eloperonto the inspection surface. lf the
inspectionsurlaceis flawed,red dots or lines will ap-
pearonthe surfacewithinseveralminutes.Whenspray-
ing the developeronto the inspeclionsurface,hold the
can about 30-&cm from the surface and sweep the Top rlog posltion
can slowlybackandforthto obtaina unilormfilm. at T.o.C.
(6)Recleanthe inspectionsurfacewith the cleaner.
NOTE:Belore using the dye penetntion tlaw detection
agent,read its usageinstructionsthotoughly. 3HM35(F)(c)
Wear limit Maintenan@ standard
Maintenance standatd
1-3 Cylinder bore m€asurcmenl c75.10 680.e-80.03 d80.10
c75.0^-75.03 (3.1496-3.1
508) (3.1535)
Cylinder dlameter (2.9528-2.9540) (2.9567)
Cylinder wear is rneasuredwith a cylinder gauge.The o-0.01 o.o2
0*0.01 0.02
amount of cylinderwear becomesgrealeras the piston Cylinder roundness (0.0008) (H.00ol) (0.0008)
nearsthe top, and it becomesgrealestat the positionof
the top ring when the piston is in top dead center.The
When lhe result indicates that eccentric and circularity
reasonforthis is thatwhenthe pistonis at ttle top position, be
wear exceed the soecified limit, the cylinder must
lateralpressureis highdue to lhe high explosivepressure,
and lubricationis verydifficultdueto the hightemp€rature.
Therefore,the amounlof wearmusl be measuredin at least
3 positions,namelythe top, middleand botlom positions
1.24 Oll md waterpass.gos of lhe cylinder.
Checktt|€oil andwaterpassageslorcloggingandbuild-up
of toreignmatter.

Chapler 2 Basic Engine
Chapler 2 Basic Engine
I. Cvlinder BIuk
I. Cylinder Block
1-3.2 Boring ih€ cylinder (2)2cM20(F)(C), 3cM30(F)(C) (.1)How to measure distorlion on the upper surface of the
When wear on the inside of lhe cylinder is excessive, rec- For processingbringthe oil pan side to the bottom,and For orocessingbringthe oil pan side to lhe bottom'and cylinder
tify by machining.This is what is known as boring. inserta pin to the2-d121013
(1smmdepth)locaterhote. (15mmdepth)locatorhole
inserta pin to the2-0121)ott The amount of distortion is measured by placing a
Wh€n boring is canied out, note the following points. straight scale on the upper surface of the cylinder and
(1) Dimension to be bored 246a0.100 (9.681 1-9,6890) inserting a thickness gauge belween the upper surface
The cylinder must be bored to the same dimension as ol the cylinderand the straight scale.
228!0 125 (8.971F8 9813)
Over-sizepiston mm(rn.) o:l

(2) Limit of cylinder's expanded l.O.
Never bore the cylinder beyond the limit of the expand-
ed inner diameter, because no over-size piston is
available for that dimension, besides which there is
danger in having too thin a wall thickness.
Limit of cylinder'sexpanded l.D. mm(in.)
Limitof LD. expansion
(3.159s-3.1606) Measurementis to be canied out on lhe 4 sidesand 2
diagonallines as shown in the figure,and the largesl
Lcater points ot cylinder block valueof clearancelor each measurement is to be taken
For the re-boring ot the piston bore in the cylinder block, use as the amounlof distortion.
the following locater positions. Before re-boring, be sure to
remove packings and dust from the locater points.
1 ) 1 G M 1 0 (C)
Main locater: Oil oan side
Sub locater:Timing gear case and F.O.fed pump side
2) 2GM20(F)(C),3GM3o(F)(C),3HM35(F)(C) Q@ N
Oil pan side and O2-pinholes
(3) Boring procedures (0.4731) b
(1) 1GM10(C) Depth15mm
For processing the bore, face the oil pan side to the bottom
and place the fixing faces ot the gear case and the feed

A{ow$le limit ot dislortbn

'7'di m ens i on (4)Honing 'rGM10(C) o.o5(0.002)
2GM20:172a0.05(6.7697^-6.7736) The inside surface of the cylinder must be honed atter 2GM20(F)(C)
3GM30 257+0.05(10.1161-10.12O1 ) being bored in order to remove machine tool matks.
1-4 Measurement of distorlionon the uppersurlace
of the cylinder
As the cylinder is repeatedlysubjectedto thermalexpansion
and high pressure it will not recover its original shape after
the engine has stopped and cooled down and will be
distorted. The distortion is mainly caused by construction
and material differences of the cylinder, but may aris€ from
t the cylinder head bolts being tightened in the wrong order
or an uneven tightening torque ot the bolts when assembl-
ing. lf there is any distortion at the upper surtace of the
cylinder, it will cause a compression pressure leakage, g:ls
leakage or water leakage as a clearance is tormed around
the cylinder h€d even though the cylinder hsd is
thoroughly secured.

0000A0A1361 361
Chapter 2 Buic Engine
Chapter 2 Basic Engine
I. Cylinder Block

1-5 Cup plug

1-5-1Purpose ofcup plug 2. CylinderHead
In order to minimize the danger of cylinder block breakage
caused by the cooling water freezing, a cup plug is provid- 2-1.Construction
ed al the side of the cylinder block lo prevent damage by
The cylinder head is an integral lwo/three cylinder type and precombuslion chamber are uniformly cooled by an
trost. ample watertlow.
which is bolted to the block.
In the event thal cooing water fr€zing has caused the cup
The unique Yanmarswirl type precombustion chambers are The thermostat is installed on the side surface of the
plug to come oul repair in the tollowing way.
at an angle in the cylinder head, and form the combustion cylinder at the timing gear case side. (On models 2GM20
In cold weather il is necessary to drain the cooling water (C )(F), 3 G M3 0 (C )(F)a n d 3 H M3 s (C )(F),i t i s i n t e g ra t e dw i t h
chambers, together with the intake and exhaust valves.
cornpletety trom the inside of the cylinder block through l-rrge diameter intake valves and smoothly shaped intake the alternatorbracket).
the cooling waterdrain pipe.
and exhaust ports provide high intake efficiency and In addition,on models2GM20{C),3GM30(C}and 3HM35(C)'
superiorcombustion performance. the anlicorrosion zinc is set on the side surface at the
Sp€cial consideration has also been given to the shape of flywheel end, and preventselectrolyticcorrosion.
the cooling water passages so that the combustion surface

2-1.1 cylinder head ol model 1GM10(C) engine

1-52Howlo drlveIn lh€ cup pfug

Ho. Descriplion Plcedure Tool or malerlal used
t. Clea and remre grc from the hole into .Ssfl ddvs q sw blade valve rock€l am
whichthe cup plug b to be drivm. .Thins
(Remw s€le dd s€ling mattrbl previously Valve rocker arm
Remow f@ign
mterbh with
sril drivg
q saw bhde.

Valve top retaintr

Rsmw g|€e from the cup plug. VbGlly ch€k the nick rund .Thinns Fuel valve retainer
the plug.
Valve spring relainel
Appt thebond No. 4 to the st surface Apply orer the whole ouisire of .Threebond No. 4 Valve clearance adiusting
wtse the plug is to be drivsn in. the pluo. Fuel valve
4. hsst lh€ plug into lhe hole. Inert the plug e that it sits Valve spring
5. Plae a driving t@l m the cup plug and drive it Driw in the.dug paallel to the .Ddving tot
n lsng a |mrer. |
srno sunace. I
resistanl packing

'combuslion chamber

Valve rockeaarm mounting boll


E:I- fl ll T

+;I ll
ll ;l$
Themostal covel

ll ll Cylinder head
'Using the sp€chl t@l drivethe cup 3mm(o.1tstin.)ll toomm{3.93
plug to a depth wherethe edgeof the
plug is 2mm O.om7inJbetowthe
lntake valve
Exhausl valve

0000A0, 361
Chaptu 2 Basic Engine Chapter 2 Basic Engine
2. Cylinder Head 2. CYlinder llead SM/GM(FXCTHM(FXC)
and 3HM35(FXc)
2-1.2 Cylinderhead of model 2GM20(FXC)enqine 2-t.3 Cyinder h€ad ol models 3GM3o(FXC)

Valve rocker arm suppod

top retainef

Valve rockeaarm supporl r$istst packing

Valve spring relaine( chamber

top retainer

Valve cleacnce spnng

adjosl screw Heat resastant valve clearance adiusling scaew
Valve spring retainer
Valve stem seal
(ex@pt f reh-water @ling)
ValYe r@ker am
Anticofiosion zinc
R@ker am mounling boll (except f resh-water cooling)

Themostat housinO
Themoslai ho!sing

N o . 'l E x h a u s l va l ve

I lntake valve

2 lntake valve

No.2 Exhauslvalve

0000A0All6l 000040A1361
Chaptu 2 Brcic Engine Chopter 2 Basic Engine
2. Cylinder Head 2. Cylinder lleod

2-2 Cylinder head inspection and measurement distortion of the cylinder head is caused by irregular Measure the seat width with vemier calipers, and repair or
2-21 Measu.€mentof carbon build-up al combustion tightening forces, laulty repair of lhe mounting face,-and reptac€ the seat when the wear limil is exceeded'
surfaceandiniakeandexhaustports gasket packing damage, these must also be checked. When the valves have been lapped and/or ground, measure
Visuallycheckfor carbonbuild-uparoundthe combustion the amount of valve recess, and replace the valve when the
surface and the port near the intafie and exhaust valve wear limit is exceeded. \
Whena largeamountof carbonhasbuitt up, checkthe top Seat grinder
ofthechambercombustion foroilflowattheintakeandex_
2-2.2Oepositbuild-upIn waterpassages
C) (ai:<,
Check for build-updeposit in the water passages,and
removeany depositwith a depositremover.Whena large \/
amounlofdeposithasbuilt up,checkeachpartof the cool-
ing system.
2-23 Insp€cllonof corroslon In water passagesand anti.
,.oo 4) Mix the compound with oil, and lap the valve.
corro€tondnc C 5) Finally, lap with oil.
Inspecl the slate of conosion of lhe water passages,and
replacethe cylinderheadwhenconosionis severe.
Conosionpittinglimit:2mm(O.O7B7in.) Cylinder head distorlion
Inspectthe anticonosionzinc on the cylinderheadcover,
and replacethezinc whenit is wornbeyondthe wearlimit-
Wba limit oc, \i
r..--- \\, I

rGM10(C) 0.07 p.0028)
Anticonosionzinc wear limit: Volumetric ratio with
newzinc= 12 0.07p.0028) (Common to all modelsi

sprciriei{ "A\ i
2-24 Cracklngof combustbn surfac€ s@lwidrh
\'/A\ |
The combustionsurfaceis exposedto high temperature, (1)Cleanthecylinderheadtighieningsurface.
hig-hpressuregasand low temperature (2)Placea straightedgeacrosstwo symmetricalooints al I
air,ind is repeafgd-
ly flexedduringoperation.Moreover,it is used under ex_ the four sides of the cylinder head,as shown in the B6fo@ cd*tion
f igure. (1) Lapping the valve seat.
tremelyseverecondilions,such as the high lemperature
(3)Insert,eelergaugesbetweenth€ stftlightedgeand the When scoring and pitting of the valve seat ls slight, coat (A) Grind wlth a 45" gdnder
diffe,encebetweenthe combustionsurfaceand cooling
cylinderheadcombustionface. the seai with valve compound mixed oil, and lap th€ seal (8) Gdod with a'15" orlodet
walerpassages. (C) Gtind with a 650tu75o gtinder
with a lapping lool.
Inspectthe combustionsurfacefor crackingby the color
At this time, be sure thal the compound does not flow
9hecktand reptacethe cylinder head if any iracking is
NOTE: When the valve scat has been corected with a seat
inlo the valve stem and valve guide-
detected.At the sametime,checkfor signs of ovedoajing grinder, insett an adiusting shim between the vave
andcheckthe coolingwaterftow. spdn g and cy Iinder h eacl.
-r:O o rr o
2-2.7 Meesurlng Yalve 8lnl(ag€
When the vatve has been lapped many times, ihe valve will
be recessed and will lowercombustion per{ormance. There-
fore, measure the valve sinkage, and teplace the valve and
cylinder head when the wear limit is exceded.

(4) The thickness of the largest leeler gauge that can

be in_
serted is the amount ot distortion-
(2) Conecting valve seat width.
2-2.6 Cylinderhead valye seat When the valve seat is heavily pitted and when the seat : \- Va\.-\rrl J{
2-25 Cyflnd€rheaddistorfion The valve seats become wider with use. lf the seats width must be conected, repairwith a seat grinder. <> c.l----Z c) c,-) O
become wider than the mainlenance standard, carbon 1) Repair pitting of the seat face with a45o grinder.
rhe cytinderhead causes gasker packing 2) Since the valve seat is larger than the initial value, cor'
9:1Y" 9! built-up at the seats will cause compression leakage- On
teakage,chdnge in compiessionl lhe other hand, if the seats are loo nanow, they will wear reci the seat width to the maintenance standard by grin-
!ijln", -r*."ion ding the inside face of the seat with a 70o grinder.
quickly and heat transmission efficiency will deteriorate.
Meesurethe distortionas describedbelow,and 3) Grind the outside face of the valve seat with a 15o
reptacethe Clean the carbon and other foreign matter from the valve
cylinder head when lhe wear limit ls exceeOed. grinder, and (inish the seat width to the standard value.
Since seats, and check that the seats are not scored ordented.

2-'12 2-13
Ptint.d ia J6pon
000040A1361 0000A0A1351
Chapter 2 Basic Engine
Chopler 2 Basic Engine
2. Cylinder Head sM/GM(F)(CIHM(FXC)
2. Cvlinder Heod
(3)lnstallingthe cylinderheaclassy-
2) For model 2GM20(F)(C)
Positionthe cylinderheadass'yparallelto the top ot the
cytinderblocK and install the ass'yon the blocK being
carefulthat the cylinderheadass'y does not touch the
'o;c-"o threadsof the cylinderheadbolts.

Gear side
Fl yw h e e l end

Cooling water
(cylinder side
hole is ddlled)
Kep the surface
marked TOP uPward
(cylinder head slde)

3GriFF{FXc) 3HM35(FXC) C@lin9 waler Passage
(cylinder side hole is casl)
Mainteme siandard V,/ea limit Mainteme stildard \,,leil limil

Valw sinlGge 035 0.0374) r25 0.0492) 12s0.0492) 155 0.0610)

3) For models 3GM30(FXC)and 3HM35(F)(C)
2-ZORockeratm suppod posl$,oningPin C@linOwate'Passaoo
(cyllodersideholeis cast)
lror model1GM10(C)]
Checkit the guidepin is damagedor if the holeis clogged,
andreplacethe pin if faulty.

2-3 Dlsmounllng and remounting the cyllnder head

Whendismountingand remountingthe cylinderhead,the
mountingbolts must be removedand Installedgradually
and in the prescribedsequence to pGvenl damaging the
gasket packing and to prevent distortion of the cylinder
head.Sincethe tighteningtorqueandtightenhgs€quence
of the mountingbolts when remountingthe cylinderhead
are especlally knportant trom the standpoint of engine
perfolmance, the following items must be striclly
oos Keo the sudace marked TOP upward
(cytlnde, h€d sHe)
c@lin0 waler pasge
(cylindar slde hol€ is drilled)

2-3.1Cyfindorhoadlssembly s€qtr€nco
(1)Check for loose cyllnder head stud boas, and lock any 2-3.2Tight6nhgthe cyfndorh€ed bolts arxl nuts
loo€e bolts wlth two nuts and then tighten to the (1)Kindsof cyllnderh€adfixing nuts and bolts,tightening
prescribedto(que. totque,tighteningsequence
The cyllnder head ls fitted to the engine with 4 stud
bolts in model 1GM10(C),but in other enginemodels 1) Model 1GM10(C)
bothstud boltsand collarheadboltsareused.
Strd botl dlatr€ts ol cy'indor hd M 12
G6r s'rJe
10.o Flywh€l
C:yllnde.h€d stud bolt tightming to(q€ (72.31

(2)Checkingthegasketpackingmountingface. 'l) For Model 1GM10(C)

Cronfim coriect alignment of the front and rear of the
/O O\
gasketp&king, and Installthe packingby coatingboth
sides wlth ThreeBond 50. Dia To(q@
sequeffi Kindsol fixing
Assomble the gasket packlng keeplng the flat surlace
upwad (cyllnderhead side). Make sure thal the gasket 1
7.5ksl-m(54.2 ftlb)
hole aligns wlth th€ drilled hole in the cooling water Flywh@l end G€ar slde ? Stud bolt fixing nul M10
passageInthe cylinderblock 0ntak€ side)

oV-o K@p lhe aurlace marfted

TOP upwad
(cylinder h€d 3ide)

C@liog waler pas$ge hole

(Hole al cylinder slde is not drllled.)

00004041361 0000A04136I
Chapler 2 Basic Engine
Chapter 2 Basic Engine
2. Cylinder Head SM/GM(FXC}HM(FXC)
2. Cylinder Hetd
guide and valve
2) Model 2GM20(F)(c) 2-4 {ntake and exhaust Yalves' valve

top retainel

Collar head
lnlake aod exhaust valve
bolts, M8
spring collar Valve slem diametet

lntake and exhaust valve

spring seat
Collar h@d
bolts. M12 lntake and exhausl valYe
Valve seat width

Valve lhickness
Valve slem s€al

Valve spting
mm (in.l

3) Models 3GMIX)(R(C) and 3HM35(F)(C)

Fhrwh@l.nd G€r side

iOte uot" tn"t tne intakevalveand exhaustvalvehave
t1 @ 9 @ t0 diltercnt dhmeter.
kgf-m(fr-lb) tGM'r0(c), 2GM20(FXc) 3HM35(FXC)
24.l'lnspecting and measudng the intake and exhaust
Nut & bolt Yalves Maintflan@ Maintemne Werlimit
Trght€ning seq@ne Dia. W€r limit standard
to be tightend rcrrm(Fxc) 3HM35(FXC) standard
(1)Valveseatwearandcontactwidth' 0.8F1.15
Stud bott tixing nul M12 12.0(16.r) 13 (9,1.0) 0.7F1.15
Valve (0.0295 (0.0335
9. 10.11 M8 3.0( 21.?) 3 (21.71 llso ctrecf if eacnvaFe seat contact width is suitable' thick|6 ^-0.0453) --{.0453}
the valveseat contact width is nanower than the valve
Collar h€d bolts
1 ,2 ,3 ,,1 .68, M12 12.0(t6.r) 13 (94.0)
seat width, the seat angle must be checked and
cor' (2)Valvestemberding and w€ar'
' 'ctreck lor wlve slem w€ar and strain, and Epair when
e) Cylind€rheadnut tlghlenlno seguence a Fkst, tlght€n the nuts sequeflthlly to 1B of the 0"","q" i" light. Measurcthe oulside diameterand
is ex'
1) Coat tt|e thleads o{ th€ cy'ind€r h€ad bolts wlth pGscdb€dtoqu€. OenO,and Lphce tte valve when the wear limit
lubdcallng dl, and sq€w the cylind€r h€ad nuts onto 3)Secood, tighten the nuts sequ€nthlly to 2/3 ol ih€ ceeded.
lhobolts. prsscrlb€dto{que.
4) Thlrd,tighten the nuts to the presctlb€dtoque.
O Rech€ct that all the nuts ha,€ beenp.operlytlghtened.

233 O/lnderhad nul looconho 8€g|rcnce

Wtpn bosening the cylinder head nuts, reverse the
tlghtenlng sequence.The cylinder head nut loosening se
quenceis shownin the figure.

Maintemne sfandad V,/errlimit
MaintenatEestandad Wedlimit
67 p2756;, 069 p271n
67 p27fi1 069 (02717)
0o3 po01a
Valve stm

2- 16R
0000A04r361 00004041361
Chapter 2 Buic Engine
2. Cvlinder Head Chapler 2 BosicEngine
2. Cylinder Head
(3) Valve seat hairline cracks.
Inspeci the vdfue seat by the color check, and reolace euide
Prorrusion (3)Rephcingthe intake/exhaust valveguide
t 1) Using a specialtool for extractingand insertingthe 2) Using the above tool, drive the valve guide into po€ition
lhe seat if cracked.
I vatveguide,extractthe Yalveguide. by starting from the valve spring side and finish th€ In-
2-{.2 Insp€cting lnd measu*tg valyo guues side diameterwith a reamer.
The same valve guide is used both for intake ,
and exhaust
valves in the model 1GM1O(C)engine. lt nas gas
a Ofow
M-varve I

op€ning cut in the inner face at the bottom-

I All models
As modets 2GM20(F)(C), 3GM30(F)(C) and
_for 3HM3S Vatueguide potrusbn
(F)(C), the valve guide is different for the
iniate vatue anJ
exhaustvalvein that the innerfaceofthe exhaustvalveguide
(2) Measuring the valve gulJe inside
has a gas blow opening cut. diameter. \s-tlg\tJ v-lo
Measure lhe valve guide inside diameter o G- /a Oo - .- aO
Be. sure that the correct one is used and clearance,
when replacing the and replace the guide when wearexceeds I g ) o - ::l o e I
guides. the wear limit.
For model lGM1o(C)
Erhausl and Intake valve Ouide

Gas cut
0.018! 0.047
Amount of hterteere ot valve guilg
For models 2cM2o(F)(C), 3GM3O(FXC), and gHM3S(F)(C)

Fit the intake and exhaustvalve guues until the bottom of

the groove around the outside of the tve guide is llush
with the endof thecylinderhead.
As the valveguide lor model 1GM10(C)does not havea
groove,fil it aftercheckingits dimensionand markingit.
Square gauge
/ Relationship b€twen YalveOUide
y' lilli^g g@@ and he.d surfrce

(1)Floatingof the Intakeand exhauslvatveguides.

Checkfor intakeand exhaustvatv€guidJ mseness mtln,)
tloating with a test harnm€r, and replac€ foo* 2-4.3Vdvesprhg
floatlng guldes wlth guldes havingan orersize
ouGUe (1)VatuesprlngIncllnation.
Since Inclinationof the valvesprlngis a directcauseof
eccentric contact of the valve st€m, alwayscheck it at
disassembty. (2)Vahe spdng free l€ngth.
Standthe v'alveupright on a stool, and check if th€ entire Measureth€ fr€e l€ngth of the Elve spring,and rephce
spring contacts th€ gauge when a squategaugeis phc- the sprlngwhenthe wearlimit is exceeded.
Maintenance CleaGnce at Maximum ed agalnsttheoutsldediam€terofthe valvespring.
standard assembly allowable
Wear limit lf there is a Oapbetweenthe gaugc and spring,measure
Valve guide inside diameter the gapwith a feelergauge.
(aner asmbty)
Intake 67 {l0.27fi)
0.045-0.070 47.08 When the valve spring inclination exceeds the wear
(0.m18^O.00028) 0.15 (0.0059) limit, replacethospring.
Stem outside diameter
rGMl0(C) 67 1027fi)
Valve guide inside diameter
Exhaust (after assmbly) 67 (0.27ffi1 d7.08
(0.0018-0.@28) 0.15(0.m59)
Stem outside diameter
67 (0.275) d6.9
Valv guide inside diameter
Intake (afler assemblv o7 {o.27fi\ d7.08
2GM20(FXC) 0.04H.065
m outside diameter (0.0016-{.@26) 0.15(0.m59)
3GrirDF)(c) o7 (0.27ffi)
3HM35(F)(Ci Valve guide inside diameter
(arter asmbly) 67 (0.2756) 0.04H.0070 d7.08
Stem outside diameter
(0.0018^-0.0028) 0.1s (0.m59)
47 (O.2756J d6.9

0000.{0.{I 36I 0000A041361
('hapter 2 Basic Engine
2. Cylindu Head
Chapter 2 Basic Engine
sM/GM(F)(CIHM(F)(C) 2. Cylinder Head
..9T.r. the tensionof the spnng SM/GM(FXCTHM(F)(C)
lt-T, with a sprino
A valve slem seal is assembled
pL"f,io;"if ii a
'n" ;i,1,""1???i..j:J""H#ir":
2-5.2Insulalbn packlng 3) Lowerthepislonat the sideto be measued.
4) Insertqualityfuse wire (612mm,O.4Z2in.)
u The insuhtionpackingpreventstransmissionof heatlrom throuohthe
Increasein oil consumption. suid"t o"r"ji. J*i"^",
the precombustion chamberto the nozzlevalveandserues nozte hotderhole.(Be carefulthat the wire does mt
I ne.vatve stem seal must enter the intakeand exhaustvalv€and the groovein th€
always be replaced whenever to improvethe nozzle'sdurability.
has been removed it combuslionsurface.)
Alwaysput in new insulalionpackingwhen it has been
When assembling, coat 5) Crushthe luse wire by movingthe pistonto top dead
the valve stem with engine disassembled.
oetore insertino. oil centerby slowlycrankingthe enginebyhand.
2-5.3 Top clearance 6) Lower the piston by hand crankingthe engine and
Top clearance is the size ol the gap between the cylinder removethe crushedfusewire,beingcarefulnot to droo
head combustion surface and lhe top of the piston at top it.
dead center. 7) Measurethe thicknessof the crushedpart of the fuse
Since top clearance has considerable effecl on the com- wirewith vemiercalipersora micrometer.
bustion performance and the starting characterisiic of the
engine, it must be checked periodically.

