YANMAR - Service Manual

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DIJELOW IIOTORA
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
290
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
290
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
104500-557
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
123482-91291
127695-35150 12761042200 1218s0- 49810
121850-49550 121850-42280 231
119100-11320 123482-9'1
5D 4 1650-502320
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
0
12769S35r50 121857- 55710 1233254202024321-000700 ZRAKAX 1 12 1850-42280 1320 1?3482-51291
119100-1
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

27210-2005s0
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Models
n-
^/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
CHAPTER 1 GENERAL CHAPTER 8 FRESH WATER COOLING SYSTEM

'| "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
CHAPTER 2 BASIC ENGINE
1. CylinderBl@k ......... . 2-1
2. Cylinder H@d . . 2-9 CHAPTER 9 MODIFYING THE COOLING SYSTEM
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$embling modified pars
6. Flywh€l and Housing . . . . . 249 to the Fr6h Water-Cooled Engine 9-7
7. Camshaft. . 2-53 4. CautioN whs the Engire is Install€d Inb@rd . 9 -1 2
8. Timiog G€r .
CHAPTER IO REDUCTION AND REVERSING GEAR
3 FUELSYSTEM
CHAPTER and3GM3O(FI
lAl For EngineModels1GMl0,2GM2O(F)
'1. Fuel ini*lion Systm . . . . . . . . . 1 0 -1
l . C o 6 t ru c t i o n .
2. Inietion Pump 2. Shifiing Dwice . 1 0 -7
3. Ini€lion Nozzle. 3- Insprction and S€ryicing. . 1 0 -1 4
4. Fuel Filter 3-29 4. Disasmblv
5. Fuel F@d Pump. 5. P€smbly 10-24
6- FuelTank (Oprion). .
lBl ForModel3GM35(F|
CHAPTER 4 GOVERNOR l.construction ""'1G29
1. Gowrnor. 2. lnsbll€tion .""'10-33
2. Inietion Limiter.. 4-9
4-11 3- OrrationandMainrenane ... - 1034
3- No-Load Maximum Speed Limiter 4. l6Btionandsewicing. ...1G35
4-12 -.
4. ldling Adjuster 5. oisa$emblv """1040
5. Engine Stop Lffr . . . 4 -1 3
6. ReawblY ""-'10.44
CHAPTER5 INTAKEAND EXHAUSTSYSTEM [Cl Marire Ger Models KM2P. KN'!3Psnd KM3V
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
1O€5
CHAPTER 7 DIRECT SEA.WATER COOLING SYSTEM 5. Piping Diagrams. "
."
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
0000404136r
A.Engine Model Name
B. Engine Model Name Phle ond Clulch Model Name Plale
SM/GM(F)(C).HM(F)(C)
A. EngineModel Name
The nomenclatureoJ the New GM(F)/HM(F) series lollows
the order shown below.
".n.'2 GM 20 F
2-cylinder I
I
Marineengineseraes
Discriminationof old GM(F) Model
B. EngineModelNamePlate
C'{APTER 11 REMOTE CONTROL SYSTEM
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
CfIAPTER 13 OP€RATING INSTRUCTIONS

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
CIIAPTER 14 DISASSEI,IBLYANO REASSEMALY
(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
iffi,rroP
Clulch model name olate
GM-series
GEARMOOEL KM 2
MARINE
orL sAE20i30 H0
OILOTY LTR.
Yourclutch gear ratio

KANZAKIKOKYUKOKI
MFGCO,.LTD
HM-series
MAffINEGEAflMODEL KBW 10
6d';: ::::
ô, ,,,
@;ioi,
Ptided it Jw osaxa l!.Ll!!f!!J uenru
0000 A0 A l36l
0000A0A136r
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)
s-3.22cM2o(FX
B-2"11GM10(C)
Engine model 6ame Plate
C. GylinderNumber
The cylinder numbersoI the 2 cylinder engine and 3 cylinder
model
nare Plate engine describ€d in lhis manual are designated as follows.
2GM20(F)(C), mdel
3GM3o(F)(C) nare plate
1GM 10( C ) ,
2GM20(F)(c),
3GM30(F)(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.
00004041361
0000404r361
CHAPTER1
GENERAL
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
0000404r361
o'T,k,",,
('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
Oispl&ment
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
I
24.8
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)
I
1@X5lU4-2!
F(Fl ini€lon pr6u@
take off at Flywhel side

Main @rer
I
at Crankshaft V-pulley side
Frodt pwer take ofl
Cdntsrl€tli* vi,ew€d tam stern
tI
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
E|ectric
Sla.ting system
KBWl0€
)
I
I
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)
rr2980
?a5€ar4) 786 ($.94)
410( r 6 14) 4s5(r7.91) 455(11r1) 485 (19.0S)

cI|11sions
617(24.29) i
Lubri@ling oil €pacity

r.6 (97.631 2.7 116l.751
t,
(rake angleS"l
r3o (287) 158 (348)
Engi@ reighr with cluth (dry)
Printed in Japan
a0At$tJc0l
Chapler I Oeneral
l. Specifiealions
SIVI/ GIVI(FXCTITM ( FXC)
1-2. Fresh Waler Coollng Typ€

Model
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)
9.07(29.761
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)
9,63(31.59)
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
K8W10€
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
A0At$t-Jc0l
(-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 )
SPECIFICFUEL CONSUI\,'lPTlON(DlN6270B rating) SPECIFIC FUEL CONSUMPTION {DlN6270B rating)

g/kw h 240 g /H P h
g/kw.h 240 g/HPh
300 300
220 220
280 240
200 2IJIJ
260
2ffi
ENGINE TOROUE (DlN6270B rating)

ENGINE TOROUE (DlN6270B rating)
Nm 2.0 kgt'm Nm kgf-m
18 1.8 40 4.0
16
14 1.4 30 3.0
12
OUTPUT
HP
OUTPUT
HP
7
I l8
6 I
5
7 7
'/
14
^s\ 6
--
4 T2'
ô'
(t
ô-
5
i.F-
K -
l.6N
o 1
--o
. '1 7,
.tttt"
6l 10
2
3
,/o !."> 8
e1"
2
I
1 2
0 0 0
12@ 1600 2000 24tn 2800 3200 3200 3600
12co 1600 2oOO 24@ 2800
SPEED OF CRANKSHAFT: rpm

SPEEDOF CRANKSHAFT:rpm
THE ENGINE FLYWHEEL OUTPUT IS APPROX 3% HIGHER.
HIGHER
OUTPUTlS APPROX3olo
THE €NGINEFLYWHEEL
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.
0000.{0Ar36l
0000A041361
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)
(DlN6270B
SPECIFICFUELCONSUMPTTON rating)
g/kw.h g/HP.h
SPECIFIC'R EL CONSTJMPTION (D|N6270B rating) 300 2n

g/kW.h zlo.qR.€.t{
280
2@
300 220 260
180
280
2@
2&
ENGINETOROUE(OlN6270Brating)
N.m 8.0 kgf-m
ENGINE TOfr€I{JE'DIN627OE
rfr. 6.0 kgrf-m 70
I
50 5.0 @ 6.0
& 4.0
OUTPUT
KW 36 HP
OIJTP{JT
KW HP 25
n 27 7 27
24 24
15
7 21 2'l
.+"", .a$
18 18
.ta$ V 15 dt 15
"4t""
12 b4 12
v 9
ic
I
1600 m6 2400 2800 3200 3600

J
0
2000 2400 SPEEDOF CRANKSHAFT:rpm
SPEEDOF CRANKSHAFT:Cm
0\T::ill
'*nn^.Pl
THE EI'IGINEFLYWHEELOUTPUTIS APPROX3%HIGHER
OUTPUTIS APPROX3% HIGHER.

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.
0000A04r35r
00004041361
Chaplar I Cotrul
l. Spet(i<'atiuns s iv / Givl(Fx(' ).Htvl(F)(c)
1-3. Direct S€a Water Colling Type (Sail-drive)

Model
Verli@|. 4{ycle mttr @hd diel engire
Type
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
r.282(78.23)
Displacemenl
11.8/34m(16.0/3400) t7.1t340o(24.'il3dcol 22.4/32fi(n/ncnl
Conlinuous rathg
5.58(93.57)
kgi/cmz (lb/in.')
output (DlN 6270A) 9.07(29_76)
k W /r pm ( H Pl r pm ) 18.2/3600)
r3.4/3600(
Ore hM 6trng 7.O7(1o0.54l 7.@ (99.82)
kgf/cm'(tb/in.2)
@tput (OlN 62709l g.dr (31.59)
Codp(sioo ratio
b.Toc 21tt
F€l injecrion timing (FlO)
r@filz?o4-?3471
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
Cankshatt
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
2.64tZU
Sail-driw 1212
Propellq sp€ed DlN. A aling
2.2(1
Lubri€taing oil €pacity

(Engare side)
2.1 llu.7sl
180(a)71
Engire reight wilh Saildriw uoit (Ory)
Printed in Japan r-3

A0At6tJC0l
Chapler I General
2. Principal Condrudion sM/GM(FXCTHM(F)(C)
2. PrinciPalGonstruction
Construction
Integnlly€st wattr iacket and crankes
Sldels
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
fdldng
frchoid pump
Lubricatis system Full-'flfl ertridg€ type, papers|€ment

Dp6tick
Rubber lmpd|€r tYPe
fuling syslem Wil pslbt type
YPFR-0707-3
osDYol
Fuel sastm fihafi&lcsltYPe
Fill€r Fpet
Go€mor ffi ltkFodmc(fiaricdtt"o
S'tadingsyst€m
lillrrfrr{ltth bulltin lC
El6trical
tldiel 94r @nstanl-m6h sryslem
Beductkr rewcing
Wetrulii{i$
Clutch sysrem Mhank:l tYPe
FEd|{ier doling.yttm (2dnoF Cq|ItF rd 3Hil35R
0000404r36r
Chapler I General ChaPter I Ceneral
ions
1. F-ealures 5. ingine C rossS ect
SM/GM(F)(CIHM(FXC)
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
engineroom.
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
z!
[t[iffii1,v-eurrev
*?i,ill"'.rns
i ililX"'j.i[t"t ns
housi 15. Mixing elbow
16. Camshalt
26. Oil Pan
valve
6. Exhaust 17. Camshalt gear oirinretpipe
?1.?ltilcalins
?. lntake valve 18. TaPPet zlnc
anticodosion
8. VatYesPring 19. Push rod ^
ii. Fuel iniection PUmP cam
g- Vatse rocker arm suPPofi
20. Pislon
lO. ValYerocker am
t- tz
Il- 00004041361
000040A1361
e,l*$-*r,
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
1-12
00004041361
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(
r-10
00004041361
Chapta I General
5. Engine Cros-S ecy'iotts
SM/GM(FXC}HM(FXC)
5-22GMm
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
'1.
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@
00004041361
I
Chapler I General
5. Engine CrosstS ectiorc
SM/GM(F)(C}HM(FXC)
5-4 3HM35
;ffi,
': ,.: i':r:i!:;
23
. -ll.;:i.: ,:i.rjl :
"*&.#
i:S#
i;j
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
3,a.Ttmosdt
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
00004041361
(lhapler I Gen
6. Dimensiorc sM/cM(FXCIHM(F)(C)
SM/GM(FXCIHM(FXC)
6. Dimensions
& 1 1GM10
Fuelover{lowO8 3(O033)
4 ol o5tao4 1 t 7 t o2 8 )1 7 5 { o 3 0 ) _5:
l:i_
/rcozatotot) LlL,rn 161
-11 ^,-e-ff"'"
lA'tl3r;ffi
\Y.V,7 EIE}LV
\igl el u
'l)
Dsrrll ot 49llr|g (A} i-L: -=
Mrxingelbofl d45(d1.77) Water outlel 014(d0.55)
E
;
o
u7Q1
water inlel d14(d0.55)
ri@lion pump 41. Output shalt coupling

rta€lion nozle
s pump
Iht
rcloa
{ disc
iMfl
! rhdt
.d lrrge oear
c lrrge gear
0000A0A1361
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
00004041
361
Chopler I General
5. E ngine C ross-Sections
sM/GM(FXCIHM(F)(C)
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
000040A1361
Chapter I Generul Chapler I Gencral
6. Dimcnsiorc 6. Dimensions
SM/GM(FXC/HM(FXC) sM/cM(F)(CIHM(F)(C)
6-22GM20 G.33GM30
F uel overilow o8 3(o0 331
/ 51030) G) .
16)
(A): 5
Delall ol cqJplir€ (A) (A)

Detailof @dirE
-'
l--174(6
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,
d
& SJ
sv
i
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)
SM/GM(F)(CIHM(F)(C)
6-4 3HM35 6-5 2GM20F
F uel over{low d8 3(d0 33)
1-
a
(A)._:
--
tHril ol cddi.|g (A)

Detail o{ d$liig (A}
t2x3O(047x1.18) 4 o17i6O671
485(19.@)-
FuelrnleloB 3(o0 33)
r U.Mixrngerw-..-..._
/
I
€xhaustoiF f€-r'F.:
I Exhausl PrF
cso.8(c2 ; d50 8(o2 m)
!J
ntet
d1? 3(d0.68)
d17.3(c0.68)
9{03s)
0000A0A1361 0000A0Ar361
Chapler I General
Chapter I General 6- Dimensions
SM/GM(F)(C}HM(FXC)
6. Dimenions SM/GM(FXCIHM(F)(C)
6-7 3HM35F
6-6 3GM30F
n ori.5to0 41)
,,o ru, 7 5(0 30)
. rco78(d3 07'
4{0 16}
Ddril.'l ddhg G) D*ilolddi.E(A)
12x 30(047 x 1.18)
12x30(0.47x118) 4O17(O067)
Fuel inlet08.3(60.33)
water oullet d17 3(d0 68)
Fwr inbi oa.3fu&3)
U Mrxrng elbow \
€rffi*lipe Exhau$ fipe

6sO.8(o2.(n) d50 8(d2.m)
285(1123)
3(o0.68)
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)
I
7-22GM20
7, PipingDiagrams I
7-1 1GM'10
t 8&
'da.9 E
lS E
aB. E
_sBt*$taE eis
*E Ep g - . 8 ==s B 3-- q=
+
Y9
,/z
*
;iF:PEF
3 -1
; '; 6 I c E i i E € E
a e
EE;E
g
:
3 \A
;Y F qs E f l ; F . 3s s s
i/: 'i : 8 E F t 6 o a e ;
n
Et||ii llll
Y
6 t t t ii
Fliiii
tlllos--
lll I
6 l i i i i I I d YH U =
I
I
q I | | | ii + + [ T b t * g
:l
t rt .9
'l l a a
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il
e o
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o
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os 3
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c
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o
-9
c ]
u
, t\ 8
o
t-
3
I
: s
t U
o .9
= g
.9
r
":t
6S
-a
I
o000A0Ar35r
0000A04r361
Chapter I Gcneral
ChaPkr I General 7. Piping Diagrams
sM/GM(fr')(C/HM(F)(C)
7. Piping Diagrams SM/CM(FXCIHM(FXC)
742GM20F
7-3 3GM30 and 3HM35
(-r-t i*
Y\ 3
z
gE=
t pt
U: " ,6E
.+dggoo- u" ,bg
EE i e *-
CJ) ;
i: E E E - ! pi \X
:;
.a
_i ;:;gi-09IeqE E E E
6l
;:35.'36r i 6c ' 0I E
- el,
o:l ttrt!l
|
lll f
]
I
| I lt | | tA^
liiii l l A Y *r - E AE
c:
aolli , ;
I I I ll + t U I aDcc>
"l I
o
o R I
xl
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B! o
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o
] z9
] 6
t-
t-..
I
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B
s
3
I
6
a
*f
L
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I U
l--niir-' oo ?
I
I : I
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I
= g
s q
:
-l I
o -ei ;
66
"l
rl
6
oi
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!
;
= "a
3: e
Ec E g
"i;
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s
t :3J$si3
6i? 5
riE
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3'
9trr
3! E
k trl
Slii
I !ittll
ii lll0P- o t r
I ti + u I
'f
.!
E3l
6c
2
E-
u3
1-26
0000A0A1361 0000A041361
Chapler I General
7. Piping Diagrans
SM/GM(F)(CIHM(FXC)
7-5 3GM30F and 3HM35F

6
.
'
c
I
c;-l CHAPTER2
o
a a
BASICENGINE
o
c
D
f
F
i
3
Iq
d
a
c
F
F -a
-G
o at
L
T
iE
I
EEi Z
is "'F;Ft55i sl
tt
,3 g 5 5 s B;5 ri !
E lilililll{;*
$00A04r361
0000A04r36r
Chapter 2 BasicEngine
I. Cylinder BIuk
sM/GM(F)(clHM(F)(c)
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
Camshali
Casl hole lor lubricatingoil
m00A0Al36l
Chapler 2 Basic Engine

I. Cylinder Block Chapler 2 Buic Engine
I. Cylindo Block
sM/GM(F)(CIHM(F)(C) SM/GM(FXC'HM(FXC)
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
Cylinderbody
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
Crankshafl
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

cottros|on
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 )
Cranksha{t
Eolt diameter M12
Casl hole tor lubicatinO Tightonrngtorque 8.oksr-m(57.0fFlb)
000040A1361 0000404136r

Chapter 2 Basic Engine 1. Cylinder Block SM/GM(FXC}HM(FXC)
l. Cylinder Block
sM/GM(F)(CIHM(F)(C)
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
qtslr9
-!!q$9t' o
-9% 4goJ
Top ring at T D.C.
if l r-l E
kgf-m(ft-lb)
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
cleaner.
\ 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
surface.
(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)
1GM1o(C),2GM20(FXC),3GM3O(FXC)
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)
(H.0004)
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,
rebored.
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.
2-5
0000A041361
0000A041361

I. Cvlinder BIuk
I. Cylinder Block
SM/GM(FXCTHM(F)(C) SM/GM(FXC}HM(FXC)
1-3.2 Boring ih€ cylinder (2)2cM20(F)(C), 3cM30(F)(C) (.1)How to measure distorlion on the upper surface of the
(3)3HM3s
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.
anover-sizepiston-
228!0 125 (8.971F8 9813)
Over-sizepiston mm(rn.) o:l
.6010
e.2a1*-2.28541
(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
1GM10(C)
2GM20(FXC)
3Gr,rs(FXC)
d80.2F80.28
(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
5t
2) 2GM20(F)(C),3GM3o(F)(C),3HM35(F)(C) Q@ N
Oil pan side and O2-pinholes
2-6122'"
(3) Boring procedures (0.4731) b
d
(1) 1GM10(C) Depth15mm
(0.5906)
For processing the bore, face the oil pan side to the bottom
and place the fixing faces ot the gear case and the feed
pump.
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.
0.05(0.002)
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
0000A041
Chapter 2 Buic Engine
Chapter 2 Basic Engine
I. Cylinder Block
SM/GM(FXCIHM(F)(C) 2. Cylindet Head SM/GM(FXCTHM(FXC)
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

Step
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
appr€o.)
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
@reclly.
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

.Hmm
--
E:I- fl ll T
+;I ll
ENI
ll ;l$
Eig
Themostal covel
ll ll Cylinder head
-l-
'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
cylindersurfae.
lntake valve
Exhausl valve
0000A041361
0000A0, 361
Chaptu 2 Basic Engine Chapter 2 Basic Engine

2. Cylinder Head 2. CYlinder llead SM/GM(FXCTHM(FXC)
SM/GM(FXC/HM(F)(C)
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
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
Valvespring
zmc
Plu0
(ex@pt f reh-water @ling)
ValYe r@ker am
moun(ng
bolt
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
SM/GM(FXC}HM(F)(C) SM/GM(F)(C}HM(FXC)
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. \
seats,andremoveanybuild-up.
Whena largeamountof carbonhasbuitt up, checkthe top Seat grinder
ofthechambercombustion foroilflowattheintakeandex_
haustvalveguides,andtakesuitableconecliveaction_
r-a
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

Chopler 2 Basic Engine
2. Cylinder Head sM/GM(F)(CIHM(FXC)
2. Cvlinder Heod
SM/GM(FXC}HM(F)(C)
(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
passage
(cylinder side
hole is ddlled)
Kep the surface
marked TOP uPward
(cylinder head slde)
1GM10(c),2GM2o(F)(C),
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
observed.
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.
3HM35(FXC)
Strd botl dlatr€ts ol cy'indor hd M 12
slde
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\
'r-lt
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
7
(cylinder h€d 3ide)
C@liog waler pas$ge hole

(Hole al cylinder slde is not drllled.)
2-15
2-14
00004041361 0000A04136I

2. Cylinder Head SM/GM(FXC}HM(FXC)
2. Cylinder Hetd
sM/GM(F)(CIHM(F)(C)
guide and valve
2) Model 2GM20(F)(c) 2-4 {ntake and exhaust Yalves' valve
spring
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
a
iOte uot" tn"t tne intakevalveand exhaustvalvehave
t1 @ 9 @ t0 diltercnt dhmeter.
kgf-m(fr-lb) tGM'r0(c), 2GM20(FXc) 3HM35(FXC)
3crf,D{R(C)
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
lnspectvalveseatsforcatbonbuild'upandheavywear'.-
Stud bott tixing nul M12 12.0(16.r) 13 (9,1.0) 0.7F1.15
Valve (0.0295 (0.0335
lf
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
rected.
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
"u"t
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.
NOTE:Attertlgh'€nlng,valveclea/8,nc€mustbe
adiuste<t.
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.
iiluto(c),zcnzo(rxc)'3cruGxc)
Maintemne sfandad V,/errlimit
MaintenatEestandad Wedlimit
67 p2756;, 069 p271n
67 p27fi1 069 (02717)
0o3 po01a
bend
0.030.m14
Valve stm
2-17
2- 16R
0000A04r361 00004041361
Chapter 2 Buic Engine
2. Cvlinder Head Chapler 2 BosicEngine
i
2. Cylinder Head
SM/GM(F)(C}HM(F)(C)
t sM/GM(FXCTHM(F)(C)
,i
(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.
It
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,)
anO
tloating with a test harnm€r, and replac€ foo* 2-4.3Vdvesprhg
oi
floatlng guldes wlth guldes havingan orersize
ouGUe (1)VatuesprlngIncllnation.
dlameter.
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
clearan@
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.m18Ô.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
0.04H.070
(0.0018-0.@28) 0.15(0.m59)
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
Exhaust
(0.0018^-0.0028) 0.1s (0.m59)
47 (O.2756J d6.9
1o.2717)
2-18
2-19
0000.{0.{I 36I 0000A041361
('hapter 2 Basic Engine
2. Cylindu Head
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
is
ffif:;ll,ili.'LTsionberow
A valve slem seal is assembled
pL"f,io;"if ii a
'n" ;i,1,""1???i..j:J""H#ir":
"nor.,"oru"si".1il",iffi
tlroushrhevatve
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"^",
:r:i:!amTr
an
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"
:l:le-:pdng
nead oI,the valvestem.Replacethe
spflng ^"tJ"i"-iff
retainerandspr-
Ing cotter pin when the contact
areais
th" springcotter pin has been Lss fn"n iOlZ",T,
:Tl recessedbecauseof
wear.
1S"}'6H4,,"'
Maintenance
3HM3s(F)(C)
No reess (2) Top clearance value.
Wear limit Maintenance
standatd Wear limit
standard
3HM35(F)(C)
sDnno 38.5mm
- 37mm s.fmm
tie (1.5157in.) (t.4567in-) (1.5157in.) 37mm 0.66-0.86
Top clearanc€
:1:
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
applied
attached (3s.sod) (30.20t6)
14./Eko
(31.81tb-l
;,*
(26.90t6) l-".1::" th"
p.*!ing and insurationpacking
at th€ precom-
malcondilions.
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-
charnber-
ed.
2€.1 Compon€nfs of valve aockerarm