2-4.5Sprlngretaine,ard spring
cotte. pin
lnspectthe insidefaceof the
springretainerand the out.
of rhe springcote; pin, anOil,,e
::o:_":1i". conta"ia-,L
cotrerpin insidesurfac" *o ,n"
nead oI,the valvestem.Replacethe
spflng ^"tJ"i"-iff
Ing cotter pin when the contact
th" springcotter pin has been Lss fn"n iOlZ",T,
:Tl recessedbecauseof
No reess (2) Top clearance value.
Wear limit Maintenance
standatd Wear limit
sDnno 38.5mm
- 37mm s.fmm
tie (1.5157in.) (t.4567in-) (1.5157in.) 37mm 0.66-0.86
Top clearanc€

length (0.026H.0339)

when 29.2mm 30.2mm 2-5 Precombustion chamberand

pttached (1.1496in.) (1.1890in.) top clearance range,check for darnagedgasket packing,dlstortion of
L@d 2-5.1Preclmbustion chamber the cylinder head combustion surface, or other abnor-
16.16ko 13.7ko
attached (3s.sod) (30.20t6)
(26.90t6) l-".1::" th"
p.*!ing and insurationpacking
at th€ precom-
Dusrron chamber's frontandrearchamu"., *Ji"1'p*r.',"-
q bumins ar the ,ront end or 2-6 Intake and exhausl vaho roc{<erarm
2-4.4 Valve ctem s€al :l:l rn"'pr"o,i'oiliio" (1)Topclearancem€asurement
front chamber,ackl corosion Sinca the intake and exhaust €lv€ rocker arm shaft and
.cnamber al ti," p.*..0L-.- 1) Checkth€ cylinderheadmountingbolts andtightening
pl,iTTF. l* "hamber, and for bur"o p""fi"sl"',,""" totque. bushing cleaGnce and valve head and push rod contact
Hephceif faultv_ wearare directly relatedto the valvetiming, and havean ef-
4 Remove lhe tuel inlection valve and precombustion tect on engineperformance,they must b€ carefully servic-

2€.1 Compon€nfs of valve aockerarm

(1) Model 1cM10(C)
P.e@mbustion chahber

chamber a

adjusl scGw

I 0000A0Al:]6|
* 0000A04136t
Chapler 2 BasicEngine
Chapler 2 Bosic Engine SM/GM(FXC}HM(FXC)
2. Cylinder Head
2. Cylinder Head
arm shatt and bushlng
2{.2Measuring the valve rocter
The sarnepart is used for both intake valverocker am clearan@
and exhaustvalver@kerarm.The bush is not fitted to of the valve rocker arm shaft
Measure the oulside diameter the
the valverockerarm. ffiT;;.lJ Jiameterol the bushing'and replace
ln hasa simpleconstructionas thevalverockerarmsare lJ"i or il"ning if the measuredvalueexceeds
fitted to the valve rocker arm support from both sides "-
bushingwith a new
withoutusingthe retainer-In the placeof a relainer,the t6'rr""'" roo"" ualverockerarm shaft
rib of the bonnetcover preventsthe rockerarms from is no tighteningallowance'
O,i5ning.Ho*"""', whenthere
comingoul. reolacethe valverockefarm'

NOTE:Takecate that the valve rocker ams do not get

dehched trcm the valve rocket arm shaft when
dismantling orassembling. Replace the bonnet
carclully when assembling. Valve rocker am shafl
The intake and exhaust valve rocker arms tor two
cyinders are fitted to a vake rocker arm shaft at both
sides of the spring. The same part is used lor both in-
takeand exhaustvalverockerarms.


mm (a)

Cleanne al Milimum allowable Wearlimit

Maintenan€ clearare
dsndard assembly
Valve cleaEoce
adrust scGw 6t1.9
lntake ild exhaust valve rGKd A 6',12(0.4724], 0.olH.O52 0.15 (0.00s9)
Valve rccker am slppoat am shaft outside diameter- (0.0006-a.0oz0) 612.1
1GM1O(C) (0.4764)
lntake and exhaust valre rcker.arm. 612 (0.47241
exhausl valve a@ker am
bushinq inside diameter
(asmols) ---..--.--..- 613-9
(3)Mod€ls3Gil3O(F)(C)and 3HM35(F)(C) (0.5472)
lntake and exhaust valw r@Ker A 014 (0.5512) 0.01H.052 0.15 (0.0059)
Tt|e inlak€ and exhaust valve rocker arms for lhree Valve r@ker am shalt arm shaft outside diameter (o.0o0H.o02o) d14.1
cylindeGiare fitted to a valve rocker arm shaft at both 2GM20(F)(c) Inbke and exhaustvllw.'@!91-a,r]l. B 014 (0.5512) - -
sides of the spring. The same intake and exhaustvalve 4t3'
Shafl sp.lnO 1 intake valve (0.5472)
rockerarms, valve rocker arm support,spring and valve lntake and exhaust- llw r@ker A c14 (0.5512) o_016.-0.052 0.15(0.00s9)
arm shatt outside diamerer (0.0006-0.0020)
clearanceadjustingscreware usedfor modelsgGM30 I exhaust valve 3GMs(FXC) , 6*,,
(F)(c)and3HM35(F)(c). r@ker am 3HM35(FXC} lnlake and exhaust €lve rdker
arm b 614 (0.5512) I (0.5s51)
2 intake valve rocker arm
bushing inside diameter (assmbled)
Valve r@ker am supporl 2 exhausl valve r@ket arm

-1-t- -IT- tomm (0.3937in.1

2-6.3 valve mc*er arm and vahe toP
Gtalner contact and 2-6.5 Classllicai'ronot the lntake and oxhaust
valve rod(er

woal rocker arms have dif'

since the intake and exhaust valve
t.@ rPl Check the vatverocker arm and valvetop
rciainer contact'
,here ls any abnormalwearor
peeling' ferenl shaPes, care ;;;f; exercised in s€rvice

(lh 11N
J-l-l l-
"n"" assembly.
3 intake valve r@ker arm
r#J IIPJ 2'6.4 Vahe cloarancoadiusiing scr€w
lnspectthe Yalveclearanceadiustingscrew

3 exhaust valve a@ker ah

f, 0
tl "o-,it""i,
peeling. "nO
replacewhen there is any abnormalwear
Valve cleaGnce adiusting screw
i. in Jqaa
2-22 Printed
i .1 0000.{04I 361
Chaptu 2 Basic Engine
2. Cylinder Head ChaPler2 BasicEngine
2. CYlinderHead SM/GM(FXC}HM(FXC)
2-7 Adiusling intake and exhausl yalve head
(3) Check and adjust the intake and exhaust valve head 3-72Adiustingwithouta feel€rgauge
by tighteningtheadjusting
S"t tn" i""O clearancelo zero.
clearances of lhe No. 1 piston.
Adjustmentof the intakeandexhaustvalveheadclearance Loos€n lhe valve clearance adiusting screw lock nut, ad-
Sr"urlu"ing not to tightenthe screwtoo tight'
govems the perfornance of the engine, and must be iust the clearance to the mainlenance standard with a iil^'loirit"tt" valveclearancelo the maintenancestan-
perlormed accurately.The intake and exhaust valve head feelergauge, and retighten the lock nut. the adjustinsscrewbv the anslesiven
clearancemust always be checked and readiusted,as re- "ff
quared, below.
whentheengineis disa&sembled and reassembled.
and after every300 hours of operation.Adjust the valve nul
headclearanceas descn'bedbelow. /,Lock

Makethisadjustmentwhenthe engineis cold.
(2)Crankthe engineand set the pistonto top deadcenter
The matchingmark is made at the setting hole of the @rzsP'gtael'i'oae21
startermotoron all models. ilai""tns"**@
NOTE:Calculating the backofl angle'
""'-'Jiiiit"in" o'z^' advinceangtetrom1'xmm
616ng1urn= W" 3Gtr3O(R(C)and3HM35(FXC)
0.2t1.25x3@o= 58o
be used
oie side(60o)ot the hexagoal nut should
to measure.

2-8 DecomPrcssion mechanlsm

The decompression mechanismis used when the starter
.r:to'ii.liti"-ttt"t" sutficiently because the battery is
weahandto tacilitatestartingin cold weather'
ifi;;;-iec"mpression lever is operated'the valve.is
lriiJ I"*", tni, engine is decompressed'the
i"-ti. ou", and ihe flywheelInertiaincreases'thus
Matching ma.* makingstarting "r"irveasy.

with respectto models1cM10(C),2cM20(F)(C)and3cMgo
.(F)(C)only,a projectionwhichservesasthe matchingmark
is providedin the castholeot the clutchhousing.

In the case of 2GM20(F)(C), adjust the vatve head

clearanceof the No. 2 cytinder in the same manner after
turning the crankshaft180p.
In the case of 3cM30(F)(C), 3HM3S(F)(C),adjust the
valve head clearance on the No. g cylinder in the sme
manner after turning the crankshaft 24Oeand then adjust
the No. 2 cylinder after turning the crankshaft another
NOTE: Il you adiust the valve head clearance ol the No.
/VOIE: Sef to the position at which the vatve rocker 2 cylinder first, turn the crankshaft S4e. Adiust
stratf does not move even when the cnnkshatt is the clearance ol lhe No. I cylinder in the same
tumed to the lelt and right, centercd arcund the manner on a 2 cylinder engine.
matching maft.

ti 2-25

*l 0000A0A1361 0000A041361
Chapter 2 B6ic Engine ChaPler2 Basb Engine
2. Cylinder Had 2. Cylinder Head sM/GM(F)(CIHM(F)(C)
.2)Removingthe precombustionchamber
'-'it' ili.""in" tirt pt€combustionchamberandpacking' B€lore reassemblingth€ cylinder head,wash all the parts'
ii il"to"" in" lront precombustion chatnb€r
and pack' insD€ct and mgasure the dimensions of €ach part' and
Ing. reoairor teplaceany patts that ar€ abnormal'Be caretulnot
ro conluse the parts grouped by cylinder numb€r and in'
(1)Assemblingthe intakeandexhaustvalves
' presstne vatveguideinio the cylinderhead'

2i Install the vatve stem seal' Glways replace the
stem sealwith a new seal.)
$ Installthe valvein the cylinderhead'
4i lnstallthevalvespringandvalvesptingseat'
Deomp. l i fl $ Installthe sPlitcollar.
. Usingthe sp€cialtool
. Usinga wrench
(2)Installingthe valvearmassy
A=t(\t '-il'insralt tie tnt"t and exhausttocker ams on th€ rocker
i\--l6J- armsuppon. "
z) instatt botn tne rocker am supports and
rockerarm re
Pa@ombustion -;i-*^ on the cylind€rhead,th€n tight€n th€m
Withthis engin6,therels no needto adjuslthe decompres-
sion litt. nuts.
f;l) Installingthe ptecombust'loncharnber packing'
iii.-"t rrtn" t.nt prccombustionchamberand
@ zi i^"iii in" *t precombustlon chamberandpacking'
rephcethe insubtionpacking')
e (Ahivays

2-9 Dlsassembllngand Fassombling the cylinder 3) Removethe rockeram retainer,and pull the rockerarm
h€ad from the rockeram support. (3) Remo/ing the lntake and exhaustvalveassy
2-9.1Dbe$.mbhg the ca6n<lec hed
When dlsassernblingth€ cylind€r head, group the parts
soparatelyaccoding to cylinder, intakeor exhaustto avold
confusbn. OO
(1)Disassembllngthe rockerarm assy

'l) Remor/€the rocl(erafmassy mountingnuts.
4 Remol€ th€ rockerarm ass!.


NOTE:A retainet ls not used lor the valveroc-kerarm on

and exhaust valve
nodel 1GM10(C)and is kept tree, thercIorcthe 1) Set the sp€ckrl tool at the intake
rocker am can be removeddirectlY. " IJ"V'"nJi"p** the valvespringby tumingth€ lever'
a ilfri"ln" tool is not available'depressth€ vawe
springwith "p*ial
a wrench'
3) Removethe springcotter Pln'
;i iili; i;ilf tie special tool In the looseninsdirec-
-'i.i. *i""* tte valvespring retainer'and
u.t"" spting ,etalnerand valvespring'
5l Pullthevave fromthe cylinderhead'
6i Removethevalvestemseal'
7) Removethevalveguide'

000{.{04 | 36I 0000A04136r
Chopler 2 Brcic Engine Chapter 2 Basic Engine
3. Pislon 3. Pidon sM/GM(FXCTHM(F)(C)

3. Piston Detail of A (heal dam)

Mdnttrme standard V,/e{ limit Mainterc stmdard tr,re{ limtt

3-1Pistonassemblyconstrucllon Piston dtskle diafrPter. . 74.85 c79.902^-79.932 79.84

Thepistonsaremadeof LO-EX(AC8A-T6)
for lightnessand E. (t1"19i'"ffiffd3'liH &5&"r
(2.9468) (d3.1,ts7-3.1470) (3.1€3)

are designed tor reduced vibration. The outside of the dl

piston is machined to a special oval shape. During 622.99''-23.W

opera- c19.995-20.008
tion, thermal expansion is small, the oplimum clearance Pistonpin hole insidedimter (09053 0.9058)
P.7a72N O.lAm -
between the piston and cylinder liner is maintained. and a 0.n 0.066 0.10 020
0.065 0.10
stablesupply of lubricatingoil is assured. Fi6t @mpresion Piston (0.0026- 0.0039) (0.0079) O.om -- 0.0039) p.0079)
- 020
0O35 0.07 020 0O35 0.07
Se€nd cmpre$ion Piston - om79)
- 0.00u)
p.0014 tu p.m7g) O.001a- 0.0028)
0.15 0.020 0.056 0.15
0.02- 0.05s
compression aing Oil ring-tog@reclem€ O.omB 0.0022) p.oca) P.om --0.0022) p.005st
S@ond compr6sion ring
rang (3)Pistonpinoutsidecontactand ringgroovecarbonbuild'
cieck if the piston ring grooves are clogged with car-
bon, if the rings movefreely,and for abnormalcontact
aroundthe ouisideof the piston.Repairor replacethe
pistonif faulty.

+22 RephcingaPblon
lJthedimension of anypartiswornpastlhe wearlimiiorthe
outsideof the pistonis scored,replacelhe piston'
1) Installthe pistonpin circlipat one sideonty'
A lmmersethe pistonin 80oCoil for 10tu 15minutes'

A completeset of piston rings consistsof two comDres. Piston

s'lonringsaM oneoil ring.
Toimprorcthe rigidityof the pistonskirt no ring is installed
on the skirt itsell so that the piston seldom becomes
deformedand retainsslable conlacr. (2)Measurethe clearancebetweenthe piston ring or oil
The piston pin is of th€ floating type. Both ils ends are ringandthe ringgroovewith a thlcknessgauge.
Groovescalleda heat dam are cut round the top section of
the piston. These grooves h€lp to dissipate heat and pre

3-2 Plston
3-21 Insp€G1ion
Measureeach importantdim€nsion,and reDlacethe
pistonwhenthewearlimitis exceeded-
Fi6t compresslon
3) Remove the piston from the hot oil and place it on a
gr@ve width bench with the piston head at the bottom'
Seond compression 4) lnsert the small end of the connecling rod into the
9r@ve widlh piston, insert the piston pin with a rotating motion, and
install the other piston pin circlip.
Use wooden hammerif necessary'
Oil ring grcove width

Piston pln hole

r*"l:l t?,?ffi$i":"ins, pistonpinls in the
inside diameler checkwhetherlhe
\ fl:J*,"o.,..n.oovecreaance
pinwithoil to tacilltat€Insertion'
Piston outslde cliameter
,t illf;:i;i"t*
;( ffi;i tilii.; ;"nnectinsrodandplstonmovefreelv'
ii in"..rri." pi" qrickly,beforetheplstoncools'

Chaptu 2 BasicEngine
3. Pislon Chapter 2 BasicEngine
3-3 Piston pln and piston pin bushing
(3) The oil ring is a chrome-pbted coil expander having a
3-4 Piston rings small contacting face, and exerts high pressure against
+3.1 Pislon pin
the cylinder liner wall. Oil splash at the bottom ol the
Measure ihe dimensions of the piston pin, and replace the 3-3.1 Piston ring @nligumtion
sliding face is excetlent, and its oil control etfect is hjgh.
pin if it ls wom past the wearlimit orseverely scored.
Fi6t comPclion rioo
(Barel fa@l
l . r: I
t"* This part i3 hard chromium
plated. Thickress ls 0.1mm
(0.0039in.)or more.
Srcond comPcssion ring
-/ (TaP€t ringl

-r ll

Mdimum wea, mesucd in (a) (b) direc

tions al central gosition mafted.
mh ( i n .)
3GM3O(FXC) 3HM35(B(C)
Maintffie slandard l bslimit MaintesE sladard t€alimit
Pbton ph outsue dhfiEter o20_3mp.7870ry0.7874) o19.98p.7866) o23:3m@.9052 s2-*p!o{n
hole and pislm pin -0.005 tu +0.017
-O.9o5s) (1)Thetirst comgesslon .lng ls a banel face ring that eflec- oil tlot
-OO05 +0.017 ' '
allorc (-{.0@2 tu +OO@n - +0.0@a
{<).0@a tu tively pteventsabnormalwear causedby engineloading
andcombustiongasbbwby at initialrun'in'
3-3.2Pblonph bushing Theslidingsurtaceis hardchromiumplated'
A copper alloy wound bushing is pressedonto the Diston 1GM10(C),
Model3HM35(F)(C)l ' 'in.p."t de plston rlng contact, and replacethe ring
pin. 3cr&(a(c) 3HtuBs(R(c) is
whencontaciis fauity.Sincethe oil ring sidecontact
Since a m€tatlicsound wilt be producedif the piston pin Maintemne War r"f"t.O to oil consumption, lt must be checfted
Mainlffi@ W€r
and plston pin bushing wear is excessive,reolacethe standard limit standard "foofy
lihil Thb Dart is flBthard wnh Particu|arcarc.
bushingwhenthe wearlimlt is exceeded. chomtum Pbted (thlckness
Pislon pin
e) Measuringthe Plstonring gap
The plston pin bushingcan be easityremovedand installed businq 6m.o O.lmm (r.0c'91n.) d |!1@l '-' by
ireide (o.7874' on.1
623..1 th€n tln Dltlcd. insert tnJ pSton Into the cylinderor cylinderliner
with a p.ess. However,when installingthe bushing,be diameler
pushing the piston rlng at th€ head of the piston as
ca.etulthat it is nol tilted. Models1GM10(C), 3cM{n(fl(C)
2GM2o(FXC), gap
"Piston pin inown-ln the figure, end measurc the piston tlng
*itn a feeter gauge. Measute the gap at a point about

sionatterpressingonto theconnectingrcd.
lmmm €.g:fotnJ fromthetoP of the cylinder'
Thlr part i9 hard chomlum Measureby insertlnga thicknessgauge
Dtatsd. Thlcktrs ls O.l mm
0.0039in.) of moE.

e) The second cdnpr€ssion ting ls a taper ring having a

o30'.Slncethe cylinderliner
slidingfacetaperof 30' tu 1
is striignt, and the contact area at initial operation is
small,it is easilyseatedto the cylinderliner'
Moreover,the bottom of the sliding face is sharp,and oil
splashis excellentandair-tightnessis superb'
Cylinder galge

l. e lcd'

Chopter 2 BasicEngine
Chapter 2 Basic Engine 3. Pbton SM/GM(FXC}HM(FXC)
3. Pislon
SM/GM(F)(C}HM(FXC) Sincerhe oil ring is equipPedwith a coil expander'at-
it to the piston so that the ioint of the ring is
oppositethe gapof thecoil expander'


lGMlo(c). 2cM20(Ftfcl, SGlns(FXc) 3HM35(R(C)

Maintenane standard Wear limil Maintenan@ siandard Wear limil
width 1.97-t.99 1.90 1.97-1.99 1.90
(0.0r/H.0783) (0.0748) (0.0776-0.0783) (0.0748)
lst. Piston ring
Thickres 3.1G"3.30 3.20-3.40 Joint of
(0.1&.1299) (0.1&.1339) coil expandea
widh 1.97-1.99 1.90 1.97-1.99 1.90
(0.02H.0783) (0.07,18) (0.02H.078i1)
Thickre 3.10-3.30 3..|o-3.60
(0.1&.r299) (0.13H.1417)
width 3.97-3.99 3.90 3.97-3.99 3.90
(0.1563.{.1571} (0.1s35) (0.1s6H.1571) (0.1535)
Thickre 2.&-2.& 2.70-.3.10
(0.094H.1102) (o.106H).1220)
lst. Pistq ring gap 0.N.40 1.5 0.25.-O.45 r.75
(0.007H.01s7) (0.059r) (0.0098-.0.012) (0.068e)
2nd. Pistm ring gap 0.H.40 1.5 0.H.40 1.5
(0.m7H.0157) (0.0s91) p.m7H.0157) (0.0591)
Oil ring gap o.M.& 1_5 02H.45 1.75
(0.m7H.01s7) (0.0591) (0.0098.{.01n) (0.0689)

(3)Pistonring replacementprecautions
1) Clean the ring grooves carefulty when replacing the
2) When installing the rings, assemble the ,ings so that
the manufacture/s mark near the gap is taciig the top
ofihe plston.

Uat^",t*r'"*ffi lst comp.ession rinO

2nd comprcssion dng

oll rln€
3) After ass€mbly,check that the rings mo\€ freely in the
4) The rings must be Instafiedso that the gaps are 12Oo Diaeclioo ol pislon pin
apart.At this time, be careful that the ring gap ls not lin-
ed up withthe pistonskje pressureoan.

Gap position ol No2

ol T

Gap position ot oit rinO


Chapter 2 Basic Engine Chapter 2 BasicEngine
4. CorutetingRod 4. Cornecting Rod SM/GM(FXC}HM(F)(C)
3) Tighten the connecting rod bolt to the Drescrib€d

4. ConnectingRod tightening torque.

&1 Connecting tod assy conslruction Passa test barthroughthe brge end andsmallend holes
The conneclingrod connectsthe pistonpin and crankpin ol the connectingrod, place the bars on a V-blockon a
and transmlls the explosi\re force ol the piston to the stool and centertt|e large end test bar.Thens€t the sensor
crankshaft.lt is a slamp forging designedfor exlreme ol a dial indicator againsl the small end test bar and
lighinessand ample strengthagainstbending.A kelmet measuretwist andparallelity.Whenthe measured valueex-
bushingsplit at right anglesis installedto the brge end of ceedsthe wearlimit, rephce the conneclingrod.Twisting
the rod,anda roundcopperalloyis pressedonto the small and poorparallelitywill causeunevencontactof lhe piston
end. and bushingand shifting of the piston rings,resultingin
Connectingrodtwist and parallelity m m ( r n .)

Piston Din

1GM10(C),2GM2O(FXC), 3HM35(F)(c)
Maintenan@ W€t W€r
standard limit standard limil
Cond6ting rod Crank Pin
bshing o/o.0 d4O.10 o44.O 614.1O
(1.5748) (1.5787) (1.7323) (1.7362)
Csnk Pin 0.02H.086 0.@6-0.092 0.13
and 0.13 (0.m14 (0.m51)
(0.0011 (0.0051)
bushingoil {.003r) --0.m36) 12mm(0.4724in.) l3mm (0.5118
M9 x P1.0 4) Loosenthe connecting rod bolt and slowly removethe
M7 x P1.0
Conn@ting rod
rod bolt
Thread (0.2755x 0.0:P3) (0.3543x 0.m3) conn€ctlng tod big end cap, ihen measurethe crushed
dbreter Plasti gauge wlth a gauge.
rcd bott 2.5kqf-m 4.5kqf-m
( 18.ffr-rb) (32.5ft-lb)
M6uring twist and pacllelity NOTE:TheCnnkpin bushinginsidediametermustalways
be measuredwith theconnectingrcd boftstightened
.l-2 Insp€cllon tF3 Crankpln bushlng to the Prescilbedtorque.
4-21 L!.!€ e.rdsmafi end t$rbt and paral€lity Sinc€the crankpin bushingslideswhilerec€ivingthe load
from the piston,an easy-tGreplacekelmetbushingwith a 4-3.2Ct|ankPh lnd bGhlng cbaranc€(oll clearanco)
wea(-resistantoverlayis used. Since the oll clearance atfects both the durability ol th€
bushing and lubricating oll pressure'it must alwaysbe
vatue. Replace the bushing when the oil
clearanceexceedsthe wearlimit.
pin sec'
i) Thoroughlycleanthe insidesurfaceandcrank
tion ofthecrank Pinbushlng.
a hstall the connectlng tod on the crank pin s€ction ol
the crankshaftand simultaneously lit a Plastigaugeon
the insldesurfaceof the crankpin bearing'

4-3.1 Crank pln bushlng lnsld€ dhm€te.

machinethe c,?,nkpin
- Nevet adiustby stims ot
Tighten the large end ol the connecting rod to the prescrib-
bushing.'Atwaysreptacethe cl?lnkpin bushingwith
ed torque wilh the connecling rod bolts, and measure the
a newone.
inside diameler ol the crank pin bushing. Replace the
bushing if the inside diameter or the clearance at the crank
pin part exceeds the wear limit.

000040A1361 0000A041361
Chaplu 2 Basic Enginc Chapter 2 Basic Engine
4. Connecting Rod 4. Connecting Rod SM/GM(FXC'HM(FXC)
tightened to the
5) The crank pin and bushing clearance (oil clearance) The connecting rod bolts must also be 1GM10(c),2GM2O(FXC), 3HM3s(F)i
may also be measured with a micrometec in addition to prescribed tightening torque in this case' c)
measurement with a Plasti gauge. With this method, Maintena@ Wear Maintenan@ Wsl
the outside diameter of the crankshaft crank pin sec- slandard limit standard limit
tion and the inside diameterof lhe connecting rod's big Piston Pan
end bushing, when lhe connecling rod boll has been bushang d2O.0 o20.10 623.0 623.1
inside (0.7874]. (0.7913) (0.905s) (0.9094)
tightened to the prescribed torque, are measured, and
the difference between the large end bilshing inside
Piston 0.025.-0.047 0.025^o.047 0.1'l
diameterand crank pin outside diameler is set as the oil 0.11
and (0.0010 (0.m10
clearan@. bushing (0.0043) {0.0043)
^{.0019) -o.0019)
(2) Measurement precautions clearan@
1) Be careful that the plasti gauge does not enter the oz2.v-2..u2'l 623.O-z}.021
rod hole 0.8661-0.8670) 0.9o55-O.90631
crank pin oil hole.
2) Be sure lhal the crankshaft does not turn when tiohten-
ing lhe connecling rod bolt. (4) Check that there is no sand or metal particles in the
Rophdng lh€ Pislon Ph bushing
lubricating oil and that the crankshaft is not pitted.
+3.3c€nk ph bushhg replacement prccautbns (l) Whenihe bushingfor the connectingrod pistonpin is
Clean lhe oil holes with particularcare.
(1) Thoroughly clean the crank pin bushing and the rear of eilher wom out or damaged,replaceit by uslng the
thecrank pin bushing. "piston pin extraciing tool" installedon a
tl..4 Tightening the connecting rcd bolts
(2)Also clean the big end cap, instalt the crank pin bushing
and check if the bushing contacts with the big end cap When iightening the connecting rod botts, coat the threads
closely. of the bolts with engine oil.
(3) When assembling the connecling rod, match the Tighten the two botts altematety and gradualty to the
number of the big end section and lhe big end cap, coat prescribed tightening torque. lf a torque wrench is not
the bolts with engine oil, and aftemately tighten the available,make matching marks (torque indication lines) on
bolts gradually to the prescribed iightening torque. lf a the head ol the bolt and the big end cap and tighten the
torque wrench is not available, put matching marks (tor- bolts until lhese two marks are aligned.
que indication lines) on the bolt head and big end cap
before disGsembty and tighten the botts until these two
4-6 Plston bushing and Plston Pln
lines are aligned.
The pistonbushingis a roundcopperalloy-bushingdriven
ontoihe smallend ot the connectingtod' Duringuse' the
oiston pin bushingand piston pin will wear' lf this
becomesexcessive, a metallicsoundwill be producedand
lhe enginewill becomenoisy.
c,n eting tod/,/pistonpinbushino
! ,*riton
otn NOTE:Forr' the pbton pin bushtnglnto positionso..that.
Y-t.=.rttat- ttsoil hole coincideswlth the hole on the smallenct
f | | lPistonPinbush,ng i===-
llllinsidedhm€lerE@l ol theconnectingtod.
{2}Afle;forcingthe pist6npin bushinginto
'-' in" inno of the bushingby uslnga pln honing

pistoJpln outsiob diameter
-'{iF- machineor reamerso that it fits th€ piston pin to be

Alignment mark (Punched ma.k)


pin so that the pin'

4-5 Connecting rod side clearance NOfE: Attach the bushing to the piston
into position
Afterinstallingthe connectingrod on the crankshaft,push coated with engine oil can be pushed
the rod to one side and measurethe side clearanceby in- with vour thumb
sertinga feelergaugeinto the gap producedat the oiher
Alignment mark (Casting mark) sroe.

Chqpler 2 Basic Engine
Chopler 2 Basic Engine sM/GM(F)(clHM(F)(c)
5. Crmkshal
5. Crankshatt
5. Crankshaft The following figure shows the crankshaft assembly
"'i 'ii6,"rs,ittlic). on model 2GM20(F)(c) the intermedi-

5-1 Crankshaft assl and bearing conslruction 5-1.1 Construction ot model 1GMlo(C) .r .nor r i no atthe qearc a s e e n d i s n o t f i t t e d Th e c o n s t ru c -
The crankshaft is stamp-forged, and the crank pin and jour- assemblyis the same
irankshafl assembly io"n-of.oi"rsHru3s(F)(C) crankshaft
nal sectlons are high-frequency induction hardened, and The crankshalt is supported by the metal housing at the as that oJ model 3GM30(F)(C)'
ground and polished to a high precision finish. Therefore, flywheel end, and by the bearing metal which is inserted in'
the contact surface with the bushing is excellent and lo the cylinder body hole at the gear case end. Thrust
durability is superb. metals are set at both sides of the bearing at the gear case
The crankshaft is a balance weight integral type. Engine un- end.
balance, which causes vibration, has been minimized by
balancing the V-pulley, flywheel, and crankshaft.
The flywheel is fixed at the end of the crankshaft with hex-
agonal bolts and a locating pin. The crankshaft gear is fixed
and keyed to the crankshaft inside the timing gear cas€,
and the govemor weight support is lixed with a hexagonal
nut together with the crankshaft gear. lt is so designed that
lhe govemor sleeve and the thrust bearlng can be slid onto
th€ crankshaft to get the gear skie end of lhe crankshaft to
perform as the govemor shaft. The V-pulley is fitted oulside
the timlng gearcase and il drives the altematorand cooling
water pump fon models 2GM20(F)(C),3GM3O(F)(C)and Metal housing

end (bGb m€tal)

tnlmediate beting metal at llywh€t

metal housing (at llywh6l end)


\S€t bolt

Cank metal
ln;ediate metal houslng (at gear caso end)


C€nk m€tal at €@r

Thrust metal Govemor wei9hl cass end
Cdkeh.ft g@r
Cc n k metal

Go€mor reight
Thrust melal
Hexag@al nui
Thruit metal retainel

0ear Gowmol awe

Governor weight support
Thrust b€atlng
H e xa g o n a l nul

Thrust bearing

Eall bearing


0000,{041361 0000A0Ar361
Chaptcr 2 Baic Engine Chaplcr 2 Baic Engine
5. Crankshatl 5. Crankshatt SM/GM(F)(C}HM(FXC)

1GM 10( C )
(1)Cracking (2) Crank pin and crank joumal outside diameter measure
lf crackingof thecrankjoumalorcrankpin is suspected, ment.
thoroughlyclean the crankshaftand perform a color When the difference between the maximum wear and Flywhel end
Gearca* eno
check on the shaft, or run a candie flame over the minimum wear ol each bearing section exceeds the
crankshaltand look tor oil seepagefrom cracks.lf any wear limit, replace the crankshaft. Also check each bear-
cracksaredetected.replacethe crankshaft. ing section lor scoring. lf the scoring is light, repair it
with emery cloth.

Intemediale iournal
Crank ioumal

Flywhel end
G€r case end

1GMlo(C),2GM2O(FXC), 3HM35(FXC)
Maintffistmdad U,ler limit MdnteMe standard l Jetr limit

Gswsbe A
o44xB a439i) c,47m o46.90
3HM35(F) C€nk 9in
(1.791tu 1.7S9) (t8l fla,|84 tu 14a90) (18465) 3GM30(FXC),

Cmk iournal disile InteFndiat€ bearing B

641xffi o4390 ata4ffi
- '{m
diaretq (1.7S tu 1.7309) (1.7283) fl4484 & ra49q fl846q

Flnvhel side C
o6oiffi a'5€30 s6siffi 66490
e3602- 236m) @583) Qs571 N2-55761 e5561) Flywh@l end
G€r cs€ em
Cnnk oln outsile dkmts O
o4oiffi o3930 o44*ffi s43.90
(1578 fr 15734t (157€) fi.73G tu 1.73@) (1.7?fBl,
0.01 0.01
Crank lournal/pin eccentric w orxD4) pom4)
0.0$ 0-092 0.t5 0.0$ tu0.G5 0.'t5
P.m14 -tu 0.0036) p.005s) O.m14
oo05s) lntemediate

Cmk iournal and bushing 0.0S 0.15 0.0S 0.15

IntffEdiate bearing -0092
O.m14 tu0.0@) o.0059) -0fi5
{0,0014tu 0.0004 p.m6e)
0.O$ 0.095 0.15 o.oib* 0.099 0.15
Fb/whel sUe - 0.00c4
P.m14 tu p.005s) 0.0014tu0.0@) o.ocs) (3)Measuringthe crankshaftbend [2GM20(F)(C)'3GM30
0028 0.086 0.13 . 0.036 0.092 0.13 (FXC),3HM35(FXC)I
irt'."sut" on a surlace plate. Place the ioumal parts of
pin and cmk pin beding oil deffince - 0.@36)
P.0011-tu 0.0034) o.ms1) 0.0014 tu pm51)
NOTE:Thecnnkshattot model1GM10(C)doesnot havean both ends of the crankshafton a V'block and m€asure
intermediatebearing. with a dialgaugewhilemovingthe crankshaftin an axial
direction. lf the deftection ol the mlddle of the
Measurement musl be takenin at least2 oositionsin the crankshaftexceedsthe limit,replacethe crankshatt'
directionof crankshaftcenter line lor eachiournal,and in
each measuremenl, maximumand minimumwear direc-
tlons must be measured.From these resulls, eccenlric
wearandmaximumwearcanbe determined.

000040A1361 000040A1361
Chapter 2 BasicEngine
Chapler 2 Bosic Engine 5. Cranksh$l SM/GM(FXC}HM(FXC)
5. Crankshott SM/GM(F)(C}HM(FXC)

On models 2GM20(F)(C)and 3GM30(F)(C),the value of the l-l

side gap is the difference between the width of the basic
bearingmetaland the width of the iournal.The basicbearing
lor model 2GM20(F)(C) is the intermediatebearing,and for
models3GM3O(F)(C)and 3HM35(F)(C)it isthe intermediate
bearing at the flywheel end
Oial indicator


b e a r i n g m e ta l

and wear limll

Oellection 5-3.3SUegaP malnlenatrc€ standad gHM3s(FX?
zcr,,lzoar,,lzoaxcl I
tl'rear limit MdnleEE sta|dard t/'Jer llmit
MaintsEre standad \r,learlimtt Maintenae standard
0.09tu 0.19 030 0.09 0.18
0.06 tu 0.19 030 p.0014 -
03035 - 0.m71)
Crank shaft p.mla 0.065 - 0oo7q
cLla dm OO@a - 0O07q
54 Di**"mbtv A the gankshaft [2GM20(FXC)'
5-3 Crankshaft sHe gap and
For modelIGMIO(C)seethe chapleron disassembly
5-3.1Sld€g+ reassembly. Becausetherearepointsoverwhichcaremust
L"-ot""'i " mode l s2GM2o(F)(C ), 3GM30(F)(Cand)
The clearancein the axiatdirection after the crankshafthas
3HM35(F)(C)'disassembly and reassemblyproceduresare
been assembledis call€dthe side gap.
lf the sid€ gag is too hrge, contact with pistons will be exglained below'
uneven.the clutch disengagement position will change' 5-4.1DlsassomHy
and other t.oubl€s will occur. lf it is too small' the $32lleasudng s|de gap (llWhen disassembling'lay the cylinder down with.the
crankshaftstidingresistancewillincreaseandcrankingwill t ''
Seta di:rlindicatoragainstthe endof the crankshaft(orend ;i; ;;"s h.usin6 side on top so that the crankshaft
ol the flywheel) and measurethe amounl ol movementof will b€verticalforeasyop€ration'
the crankshatt In the axial dlrection. ll th€ measuredvalue ii i"tn*" tt* g€arand f t!^'vheelbeforehand)
For model1GM10(c) "rank
Adiustthe sidegapto the maintenance standardaccording exce€ds the wear limlt, replace th€ crankshaft thrust Pl hemovethe main beatlnghouslng
washer. Main bearing housing packing of the prescribed ro the crankshatLgraduallvliftins.n wlth
to the thickne$ of the crankshaftthrustmetal. iiiaiitt
'-' chain block ";p" etc. and rcmo/e the two set bolts ot ihe ln'
Thrust metals are installedon both sides of the crankcase thicknessmustb€ used.
i;;i;t. nrain bearing housing (f the cran!.fltaft.is
andgearcas€. wlll be orl-
Thtustmeral titteOtoo much ot nol enough'the set bolts
ficult to release.)
(4)iifi;; ;;ole the crankshaft (with the Intermedbte
Of iilo"" intermldbte main bearing housing lrom
the crankshaft.

Pdmary maln b€nng

i 0000A04r36r

Chapler 2 Basic Enghrc
Chapler 2 Buic Engine
5. Crmkshatl
5. Crunkshaft SM/GM(FXCIHM(FXC)

5-4.2Reassembly 2) Be sure to place the "down" mark on the main bearing

(3)Set the cylinder block up vertically,suspend lhe crank- housingsideinthedownwarddirection-
(1) Clean each part before reassembly. ko{--(f, rb)
shatt and match the positions of the cylinder block oil
(2) Attach the inlermediate main bearing housing to the hole and the intermediate main bearing housing set bolts
crankshafl and confim that lhe cankshaft rotates to the intermediate main bearing housing.
1) Assembling position and direction ol the intermediate
mdn bearing housing.
. The "F" mark on the inlermediate main bearing hous- 5-5 Main bearing
ing indicates the direction of ass€mbly on lhe 5-5.'l Consiruclion
crankshatl llywheel. ( 1) M odel1G M 10( C )
Set boll
nole The main bearing consists of a crank bearing and thrust
metal. The crank bearing is a round copper-leak sintered F langed lype
alloy bearing f eaturing superior durability.
The crankshaft bearing at the gear case end is inserted
into the cylinder block, and at the llywheel end it is filted
into the metal housing. n
Two thrust metals are set on lhe beaaing part al the gear
cas€ end: one is at the crankcase end and the other is at
\Flat typ€
\\--J-z a\
the gear case end. g
\*1 v
- \
(4)Attachingthe intermediatemain bearinghousing set
1) Firsl temporarilyscrewthe set bolt in the intermediate
rnainbearinghousingon th€ timing gearhousingside
.Align the anow marlGpointingup and down on the andwith the prescrlbedtighteningtorque,start tighten- al gearca* ono
side ot the intermediatemain bearinghousingand ing ftom the inlermediatemainbeding housingon the lmodels and3HM35(FXC)]
ass€mbleit so that the "F" markis in the directionof ,lywheelside. After tighteningthe bolts confirm that
the ftywheel. the crankshaflrotales smoothly.(Eachset bolt hole can 5-5.2Insp€ctlngth€ crankb€alng
. Assemble,integratedwith lhrust bearing,the in. beadiustedvertically.)
termedhte main bearing on the flywheel side Metal housing for model 1GM1o(CI (1)Check the crank b€aringmetal for scaling,deposited
(betweencylinderNo. 1and 2). metaland selzure.Also checkthe conditionof the con-
tact surface.lf clefectsare found, replace.
4 Tighteningtorque of hexagonalbotts for affixing the
top and bottom of the intermediate main bearino
!lo lf the bearing metal contact is too unsymmetrical'
housing: carefullycheckall relatedcomponentpartswhich might
\i be resDonsible,and take paopermeasures.
(4 Determine the oil clearance by measuring the Insbe
diameler of the crankshaft bearing and tt|e outslde
Thrustmetalal O€r caseend Thrustmetalat crank@se€nd diameterof the crankshaft.
tormodellcMlo(c) formodellGMlo(C)

(2)Moders2GM20(F)(c), 3GM3O(f)(C) and 3HM35(F)(C)

For the intermediate main beating on the flywheel side' a
llang€ type bearing integrated with the thrust bearing is us-
ed. Because lhis ls the primary main bearing, those wilhout
the thrust bearing on the sides ol the flywheel and timing
gear housing are whole circle beatings, while the in-
iermediate main bearing on lhe timing gear housing side is
kgf-m(ft-lb) the divided circle type.

(5) Feassemblyof the main bearing housing:

1) Enclose a small amounl of oil inside the oil seal and
ass€mble aflercoating the bearing with oit.

000040A1361 00004041361
Chapler 2 Basic Engine
Chapler 2 Basic Engine 5. CronkhaJt sM/GM(F)(CIHM(FXC)
5. CrmkshaJt SM/GM(F)(CTHM(FXC)
e) Intermediatemainbeanng sid€ is diameter. As the flange wears away the side gap of the
NOIES: t) Measure the cnnk bearing at the lour points The intermediaternainb€aringon the flywh-eel crankshatl increases.
a llange type
shown in the figure and rePlace the bearing it tn" pti."w mainbearing.Becausethis is
as the inside
the wear limil is exceeded at any ol these l ing, t'"""rr" the tlangewidth as well
2) When measuilng the innet diameter ot the lniem€diate
Easic beaflno

cnnk beaing, the cnnk bearing should be in- beann0

stalled on the bearing housing andlot cylinder

Cy lioder gauge

Crank metal

b@ring housang
m m ( i n .)

2GM20(F)(C).3GI'/t3P(FXC) 3HM35(F)(C)
Mdnim@ staodard larearlimit Mdnlffin€ standard \ lea limit

Main b€ting insile dhretet @.Oe.Sat @60.12€3@) o65.0es5s0) o65.12(25638) mm (in.)

C€nkshaft Furnal outsire @.oe.Szl o5S30 e3583) o65_0e55S0) s64.90P5551)

FtyN/tEl side dbreter
Maintenarrcestmdard \t'lear limil Maintemru siildatd
0.036 0.095 0.15 0.036 0.099 0.15
Oil cleence - - 0.0009) o.mso) o47.0 (18501) .r2 fla561)
P.m14 a0.084 o.06s) Pm14 e o44O(1:l@ ,41.12{JZ3ilt,
G."t side i"l"ttt"diate @ing inside diar€ts D' .1204551)
Main b€Jing insid€ diaretet 644p(1:t3p3.l 644.12(17370l. 6470 0A5Or) o47.12|I.A$11 6445(1:l@ ,44.12(1:13?CJ 0ff)
"a* @"'s
Frywnel spe nErrrEbts '"
Opposite sue Crfikshaft jourml outside 614.0(17 1 ,41.90 0.7283) 617.O(450,41 o16.9008466) 2sil? 24.63 sl99 2963
ol tlywh€l direls w (o96S4 (1.1714tu 1.1/t6) (1565)
beating (FM{tEl stide}
0336 e 0.0S5 0.'t5
Wklth ol Intefinediate {0.926 - 09@A
0.036 0.092 0.15
Oil c|eaance - 0.066)
pofia tu p.06s) p.0o1a tu 0.0037) p.0059)
noEt O"ly ,t tl" tlv"l"el end for model
S5.4 Inspecling lhe Inlemediate maln bearing
5-5.3lnspecfinglh€ lhrustmelallfor model1GM10(C)] Jlor models 2GM20(F)(C),3GM30(F)(C)and 3HM35 5F5.5Rephclng tho crankb€arho the figure'
Measurethe thicknessol the thrusl melal and replace the
crankshaftare Ass€mblelhe spacerand pbte A as shown in
(t) Cautionwheninspecting Since the crank b€dings at both ends of the ;;; iil pullei/extractor against the bearing from
metalwhenwearexceeds the wearlimit. ii*nJto ttt" block and bearinghousingwith-a *O pult the bearingby tlghtenlngthe..nut
The inlermedialemainbearingis dividedinto two semi- "vlindJr 1'0 1'5 tons (2200tu 3300 I.-"it"
circles.Therefore,alwaysmeasureafter tighteningthe i[*, r"Lli - .iin" "'nO too'|.Reto"" the oil seal b€fore
tbs.)is "requked "t;pproximatelv
lo remoYe them'
inlermediatemainbearingwith the standardtightening in"u.".ing press€dagainstthe b€aringhousing'
;il;ii crankshaft not rotate smoothlv and
lorque.Measureat lour placesas in the main bearing,
finlr t.,iur" mayoccurif the beatingis distorted'it must
-' dai G outside ol the bearingwith oil and-align.the
andreplacelt if it exceedsthe wearlimit. *nr_.(u_,0) alwaysbe installedwiih thespecialtool' posltionsof the bearingoil holes ThenpressIn
pkile b

0000A041361 000040Ar361
Chapter 2 .Bosic Engine Chaptcr 2 Basic Engine
5. CronkhaJt 6. Flywheel and Housing SM/GM(F)(C}HM(FXC)

6. Flywheeland Housing
until it touches the cylinder block or bearing housing, 1) Pay careful attention to the crank bearing insertion
using the puller/extractor as a guide, as shown in the direclion. Inserl the bearing so that the side with lhe
figure. outside fillet is on the outside circumference ot the
After inserling the bearing, measure its oulside a Align the oil hole of the crank bearing with lhe oil holes inertia'to rotatethe The ring gear is shrink fitted onto the
Thefunctionof the flywheelis,through llvwhee], and this ring gear serves
lo start the engine by
diameter. lf lhe bearing is distorted, remove it again and ol the cylinder block and bearing housing. in a unilormand smooth mannerby absorbing- meshino with the starter motor Pinion'
replace it with a new b€aring. 3) After inserting the crank bearing, check that the "onf"n"tt
il;i;ffi; i";; createdourins the combustionstroke ;;;rairped letter and line which show top dead center of
(3) Crank bearing installation precaut:ons crankshalt rotates easily wilh lhe thrust metal and bear- by compensating lor the decreasein tum- the
ing housing installed.
in" are positioned either on the llywheel at
"no theotherstroKes
"nginiduring reversing
inolorce """n .io" o, at the side of the reduction and
ii mountedand securedbv 5 bolts on the
Lubdcalion hole 4) Be careful that the bearing is not lilled during insertion. lo*it.i"n
#"';;h""i arrow mark at
Ly matching these marks with the
the oppositeend to the gearcase; it is ;;;;;
(>-+- 5-6 Crankshalt oil seal
;;;;; id'""untins ilanse(tlvwheelhousing)which
is if," of the starter motor or at the hole of
h-ousing,the rotary position of the
crankshatt can
,,/j' 5-6.1 Oll seal type and size boltedto the cylinderblock il r"""n"*"1 i" to adiust tappet clearance or fuel in'
Spiral oil seals are employed at both ends of the i,"" ,i" sideol the flywheelis the f itting surlace jection timing. "rder
I I the
damoerdisc, throughwhich the rotationof
Iar the"ra"f"n"ft
\ T--T - crankshaft. This type of oil seal is pulled toward the oil pan
ittran.miited to the inputshaftof the reduction
by pump action while the engine is running so lhat there is
no oil leakage.
Since the viscous pump action will be lost il the lip of the
se:l is coated with grease, coat the lip with oil when
S"-. The reductionand reversing
ted to the mountingflange'
gearis ti!

forceon the shaftcentermustbe

""uilanced as the
Cvlinder slde.-
assembling- *"" 6"i.*,n" sp€cifiedvaluefor lhe crankshatt To
i',i'.nJ-.o,"t"t with the crankshaftat high speed
in the
tne, thebalanceis adlustedby drillingholes
side ot the tlywheel,and the unbalanced
adiusted by driltingholesin the circumference'

&1 Specificallc of 3HM3s(F)(C)

c)ilsd rGM10(C),2GM20(F)(C),
mm o252.
Size Spiral Pdt No. {YanM} Size Spiral Part No. Outside diamets flywhel 70 44
mm 70 70
Fd Main b€dng retd hqsing 6629 Yes PM.SM 668S) Yes 12155142220
'17.5 17.5 12.0
Fqgs@ m Y6 12145001800 m Yes '121450-018m k9 17.5
nq gear) 0.70 0.70
kgf-m' 0.7 0.1 -T
5-6.2 Oil s3alinserlion prccautbns GD2 value
47.5(3600rmp) (3,O0rpm)
(1) Clean the inside of the housing hole, ascertaining ihat (4)Insert the oil. seal with a press. However, when Circumfe( Intial speed 1n3.4
the hole is not dented when the seal is removed. unavoidable, the s€almaybe installedby tappingthe en- {3400rpm)
(2)Be sure that the insertion direction of the oil seal. is tire peripheryof the sealwith a hatnmer,using a block. Sped lluctualion rale
6 ,#to'., |,-it3"'Jo-l-ggqj4t-
30 25
gf{m 30 30
correct. Insertso that the main lip mounting on the spring ln thls case,becarefulthatthe oil sealis not tilted. 170
is on the inside (oil side). Nevertapthe oil sealdirectly. Pitch circle mm 150
diameter of bolts
Fixing Part ol
No. ol bolts FM8 thread equally spaced
dampet ol$
X bolt diameter
Pitch circle 4l
diameter of bolts tM10
Fixing Part ot
No. ol thread hotes mm
Fit ioint diameter KM3A
(3) Since the direction of rotation of the shatt is sp€cilied
on a spiral oil seal, be sure that the rotaling direction is Model of reducti( n and reverslng
SAENo.6 (in metricun't) (in metric unit)
conect. Mounting flange \o.
Directionof mm 246.38
Ring gea.
No. ol teth

seal inside diameter A

seal outside diameter

seal thickness

ol rotalion

Chapler 2 Basic Engine
Chopler 2 Basie Engine
6. Flywheel and Houing SM/GM(FXC}HM(FXC)
6. Flywheel and Horcing

G2 Dimensions of llywheel and tlywheel housing 6-22 For model3HM35(FXC) s

6-2.1For model1GM10(C),
2GM20(FXC), 3GU3O(FXC) S93o a
3; 8:
; 9 a3
@ !llo

o3 I
s o>
?r- S I E3
3 E-s:€
6I dLo I
1: r-: €
s:* g

x .\<
6X i
.-: o
sg 5
3.:{g ;.: b

tFi *i e
: it *i':




0000]104136r 000040A1361
Chopter 2 Basic Engine
Chapler 2 Bosic Engine 7. Camshalt SM/GM(FXC}HM(FXC)
6. Flywheel and Housing

&3 Ringg€ar 7. Gamshaft

When replacing the ring gear due to excessive wear or
damaged teeth, heat the ring gear evenly at its ciF 7-1 Construction ot the camshaft
cumference, and after it has expanded drive atgradually off intake and ex' The camshafton models I GM10(C) and 2G M20(F)(C)does
The camshaft, an integral camshatt with models
the flywheel by tapping it with a hammer a copper bar or gear and may be not have an intermediate bearing The camshalt on
haust cams, is driven by the camshatt supported by
somelhing similararound the whole circumference. 3GM3O(F)(C)and 3HM35(F)(C) however is
timed individuallY. of the
is mounted two intermediatebearings in order to avoid deflection
On top of the intake and exhaust cams a tappet
moves up and camshaft.
ouii"A uv the cytinder block The tappet with
and closes models and it is inserted into the camshaft together
iown wit-n the rotation of the cam and opens is lixed
pushrod and rocker the camshaft gearby matching the key and slot and
the intake and exhaust valves with the
by an end nut.
is exposed to Tire cam for the fuel feed pump is integrated with the cam'
During high speed operation the cam sur{ace is located
of inert'la from moving valves and spring shaft and it is machine linished' The cam
of No'.|
oeiween rne intake and exhaust valve cams
comes in contact with the tappet at high surtace
" "trJnglor""
"riO Therefore, to reduce wear the surface is tempered cylinderat the flvwheel end in all engine models'
Lv hiqh frequencyhardening,as well as a cam form
t; de;rease the forbe of inertia.Since the intake and
parabolic acceleration cam
cam protile ot this engine is'a
high speed
with a butfering curue, movement ot the valve at
G4 Position ot top dead center is smooth, improvingthe durability of the intakeand
(1)Marking valve seats.

Side surlace ol flYwheel

Stamped marking line

Stamoed marking line
Angle a ol Stamped li6
Flywhel end

(2) Matching mad( 7-1.1 Camshaft ot engine model 1GM10(C)

The matching mark is made at the setting hole of lhe With rspct to models 1cM10(C), 2GM20(F)(C) and
starler motoron all models. 3GM30(F)(C) only, a projection which serues as the
matching mark is provided in the cast hole ol the clutch

rv-. housing.