(1) Model 1cM10(C)
Nut
P.e@mbustion chahber
{rea.)
o
Precohbustion
{rront)
chamber a
adjusl scGw
2-20
I
I 0000A0Al:]6|
* 0000A04136t
It:-
Chapler 2 BasicEngine
Chapler 2 Bosic Engine SM/GM(FXC}HM(FXC)
2. Cylinder Head
2. Cylinder Head
SM/GM(FXC}HM(F)(C)
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
the
ln hasa simpleconstructionas thevalverockerarmsare lJ"i or il"ning if the measuredvalueexceeds
fitted to the valve rocker arm support from both sides "-
we2rlimit.
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
(2)Model2GM20(F)(C)
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.
ru{4H
'/:::"::::"
mm (a)
Cleanne al Milimum allowable Wearlimit

Maintenan€ clearare
dsndard assembly
Valve cleaEoce
adrust scGw 6t1.9
(0.4685)
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
(0.s551)
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
trms
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
and
(lh 11N
J-l-l l-
lô-iipi"i"
"n"" assembly.
3 intake valve r@ker arm
r#J IIPJ 2'6.4 Vahe cloarancoadiusiing scr€w
lnspectthe Yalveclearanceadiustingscrew
and
P"h:T-or
3 exhaust valve a@ker ah

il
f, 0
tl "o-,it""i,
peeling. "nO
replacewhen there is any abnormalwear
I
Valve cleaGnce adiusting screw
ilLx?""'#""
l*"*?:*"
ir
i. in Jqaa
2-22 Printed
0000A041361
i .1 0000.{04I 361
Chaptu 2 Basic Engine
2. Cylinder Head ChaPler2 BasicEngine
2. CYlinderHead SM/GM(FXC}HM(FXC)
SM/GM(FXC}HM(F)(C)
2-7 Adiusling intake and exhausl yalve head
clearance
(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-
""r"tul
perlormed accurately.The intake and exhaust valve head feelergauge, and retighten the lock nut. the adjustinsscrewbv the anslesiven
;;;'o;;;ii"s
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
2-7.1Adiustment
Makethisadjustmentwhenthe engineis cold.
(1)Removethevalverockerarmcover.
(2)Crankthe engineand set the pistonto top deadcenter
ODC)onthecompressionstroke.
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)
2-8.2Models2GM2o(FXC),
"6*rn
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
engine
lriiJ I"*", tni, engine is decompressed'the
i"-ti. ou", and ihe flywheelInertiaincreases'thus
Matching ma.* makingstarting "r"irveasy.
2-8.1Model1GM10(C)
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
24e.
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
atm
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)
sM/GM(F)(CIHM(F)(C)
2-9.2Roassemb{nglh€cyllndo(head
.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'
tak€orexhaust.
(1)Assemblingthe intakeandexhaustvalves
' presstne vatveguideinio the cylinderhead'
.vy
if
valve
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
with
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
@
a
'l) Remor/€the rocl(erafmassy mountingnuts.
4 Remol€ th€ rockerarm ass!.
n
tl
il
lt
<5
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-
removethe
-'i.i. *i""* tte valvespring retainer'and
u.t"" spting ,etalnerand valvespring'
5l Pullthevave fromthe cylinderhead'
6i Removethevalvestemseal'
7) Removethevalveguide'
2-26
000{.{04 | 36I 0000A04136r
Chopler 2 Brcic Engine Chapter 2 Basic Engine

3. Pislon 3. Pidon sM/GM(FXCTHM(F)(C)
SM/GM(FXC}HM(FXC)
mm
3. Piston Detail of A (heal dam)

rGMlqC).2GMrO(F)(c),3Gry
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
674.91-74.94
@2.949"-2.95p{.1
(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'
up.
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)Rephcement
1) Installthe pistonpin circlipat one sideonty'
A lmmersethe pistonin 80oCoil for 10tu 15minutes'
Clrclip
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.
fasten€dwlthcirclips.
Groovescalleda heat dam are cut round the top section of
the piston. These grooves h€lp to dissipate heat and pre
ventscuffln0.
3-2 Plston
3-21 Insp€G1ion
(1)Measuringimportanldimensions
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'
I
Piston outslde cliameter
,t illf;:i;i"t*
;( ffi;i tilii.; ;"nnectinsrodandplstonmovefreelv'
ii in"..rri." pi" qrickly,beforetheplstoncools'
0000A041361
m0040A1361
Chaptu 2 BasicEngine
3. Pislon Chapter 2 BasicEngine
SM/GM(FXC}HM(F)(C) 3. Piston SM/GM(FXCIHM(F)(C)
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
r:'--:::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
t
Mdimum wea, mesucd in (a) (b) direc

tions al central gosition mafted.
3l[j1n*"0*n.or
mh ( i n .)
1GM10(C),
2GM2O(F)(C),
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'
3-4.2Inspecilon
3-3.2Pblonph bushing Theslidingsurtaceis hardchromiumplated'
(1)Pislonringcontact
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
2GM2O(FXC)
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
(0.7913)
6"3.O
(0.90s5)
623..1 th€n tln Dltlcd. insert tnJ pSton Into the cylinderor cylinderliner
with a p.ess. However,when installingthe bushing,be diameler
(0.9094)
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
ffi
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'
2-30
00@A0Al36l
00004041361
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-
$-'tach
it to the piston so that the ioint of the ring is
oppositethe gapof thecoil expander'
Thickness
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)
2nd.Pistonring
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)
Oil.ing
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
rings
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
grooves.
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
z
al
€l
ol T
5l
3
o
Gap position ot oit rinO
0000A0A1361
00004041361
Chapter 2 Basic Engine Chapter 2 BasicEngine

4. CorutetingRod 4. Cornecting Rod SM/GM(FXC}HM(F)(C)
sM/cM(F)(clHM(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
compressionleakage.
Connectingrodtwist and parallelity m m ( r n .)
Piston Din
1GM10(C),2GM2O(FXC), 3HM35(F)(c)
3cr/i$(FXC)
Maintenan@ W€t W€r
standard limit standard limil
Cond6ting rod Crank Pin
bshing o/o.0 d4O.10 o44.O 614.1O
(1.5748) (1.5787) (1.7323) (1.7362)
inside
diareter
Csnk Pin 0.02H.086 0.@6-0.092 0.13
and 0.13 (0.m14 (0.m51)
(0.0011 (0.0051)
bushingoil {.003r) --0.m36) 12mm(0.4724in.) l3mm (0.5118
in.)
dea6re
Con@tang
M9 x P1.0 4) Loosenthe connecting rod bolt and slowly removethe
M7 x P1.0
Conn@ting rod
rod bolt
Thread (0.2755x 0.0:P3) (0.3543x 0.m3) conn€ctlng tod big end cap, ihen measurethe crushed
dbreter Plasti gauge wlth a gauge.
Connecting
rcd bott 2.5kqf-m 4.5kqf-m
( 18.ffr-rb) (32.5ft-lb)
lightening
FTqW
M6uring twist and pacllelity NOTE:TheCnnkpin bushinginsidediametermustalways
be measuredwith theconnectingrcd boftstightened
.l-2 Insp€cllon tF3 Crankpln bushlng to the Prescilbedtorque.
4-21 L!.!€ e.rdsmafi end t$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€
the
bushing and lubricating oll pressure'it must alwaysbe
vatue. Replace the bushing when the oil
GA6"d
clearanceexceedsthe wearlimit.
(1)Measurem€nt
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
NOTE:
'--
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)
SM/GM(FXC}HM(F)(C)
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)
-.3a*GrxFilc)
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
diameter
the difference between the large end bilshing inside
Piston 0.025.-0.047 0.025ô.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
press'
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
wear
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.
posit'on'tinish
{2}Afle;forcingthe pist6npin bushinginto
'-' in" inno of the bushingby uslnga pln honing
\Hl
pistoJpln outsiob diameter
-'{iF- machineor reamerso that it fits th€ piston pin to be
",irt""e
used.
Model3HM3s(FXC)
Alignment mark (Punched ma.k)
Itl\
A
IH
H
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.
0000A041361
0000A0A1361
Chqpler 2 Basic Engine
Chopler 2 Basic Engine sM/GM(F)(clHM(F)(c)
5. Crmkshal
5. Crankshatt
SM/GM(FXC}HM(F)(C)
5-1.,coJ':tilff
g;bitf.",:i';"i:y,'"191{fi
}3cmocxc1
5. Crankshaft The following figure shows the crankshaft assembly
"'i 'ii6,"rs,ittlic). on model 2GM20(F)(c) the intermedi-
ot
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
3HM3s(F)(CD.
end (bGb m€tal)

tnlmediate beting metal at llywh€t
metal housing (at llywh6l end)

lnte;ediale
\S€t bolt
Cank metal
ln;ediate metal houslng (at gear caso end)
C.ankshaft
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
2-39
0000,{041361 0000A0Ar361
Chaptcr 2 Baic Engine Chaplcr 2 Baic Engine
5. Crankshatl 5. Crankshatt SM/GM(F)(C}HM(FXC)
SM/GM(FXC}HM(FXC)
92Inspection
1GM 10( C )
5-2.1CrankioumalandcrankPin
(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
2GM20(F)(c)
Crank ioumal
Flywhel end
G€r case end
sci'rb(f'Xo)
1GMlo(C),2GM2O(FXC), 3HM35(FXC)
Maintffistmdad U,ler limit MdnteMe standard l Jetr limit
Gswsbe A
o44xB a439i) c,47m o46.90
(C)
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
s4630
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
Gs@skte
P.m14 -tu 0.0036) p.005s) O.m14
-0!64
oo05s) lntemediate
Cmk iournal and bushing 0.0S 0.15 0.0S 0.15

oilc+em
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)
C6k
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
rj
Oial indicator
T
Flywh@l
b e a r i n g m e ta l
and wear limll

Oellection 5-3.3SUegaP malnlenatrc€ standad gHM3s(FX?
scilsurxcl
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)
p3fia
Crank shaft p.mla 0.065 - 0oo7q
cLla dm OO@a - 0O07q
54 Di**"mbtv A the gankshaft [2GM20(FXC)'
3GM3o(FXC),3HM3s(n(c)l
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 $32lleasudng s|de gap (llWhen disassembling'lay the cylinder down with.the
crankshaftstidingresistancewillincreaseandcrankingwill t ''
Seta di:rlindicatoragainstthe endof the crankshaft(orend ;i; ;;"s h.usin6 side on top so that the crankshaft
b€comestiff.
ol the flywheel) and measurethe amounl ol movementof will b€verticalforeasyop€ration'
the crankshatt In the axial dlrection. ll th€ measuredvalue ii i"tn*" tt* g€arand f t!^'vheelbeforehand)
For model1GM10(c) "rank
Adiustthe sidegapto the maintenance standardaccording exce€ds the wear limlt, replace th€ crankshaft thrust Pl hemovethe main beatlnghouslng
washer. Main bearing housing packing of the prescribed ro the crankshatLgraduallvliftins.n wlth
to the thickne$ 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
mainbearinghouslng)'
Of iilo"" intermldbte main bearing housing lrom
""Jtt
the crankshaft.
Pdmary maln b€nng
i 0000A04r36r
00004041361
I
I
I
Chapler 2 Basic Enghrc
Chapler 2 Buic Engine
5. Crmkshatl
5. Crunkshaft SM/GM(FXCIHM(FXC)
sM/GM(F)(CbHM(F)(C)
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.
smoothly.
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€
u
EI
\\--J-z a\
the gear case end. g
\*1 v
\
'Y>;/-(
- \
(4)Attachingthe intermediatemain bearinghousing set
bolts.
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
beadng
Intermediale
side ot the intermediatemain bearinghousingand ing ftom the inlermediatemainbeding housingon the lmodels and3HM35(FXC)]
3Gt\r3O(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-
1i
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'
I
housing: carefullycheckall relatedcomponentpartswhich might
\i be resDonsible,and take paopermeasures.
\o
(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.
245
000040A1361 00004041361
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
Points'
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
block.
Cy lioder gauge
Crank metal
n\
'1\:_ffi'
b@ring housang
\+/
m m ( i n .)
1GM10(C),
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)
1GM10(c)
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
(FXc)l
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
the
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"
pulling
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'
"pectf
;il;ii crankshaft not rotate smoothlv and
will
(2)Installation
lorque.Measureat lour placesas in the main bearing,
finlr t.,iur" mayoccurif the beatingis distorted'it must
"i;th"
-' 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
(1)Removal
0000A041361 000040Ar361
Chapter 2 .Bosic Engine Chaptcr 2 Basic Engine
5. CronkhaJt 6. Flywheel and Housing SM/GM(F)(C}HM(FXC)
SM/GM(FXC/HM(F)(C)
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'
ol
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
""finO"t
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
i*"tin"li""J"t
;;;;; id'""untins ilanse(tlvwheelhousing)which
is if," of the starter motor or at the hole of
h-ousing,the rotary position of the
""uing'nof"
iiuwneer
the
crankshatt can
pad(
,,/j' 5-6.1 Oll seal type and size boltedto the cylinderblock il r"""n"*"1 i" to adiust tappet clearance or fuel in'
Rounded
corner
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
\t_J
(v:
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
"Lxtn"tt
""?'t"""*i"S
S"-. The reductionand reversing
ted to the mountingflange'
iilllv*n""r.
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
momenlsare
side ot the tlywheel,and the unbalanced
"iill""
adiusted by driltingholesin the circumference'
&1 Specificallc of 3HM3s(F)(C)

c)ilsd rGM10(C),2GM20(F)(C),
3GMIB(FXC) 3HM35(FXC)
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)
m/s
(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
46
Pitch circle 4l
mm
diameter of bolts tM10
Fixing Part ot
No. ol thread hotes mm
crankshatt
o@M7
Fit ioint diameter KM3A
(3) Since the direction of rotation of the shatt is sp€cilied
gear
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
2-48
00004041361
0000A041361
Chopler 2 Basie Engine
6. Flywheel and Houing SM/GM(FXC}HM(FXC)
6. Flywheel and Horcing
sM/GM(F)(CIHM(F)(C)
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
; 9 a3
@ !llo
IO
o3 I
o6
>o
s o>
oG
?r- S I E3
53
6g
E
c;ig:
3 E-s:€
5a
2'd
6I dLo I
1: r-: €
s:* g
"
266q!
s
q
9c\
:o<
x .\<
;o:
6X i
=id:
€el
.-: o
sg 5
3.:{g ;.: b
tFi *i e
: it *i':
=ds
isp'
-r;
x
ui
o
sBs
d
z
ts
:
FE
:e
0000]104136r 000040A1361
Chopter 2 Basic Engine
Chapler 2 Bosic Engine 7. Camshalt SM/GM(FXC}HM(FXC)
6. Flywheel and Housing
SM/GM(FXC):HM(FXC)
&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.
alm.
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""
ioua,
"riO Therefore, to reduce wear the surface is tempered cylinderat the flvwheel end in all engine models'
pressure-
selected
Lv hiqh frequencyhardening,as well as a cam form
exhaust
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
exhaust
(1)Marking valve seats.
Side surlace ol flYwheel
Stamped marking line

Stamoed marking line
ilti
Angle a ol Stamped li6
f,
/r-(\
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
2-53
2-52
0000A041361
0000A0A1361
Chopter 2 Basic Engine
Chapler 2 Buic Engine
7. CamshaJt SM/CM(FXCIHM(FXC)
7. Camshol
SM/GM(FXC/HM(FXC)
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
7.3Inspectlon
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
7-3.1Camshatthelght
LV
gall bearing retainel
Wear limit
standard
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)
feed
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
33.5
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
standard
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 ) .
00004041361
0000A041361
Chapler 2 Breic Engine Chapler 2 Baic Engine
7. Camslml 7. CamshaJl SM/GM(FXC'HM(F)(C)
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
is
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)
3Gr.i|O(FXC)
136(5.3s43)
length
3HM35(F)(C) 171(6.7323)
rAfifhrNilm
7-5.1Tapp€ldlsassembt prccautions
Thecylindernumberandintakeand exhauslmustbe clear'
vv\-yqryy
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
valve
the
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
Maintenan@
mm
Wear limit
o@ con-
Also,theremaybe perforatedpittingsorcrackson the
standard
acreo(c) 0.02
(0.0008) tacl'surface of the tappet.In such cases, discoverthe
Cachaft reasonforabnotmality and repbce the tappet'
o.o2
defl@tio 3HM3s(FXC) (0.m08)
7.6 Push tods
prevent
Maintenance
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
guidehole
clearance 2GM20(F)(C) 0.01H.0i10 0.10
Ball b€aring type 3GM3o(FXc) (0.0004-{.0016) (0.003s)
3HM35(F)(C)
model
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
iJi""
the contrct surface. not start.
W-n"n the fuel cam, be sure that the'!" marl(
""""tOflng
ortn" iJopPositethe camshaftgear'
"iou ""rn
0000A04136r
0000,{0Ar361
Chapler 2 Basic Engine Chaptu 2 BasicEngine

7. Carchaft 8. Timing Geu SM/GM(FXC}HM(FXC)
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
C6nkshalt
Lubrlcating oll pump
The c@ling wate. pump is ddven

by this 3llt
Lubrlcating oll pump g€a.

(also driYes the c@llng water
rGM10(C)
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"ôn" 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
(2)Fuelcam
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
0000A04t361
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
(2)'measured
'
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.
,a.\
w Q,
. J)r
\ .l- z ,i tl
\ \-\
#a^^'l
-\D \:-
i;ts-oz
Cooling waler pumpl
8-3 Inspeclion
8-3.1Ba€*lash
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'
2-63
0000A041361 0000A0A1361
CHAPTER3
FUELSYSTEM
1- Fuel Ini@tion System .....
2 Inj6tion PumP . . - a-25
3. In,ection Nozle . .
4. Fuel Filter .......
r29
5. Fuel F@d PumP . . -" " ' 9 3 0
6. Fuel Tank (OPtion)
0000A0A1361
Chopler 3 Fuel System

I. FueI Inieclion Systern
sM/GM(FXCTHM(F)(C)
1. FuelInjectionSystem
Fuel tank (option)

Capacity 301
0000404t361
Chapter 3 Fuel Syslem
Chapter 3 Fuel SYstm
2. Injection Puntp SM/GM(FXC}HM(FXC)
I. Fuel Injeclion System
sM/GM(F)(CIHM(F)(C)
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.
load.
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
menl.
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)
2-1.1'lGM1o(C)
Type of inj€tion pump YPF R-07 07-l YPFR47O7-2 YPFR{7 07 YPFR-0707
O-ring
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
Plungersp(ng
--Plunger spring lower relalnel
PlungerPositionshim_
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
SM/GM(FXC}HM(FXC)
sM/GM(FXCIHM(F)(C)
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
Ptunge,springlowerretalner---S
consist of the detivery valve aN delivery valve
ptung{posttion
r-@ hotdet and plunger and plunger baftel rcspectlve
shim--re
re ly.
Ptunse.suide
---F?
Pluneer p
rotrer
euide
" OH
Plunger guide .oller (ouleo
K Plungerquide .oller (inneo
fc
000040At361 0000404t35r
Chapter 3 Fuel St'stem
Chapta 3 Fuel SYstem 2. Injection PumP
2. Inieaion PumP SM/GM(F)(C}HM(FXC)
SM/GM(FXC}HM(FXC)
3HM3s(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
sM/GM(F)(CIHM(F)(C) SM/GM(FXC}HM(FXC)
2.2 Specilications and performanceof luel injection pump (2) Model 2GM20(F)(C)
2-2-1Specificalionsol luel inirction pump
E
Static mehanical lift at iniection lat slarting 3.2mm(0.1260in.)]
2.5mm(0.09&1in.)
b
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

pumP
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
E 0
10
t5
:
!
20
E
E
A /r
E
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
(mm)
Movino distance of the rack pin ftom the cenler of lhe pump body
3-8 3-9
0000A0A1361
0000A04136I
Chapler 3 Fuel Syslem
Chapler 3 Fuel SYstem 2. Injection PumP SM/GM(F)(C}HM(FXC)
2. Injelion PuntP
SM/GM(FXCIHM(F)(C)
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
E
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.
.9
N o inieclron Hall iniection
1614121086420-2 Delivery chamber

Movino distance of lhe rack lrom the pump body (reference face) (mm)
468101214161820
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
irooi.
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

luel
The deliveryvalveon lop of the plungerpreventsthe.fuel
insidethe i;iection tubefromflowingbackwardtowardthe
plungerside and also seryesto suck backthe fuel to pre'
Printed in Jaean
0000404136r
00004041361
Chapter 3 Fue! System
Chopter 3 Fuel System
2. Injeclion PmP
2. Injeclion Pump SM/GM(FXC}HM(F)(C)
SM/GM(FXCIHM(FXC)
(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)

engine.
NOTES:I) Betorc disassembly wash the pump in clean
oil, and alter assembly anange all parts caretul-
ty.
2) Make surc the work arca is exceptionalty clean.
(1) Remove the plunger guide stopper pin wilh needle
nose oliers.
@o
(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.
eê
NOTE:Be carctul not to lose the plunger slrcke adiusting
shim which ls located insidethe plungerguide.
%Q
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
@"
o"%ru
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
0000A041361
0000404r361
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
unevenly
(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'
OF FO
plunger should slide slowly and smoothly' ll it slides too
quicily, orbinds along lhe way, repairorreplace it'
Er
sleeve
O) hemove the No 1 control
[-r{r
a force
ffi (3)ll lhe controlrackdoesnot movesmoothlywhen
t"' rack and pinion
oi *,-itttinoog is applied,replacethe
@
Kp
assemblY.
2.5.4Plunger
(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.
2-5lnspectinginiectionpumpparts
2-s.t BinseeactcomponentPartin cleanlighioitbelore
Insp€cfinglt.
plungerano
NOTE: Do not touchthe slidingsudaceof the
" -' -' handling'
li" ditir"ry vaNewith your tingersduting
For model 3HM35(F)(C)
2.52TaCPel
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
(2)
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
slidingsurface{or
tllCheck the controlrack teeth and reDlacethe deliveryvalveasa set.
damageandabnormalities lf found'replace'
dis'
replacingthe controlrack' adiusttuel
"udiitvin",
- ' -' a
inh a tiet iniectionpump testerand stamp
"nirg"
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
"onttor
exceedsthe sPeciliedlimit'
3 -1 5
3-'14
0000A041361 0000A041361
Choptu 3 Fuel Syslem Chapter 3 Fuel Syslem