Ball b€anng\


Ball bearin0relainingscrew

G€r case eno

Chopter 2 Basic Engine
Chapler 2 Buic Engine
7. Camshol
7.2 Valve timing diagram
All models

02m (OOOtginJ
l n l a ke va ;ve o Pe n Exhaust valve close
lntake valve o@n b. TDC
lntake vahe close a BDC 50"
exhest vahe open b. BDC 500

Exhaust valve cbse a TOC

lntake valve close Exhaust valve open

I exhaust valve cam

7-1.2 Camshatl ol engine model 2GM20(FXC)
le€d 9ump cam
Visuallycheckfor stepsot wearon thecamsurfaceand
No.l lntake vaNe cil

inlake valve cam replaceif excessive.

Flel feed pump cm
'No.2 exhausl valve cam
Since the cam surface is tempered and ground, there is lnlak€ aod exhaust cam

almostno wear.However,measurethe heightof the intake

and exhaustcams, and replacethe camshattwhen the
measuredvalueexce€dsthe wearlimit-
""-*nrfA Cam height
gall bearing retainel

Wear limit
a n.70
1GM10(C) (1.1417) ft1?9'2t
lntake and
exha6t €m u.70
(1.3780) 0.3661)
I intake
rGMl0(C) (0.8661)
pump cam
Frelled 2cM20(FXC) 33
I oxhaust pump €m 36rrs(R(c) (1.2992)
7-1.3 Camshaft ol engine models 3c*i!o(F)(c) and varye cam
3HM35(FXC) 3HM35(F)(C) (1.3189)
inlake Yalve cam

exhaust valve cam

Jo u m a l 7.32 Journalsof camshatl

Measurethe amounlof wearand eccentricityof the cam-
shaftloumal.Measurements must be caniedout in at leasl
No.3 exhaust valve cam two directionsforeachPosiiion.
Replacethe camshaftwith a new one if the valueexceeds
the allowablelimit.
trarnlenance Cleannce at asmoly
The cam pr o l i l e i s c om m on to m odel s 3GM 30( F ) ( C ) , allowable cl@6ne
Hexagonal nut
Sali bearing 3HM35(F)(C) and 2GM20(F)(C). The camshaft of model
1GM10(C) 6n p.78741 0.15(0.m59)
aetaining screw 3GM30(F)(C)has drilled holeslor lubricatingthe intake and o.osH. 10O(0.m2H.0039)
Flywhel side 3GM$(FXC),3HM35(F)(C) d30 (1.1811)
exhaustvalvecams.The camshaftgear,tappet,ball bearing, 2GM20(F)(C),
0'1s (03059
hexagonal nut, and tuel cam are the same lor models Center 3HM3s(FXC)
3GM3O(F)(C), 641.5{1.6339) 0.05H.100 (0.00N.m39)
3GM30( F) ( c)a nd 3H M 3s ( F ) ( C ) .

Chapler 2 Breic Engine Chapler 2 Baic Engine
7. Camslml 7. CamshaJl SM/GM(FXC'HM(F)(C)

in Check both ends tor wear and peeling, and replace the
7-3.3 Camshaft dellection [models 3Gtl3o(FXC) and Since the tappet and cam are offset, the tappet rotates pushrodif faulty
is no
3HM(R(c) in up and downmovementduringoperalion,so there Maintenan@
Support the camshaft at both ends on V'blocks, and unevencontact. standard
Wear limit
mesure the concentricity of the intemediale iournal with iin". *""ntti" wear will occur if cam tappet contact 0-03or less 0.3
a dial gauge. lf the camshaft is excessively bent, replace it.
poor, replacethe tappetit there is any unevencontaclor Push rod bend (0.001'18or ls) (0.0118)
NOTE: lndicated value on the dial gauge is the amount ol deformation. 1cM10(c) 1,13(5.6299)
swing, and the amount ol bend is haff the reading
given- Contactsurfaceconditionsareshownin the following: Push rod 2GM20(F)(c)
3HM35(F)(C) 171(6.7323)

7-5.1Tapp€ldlsassembt prccautions
Thecylindernumberandintakeand exhauslmustbe clear'
t1) (2) (3) (4)
7-7 Fuel cam
7-7.1Fuel cam check
The fuel cam is s€paratefrom the intake and exhaust
cams anO is secured to the camshaft together with
the camshaftandtappels. pump'
ly indicatedwhendisassembling carnshaftgearby a key-The cam drivesthe fuel
tlL e) Traceswhen the tappet is rctating nomaily' The fuel &m like the Intake and exhaust valve
cams is
the contact
7-52 Tappetstem woarandcontacl lsj.' (l) tru.rt when the tappet does not rotate' o-unO-finian"O after being quenched' Therefore'
it is
surlace remains stitl and the point ol contact wears is
Measurethe outside diameterof the tappet stem, and lack ot limost tree trom wear.However,i{ slep or eccentric wear
away excessively. Discover the reasontotthe
replacethe tappetwhenlhe wearlimit is exceededor con- tound to b€ excessive,replacethe cam'
tact is uneven. rctation and rcPlace the taPqeL

Wear limit
o@ con-
Also,theremaybe perforatedpittingsorcrackson the

acreo(c) 0.02
(0.0008) tacl'surface of the tappet.In such cases, discoverthe
Cachaft reasonforabnotmality and repbce the tappet'
defl@tio 3HM3s(FXC) (0.m08)
7.6 Push tods
Wear limit
The push rods are sufliclentlyrigid and strong to
standard bending.
7.0Camstufi ball bea.lng
rGM10(C) O10.0 c9.95 Ft""" t6" push rcd on a stool or flat surface and measure
The camshaft beadng is a single row deep groove ball bear- Tappet stem (0.3s37) (0.3s17) in" betweenthe center of the push rcd and the
ing. The constructlon and material of this ball beding is 2GM20(F)(C) c10.0 "f""ra;t"" andreplacethe pushrod lf the wearlimit is ex-
itat surface,
such that it can withstand the radial load, thrust loads in 3Gri!0,(FXc) d9.95
(0.3937) (0.3917 ceeded.
both directions, and a combinaiton of both of these loads. 3HM3s(F)(C)
When the ball bearing does not rotate smoothly, orwhen lhe 0.025-0.060 0.10
1G M 10( C ) (0.m1H.0024) (0.0039)
axial direction play is large, replace the b€aring. Tappet stem and
clearance 2GM20(F)(C) 0.01H.0i10 0.10
Ball b€aring type 3GM3o(FXc) (0.0004-{.0016) (0.003s)
For models 7-5.3Tapp€tand cam c{tnlac{ surlace

7.5 Tappets
Th€€e mushroom type tappets feature a special iron 7-72 Fuetcam assombtyPrccaulions
key ol the cam'
castlngwith chill-hardened contactsurfacesfor high wear lnstallthe luel cam by aligningit with the
the luel itts
resistanc€.The cenler of the cam surfac,ewidth and the utr"tt. fi tn" Installationdirection is not cofiect' enginewill
center ol the tappet are ottset to preventeccentricwear of ti.r"g ;in b€ considerablv off and the
the contrct surface. not start.
W-n"n the fuel cam, be sure that the'!" marl(
ortn" iJopPositethe camshaftgear'
"iou ""rn

Chapler 2 Basic Engine Chaptu 2 BasicEngine
7. Carchaft 8. Timing Geu SM/GM(FXC}HM(FXC)

8. TimingGear
E.l Tlmlngg€artEinconstruction
ot the valve
whichls the basiccomponent
Thecarnshaft, The crankshaft gear also drives the govemor weight ard
opening and closing mechanism, and the fuel cam, which the lubricatingoil pumpby meshingwith the lubdcatingoil
determinesthe luel injectiontiming, are driven by the timing pumpgear.
gear. Forthe timinggears,helicalgearsareus€d.
The timing gear consists of the crankshalt gear and the The timinggearcase,which coversthesegears,is fitted to
camshaft gear. the cylinderbodywith bolts.

8-1.1 Timing gear ol model 1GM10(C)

The timing gear of model 1GM10(C) is as shown in the
figure. The slit, which is at the end of the rotor shaft of the
lubricating oil pump, is providedto connect with the shatt of
the cooling waler PumP.

Camshaft gear


Lubrlcating oll pump

The c@ling wate. pump is ddven

by this 3llt

Lubrlcating oll pump g€a.

(also driYes the c@llng water

Module (m) T@th profile No. of teth Cenltr dislil€

CatrEt€tt gs zo Full depth 52 84+3mmm P3071 o 33o90in)

Canksi€fl 20 Full depth 26
66tffimm es$a - 26002in.)
oil pump g@ 20 Full depth 36

0000A04r361 00004041361
Choptu 2 Buic Engine
Chapter 2 Basic Engine L Timing Gear SM/GM(FXC}HM(FXC)
8. Timing Geu SM/GM(F)(CTHM(F)(C)
and reassembly of tt€ timing gear 8.22 Disassembty and reais€mbly pFcaulions
8-2 Disassembly
8-1.2 Timlng g€ar ol models 2GM20(FXC), 3GM30(FXC) Reassemble in the reverse order of disassembly.
8-21 Disassembly
and 3HM 3s(FXC) Pay attention to the following poinls when assembling.
(1) Remove the altemator- (1) Timing mad(
clip on
The same crankshaftgear and camshaftgearsare used lor izi Remove tne rubber hose by toosening the hose A timing mark is prcvid€d on the crankshalt gear and
thesethree models.Only on the lubricatingoil pump gear for the cooling water PumP.
camshaft gear to adtust the timing b€iween opening ard
model 3HM35(F)(C)is a different gear used, bul it has the NOTE: For models 2GM2O(FXC), 3GM30(F)(C) and 3HM35
closing of lhe intake and exhaust valves ad fu€l inlec'
same number ot teeth and the gear train itselfis of the same (F)(C), the cooling water pump does not need to be
Camshafl g€r tion when the Piston is oPei"ated-
construction as thal of these three models removed. Modet 1GM10(C) can be dismantled
Always check that these timing marks are aligned when
Helical gearsate used as in model 1GM10(C). without removing the cooling watet pump However'
disassembling and reassembling the timing gear.
when assembling,it is dif ficult to connect it with the
First, tit the crankshaft gear to the crankshaft by maf
rctor shatt ol the lubricating oil pump it the gear case
ching the key and slot. Next, by rotating the camshaft fit
has not been PreviouslY a$embled.
the camshaft gear in the position where the marks on
(3) Remove ihe crankshaft V-pulley.
the camshaft gearand the crankshaft gearalign'
(4) Remove the fuel iniection PumP
NiOTE' R"^on" the caP ot the oil supplY port in model
1GM, or the cap at the timlng gear case end in other
models, and rcmove the tuel iniection pump by
movtng the governor second lever while obseNing
through the hole.
(5) Loosen the hexagonal bolt with the hole, and temove
the stEighl pin from the manual starting handle'
(6) Remove the gear case'

CEnkshaft 0€r
oal pump geat

Whenthe fuel cam is fiited to th€ camshaft,assembleil
O) Removethe govemorsleeveand needlebearingcollar' keepingthe surface marked'O' towardsthe front'
(8) Loosen th€ hexagonal nut, and remove the govemor (Relerto 2-57)
weightsuPport. (3)Tighteningtorqueol nut
B) Removethe camshaftnut,and takeout thefuelcam'
itdneto"e the camshaft gear, crankshaft gear and
lub'ricatingoil pumP.

2GM20(F)(C),3GM3o(F)(C)and 3HM3s(F)(C)
Module(m) T@th prctile No. of teeth C€nts distam
Camhaft 2.O Full depth 99+*mmm 08976 339g5in)
Ccnkshaft g€r 2.0 Full depth 31
65.98+lffimm @.5976& 25995in.)
Lubri€ting oil pump gs LO Full depth

Chapter 2 Basic Engine
Chapler 2 Basic Enginc
8. Timinp Gear SM/GM(FXC}HM(F)(C)
8. Timing Geu SM/GM(FXCTHM(FXC)

ksf,m(fLlb) (4)assemblingmodel 1GM10(C)cooling water pump tns€rt a piece of qualiiy solder belween the gears lo be
All models When model 1GM10(C) cooling waler pump asassem- and tum the gears. The backlash can be
bled, ensurethat the pump shaft engageswith the slit of measured by measuring the thickness of the crushed
Camshaft end nut 7.o 8-0 @,6 573)
- - parl ol the solder.
the rotorshaftend oflhe lubricatingoil pump and with the
8.0 10.067.9 723)
- - bearing.Check by rotatingthe crankshatt. t\
NOTE: When tightening ot loosening the cnnkshalt nut, ,-- o o\
take care that the spanner does nol touch the gover'
not weight or weight suqqott.
w Q,
. J)r
\ .l- z ,i tl
\ \-\
-\D \:-
Cooling waler pumpl

8-3 Inspeclion
Unsuitablebacklashwill cause excessivewear or damage
at the tooth top and abnonnal noise during operatiofl,
Moreover,in extreme cases, the valve and luel iniection
tkningwilldeviateandtheenginewillnot runsmootirly. 8.32 Insp€ctlngthe gearlootft sudace
Whenthe backlashexceedsthe wearlirnit,tepairor relace
Check the tooth surtace for damage caused by pitching
the gearsas a set. mm (in.)
andchecktooth contact.Repairif the damag€ls light' Also
1GM10( C) 2GM2o(F) (C),3GM30(R(C),3HM3s(FXC) inspectlhe gearsforcrackingandcorrosion.
Mainlerc standard \ rer l(mit MaintsErice standard V\ba limit When gear noise becomes high because of wear ol
C€nkstBft g@ and €mshatt 0.05 0.130.0020 0.m51) 03 p.0118) 0l)5 a 0.13 O.fiI2o 0.0051) 03 p.0118) damage,replacethe gearsas a set.
- - -
C€nkshatt gs md lubrl€ting oil pump 0.05 N 0.130.0020 ry 0.0051) 03 oo118) 0.06 0.13 p.0@ 00051) 03 {o.01181
driven os backhsh - -

Measuring backlash
(1) Lock one of the two gears to be measured and measure
the amount of movement of the other gear by placing a
dial gauge on the tooih surface.

8.3.3 Inspecting the gearboss

Check for ptay between each gear and the gear shaft, bum-
ing caused by Play, key damage, and lor cracking at the
edge ol the key groove. Replace the gears when faulty'

0000A041361 0000A0A1361

1- Fuel Ini@tion System .....
2 Inj6tion PumP . . - a-25
3. In,ection Nozle . .
4. Fuel Filter .......
5. Fuel F@d PumP . . -" " ' 9 3 0
6. Fuel Tank (OPtion)

Chopler 3 Fuel System
I. FueI Inieclion Systern

1. FuelInjectionSystem

Fuel tank (option)

Capacity 301

Chapter 3 Fuel Syslem
Chapter 3 Fuel SYstm
2. Injection Puntp SM/GM(FXC}HM(FXC)
I. Fuel Injeclion System

1-l Construclion
The luel system consists mainly of an intection pump, in- through a high pressure pipe. The pressurized fuel is
2. InjectionPumP
iection pipe, and an iniection nozzle, plus a fuel tank, feed atomized and iniecled by the injection nozzle into the The fuel inlection pump is constructed from the following
The iniection pump is the most imporlant part ol the fuel
pump, tuel filter and oth€r associated parls. The inieclion precombustion chamber. main oarts.
system- This pump feeds the proper amount of luel to the
pump is driven by a luel cam mounted on lhe camshaft and Fuel lhat overllows the injection nozzle is returned to the (1) Pump parts which compress and deliver the fuel:
engine at the proper time in accordance with the engine
is controlled by a governor. Fuel stored in lhe fuel tank is luel tank through the fuel retum pipe. The quality of the plunger, Plunger banel.
fed to the tuel tilter through the feed pump. (The feed pump equipment and parts comprising the fuel injection system pump tor (2) Parts which move the plunger: camshatt' tappet'
This engine uses a Bosch integral type iniection
is indispensable when ihe tuel tank is installed lower than directly allects combustion performance and has a con- plungerspring, plungerspring reiainer.
two/three cylinders. lt is designed and manutactured by
the iniection pump.) siderable effect on engine perlormance. Therefore, this (3) Parts which control the iniection amount: control rack'
Yanmar, and is ideal for the fuel system of ihis engine'
Dirt and other impurities in the luel are removed by the system musl b€ inspecled and serviced regularly to ensure control Dinion, cPntrol sleeve-
Since the injection pump is subiected to extremely high
filter and the clean tuel is sent to the injeclion pump, which top performance. (4) Parts which prevent back flow and dripping during in-
pressures and must be accurate as well as defor-
applies th€ necessary pressure for injection lo the fuel and The pipework diagram of the fuel system is for the model
mation and wear-lree, stringentty selected materials are iection: delivery valve.
atomizes the fuel by passing it through the injection nozzle. 3CM30(F)(C)engine. Models 1GM10(C)and 2GM20(F)(C)
used and precision linished after undergoing heat treat-
The iniection pump also controls the amount ol fuel in- are the same except for the shape of the fuel injection pump
iected and the iniection timing according lo lhe engine and luel teed pump, and the numb€r of fuel injection valves.
The iniection pump must be handled carefully' Since the
load ard sp€ed by means o{ a govemor. It is alsothesamelor models3GM30(F)(C)and 3HM35(F)(C)
delivery valve and delivery valve holdet and the plunger and
The iniection pump leeds the luel to the iniection nozzle except tor the luel injection pump and fuel injtrtion valve. plungei barrel are lapped' they must be changed as paiB'

1-2 Fuel inlection system specifications

2-1Construction Oelivery vaNe spnng
1GM10(C) 2GM20( F) ( C) aGlJliD{F)(c) 3HM 35( F) ( C)
Type of inj€tion pump YPF R-07 07-l YPFR47O7-2 YPFR{7 07 YPFR-0707
Type of in j@tion rczzle YDN-OSDYD I (Throttle) YDN-0SD YD 1(Throttle)
Inj€tion prssure 170kgf /cm'z(2418lb/in.') 160kgf /cm' (2276lb/in.'2) Delivery valve sPrlog --

diameter x strcke dOmm(0.2362in.) x 7mm(0.2756in.) d6.5mfr (0.2559in.) ! 7mm(0.2756rn.) -Delivery valve

Delisy valve srction cap@ity 3/st)
23.5mm'/st(0.m14in. 23.5mmr/st(0.0014in.3/st) Ddivery valve Packing-
valve holder
luel le€d or6sure 0. lkgf /cn' (1.4n4 lb I in.' ) O.lkgl / cml (1.4224lb / i^.'z)

Plunger barel Packing

Plunger ba(el

Plunger ba(el slopper

Plunger guide stopper

uel conlrol Pioion

PlungersF'ing retalner


--Plunger spring lower relalnel

g urce

Plungerguide toller (outei

Plungerguide PlungerOuide
roller pan roller (inner)

000040A1361 00004041361
Chapta 3 Fuel Sydmt Chopta j Fuel System
2. Inju'lion Pntp 2. IQedion Pntp

2-r2 2GMm(R(c),
ill{c), 3HM3s(R(c)

Oolivsy Yahe sp,ing holder

Oelivery valve sp.iog

Delivery valve

Deliveay valve Packing

Oelivery valve holder

Plunger barrel

Plunger barel

Fugt inl€ction vdu@ .diusting pl.le

EccentJic rcw
Sel 3ccg

Plunger barel 3loppe,

Fuel control rack

guide stoppet

lnjection timang adjust

\Plun!€r 0qidc atopper pin

NOTE:Thesame construction patts are used tor the tuel

"r.**lF iniection pump ot the 2GM20(F)(C)and 30GM
qF)rc). Only the tuel iniection pump body itselt,
1 80dy
2 Deliv€ry vtlve spring holder
3 D€liv€ry lalve sprino
11 Plunoe.
12 F!€l cont.ol Dinion
13 Fuel conlrol ,ek
21 Plunger Oulde roll€. (inne0
22 Ptung{ guide.olle. (o!ter}
u plungerspilng upperretainer,plungorguide stoPpar
Dinand luel control rackare dilt€rent, and it maybe
4 Dallvery valve l,a Plunger sprino ruet contot otnton--@ understood that the iniection pump ot the 3CM
5 Ogllv€.t valve houer l5 Pl!nger sp.lnO retaine, with
6 O€llvqy valv€ p&king 16 Pluooer sp.ing lowe, .elaioer 3O(F)(C)isthe sameasthatofthe2GM20(F)(C)
7 O-.lng 17 Plungd 0uid€ stopp€r Ptunge,spring rddn€r---@ the additionot on:amorc cYlinder.
8 Pludtq barel 18 Cllp pump bodY'
I Pturlger barel peking 19 Plunger guile the s€meex@pt for the tuel lnlection
t0 Pldge. badel stopper 20 Plunge. Ouide .oller pin qlungerand Plunger bafiel.
"t.n-"on"n-@ Howaner,carremust be takenas the basic sudee
ol lhe luel volume adiusting is dilletent.
'ack valveaN plunger
'Genulne parts tor the delivery
consist of the detivery valve aN delivery valve
r-@ hotdet and plunger and plunger baftel rcspectlve
re ly.

Pluneer p
" OH
Plunger guide .oller (ouleo

K Plungerquide .oller (inneo


000040At361 0000404t35r
Chapter 3 Fuel St'stem
Chapta 3 Fuel SYstem 2. Injection PumP
2. Inieaion PumP SM/GM(F)(C}HM(FXC)
2GM20(F)(C) 3GM30(F)(C) The construction is the same as the tuel iniection pump on
model 2GM20(F)(C) or 3GM30(F)(C) engines except for the
di{ferences of the plunger diameiers, shape of plungers and
plunger barrels. Take care as the position of the basic
surtace for adiusting the injeclion volume is different.

Reference ta@

1 O-rino
1 O-ring 2 Inlectlon timing shim
2lni€ctlon timing thlm 3 F@l contrcl Pinion
3 Fu€l control pinion a Pluogor gpring
,l Plung€r sp,ing
5 Pl0ogs 9!ide slopps
5 Plunger guide stopper 6 Pllngtr 00ldo 3tgpp€t Pin
6 Plunger guide stopp€r pan 7 Plung{ position shim
7 Plunge. pGition shim 8 Oelivcry valvc 3p.log holder
E Delivery valve 3prlng holder I Deliv€ry vah€ 3p.inc
I OqliYery valv€ sprino t0 Dellvery €lY€
10 D9livery valve 11 D€llvery valve holdor
11 Delivery tatve holder 12 Body
't2 Dslivtry valve packing
13 Plunger barel
13 Sody 1,1Plunog bargl packing
1,1Plungd barel 15 Fu€l cst.ol rack
15 Plunger barel packing 16 Plunge. sprlno relainer
16 Fu€l control rack 17 Plunget
17 Plunger spdng ,etainer 18 Plunger spaing lowot,elaind
18 Plunger 19 Pluncg 9uide
'19Plunger spaing lower retainer
20 Pluogtr OUide roller (outerl
m Plunger guide 21 Plunqer guide roller (inneo
2l Plunger guido roller (ouleo 22 Plunger guide rolle, Pin
22 Plunger guide roller (inneO
23 Plunge. guid€ .oller pin

0000A04r361 0000404136r
Chapter 3 Fuel SYslem Chapler 3 Fuel Sysletn
2. Injeclion PumP 2. Injeclion Pump

2.2 Specilications and performanceof luel injection pump (2) Model 2GM20(F)(C)
2-2-1Specificalionsol luel inirction pump

Static mehanical lift at iniection lat slarting 3.2mm(0.1260in.)]
Sliding resistane of fuel volure adiusting Eck
609 (0.002lb) or less .9

(at the set dimension of 76 a0.05mm)

Thickness ol plunger position adjusting shim 0.1mm(0.0039in.), 0.3mm(0.0118in.)

02mm P.0079in.),

25.1kg (5s.3lb)

235mm' 0.00'l4in.')e4.5 acmrding lo 1GMl0(C) drawing)

Openingp@ssureof deliveryvalve Approx. 16.3kgf/cmz(231.8 lb/in.')

-ro r 3 5 7 9 11 13 15
Moving distance of the rack lrom lhe pump body ('eierence face) (mm)

2.2.2 lnieclionyolumecharaclerislicsol fuel ini€clion

i --6 4 ro 2 4 6 8
pump body (mm)
(1 ) Model 1 G M 1 0 ( C ) Movino distance of the rack pin from the center ol lhe

(3) Model3GM30(FXC) o

E 0


A /r

v )
-9 7 ,*2

Moving dislance o f t h e r a c k l r o m l h e p u m p b o d y ( . e l e r en ce l a ce ) ( m m )
0ffi13 15
Moving distance ol the rack lrom the pump body (reterence face) (mm)

6 4 2 0 2 4 6 8 10
Moving distanceol lhe rack pin from lhe cenler ol the pump body (mm)
-1- ro i2 14 16 18 20
s e
Movino distance of the rack pin ftom the cenler of lhe pump body

3-8 3-9
Chapler 3 Fuel Syslem
Chapler 3 Fuel SYstem 2. Injection PumP SM/GM(F)(C}HM(FXC)
2. Injelion PuntP
2-3.1 Fuel conirol
( 4) Model 3 H M 3 5 ( F ) ( C ) o re s s u reb u i l d s u p t o 1 5 5t o 1 0 5k g f / c m' , t h e n o z z l eo p e n s ,
When the plunger (1) is at bottom dead center, the oil,
a n d t h e f u e l o i l i s i n j & t e d i n t o t h € s p i ra l v o rt e x t y p e
which comes in through the oil hole, lills the delivery
pressure then mmb u s t i o n c h a mb e r. H o w e v e r. i ft h e p l u n g e r k e e p sri s i n g
chamber (3) to above the plunger- The oil
a n d t h e l e a d g ro o v e (4 )l i n e su p w i t h t h e o i l h o p e (z )t h eo i l
buitds up as the plunger risesand closesthe oil hole, and by
u n d e r h i g h p re s s u rei n t h e d e l i v e ryc h a mb e rp a s s e su p t h e
opening the deliveryvalve,the oilis torcFted toward thefuel
guide' l e a dI ro m t h e l o n g i t u d i n s l g ro o v ea n d i s d ri v e nb a c k i n t o t h e
injection tube. As the plunger.pushed by the plunger
:E rises further, lhe pressure cf the oil belwen the delivery s u c t i o n c h a mb e r f ro m t h e o i l h o l e A t t h e s a me t i me ' f o rc e
chamber and the nozle also increases' when this oil feeding of the fuel is suspended.