2. Injrtion Punp 2. Injeclion Pump
SM/GM(FXCIHM(FXC) SM/GM(F)(C}HM(FXC)
(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 valveguide. 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.
(-_--o
mre
Clem@limlt
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
îOTEt Ihicknessas those tnsertedEfo'e disassembling
thepump.Atler re-assembling the pump' measure
and adiust the top cleannce of theplungeL
3-16
0000A041361 00004041361
Chapler 3 Fuel System
Chapter 3 Fuel SYaem 2. Injection Pump
2. Injection PumP SM/GM(FXC}HM(F)(C)
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).
2GM20(FXC),3GM30(FXC),3HM35(FXC)ksr-m(rr-rb)
Plunger
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
Packing.
3GM3O(FXC),3HM35(F)(C)
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.
3-1I
00004041361
0000A0A1361
Chapler 3 Fuel SYslem Chapter 3 Fuel Syslem

2. Iniection PmtP 2. Injection Pump
SM/GM(FXC}HM(FXC) SM/GM(FXCIHM(FXC)
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
/'i
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)
specialcaremustbetaken).
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-
seat.
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"')
mat'
(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
(8)
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
121450-01931
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
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)
sM/GM(F)(clHM(F)(C)
(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

iig
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.
gaugepointertoO.
3) Removethe pumpdeliveryvalveand installthe measur-
ingiig.
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'
rackslidessmooihly
...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
injeclion
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
rffl
l+l
_H-
2.8.2 Measurlnglh€ slidingr€slstanceol lhe fuel |
l+l
|
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
y
-
l-.r
tr-V--
| --/'+<_ |
| 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
l.t+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
I]:+l
0000A0A1361 0000A0A1361
Chapler j Fuel SYdem Chapter 3 Fuel Syslem

2. Injection PumP 3. Injection Nozzle
sM/GM(F)(cIHM(F)(c) SM/GM(FXC,HM(FXC)
(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),
sGM3O(FXC)
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.
YON-OSDYDl YDN.OSDYl
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
lSlil]3"rio"-
Averageinjectionvolut"= "r
*nlu"roi*tinoo. Nozzle spring seal 7
Inter spindle 8
Maximuminiectionvolume
9
- 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
28.7mm(1.1299inj
14.14kg (31.17
rb)
Nozzle spring adjusting plate
Increase - Decrease
(for adiusting nozzle opening pressure)
3-25
0000A0A136r 000040A1361
Chapler 3 Fuel SYslem 3. Inieclion Nozzle
j. Injection Nozzle SM/GM(FXC}HM(F)(C)
SM/GM(F)(C/HM(FXC)
(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'
ksr-m(rt-rb)
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,
(i#
holder
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
:rilliil;\
ii'ilia.,i
(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.
N8**,-%mnED
3-27
3-26
000040A136t
0000A0A1361

Chaptu 3 Fuel SYslem 4. Fuel Filtu
3. Iniection Nozzle SM/GM(F)(C}HM(FXC)
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
Cott6fiber
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
Spike
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.)
tJ
fi\
//\\\
\
..'il
. UBss€lcmtact
Slanted
* . 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).
3cilry5)(c).
5-2.1Disassembly
markon
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-
Component
stalled at a higher position than the fuel filter and injection

{?q
pump, lhe fuel witl be led by its head pressure, but if the' Feed Pr ess ur e <q>'{
pump
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-
o
tA\ @
5-3.1 Checking lhe PumP for luel oil leaks
After removal, immerse the pump in kerosene, stop
its
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
point
which should be replaced.
5-32 Ch€ckhgthe pumplorenglneoil leaks

pump
Checkpump mountingbolts lor loosenessand the
packing for breaks.Retighten any loose bolts and replace
defectivePacking.
5.22 Rer$€mbly
prc
Assemblethe pump by reverslngthe dlsassembling 5-3.3lleasuting th€ sucklng power
cedures.Paycloseattentionto the following: Attacha pieceofvinyl hosetothe inletport,keePthe
pump
('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
pon
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
u"ii."t"
it can
on'tn" fing"t, nff'ough this is not an exactmethod' are
elc'
1 GM1 0( C) 2GM20(F) (c)
(C),3GM3o{fxc),3HM35(F) Outlet valve ai ieasr lonfirm that lhe diaphragm,valves'
operating.
3-30
0000404r361
000010Al 36I
Chapler 3 Fucl SYstem

Chapto 3 Frcl SYstant 6. Fuel Tmk (OPtion) SM/GM(FXC'HM(FXC)
5. Fuel FeedPunP
SM/GM(FXCIHM(FXC)
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.
5-3.6Dhphragmspdngandrockerarmspring
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
rcplaced.
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.
00004041361
00004041361
Chap@3 FuelSYdem
5. Fud Tank (OPlion)
SM/GM(F)(CIHM(FXC)
CHAPTER4
GOVERNOR
1. Gowmor .. +1
0000404r361
00004041361
Chaplu 4 Governor
I. Govqnor
SM/CM(FXC}HM(FNC)
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.
suddenlyaccelerated.
1-l Construction
(1)1GM10(C )
.diuster b.acket
ldl€ adiustq
No-load maxifium so€€d limite.
Regulator hadb
Regulato. levea
€ngine slop
l€ver
inlection plmp
rp,ing (main)
Gowdreiohl
Crnkshatt 9@
Fu€l inlection llmiter
GoverM ldg 2
Control lever
Govqnor lever shall
Govemor sleeve
Leve. shaft
CEnkshaft
0000404136r
Chapler 4 Governor
Chaplu 4 Govunot
I. Govsnor
I. Governor sM/GM(F)(cIHM(F)(c)
sM/GM(F)(c).HM(FXC)
1- 1.11G M 10( C )
3HM35(F)(C)
(2) 2GM20(F)(C),3G[A3O(F)(C),
o
= 0
)
il\
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
i5!
95S F'
PEi <
c5
t3
a
00004041361
0000A041361
Chapter 4 Governot
Chapter 4 Governor
I. Governor
1. Governor SM/GM(F)(CIHM(FXC)
1-2 Operation
3HM3s(FXC)
3GM30(FXC)'
1-1.22GM20(FXC),
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

srabirized
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'
4-5
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)
il
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.
Governor
conlacl
weaghl
Cleere
.ffi Maximumallowable
mm(n.)
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)
2GM20(FXC),
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
lb/in.)
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
00004041361
00004041361
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
conditions.
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
clockwise.
(5) Align the center mark ol the rack with the reference
face-
(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
4-9
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.
lew
ll
rl
I
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
GoYmof
'lqq2
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'
1,
li
tl
ll
llr 0000404t36t 0000404t361

CHAPTER5
INTAKEAND EXHAUSTSYSTEM
000oA0At36l
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
outlet-
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@
t
C@ling wat€r
(from lh€mstat c&) Bfedh€r ho*
Exhaust gs
To intake port
lnlake alt salencer
U-type mixing elbow (opliq)
00004041361
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
3llM35(FXC)
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
"*ptoy"O
cvlinder head from the intake port'
also acts
Besides providing a sitencing effect, the silencer
as an air cleaner.
3HM35(F)(c)
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
"ir,
LIome ctog'ged and this decreasesthe amount ol intake
air.and may alsobe a causeot decreasedoutput'
2-3Washingthe Intakesilencarelernent
detergent'
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)
5-2
0000404r361
0000A0A136r
Chapter 5 Inlake md Exhausl System

Chapter 5 Inlake md Exhausl SYstem
3. Exharct Systm
3. Exhaust SYstem
sM/GM(F)(C).HM(F)(c) SM/CM(FXCTHM(F)(C)
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
L-
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)
Formodel2GM20(F)(C)
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

Exhausl
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.
0000A0A1361
0000A041361
CHAPTER6
SYSTEM
LUBRICATION
i li.
i:" . 000040,tt361
t'*
Chopter 6 Lubriulion SYslem

1. Lubricalion SYlem
SM/GM(FXC).HM(FXC)
System
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
0000404136r
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
Camshaft
To oil pan
Camshall gear
I
Crankshaft
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
sM/GM(F)(CIHM(FXC)
SM/GM(F)(CTHM(F)(C)
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
2-1Construction
12.5 12 irochoid
Discharge volure
l/min
l/h
3.9
a4 760 7n Theoitpumpis a compet,lowpressure
varbtion
Lubricating oil PumP pump comprising trochoid curue inner and outer rotors'
kgf-cm'
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
ki
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}
2-2DlsassemblY
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\\
Camshaft
Y.c
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
suppon.
(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
I
t)
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.')
-
6-7
0000A041361 0000A0At361
Choptu 6 Lubricolion SYslem

Chaptu 6 Lubrication SYslem
3. Oil Filter
2. Oil PumP sM/GM(F)(cIHM(F)(c)
SM/GM(F)(C}HM(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.)
6-B
0000A04136t
00004041361
Chapter 6 Lubricalion SYslem

Chapler 6 Lubricalion SYstem
3. Oil Fiher
3. Oil Filta SM/GM(FNCTHM@XC)
sM/GM(F)(CIHM(F)(c)
1GM10(c)
tGM10(C)
Oil pressure
2GM20(F)(C), 3GM30(F)(C) and 3HM35(F)(C)

Oil prcssure regulalor valve
Filter etefreot
3-2Replac€ment
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
scored.
6-1 1
6- 10
0000A0A1361 00004041361
Chaptu 6 Lubricalion SYstan

Chaoter 6 Lubrication SYslem 4. Oil Presrure Regulalor Valve
sM/GM(F)(cIHM(F)(c)
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
Valve
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
I
Oil pressureregulatd valve
Lubri@ling oil PUmP

B€dn9
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)
filter
loil
whs lhe prGsure is higher lhat the regulatedpressure

{
"""rinn
When the pressureis higherthat the reguhtedpr6sure
6 -1 3
0000A041361
fl)00A0A1361
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.
CHAPTER7
Secondaryoil pressureis especiallyimportant.ldle the
engineat mediumspeedwhenmeasuringthe oil pressure.
Also checkwhetherthe oil pressurerisessmoothlyand to
the standardvalue.
DIRECTSEA.WATER
COOLINGSYSTEM
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

caus€sare:
(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
rockerarmsupportarerequired.
6 - 14 0000404136r
0@0A0Ar36l
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.
1.2Coolingwaterroute
Th€coolingwateris suckedupbythewaterpumplhrough
cockinstatled
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
circuit.
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.
7-1
,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)
sM/GM(F)(cIHM(F)(c)
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
Themostat
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
ii
il
t,i 00004041361 0000A041361
1,.I
Chapter 7 Direct Sea-llaler Cooling System

Chapru 7 Dbect Sea-Waler Cooling Syslem 2. Waler PumP
SM/GM(F)(C}HM(F)(C)
I. Cooling SYstm
sM/GM(F)(CIHM(F)(C)
1-23 Cooling water pasge ol engine models 3GM3O(C)

Temperalureswatch
2. WaterPump
and 3HM35(C)
The construction of model 3HM35(C)is almost the same as ard operation
2.1Construction
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*,,ô.^,.,
.-tB''
*e' engines. =4*-r
Effie)JF =^= g1ffi710";o*'
.ffi@uF
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
Cylinderblock
i.
fhemostat cover
i*
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
-Kingston
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
000040A1361
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)
3Hlt35(C)
2-1.3 Cooling water pump of engire model
2-12 and
pumpol ensinemodels2GM20(c)
3cd$S?6ate(
""""'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
,a.Coltrt
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
)/
\\q.9
3.0m 3.0m 4.0m
Total head (9.84ft) (9.84ft) (13,12n) centerwith Your fingers.
tleliwry €pacrty 300//h 700tlh r500/h
2-2DisassemblY
2-2.1Formodel1GM10(C)
(1)Loosen lhe water pump mountingbolts, (emovethe
waterpumpass! fromthe timinggearcase'
Coat lhese Pans with otease
(2)Be sure that the directionof curvingof the impelleris

conect.
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
impellershaft.
(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.
U-q
/ .
ry
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
000040A1361
0000A041361
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)
wg
2) Modets 2GM2O(C)and 3GM30(c)

Mdimum \wea
Mainteffie Cbmne allowable
standad ataMbly limit
cffire
lmpdler 191{.1
widlh 0.7aa a 0.7sq
1A9p.7441)
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)
w
3) Model 3HM35(C)
Muimum li\len
Mainleme Cleamne allowable
siaodard at as*mbly limit Cylinder head
cbence
lmpeller
2.;l !4-1
width o8661
0a740)
-
(wiihout packing) o2 0.4
Hdsing
width o.0079) p.01s4
p8661)
t/t ear o2
plate p.0079)
wg
7-'11
00004041361
000040A1361
Chaplu 7 Direcl Sea-Water Cooling Syslem

Chaptu 7 Direcl Sea-llaler Cooling Syslem
3. Thermostat
3. Thermodat SM/GM(F)(CTHM(FXC)
sM/GM(F)(clHM(F)(C)
(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.
the]mostal
with the arow
Thethermostatcovermustbeassembled
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
volume.
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
t
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
Zinc
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
1
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
Numbs
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--
e]"-T--ll
--fl- Il I
il?t--
3r_+_____.1LJ tf-t
I so.. | \LJ
l_!\
*--]iseiirnJ* ea"tins
prug
zilcmounrins
Mounting position for model 2GM20(C)

Mounting positon for model 1GM10(C)
Antlcoroslon zlnc (cylinder blockl
il ,/i
0000A041361 36r
000040A1
Chapler 7 Direcl Sed-Water Cooling Syslem
6. Bilge Pump md Bilge Strainer (Optional)
SM/CM(F)(C).HM(F)(C)
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)
3.s4.5(0.1772)Holes
Kin gston cock c ov et
\A 1
iK$w/ ;
AN#
U FtJH J
HJ TH
(2.16
4.o55
I I
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.
't2v
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
pump.
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.
00004041361
0000A041361
CHAPTER8
FRESHWATER
COOLINGSYSTEM
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
ofitoAoAl36t
Chapler 8 Fresh Wa@r Cooling Syslent
1. Cooling System
sM/GM(F)(crHM(F)(C)
1. CoolingSystem - U-type mixing

elbow
1.1.SystemDiagrams
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
t
F F6hwats
€ seamter
ri::: tntet and outet fo. waitr tHttr
00004041361
Syslettr
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'
2GM20F'
The same sea water pumps are used lor models
types as useo
3GM3OFand 3HM35F;theseare also the same
However'
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
jn
water'
.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
passagesano
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
ili"g;irb""-b""t"d
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
"t"t
*"to rlowsthrough the by-passpassage to the l. C@ling water PUmPshaft
iignr-tt".n 2. V-Pulley
inside
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
NOTE:
"Chapter 7'
precautions and inspection' rcfer to
Section 2. Water PumP (P'7-5)':
Printed i^ Jqan
a-2 0000A041361
0000A0Ar361
Chapler 8 Fresh |l'oler Cooling Systcttt Chapler 8 Frrh Waler Cooling Syslent
3. Fresh ll/alu PumP 3- Fresh Waler PumP
SM/GM(F)(CIHM(F)(C) sM/GM(F)(cIHM(F)(C)
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
shaft.
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.
Mechanical
Plug fo. water heater PT 3/8
Oischarge Q (l/min.)
4-Q diaoram Water l€mp€rature 80r2oc
I
IJ
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
c
erchoger hand.
When the rotationis not smooth,due lo bearingplay
] or friction.or abnormalnoiseis heard,replacelhe entire
pumpassembly.
(2)lmpellerinspection
oain hole/
Check impeller lor damage, conosion and waler'
Mechanical sol/ Replaceil tequired.
(3)Check the holes drilled in lh€ cooling water passage
I or by-pass passage, and clean or unblock where
necessary-
8-5
00004041361 0000A0A1361
Chapter 8 Fresh H/aler Cooling S1'slent

Chapler 8 Fresh llalcr Cooling Sysletn
4. Heal Exchanger
3. Fresh tlater PumP SM/GM(F)(CrHM@XC)
sM/GM(F)(c).HM(F)(c)
M6udno clea€nce betwen imp€ller a.d pump body
4. HeatExchanger S€ water outl€t
(lo mixho elbow)
4-1. Coflstruclion
a
pass pas$ge
F iller cap {wilh pressure relief yalve)
H€t exchanger body
Cooling tube cdei
M6uaing cloaBnce b€twen impellor and pump body bracket

l-
I
C@ling tube assedbly
FGsh water inlet

(frcm cylinder head)
8y-p6s pas$oe
F6h watsr outlet

(to l.esh waler pump)
Detn sd(
Sea water Inlet

(from sea water pump)
(4) Wherewaterleal€ge is heavy,due to wearor a damaged

m€chanlcal seal and lmpeller seal, replac€ the pump
assemblywlth a newone.
(5) Pump body and pump bracket Inspection
Clean deposils and rust from body and bracket.
Replacelf heavilyworn o( cofioded. The heat exchanger uses sea water 1o cool the lresh water, water passes through the flow path formed between the
(6)lmpellerclearances- mm(.n) which has reached a high temperature, while being cir- tubes and baffle plates inside the cooling tube cover.
culated in the cylinder block. The lower part of the heat exchanger stores the fresh
The heat exchanger is a cooling lube which consisis ot 24 water, acting as a fresh water tank. An exhaust gas passage,
0.3 1.1(0.0118 0.0a$) slender tubes and baffle plates, and a cooling tube cover. leading out of the storage position, is integrated with the
- -
Sea water pass€s through the slender tubes, and fresh water-cooledexhaust manitold.
To measure clearance between impeller and body, in-

sert a thickness gauge between the two Parts at an
oblique angle betwe€n the two parls.
To measure clearance between impeller and bracket,
ptace a straightedge on the pump body surface and
insert a thickness gauge between the straightedge
and imoeller.
8-7
0000A041361
0000A041361
Chapler 8 Fresh ll'aler Cooling Syslem

Chapler 8 Fresh ll'ater Cooling Syslem 4. Hea! Exchanger
4. Heat Exchanger sM/GM(F)(c)'HM(FXC) SM/GM(F)(CTHM(FXC)
On the other hand, when the cooling syslem pressure 4-Z Water flow in water cooling tube
The liller cap on top of the heatexchangeris equippedwith a
pressure reliel valve.When pressureexceeds the specified becomes negative in relationto the aimospheric pressure, Fresh water enters the cooling tube from a hole drilled at
limit, this valve opens to release pressure through the air enters lrom the overllow PiPe. one end ot the tube. lt then passesthrough the flow passage Sea water outlet
overflow PiPe. tormed by the baffle platesand the tube cover and into the
water storage through a hole of the other end.
Fresh water inlet
Side cover
F S€watsinlet
Beffle plate
Sa waie,
outlet
Frcsh waier oullet

(to lresh water ae*froi4
C@ling pipe cover
Fitler cap (wlth pr€ssure rel:ef valvel
plate Fresh water Inlet

Ealfle
(from cylinder head)
S€a
outlet
Sea water enters the side coverat the sea waterinlet side,
Side cover passesthrorJgh8 tubes guided by the side coverribs and
thenleaves thesidecoveratthesea wateroutletside.Hereit
passesthroughanotherI tubesguidedby the side cover
S€a ribs,and returnsto the sidecoverat the inletside.
At the inletside,it is gukJedby the remaining8 tubesas at
inlet the outlet side, and then flows out to the mixingelbow
a from the outlet connection via the side coverat the outlet
F,esh wate. @llel
Erhausl manllold
side.
4.3. Specificatioos
tkaln plug 2GM20F 3GM3OF 3HM35F
Model of sgire
Output (DlN 6270 B kw/rpm 18.2/3600 27.3tffi fr.4t3/[o
dia X mm a6168x24 z61'8x21
',6168x24
0.119 0.163 026
Radiation trq
m'/HP 0.0066 o.0060 0.0061
Radiation tr€lHP
caFdly , (cu.in) 2.902.0) 3.4@7.5) 1.9e99.0f
F6h mts
I
tI 8-8
0000A041361 0000A0A1361
8-9
I ;,r:
Chaplcr 8 F-resh ll'aler Cooling Syslent

Chapter 8 Frah Waler Cooling System 5. Fillcr Cop and Sublank
4. Heal Exchanget sM/GM(F)(C).HM(F)(c) s L / G (r,')(c:,tr M(F)(c)
^'
4-4. Disassembly 4-52 Haat exchanger body
(1) Check lor dirt and conosion build'up inside body and on
5. FillerCapand Subtank
(1) Removethe side coversand pull oul the cooling pipeand
rubber Packings. side covers. Replace if conoded, broken or otherwise 5.1. Filler cap conslruclion When the coolino systom pressur€ is within the sDecified
NOTE: Alter the cooling pipe is removed, always replace the damaged. range 0.9kgf/orl(12.80lb/in.,), the pressure vatve and
(2) Check ioints at sea water inlet and oullet ports and fresh The filler cap is placed on the fresh water inlet port and is
rubbet packings on both side covers. vacuum valve ar€ tightly closed on their valve seats.When
equipp€d wilh a pressure control valve.
(2) Remove filler cap aM Port. waler inlet and outlet ports. Relighten any loose screws pressure rises, llle pressure valve opens and vaDor is
To attach, place ihe rocking tab (extension on the atlach-
(3) Remove lower cover and packing. and clean pipes as required. discharged from lhe overtlow pipe. When the water coots
($ Check drain cock forclogging. lf clogged, clean or repair ment section)on the flyneck cam. Then, tum and tighten.
down and the prnssure in the system is lower than atmos-
The top seal touches the flyneck tap seat while the pres-
as required. Retighten screws if nec€ssary. pheric pressur€,the vacuum valveopens and air enters the
(4) For inspeciion of filler cap, anticonosion zinc, and ther- sure valve touches the lower seat-
system through lho overllow pipe.
mostat, see below. To prevent the pressure valve from opening and resulting
water loss, the cooling syslem can be equipped with a
Heat exchange( body 4-5.3 Leakage tesl subtank, described below.
(.1)Test with compressed air and test lank. Seal fresh and Action of Pressure control Valve
sea water ports with rubber caps and immerse tank in a Pressure Valvl
test tank filled with water. Iniect compressed air through
the overflow pipe and check forair bubbles-
NOTE: Ait pressure should be 0.5 * 2.0kgf/cm'(7.11 -
28.15 lblin').
5-3. Fillercap Inspecllon
(1)Removeall d€positsand rust, check for damageand
wearon lhe seatcontactingsurfaces,and checkspring
Side cryer
for propertunctloning.Repairorreplaceas required.
(a Testerinspection
Atlachadaplorandfillercapto tester.
Increasepressureand if pressurelemainsconstantfor
six seconds,the cap is notmal. lf pressuredoes not in-
@ ^"o*, irease or does not remain conslant tor six seconds,
checkfor defects.Repairorreplaceas required.
5-2 Flllercappressurccontrol
Prcasurc valve sprino
4-5. Inspeclion and cleaning