N o inieclron Hall iniection

1614121086420-2 Delivery chamber

Movino distance of lhe rack lrom the pump body (reference face) (mm)

M ov ing d i s t a n c e o f i h e r a c k p i n l r o m t h e c e n t e r o { t h e p u m p bo d y ( m m } Eflective stroKe

2-3Operationol luelinieclionpump
The fuel iniection pumP torce-feeds the fuel by means ol
When the
the plunger (1) which ope.ates at a constanl stroke. Since vent the backward dripping ol the nozzle valve'
Asa resultof the aboveaclion,the plungeris rotatedby the
the plunger is lap fitted into the plunger banel (2) for super not"n 1t".01 ot ttt" pltrnger comes up lo the oil hole-of-the
delivery valve fuel controlrackandthe angleof ihis rotationchangesthe the fuel oil
precison, it can b€ reptaced only as a set- The cylindrical olunoer banel, tne ieeding p{essure acting on
etlectivestrokeot the plungerand controlsthe discharge
surface of the plunger has an obliquely cut lead (3) and a the delivery valve lalls due to the force of lhe
of th€ pump.Also,wtrenthe luel controlrack lines up the
groove which connects the lead to the plunger head. The sorinq."noAfter the sucking-backcollar haslirst shut ofl the fuel
longitudinjlgrooveon the plungerwith the oil hole,the oil
plunger has an intake hole (4) through which the fuel ini.cti-on tuUe and the delivery chamber, the delivery valve
troli does not close,<lespitetlle rise of lhe plunger,but surface' in
pass€s and is force-ted by lhe plunger. Then the luel opens diops further until comes in contact with the seat
ratherlhe tuel is drivenb3ckto th€ suctionchamber'As a (i'e increase In
the delivery valve (5),goes through the fuel injection lub€, intake hole (4)
coriespondence with the amounl ol fall
resultthe fuel is not force-fedbut the amountol iniection '
and is injected into the spiral-vortex type pre-combustion l) prunger
votume), the fuel oil Pressurewithin the iniection tube drops'
is reducedto zero.At this timethe luel controlrackis at the up
chamber from the iniection valve. The plunger is fitted with speeding up the closure of th€ nozzle valve, and sucking
(3)obliquely cu t l e a d
cylinderside end; when il reachesthe opposileside end
the fuel control gear (6), and its flange (7) tits into the the fuel belore it drips back. This enhancesthe durability of
the maximumamountol fuel is iniected.Beforethe maxi-
longitudinal groove which is cut in the inner surface of the the nozzle and improves luel oil combustion'
mum iniection level is reached,the luel iniectioncontrol
(2) plunger barrel
lowerend otthecontrol gear.The fuel control gear is in mesh
with the {uel control rack. the motion ot which rotates the Fu e l i n j e cti o n st,-ft regulatesthe amountof fuel inieciedto the normal
plunger to constantly vary the amount ot fuel injected from
vo l u m e d e cr e a se s operationlevel. Delivery valve
zero to maximum.
iOTE: Theptungeris an integnl patt ot the plungerbarrel
and takesin and compressesluel by reciprocating
insidetheptungerbatel. Theplungerand plunger Returncollar Fletractaon
fu e l co n tr o l ta ck baffel are precisetymachined,and becausethe
plunger is dtven in an extremely small space' the
two shouldbe used togetherand should not be
Iu e l co n tr o l gear changedwilh othercYlinderc. Oelivery valve holder

2-3.2Ac.tionof the deliveryvalveand the sucking'backol

The deliveryvalveon lop of the plungerpreventsthe.fuel
insidethe i;iection tubefromflowingbackwardtowardthe
plungerside and also seryesto suck backthe fuel to pre'

Printed in Jaean
Chapter 3 Fue! System
Chopter 3 Fuel System
2. Injeclion PmP
2. Injeclion Pump SM/GM(FXC}HM(F)(C)
(6) Remove the fuel control rack. (l) Remove the plunger guide stopperpin with needl€
2.4 Disassembly of fuel injection pump nose pliers.
f/) Remove lhe delivery valve holder; be careful not to
As a rule, the iniection pump should not be disassembled, damage the O-ring.
but when disassembly is unavoidable, proceed as describ- (8) Remove the delivery valve spring.
ed below. (9) Remove the delivery valve.

2-4.1 Dismniling of f uel inleclion pump of model 1GM1 0(C)

NOTES:I) Betorc disassembly wash the pump in clean
oil, and alter assembly anange all parts caretul-
2) Make surc the work arca is exceptionalty clean.
(1) Remove the plunger guide stopper pin wilh needle
nose oliers.
(10)Removethe plungerbarel by pushing it toward the (2) Removethe No.1plungerguidestopper.
deliveryvalveside. The stoppercan be removedby pushingthe plunger
(1'l) Removethe plungerbarrelpacking- guidedownwiih the palmof yourhand.
B) Removethe No.l Plungerguide.

(2) Removethe plungerguidestopper.

The stoppercan be remo\tedby pushingthe plunger
guidedownwith lhe palmof yourhand.
(3) Removethe plungerguide.
NOTE:Be carctul not to lose the plunger slrcke adiusting
shim which ls located insidethe plungerguide.

goilj- NOTES: 1) Line up the plunger banel and the plunger, and
Dutthem in order.
2) lmmeA,e the delivery valve, plungeL etc. in
c@an oil.
3) Do not bosen or rcmove the plunger baffel
/- stoppe| etc. (4) Removethe No.1 plunger,plunger spring lower retainer
strck€ adiuslrent thim
and plungershim; be careful not to damagethe plunger.
2-4.2 Dismaniling of luel pump ol model 2GM20(FXC)' (5) Remove the No.1 plungerspfing.
(4) Remo\rethe plungerand plungerspringlowerretainer. 3Gt3o(R(C) and 3HM35(FXG)
Be carefulnot to damagethe plunger.
Thecylinders are classifiedas No. 1, No.2and No.3 from ihe
6) Bemovethe plungerspring, fuel control pinion and left, when facing the name plate fitted on the upper part ol
plungerspring upper retainer,using your fingers or
thefuel injection pump.When dismantling,it is necessaryto
tweezers. prepare pans or vessels in which to keeP the dismantled
lncreGe in parts lrom each cylinder; each part must be placed in the
corresponding pan or vessel lor each cylinder, namely, No
'1,No.2 and No.3cylinder. lla part is placed in the wrong pan
or vessel,reassemblybecomes impossible without a pump

tester.The following explanationis tor to the pump of the 2
cylinder type engine [model 2GM20(F)(C)]' but it applies

s@ equal l y to l hat of th e 3 c y l i n d e r t y p e e n g i n e [ mo d e l
3GM3O(F)(C)l which merely has an additional set. The
construction of thetuel pump of model 3HM35(F)(C)engine
is the same as that ot model 3GM30(F)(C)engine except for
the diflerencesof plunger,plungerbarrel,and the position of
the injection volume adjusting rack.

Ptiated ;^ JoNn
Chapler 3 Fuel SYstem
2. Inieclion PumP sM/GM(FXCIHM(F)(C)
ChaPter3 Fucl SYstem
2. Iniection PwnP SM/GM(F)(CftM(F)(C)
(4) After cleaning the plungec tilt it approximateu m', 6
(2) Replace pinion it teeth are damaged or wom shown in the figure, and slowly slide it down' Repeal
(15) Removethecontrol rack' plunger' The
(6) Remove the No.1 plunger spring
upper retainer' uslng this several times while rotating the
your fingers or tweezers'
plunger should slide slowly and smoothly' ll it slides too
quicily, orbinds along lhe way, repairorreplace it'

O) hemove the No 1 control


a force
ffi (3)ll lhe controlrackdoesnot movesmoothlywhen
t"' rack and pinion
oi *,-itttinoog is applied,replacethe


(1)Inspectthe plungerfor wear,scoringand discoloation
"';;; th; t'".0.-tt problemsare found' conducta
"ny plungerand plungerbanel
iti"""* i"ti""o t"plice rhe
assemblY. 2-5.5Doliveryvalv€
and seat
and 3GM30(FNC) (1)Replacethe deliveryvalveil the retum collar
plungeL ano Fot models1GMlo(c)' 2GM2o(F)(C) arescored,denledorwom'
NOfESi t) Line up the plungervalve and the
valve holder; be careful not
€) Remove the No.1 delivery Put them in ordet' in
to damagethe O'ring' z) Ti^"o" the detivery vatve' ptunger' etc'
vaNe sprlng-
B) Remove the No-1 delivery clean oil.
valve, delivery valve seat ano iniection conttol
fr'6i nemove tne no.1 delivery 3) Do not loosen or rcmove the
Packing. Plate' etc.

2-s.t BinseeactcomponentPartin cleanlighioitbelore
NOTE: Do not touchthe slidingsudaceof the
" -' -' handling'
li" ditir"ry vaNewith your tingersduting
For model 3HM35(F)(C)
the tapp€i roller for
Inspect the cam sliding surfaceof
tapp€t and roller
*Jr.l"oring and peeling;replacethe andput a fingeroverthe hole.on
t'' Raisethe deliveryvalve go the deliveryvalve'lf it
l$i"-uit ,ne total-iappet and roller plav exceeds iil *i"" ootto.. L"t of
0.3mm. "i." "ot
iii*I" q,r]"r.]v stops at ttre position wherethe suck-
""0 the valveseathole'lhe deliveryvalve
uiii. Jori"idr.*"
2-5.3Control rack and Plnbn not the case'
iray Ue consiOereOnormal' lf this is
tllCheck the controlrack teeth and reDlacethe deliveryvalveasa set.
damageandabnormalities lf found'replace'
replacingthe controlrack' adiusttuel
- ' -' a
inh a tiet iniectionpump testerand stamp
rack marK-
plunger barrel; be careful not to
111) '' Remove the Nol
' valve seat'
darnage the face that matches the delivery plungerwilh a
(2)Inspeclthe outsideslidingsur{aceot the
(12) Remo:vethe No.1 plunger barel packing' ' 'magnitying glass. Lap or replace the plunger and
above steps (2) througn
iiii ro, uo.z cvlinder, repeat the oruio"i u"'""j whenconosion'hairlinecracks'
(11). """embly
3 stainingand/or scoringaredetected'
item also applies to No 3 cylinder tor the and
Oll ini
"0"u" tsl;h;tin" clearancebetweenthe plungercollar
engine. wear
cylindertYPe '-' sleevegroove.Replacethese parts when
exceedsthe sPeciliedlimit'

3 -1 5
0000A041361 0000A041361
Choptu 3 Fuel Syslem Chapter 3 Fuel Syslem
2. Injrtion Punp 2. Injeclion Pump

(2) Attach the delivery valve seat and the delavery valve to NOTE:Atter attachingthe tuel controlpinion to the main
(3) Place yourfingeroverthe hole in the bottom of the valve 2-5.7 Plungerguue
the main unit. unit, check its meshingby movingthe luel contrcl
seat and insert lhe valve into the valv€ body. lf the valve Check lhe tappet roller (lnside and outside) and roller pin rcck.
retums lo its original position wh€n you remove your fordamage and uneven wear, and replace if required. (6) Insert the plunger spdng relainer and attach the
finger, the valve is okay. lf some defect is found, replace Measure the clearance between the plunger and plunget plungerspringto the mainunit.
with a new valve- guide. lfthe clearance exceeds the limit, replace.
(4) ll the valve closes completely by its own weight when
you remove your finger from the hole on the bottom of
lhe valve seat, ihe valve is okay. lf it doesnl close
perfectly replace with a new valve.


2-6Ass€mblingthe tuel Ini(,G.llonpump

/VOIES:t) Atter inspection, divide the components into
two groups, l.e- the cgmponentsto be replac- NOTE:Theplunger ,pilng retainer shoud face the undet'
NOfE: Whenusinga bnnd-new set,washott the rustprool ed, and those that are reusable.Rinsethe com- Ailachinglhe deliveryvalveto the mainunit sideot thePumP.
oil with cleanoil or gasoline.Then,washonce more ponentsand stote thetwo groupssepantely.
O) Afteraligningthe matchingmatkon the Plungerflange
wlth cleanoil, and follow the stepsoutlined above. 2) Replacethepacking with a new one. with that on the fuel control pinion,attachthe plunger
NOTE: li the delivery vahte tip noticeably above
the top ot the main unit 'fgiects
of the pump' the plunger to themainunit.
2-5.6Plunge.sp(hg anddeliveryyalvespring 1GM1o(C)
banet has been installed lncoffectly, and must be
lnspecl the plungerspring and deliveryvalve spring for (1)While lining up the plungerbarrelpositioninggroove rc-aftached.
fractured coils, rust, inclination and pennanentstrain. with the dowelof the mainunit,attachihe plungerbar. (3) Attach the delivery valve packing and the delivery valve
Replacethe springwhenfaufty. rello the mainunit. spring to the maln unit and carelully tighten the
delivery valve holder.
Allaching lhe pludger baffel to the maln unil NOTE: Tuhten the delivery vatve hoder with a to,que
wrcnch dlter altachlng the ptungq and whlle check'
lng thefuel control rack fotsliding motion.
1GM(10(c) k9t-m(fr-lb)
a5@.C2a325/l NOTE:lnved and stand the main unit ot the pump upright
and attach the plunger to it carclully.
(4)With the matching mark of the luel control rack
directed towards the lower part of the main unit of the
pump,attachthe tuel controlrackto the mainunit'
NOTE:Make surc the lt@l @ntrol 6ck moves smoothlY
along lts entire strcke.
(5) By aligningthe matchingmark on the luel control pi-
nion with that on the fuel control racK attachthe fuel
controloinionto the mainunit'

Matching mafts

(9) Insertthe plungeradlustingshims.

tnsert the same numbet of shims with the same
^iOTEt Ihicknessas those tnsertedEfo'e disassembling
thepump.Atler re-assembling the pump' measure
and adiust the top cleannce of theplungeL

0000A041361 00004041361
Chapler 3 Fuel System
Chapter 3 Fuel SYaem 2. Injection Pump
2. Injection PumP SM/GM(FXC}HM(F)(C)
(5) Tighten the No.l delivery valve holdel (8) Insert the No.l plunger spring retainer and attach the
(10)While adiustingthe direction o{ the plunger guide ('l) Installthe No.1 plungerbanel packing. plunger spring to the main unit.
stopperholetor the plungerguide,insertthe plunger (2) Insert the No.1 plunger barel by aligning lhe groove of
guidecarefullY. the barel lock oin.
When the plungerguidesiopperhole is lined up with
the plungerguide,insert lhe plungerguide stopper.
Thenmountthe retainingring(clip).


NOTE:Tighten the delivery vave holder with a torque spring retainer

wrench alter atlaching the plunger and while check'

ing the tuel contrcl nck tor sliding motion-
Attaching lhe plunger guide
to the main unit
o) with the matching mark ol the tuel control rack
directedtowardsthe lowerpart of the mainunit of the
pump,attachtheluel controlrackto the mainunit.
NOTE:Make surc the luel control nck moves smoothly
along itsentirestroke.
C4 By aligningthe matchingmark on the luel control pi- NOTE:Theplungetspringrctalnershouldlace the under'
nion with that on the tu€l control rack,attachthe fuel sidethepumP.
controlpinionto themainunit. €) Afteraligningthe matchingmatkon the plungerflange
with that on the fuel controlpinion,attachthe plunger
(l1) Afterattaching tighten the delivery valve holder wilh a 2GM20(F)(C) Punched fra* to the mainunit.
torque wrench.

(3) Inslall the No.1 delivery valve, delivery vake seat and

Punched mad

1G M 1 0 ( C )
Tighlening 4.5P8.92 3a5a)
- -

2GM2o(FXC), 3GM3o(F)(c) and3HM3s(FXc)

Toensurethatthe inieclionpumpis conectlyreassembled, Redline
the followingpointsmustbe keptin mind:
.The partsforeachcylindermustnol be mixedtogether.
oWhenparlsarereplaced, the parts tor eachcylindermust NOTE: lt the delivery vatue tip proiects noticeably above NOTE: Alter attaching the luel conlrcl pinion to the main
alwaysb€ replacedat thesamelime. the top ol the main unit of the pump, the plunger unit, check its meshing by moving the luel control
.When assembling,partsmusl be washedin fuel oil and barrel has been inslalled incoffectly, and must be rcck.
matchingmarksandscribelineslinedup. rc-attached. NOTE:By invertingand standingthemainunit ol thepump
(4) Insert the No.1 deliveryvalvespring. upright attachthe plunge(to it carelully'
(10)Install the No..l plungerspring lower retainer.Make
surethal il is not installedbackwards.

Chapler 3 Fuel SYslem Chapter 3 Fuel Syslem
2. Iniection PmtP 2. Injection Pump

The thickness of the plunger localion adiusting shlm

(11) Insert the Plunger shim.
and the iniection timing adiusting plate is 0.1 mm. With
NOTE: lnsert the same number of shims with the same
this the iniection timing can be changed by approx-
thickness as lhose ,hserled belorc disassembling
imately 1 o on the crankshaft-
the pump. Aftet re-assembling lhe pump, measure
and adiust the topcleaance ot the plunger- For all modeb engln6

02) Inserl the No.l plungerguide.

(13) Insert the No.l plungerguidestopper.
(14) For the pump of lhe 2 cylinder type enginc, repeat the
above steps for No.2 cylinder.
(15) For the pump of the 3 cylinder type engine, repeat the
above steps for No.3 cylinder.
(16) Installthe plungerguide stopper pin.
(17) Afterattachmenttightenthedeliveryvalveholderwitha
torque wrench.

2GM20(FXC),3GM30(F)(C),3HM35(F)(C) ker-fr(rt-rb) (a)Resistanceof the rotatingand sliding parts of the i Tlmlng maft

3254) plungerassembly is too high.
O)Delivery vatue holder is too tight (plunger barel
NOTE: When the tightening torque of the delivery yalve distorted).
holder exceeds the prcscdbed toque, the plunger (c) Control rack or conlrol pinion teeth and control rack
will be distoned, the slidlng reslstane ol the con- outside circumferenceare d irty or damaged.
trct nck wlll increase, and proper peilomance will (d) Ini€ction pump bodycofltrol rack hole ls damaged. \
not be obtained. Moreover, excessrve tightening (e)Plungerbanel packingis not installedcorectly and A mark is d$ Punched on the \
will damqe the pump body and delivery valve clutch housing lor models of
the banelis distorted.(Sincein this casefuel will leak 1GM10(C),2GM20(FXC) _
gasket, and cause a vaiety o{ other problems. Into the crankcaseand dilute the lubricatingoil, and 3GM3O(F)(C)
2.7 Inspectlonaftereassembly 2-72 Fuel injection llmhg
Whentheenginedoesn'trunsmoothly andthe injection Fuel iniectiontiming is adiustedby timing shims inserted
pumpis suspected or whenthepump
asbeingthecause, betweenlhe pump body and gear case pump mounting
has been disassembledand parls repbced, always con-
duct the followingtests.
The Injectionpump must be mountedon the engine,and
2-7.1Conlrol r|d( rssistancotest eachcylinderiniectiontlmingadiusted.
Adiustingthe in,ectiontiming
After reassemblingthe pump, wash it in clean fuel, move (1)Removethe highpressurepipefromthe pump.
ihe rackand check resistanceas follows: \-\-
(2)lnstalla measuringpipe if the injectionpump do€s not Fu€l inieclion\\
(1)Thistest is performedto detemine the resistanceof the timing shim
havea nippleon the deliveryside.
control rack. Wh€n the resislance is large, lhe engine (3)Bleedthe airfromthe iniectionpump.
will runineguhrlyor racesuddenly. Timino maft
(2) Placethe pumpon iis side,hold up the controlrackand
allowit to slidedownby its own welght.Therackshould (6)lf the iniecliontimingis ott, add plungershimswhenthe
slide smoothlyoverlts entirestroke.Placethe pumpon timing is slow, and removeshims when the timing is
end and performthe abovetest agaln;check for any ab- fast. Adiustthe timlngof everypump in lhe sameman-
normalilies.fFesistance below609 p.132lb)l ner.(Refertoitem,"Plungerheadgapadiustment"')
(3)Sinc€a highslidingresistanceis probablya resultof the O)After the iniectlontiming of every pump has been
following,clisassemble the pumpandwashorrepairil. ched,recheckthe iniectiontimlng as describedin item
(5)above.lf the iniectiontimlng is not properlyset, ad- slowly and confirm that it
' Finally,tum the crankshaft
lums easily.lf it is stltf or does not rolate,the plunger
Iniection timing shim
iust it withthetimingshims.
headgapis too small.
2GM2O 3GM30 3HM35
1GM10(C (FXC) (FXC) (F)(c)
bTDC15. )TOC15' )TDC1a bTDC21.
Fuel inl@tion timing (FrD) (FrD) (FrD) (F(D)
1 shim 2 shims 2 share
0.2mm 10/.271- 124950-
(0.m8in.) nt@ l
I Shrm z sntms 2 shims
(4) Set the control rack to lhe middle f uel iniection position 0.3mm
Fuel (0.012in.) 104271- 1249sG 121,15G01941
(Pull the leverwhen setting the acceleralor lever.) instaon 019,1o 01941
(5) Tum the crankshatt slowly by hand, and read the timing timing 1 shim
shim 0.5mm 1 shim
mark (TD) on the flywheel the instanl fuel appears al the (0.020)
12495G 124950-01961
measuringpipe or pipe joint nipple.
104271- 12495G '12 1450-01951
(FlD+ Fusl ;n1s611sn from deliveryvalve.) Set No.
01950 01951

0000A0A1361 0000A0A1361
Chapter 3 Fuel SYslem Chapler 3 Fuel System
2. Iniection PmP 2. Injection Pump SM/GM(FXC}HM(FXC)
(3) lf both the plunger and the delivery valve fail lhe lest,
2.8 Iniection pumPadiustmenl NOTE: lt the sliding resisrance is unsatislactory, disassem- (3)When the plungertop clearanceis largerthan the
prescribedvalue,removethe plungerguide and insert reolace them.
The iniection pump is adiustedwith an iniection pump ble, inspect and repair the luel contrcl rack.
ptunger shims betweenthe plunger spring lower re'
lesterafterreassembly. 2-8.6 Plunger Pessure lest
2-8.3 Adiusling lhe plungerlop clearance tainerand the plungerguide.Adjusteachpumpin the
(l) Set the pump installation dimension (end of plunger bar- samemanner.
rel when the roller is on the cam base cycle) at 76
i0.05mm (2.9902 2.9941in.),remove the delivery valve
holder and delivery valve, and set the plunger to top
dead center by tuming the camshaft. Measure the dif-
ference in height (head gap) between the end of the (4) Alter rechecking adjustment, install the delivery valve
plunger and the end of the plunger banel using a dial
Oelivery valve hokler 4.0 - il.5 kgf-m
gauge. (29 - 32.6 lbjl)
mm(in.) torque

cpaan€ 1O {.05 0.0374 0.0398)

(4 Usingthe plungertopclearancemeasuring 2.8,4Checkingthecy'inderlnirctlon Interual

1) Installa dhl gaugeon the measuringiig. (1)Align the conlrol rack punch mark with the pump
2) Stand the measuringiig on a stool and s€l the dial referencetace.
3) Removethe pumpdeliveryvalveand installthe measur-
4) Tumthe camshaft1oset the plungerto top deadcenter
and readthe dial gauge.Thevaluegivenis the plunger (l )l n s t a l l a 1 , 0 0 0k g f / c m' ? (1 4 , 2 2l3b / i n ' )p re s s u re g a u g e o n
2€.1 Sotting pumpon leste.
top clearance. the delivery valve holder.
(1)After the iniectionpump has been disassembledand (2)Checkthat there is no oi I l€ki ng from the d€livery valve
reassembled, installit on a pumptester h o l d e r a n d h i g h p re s s u rep i p e mo u n t i n g s . a n d t h a t t h e
...camlitt: 7mm(0.276in.). pressure doeJnot drop suddenly wherr raised to 500
e) Confirmthat the controlrackslidessmooihly.lf it does K g f / c m' (7 , 1 1 2 l b / i n . ' ) o r h i g h e r.
not, inspectthe iniectionpumpand repairit so that the P re s s u re g a u g e A V T l / 2 x 1 5 0x 1 , 0 0 0k g f / c m'
...controlrackfull stroke:15mm(0.5905in.). Fuel conlrol
2-8.7 Measurlng the luel InFctbn Yolume

(2) Tum the pump by hand to check the No'1 cylinder iniec'
tion timing.
(3) Tum the pump in the prescribed direction and check the
No.2f3 cylinder injection timing.
(4) Using the plunger shims' adiust each cylinder in,ection

(3)Runthe pumptesteral low speed,loosenthe airbleeder \

screw,andbleedlheair tromthe injectionpump. M6surino the fuel inieciion volume
2.8.2 Measurlnglh€ slidingr€slstanceol lhe fuel |

control rack 2-8.5 oeliv€ry vahe oil'lighl lest t- - +l

Measurethe slidingresistanceof the luel controlrackwith | --H- |
(l ) | nstal I a 1,000kgt /cm'(14,223 lb/ i n.'?)pressuregauge on | --f--r I
a spring scal€(balance). l.ffl
(1)Numberolpumprotations/sliding resislance:orpm/less the del i v er y v al v eh o l d e r'
than60g. 0.132lb) {2)Drive the fuel pump to apply a pressureof approxi matel
| --/'+<_ |
| 20k gf/c m '?(1,70 7l b / i n . ' z)a n d me a s ure t h e t i me re q u i re d l14 l
for the oressureto drop f rom 100kgf/cm'?( 1,422lb/in''?)to l...l'..,,+l
90 k gf/c m '( 1280 l b / i n ' )
I t_+F I
200 rpm lf f l

lf f il
20 sd- or mre
I . } i4-I


0000A0A1361 0000A0A1361
Chapler j Fuel SYdem Chapter 3 Fuel Syslem
2. Injection PumP 3. Injection Nozzle