4-5.1CoolkE pipe
(1) Inspect tor dirt and deposits in the tubes. Cleanas te Leakag€ t6l u3ino compaesscd ak tnd lost tadk
quired.
(a Test using pressure lester
Seal fresh and seawater ports with rubbe.capsand fill the
tank completely with waler. Replace the filier cap with a
pressuretester and pressurizethe tank. lf there is a leak,
the tank cannot be pressurizedor it will only be able to
retain pressure lor a short lime.
Pressure valve o@niion
5-4.Subtankfunction
Whenthe cooling systempressurerisesabove0.9kgf,/ori
(12.80bnn'.), the pressurelralveop€ns ard yapor is |€l@s-
Rubbor cap
ed, reducing the amount of water ln the cooling system.
The subtankcollects this vaporwhere it cond€nses.Then,
when cooling sygtem pressure lalls below atmoopheric
pressurc,the water in lhe subtank is siphoned back to the
maintank
Useof a subtankls hlghlyrecommended, sincethis allows
(2) Inspect caulked portions of tubes and flanges for the engine to be run for langer periods betwoen water
damage. Repair or replace as required. replenishment, andthe needto openlhe tillercap is elimi-
(3) Insp€ct the cooling pipe and tubes for leaks. Repair as nated,therebyremovingone possiblecauseof a@idents.
required.
(4) Check forclogged waterpassages. Clean as required. Leakaoe iesl using a pressur€ lester
8-10
00004041361 000040A1361
Chapler 8 Frah l(aler Coolittg Syslem

Chapter 8 Fresh ll'ater Cooling Syslent
6. Thermoslal
5. Filler CaP and Sublank sM/GM(F)(CIHM(F)(C) sM/GM(F)(cIHM(F)(C)
Filler c ap
I
Sublank mounling plate (attached to sublank)
6. Thermostat
6.1.Operation
ggmm hole
{0.354in)
To heat erchangel
Cylinder head outlei

connectiof, (conneted
lo heal exchangeo
e8(0.31) ( l) Mount the subtank at the same height as the fresh water
lank. Themstal valve
(a Ensure that the length of the overflow pip€ is no more
than 1m (3937 in.), and thal it does not break
NOTE: lt asubtank is not used, becaretul not to immerse the
oveillow pipe in the bilge, srnce llris can cause
bilge water to be siphoned into the cooling system.
5.6. Maintenance during us€

(1) Check that when the cooling water is cold the level is By-p6s pasege
wilhin the specified range.
(2) Check that the overflow pipe is not broken, and also that
the holes are not blocked up.
5-5. Installationof subtank

Cylioderhead
whenvalveis closed(by'p6s pas$oe is opened) Wh€nvalveis op€ned(by-passpas$g€ ls closed)
The thermostat opens and closes the by-pass valve and temperature is low, and fresh water is fed to the fresh water
Fresh water thermostat valveaccording to the temperature changes of pump inlet through the drilled hole in the by-passpassage'
tank lhe lresh water in lhe engine, adiusts the flow ol fresh to be circulatedinsidethe engine
water to the heat exchanger'and keeps the fresh water When the fresh water temperalure rises over the valve
temperature in the engine at the correct level. opening temperature, the thermostat valve opens, and
The thermostat in the tresh water"cooled engine is a tresh water is fed to the heat exchanger and where it is
bottom-by-pass type, as shown in the figure, and is in- cooled and then led to the fresh water pump. With the
stalled inside lhe fresh waler pump bracket which com- thermoslat valveopen,the by-passpassageis throttled.The
bines with the cylinderhead cooling wateroutlet passage. by-pass passage is completely closed as the temperature
The thermostat valve is closed while the fresh water nses.
0000404136r 000040A1361
Chapler 8 Fresh Water Cooling S1'stcm

Chapler 8 Fresh Water Cooling Syslem 6. Thermoslal
SM/GM(FXCTHM(F)(C)
6. Themostst sM/GM(F)(CIHM(F)(c)
6.3. lnspection
(3) In general.insJect the thermoqtatafte( evgru5q0 hours
of ooeration.However,alwaysInspecln wnenthe c@1.
6-Z Construction (1) Remove the cooling waier outlet connection at the lop
ing water temperaturehas risen abnormallyand when
A wax-pellettype thermostatis used for this engine'The the cooling water rises, the wax melts and its volume ex- of the fresh water pump mounting bracket and take oui
pands. The valve is opened or closed by these variationsin whitesmokeis emittedlora longperiodof time atterthe
'wax-pellet"type is the descriPtiongivento a quantityot the thermostat. enginestarts.
wax l; the shapeol a smallpellet.Whenthe temperature of volume. Remove all deDosits and rust, check functioning and in- (4) R€placethe thermo6tat wt|en it has been in use for a
spect parts. Replace il performance has deleriorated or year,or after every2000hours of op€ration.
if the spring or other parts are excessively coroded,
Part No. code of themtal 121750,$8m
deformed or otherwise unsuitable.
C@ling water outlel coon*tion
Synthetic rubbel
pasege
-N-By-pass
Wh€n valv€ i9 closd When valvs is op€ned
(a Testingthe thermostat
Place the thermostatin a contalnerfilled with water.
Characteristicof Thermostat Heat the container with an electric heater- lf the ther-
ThermostatoperatingtemPerature mostat valve beginsto open when the water temp€r
ature reachesabout 71oCand becomesfully open at
Full odl tsf,D€rduo 85'C, the thermostatmay be consideredall right. lf its
{Tempeettre mroPording to 8|m behaviourdiftersmuch from the above,or if it is found
q m m l w l i tt)
to be broken,replaceit.
C@llng wale. temperature (oC)
I Fully opened llft checking

Vatve opening tempeature 7'l Il.soc lemperatlre 85oC (185oF)
(157.1tu 162.5oF1
8- 14
000040A1141
0000A041361
S1'slent
Chapter 8 Fresh ll'aler Cooling
Cooling System 8. Precaulions
Chapter 8 f 16ft ll/aler sM/cM(F)(c).HM(FXC)
ll'sIer Tcmr(dlurc S wilch sM/GM(F)(cIHM(F)(c)
2."i:""t*g
steam will escape and may cause serious injury. lf
Switch 8. Precautions removal of the filler cap is unavoidable, place a piece of
] z. CoolingWaterTemperature 8-1. Ventilator

cloth over the cap and tum the cap sloti/ly, making sure
you are in a safe position even if steam escapes.
is identicalto that The sur{ace lemp€ralure of fresh water cooled engines is

The coolingwatertemperatureswitch higher than sea water cooled engines. Therefore, if th€
8-3. Antifrceze
*J*"t"t'cooled engine in shape and dimension' (l) Use permanent type anlifreeze in the winter. Freezing of
iiitiJ
parts are replacedas the engine room is not well ventilated, engine room temper-
Lirt'".r" tr., b€ taken when aturescan riseto a point where they will adverselyin{luence
the fresh water will damage lhe heat exchanger, cylinder
operatingtemp€ralure is different' head and waterjacket.
engine performance.
iiri. can-oecnecteo by the sealcolor' (2) Antitreeze use
1) Betore adding antifreeze,clean the cooling system and
8-2. Cooling wate(
check for leaks.
(1) Fresh water
a Se|ect mixing ratio according to the following table.
Use clean soft water as cooling water. Hard water will t (cu. in)
cause calcium build-up, poor heat transmission and a -5"C -10"c -15.C -20"c -25.C -s.c
Tempe€tute
B@m lor |tesh water'c@led engine
drop in the cooling affect, resulting in ovethealing.
Mixing €tio 12"/" 2"/" 8"4 35% 40v" 44"/"
Yellow for s€ waterc@led engine
(2) Fresh water tank capacity I (cu. in)
0.64 0.84 1.U2 1 . 1 6 1 A
2GM20F 21.10 39.10 51.30 @..n 70.80 78.10
Model Capeity 1.$ 1.50
0.41 0.75 0.99
2GM20F L9{in.ol 3GM3OF 25.m ,15.80 60.() 72.@ &.m 91.50
3GM3OF 3.1@7.s\ 1.6 1-42 1.72 1.96 221
3HM35F 36.m 66.S 86.70 16.m t19.60 1?F.4
NOTE: The temperature selected in the above table should
Remo/e the cap lrom the lresh water cooler, and check be ,oC lowet than the lowest expected temperature
the water level. lf the water level is below the top of th€ in tne area.
cooling pip€, add clean soft waler up to the iron Plate at NOTE: Check the mixing ratio caretully, especially when
the bottom of the tiller. using ptemi xed coolant-
ll water is added up to the mouth ol the tresh water tank, 3) Tighten the draincock and fill the cooling system.Then,
Parls 6de about 50cc of waler will overflow trom the filler im- run the engine for approx. 5 to 30 manutesto make sure
lff peature apeity Ft6oo€iift lndi€tim @ld
Curst mediately after the engine is started. This is normal, and the solution is well mixed.
Wtthin 60 sc. Gr€o is caused by the increase in the volume of the water as
88"C(l87.F) orhigher DC 12V 1A
95.c(20F193'F) its temperalure rises. lf the waler filler cap is removed
after the engine has been stopped and allowed to cool'
the water level will be 2-3cm from the top of the liller.
This is also normal, and is caused by lhe overflow of the
unnecessary water as lhe temperature of the water
nses.
(3) Cooling water(fresh wateo level check

Check the level of the cooling water (fresh wateo before
daily operation. A low cooling water level can cause in-
sufficient pump discharge and the accumulation ol
scale in the heat exchanger.
(4) Cooling water leakage checkduring operation
Although checking lor water and oil leakage during
operation is generally necessary, check for fresh water
leakage with special care.
Fresh water leakage is directly related to seizing of the
engine.
(5) Fresh water replacement
Replace water eyery 500 hours. Always use an anti-rust NOrE:Some antilreze solutionswill conodealuminum'
agent. Checkcaretullybetore use-
To drain the water, open ihe cooling water drain cock NOTE:Whenantilreezeprctectionis no longernecessary,
and remove the water filler cap. lf the filler.cap is not drain wateL ltush cooting sYstemand reliil with
removed, a vacuum will be created in the water iacket trcshwater.
and not all the water will be drained.
(6) Removing the filler cap
Do not attempt to remove the water filler cap at the top
of the lresh waler tank while the engine is running, or
while the engine is still hot after il has been stopped;
8 -1 7
Pr i n tcd i n J@a n
0000A0A1361 0000A0A1361
Systenr
Chapter 8 Fresh Walet Coofrng
E. Prectulions sM/GM(F)(clHM(F)(c)
8-4" Rust Inhibitor

Inhlbitot musl be
When the fresh water ls changed,a rust
fu"d to th" nt," *aterto preventrusting'
Rust inhibitor Freshwater = 1 : 10
fill with properrusl
Flusn 6ling systemwlth fresh water'
i.iiuit"t top-upcoolingsystemwith treshwater'
"no-tnin
CHAPTER9
MODIFYING
THECOOLINGSYSTEM
3. Asmbling moditiqt Parts
to ttF FGh Wats€oded EngiG . . .
4. Cautifis Whenthe E.€|re is tnstalledInb€rd -. . . . . . -. ..' 912
8-5.Kling theenglm whsn stopplng

frrtn'm'le|l' dler
#il llb tre engim lor |.rf,lffitc'
ffi; ptrot ti s.Pgit'g' 8€ sr€.to ido he ry
Ed*, ;*ury oo{w r*opplno stop ttp engin€orr
tf the
iJ-rI* itU temperaturetus dropp€d sufiicientty-'.
Jtoin" f" while hot' tt|e hot ft€sh waler will cause
;#i;;d; "topp"O the rvaterIn tt€ heat exctungpr pipe to
"f
i"l, il',i"r"g ; hrild-up of calclum deposits in the pipe and
adtop in the coollngaffect
&6. Cbanlng tho hsatsxcfiangprlube

the tresh water
It the h€at exchang€rtube thtough which
iid';;;;lretn€lv dirtv;the coollns et{ect will
d€teriorale. tT
iiil;lw. waming lamp lights periodicallv.'tr".
linJr"-" i=.^ til"d output, ttp tube in the t(esh
*ii* t""r with "t,n"a cl€anlng agent atd then flush the ac'
"1""n
trom
c|i.uLt* o"r" producedby cooling th€ lresh water
the tubo.
8-18 00qlA0Al36r
0000A04136r
Chaptu 9 Modilyine The Cooling System

I.Gmqal sM/GM(FXCIHM(FXC)
1.General
t.'1. Dl|€ctsoawats'cooled engineandlr€sh water'
cooledenglm
Engine models 2GM20, 3GM3o and 3HM35 are sea water-
cooled, and models 2GM20F, 3GM3OF and 3HM35F are
fresh water-cooled.
The main parts ot bolh sea water-cooled and fresh water-
cooled engines are the same; only the cooling systems are
different. Sea water-cooled engines can therefore be
modified into tresh water cooling by the special parts kit
prepared by YANMAR for this modilication.
1.2 todillcallon method

When modifying a seswatertooled engine into a lresh
watercooled engine, follow th€ sequencedescribedin
Section2.
l-3. T€6dng a modlfted onghe

Any engine modified as a fresh water€ooled engine must
Oe gi\renan op€rating test (running)to check tor leakage-
This test shall be madebefo{edelivery.
1.4.warrfity
Engines rnoditied as frcsh wat€rcool€d engines ar€ not
cor€rcd bythe generalwananty.
1-5.Ktt for modiffcaton into a lresh waler-cooled

englne
The kits tor modification into a fresh water-cooledengine
ditteraccordingto the enginemodel.
when odering ihe fi|odlffilon kit state the tolloi,t/ing
cod€ number.
V-beltand oths parts A$l
/VOIESi O oarts m arked are those i n clu ded in t h e mod i f ic a'

tion kit (necessary fot moditication).
- parts ma*ed are those not included in the kit
(u n necessary tor modif ication ).
'O pads marked are those which ditter according
to the engine model (not interchangeable)-
0000404136r
Chapter 9 Modilying The Coolittg Syslem

Systcm
Chanler 9 Modilying The Cooling 2. Dkassembly oJ Sea l(ater-Coolcd Engine
En&ine SM/GM(F)(C).HM(F)(C)
2- dkassembly olsea Water{ooled sM/GM(F)(c)'HM(F)(C)
2-4. Remove the fuel filter (2GM20) 2-8. Remove the cooling water pip€
2. Disassembly engine
of seawater'Gooled For models 3GM30 and 3HM35, the f ilter may be removedas
assembledto the exhausl manilold.
Removethe CSW hose between the CSW pump and by.
passmetaltitting.
Note: CSW = Cooling Sea Water
2-1.Drainth€ coolingseawaler CFW = Cooling Fresh wate( 2-5. Remove the remote control bracket (2GM20) By-pass melal fitting
Locations WaterDrainPlugs
of Cooling For models 3GM30and 3HM35, the bracket may be removed
2GM2O 3GM30 3HM35 as assebledon the exhaust manitold.
o o
Cvindq bl@k (lntakeside) (Exha6t sirje) (Exhaust
side) 2-6. Remove the mixing elbow (2GM20)
For models 3GM30 and 3HM35 the elbow may be removed
Cmling mter o
pump Ethausl manifold as assembledon the exhaust manifold.
Exhausl
|mitold 2.7 Remove the exhaust manilold (3GM3O,3HM35)
(1)For models 3GM30 and 3HM35, the exhaust manifold
may be removed with the fuel filter, remote control
bracket and mixing elbow assembled on the exhaust
manifold. CSW ho*
C@ling waterpump
(2)Remove the exhaust manifold fixing studs.
2.9. Removethe electrlcal wlrlng

Removethe wiringconnectedto the altematorand cooling
2.2. Remove the cooling water PiPe
watertemperaturesender.
bl@k (1)For modet 2GM2O,remove the CSW hose betweenthe
waleadrain plug thermostat and mixing elbow.
(2)For models 3GM30 and 3HM35, remove the CSW hose
between the thermostat and exhaust manifold.
C@llng waterPlpe
2-10.Removethe allemator
Removethe altematorcoverand V belt atterlooseningthe
altematoradiustingbolt.
The alternatorcan be more easily removedwhen removed
2.3. Remove the fuel dl PlPe as assembledon the thermostatbrackel.
(1)Removethe fuel pipe betweenthe oil filter and fuel
Pump.
(2)Removethe fuel pipebetweenthe fuel feedpumpand
fuel filter.
:H\
H)
S€waierpump
9-3
9-2
0000.{0Al36l 00004041361
Chonter 9 Modifying The Cooling Systetn
'':;If
i:tr#:xf "'w"#xil;'#,-. sM/GM(FXC)'HM(F)(c)
2. iisrcsembly o! Sea |Vater-Cooled Engine SM/GM(F)(CTHM(FfrCI
2.16.Removethe intake silencer 2.19. Removethe lifting hook at lhe Garorlhe

cover 2-14.Removethe cloling water by'pass conneclion engine togethet with the t€ar cylindor head
thethermostat
2-11.Remove (1)Removethe coolingwaterby'passmetalfitting (L-type @ver
(1)Loosenthe crampof the coolingwater hose between joint).
"'ii"-ovft" metaifitting and thermostatat the bv-pass l n ta ke si l e n ce r
metaltittingside'
Liltlng hook
Themostal covea
.pass m€tal fittino
screwed into the

€) Enracl the by-Pass connection 2-17.Removelhe luel hQh pressure pipe
cylinderblocK
€) Removethe thermostatcover'
By-pa$conn@tion
Themoslatcovs
2-18.Remove the lifting hook at the tront ol the

engine (3GM30,3HM35)
2-12Remove thehighPressure plpeanti'swing 2-15.Removeth€ CSWPumP Lifiing hook

-'- ft;iiini"s trdmitre ttrermostatbrac*el'
2.13.R€movethe thomostat bracket J
ihe coolingwalertemperature sensorandalter (
Remove
bracket'
nator as assembled on the thermostal
\
Thomostai
:
,l
I 9-5
I 9-{
00004041361
;t 0000A0A1361
6]i
Chaptcr 9 tltodilying The Coolittg S1'stctn

System
Chapter 9 Moddying The Cmling 3. Assembling Modirted Puls lo lhe Frcsh
H ater4'oolcd Engine
Engine SM/GM(F)(CIHM(FXC)
i. tiitux^bty oJ SealloterCooled SM/GM(F)(CIHM(F)(C)
The disassembly necessary to modify

a sea water-cooled
engine is completed with
this step. The removed parts, and the appearance
engine atterdisassembly are shown below:
of th€
3. Assemblingmodifiedparts to the fresh water-
engine into a lresh water-cooled
cooledengine
Remov€d Pads
@ Thepartsrequiredto modifya seawater-cooled
@*'
engineto a freshwater-cooled
shownbelow.
engineareas
FoE
/-*ffip
r lili
qnrauuu
f r--1 t:)
bJ,
e's ;;"
@3 g '
r llll.,
utfl
@qfl
k_j\J
3.1. Assemble the rear cy'inder head clverlogelher 3.3. Ass€mble tft€ fuel Injectlon tube
Model' 3GM30)
Appearanc€ ot mgine aller disassembly (ExamPle with the rearlifting hook.
NOTE U* the speclalhlgh pressurepipe lot a lrcsh water.