(1) Set the fuel pump camshafl speed

(2) Check the injection nozzle.
By loosening lhe set bolt and turning lhe eccentric bolt
clockwise, the position of the pin moves to lhe lett to 3. InjectionNozzle
increase the injection volume, and by turning the ec-
1 GM1 0 (C )2GM20(F)(C),
3HM35(F)(C) centric bolt counterclockwise,the pin moves to the right 3-1 Consiruclion
to decreaselhe injection volume. The injection nozzle alomizes the fuel sent from ihe injec. the pressure of the fuel, high precision is required- Boih are
Pump 1800 rpm 1700 rpm
After adjusting the injection volume, tighten the set bolt tion pump and injects it into the precombustion chamber in made of quality alloy steel that has been sp€cially heat
Plunger diametef 06 x 7mm 06.5 x 7mm
x stroke (0.2362 x 0.2756in.) 559 x 0 2756in the prescribed inieclion pattem to obtain good combuslion lreated and lapped, so they must always be handled as a
Injslion nozle lhrough optimum fuel/airmixing. palr.
The main parts of the injection nozle are lhe nozzle holder Common parts are used tor the fuel valve of models
Pressure for 170kof/cm' 160kgf/cm' and nozle body. Since both these parts are exposed to hot 1 G M1 0 (C ), 2 G M2 0 (F)(Ca) n d 3 G M3 0 (F)(C ).Th e o n l y d i f f e r-
fuel injtriton (2416lb/inr) (22761b/in'l
combuslion gas, lhey must be extremely durable. ence betweenthe GM model seriesand model 3HM35(F)(C)
Amount of Moreover, since their operalion is extremely sensitive to
inj@tion at rack
22.?'23.5c\ 21.5cc-22.5@ 27.5-2g.5ca is the nozzlecase nut.
(1.37-1.{3in.l 1.31-1.37in.r) (1.68-1.74in.')
mark position
Allowable error 1cc (0.06in.') 1cc (0.06in.')
betw@n cylinder of t6 or less
1000 r000
NOTE: Mainting the pressure for feeding oi I to the in jection Nozle spring nut
pump at 0.5 kgflcn2.O.l lb/in.,)

2.8.8 Adiustment of inie.clion volume for each cylinder

(1) Fluctuation of injeciion volume spring adjuslment shim
The lniection volumes of each cylinder must b€ ad-
iusted to within 3% of each other-
Nozzle spring

or rlovtfl
Averageinjectionvolut"= "r
*nlu"roi*tinoo. Nozzle spring seal 7

Inter spindle 8
- averageinieclionvolume
Difference = x 100 holder body
Average injection volume

When the difference exceeds 37o, adjusl the iniection

volume by sliding the control sleeve and pinion, when
1. Nozzle spring nul
the difference exceeds 3"/., the engine oulpul will drop 2. Nozle spring adjugtment shim
and/orone cylinder will overheat. 3. Packing
(2) Adiustment ot inieclion volume 4. Nozle spring
5. Nozle holder body
In order lo adiust the fluctuation ot inieclion volume for 6. Noale spring seat
each cylinder, aller the position ol the injection volume 7. Inter Spindle
8. Nozle valve
adlusting plate at the side of the fuel injection ot pump 9. Nozle body
body. 10. Nozzlenut
The iniection volume adiusting plate is operated by the
eccentric boll which is integrated with the locking pin of
lhe plunger banel and changes the position of the
plunger barel. When lhe plunger barel is tumed, the
relative position of the suclion hole with respect to the
lower lead of the plunger changes the iniection volume.
3-2 Specificalions for nozzle valve

n'. (2317 - 2180 lblin.'z ) | 16015 kgl l cm1 (/205 - ?347 lb / in.' )

ockrng prn ol plunger barel

14.14kg (31.17
Nozzle spring adjusting plate
Increase - Decrease
(for adiusting nozzle opening pressure)

0000A0A136r 000040A1361
Chapter 3 Fuel Syslem
Chapler 3 Fuel SYslem 3. Inieclion Nozzle
j. Injection Nozzle SM/GM(FXC}HM(F)(C)
(2) Parts for No.1 cylinder and No.2 cylinder must be kept (5) When inslalling the injection nozzle on the cylinder
3.3 Yanmar throltle nozzle 3-5Disassembly andreassembly separale. The nozzle body and nozle must always be head, tighten the nozle holder nuts altemately, being
Thesemi-throttlenozzlesusedin this enginearedesigned 3.5.t D'rsassembly
sequence handled as a pair. careful to tighten them evenly'
and meufactured by Yanmar.A semi-lhrottle nozle (3) Precautions when using a new nozle.
resembl€sa pintlenozzle,exceptthat with the formerthe Firsl immerse the new nozle in rust-preventive oil, and
nozzlehole at the end of nozzleand nozzlebodyare longer then seal it on lhe oulside with seal peel. After removing The nozzle holder must be installed with the notch sideon
and the end of the nozzleis tapered.This nozzlefeaturesa the seal peel, immerse the nozzle in diesel oil and the nozle side.
"throttling effect":relativelyless fuel is iniectedinto the remove the rust-preventiveoil from both inside and
precombustionchamberat the inilial stage ol intection,
outside the nozzle. Nozle

and the volumeis increasedas the nozzlerises. This type Stand the nozzle holder upright, lill the nozle about 1B
of throttlenozzleidealforsmall,high-speedengines. ot its length: it should drop sm@thly by it own weight
when released.

Inieclion nozle


(1) Remove the carbon from the nozzle end.

(2) Loosen the nozzle spring holder.
Pintl€ nozle YANMAR $mi'tn@ule nozE (3) Remove the nozzle holder body from the nozle moun
ting nut-

3-4 Nozdeoperation
Th€ nozzle is pusheddown to its lowest position by the
pressure-adjuslingnozzle spring and conlacls th€ valve
seat of the nozzlebody- (4) The nozzle must be litted on the nozle holder with the
Under high pressure,luel from the fuel pump passes nozle spring retainerloosened.
throughthe holedrilledin the nozzleholde( entersthe cir- lf ihe nozzle is installed with the nozzle spring tighten-
cular grooveat th€ end of the nozzlebody and th€n enters ed, lhe nozzle mounting nut will be tightened unevenly
the pressurechamberat the bottom of lhe nozzlebody. and oil will leak from between the end of the nozzle
Whenthe forceactingin the axialdirectionon the difteren- 3-OInjectionnozzlelnspectionandadiustment
holder body and the end of the nozzle mounting nut'
tial areaol the nozzleon the pressurechamberovercomes causing faulty iniection.
3-6.1Carbonandcofloslononthenozle My
the forceofthe spring,the nozzleis pushedup and the luel k9f -m(fF lb ) lnsDect the end and sides o{ the nozzle body for catbon
ls in,ected inlo th€ ptecombustion chamber through th€ build-up and conosion. lf there is considerable carbon
throttlehole. (4)Removethe nozzle body and nozzleass'y from the build-up, checklhe proPerties ofthe fu€l used' etc-
The nozzleis closedagainwhen the pressurein the nozzle nozzlemountingnul. Replace the body if heavily conoded.
body's pressur€chamber drops b€low the torce of the (5)Remove the nozzle spring retainerfrom the nozzle
spfing. holder body, and removethe nozzlespring retainer, 3.62 Checkhg nozzle acllon
This cycle is repeatedat each opening and cbsing of lhe inter-spindle
eic. Wash the nozzle in clean tuel oil and hold the nozzle body
iniectionpumpdeliveryvalve. Reassemblein the reverseolder ol disass€mbly,paying upright, then lift the nozzle aboul 1/3 of its length with one
specialattentionto the lollowlngitems. hand. The nozzle is In goad condition if il drops smoothly
by its own weight when released. lf the nozzle slides stitfly'
3.52 Dbass€mblyandreassemblypr€cautions repairorreplace it.
(1)The disassembled partsmust be washedin fuel oil, and
carbonmustbe completelyremovedtromihe endof the
nozzlebody,the nozzlebody and the nozzlemounling
nul fitting section.
lf reassembled whileanycarbonremains,thenozzlewill
not tightenevenly,causingtaultyinjeclion.

Chapter 3 Fuel Syslem
Chaptu 3 Fuel SYslem 4. Fuel Filtu
3. Iniection Nozzle SM/GM(F)(C}HM(FXC)

3.6.3 Adiusting the nozle iniection ptessure

Fit the injection nozzleto the high pressurepipe ot a nozzle
4. Fuel Filter
tester and slowly operate the lever of the tester. Read the rh .
Injeclion pressure low
Nozle seized 4-1Construction 42 Specification
oressurewhen instantinjection from the nozzle begins.
lf the iniection pressure is lower lhan the presctibed i-T .
Nozle spring broken
Dirt on valve s@t The fuel filter is installed between the feed pump and injec-
tion pump, and serves lo remove dirt and impurities from
(Common to all models)
FilteringAr€ 333crf @3in.')
pressure, remove lhe nozle spring holder and adiust the
pressureby adding nozle spring shims.
The injection pressure increasesabout 10 kgl/cm'? (142.2
lb / i n . ? ) w h e na 0 .l mm/0 .0 0 4 i n .)shim is added.
Tli the oil fed from the fuel tank through the feed pump.
The fuel filter incorporates a replaceable filter paper ele-
ment. Fuet from the fuel tank enlers the outside of the el+
ment and passes through the element under its own
Filttr nEsh

oressure- As it passes through, the dirt and impurities in 4-3lnspection

the fuel are filtered out, allowing only clean fuel to enter ihe
The fuel filter must be periodicallyinspected.lt there is
interior of the element. The fuel exits trom the outlel al the
waterandsedimentin the filter,removeall dirt, rust,etc. by
d-l . Injectionport damged ordarty
. Carbonbuild-uD toD centerot the litterand is sent to the injection pump.

t-T . Nozle endabrcmlly wom A cross-headed hexagonal bolt is fitted to the fuel filter
body. Loosen the bolt with a cross-headed screw driver
w6{ling thefilterwith cleanfuel.
The nomal replacemeot interval lor the element is 250
hours,but the elementshould be replacedwheneverit is

4 before starting or after dismantling and reassembly to

bleed the air in the fuel system to the fuel oil filter.
dirty or damaged,evenlf lhe 250hour replac€mentperiod
hasnot elaos€d.

Fuel filter body
+To iniectionpump

sp€y rh . Iniectionpon wom

. Carbonbuild-up
T-I --\ rro. t*o pr.p

& t = 0.1mm (0.0039in.)

0.2mm (0.0079in.)
0.3mm (0.0118in.)
0.5mm (0.0197io.)

. UBss€lcmtact
* . lnjection port daffEg€d or wm

3-6.4 Nozzle seat oil tightness check

Aft6r inisting the fuel severaltimos by oporatinglhe l6v€rot
t-T . Carbonbuild-uo

ths nozzletostor,wipotho oil off the inrectionport. Then raise

tho prossureto 20 kgf/cm'?(28,1.5 lb/in.') 110kgl/cmt (1991 \ Fuel filtet
lb/in.t) lowor lhan the proscribodinioction pressure. The \\
nozrle is laulty iI oil drips trom tho nouzle.In this case,clean,
ropair or r€placotho norrlo.

3-6.5 Checking lhe spray conditbn

Adiust the nozzle iniection prcssure to the prescribed value
and check the condition of the spray while operating the 3.6.6 Inspecting the nozzle sPring
tester al 4-O times/sec. Judge the condition of the spray Inspect the nozzle spring lor fractured coils, conosion, and
by refening to the below figure. permanent strain, and replace the spring when faulty.

3-6.7 lnspecting lhe nozzle gPting r€lainerand inler'spindle

Inspecl ihe nozzte spring retainer and inter'spindle for wear
and peeling of the contact face, and repair or replace the
spring if faulty.

0000A0A1361 0000A041361
Chapler j Fuel St'slcm
Chapler 3 Fuel SYnan 5. Fuel Feed PumP SM/GM(FXCTHM(FXC)
5. Fuel Feed PumP SM/GM(FXC}HM(FXC)
(4) Make sure the diaphragm mounting hole is in the cor-
5-2 DisassemblYand reassemblY rect position and gently attach the diaphragm to the
5. FuelFeedPumP Specilications
2cM20(F) (C).
Cleantheoutsideof thepump,inscribea matching
pump body.
(5) Line up the matching marks on the pump body, and
3H M 35(F ) ( C ) ihe upperbodyand lowerbodyof the pump,disassemble clamp on the PumPbodYeventY.
5.1 Constnrction and Dutthe comPonenisin order. 30110 kgf+fr
The fuel pump feeds the fuel from the fuel tank to the iniec- Tighteningtorqueof screw (1.15 2.89 ft-rb)
Pa d s o { luel feed PUmP -
tion pump lhrough the fuel filter. When the fuel tank is in-

stalled at a higher position than the fuel filter and injection

pump, lhe fuel witl be led by its head pressure, but if the' Feed Pr ess ur e <q>'{
5.3 Inspecting and adiusting the luel leed
fuel tank is lower than the liller and iniection pump' a fuel
pump is required.
The luel pump of this engine is a diaphragm type and is in-
tA\ @
5-3.1 Checking lhe PumP for luel oil leaks
After removal, immerse the pump in kerosene, stop
stalled on the exhaust side of the cylinder body. The \:r' outlet port with a finger and, by operating the
rocker am'
diaphmgm is operated by the movement of a lever by the
fuel leed pump cam at the cam shaft.
@ o check for bubbles.
lf any bubbles are present, this indicates a delective
which should be replaced.

5-32 Ch€ckhgthe pumplorenglneoil leaks

Checkpump mountingbolts lor loosenessand the
packing for breaks.Retighten any loose bolts and replace
5.22 Rer$€mbly
Assemblethe pump by reverslngthe dlsassembling 5-3.3lleasuting th€ sucklng power
cedures.Paycloseattentionto the following: Attacha pieceofvinyl hosetothe inletport,keePthe
('l) Cban the components,blow compressedalr against netght(herd) abovethe fuel oil level'and
them,andInspect.Replaceanyd€tectivecompon€nts' "i "-*.i,ffi"O
.*ra6 tn".ct"iarm by hand' lf the fuel oil spurts out
(a Replacethe packings,etc.with newones'
irlm itre ourtetport,ihe pumpis all right'A simPlermethod
iiiwn"n *ounting ihe YalYes,be careful not to mix up oitesting pump poweris as lollows: coverthe inlet
the inlet and outlet valves.Also, don't forget the valve *itir tiid"t and, by operatingthe rockerarm by hand'
Packing. " ti" pr.p's suiking powerby iudgingthe suction
it can
on'tn" fing"t, nff'ough this is not an exactmethod' are
1 GM1 0( C) 2GM20(F) (c)
(C),3GM3o{fxc),3HM35(F) Outlet valve ai ieasr lonfirm that lhe diaphragm,valves'

000010Al 36I
Chapler 3 Fucl SYstem
Chapto 3 Frcl SYstant 6. Fuel Tmk (OPtion) SM/GM(FXC'HM(FXC)
5. Fuel FeedPunP

5-3.5 The contacl area and mounling condition ol Yatve

Test the valve seat as follows: Remove the valve and blow
6. FuelTank(OPtion)
into the valve seat from the direction in which the valve spr' The luel tank is optionally available lts capacity is 30 litres
ing is mounted. lf air leaks, replace-the seat wilh a new one. for all engine models and is triangular to fit compactly into
lf fuel oil leaks as a result of dust, foreign objects, etc. the engine room. As an accessory' a rubber hose of 2m
caught in the valveseat,rinse it and clean it by blowingit with length is attachedto feed fuet oil trom the fuel tank lothe fuel
atr. pump. A connection to return luel oil is providedat the top of
the fuel tank, and by connecting a rubber hose from the fuel
valve. the overflow oil can be returned to the tank.

Checkthe diaphragmspringand rockerarmspringlor per-
manentdeformation,and the rockerarmand rockerpin lor B€tum con€tioo
wear. lf any of lhese componentsare detective,replace
themwith newones.
NOTE:Whenit becomesnecessaryto replaceanyol these
parts,the entire luel teed pump assemblyshouldbe

Level gluge

5-3.4 Aging, beakdown and cracking of the dbphragm

Since the diaphragm is constantly in motion, lhe cloth on
its flexible parts becomes thin, cracked, aM sometimes
breaks down after long periods of use. A broken diaphragm
causes fuel oil leakage and fragments of the diaphragm often
contaminale the engine oil, seriously hampering fuel oil
discharge or blocking it altogther.

Chap@3 FuelSYdem
5. Fud Tank (OPlion)


1. Gowmor .. +1

Chaplu 4 Governor
I. Govqnor

1. Govern(N
The governorservesto keep engine speed constant by This engine employsan all-speedgovernorin which the
automaticallyadiustingthe amountof fuel suppliedto the centrilugal force ol the governorweight, producedby rota-
engineaccordingto changesin ihe load'This protectsthe tion of the crankshaft,and the load ol the tegulatorspring
engineagainslsuddenchangesin the load,such as sud- arebalanced.
den disengagement of the clutch,the propellerleavingthe Thegovernoris remotelycontrolledby a wire-Relerto the
waterin roughweather,or oiher caseswherethe engineis "ControlSystem"chapterfordetails.

1-l Construction
(1)1GM10(C )

.diuster b.acket

ldl€ adiustq
No-load maxifium so€€d limite.

Regulator hadb

Regulato. levea
€ngine slop

inlection plmp
rp,ing (main)

Crnkshatt 9@

Fu€l inlection llmiter

GoverM ldg 2

Control lever

Govqnor lever shall

Govemor sleeve
Leve. shaft


Chapler 4 Governor
Chaplu 4 Govunot
I. Govsnor
I. Governor sM/GM(F)(cIHM(F)(c)
1- 1.11G M 10( C )
(2) 2GM20(F)(C),3G[A3O(F)(C),

= 0


I Regulator lew 11 Regulato(haodle 21 GovemoJ lov€a I

2 CBnkshaft gs 12 Englne stop levq 22 Goremo. weighl
3 Noload maxlmum sPe€d llmiter l3 Regulsto. spdng (sub.) 23 Lubdcating oil driving 0@r
o ,l Govemo, leg 2 1a Reguhtor spting (min) 24 Engln€ atop 3Pdn0
5 Engin€ stop cam 15 Goremor love. 3hatl 25 Thrust collar
6 Fuel ini@llon limil€r 16 Gmmq lerer shaft suppod 26lhrust nedl€ b@dng
'17Staal sprlog
7 Fuel cotrol levd
8 C€nkshaft 18 Fuel cont@l Eck
I Gorcmor gbde 19 Fuel ini€clion PumP
lO ldle adlusler 20 Camshaft oar

95S F'
PEi <


Chapter 4 Governot
Chapter 4 Governor
I. Governor
1. Governor SM/GM(F)(CIHM(FXC)
1-2 Operation
The Dosition of the two governorweights (open and closed) lever is stabilizedai the point at which the torce produced by
is regulated by the speed of the engine. The centrifugal the governor weight is balanced with the load of the
force of the governor weights pivots around the governor regulator spring connecting the rsgulator lever and fuel
weight pin and is converted inlo an axial lore that acts on control lever. When lhe speed is reduced by application of a
the sleeve. This force is transmitted to governor lever 2 load, the force of the regulator spring pushes the governor
through governor lever 1, and lever 1 shifts the luel control sleevein the "fuel increase"direction, slabilizingthe engin€
rack to increaseor decreasethe tuel supply. The governor speed by changing the posiiion ol the regulalor lever.

R e g u l ator handle R€g!lator lever

Fuel control rack

Fuel iniection pum9

Gov€mor lever 2

Regulalor sp.ing C6nkshafl gear

+Cenldfugal force

Fuel conlrol lever

F uel
1 Regulalor lever 11 Locking screw 21 Fuel cootrol aack
2 Reoulator sprino (sub.) 12 Engine stop cam 22 Camshaft 0€r
3 Regulalor spring (main) t3 Reoulator h{dl€ 23 Lubricatino oil PumP
,l CBnkshaft oea. 14 Engin€ stop levet 2,{ Goremor lever 1
5 Govemo. weighl 15 Engioe stop gprlng 25 Thrust nedle b€rino
6 Govemor sleeve 16 Gove.nd leve( shafl 26 Thrust collar
7 CEnkshaft 17 Goremor lever shaft suoport nr: Ratedspeed
6 Govemor lever 2 18 Start sprino ts: Stabilizationtime:
I Fuel conlol lever 19 No-load maximum sped limiter
10 Fuel iniection limiter 20 Fuel Iniection pump The time it takestor engineto returnlo the set speed
after a change.

(Wheo load ls suddenly chang€d fom rated load to low load)

rnstantsped regulation ai =l\fl1' rm

sp€d resubtionds =l ""0;* 1' too


ni: Instantmaximum(minimum)speed:
The maximum or minimum engine speed which is ni: Instant maximum sPeed (rpm)
momentarily reached immediatelyafter the load has ns: Stabilizgd sped (rpm)
Rated speed (rpm)
beensuddenlychangedfromthe ratedloadlo another ts: Stabilizalion tim6 (sec.)
loadorfrom an arbitraryloadto the ratedload.
ns: StabilizedsDeed:
The soeedwhich is set accordingto the lapseot time
after the load has been changedfrom a rated load to
anotherloador fromanarbilraryloadto ihe ratedload'

Ptintcd in Jatun

0000404136t 0000A0A1361
Chapler 4 Covernor Chapler 4 Gortcrnor
I. Governor I. Govunu
sM/GM(F )(C/HM(FXC) sM/GM(F)(crHM(FXC)

1.4 Disassembly 1.5 Parts inspection and replacement 1.5.2Sleeve
1-4.1Disassembly 1-5.1Regulatorspring (1)Slide the sleeve on the crankshalt to check that it slides
(1) Remove lhe injeclion limiler and no-load maximum (1)Inspect the spring for coil damage, corrosion and hook smoothlY.
speed limiter from the gear case. delomalion, and replace if {aulty. (2) Measure the clearance between the crankshaft and the
(2)Measure the spring's dimensions and spring constanl. inside of the sleeve, check the contact between the

(2) Remove the idle adjuster and adjuster bracket.
(3) Removethe coverat the gear caseend [oil supply port in Since the spring constant detemines the governor's governorweight.
the caseof model 1GM 10(C)l move the governor lever2 performance, it must be carefully checked.
to match the conlrol rack to the pulled-out position of
lhe fuel injection pump (indicated by a slot in the gear Springspecifications
case to show the position): then take out the fuel 1) Flegulalorspring (main)
iniection pump.
(4) Remove the gear case from the cylinder block.
(5) Pull the thrust collar, the lhrust needle bearing and the
governor sleeve f rom the crankshaft.
(6) Loosen the end nut of crankshaft, and remove the
governor weight assembly.

.ffi Maximumallowable

MainteM@ standard \r'letr limtl

when ssmbled clea€nce
O) Remove the regulator spring (main€ub.) from lhe
reguhtor lever2 and luel control lever. 02519 @s831 0.e84o)
Cankshaft outside dhruter - 0.06 0.111
(8) Remove lhe circlip of lhe regulator lever, and remove p.002/t-t 0.0041) 02 p.0079}
the regulator lever and handle. lwithout circlip in the Govsnd slese inside diareter o25*ffi P.e863tu03875)
case of model 1GM10(CD. 1GM10(C) 3GM30(F)(C), Govsnor sleere oveEll lenqlh (t) 15 r0.1 05866 05945) 144 p5824
(9) Remove lhe governor lever shall support bolt from the 3HM35(F)(C) -
rear of the gear case, and take out lh€ governor lever
Wire diameter 01.8mm C2.3mm
shaft assembty. (0.0709in.) (0.0S06in.) 1-5.5Govemorweight
1.5.3Thrust collat
(10) Loosen the nul of engine stop leve( and pull the cam. 018.3mm
O13.8mm (1) Check contact with the sleeve and forwear.
(11) Draw oul lhe locking screw trom lhe rear ot the gear Coil outside diameter (0.9:Bin.) (0.7205in.) Check the @ntact between the govemor lever 1 and
case, and remove the tap€r pin for setting the return Nmber ol coils 8.5 reolace the collarwhen wearexceeds the wear limit.
spring. 0.7l5kql/mm 0.922k9flmm mrn(in.)
Spring @nstant (0.4001b/in. ) ( 0.516
l b/i n.)
(1a Bemove the engine stop lever and lhe spring.
t6 m m
1.42 Reassembly and pr€cautions (0.7087in.) (0.7874in.)
Fr€ length
76mm /6mm
Reassemble in lhe reverse order of disassembly, paying (2.992in.) (3.0709in-)
1.5.4Thrust needle bearing
special attenlion to the folowing items.
(1) Check the govemorweight movemenl. Replace ihe bearing when wear exceeds the specified limit.
(2) Check for lhe movement of the govemor sleeve sliding a RegulatorsPring(sub)
on the crankshaft.
(3) Since a common taper pin hole is drilled in the govemor
lever shaft and govemor levers 1 and 2, they must be
replaced as an ass'y.
(4) Since the movement and play of lhe govemor lever have
a direct etfect on the govemor's performance, they must
be carefully checked- 1.56 Govetnor lever shaft
Governor lever 2

2GM20(FXC), Taper pin

1GM r 0( c ) 3GM30(FXC),
3HM35(F)(C) Oistance piece
Wire diameter C1.8mm C 1.2m m
(0.0315in.) (0.0472in.)

Coil outside diameter 06.8mm @2mn

(0.2677in.) (0.3622in.)
Stad spring
Nmber of coils 4
Governor lever shafl

Spring constanl
0.474kaf/mm 0.578k9f/mm
( 0.2651b/i n.) (0-3237
N@dle beanng
5mm Nedle bea.ang
Lo (0.1969in.) (0.3937in.)
Fr@ lenglh
26mm 23mm
(1.0236in.) (0.9055in.) Spring pin

Governor lever I

Chopler 4 Governor
Chapter 4 Governor
2. Inieclion Limiler
I. Governor sM/GM(F)(CIHM(F)(c) SM/CM(F)(C'HM(F)(C)

(l) Replace the governor lever shaft il there is play between

the shaft and needle bearing, play when the lever is mov-
2. InjectionLimiter
ed, or if the shaft does nol move smoothly.
if is play between lever 2-1 Construction
e) Repair or replace the shalt there
'1,lever 2, luel control lever or support and the shaft, or if Since surplus power is required from the standpoints of Pay close attention when handling the sealed-wire.
sudden overloads and durability, the engine is equipped lf ihe engine does not ac'celerate smoothly (i.e. the speed is
the taper Pin is loose.
(3) Inspect the conlact between the govemor lever 1 and with an iniection control shaft that limits the amounl of f uel not well controlled), tum the limiter slightly counter-
lhe govemor sleeve, replace it if it is too damaged' injected into the precombustion chamber lo a lixed clockwise.
amount. Since the inieclion control spring (torque spring) NOTE: ll it is tumed back too much, it will ptoduce exhaust
1-5.7 Regulator leverand handle alfects engine performance by adiusting engine torque, smoke.
Yanmar has selected the best position lor the operating

conlrol shatt

(1) Check for play in the regulator lever and regulator han'
dle if faulty, rePlace them as a set.
(2) Check torO-ring damage. Replace if laulty.
2.2Inspection (1) Setthe governor leverto the free position and remove the
(1)Hotd the end ot the spindle,and check ii lor smooth iniection pump adjustment cover [oil supply port in the
movetnent. case of model 1GM10(C)I
(2)Repbce the spring if it is damaged,corrodedor per- (2) Remove the iniection control shaft cap nut, loosen the
manentlystrained. hexagonal lock nut, and loosen tt|e iniection control
shaft (so that the spring inside the iniection control
2.3 Adiustment shaft is disabled).
(3) Move govemor lever 2 slowly to lhe lett until the tack
In lhe case of models,1GM10(C),2GM20(FXC)'and and injection control shaft touch lighlly.
3GmsxFxc) (4) Set the gpvemor lever to the free positbn and push the
rack by slowly tuming the iniection control shaft
(5) Align the center mark ol the rack with the reference
(6) Lock the iniection control shaft with the hexagonal nut
and cao nut.

Reference face
Rack mark

Fuel conlrol r&l

Fuel conkol rack

Relerene {ace

00004041361 0000A041361
Chtpter 4 Governor
3. No-Load Marimmt SPcedLimiter
Chapter l Govanor sM/GM(FXCTHM(FXC)
2. Iniulion Limita SM/GM(FXC'HM(FXC)

ln th€ caso ot model 3HM35(FXC)

3. No-LoadMaximumSPeedLimiter
3-l Consfrudion
A stopperis installedon the rcguhtorleverso that th€
enoine'speed at no'load does not exceed a fixed speed'
ttri luel control rack is sloppedwhen the regulalorlevel
contacts the stopPer-

R&k mrk
Begulator handle

Relersce fee

NOT? When tlE engifle It slopped, the cantrcl nck will

automatknttYstayat the posltion which altows the
maximum t uel In Bction volume' 3-2 Handling pGcautions
Theretoe,to match the Elckmaft, movethe engine The no-lod maximumspeed is adlusted during bench
stopEver to the position where the mark is match' testing at the factory, and is bc*ed with wire and s€aled
ed'atfr llx the teverat that positidl, then actiustso with lead.Caremust be taken to keep the seal lrom being
that tt e luet limfter comes into contact with the accidefltallybroken.

il 0000A04136r
U 000040Ar361
Chapter 4 Governor
ChaPta I Govanor 5. Engine SloP Lever sM/GM(FXCIHM(F)(C)
1.Idhg Aquda sM/GM(F)(clHM(F)(c)

4. ldlingAdiuster 5. EngineStoPLever
5-l Construclion
Wtlencontrollingthe speedwith the push-pullremotecon' With this device, oovemor lever2 is moved by the cam of
trol, the idling adiustor operatesso that the regulator han- the englne stop bver shaft r€gardlessof the position of the
dle does not movebeyondthe klling positionin order to regulator leve( so as to adiust the fuel conttol rack and
keepthe enginerunning- reducethe suPPlYof tuel.
Rilsdcrite ca?b€ rcrftt'cd{tlllEts"
4-1 lcMlo(c)
Tape. pin (not povided on model lGM)

L@king screw (not provided on model 1GM,

Pullad by ,qrct€ contrcl d€vice

Engine sloP lcvs.

(1)1GM10(c) (2) 2GM20(FXG),sCtMqF(c), 3HM35(F)(c)

+2 2cn2o(Fxc),3cM3{uq(c)'tnd ruC)
@otrcl ecf,

Fucl qdiol r*t

Eetum aprino

Govmor lever 2

Lcklng sccw

(1)When the control leveris in the neutralposilion' set the

push-pull cable so that clearanceC is I to 3mm (0.0:X)7 5-2 Inspec{ion
a0.1181in.). (1)Check for phy in the Cam or Taperpin and the engine
e) Takecate not to fit th€ ioint In the wrong direction. stop lever.lf fautty,replacethem as a set
(2)Checkfor O-ting damage.Replaceit laltty'
bi ;;Gi th; sping for-coit oamageand conosion and
rephce if taulty.
1 (/t! lnsoect the contact between the govemor lev€r 2 and
i ' '
thodam.Replacethe cam if it is too damaged'

llr 0000404t36t 0000404t361



Chopter 5 Inuke and ExhauslSYstem
I. Intake and Exhausl SYslem SM/GM(FXC'HM(FXC)

1. lntakeand ExhaustSYstem
side for the A water-cooled exhaust manifold is installed on engine
The intd(e air silencer is installed at the intake
models 3GM30(F)(C) and 3HM35(F)(C)' and the mixing
DurDoseof rcducing nois€ and cleaning the air'
ihe exhaust system tor model 1GM10(C) and 2GM20(FXC) elbowislittedtotheoutlet portoltheexhaustmanilold.The
cooling water, after passing through the water iacket and
engines is so construcled that the mixing elbow is fitted
passs into cooling lhe exhaust 9as, is mixed with the exhaust gas in the
dir;dly to the cylinder head. The cooling water
pipe mixing elbow.
this mixing elbow and is mixed with exhaust gas at the

l-1 Intake and exhausl sys{ernol model 1GM10(C!'

Rubber hose
To oslglde
C@lino water of b€t
atrom lheretal cde)

lntake air silencer

Cylindea head

t-2 ldd(e md erhauli system of model 2GM2O(n(C)

Rubbsr h@

C@ling wat€r
(from lh€mstat c&) Bfedh€r ho*
Exhaust gs

To intake port

lnlake alt salencer

U-type mixing elbow (opliq)

Chopler 5 Inlake and Exhausl Syslen
Syslem 2. Inloke Silencer SM/GM(FXC).HM(FXC)
Chopler 5 Intake and Exhautl
I - Intakc and Exhousl SYstem sM/GM(F)(cIHM(F)(c)

1-3 Intake and erhaust system ol models 3Gilt3o(FXC)

and 2. IntakeSilencer
The intake and exhausl system lor models 3GM30(F)(C)
and 2.1Construction
3HM35(F)(C) is the same except for the construction
of the A roundpolyurethane soundabsorbingtypeintakesilencer
breather. i" to silencethe intakeair suckedinto the
cvlinder head from the intake port'
also acts
Besides providing a sitencing effect, the silencer
as an air cleaner.
mO lmin
Rated air volume (arefage)
Draft rGistane

2.2 Inspection ol the intake silencer

Occasionally, disassemblethe intakesilencer,temovethe
ootvurethane elementand inspectit' Becausethe elernenl
hffh tf," if it is usedovera bng periodof time.it will
LIome ctog'ged and this decreasesthe amount ol intake
air.and may alsobe a causeot decreasedoutput'

2-3Washingthe Intakesilencarelernent
Wash the air intake silencerelement with a neutral

U-lype miiing €lbow

Rubbe. ho$

U-tvE mixinq elbow

and 3HM3s(FXC)l
lopitn tor moOets sCM3o(F)(C)

Chapter 5 Inlake md Exhausl System
Chapter 5 Inlake md Exhausl SYstem
3. Exharct Systm
3. Exhaust SYstem

For models 3GM30(F)(C)and 3HM35(F)(C) (1) Gasket packing

3. ExhaustSystem Inspect the gasket packing and replace tfdamaged.
(2) Carbon build-up in the exhausl passage
Remove the exhaust rnanilold elbow and cover and
The mixing elbow ot models 1GM.l0(C)and 2GM20(F)(C)is +1.2 For models 3GM30(FXC) and 3HM35(FXC)
check carbon build-up in the exhaust passage. Remove
fiited directly tothe outlet portolthe cylinder head instead of Both exhaust manifold and mixing elbow are installed. any carbon in the passage. lf carbon build-up becomes
being titted to the exhaust manifold.
Outlet porl o{ cylinder head heavy, the exhaust pressure will rise, causing
However, on models 3GM30(F)(C) and 3HM35(F)(C), an
from thermostal.cover overheating of the cylinders and difficult startlng.
exhaust manifold is also installedand the mixino elbow is
(3) Conosion and scale at lhe cooling wateriacket
fitted to the manifold outlet port.
lnspect the water passage lor the build-up of scale and
loreign matler and remove iI found. Also ch€G* fd cor.
3.1 Exhaust manifold and mixing elbow
rosion of the antlconosion zinc installed on lhe cylinder
The high temperature,high pressure exhaust gas inter- hed and lhe cylinder head water,acket and replace i{
mittently emitted from the cylinders at the speed of sound corrosion is severe. Also, replace the cylinder head if it
enters theexhaust manifold where it is muffled by expansion has been cracked by local overheating.
and water cooling. lt is then mixed with the cooling water at (4) Dratn cocft
the mixing elbow to lower its temperature and mutfle it Inspeci the drain cock for clogging and check lts aclion.
further, and is discharged. Repalr or replace if faulty.
A water-cooled exhaust manifold is employed for a high
mutfling effect. 3.3 Mixing elbo{v lnspeclion

&1.1 For models 1GM10(C) and 2GM2o(FXC)

3-2 Exhaust manilold inspoction

C@ling water

+Exhaust O*

Mixino elbow
The constructionof the exhaustmanifoldis shownin the
ligure,and a waterchamberis tormedbetweenthe exhaust Jz -/
Exhaust 96
manifoldand the coverto cool the exhaustgas.The con-
struction ot the mixing elbow is the same for models
Outlel port ol cylinder head 1GM10(C)and2GM20(F)(C)
lrom lhemoslat cover
3-13 U typo mixlng elbow (optional)
Check for carbon build-up and for conosion inside the
pipe,and r6palrorreplacethe pipeif laulty.
gas U.type mixing
Also,inspgatthe mixingelbowmountingthreadslor crack-
-Exhausl elbow Rercving the oxhaust manitold cover ing and corrosion.
This sectionls affectedby exhaustgasandvibration.
NOTE:The pad where high tempenture gas and cooling
waterate mixed is eswiaily likely to coffode, so it
mustbe inspectedwith specialcare.

A s s h o w n i n th e l i g u re , th e constr uction lor models

1GM10(C)and 2GM20(F)(C)is such thatthere is no exhausl manllold
manifold and the mixing elbow is fitted to the exhaust gas
outlet port. A double construction technique has been
adopted for the mixing elbow: as ihe exhaust gas passes
through it the cooling water passes round the outside to cool
the exhaust gas and then the gas and water mix close to the
outlet port.

000040Ar36r 00004041361
Chapler 5 Inlake and Exhausl Syslem
Chapter 5 Inrake and Exhausl S1'stcnt 4. Breather sM/cM(F)(CIHM(FXC)
4. Breother SM/CM(F)(CTHM(F)(C)
4-1.3 Breather for model3HM35(FXC)

4. Breather
4.1 Construction of beather 4-1.2 Brealher fd models 2GM20(FXC) and 3GM30(FXC)
The same conslruction is adopted for each model of
engine in thai the breather device is litted to the bonnet
cover, and the vapor in the crank case is sucked into the in'
take port or intake manifold through the tappet hole and
brealher. However, the construction of the breather itself
ditfers from model to model.
NOTE: tl trouble is expedenced with the breather, take care
that the engine does not iolt when running as the
lubricating oil may enter lrcm the inlet porl and mix
with the tuel oil.

4-1.1 Ereather ld model '|GM1o(C)

The vapor which lifts up the leaf spring fitted at the top of
the bonnet then enters the olher air chamb€r, and is suck-
ed through the intake Port.

Breather Oipe

The deflector panel fitted to lhe breather lid enters the air
charnber. and forces air circulation.



i li.
i:" . 000040,tt361

Chopter 6 Lubriulion SYslem
1. Lubricalion SYlem

1. Lubrication
Engine parts ate lubricated by a trochoid pump forced 1-'l Lubricaling oil passage of mod€{ lcillqc)
lubrication system.To keepthe engine exterior uncluttercd The lubrication oil filling port is located at the top of the
and to eliminatevibrationdamageto piping,exteriorpiping timing gearcase, and the lubrication oil.poured into the filler
has been minimizedby transportingthe lubricalingoil is stored in the oil sump after passiirg through the casting
through passagesdrllled in the cylindersand timing gear hote in thecylinderwall. The lubri9atingoilin the oilsump is
case. drawn up the suction pipe th,forlgh the drilled hole in the
cylinder bythe action olthellbchoid pump, and it isthen{ed
to the lubricating oil filter after passing through the drilled
hole inthe filtermounting base. Thelubricating oil which has
p6sed through the filter is fed through a pipe to the main
gallery ot the cylinder, and then ted to the main bearing
through the oil pressure regulator valve.

Valve r@ker am supporl

Valve .@ker aam

Camshafl gear

C€nkshafl gear

otl To oll pan

Oil paessureswitch aegulatfr valve

Lubricatins oil pump

oll suction PlPe

Chapter 6 Lubrication SYslem
Chapler 6 Lubricalion SYslem 1. Lubricalion SYslem SM/GM(FXCTHM(FXC)
L Lubrication SYslem sM/GM(F)(cIHM(F)(c)
'l-3 Lubrication oil Pa$age ot model 3GIuIO(FXC) and
1-2 Lubri€tion oil pasge of model 2GM20(FXC) 3HM3s(D(c)
in the rocker the hole drilled through the cylindersand cylinderhead'
The lubricatingoil supplied trom the oil filter
pan From the rocker am shaft, the lubriGting oil f lows through
arm cover is collectedthrough the tappet holes in the oil push rods
lhe small hole in the rocker arm to lubricale the
at the bottom ol the cylinder block tn the case of Model 3HM35(F)(C)
lubricating and part of the valve head.
The tubricating oil is drawn back up through lhe
to the oil The oil that has dropped to the push rod chamber from the
oil suclion pipe by the trochoid pump and led cam
rocker arm chamber lubricates the tappeis, cam and
filte( where impurities are liltered out' Then il is adjusted
pressure reguhtlng bearing, and relums to the oil Pan'
to the prescribed pressure by the oil
fne piiions, piston pins and contact faces of lhe cylinder
valve and sent lo the main bearing.
flows liners are splash lubricated by the oil thal has lubricated the
The lubricaling oil sent to the gear side main bearing provided in
crank pin. Moreover, an oil pressure switch is
in two oaths: one from the main bearing lo lubricate lhe and the
the lubricatingsystemto monitor normal circulalion
crank pin through the hole drilled through the crankshaft'
oressure of the lubricating oil. When the lubricating oil
The lubricating oil sent 10 the llywheel side main bearing
pressure drops 0.5kgf/o'i (7.114 lb/in'?)'the oil pressure
also flows in two paths: one lrom the main bearing to Valve r@ker am shalt
swilch itluminatesthe oil pressure lamp on the inslrument
lubricate the cEnk pin lhrough the hole drilled through the The €mshaft d@s not have an oil center hole.
panel to notify the operator.
crankshaft, and the other to the rocker am shafl through
Valve @ker am

Valve sping

Valve r@ker arm shafl


To oil pan

Camshall gear


Caankshalt gear

Suction PiPe
Pressure Tegulald hlv€
O il pr es s ur e t egulalor v alv e

Suction pipe

To oil pan
Lubricaling oil
pump drive gea.

orl DUmP Oil pressure switch Lubricatingoil pump

L u b r i c a tr n g

Lubftcating o i l P u mP d r 've g e a r
Oil pressureswilch

0000404r361 000040A1361
Chapler 6 Lubrication SYslem
Chapter 6 Lubricolion S1'slenr 2. Oil PunP
I. Lubricolion SYslem

1.d Tableof capacity for lubricaling oil system

1GM10(C) 2GM20(F)(c)| 3GM3o(F)(c) 3HM35(F
2. Oil Pump
PumO sp€d rpm 2600 m 3400
12.5 12 irochoid
Discharge volure
a4 760 7n Theoitpumpis a compet,lowpressure
Lubricating oil PumP pump comprising trochoid curue inner and outer rotors'
Dischargepressure ( l b/in.'1) (42.67 56.89 Pumping pressure is provided by the change in volume
between the two rotors caused by rotation ol the rotor shaft-

**@ @ "@ @
Filter €pacily
Lubricating oil lillet kgf-cm" 1 t142?
Discharge Pressu.e ( lb/ in.'?)

kof{m' 3.6,1d)5
Standardpressure ( ii,/ i n.' ) (a2.67tu 56.89)
regu6ror 4
Full open pressure kgf-cm'
(Max) (lb/in.'?)

kgf{m'? 02 r0.1 0.5t0.1

Lubrhating oil P(ssure ON (lb/in.?) (1.42.N 12f6l, 6.689 tu8.534)
abtm $iich
cageily, 13 zol 26 5.4
Oankwoil (1.6) (2.7\
Lubbating oil tank Total Gtleclivel o5) fl.3' |
\lnn{ olor

Thelubricatingoll putnPis installedon the cylinderbodyat

the timing gear case end, and its rotor shaft gearis driven
by the crankshaftgear.
The lubricatingoil is drawnin and dischargedthroughdrill-
lnnel rotof

ed holesin the cylinderbody.

2-1.1Lubrlcatngolt Pumpo.l trpdel 1GM10(C)

Rotor shaft

cyllndet body

Oil pressure

0000A041361 00004041361
Chopto 6 Lubication SYstem
Chopter 6 Lubricalion SYslem
2. Oil PunP sM/GM(F)(clHM(F)(C)
2. Oil PunP sM/GM(F)(C).HM(F)(c)
2-2.2Models2GM20(FXC), 3cma{q(c) and3HM3s(FXc}
2-1.2 Lubricating oil pump on models 2GM20(FXC)' 3cilin (1)Removethe timinggearcase-
(FXC) and 3HM3s(FXc) 2-2.1 Model 1GM10(C)
(1) Remove the timing gearcase

C r a n k s h a {l
(1') Removegearcase
tZi witno.a* the govemorsleeveand lhrust bearing,and (a Removethe lubricatingoil pump drivinggearand pump
also take out ihe govemorweight support after remov' ass€mblY.
ing the hexagonalnut.
NOTE:The lubricatingoil pump drive geat cannot be
temotrcd without removing the governot weight
(3) Removethe hexagonalnul ot the lubricatingoil pump
rotorshaft.thenremovethe pumpdrivegear'
(4) Removethe pumpbodyfrom the cylinderby removing
2.78+303mm(0.1094- O.l1O6in.) th€ fixingbolt with a hexagonalbarspanner'
(4') Removethelooseningboltwithahexagonal barspanner.
Rouod hole in cylinder bl@k
Sh@d hole on pump covd
Outer rolot

lnner rolol

Shaped hole on PUmP covel

Round hole in cylinder bl@k NOTE:Do not sepaate the tubrlcatingpump geat frcm the
rctor shaft. lt rcmoved, it cannot be used agah'
it Whenany partis unusable,replaceit as a complete
:t assembly'

(5) Removethe PumPcover.

(6) Takeout thd outerrotor andthe assemblyof the inner
,rotorand rotorshaft.

2-1.3Soocitications ol lubrication oil pump

1GM10(C) 3GM30(FXC)
2GM20(F)(C), 3HM35(F
36m rpm 34OOrpm
Enginespeed 3600 rpm
2600 rpm 3600rpm 3400rpm
Pump spe€d
12.5t/min 760t/h 12 l/min ?20 l/h
Oischtrge rclure 33 l/min 234 t/h
3.5:10.5ksf/c m? 3.5i0.5 kgf/cm'
3.540.5 kgl/cm'
Oischarg€presure (12.67 56.89lb/in.') (12.67- 56.89lb/in.r) (12.67 - 50.89lb/in.')

0000A041361 0000A0At361
Choptu 6 Lubricolion SYslem
Chaptu 6 Lubrication SYslem
3. Oil Filter
2. Oil PumP sM/GM(F)(cIHM(F)(c)

2-3 Inspection 3. Oil Filter

When the discharge pressure of the oil pump is extremely
low, check lhe oil level. lf it is within the prescribed range, C l e a ta n ce 3-1Construclion
lhe oil pump musl be insp€cted. measure, without passing through the tilter, as shown by
The oil filter removes the dirt and metal particles lrom the
(1) Ouler rolorand pump body clearance
lubricating oil lo minimize wear of moving parts. The con' arrow B.
Measure the clearance by inserting a fe€ler gauge The oil tilter is located at the fitted position ol the oil
slruction of the oil {ilter is shown below.
between the outside of the outer rotor and the pump pressure regulator valve on the side surface of the gear
In n e r r o to t The lubricaling oil from the oil pump is passed through the
body casing. lf the clearance exceeds lhe wear limil, case together with the oil pressure valve for engine models
filler paper and distributed to each part as shown by anow
replace the outer rotor and pump body as a set. 2GM20(F)(C),3GM30(F)(C)and 3HM35(F)(C).However,in
A in the figure.
Outer rotor
Al ter ex tendedus o, th e l i l t e r p a p e r w i l l b o c o mec l o g g e d the case of engine model 1GM10(C),the filler alone is fitted
mm (in.)
a nd i ts l i l ter per for m a n c ow i l l d ro p . W h e nt h e p re s s u rel o E s on its mounting base at the gear case end, cylinder end
0.050 0.105 caus€dby the tifter paper exceedslkgl I cm'(14.22 lb /in.2 ), surface. The oil pressure regulator valve is installed separate
Maintem@ standard - 0.00a13)
P.00197& ly on the end surface of the cylinder, in the gear case.
the by pas sv al v ei ns i d e t h € f i l t e r o p s n sa n d t h e l u b ri c a t i n g
W€rlimit oil is sont to 6ach part automatically as an em€rgency

(3) Pump body and inner rotor, outer rolor slde clearanc€
Install the inner rotorand outer rotor into the pump body
casing so that they fit snugly.
Check the clearance by placing a ruler against the end
F@ler gauge
ot the body and inserting a leeler gauge belween the
ruler and the end of the rolor. Replace as a s€t if the
wear limit is exceeded.

Straighl scale

mm (in.)

(2) Outerrolor and inner .otor clearance

Fit one ol the teeih of the inner rotor to one of lhe
groovesof the outerrotorand measurethe clearanceat
the point where the teeth of both rotors are aligned.
Replacethe innerrotorand outerrotorass'yif the wear rGM10(C )
limit is exceeded.

lnner rotor

Outer rolor
(4) Rotor shatl and body clearanco
Measure lhe outside diameter of lhe rolor shaft and the
inside diameter ot the body shaft hole, and replace the
Feeler gauge
rotorshatt and body as an ass'y it the clearance exceeds
the w€r limit. mm{in.)

Chapter 6 Lubricalion SYslem
Chapler 6 Lubricalion SYstem
3. Oil Fiher
3. Oil Filta SM/GM(FNCTHM@XC)

Oil pressure

2GM20(F)(C), 3GM30(F)(C) and 3HM35(F)(C)

Oil prcssure regulalor valve

Filter etefreot

When the oil filter has been used lor an extended period,
the filter paper will become clogged, unfiltered lubticating 3.21 Rephdng the oil litter
oll will be sent direclly to each part from the bypass circuit'
{1} Clean lhe oil filtermounting face on the cylinderblock.
and wear of moving parts will be accelerated- Theretore' it (2) Before lnstalling the new filter, coat the rubber packing
is important that the tilterbe p€riodically replaced. with a thin coat of lubricating oil.
Because this is a cartridge type oil filter' it is replaced as a (3) Tum the filter gently until it contacts the rubber packing
comDleteunit. of the seal surtace, then tighten another2/3 tum.
Esy @ houF ol mgine (4) After installation, run the engine and check the packing
Oil filtsrephffint pedod
ffition face foroil leakage.

3-22 In case ol oll bakage

lf there is oil leakage, remove the oil filterand replace the
packing. At the same time, inspect the qylinder block
mounling lace and repair the face with an oil stone il it is

6-1 1
6- 10
0000A0A1361 00004041361
Chaptu 6 Lubricalion SYstan
Chaoter 6 Lubrication SYslem 4. Oil Presrure Regulalor Valve
4. dil Prasure Regulalor Valve sM/GM(F)(CIHM(F)(C)
4-1.2 Models 2GM2o(FXC), 3GM30(FXC) and 3HM35(FXC) 4.1.3 Spocitications

4. Oil PressureRegulator
4-1 Construclion 4-1.1 Model 1GM10(C)

The oil pressure regulalor valve serves to adjust the

oressure of the lubricating oil to the prescribed pressure As lhe lubricatingoil pressureregulatorvalvehas been
during operation- When the pressure ol the lubricating oil calkedduringmanulactureso lhat it cannotbe dismantled,
Spring retainer
from ihe oil filter exceeds the force of the spring, the metal replaceit as a unit if anyteplacementbecomesnecessary.
ball is pushed away from the valve seat and the lubricaling
oit llows to the oil pan through the gap between the ball
and seat. The spring's force is adiusted with a shim'
In engine model 1GM1O(C),the oil pressureregulatorvalve
is located at the end surface ol the cylinder in the gear case
and the pressure is regulated at the intermediate section of
the oil passagewaybetwen the lubricatingoil main gallery
and the main bearing at the gear end'
The regulator valve is located in the mounting position ol the
lubricatingoil tilterotthetiming gearcaseforengine models
2GM2O(F)(c),3GM3o(F)(C)and 3HM35(F)(c)

Mounting position for model 1GM10(C)

oil filter

Oil pressureregulatd valve

Lubri@ling oil PUmP


Whs the p|sue ls lows lhal the reguhted pesure

| .u"nnn
When the D|6ure is lower than the regulatedp{sure
Mounting position for model 2GM20(F)(C)


whs lhe prGsure is higher lhat the regulatedpressure

When the pressureis higherthat the reguhtedpr6sure

6 -1 3
Chapter 6 Lubricotion SYslem
5. Oil Pressure Measuemenl SM/GM(F)(C}HM(F)(C)

5. Oil PressureMeasurement
The lubricating oil pressurels mooitorcd by a pilot latnp,
but it mustalsobe measuredusinga pressuregauge.Con-
nect the oil pressuregauge to the pilot lamp unit for
primarypressureand to the lubricatinqoil pipe connecior
tor secondary pressure, as shownin the figure.
Secondaryoil pressureis especiallyimportant.ldle the
engineat mediumspeedwhenmeasuringthe oil pressure.
Also checkwhetherthe oil pressurerisessmoothlyand to
the standardvalue.
1. Cooling Systfl
2. Water Pumo
3. Themctat 7-11
4 . A n t i c o ro s i mZn c . . . . . . . -. 7-14
5. Kingst@ C@k (Optimal) ........ 7-16
6. Bits€ pump and Birse st€ire. (opti;;i. :..: : . :. . :. .. : 7-17 |

Pressure gauge

It theoil pressureis lowerthanthe standardvalue,probable

(1)Clearance of lubricatedbearingsin the lubricatingoil cir-
cuit is too large(Shaftor bearingis wom).
(2)Excessiveoll escapingfrom rockerarm support.
Therefore,inspectionand repair of the bearingsand

6 - 14 0000404136r
Chapler 7 Direct Sea'Water Cooling Syslem
I. Cooling System sM/GM(F)(CrHM(F)(C)

1. CoolingSYstem
1.1Composilion 1-3Piping
(1)A sea waterdirect cooling syslem incorporating a rub' To simplifythe coolingsystempipingand eliminatecrack'
berimpellerPumPis employec. ing ol the brazedparts by vibratbn, rubberor vinyl hoses
(a A thermostatis installedanda bypasscircuitis provided connectedwith hoseclipsareadaptedforthis engine.
to keep lhe cooling water temperatureconstantat all Therefore.the lollowing items must be distortedwhen
times. inspectingthe coolingsystem:
This not onv prevents overcooling al initial operation' (1)Theremustbe noextremebendsin the piping.
but also improves the combustion performance and (2)Thecrosssectionol the pipingmust not be changedby
increases lhe durability of moving parts by keeping the heavyobiectson the Piping.
temperature constant.
(3)Theremustbe no fracturesor crackswhichallowwater
(3) Anliconosion zinc is provided at the cylinder and the leakage.
cylinder head to prevent electrolytic conosion of the (4)Pipingmust not touch high temperatureparts'and pip-
cylinderiacket and cylinderhead by the seawater. ing mustbe securelyclamped.
(4) A cooling water temperature sender is installed so lhat (O Hose clips must be securelytightenedand lhere must
any abnormal rise in cooling water temperature is indi- be no leakagefromthe insertionsections.
cated by the lamp on the instrument pansl'
(5) A scoop strainer is provided at the water Intake Kingston
cock to remove dirt and vinyl ftom the water.
(6) Bubber hoses are used for all interior piping- This
eliminates pipe brazing damage due to engine vibration
and simplif ies th€ engine's vibration mounting.