NOT* Newpacking should be used. cooled engine. The shapeand dimensionsare dif-
Apply ThreebondNo.1on both surfa@sot packing. fei€,il from thosefor e seawateroooled engine.
3-2. Assemble the lront lifting hook (3GM3{1,3HM35) 3-4. Assemble the inlake sllencel
Thehookon themodel2GM20is in a positionnotaffectedby
the moditication.
-)
I
Llftlng h@k
NOTE: Use the special litting hook tor the tresh water NOTE: The intake sitencet is the same tor both the lrcsh
cooled engine. water and sea water'cooled engines.
9€
0000A0A1361 0000A041361
Chapter 9 Modilying The Cnling System

Chaplu 9 Moddying The Cooling Syslem
Engine 3. Assembling Modilied Pails lo the Fresh Waler4nled Engine
i. ,lsrembling ModiJied Ports lo lhe Fr6h Woter-Coofud sM/GM(F)(c).HM(F)(C) sM/GM(F)(c).HM(FNC)
(2) Connect the CFW hose between the CFW pump and 3.11.Assemble the heal exchanger 3.13.Ass€mblethe fuel oll pipe
3-5.Assemblo tho CFW jolnt to the cylinder block
heat exchanger by connecling it to the CFW pump: (1) Connect the fuel oil pipe between the fuel feed pump
ApptyThreebondNo.20tothe threadsandscrew. tighten the hose clamp slightly. The hose clamp will be and f uel injectionpump.
securely tightened a{tel the heal exchanger is assembl' (2) Connect the fuel oil pipe between the fuel lilter and fuel
ed. iniection pump.
Bolt forC.W
F uel oil giDe
daaincock
For model 3GMD, connect the pipes after removing the CW

drain cock bolt at the boltom of the heat exchanger to pre-
3-6.Assembl€th€ CFWpumpassembly vent the pipe lrom jamming against the fuel feed pump. 3.14.Assemble the CFW hose
Ass€mbleatterapplying No-4to bothsurfaces
Threebond
3-9. Assemble the CSW PumP Conneclthe CFWhose betweenthe CFWpumpand heal
of the packing.
exchangerandtighlenthe hoseclamp.
Se watd pu mp daiv€
v'belt pull€y
cFok Bhafi v-6qtt pufley
tenrng tor 2 -2.5 - m ( 1 4 .5- l8 ft- lb NOT* Newgasketpacking mustbe used.
Vielt teckm 5tu7mm
ai"-rreo-*iina tae of loks @ h.) | p.ts0s - o:zso in.1 que | 2-2.5 3-15.Assemble the CSW hose
3-7. Assomble th€ thermosla{ and thermoolat @vet
NOTE ApplyThreebondNo.1to both suilees ol the pack- Connectlh€ CSW hose b€tween the qSW pump and heat
3.'10.Insertthe stud bdl forfitting the heat 3-12Assemblethetuelfilte. exchangerandtightenlhe hoseclamp.
lng. exchangef
3.8. Ass€mbl€ th€ CFI|Yhose ApplyThree bond2SMto thethreads.
(1)Connect the CFW hose between the CFW pump and
cylinderblock and tlghten the hose clamp. H@texchangel
Oe
CSWhose -
NOTE: fhe same tuel lilter is used as tor a sea watel

10.
cooled engine.
00004041361 000040A1361
Chonter 9 Itodilying Thc Culhtg S1'stem

H aler-Cooled Enginc
3. issembting Modilied Puts to tha Fre;h sM/GM(F)(C/HM(Ftc)
Chanter 9 Modtlying The Cooling System
's."irri^tti"s Engine S]IT/ GM(F )(C ).H M(F )(C )
l;ioaifieanarc o ne rresn WaterCooled
3-22 Assemble the Gmote control bracket'
3-19.Assemble th€ altemator
3-l6.Assomble the mlxing elbow
Fresh waterPUmP ddve PUlleY
o@
Adjustingbolr
(V'belttensaonl
be used'
NOqE: New gasket packing musl
tt'eff#rffieffi:?$tlE;H
7conneci
3-1
the hoseclamP- Crsk shaftV-belt PulleY The sea water-cooled engine has now b€en moditied as a
f resh water{ooled engine-
3-20.Assemblethe coolingwateriemPeratue
sensor
Firstfit thecoolingwatertemperaturesenderto theCFW
o pumpandthenassembl€ bothunitstogether'
pull€y
3-1&Assomblethe CFWpumpV'belt
NOTE:AWty ThteebondNo'1 to the threads'
3-21. Contrect electrlcal wirlng

coollng
Connectthe electricalwiringsto the altemaiorano
watertemp€ature sender.
C@ling water lempe€ture sonogr
0000A04t36r
00004041361
g ModiJying The Cooling Systetn

Clnpter
Inbourd
i Foutiorc Whin the Engine is Inslalled sM/GM(F)(c)'HM(F)(C)
4. cautionswhenthe engineis installedinboard

(11ln the case of a fresh water'cooled engine, a fresh water
'" be installed' For the installationmethod'
"rdir"t.r"t
refer to the "lnstallation ol the subtank" section'
(2) A seawaler drain cock and the fresh water drain plug are
be
orovided in the heat exchanger; a drain hose should
litted to each Plug. CHAPTER10
REDUCTION
GEAR
AND REVERSING
[A] For Engine Models 1GM10.2GM20(F) and 3GM30{F)
Co6rruction. ...10-1
Shitring Device ...10-7
Insp<lron and Seruicing . . . 10'14
DrssFnbly ...1019
Feasembly . . . 10-24
[B] For Model 3GM35(FI

in a 10-29
(3) There is no problem when the engine is installed 1. Const'uction.
r 0-33
2. Installalion
newly built ship, but when an engine in use is modified' 3. Operationand Maintenance 10-34
pipinq is
care must be taken becausethe cooling water 4. Insp€tioa and Servicing. 10-35
different. 5. Diwmbly 1040
6. ReNmblY 1044
3HM35- 3HM35F
lcl Marire G€r Models KM2P, KM3P and KM3V
O24/17 = O24/ t7 for EngineModels 1GMlO.2CM2O{FI and 3GM30(F)
3'[%1ff dia
omol outerdiarnner t. ConstMtion. . . 10-50
c@k to be uss 2. Shifting Ddice . . 10,56
lcp€tion and Sefricing . . . . 10$1
NOTE:KingstoncocksareoPtional' 4. Disassbly .. r0 6 8
5. Rffibly -. 10-73
1GM1O,2GM2O,3GM3O
ID I Vdri€ Gear, Model KM3V
l. Coctruction.
2. Sp6'fi€tions
Pin diameterof mixing elbow is differenl 3. Peer Transmision System.
2GM2O .2GM2OF Cooling System (Sea-waterCooling Engine).
5. Piping Diagrams. . . .
(44mm) (51mm) Inspelioo and Servicing
(1.7323in.)(2.0079in.) 7. Shim Adiustment for Vdrive Gear Shaft,
and 8&kl6h Adjustment lor Vdrive Gear Shaft and
Driw Gear. ' - 1C!92
Oissgbly - 10'94
9. BeMblv ''' 10'97
Printed in Jopan
0000A0A136r
0000A0AI361
Chapter I0 Reduction and Revcrsing Geot

1. Conslruclion
SM/GM(F)(CIHM(FXC)
lA] Forenginemodels
1c M10, 2GM20(F)and3GIWO(F)
1. Construction
1.1 Construclion
This clutch is a cone-type, mechanicallyoperated clutch. This preventsgearnoise due to torsionalvibrationas
When the drive cone (which is connecled tothe output shaft well as absorbingshockwhenengaging.
by the lead spline) is moved {oruard or backward, its taper
contacts with the large gear and transfers power to the
output shaft.
Stage aftangemenl
The construciton is simple when compared with other types
of clulch and it serues to reduce the number of components, Absorbs shock
making tor a lighter, more compact unit which can be wnen engagrng
operated smoothly. Although it is small, the powertransmis-
sion efficiency is high even under a heavyload. lts durability
is high and it is reliableas high grade materialsare usd lor
the shaft and gear,and a taper rollerbearingis incorporated.
Power transmission is smoolh as connection with the engine
is made through the damper disc.
.The drive cone is made lrom sDecial aluminum bronze
whlch has both higher wear-resislance and durability. The
drive cone is connected with the output shaft through the
thre3d spline. The taperangle, diameter of the drive cone,
twist angle, and diameter of the thread spline, are design-
ed to give lhe greatest efficiency, thus ensuring that the
drive cone can be readily engaged or disengaged. .The oil level dipstick hole doubles as a brealher in addi.
.Helical gears are used for greater strenglh. The inter- tion to being the oil supply port. There is a small
mediate shaft is supported at 2 points to reduce deflec- clearance between the dipstick and the inside of the
tion and gear noise. diostick tube which functions as a breather.
.The clutch case, mounting flange and side cover are . The engagement between the cone and the large gearcan
made from an aluminum alloy of special composition to be maintained even when the load on the oropeller is zero-
reduce weight. ll is also anticorrosive against seawater. This is done by the action ot the notch and spring.iointon
. As the damperdisc is fitted lo the outpul shafl, powercan the operation lever in lhe operation device.
be transmitted smoothly. For the damper disc, springs of The oDeration device can still be used without adiustang
diflerent strengths are used so that 1wo stages of torque the remote operation device when the con€ is intemally
and lwist angle are applied. That is, in the lirst stage, only worn, because it is compensated for by the spring ioint-
the weak spring is used, and the strong spring comes inlo . ln order lo reduce lriction on the operation lever shaft, a
action fora torque higher than a predetermined value. needle bearing is used to allow smooth operation.
1 0 -1
0000A0A136r
and Reversing Gear

Chapter I0 Reduction
Reversing Gear I. Conslruction
Chapler I0 Reduction and SM/GM(F)(CTHM(FXC)
l. Condrudton SM/CM(F)(CTHM(FXC)
1.3 Power transmission sYstem
1-2 KM3.A
1.3.1Arangementof shaflsandgears
Model 3GM30(F)
For €ngine frPdels oaward small gear of inPUt shall
Comtilt resn with *rvo one clutch (wet tYPe)
Clutch 3.20
Reverse small gear of inp0t shatt
Fopetter stratt rpm (Foruard) rpm

Cpunter-cl&*wis, viewedfrom sttr
Clc-kwise, viewed lrom stsn
Oirstion of rctation viewed from stm
Couni4.clockwi*,
gear ot oulpul shan
levercontrol
lntermediate shalt
Mre,33-C
Rsmte contol YANMARmade,stddard rcGsory
olmmm F.93)
o78mm (3.0f)
Outout stEft flPling
4-o105mm (4-@0.41")
small gear of inPUt shaft
Left side. view€d lrm stsn
Position ot shift le€r
SAE#101/-30,C€ class
Lubri€ting oil
small g€at
gearboxes'
ModelsKM2CandKM3Areductionandreverse
ol input shati
stratts gears are the same except for the following Shall adangemenl lntem€diate shatt
items: "nO viewed lrom lhe stem
. No.of oearteeth(derivesdifferentgearratios)'
. oGt"ni" o.t**n bearingsfor inputandoutputstufts'
. Clutchcase,mountingflange.
Outpul shatt
Forward large
Revea* large oear
1-32Reductbnralio
Forward
No. of teth No. o{ teth Redrctim ntio Zoflzif
Model of tomard smll ged Zif ot fwnd hrge gs Zof
24
9121 = L@
KM2.C
18 58
a 60
KM}A
n 64
Reverse
No. of teth No. of teth No. of leln R€i/wlion alk'zjlzi(dddzi
Model of €vNSmll gsZir of inietrn€diate shalt g€r Zi of rwffi hrge gBr Zdr
55 55/18 = 3.06
KM2-C 18 fr
m 60/tg = 316
KM}A 19 a
i
I 10-3
I
I
I 00U":\0Al36l
0000A04136t
!n*,.
and Revasing Gear

Chapter I0 Reduclion
Revasing Gear I. Conslruclion
Chapter I0 Reduction utd sM/GM(F)(c).HM(FNC)
SM/GM(FXC).HM(FXC)
L Construclion
1-4 D6wing
1.3.3 Pouer transmissbn ro{dine-Fon"atd
E,&
;_M
E -g
's E\i -
!
p
P
Oltput shalt coupling

P
1-&4 Powcflransmbsion routire- Re{€ts€
Ff
I
z !
E ! <3
:6 5z
e\ ;\ !
[3::'o'"'n" \
2
lntemediate gear
d\
nrc targe gat
Fw..d laro€ 9€r I
0000A0A1361 0000A0Ar361
Chopler I0 Reduction and Revetsing Gear

I. Conslruction
SM/GM(F)(CTHM(FXC)
:=-:
52.1 MOUNTINGFLANGE
52-2 BOLTM8 x 25
52-3 WASH€R 8
52.4 PARALLELPIN 10 X 16
52,5 DAMP€RDISK
53-1 CLUTCHHOUSING
56-1 53-2 SrD€ COVER
53-3 0.RrNG60-S
56-20 5+4 BOLTM8x20
56-19 53.5 WASH€R8
53,6 SH|M SET
56,18\ 53,10SHtM SET
56 19 53-15DTPST|CK
53-16PACKTNG 16
56-21 53'17 LABEL, foqard
53'18 LABEL, reveGe
53'19 LAB€L, clutch model
56,6- 53.20 RIV€T
53-21 orl SEAL SC25408
56-5 53-22 0tL SEAL MHSA34448
16 53-23 0tL SEAL SCm305
56-4
53-r5 53.24PLUGMIO
53-2
.19 54.1 ROLLER B€ARING #32005
54-2 INPUTSHAFT
'4 54,3 INTERMEOIAT€SHAFT
54.{ G€AR
56.3 5,{-5 NEEDLE 8€ARING #K162213
54.6 WASH€R
53,23 54-7 o-R|NG 12-S
56-t0
5$1 OUTPUTSHAFT
5'2 DRIVECONE
53-3 55-3 FORWAROLARGE GEAR
55-,1 R€VERSELARGE GEAR
56-8 55.5 BEARINGINNER RACE
55-6 NEEDL€ BEARING #K3035'I7
55.7 COLLAR
55-8 COLLAR
5'9 LOCK NUT
o6oo666 6 66ory 6:
55.10 OUTruT SHAFT COUPLING
5t1 1 o.R|NG 18-P
5t12 ROLL€R BEARING #07087/07204
55-13PtN
55-14 COLLAR
56,1 SHIFT LEVER

56-2 BOLT M8 x 25
5S3 SHAFT
56-4 PtN
56-5 SPRING
56-6 SCREW M10 x 10
587 PLUGMlO
5&8 PACKING 10
56.9 SHIFTER
56..10NEEDLE B€ARING #HK3O26
56.12 R€MOTE CONTROL CONNECTOR
56-13SPRTNG
56.14 REIAINER
56-15C|RCLTP
56-16CTRCL|P
56.17HOLDER
56-18 CONNECTOR
56-19 WASHER6
56.20 LOCK NUT M6
56-21 COI-TERPIN 2.5 x 15
10-6
0000A0A1
361
Chapler I0 Reduclion and Revusing Gear

2. Shilting Device
SM/GM(FXC).HM(FXC)
2, ShiftingDevice
2.1 Construction ol shitlir€ device
shllr
shaft
On model KM3A, a mark is engmved on

the ooposlt€sld€ of lhe shift lever.
10-7
0000A0A1361
..;.
t':i!:".
Chapter I0 Reduelion utd Reversing Geu
Chapter 10 Reduclion md Rcversing Gear 2. Shifling Device SM/GM(FXC).IIM(FXC)
2. Shilting Device SM/GM(F)(CIHM(F)(C)
By pushing ihe remote control ioint the holder moves, and the holder is moved by the spring reaction so that the shlft
the shift lever and the shift lever shatt also move to leveris pushed lorward.
l e ve r
- Sh i ft
disengage the notch from the neutral posilion. By the aclions of the notch spring and spring iolnt, the
shiftermaintains pressure on the drive cone.
Tolalslrckeol remotecontrol L,
Engaging posilion for lo(ward
By means of the shift lever shaft luming force which ls
Remote control wlrq caused by the spring in the ioint and the notch (A), the
Sprin9 joint shifter is moved dislance L' and engagement is complete.
Pressure is maintained on the drive cone after engage-
menL
2-22 Engagemeni lrcm forward lo neulral

shift shilr
lever shalt - l e ve r sh a l l Engagement for reverse is the same as lor forward, that is,
retum to the neutral position and move the remote control
ioint foruard
targe geaf
B@u$ of distance L.
{1} W€r amunt of lhe cone,
(2) Increased play in lhe remote
conkol wite, Notch (A)
{3) Fluctualion ol remote control
wire length when conneling,
@n be compen$led for.
Neutral position
The shift lever is kept securely in the neutral position by Forced mo{ing po€ition
notches (A) and (B). when the shift leveris forciblymovedthroughdislanceL'
the shifter movesdistancet,. In this position, the drive
Changing the power transmitting direction lo forward is ex' cone has not yet madecontact.However,notches(A)and
olained below. (B) are disengagedfrom the neutral notch slot, and notch
When oushed loruard, the remote control joint moves the (A)is positionedon the tapercdsurface.
spring retainers.The spring is compressed until the two
spring retainerstouch. The shift lever shaft is tumed by the movementol the
remolecontroljoint. Whenthe notch touchesthe tapered
Theshift levershaftis supportedby the sidecoverin which part of the forwardsettingslot, it is Pushedby the notch Engnging position for lofwald
it rotates.Aroundlhe shift levershaft, there are slols which springforce and tums the shift leverforward.At the same The drivecone,which is movedby the springin the ioint
engagethe notch in order to control transmissionof rotary time, as the remotecontrol ioint is lixed by the two re- and notch (A), is kept under force uniil distance L
power either lorward or reverse,or to keep it in neutral The becomeszero even when the cone is wom.
tainersof the springioint beingin contactwith eachother,
notch etrgag€seachstot by the force of the notch spring'
The shift;r is set at the end of the shift levershaft eccentric
to the shafl cenler line and tt|e angular movementof the
shift shafl (.e. rotation).The shifter ls moved torward or
backwardalong the line of the output shafl and this in tum
movestt|e ddveconeloruard or backward.
The springloint containsa springand 2 springreiainersin
the holder,and the remotecontrol ioint is connectedto th€
spring retainersso that it can slide a fixed distance.By
pushingor pullingthe remotecontrolioint with the holder
fixed. the remotecontrolioint movesto a positionwhere
the two spring retainerstouch-
2-2 Action of lhe shifiing device

2-21 Chs€hglrcm n€utrallo to(ward
The rehtlonshipbetweenthe springioint and the notch is
as shown in the followingfigure,and the two spring re'
L' position of remole op€ralion slroke
tainers arethe maximumdistanceaoart.
The spring in the spring joint is compressed, but the
shift leverdoes not move.
000040A1361 0000A0A1361
Chapter I0 Reduclion and Reversing Gear Chapler l0 Reduction md Revcrsing Gear

2. Shitting Device 2. ShiJting Device
sM/GM(F)(CIHM(F)(c) sM/GM(F)(CIHM(F)(C)
I
2-3 Clutch shifting force (1)Shift the slot into the drivecone so that it extends as far (4) Fit the shitt lever locating iig into the holes of the side
Position ol remote conlrol slroke ,'
as the center of the two large gears. coverthrough the 1smm dia. holes as shown.
The shift lever do€s not move although the spring in the (referencevalue)[Engineat 1000rpm]
ioint is compressed. The cone is kept in contact due to the
transmissionol lorque when idling.
Remotecontrol handle
positionat 170mm
Remotecontroltoial slroke (cablelength,5m) dia. (0-5900in.) hole
6- 8k S
(132 17.6lbs)
-
Disengaging stroke:
(1) At the initial stage of usage, the stroke may be heavier
than the above value, bul the stroke gels light when
adooled.
(2) lt varies according 10the idling sp€d of the engine The
lower the rotation becomes, the lighter the stroke
becomes.
(3)The lcnger the remote control cable, the more bent it l5mm dia. (0.5906in.) hole
becomes,and the smallerthebending radius,the heavier
the disengaging stroke.
[33-C minimum bending radius 203 2mm(8")]
(4)When the spring joint is attached to the shift lever at
52mm distance from the center of the lever shatt' the Shilt lever locating iig (optioEl)
disengaging stroke will be 150,6heavier then when (2) Set lhe shift lever at neutral position. (Note that the
attached at a distance ol 60mm. shift lever can be rotated 3600 when it is removed lrom
case.) The neutral position is the position where the
(5) Put the shift lever in neutral and check that the tip of
2-4Adjuslment shiftercomes downwardswhenthe plug is below.When
The shift lever is forcibly moved through distance ,', over' lhe plug is at the bottom, in the neutral position the the lever isaligned with holeAof the jig. lt is not,loosen
When the clutch side cover is removed, make the following the lixing bolt on the shift lever, align it, lhen tighten the
coming light friction due to the transmitting torque and the shifter ooints downwards.
drive cone separates. Notch (A) disenga.ges and notch (8) adiustments at the time of reassembly. bolt. Take careto leave approximately 0.5mm (0.0197in.)
en9ages- clearance between the shift lever and the side cover.
Shilter selting hole
(3) Put the shifter of the side cover at bottom, and set the
shifter to the ditch in ihe drive cone at the center of the Clea6nce
forward and reverse gears. Do not move the drive cone appror
Th€ shift lever is retumed to neutral by the tuming lorce from the center of the two gears at the time of the
generaled on the shift lever shaft by the spring in the joint reassembly. (Note that 2mm diameter clearance is
and notch (B). orovided in the holes ol the side cover, and the gear
case.) This is for adjustinglhe diJferencebetween the
engaging, and disengagingstrokes.)
1 0 - lo 10-11
0000A0A1361
in Jry^
Pri^ted
0000404r361
Geu
Chapler I0 Reduction and Reversing
Geor
Chapter I0 Reduction and Revercing 2. ShiJting Device SM/GM(FXCTHM(FXC)
2. Shilling Device sM/GM(F)(C)'HM(F)(c)
2-6 Cautions
2-5 Inspect for the following points
(6) Move the shift leverfoMard or back and visuallycheck (11) Allhough these distances may be equal both for (1)Alwrys stop the enginewhenattaching,adiusting'and
{to de insPecied every 2'3 months}
lever foruard and reverse, there might be some discrepancy
the respeclivedistancesbetweenlhe tip of the shift (1) Looseness at the connection of lhe spring ioint and the insPecting.
between holes B and C due lo difference in machining' (2)When conductinginspectionimmediatelyafter stopp-
and holes B and C. Also check the difference between remote control cable.
However, il the discrepancy is the same for forward ing the engine, do not touch the clutch' Tt|e dl
these distances. (z) t-ooieness of the atlaching nul of the spring ioint and
(7) When these two distances are not equal, slightly and leverse there is no Problem'
the shift lever. temperatureis often raised to aroundSoC (194oR.
lms€n the four setting bolts of ihe side cover so that it (3) To make sure that the value of A, and B is not "Zero" at 1Q Half-clutchoperationis not Possiblewith this design
' '
can be moved a little in the shaft direction'
'-'
tne engaging position of the remote control lever'
lf the and construction.Do not use with the shift l€verhallway
€) When the distance is largerthan nomal
in the {orward
value i! 'iero;', untighten the bolt of the side cover'
and to the engagedPosition-
setting, move the side cover slightly to the engine side' adiusl according to the sleps described in 2-4' (4)Setthe idlingenginespeedat between750and800rpm'
'uiote:
When the cone for the forward side gets worn' the value rne dua! (Two)levet rcmote control device cannot
Distance is smaller
ol I is decreased, and for reverse side, the value o{
A is be used.
than normal system
decreased. When the play in the remote control
is increased, both values ol A and B are decreased'
Oi scr e p a n ce
Distance is latger
than normal
To speed control
in the reverse
B) Whenthe distanceis largerthan normal
setting,movethe side cover slightly to the pfopeller
si.le.
Discrepance
Oistance is larger than normal
Distance is smallel
than normal
(12) Install the spring ioint on the shift lever' To soeed conlaol
(Only when it is dismantled in the boat)'
NOif: when the shitt device is removed in the boat'
engine mustalwaYs be stoPqed'
(10) When the distances are equal betweenneutraland

forward and neutral and reversetighlen the setting
bolts ol the side cover.
lo-12
00004041361 0000A0A136I
Chapter I0 Reduclion and Reversing Geu
Chapter I0 Reduction and Reversing Geu 3. Irrspection and Seruicing
3. Inspection md Servicing SM/GM(F)(CIHM(FXC)
sM/GM(F)(c).HM(F)(C)
mm (in.)
3. Inspection
and Servicing Oimmsions I
KM2-C
Stedard dimmsioc
24.4 tu 24.7 0.9606 tu 0.9724)
Umited dimsiore
24.1p.9488)
KMSA 29.9tu 302 (1.122 tu 1.18S) 29.6(1.16t1)
3-l Clutch case (2) Forward/reverse gear needle bearing.
NOTE: When dismantled, the forward or rcverse direction
(1) Check the clutch case with a test hammer for cracking. When an abnormal sound is produced at the needle of thedrive cone must be clearlv identified.
Perform a colorcheck when required. bearing, visually inspect the rollers; replace the bearing
lf the case is cracked. reolace it. if the rollers are faulty. (4) Measure the dimension of the slot width ol the drive
(2) Check for staining on the inside surface of the bearing
cone, and replace the cone when lhe dimension is over
section.
the soecified limit.
Also, measure the inside diameterof the case.
Replace the case if it is wom beyond the wear limit.
3.2Bea.ing
(1) Rusting and damage.
lf the bearing is rusted or lhe taper roller relainer is 3-5 Drive cone
damaged, replace the bearing. (1)Visually inspect that part of the surface lhat comes into
(2) Make sure lhat the bearings rotate smoothly. contact with the circumterentialtriangular slot to check
It rotation is not smooth, il there is any binding, or if any for signs of scoring, overheating or wear. lf deep scoring
Slol wldth
abnormal sound ls evident, replace the bearing. or signs ot overheating are found, replace the mne.
Standarddi|Msbns Standafd derc Allow$bdee@ Umiteddeffi
3-3Gear 8*tt &3
Slot wlJth ot drive @re p3268)
Check the surface, tooth face conditions and backlash of tu031e0
(03150 0.15 03 05
each gear. Replace any derective part. - 0.0118)
P.005s tu
(1) Tooth surJace wear. Shittorwbth 8x* p.0236)
7.7
O3O71tu 030S0) o3031)
Check lhe looth surface for pitching, abnormal wear,
dents, and cracks. Repair lightly damagdd gears and
replace heavily damagbd gears
(2) Tooth surtace contact.
3-6Thrustcollar
Check the tooth surface contact. The amount of tooth
surface contacl between the tooth crest and tooth flank Helical involutespline
must beal leasl 70% ol the tooth width.
(3) Backbsh. (2)Checkthe helicalinvolutesplinefor any abnormalcon-
Measure the backlash of each gear, and replace the gear ditionon the tooth surface,andrepairor replacethe part
when it is wom beyond the wearlimit. shouldany be found.
mm(in.)
(3)Measurethe amount ol wear on the taperedcontact
surfaceof the drive@ne, and replacethe cone when
lnput shaft fward gs lhe wearexceedsthe sosified limil.
and outDul shatt foryard
Inoll shafl rrc 0.06 0.'12

- 0.0047)
P.0024 tu
Intemedhte gq ar|d 0.06 0.12
- 0.@44
P.0024 tu
(fhe sre dimensiore apply to both KM2-C and KMIA)
3-4 Forwa.d and reverse large gears

(1)Contactsurfacewithdrivecone.
Visuallyinspectthe taperedsurlaceof the forwardand
reverselargegearswherethey make contact with the
driveconelo checkif anyabnormalcondilionor sign of
l 0 -1 5
10- 14
0000404136t
00004041361
Geu Chapter I0 Reduclion and Reversing Geu
Chaptu I0 Reduction ond Revuing
3. Inspection utd Servicing
3. Ircpeclion and Suvicing SM/GM(FXC}HM(F)(C)
SM/GM(FXCIHM(FXC)
(1) Visually inspect the surtace in contact with the drive
('l) Visually inspecl the sliding surface of thrust collar A or 3-9Outputshaft
cone, and replace the shifter when signs of overheating,
B to check forsigns ofoverheating, scoring, orcracks.
damage or wear are found.
Replace the collar if any abnomal condition is found.
(2) Measure the ihickness of lhrust collar A or B, and
replace it when the dimension exceeds lhe specified
limit.
{2) Measure the widlh ot the shifter, and replace it when the
wear exceeds the specified limil. Also measure lhe
diameter of the shifter shaft, and replace it when the
rl
fi+
wearexceeds the specilied limit.
*tt*
il+ s"t""" slidino *fi
sunace
IT
lt
'B'
Jl'-stiolno
-|f""*'"^,
1-_-.| n.",""o,"+ Slot width of drive cone
Shifts wfttth
Stmdard dim6sbns
8'3'
P3150 tu 03189)
8ii13
Clemrc
0.15 tu 03
0.0059 tu 0.0118)
Allowable
05
p.046)
cleame Specified
d-J
03268)
p3031)
mm (in.l
limit
ri l
Stepp€d ws Limil ttr u*
(1)Visually insp€ct the spline and the helical involute
spline,and repairor replacea part when any abnomal
conditionis loundon its surface.
Shifts shatt diarEls
O3O70- 0:X)91)
$x3!:
O3S1 -0.sxl5)
1O*8otu
0.005 0.029
-
P.0@ tu0.m11)
0.06
p.0@
995
(03s14
r0.05
Shift les shaft dianrets 03957)
Thrust @llar A, t, 0.05 p.0020) 3-10Intermediateshaft p3$7 ry oJsaq
3.112 Notch slot of shill levershaft

3-7Oil sealof outputshaft Visually insp€ct the notch slot of the shift lever shaft to
Visuallyinspecttheoil sealof theoutputshaftto checkif check for any abnormal wear or cracking, replace any
there is any damageor oil leakage;replace the seal when defective part it found.
anyabnormalconditionis found-
3{ Input shalt
3.113Notcft
levq shaft Visuatly inspect the tip of the notch to check tor wear,
daanageor detormatbn. Replacethe notch if it is found to
(1)Needleb€aringdimensions,slaining- bedelectivein anyway.
Check the surface of the roller to see whether the
needle bearing sticks or is damaged. Replace il 3-11.4Notchspdrg
necessary.
visuallyinspectt;,e notchspringto checktor any damage,
conosionor permanentset; teplacethe springwhen it is
3-11Shifting devic€
foundto bedefective.
3-11.1
Shiftet
Fe length 34mm (13iB6inJ
Spdnq coeffkrienl 0.45qq 0992 lb)
Set length 255mm (l.ofix)in)
Sliding surface
(1) Spline part.
Whenever uneven wear and/or scratches are found.
replace wilh a new part.
(a Surface ofoll seal.
lf the sealing surface of the oil seal is worn orscratched,
reolace.
10- t6 10-17
0000A041361 0000A0A1361
Gear Chapter I0 Reduction ond Reversing Geu

Chapter I0 Reduclion md Reversing
4. DisassemblY
3. InsPection md Suvicing SM/GM(F)(CIHM(FXC) SM/GM(F)(C}HM(FXC)
3-12Spdng ioint 3-13Damperdisc

4. Disassembly
4-l Dismantling the clulch (4) Remove th€ end nut and output shalt coupling.
(1) Removethe remotecontrolcable.
Remote conlrol ioinl e) Removethe clutch assemblyfrom the enginemount'
ing flange.
(1)Splinepart.
Wheneveruneven wear and/or scratchesare found,
replacewilh a newParl.
(2)Sprlng.
Whenever uneven wear and/or scratches are found,
replacewilh a newPart.
(3) Pin wear.
Wheneverunevenwear andlor scratchesare found,
replacewith a newPart.
(4)Whenevera crackor damageto the springslot is found
replacethe defectivepartwith a newone.
(3) Drainthe lubricatingoil.
Drainthe lubricatingoil by looseningthe plug at the
bottomof the clutchcase.
(1)Checkeachpartforabnormalplay,andreplaceif playis
excessive.
(awhen the movementof each part is not smooth'
measure the tension and replace as a complete unit
$/henit exceedslhe specifk# limit.
Spring scale Remot€ control iolnt Spring lolnt
(,rA NOTE:Takecareas it hasa left-handedthrcacl.
6) Removethe oil dip stickandpacking.
(6) Removethe fixing bofts on the side cover, and also
removothe shifl levershatt,shift l€verandshifter.
Strcke smm (0.1969in.1

Draln pluO
(at th€ pcitbn ol smm slroke)
t0 - 1 8
00004041361 0000404r361
Chapler I0 Reduclion and Reversint

4. Dkusembly
Geu i Chapler l0 Reduclion and Rcversing Gear
4. Disassembly
sM/GM(F)(CIHM(F)(C) SM/CM(FXCIHM(F)(C)
(7) Remove th€ bolts which secure the mounling flange to
(10) Remove the oil seal of the output shaft from the case (12)Remove the oil seal of the input shaft from the
the case body, give light taps to the left and right with a body. mountingflange.
plaslic helded hammer while supporting th<i clutch (13)Removethe outer bearingrace lrom the mounting
case with your hand, then remove the mounting flange. tlangein the samewayaswilh the casebody.
htemediate shaft
(14)Removeeachadjustingplatefromthe inputor output
shaft.
NOTE:The sameadiusting platescan be rcused when the
tollowing partsare not replaced.Whenany parl is
rcplacedhowever,re-adiustment is necessary.
4-2 Removal of the outpul shaft

(1)Takeout the reverselargegear,thrustcollarA and inner
bearingrace.
B) Take out lhe inlemediate shaft and input shaft. When Thereverselargegearmustbe withdrawnusinga pulley
laking out the intermediate shaft, place a bolt or extractecby fixingthe nut at the forwardendin avice.
spacer on the shatl hole ot the case, and drive the
shaft out by tapping it lightly.
0 1 ) Remove the outer bearing race from the case body by
using the special tool.
Mounting flange h€ded

hammel Pulley puller
Reve6e large g€r
, 4(
€) Withdrawthe oulput shaft assembt. /Y\\
(2) Loosen the calking of the forward nul and remove the
nut andsDacer.
Removelhe nut by using a torque wrench after setting
ihe outputshaftcouplingand fixingthe couplingbolt in
aYice.
Cold chisel
Outplt shafl
b€aring aa@
10-21
0000A04r36r 0000A0A1361
(.'hapler I0 Reduclion and Ret'ersing Geu
Chapler I0 Reduclion and Revtrsing ()eu 1. Disassembly
4. Disusembly SM/GM(F)(C/HM(FXC)
sM/GM(F)(clHM(F)(C)
4.4 Dismantling the side cover assembly (4) Withdraw the shift lever shafl
(4) While gripping the drive cone, tap the end ot the shaft (Shifting device)
with a plastic beaded hammer, and withdraw lhe thrust (1)Loosenthe bolt of the shift lever,and removethe shift
collar B and inner needle bearing race. A pulley extraclor leverfromthe shaft.
mav be used.
Side covea
(5) Remove the oil seal.

(6) After removing lhe calking for locking, heat the needle
(3) Place the pulley extractoragainst the end surface of the bearing portion up to about 1moc, and extract the
forward large gear, and withdraw the forward large gear, (2)Removethe slop screwlor the notchand plug,andtake needle bearing from the side cover.
thrust collarA and inner bearing race. out the notchandspring.
Calking lor locking
Nedle bearin0
Forwaad large geaa
4.3 Removalof the intermediate shafi

(1)Removethe "O" ring.
(2)Removethe thrustwasher.
lever shalt
(3)Removethe intemediategearandneedlebearing.
(3)Takeout the shifter.
lnlermediale shaft
q.
O-ring
\) Thrust washer
NOTE: Takecarc as the nut has lett-handed thrcad.
10-23
10-22
00004041361
0000A041361
C'hapler I0 Reduction md Rotsing Geu (:hapter 10 Reduction and Reversing Geu
5. Reusembly
5. Reassembll'
sM/GM(F)(ClHM(F)(C) SM/GM(FXCIHM(FXC)
5. R@ssembly 5-2 Reassemblyof the clutch

(1) Fit the oil s€al and bearingouler race in the clutch
5.1 Reassemblyof output shatt cas€.
(21Insert the input shaft into the clutch case.
(1) Fit the forward side thrust collar B onto the shaft.
(3)Drive the intermediate shaft into the clutch case.
(2) Drive in lhe forward end inner needle bearing race using
a ltg.
,/lnput shall
Fl o l l e r b e a r i n g
(7) Insert the drive cone while keeping the output shafl
for reverse.
NOTES:1)lt the output shattis not titted into the clutch
case belore driving-in the intermediateshaft, it
cannotbe assembled.
2) Note the asserrbry direction ol the thrust
NOfFSj t/ Dilve in with a plastic headed hammet. Do not
washer.
hit il hard.
(4) Insertthe outputshaflinio the clutchcase.
2) When titting the thrust coltar A, note the littino
(3) Assemble the needle bearing and forward large gear.
dircction. Fit it keeping the stepped surhc;
NOTE: Check that the loward large gear rctates smoothty. towad the bearing side.
(4) Fit the lhrust collarA and pin, and drive in the inner bear-
3) Note that the pin cannot be titted alter the innel
ing race using aiig. beailng race has been driven in. Intemediate shaft
stepFd surface (5) Assemble lhe coilar and pin so that the pin is in the
groove of the collar.
(6) Set and tighten the forward end nut. Insert the bott into
the coupling, and tix it in a vice, keeping the sptine part
(8)Applyprocedures
1 through4 to the forwardend
uowafo.
lnsert lhe shatt into the spline of lhe coupting, fil the
Thr!st collar A spacer, and tighten the nul with a torque wrench. Stepped surlace
Outgul shaft Thrust coller A
OutDutshafl
(5)Checkthe lhicknessof shims lor bolh inputand oul-
put shafls.Whenthe componenlpartsarenot replac-
ed after dismanlling,the sameshims can b€ reused.
Whenthe clutchcaseflangeor any one ol the follow-
ing parts is replaced,the thicknessof shim must be
deieminedin the followingmanner.
For inputshattparls:inputshaft,bearing.
For output shaft parts: output shaft, thrust collar A,
Tightening tor que 10t 1.5 k qf- m NOTE: Fit thtust collar A so that the stepped surface laces thrustcollarB,gear,bearing.
61.5 - 83.2 ft- tb '!) Measurethe distancebelweenthe clulch case body
(Theeme torqu€apptaes the beailng side.
to both modetsKM2-Cand KM3_A). andthe mountingtlange,A or D foreachshaft.
NOf€S: 7/ Takecare as it is a lett-handed thread. 2) Fit the outer b,earing.ace to each shaft,and meas-
2) Use the reverse side nul used belore dis. urethedistance(BorC) betweenb€arings.
maniling as the forward end nut fhls ls so as
not to match the calked portion to the same
potnt.
10-25
00004041361 00004041361
Chapter I0 Reduclion and Revering Gear Chaplcr I0 Reduclion and R(rusing Geal
5. Reurembly 5. Reassembll'
SM/GM(FXCTHM(F)(C) sM/GM(F)(CIHM(F)(C)
NOTE: Apply non'drying liquid pac4ing to either the (2) Fit the shift lever
mounting llange or the case bodY.
(10) Assemble the oulput shaft coupling on the output
shaft, and fit the O-ring.
(11) Tighten the end nut by using a torque wrench, then
calk it.
-_- U{ - - 1 r J I outputstraft
-I Inplrshart i | | I | I ],
li-
.-rEl r t l, rr
ri jr liq
-. + I I
/ --_1 L r' , J_)_/ |
Needle bearing
I D Shilt liver shaft
116.40 116.75 1152 'l'16.'l '121.48N 12..53 N 172.95
KM2.C (45827- (45311 -tu 4.5709) 14.7827N 4.82401 r a.8a$)
(3)Fit the notchand spring,and screwin the plugand stop
-,ts$l) '136.0a 13635
127.4N 127.7s 1?6.2* 127.1 13456 136.0 screw.
KM}A - 5331i1)
F2976 tu (5.3tli| o 5.3681)
F.0157 a 5.0295) 6.9685 tu 5.0@)
3) Determine the thickness ol shim so that the values of

clearance and interference after fitting comply with
the values in the following table.
Clearance (or inlerf erence) for each shafl mm {in.)

Input shaft a0.05 (10.0020)
Output stEft 0 tu -0.1 (0 -0.069)
-
NATE: Negativevalueshowsinterlerence.
Adjustingplate
Part No Thickre mm (inJ No. of shims liqukl packing
Input
__i{_qq11 liquid packrn9 NOTE: Take care as it is a left-handed thread.
shaft 1r/@{2350 0.4 p.fi54 ' 10t1.5k gf-m
03 o.0118) T i ghteni ng tor que 61.5- 83-2ft-l b
1.0(o.@4) (The sme torque appli6 to both models KM2-C and KM3-A)
Output 05 pole7}
lTtwQ8
shatt 03 0.0118) 5.3 Reassemblyof the shifting devic€
0.1 p!@ (1)Fit the oil sealandneedlebearinglo the sidecover
(4) Fit th€ shilt leverand set the bolt.
(6) Fit the adiustingpbte to the mountingflange,and A m.k (KM3-A)
drivein the outerbearingrac€.
NOTE:The oute( beailng taae can be easily driven in by (9) Insert the input shaft and output shalt into the shafl
heating the mounting tlange to about 100oC,or by holesof the mountingflange,assemblethe mounting
cooling the outet race with liquid hydrogen. flangeon the casebody,andlightenthe bolt.
Shift lever
(7) Apply nondrying liquid packing around the outer
surfaceol the oil seal.and insert the oil s€alinto lhe
mounlingflangewhile keepingthe springpart of the
oil sealfacingthe insideof the case.
(8) Apply non{rying liquid packlng to the matching
surfacesotthe mountingflangeandthe casebody.
Output shafl
lnlemediate shall Clearance

approx. 0.5mm (0.0197in.)
'10-26
0000.{0.{I 3i;l 0000A041361
Chaptcr I0 Reduction and Revqsing Geu Chapter I0 Reduclion and Reversing Cear
5. Reassembly 1- Conslruclion
SM/GM(FXC}HM(F)(C) SM/GM(FXC}IIM(FXC)
NOTE: The clearunce between the surface of the side

cover and the operation lever is to be 0 * 0.5mm
(0 * 0.0197in.)
(5) Fit the shilter to the shift lever sha{t.
(6) Fit the side cover to lhe clutch case. Ensure that the
shifter engages the groove of the drive cone-
For model3GM35(F)
1. Construction
1-1 Conslruction
The Kanzaki€arlHurth KBW10reductionreversinggear much smallerand simpler than other types of reduction
was developedjointly by KanzakiPrecisionMachineCo., reversinggears.
Ltd., a subsidiaryof Yanmarand one of Japan's leading 'The lriction discs are durable sinter plates, and the sur-
gearrnanulacturers,and CadHurth Co. face ol the steel platesarecorrugatedin a sine curveshape
The KBW10consistsot a multidisc clutch and reduction to ensure pcilive engagement and Clsengagementard
g€ar housed in a single case. lt is srnall, light simply minimumlossof transmissionforce.
constructedandexlremelyreliable. 'Because of lhe special construction of this gear, the
'The torce requiredto shift between forward and reverse optimum pressureis automaticallyappliedto the clutch
(7)Checkthatthelevertumssmoothly. plate in direct proportion to the input shaft torque.
can be controlled by a cable type remote control system
NOTE:The levermay not turn smoothly if the housing is
not tilled with Iubilcating oil.
(8)Fil the springFint, and set the remole control cable
afteradjusting. 1.2 Specilicalions
For fittingandadjustmenireferto the detailedexplana-
tion in theappropriate section.
Clockwi* 6 viewed lm stsn

Ceotmlockwi$ 6 viewed frm slsn
000040A1361 0000A0.{r 361

Chapler I0 Reducliur and Rcvtrsing Ocar

Chaptcr l0 Reduclion and Rcversing Geu
I. Conslruclion
SM/GM(F)(CTHM(F)(C) I. Conslruclion
SM/GM(FXCIHM(F)(C)
1-3 Power transmission syslem 1-4 Drawing
Reversesmall gear ol input shaft

Forward small gear of input shalt
- e
ldle g ea r \ 6
t
large gear
Forward small qear of input shaft v
E
g
Rever* small gear
o f j n p u l sh a ft =
Fleverse large gear
Fbrward laroe gear- !
Viewed from stern
:
Foruard Reverse
Numberof leth Numberof teth
Foruard sroll gw F(ryad Reduction ctio Revresmll os Reree Redrction atio
of inpul shaft ET€ Oq ldb g€r
of input shaft large 96
2 47 4712 = 2.14
18 ,t5 45/18= 250
18 51 51/18= 283
Forward Reverse -
!;
Fc
ei
Reverso smll geal

, aP
iE
Reverse large gear

Reverse large gear
Oulput shaft coupling
Output shalt coupling
(\\{f0Al36l
0000A04r361
Chapler l0 Reduction and Revuing Gear
I. Conslruclion
sM/GM(F)(CfiM(FXC)
KBW1().E
23-1 HOUSING.clutch 24-1 DISC,damper

23-2 FLANGE, mounling 24.2 INPUT SHAFT
23.3 PARALLEL PIN 21.31 ROLL€R AEARING
23-4 EOLT M10 x 30 LM67q8/1M67010
23-5 LOCKWASHER 10 25.3 IOL€ G€AR
23-13 COVER (side) 2t{ SHAFT, idl€ geat
23-14 PACKING, @ver 25-5 GR|NG S-ls
23-15 STUDM8x22 25-6 WASHER, lhrust
23.16 NUT M8 25-7 NE€OL€ BEARING
23-17 LOCKWASH€R8 26.1 OUTPUTSHAFT
23-20 SHIM SET. output 26-3 o-R|NG S-30
& input shaft 16-1 COUPLING, @tput
23-23 DTPSTICK 26.5 LOCK NUr
w/EREATHER, 26.5 ROLLEB BEARING
lube dl LM67q8/1M67010
23-24 PACKING 16 a6-8 PLATE, dsmbly
23.25 LASEL driving (inc.26-9 a 11)
23-26 R|VET :6-9 PLATE, d.iving
23-28 otLSEAL{TC30528}, 2G1O PARALLEL PIN
inDut shatt 2S11 PARALLEL PIN
23-29 o|LSEAL(TC,(}528), 26.12 KEY
output shalt 2613 PtN
2&30 OrL SEA!(SD 20264), 2G14 SPRING
cover. 4615 RING, thifting
23-31 PLUq,Ml6 2Gl6 PLATE, p.6sure
23-32 PAC4NG 16 i617 STEELAALL(8mml
23-33 BRAC|<EI (A) 2S18 SPRING, return
23-3,1 ERACF€I(B) 2+I9 GEAR
23-35 BOLTillo x 3X) 2G2O GEAR
23-36 LOCKW SHEF 10 262I RETAIN€R
23.37 LABEL, F()RWARO 2e22 C|RCL|P
23-38 LAAEL REVERSE 2E23 SPRING
23-39 FORKAs$mbly, 26-2r OISC, lriction
shlfi (inc. 23-,tol i625 PLAT€, steel
23.40 ORY EEARING 2S26 SPACER
23-!tl SHAFT, shift iS27 WASHEn, thrust
23-,02 PLUG 2S2E SHIM SET, @tput, shaft
2343 CAM, shllt 2S29 NEEOLE AEAAING
23-4,1 PIN 2s3o RAce inns
23-,{5 CTRCLIP
23-46 SPRTNG(A)
23-47 SPRTNG(B)
23-48 LEVER, shirl
23-li9 AOLTMET25
0000A041361
Chapler I0 Reduction and Reversing Gear

2. Inslallation SM/GM(F)(CTHM(FXC)
2.Installation
Installalion angle when the cabte is attached to the hole 52mm
2.1
-ouii*
oo.""tion ttd angutarinclinationof the geadox in (2.0172in.)trcm the cenler ot the rctation ot the shift
directionmust be lesslhan 20orelaliveto tevet,thesestrckesmust begmm (1.1811in')
Ge fo-ngiiuOinaf
mmon )
the walerline.
. , 6(0.24)
2.2 Remote conttol unit
This marinegearboxis designedfor singleleverconlrol
to
l[
oermitreversingat lull enginespeed(e'g to avoiddanger'
!rc.). ttormatty,t"lorse or Teleflexsingle levercontrol
employed.Duringinstallation,makesure that the
remote
is
a
TT
control lever and shift lever on the marin€
gearDoxare
a
loordinated.Shitting the lever towardthe
oroduces lorward movetn€nt,while moving the
propellerside
loward ttp engineside causesthe vessello move in

reversedirection.
lever
the a
io-*n"*t the linkage, the operating cable must.be
po"iii-"0 at right angaesto the shift leverwhen the shift
levq is in the neutralPosiiion.
ttre strift play,measuredat the pivot point ol the shitt lever'
.u"i O" it liitt 35mt on each side (reverseand forward)
of in" n*trat po"ition. Grealershilt ptayhas no adverseef'
fect on the marinegearbox.After connectingthe linkage'
cofllirm that the remotecontroland the shift leveron the
marinegearboxwork Properly.
e typical linkageanangementis illustratedin the tigure
below.
Cross s@tion ot the Clevis