Th€coolingwateris suckedupbythewaterpumplhrough
a Kingston on thehull.Thewaterdelivered
from the water pump branches in two directions at the
cylinder intake coupling. Some ol the water enters the
ctlinder iacket and the rest bypasses the cylinderiacket and
enters the mixing elbow or the exhaust manifold.
The water that enters the cylinder ftrcket cools th€
cylinders and then rises to the cylinder head lhrough the
passage between thecylinderand cylinder head and to cool
the cylinder h€ad.
Ttle cooling water lrom the cylinder head, alter passing lhe
thermostat, enters the mixing elbow in models 1GM10(C)
and 2G M 20( C ) . H ow e v e r, i n mo d e l s 3 G M3 0 (C ) a n d
3HM35(C), it first passes to the exhaust manilold to cool the
exhaust gas and then enters the mixing elbow.
After tha! the water is discharged to the oulside of the boat
through the rubberhose from the mlxing elbow-
The. thermostat ls closed until the cooling waler
temoerature reaches a fixed temperature (42'C)' making
the llow go to the cylinder head and then through the bypass
When lhe cooling water temperaiure exceeds 42oC, the
thermostat opens, and the cooling water begins to flow
through the entire system. At 5?C, the thermostat valve is
fully opened and the cooling water temperature is maintain-
ed at that level.


,ri, 0000AoAl36l
Chopler 7 Direct Sea'llalet Cooling System
Chapler 7 Dbecl Sea-Waler Cooling Syslem
I. Cnling SYstem 1. Cooling SYstem SM/GM(F)(CTHM(FXC)

1-22 Cooling water Passageol engine model 2GM20(C)

1-Zl Cooling water passageol engine model 1GM10(C)

U-iype mixing elbw

Mixing elbow
Rubber hose

To oulsideol boat
- +Tooutsideol boal

Aoticorrosion zinc

Cylinde. head

U-typ€ mixing elbqt (optlm)

C@llng waler tempg€ture swltch

Water drain PiPe l6m cylinder


Cylinder bl@k

Themostat covd

Cooling wattr PumP

Cooling waler pumP

Kingstonc@k (ex@pr1GM10C)

Kingston @k (ex@Pt 2GM:0C)

+ When the coolin9 water is al lhe corr€ct temperatrc € when the c@ringwaloris at ttE c6@[t#,Ta?11f" **t tempo€tuc
i +-. When the colini water temperature is lower lhan the corecl lehperalure +-. Whenlhe c@lingwatortemp€arur

t,i 00004041361 0000A041361
Chapter 7 Direct Sea-llaler Cooling System
Chapru 7 Dbect Sea-Waler Cooling Syslem 2. Waler PumP
I. Cooling SYstm

1-23 Cooling water pasge ol engine models 3GM3O(C)

2. WaterPump
and 3HM35(C)
The construction of model 3HM35(C)is almost the same as ard operation
that ol model 3GM30(C).As well aslhe ditferentshapeol the typepump.Therubber
Thewaterpumpisa rubberimpeller
thermostat cover, model 3HM35(C) has 2 thermostats. Thetmostal covel
impeller, which has ample elaslicity, is deformed by the off-
sel plate inside the casing, causing the water lo b€
discharged. This pump is ideal for small, high'speed
, )"J*,,^o.^,.,
*e' engines. =4*-r
Effie)JF =^= g1ffi710";o*'
The cooling water pump of engine model 1GM10(C) is =H.E}T-
driven by connecting the cooling wattr pump shaft to the slit
on the end of the lubricating oil pump drive shaft.
)sl( )$ryi. ,XSA-,.0"u",
Mixing elbow 2-1.1 Cooting waler pump ot engine model 1GM10(C)

Anticorosion zinc I

Thermostal housing


fhemostat cover

U-tvpe mixinq elbow {
[opiibn for m6dels 3GM3o(C) and 3HM3s(C)]
Drain plug

C@linO waler pump

1. Cooling water PumP shafl

2. Ci.clip
3. Circlp
4. Sall b€rlng
c@k (except 3GM3OC and 3HM35C) 5.Ollsl
6. lmpollet
7. Pac*lno
6. Cam
+ when the cooling waler is at lhe correcl lemperatute
+-. When the cooling water temperature is lower than the coffel lemperat!re

74 0000A0A1361
Ptialed in Jopon
Chopler 7 Direcl Sea'llaler Cooling System

Cooling Syslmt 2. l{do PunP SM/GM(FXC}HM(FXC)

Chqta 7 Dbecl Seol{da
2. l{ater PumP SM/GM(FXCIHM(FXC)
2-1.3 Cooling water pump of engire model

2-12 and
pumpol ensinemodels2GM20(c)

""""'P'ot b€ring

N*,.be{ins V.pullsy

t. C@llng {3td gom9 lh!ft

2. v-Pull.Y
l. C@ling f,ater PumP shaft 3- Clrcll9
2. V-pull€Y
3. Cl cllp 5. Bril b.atlog
Colla. 6. Eodng cmr
't. Eall bqadno
5- t. Watd r€.1 .lno
6. Bsing cover &O{61
View€d ttom oulley sid€ 9. crm
7. vrate. seal rino
E. oil s6l 10, Psldng
g. Cm t1. lm9.ll€.
t0. P&khg
l l. lmpeller

;i 0000404t36r
ii 000040A1361
Cooling Syslem Chapler 7 Direcl Sea-Water Cooling Syslem
Chapler 7 Direct Sea-Watu
2. l{aler PunP SM/GM(FXCTHM(F)(C)
2. l{ala PunP sM/GM(F)(cIHM(F)(C)
(3 )A d j u s t t h e V -b e l t t e n s i o n . [ f o r mo d e l s 2 G M2 0 (C ),
2-1.4 Speciticatbns 2-2-2 16 modds2cM2o(C), 3GM30(C) and 3HM35(C) 2.3Reassembly Pccaulions 3GM30(C)and 3HM35(c)l
2GM20(C), 3HM35(C)
(1) Atter removing the V-belt by loos€ning the mounting (1)Beforeinsertingthe rubberimpellerinto the casing' lf the V-belt tension is slack, the discharge of the cool-
1GM10(C) the
3GM3o(C) bolts of the cooling water pump b€cket, remove coat the sliding tace, pump shaft and impeller fitting ing water will diminish; if it is too tight' the play of the
Rated speo 2600rpm 272oem 2660rpm cooling water PumP assemb[' section with grease or Monton X. pump beadngs and the wear of the wear plate will be ac'
'1.0m 1.0m
Srction h€d
O.5m celerated. Adiust the tension to the specilied value.
(1.64 ft) (3.28ft) (3.28 ft)
/-\ Check the deflection of the V-belt by pressing it in the
3.0m 3.0m 4.0m
Total head (9.84ft) (9.84ft) (13,12n) centerwith Your fingers.

tleliwry €pacrty 300//h 700tlh r500/h

(1)Loosen lhe water pump mountingbolts, (emovethe
waterpumpass! fromthe timinggearcase'
Coat lhese Pans with otease

(2)Be sure that the directionof curvingof the impelleris

The imDelleris curved in the direction opPositethe
directionof rotation.
el Removethe coolingwaterpumpbracket'
(3) Remo\re theV-pulleymountingboltandV-pulley'
(4) Removethe coolingwater pumpcoverfixing screws' Model1GM10(C)
and then removethe cooling waterpump coverand To b€ 5 tu 7mm O.1$4 ru 02756in)
packing. dl6tim when PUstPdbYthe
(5) Pullthe waterPumPimp€ller. thumb wlth a force of 10kge2o b)
(6) Remov€the set screwand removett€ of{set p|ate'
(n In enginemodel3HM35(C), removethe keylrom the
(8) Remor/ethe bearingsnap ring and removethe impeller NOTE:Mount the bettin thedirectionol pumprctation'
(4)ll the slidingsurtaceof the V-beltis cracked'wornor F
(2)Removethe coolingwaterpumpcoverand packingby shattand bearingassy whiletappingth€ imp€llerside
stainedwith oil, etc.,replaceit with a newone'
removlngthe 3 sctewswhichsecurethe coolingwater of the impellershaftlightly. (5)Checkafter assembty
pump co\ref. At the same time, the bearingcoverand seal ring can
be removedtogetherwiththe impellershatt' After assembly,attach the belt and run the engine to
(3)Pullthe waterPumpimPeller-
phte' (9) Pull the oil seal from the pump body' ascertain whether or not it pro/ides the specified
i4) Removethe set screwand removethe offset the impeller discharge.
isi Remore the bearingsnap ring and removethe
lmpeller itb pul ttr" ball bearingand spacerfrom
shaft and b€aringass'ywhiletappingthe impellerside shaft.
Models 2GM20(C), 3GM30(C) and 3HM35(C)
2.4 Handllng Pr€cautlons
of the impellershaftlightly.
(1)Neverop€rat€th€ water pump dry as this will damage
€) Pullthe oil seallrom the pumpbody.
izi purttne oattoearingandsPacerlromthe impellershaft'
Olrection ol roiation therubberimP€ller.
(2)Alwaystum ihe engine in the csnect directionof rota-
tion.Turningthe enginein the oppositedirectionwill
damagethe rubberimpeller'
(g)tnspect the pump after every 1500 hours of operation
Eall bearinq
circlip andreplaceil faulty.

/ .

Ball beaaing cover

Water seal ring 2-5 lnsPection

(1)tnspect the rubber impeller for fractures,cracksand

s/@v- Cove(
otherdanrage, and replaceif faulty.

aano/anns )$ dpb- lmpeller

/ lJ_,t,
lmpeller shalt

Chapter 7 Direct Sca-Waler Cooling Syslent
Cooling Syslem 3. Thermoslat sM/GM(F)(crHM(F)(C)
Chapler 7 Direct Sea-llater
2- Waler PuntP sM/GM(F)(cIHM(F)(c)

e) Rubberimpellersidewear
(3)Waterpumpimpellershaftoil sealseclionwear' 3. Thermostat
3.1 Construction and oPeration
Models 2GM20(C) and 3GM30(C)
The lhermostat remains closed until the cooling water
temperaiure reaches a fixed temperature. Unlil the cooling
water reaches this fixed temperature, it collects at the
pump is
cylinder head and the water flowing from the water
dlscharged through the bypass circuit. When the cooling
Clearance water temperature exceeds the fixed temperature, the
thermoslat opens and the cooling water flows through the
main circuit of the cylinder and cylinder head The ther-
mostat seruesto preventovercooling and amprovecombus-
tion performanceby maintainingthe cooling water tempera-
ture at the specifiedlevel.
In engine model 1GM10(C),the thermostat is mounted on
the cylinder head al lhe gear case end. In engine models
2GM2O(C)3GM3O(C)and 3HM35(C)' it is mounted on the
thermostat housing which is combined with the generator
mounting base on the cylinder head at the gear case end'

Oil sl s6tion shaft diaretel M odel 1G M 10( C )

1 ) M o d e l 1 GM1 0 (C ) if
lf water leakage increases while the engine is running'.or
Mdimum disas-
Maintemnce Cbame allowable
\ /etr ihe components are found to be delective when
slildard atasbly limit
c|em@ sembled, replace them. Themostat
(4) Insp€ct the bearing lor play and check for seizing at the
12io.l ' 'impetter
lmpeller o.1685 shaft fitting section. Replace the bearing if
wiith 0.4764)
- there is any PlaY. Thermostal
(without Peking)
o2 0.4
H@sing p.0079) p.01s7)
widlh 119 0.4685)
U,€at o2
phte p.0079)

2) Modets 2GM2O(C)and 3GM30(c)

Mdimum \wea
Mainteffie Cbmne allowable
standad ataMbly limit
lmpdler 191{.1
widlh 0.7aa a 0.7sq
Housing (withdt Peking) 0./t
width 192 p.7@) o!079) po154
{with packing) Model 3HM35(C)
Wbaf 02 Thgmostal covel Themostat housang
plate p.007e)

3) Model 3HM35(C)
Muimum li\len
Mainleme Cleamne allowable
siaodard at as*mbly limit Cylinder head

2.;l !4-1
width o8661
(wiihout packing) o2 0.4
width o.0079) p.01s4
t/t ear o2
plate p.0079)


Chaplu 7 Direcl Sea-Water Cooling Syslem
Chaptu 7 Direcl Sea-llaler Cooling Syslem
3. Thermostat
3. Thermodat SM/GM(F)(CTHM(FXC)

(5) Attaching the thermostat lo the cooling water system.

When the seawater temperalure is below 42"C, the
pumped-up seawater is discharged oulside directly from Before attaching the thermostat to ihe system, be sure
the thermostat section, and circulation of the cooling water to check its packing and make sure there are no leaks.
into the cylinder is stopped until the water lemperature
3.3 Ca|€ must be taken when assembling the
rises. When the water temperature reaches ?oC, the ther-
mostat valve is fullY oPened.
with the arow
3-2Inspection martkeptupwafd.
(1) Bemove the water outlet coupling at the top of cylinder
Theamoslat covea
body to remove and inspect lhe thermostat. Remove any
dirt or toreign matter that has built up in the themostat'
and check lhe spring, etc. fordamage and corrosion.

When valve is clossd

2mm (0.0787in Valve lift 3.0 3.8mm

dia . hole (0.'1181 0.1,196in.)

{2) Testing the thermostat

Phce the thermostat in a container filled with water.
Heat the conlainer with an electric heater. lf the ther'
mostat valve begins to open wh€n the water
temoeratuG reach€s about 42oC and becomes fully
op€n at 52C, the thefmostat may be considered opera-
tional. ll its behaviour differs much trom the above, or if it
is found to be broken, replace it.

A wax-pellettype thermostatis used for this engine.The

"wax-peltet"type is the descriptiongivento a quantityol
wax in the shapeof a smallpellet.Whenthe temperature of
the cooling waterrises,the wax melts and its volumeex-
pands. The valve is opened or closed by this variation of
Themostat operating temPerature
Openhg tflpsatuE

Characteristicof Thermostal
(3) In general, inspect the thermostat after every 3O0hours
ol operation. However, always inspect it when the cool-
ing water temperature rises abnormallyand when white
smoke is emitted over a long period ol time after the
engine starting.
(4) Replace the thermostat when it has been in use for a
10 20 30 10\ so\ 60 oc C@ling water yea( orafterevery 2000 hours of operation.
ValveopeninOtefiperalure 12t2oC \ temperature (6C)
Part No. code ot thmtat | 105582-49m
Fully oponed lilt checking temperalu.e 52!2"C

7-12 7-13
00004041361 000040A1361
Chapter 7 Dhecl Sea-Waler Cooling Sydem
Chapler 7 Direct Sea-Water Cooling System 4. Anticonoion Zinc
4. Anticorrosion Zinc sM/GM(F)(c)'HM(F)(c) sM/GM(F)(CrHM(FXC)
4-2 Inspection
4. Anticorrosion Generally, replace ihe anticonosion zinc after every 5q)
hoursof operation.However,since this perioddependson
the properties of the sea water and operating conditbns,
4-'l PrinciPles periodicallyinspect th€ anticonosion zinc and removethe
Anticonosion zinc is installed to prevent eleclrolytic conc against corrosion by being itself corroded in place ol the oxidizedfilm on its surface.
cylinder,cylinder liners and other iron parts' Rephcetheanticonosionzinc aftet5O7oconosion.
sion by sea waler-
T'he anticonosion zinc is lo be put in the following posi' Rephcethe anticonosionzinc by pullingthe old zinc from
When ditferent metals, i.e., iron and copper, are placed in
a highly conductive liquid, such as sea water, the rron
tions. thezincmountingplugandscrewingin the newzinc.
gradualiy rusts. The anticonosion zinc provides protection
1GM10( c) 2GMm(C) 3GM30(C), 3HM35(C)

At the side of ttp At exhaust side Al exhaust side

Set pcition fuel valve
Cylinds block 2
Numbs I

At skle c:ffi of cYlirde( At t.l

Sel p6ilion tread (r€O "id" tFzd
"" (r€d "/i"d*
Cylinds h€d I
Fhnge type PluS type
20rnm db x 20rnm m dia x Smm
Type.Size p.7874 x 0.7874in) |74x 1.9811inj

zinc 27210-2f0m n210-M

Part No. of aniicreion
Mounting position lor models 3GM30(C) and 3HM35(C)
Models 2GM2O(C), 3GM30(C) and 3HM3s(C)
M o d e l 1 G M1 0 (C)

Anticorosion zinc

I :-t--
--fl- Il I
3r_+_____.1LJ tf-t
I so.. | \LJ
*--]iseiirnJ* ea"tins

Mounting position for model 2GM20(C)

Mounting positon for model 1GM10(C)

Antlcoroslon zlnc (cylinder blockl

il ,/i

0000A041361 36r
Chapler 7 Direcl Sed-Water Cooling Syslem
6. Bilge Pump md Bilge Strainer (Optional)
Chspter 7 Dhecr Sea-]l ater Cooling Syslcm
5. Kingston Cock (OPtional) SM/GM(F)(C'HM(F)(C)
6. Bilge Pumpand BilgeStrainer(Optional)
5. KingstonCock (Optional)
5-l Construction
The Kingston cock, installed on the bottom of the hull, con-
trols the intake of cooling water into the boat' The Kingston
cock also seruesto filter lhe water so that mud, sand' and
other loreign matter in the water does not enter lhe water
oumo. Numerous holes are drilled in the water side ol the
kingston cock, and a scoop strainer is installedto prevent
the sucking in of vinyl,etc.

48 (1.8898)

Kin gston cock c ov et

\A 1
iK$w/ ;
Kingston c@k cover C @l i n g w a l e r o u tl e t Cooling waler inlel

6.1Bilgepump 6.2 Bilgestraaner

6.1.1 Sp€cilicalions
Code No. '12034t4@10(with stBins)
Model No. BP190.10
5.2 Handling precaulions Raling 60 min.
Caution the user always to close the Kingston cock after Vottage
each day ol use and lo confirm that it is open before Output 90w
beginning operation.
lf the Kingston cock is lefl open, water will flow in reverse
and the vessel will sink if trouble occurs with the water
of pump(inPurcwaleo
6.12 Performance
On the other hand, if the engine is operated with the Voltaoe t15V
Kingsion cock closed.cooling waterwill nol be ableto get in. Self-suction
ptrfomance Max.self-suctionlift 12m (3.94ft)
resulting in engine and pump trouble. SelI-suctiontime 4 se.
Vottage 115V
5-3 Inspection
Pumpinglilt Curenl 8A
When the cooling water yolume has dropped and the pump perfoman@ Total lift lm O28 ft)
is normal. remove ihe vessel from the water and check for
Liftino vdure ol water 'l7 r/min
clogging of the Kingston cock.
Moreover, when water leaks lrom the cock, disssemble
the cockand inspect it for wear, and repairor replace it.


l.C@lingsystem ' ' " ' " " " ' ' -" " ' & 1
2 S o a \ 4 d t s P u mP """" """ "- "8'3
3 . F€ h w a t d P u mp """" " " -" " ' & 4
4 . H € t E x c t ri l g t r " """"""""'8'7
5 - Fi l l e rc a p a n a s u b l a n t " " " " --" " & 1 1
6 . Th e f f i E r . . . . . . . -. . . . -. . . -. -. . -. -& 1 3
7. C@lingWaterTemperatureSwitch.. " " " " " "''' " "' &16
8 . f t d u t i o m. . . . . ' """""""""&17

Chapler 8 Fresh Wa@r Cooling Syslent
1. Cooling System

1. CoolingSystem - U-type mixing


Models 2GM20F, 3GM30F and 3HM35F are constructed Rubbel
{rom differenl parts but use the same water flow. The hose
illustrationbelow is ol model 3HM35F.

U-type mixing elbow for option

lex@pt 1GM10(C)l

To dtlldc
of bo.l

H€l exchanoea

8y-p6s lld I

To cyllnder bl@k
F F6hwats

€ seamter
ri::: tntet and outet fo. waitr tHttr
Chapler 8 Fresh ll'ater {'ooling
Cooling Syslent 2. Sea llaler PumP SM/GM(F)(CTHM(FNC)
Chqlu 8 Frcsh llaler
l. Cooling SYstem sM/GM(F)(c)'HM(F)(c)

1.2. Cooling system diagram

2. SeaWaterPumP
The sea water pump used for the fresh water-cooled
sarne type as
engine is the rubber imp€ller pump; it is the
used lor the sea water-cooled englne'
The same sea water pumps are used lor models
types as useo
3GM3OFand 3HM35F;theseare also the same
forthe model 3HM35(C)sea water-cooledengine
to increase
in the 3HM35F model,the pulley ratrois changed
the dischargevolume.

Water seal

Cooling water PUmPbooy

Ball bearing

waler pump shalt

t-3. Cooling system conliguralion thermostal is

trom the heat As the fresh water temperature rises the
With fresh watercooled engines' fresh water ;ni ;Ji;h *ater fiows Inlo the heat exchanger'The
;;;;; i" circutatedaround the cvlinder block and iiJn t"t"ii" in the heatexchangerby s€awater
.rfino"in""O. fn" fresh water itself is cooled by sea rn" iro", rne "-led
ttesh water temperature is always keptat the
iil r;;il;;"r;umP lorces the tresh waterthroushthe "o bYthe thermostat'
properlevel Oirection of rotation
i"ri"i"i or."i and cytinder head cooling 5". *at"t is delivered by the sea water
pump and fed
#cfio ttt" n""r The fresh water is kept in corr insioe ttre cooling pipe to cool the
slant cllculation."xchanger. fresh waler.
il;eilitai is insialledat the cvlinderhead cooling flowsfrom the heatexchangerinto the mixins
As the ;;;;G;
water outlel (fresh water pump mounting bracket)' elbow,andis discharged withtheexhaustgas'
ii.**t"t id while the lresh watertemperatureis
io*-Oir""try "f"".0 enginestarting orwhentheengineloadis
*"to rlowsthrough the by-passpassage to the l. C@ling water PUmPshaft
iignr-tt".n 2. V-Pulley
siction sideof thefreshwaterpump'and circulates 3. CircliP
thc enginewithoutpassing throughthe heatexchanger' 4. Collar
5. 6all beanng
6. Boaring cos
7- Water seal nng
Viewed {rom PUlley side
8. Oil seal
9. Cam
10. Packrng
I 1. lmDeiler
and rcassembly'handling
'-- -' Fot detaitson disassembty
"Chapter 7'
precautions and inspection' rcfer to
Section 2. Water PumP (P'7-5)':

Printed i^ Jqan
a-2 0000A041361
Chapler 8 Fresh |l'oler Cooling Systcttt Chapler 8 Frrh Waler Cooling Syslent
3. Fresh ll/alu PumP 3- Fresh Waler PumP

3.2. Pump capacity and characte.islic 3-3. Pump disassembly

3. FreshWaterPumP PII Oisassembly ot the lresh water pump is difficult and
should not be attempted. Faully units should be replaced.
3.1. Pump conslruction
il The pump assembly should not b€ disassembled from the
pump body brackets, unless absolulely necessary.
Th€ fresh water pump is a centrifugaltype pump and is used @
to move tresh waler from the lresh water tank, through the
cooling passagesin the cylinder block and cylinder head, puinp *tiins dotts |
{o-80 € 89 tu 5 79)
and then back to the fresh water tank
The fresh water pump is composed ol a pump body, im-
peller, pumP shatt, bearing unit and seals. ll is driven by NOTE:The same type ol trcsh water pump is used lol
a belt and pulley arangement at the end o{ the pump Cooling fresh water models 2GM20F,3GM30F and 3HM35F. Pump assembly
outlel conneclion
The packed bearing unit supports the shaft with roller
bearings-lt cannot be disassembled. H-O dlagram Waler lemp€Eture 80r2oC
The impell€r is equipped with multiple blades and is
mounted on the PumP shaft' Th€moslat
The mechanicalseal preventswater entering from around C@linO water
the pump shaft.The impellerseal is lixed to the impellerside lemperatur€ switch
Plug for wator h€at€. PT 3/8
with spring pressure applied lrom the pump body side.

Plug fo. water heater PT 3/8

Oischarge Q (l/min.)

4-Q diaoram Water l€mp€rature 80r2oc


Di$haroe O (r/min.)
To h@t exchanger t Pump body backel

Ls-O diagram water t€mperalure 80J2oC

3.4. Inspection and measu.emenl

F.om heal { (l)Confirm smooth rotation by rotatingthe impeller by
erchoger hand.
When the rotationis not smooth,due lo bearingplay
] or friction.or abnormalnoiseis heard,replacelhe entire
oain hole/
Check impeller lor damage, conosion and waler'
Mechanical sol/ Replaceil tequired.