(Anos A-A)
Split pin
\/
+J+
Shift lever- A j^l ffiE-
Pin
two
/VOrE: Since the cable strcke may be insulticient'
holes arc drilled in the shitt levet
@mm
When the cable is atlached to the hole
(2.3622in.) trom the center ol the rctation ot the shilt
anct
lever, the strokes trom the cenler to the lorward
teverse sr?es mus t both be 35mm (1'37ffiin')'
t0-33
0000A04136r
Chaplcr l0 Reduclfun md Revusing Geu (.)hapler l0 Rcduclion and Revusing ()ear
3. Operarion and Maintenarce 4. lnspection and Servicittg
SM/CM(FXCTHM(FXC) SM/GM(FXCTHM(FXC)
3.Operation
andMaintenance 4.Inspection
andServicing
3-1 Lubeoil lobe and groove are engaged properly there wilt be no 4.1 Clutch case 44 Steel plale
(l) Oillevel clearance belwe€n lhe body and the side cover. Do not use ('1) Check the clutch case wilh a test hammer for cracking. (1) Burning, scratching, cracking
The oil level should be checked each month and must packing or gaskets when installing the side cover. Pertorm a color check when required. Replace any sleel plates that are discolored or
be maintained between the groove and the end of the
lf the case is cracked. reolace it. cracked.
dipstick. The groove indicates the maximum oil lwet -After making sure that the cam lobe and nolches are (2) Check for staining on the inside surface of the bearing (2) Warpingmeasurement
and the end of the dipstick is the minimum oil level. aligned propedy, securely tighten all the bolts. After sectron.
When checking the oil level with the dipslick, do not lightening the bolts, move the lever back and forth. positive Also, measurethe insidediameterof the case.
screw in the oil liller screw; it should rest on too ot the contact shoutd be felt and a click should be clearly audibte Replacethe case if it is worn beyond the wear limit.
oil filler hole. as the gears shift; otherwise, lhe cam and nolch are nol
propedy engaged, and the cover must be loosened and
Oil filler $rew
4-2 Bearing
readjusted until proper engagement is achieved. (1) Rustinganddamage
lf the bearing is rusted o, the taper roller retainer is
damaged, replace the b€aring.
(2) Make sure thal the bearings rotate smoothly.
lf rotation is not smooth, if there is any binding, or if an
abnormal sound is heard, replace the bearing.
4.3 Gear
(1) Tooth surfacewear
Check the tooth surface for pitching, abnormal wear,
denls, and cracks. Repair lightly damaged gears and
replace heavily damaged gears.
(2) Tooth surface contact
(2) Oil change Check the tooth surlace contact. The arnount of tooth Measure the width of lhe steel plate pawl and lh€
Change the oil atter the first 100 hours of ooeration. sur{ace contacl between the tooth crest and tooth width of the pressure plate; replace the plate when lhe
and every 300 hours ot operation thereafter. When flank must be al leasl 70% of the tooth width. clearance exceeds the wear limit.
adding oil between oil changes, always use the same (3) Backlash
stet platewidth
type of oil that is in the marine gearbox. Measure lhe backlash of each gea( and replace the wear musl be under 0.2mm (0-0079in.)
IF
gear when it is wom beyond the wear limit-
(3) Recommended brands of lube oil mm
Mainteme
stildard
W s l i mi t
Input shaft ldward gs ild 0.1 tu 02 0.3 Pressure plate gr@ve width
dtput shatt fdwd gs (0.00a0 tu o.m79} (0.0118) Wear must be
under 0-1mm(0.0039in.)
Input shaft rwee gs ad 0.1 tu 02 0.3 ^
interrrediate g@ (0.0040 tu 0.m79) (0.0118) mm
Inteffnediate gs ad 0.1 0.2 0.3 Mdntffistandtrd Wslimit
@tput shaft megs - 0.m79
{o.maory (0.0118)
Sl€l plate width 12i.z Wm02
(0.{6l|6 tu 0.4724) (o.@?9)
(4) Forward/reverse gear spline
3-2 Precaulions .^ +0.1
Wm0.1
1) Ctreck the spline fordamage and cracking. Prsure plate grff rzo
Do nol stop lhe shift lever hahway between the neutral and (0.@)
2) Step wearol spline {0.1724 N 0.476/'l
forward or reverse positions. The lever must be set to the
Step wear depth limil: 0.1mm (0.m40in.) 0ry0.3 0.3 0.6
neutral posilion or shifted into forward or reverse in a Clrc - o.qbl
(0 tu 0.or8) P.0118e
single motion.
3-3 Side cover

The intemal shitting mechanism has been carefully aligned
at the factory. lmproper removal of the side cover can
cause misalignment. lf the side cover musl be removed, \Step wear ol sDline
proceed as follows:
-Before removing the cover, put alignment marks on the (5) Forward/reverse gear needle bearing
side coverand lhe case to facilitate accurate installation. When an abnormal sound is produced at the needle
-When installing the side cover, put the shift lever in bearing, visually inspect the rollers; replace the bearing
neutral so that the cam lobe on the shift lever engages the if lhe rollersare taulty.
groove on the internal shift m€chanism. When lhe cam &
ilt \\\q--t
W-"o"""
10-34
000040A1361 000040413r-
Chapter I0 Reduclion md Reversing Gear

Chapler I0 Reduclion md Reversing Geat 4. Ircpection and Servicing SM/CM(FXCIHM(FXC)
4. Inspection and Suvicing SM/GM(FXC/HM(F)(C)
4-8 Relainer
4-7 Driving plaie
4-5 Friction Plale 4-6 Pressureplale (1) Check for stains and damage on the lriction plate con-
tact surface.
(1)Check the friction plate for burning, scoring,or cracking' PressurePlatesliding sudace
(2) Check for wear and cracking on the plate spring contact
Repair the plale when the damage is light and replace
surface.
the plale if the damage is heavy.
-L
(3) Measurement of dimensions
(2) Friction surface wear
Measure the thickness of the friction plate, and replace
the plate when it is wom beyond the wear limil. Friction plale
conlact surlace
('l) Steel ball groove

Check the steel ball groove lor stains and wear'
worn.
{2) Friction plate contacl surface
prale
contact su r l a ce
ptate
Replace the pressure plate if the groove is noticeably

\Pa
Parallel
(1) Check the key groove for scoring and cracking, and the
outDut shalt fiiting section tor burning' Bepair if the
damage is light and replace the driving
damage is heavy.
(2) Outside diameterof pressure plate sliding
plale if the
part; others
d
ill
Maintemne
s575sis
standatd
mm
V,Je{ limil
o57A
Check the contact lace for stains and damage' e2661* 22680) P2756,
(3) Shifting plate contact surlace 6-3t ffi.7
(4) Wom parls measuremenl D
e.5945a 25$4) e5866)
0
^^ 40a 2S
zb
t o.1024
0.1071 0.1104
-
4.9 Plaie spring

(1)Permanent strain
The assembled friclion plate and steel plale dimensions

must be over 1omm (0.002l0in.).
Both sides ol lhe friction plate have a 0.35mm copp€r

sintered layer. Replace the friclion Plate when this layer
is wom more than O2mm on one side (standard (3) Steel ball groove wear and stains.
thickness 1.7 -$.65mm). Howeve( the sum of the wear of i+i o"t"t inJtn" of wearand play of both the axial
the four friction plates must not exceed 0.8mm. When "mount
and circumferential direction pins.
this value is exc€eded, replace all friction plates' In (5) Permanent spring slrain.
unavoidable circumslances, it is permissible to teplace
onty the friction plate with the greatesl amount of wear' (5)Returnspringpermanentslrain.
Makesure the lenglh (free length)is within the values
(3) Friction phteand gearspline back clearance soecifiedin the figure.
Measure the clearance between the friction plate spline
(6) Pin end wear.
collar and the output shatt gear spline, and replace the
plate or spline when they are worn beyond the wear
limil.
17 a0.5mm 10.6{96& 0.689Oin.)
4-l0Thrustcollar
copp€r
The gear side of the lhrusl washer has a 0'3mm
lhe thickness
sinteied layer. BePlace the thrust collat when
mm)'
L r".r tn"n a.zsrnt (standard thickness: 5 -3 r
10-36
0000A04136r 0000A041361
Chopler I0 Reduclion ond Reversing Cear Chapler I0 Retluclion onct Reversing Geu
1. Inspeclion and Servicing 4. Inspeclion and Scrvicing
sM/GM(F)(CIHM(F)(C) SM/GM(F)(CIHM(FXC)
4.11 Shlft dng (1) Endwear.

Theshift ringcontactsurfaceof the shift fork is plated
with mdybdenum(thickness:0.04-0.05mm).lf this
plating is peeled or worn to such an extent that the
base metal ol the shift fork is exposed, replace the
Pa6ssureplate gr@ve
shift fork.
(2) Camsurfacewearandstains
Wheneveruneven wear and/or scratches are found,
replacewith a new part.
(3) Pinpartplay.
pin contact pad
Wheneverunevenwear and/or scratchesare tound,
(1) Circumlerential
groovewear. replacewith a new part.
(4) Notchendwear.
Wheneveruneven wear and/or scratches are found. Oil seal
replee with a new part. (1) Splinepart
Wheneverunevenwear and/or scratchesare found.
4-13 Oulput shaft replacewith a new part-
(a Surfaceof oil seal.
lf the sealing surlace ol the oil seal is wom or
scralched,replace-
(1) Keygroove
Whenever uneven cracks and/or stains are found.
4-14Damperdisc
(a Pressureplategroovewear.
Wh€never uneven wear and/oa scratches are lound. (1) Needlebearingdimensions,staining.
Check the surface of the rolter to see whether the
(3) Parallelpin contact part wear.
needle bearing sticks or is damaged. Replace il
Whene\reruneven wear ard/o( scratches are tound,
necessarry.
roplacewith a new part.
4.12 Shltl fork aod shift l€ver
Kn@k pin 6
(1) Splinepart
i*."::"
Wlreneveruneven wear and/or scratches are tound.
Shltt .ing @nt&t srfee

Pl.tod wlth mlybdorum o4xl^ (4 Spring.
Whenev€runeven wear and/or scratches are found.
(3) Pinwear.
Whenever uneven wear and/or scratches are lound.
GA replacewith a new part.
10-38 l0-39
0000A0A1361 0000404134'
Chopter I0 Rcduclion and Reversing Gcar

Chapler I0 Reduclion and Reversing Geu 5. Disasvmbl!
S. Disassembly SM/CM(F)(CIHM(FXC)
sM/GM(F)(CIHM(F)(c)
(.ll) Heat the case body to about lmoc and remove lhe
(n Removetheshiftlork.
5. Disassembly outer race of the input shaft and oulput shaft bearings.
lf the outer races ate ditficult to remove, tap them oul
with a olastic hamn€r from the rear of the case, or pull
5.1 Disassembling th€ clulch and accessories them by using the pulling groove in the case at the rear
(1) Removethe drainplug and packing,and drainthe oil of the races.
from the clutch. (12) Remove the outer race of the bearing lrom the
(21 Uncaulklhe outoutshaftlock nut.and removethe nut mounting llange as described in step (11) above.
usinga disassemblytool. (13) Remove lhe input shaft and output shaft adjusting
Dlates.
Outpul shaft nut wrench (177099'09010)
Shift bar\ NOTE: lt the tollowing patts arc not replaced, the adiusting
Outpul shatt coupling locN( plates may be rcused without rcadiustment.
Pulling blt However, il even one part is replaced, readiustment (17095.09170)
is necessary.
lnput shalt Patt: 21-2,24'31
shaft coupling
Output shatt patt: 26-6, 6'9, 26'26, 26'27, 26-28'
26-30
(8) Remove the M10 bolt and super lock washer on the (14) Pull the oil seal frorn the case.
mounting flange. (.15) Pull the oil seal lrorn the mounting flange. NOTE1: Whenrcmoving the shatt,place spacersbetween
(e)Screw the M10 bolt into the M10 pulling bolt hole ot
the shattand the pressto preventdamage-
theinputshaft
5-2 Oisassembling
the mounting flange, and remove the mounting flange. Pullthe bearingfromthe inpul shaft.
Do not remove the parallel pin.
NOTE2:Make sure that ahelorwad laryegear pails and
NOTE:Do not disassemb/eunlessthe inputshatt partsarc revercelarge gear parts are not mixed togethel
damaged. once lhev are removed.
lnlerrediate shalt 5-3 Disassemblingtheoutput shaft (3) Removett|eadjustingPlale.
Oltput shatt
(1) NOTE:Recod the thickness ot the adiusting plate to
Iaci Iitate reassemblY.
ll the pattsarc not replaced,theadiustingplate may
be rcused wlthout readiustment.HoweveLif even
one partis replaced,readiustmentis required.
Outout shafl nut wench
(4) Removettpkey.
To facilitate removal,clamp the keywith a vice.
O0tput shaft (5) Removethe adlustingPlale.
coupling l@k
NOTE:Record fhe ftickness ot the diusting plate to
tacilitate rcassemblr.
It the patts arenot replaced,theNiusting platemaY
(3) Removethe oulputcoupling. be reusedwithout adiustment'However,il evenone
(4) Removethe dip6tickand packing. @ Removelhe outpulshaftby pressingthe threadedend
of the outpul shaftwith a press,or tapping it with a part is rcplaccd,rcadiustmentis requirccl-
(5) Removethe case cover M8 nut super lock washer; (6) Removethe spacerand needleb€aring.
(10) Removethe outputshatt,intermediate shaft,andinpul hammer.
remove lhe case cover,with the op€rating lever,shift
cam,etc.in posilion.
shaft from the case.in thal order. I Press oa hammer 14@ver the outer race of th€
I forwad bearing, and Pull ercssor nammer
(6) Remove the shift bar plug with a hexagonal bar I
out the output shaft about
spanner(widthacrossllats: 8mm (0.0394in.), and pull
10mm (0.3[ts7in.) bY Pres'
the shift barlrornthe case,usingthe M10pullingbolt
sing the threadedend ol
at the endof lhe shift bar.
the outDut shaft with a
press,or tappingit with a
hammer.
illl/,ll4/-\ NOTE:Do not pull it out morc
r- puller, place lhe puller than lomm (0.@37in.);
i When using a
L- <r cradle (177095'09170)against the €nd othetwisedamagemaY
--t {--of the shaft. result.
rrli
l/ Eearing Inner
Hexagonal bar spannef *\
c-- 1 l, Thaust collar
\l--J
,.) B€rino
Fl,li 1 l'|q
lrru I HfiilL Workb€nch
Work bench
tqLL_IjI lommrc.3937in.)
t- T- l
10-40
00004041361
0000A0A1361
Chaptt l0 Reduclion and Reversing Geu
Chapter I0 Reduction and Reversing Ceor
5. Dismsembly
5. Dhassembly
SM/CM(FXC}HM(FXC) SM/GM(F)(CTHM(F)(C)
(8) Insertthe disas.sembly tool betweenthe colltr of the (11) Removethe retainerandplatespring- (2) Flemove the O-ring.
output shatt and the b€aring;next removethe bearing (14 Removethe parts from th€ reverse large gear as (3) Remove the idle gear, needle bearing, and thrust
inner race,thrust collar,and bearinglrom the output describedin steps(9)-(1 1)above. wasner.
shaflwith a pressor hammer. (13) Removethe pressureplate returnspring;removethe
Prs q hamrer pressureplaleandsteelball.
5.5 Dlsass€mblingth€ operatingsystem
I (l) Loosen lhe M8 bolt of the shift lever; remove the
shift lever.
(2) Pulltheshiftcam.
(3) Push in the knock pin and remove the circlip.
(4) Remove the knock pin and spring.
(5) Pull the oil seal lrom the case side cover.
Pulling suppd
(17709$0$30) (14) Removetheshiftring.
To disassemble,retr|ovethe three knock pins. When
disassemblingthe shift ring, coverit with a cloth to
preventit beinglost.
(15) Removethe knock pin and spring from the driving
Plate ftr spring retalrer (17@5-09070) Dlate.
(9) Removethe friction plales and steel platesfrom the 5"1 Disassembling the intermediate shaft
forwardlargegear. (1) Placea spaceragainstthe case side end ol lhe in
{10) Usinga disas.sembly tool, compressthe plalespring termediateshaft and removelhe shaft from the case
and removethe circlip from the forward largegear. by tappingthe spacerwitha hammer.
I eres 1.ppror.
1metric
too(2200
tb)l I er"* o.n"..",
00004041361 00004041361
Chaptu I0 Reduction snd Reversing Gear Chopter I0 Reduclion md Rcvcrsing Gear

6- Reassemblv 6. ReassemblY
sM/GM(F)(clHM(F)(c) sM/GM(F)(CIHM(F)(c)
(8) Insert th€ thrust collar, with the.sintered surface (16) Insert the drive plate into the output shaft so that the
6. Reassembly (brownsurface)facingthe gearside.
(e) Press the bearinginner race onto the output shaft,
sid€ with the id€ntification groove laces the lorward
large gear side.
1) Position the assembled large gear on the assembly usinganassemblytool. NOTE: Make sure that the ttuee steel balls are in the three
p,recautions
6-1 Reassembly grooves ol the driving plate.
(1) Belore rerssembling, clean all parts in washing oil, tool so thai the spline part is on the boitom; insert
eress or nammer At the same time, make sure that the pin tot the
and replace any damaged or wom parts. the spacer and b€aring inner race into the gear.
I driving plate lits inlo the groove of the torque limit'
Remove non-dry packing agent from the mating
ter tot the Nessurc plate.
surface with a blunt knite. Bearing i n n e r r a ce l.t I
(2) Pack the oil seal and O-ring parts with grease. t -+-l
(3) Coal the rnating surfaces of lhe case wilh wet packing.
Insediner@r
,tt*t*.,
l lIl
6-2 Reassembling the output shall +l j ll
(1) Reassembling forward large gear and plate spring Itmtl
1) Insert the two plate springs ot ihe forward large
gear so ihat their large diameler sides are opposite
each other.
l]ryl
i l i ti
Driving plate
2) Insert th€ retainer and install the circlip. 2) Adjust the thicknessof the adiustingplate until it II l t
shownin thetigure.
3) Compress the plate spring, using lhe disassembly
tool, and snap the circlip inlo the groove on the
conlormsto lhe dimension
3)Two adjustmentptates of 0.5mm (0.0197in.) ano it ll |I lt 1
]
Ind€ntlfi€tlon gr@ves
oulside of the spline of the fofward large gear. 0.3mm(0.0118in.) areavailable.

Combinetheseplates10obtainthe "1" dimension' B€.neinnerEce ..ll I ll
I e.""" 1.ppror.1 melticton (2200lb)) (4) Determinethe thicknessof the reverseadiustingplate Thruslcollar I
--rJ
by followingthe proceduredescribedin step(3)above. Bearing- Al I
b
(5) First, inserta lriction plateinto the splinepart ol the P
forwardlargegear;next insertste€lplatesand friction ,
plates altemately.Finally,insert a triction plate(four
frictionolatesandthreesteelplates). (10) Insertthe needlebearing.
(6) Insert the friction plates and ste€l plates into lhe (11) Insertthe spacerandadiustingplate.
spline part ot the reverselarge gear in the same (12) Fit the key so that the fillet side is facingthe threaded
manneras describedin step (5) above(four friction partol the outputshaft.
platesandthreesteelPlates).
fn Pressthe inner race of the bearingonto the oulput
shalt up to the collar,usingan assemblytool.
NOTE:Theinnetnce canbe installedeasilyby preheating
it to approximately 100oC.
(21Reassemblethe reverse large gear and plate spring, cressor nammer
andclrclipas d€scrlbedin step(1)above.
retainer, I _ldiusling plate
the forwardadiustingplatelhickness
(3) Oetermining Spacef
Thrust wdhea
gea.ing
(13) Insert the forwardlargegear,t€ether with the lriction

platesand ste€l ptates.At this time, align the three
pawlson theoutsideof the sleelplates.
Pawls of sl@l plale
I rdoe gea.
I
(14)Cover the friction plates and steel plales with the
pressureplateso that the pawlsof the steel plateiil
NOTE As mentioned in section 5-3. (5), if no parts need to into thethreenotcheson the pressureplate.
be rcplaced, the adiusting plate can be rcused (15)Insertlt|e threesteelballsinto the threegroovesin the
without adiuslment. pressureplate.
I 0-45
000040A1361 00004041361
Chapler I0 Reduction and Revusittg Geu

Chapler I0 Reduction ond Reversing Geor
6. Reassembly
6. Reusembly
s M / GM(F)(C I H itf (F)(c ) SM/GM(FXC}HM(F)(C)
(17) Insertthe adiustingplateandspacer. 6-3 Reassembling the Input shalt 6-5 Installing tho input shaft and output shaft
(21) Insert lhe three steel balls into lhe three grooves in the
(18)Presslt€ beadnginnerrace,usinganassemblytool. Press the innerrace of the bearing onto the input shaft. (.1)Determining the thicknessof the inputshaftadiusting
driving plale. Make sure that the direction of the bearing is correct. plateandoutputshafldjusting plate
(721 Place lhe pressure plate onto the driving plate so that
I Pre$s or
t
NOTE: The bearing inner race can be easily instailed by NOTE:As mentionedin section5-1.(13),whennoneot the
'Efrrer the steel balls enter the three grooves of the pressure
preheating it to approximately 100oC. partaarc replaced,the adjusting plate can be reus-
plate.
ed without rcadiustment.
(23) Insert the three pressure plate retum springs between
6"1 Reassembling the Inlermodiate shafl 1) Measurelength"A" "D" beiweenthe casesof each
the shift ring and the driving plate, and attach them to
NOIE: Assemble the intermediate shatt as described in shaftof the casebodyand mountingflange.
the small holes in the side ot the pressure plate. section 6-5.(il. 2) Covereachbearingwith lhe bearingouler race,and
(24) Insert the reverse large gear [see step (6)] so that the ('1)Insert the needle bearing and idle gear on lhe measurelength"8" "C" belweenthe beadngs.
thre pawls of the steel plates enter the notches inlermediate shafi. Then insert lhe thrust washer.
around the circumference o{ lhe pressure ola'te.
NOTE: Pay carelul attentian lo the assembling direction ot
(25) Insert the needle bearing.
the thrust washer.
(26) Insert th€ thtusi washer so that the sintered side
(brown side) faces the gear side.
(27) Press the inner ftne of the bearing, using an assembly
tool. Make sure that the direction of the bearing is corret.
II
Thrust washer\ ---_]-'-lnput shalt
I
NOTE: The bearing inner race can be installed easily by
ffi
.l
prcheating it to apprcximately 100oC. Inrermediare
sha,t J-A\-
I Pressor hammer It{'l
--f-
I
___f_--_-ourout snart
Viewedf.m stem
I
(4 Insertthe O-drE.
(3) Press lhe ass€mbledintermediateshaft into the case
with a pressor hammer.
(19) Ins€rtthe knockpins and springsinto the threeholes

. aroondthe circumfer€nceof the drivingplate.
(20) Cover the driving ptate wlth the shift ring so lhat the
side with the ldentification gr@ve laces the lorward
largeoearsidq installthe ring so that the knockoins
arepushedin.
3) Adiustth€ input shatt adjustingplatethlcknessso
that the clearanceor tightening allowance is less
-_)\.-'-,,=:a=
...-'- than0.05mm(0.0020in.).
-.,_ti-;::= 4) Adiustth€ outputshaftadjustingplatethicknessso
...._-- ---ti- ,--=
that the tighteningallowanceis within 0 tu 0.1mm
(0^.O.00,Oin.).
cress or hamrer
I 5) Four adiusting plates of 1mm (0.@4in.),0.5mm
ldentiti€lim Reverse laroe oear (0.0197i n.),0.3mm (0.0118i n.)and 0.1mm
Or@v€
(0.m40in.)areavailable.
Combine thes€ plates to obtain the desired
adiuslingplalemeasurem€nt.
InterdEdiate (a Insert the adjustingplate into the mountlngflange,
shaft and pressthe outer raceof the bearing.
Also, presslhe outer raceof the bearlngInto the cas€.
Forward ged
ldge NOTE:Theoutet dce can be installedeasilyby heating the
mounting tlange and case to approximately100oC,
(al Insertthe O-dng. or by cooling the beaing outer nce with liquid
(2e)With the shift ring in the reverseposition,checkthe nitrcgen, etc.
forward large gear to make sure it roiates smoolhly. (3) Coat th€ circumferenceof the oil s€al with a non-
r40e oear Next,with the shift ring in the forwardposition,check dry packing agent, and press it onlo the mounting
the reverselargegearto make sure it rolales smoothly. (4) Make sure that the idle gear rotates smoothly
flangeand caseso that the spring part of the oil sealis
insidethe case.
10-46
0000A04136r
000040A1361
()eu Chapler l0 Reduction and Reversfug Cear

Chspler I0 Reduclion and Reversing
6. Reassembll'
6. Reasscmbly sM/ GrI (r')(c'I I I r r(urc:)
sM/GM(F)(cIHM(F)(c)
(2) coat the threaded part of the shift bar plug with a non' 6-7 Instatling the output shalt coupling
(4) Coat the mating surfaces of the rnounting flange and (1) Installlhe oulput shaft coupling on the output shalt.
case with a non-dry Packing agent- dry packing agent and secure it lo the case with a
(21 Tighten and caulk the output shaft lock nul, using the
Wipe off oil arid dirt on the tnating surface of the case hexagonal bar spanner (width across flats: 8mm
(0.3150in.). assembly tool.
and coat with a thin lilm ol nondry packing agent- T i ghteni ngi or que... . . . . . .9. . 5 k g l -m(6 8 . 7 1ltb )
NOTE: Put the shilt tork into neutrcl beforc installing.
Output shafl nul wrench ('177099{9010}
Outp!t shafl couPlingl@k
{177099-0S020)
,/
Oulput shaft co!pling
\
I
(5) Insert the inPut shaft into the case, assemble the (3) Coat the circumference of the oil seal with a non-
inlermediate shaftas describedin section6-4andthen
dry packing agent and press the seal to the case
insert the output shalt into the case.
cover.
(6) Align the rnountingflangewith the case,and insert the (4) Insertthe springinto the shift cam.
parallelpin by tappins the mounting flange with a (5) tnsertthe knockpin into the shift cam from the fronl
plastichammer.
end.andlockwith the circlip.
C0 Insertthe superlockwash€randtighienthe M10bolt. (6) Insert the assembledshift cam Inlo the cas€cover. Output shalt
(8) lnstallthedipotickandPacking.
(9) Installthe drainplug and packing. f4 Fit the shift leverto the shift cam,and tightenthe MB
bolt.
NOT8 Theshittcam mustrctatesmoothly.
&6 R.sssembllngandInstallittgihe operatlng (8) Replac€the packinglf it is damaged.
system (9) Attach the case side co/er together with lhe operating
(1) lna€rttheshifttoft intothocasefromtheside,Insert systemto the casebody.
ttteshiftbar. At ihis time, rnakesure that the shilt cam is titted to
NOTE: lnsed the shift ba( with the threaded end towards the shiftlorlf andthat the shift leveris in neutral'
the oulside (output shatt coupling side). NOTE:Put the shiltlork lnto neutnl beloreinstalling.
(10) Insertthe superlockwasher,andtightenthe M8nut-
(11) Shift the shitt leverto forwardand reverselo make
sure that the leveroperatesnormally.
lf the leverdoes not operatenormally,loosenthe M8
nut, slide the case side cwer forw.ard,backward,and
to the left and right,then re-tightenwith the MBnut in
the Dositional whichthe leveroperatesnonnally.
NOTE:tf the leveropentesnormallya click will be heard
whenit is out into forwardand reverse.
(3) Shift the shift leverto the neulralpositionand make
sure the clutch engages when the shift lever is
put into forwardand reverse.
The inpuuoutputshaftswill not rotalesmoothlyif the
side gdp of the bearingis too small in relatim to the
thicknessof the adjustingPlate-
t0-49
000040A1361
000040A1361
('hapltr I0 Rcduclion antl Rev<'rsing ()eur

I. Conslruclion
sM/GM(F)(CtHM(F)(C)
tCI MarineGearModels
KM2P,KM3Pand KM3V
for EngineModels1GM1O,
2GM2O(Rand
3GM3qR
Applieble EngineModels& SerialNos.
(Effectivefrom: l
KM2P 1GM10 El#O3413 and after Aug. 1985

KM2P 2GM20(F) El#O3567 and after Aug. 1985
KM3P 3GM30(F) E/#01888 and after Aug. 1985
1. Construction
1-1 Conslruction
This clutch is a cone-type, mechanically operated clutch. This preventsgearnoisedue to torsionalvibrationas
When the drive cone (which is connected to the output shaft well asabsorbingshockwhenengaging.
by the lead spline) is moved foMard or backward,its taper Staqe arangemenl
conlacts with the large gear and transfers power to the
outpu{ shaft. snoc(
The construc ton is simple when compared with other types
ot clutch and it seruesto reducethe number of components,
making lor a lighter, more compact unit which can be
operatedsmoothly.Although it is small,the power transmis-
sion efficiency is high even under a heavy load.lts durability
is high and it is reliableas high grade materialsare used for
the shall and gear,and a taper roller bearingis incorporated.
Power transmissionis smooth as connectionwith the engine
is made through the damper disc.
.The drive cone is made from sDecialaluminum bronze
which has both higherwear-resistance and durability. The Twist angle O
drive cone is connectedwith the output shaft through the
thread spline. The taper angle.diameter of the drive cone,
twist angle,and diameter of the thread spline,are design-
€d to give the greatestefficiency, thus ensuringthat the rThere is a small clearancebetween the dipstick and the
drive cone can be readily engagedor disengaged. inside of the dipstick tube. A small hole in the dipstick
oHelical gears are used for greater strength. The inter- works as a breather.
mediate shaft is supported at 2 points to reducedeflec- .When the load on the propeller is removed, the engage-
tion and gear noise. ment of the drive cone and the largegear is maintainedby
.The clutch case and mounting flange are made from an the shifter and V-grooveof the drive cone.Evenwhenthe
aluminum alloy of specialcomposition to reduceweight. drive cone's tapered area and V-groove are worn, this
It is also anticorrosiveagainstseawater. engagementis maintained by the shift lever device and
.As the damper disc is fitted to the output shaft. power accordinglyno adjustment of the remote control catrleis
can be transmittedsmoothly. For the damper disc,springs required.
of different strengthsare used so that two stagesof torque .The cup spring on the rear oJ the larger gear absorbs
and twist angleare applied.That is. in the first stage,only rotationai {luctuations and stabilizesthe engagementot
the weak spring is used, and the strong springcomesinto the drive cone and the larqer gear. Thus, the durability
action for a torque higher than a predeterminedvalue. of the cone againstwear is enhanced.
h i n t..l i n Ja w n 1050
0 0 0 0 4 0 AI3 6 1
Chapter I0 Reduclion and Revetsing Cear

C:hopter I0 Reduclion and Revering Gear
I. Construction
I . Conslruclion SM/GM(FXCTHM(F)(C)
SM/GM(FXCIHM(FXC)
1.3Powertransmissionsystem
ol shallsandgoars
1.3.1Anangemenl
Constant |Gh Os with w co.P dutch (ret type) s@ll Os of inpul shafi
smll g€. ot inpul shalt
Oq ol output thaft
tntermediate shafl
Mre,3}C (cdlerrel 762mc
Lelt side, vbu€d ftw stsn .mall gsa. with iopur ihstl
ModelsKM2PandKM3Preductionandreve6egearboxes,
shafts and g€ars aro the sane except for the tollowing
items: Shaft araogorcnl lnternodlato stalt
. No.of gearteeth vi€{€d l,om the Sbm
. Distancebetweenbearlngslor input and output shafts.
. Clutchcas€,mountingflange.
Fward l{go
1-:I2 Redrrc{ooralb
Foilard
No. of t6ih llo ol telh Roductlon Etio Zorrzf
Mod€l ol fo.wdd srnal gg Zf of torHd latge o€a Zol
21 53 = 221
53121
K M2P 21 56 $tA =2@.
t8 58 58f18 = 322
6 5S 50125= 2,s
KM3P a 60 59123= 261
n 61 il80 =14
Reverse
tlo. of teth t'lo. of t€€dr No. of tslh Ffd'vclbnr8,,bz,, zrtm
Model ot htemediate rhaft gs A of ffi hrlp o€at Zd(
of ffi sma{ oetzk
K M2P 18 a 56 56118= 3Ib
KM3P 19 a 60 60/19 = 3.16
Pri^ted ir Jqan
Ptidd it Jq
0000.{
0A 136l
00mA0A136r
( haplr l0 Rctlutlirtr arut Ilcrcrsing Gtur (;hapler l0 Reduclion and Reversing Gcur
l. ('onstruclion l. (-onslruclion
S / GM ( F)(C ). H M( F )(C ) sM/GM(F)(CIHM(F)(C)
^.1
1.3.3 Power transmission rouline- Foruard 14 Drawing
6t
93
Fr.
1-3-4Power lransmission rouline - Reverse

6
t\--
u-3
g
Y-'E €
s
: :;:;
.9 o"
E f,
s
'r/0
F o.wa rd la.g e ge ar I Rev er s e t ar ge g e a r
Dr iv e c one
Ou l p u ! sh a l r co u p l i n g
l'rint..l h Jopon
I) ti n t.d i a Jo r d n
0 0 0 0 A0 A l 3 6 l
0000A 0A l36r
Chapter I0 Reduction and Reversing Geal

Chapler I0 Reduclion and Reversing Gear 2. Shifling Device sM/GM(FXC)'HM(F)(C)
I. Conslruclion SM/GM(F)(CTHM(FXC)
1-5 Section l Yiew

2. Shiftinglbvice
2.'l Construction ol shifting mechanism
1 Mounting flang€
Bott MB x 25 pln
Eearing
L@aton ---l
4 Clutch case j
Input shaft
Bearing
7 Oil seal
I Shim
9 Dumper disk
t0 Shim
11 Bolt M8 x 14
12 L@k nut
Collar
14 Beariog
l 5 Thruit collar A
t6 sp.ing retainer
'17 Cup spriog
18 Foilerd g€ar
19 Thruit collar I
20 Orive cone
21 Output shaft
22 Thrust collar B
23 lnner r@
24 Rew6e gpar
25 Cup .p.ing
x Spring retainer
27 Thruit collar A
2a Beariog
29 Oil sd
30 O-ring
31 1-@k nut
32 Coupliog
ldle gEar shafi
34 Bearing
35 ldle 9ear
36 Thrust wdher
37 O-ring
3a Shift lewr
39 L@k nut
40 W6h€r
41 Holder
42 Conrector of"*'
The shift lever shaft is installed on the side @ver with /,"
43 Side cowr
44 golt Mg x 25 neutral, fomard and reverse positions provided on this -o
45 Oil Fal
46 Slrift l€ver rhalt
17 L@tiofl Pin
@ver. Th€ neutral, foilard and reverselcation pins of the
shift lever shaft are @nstantly inserted into their respective Yl
,I [*.-
pin -r.=
I Stopp€r bolt grooves on the shift lever by the tension of the shifter
49 Spring Pin
50 Bolt l/€ x 25 spring. The shifter is set on the eccentrh hole of the shift
5l Spring lever shaft and moves the drive cone in the neutral positio'n
g2 ShilEr either to the fomard or reverse positions, and then bact
53 W6hfi
u oigstick to the neutral position. (The shift lever shaft mov€s slightly
55 Par.llel pin to the shift l€ver or drive cone side wh€n the shift lever is ShifEr insiallation
L@k nut placed in the fomard or reversepositions.) ceoter
67 W6her
10-56
Pti^t.d t' Japon
Printed ir JoNn
00004041361
0 0 0 0 A0 A1 3 6 1
Chaptcr I0 Reduclbn and Re+'using Gear Chupl(,r 10 [lctlu<lion and Rcvushg Gcor
2. Shifthry Deilce 2. Shiflittg Dcti<'c
s M / GM (F )( C)-H M (r' )( C) sM/GM(F)(cIHM(F)(c)
2-2 Forward al reverseclutch operation 24 Clutch shifting force
Sh i fte r ce n te r
(Neutral + Fomard; Neutral+ Reverse) C o n e ce n te r
S h i ft l e ve r sh a l t
S h i J t l e ve r ce n te r
When the shift lever is movedto the forward position from

the neutral position, the shift liver shaft starts to revolve,
and the locatif,n pin disengages from the neutral V'groove 16.6 - 8.8 lbs)
position of the side cover. (Shiit lever moves approx. 4-bk9
{B.B - 13.2 lbs)
0.5mm to the drive cone side.) At this time the shifter
which is set on the eccentrichole of the shift lever shaft,
moves the drive cone'sV-grooveto the foruard largegear. .4.
{Sh i fr l e ve r
Side cOver shatt moves approx. O-smm)

neutral pcition (V{roove}
When the l@ation pin of the shift lever shaft falls in the
foruard position grooveoi the side cover, (the shift lever
shaft moves to the shift lever side approx. 3mm), and the
shifter starts to press the drive cone V-groove to the
fomard largegearsidethrough the springforce.
2-3 Engagmmt and di*ngagement of clutch At fomard engagementposition 2.5 Adjustment of shiftingdevice
{Fomard + Neutral; Reverse+ Neutral}
Wheneverthe side cover. shift lever shaft. shifter, stopper

When the shift lever is movedto the fomard Dositionfrom bolt or drive cone is replaced.be sure to adiust the clear-
the neutral position. the shift lever shaft starts to revolve, ance between th€ shifter end and the stopper bolt by using
and the lcation pin disengagesfrom the foruard position shims. When the adjustmentof this clearanceis not proper
groove of the side cover. (The shift lever shaft moves the drive cone may not be properly fitted when the shift
approx. 3mm to the drive cone side.) At this time, the lever is moved to the neutral Dosition either from the
shifter which is set on the eccentrichole of th€ shift lever fomard or reverseoosition.
shaft is moved to the neutralside (reverselargegear side).
The drive cone. however, is engagedwith the foruard large
gear through the torque fore produed by the revolving
centrifugalfore.
Sh i fte r ce n te r
Cooe cenier
S h itt l e ve l
Further, when the shift levershaft startsto revolve,and the
positioning pin falls in to the neutral V{roove position of Shilt le w r ce fl te l
the side cover (the shift lever shaft travelsapprox. Smm to

the shift lever side),the shifter movesto the shift leverside
(to the spring side) while moving the V-grooveof the drive
cone to the reverselargegear side. The movement of the
shifter to the shift leverside,however,is stoppedwhen the
shifter end contacts the stopper bolt. The shifter only
works to pressthe V€roove of the drive cone to the reverse
large gear side. Thus,ihe drive cone is disengaqed from the
foruard largegear.After this disengagement, the transmis-
sion torque of the drive cone is dmreasedto zero and the {Sh i l l l € ve f
shift lever is returnedto the neutral position by the spring Side cover shaft moves approx. O smm)
force. neutral position (V-groove)
Pti n t.d i n Jo w n Pr ta td i n Ja p o n
000040 l 136l 0 0 0 0 A0 A t3 6 l
Chapler I0 Reduaim md Reversing Geu Chapter I0 Reduclion and Reversing Gear

2. Shifting Device 2. Shifting Device
SM/GM(F)(CTHM(FXC) SM/GM(FXC}HM(F)(C)
2€ Adi6tment of the remote contaol head

2-5.1 Measrement and adj[stment of clearane KM2P & KM3P
(alAssemble the shifting mechanism (without installing Marim gearbox control rkle
the stopper bolt oi the shifter) to the marine gear case. {1 }Equaldistribution of the control lever stroke
NOTE:Ensre the corr&t dirqtion of the dlifter before

a@mbly-
Control Head
I
side
{b}Turn the shift lever 10 - 15 degrees either to th€

forward or revers position from the neutral position.
(clMeasure tt€ Ldistance betwen the shift lever shaft end
surfae and the shifter's end.
(dlMeasure the Hdistance (the distance from the neck ol
the stopper bolt to its end). ?-7 Cautiom
The stroke betwe€n the nfltral position + fomard posi- (1)Always stop the engine when attaching,adiusting,snd
(e)Obtain the shim thickness "T" by the following formula. tion (S2), and th€ reutral position + reverse pciton inspecting.
(S1) must be equalized.
T = ( H - L + 1.25l t o.lmm (0.0@lin.) (2)When conducting inspection immediately after stopp-
When either stroke is too short, clutch engagement ing the €ngim, do not touch the clutc-h. The oil temper-
NOTE:Shim et includes one piee e*h of lmm,0.4mm, becom* faulty.
ature is often raised to arourd 9O'C (194'F).
0.3mm,0.25mm *ims (3lHalf-clutch operation is not possible with this design
( YA N MA R Part No. | 7 7 88 06380) NOTE- Shift lever must be installed in the direction of the
6-mark entuing the peified in*allation angle (2)Equalizing the travel distance of the control cable. and @nstruction. Do not usewith the shift lever
(f)lnsert shim (s) o{ proper thickness to the stopp€r bolt (0 ). hal{way to the engagedposition.
side ard tight€n it to the shift lever shaft. After ensuring the equal distribution of the stroke (4)Set the idling engine sped at between 750 and 800
NOTE:i4/hen tightening the stopper bolt. eply either a

m described in ( 1 ), connect the eble to the control head.
Adiust that the cable shift trilel of the Sr and 52
rom.
| 40- | 45-
non4rying type liquid peking (TREE EONO control lever strokes becomes klentical. NOTE: The duaUTwo) taler rdnote &rrtrcl device cannot
No.l2l,), or a s'al tape dround the bolt threds- be used.
Approx.
5mm (O.l968in.l
Oo not apply
liquid p*king
or real up€ to
thE area.
Conrol He€d
2-5.2 Inspoct fd the follwing poinrs
(to bc inspected every 23 monthsl
(l lLoo*ness at the connection of the cable @nnector and
the remote control cable-
(Z)Loosenes of the attaching nut of the cable connector
and the shift lever.
Note; (.1 Cable ihift rra€l

Sl = More than 36mm ( 1.42")
32 = More than 36mm ( 1.42")
To 6n9ine rp€ed
Priated in JaNn Ptided ir Jow

00004041361 00004041361
Chapler l0 Reduclion and Revcrsing Gear Chaplu I0 Reduclktn and Rcvcrsing Om

3. Ircpection md Servicing
3. Inspcclion and Servicing
sM/cM(F)(CIHM(F)(C) sM/GM(F)(CIHM(F)(c)
3. Inspectionand Servicing Standtrd dimtrsions Limited dimensions

mm (in.)
K M2P 29.2 - 29.a (1.1496 - 1.1732) 28.1 (l 1063)

3-1 Clutch case Dimmsions I
(2) Forward/reverse gear needle bearing. K M3 P 3 2 . 7- 3 3 . 3(1 . 2 8 7 4- 1 . 3 1 1 0 ) 32.411.27561
(1) Check the clutch case with a tesl hammer lor crackino. When an abnormal sound is produced at the needle
Perform a color check when reouired NOTE: When dbmantled, the lorward ot rcverse direction
bearing,visually inspect the rollers; replace the bearing
lf the case is cracked, repiace il. ol lhe drive cone must be clearlv identilied.
if lhe rollersare faultv.
(2) Check lor staining on the inside surlace of the bearino
section. {4) l f the w ear of the V -g ro o v eo f t h e d ri v e c o n e i s e x c e s -
Also, measure the inside diameterof the case. s i v e.r epl ac ethe par t.
Beplacethe case if it is worn beyond the wear limit.
3-2 Beadng
(1) Rusting and damage.
lf the bearing is rusted or the taper roller retainer is 3.5 Drive cone
damaged, replace the bearing. (1)Visually inspect that part of the surface that comes into
(2) Make sure that the bearings rotate smoothly. contact with the circumlerentialtriangular slot to check
.lt rotation is not smooth, if there is any binding, or if any for signs of scoring,overheatingor wear. It deep scoring
abnormal sound is evident,replacethe bearing. or signs o{ overheatingare tound, replacethe cone.
3-3 Gear 3-6 Thrust collar

Check the surface,tooth face conditions and backlashof
each gear.Replaceany defectiveoarr.
(1 )Tooth surfacewear.
Check the tooth surface for pitting, abnormal wear,
dents, and cracks. Repair the lightly damagedgears
and replae heavilydamagedgears.
(2)Tooth surfacecontact.
Check the tooth surface contact. The amount of tooth
surface contact betwen the tooth crest and tooth flank H e l ;ca l i n vo l u te sp l i n e
must be at least70% of the tooth width.
(3)Backlash.
(2)Check the heliGl involute spline {or any abnormalcon-
Measurethe backlashof each gear, and replacethe gear
dition on the tooth surface,and repair or replacethe
when it is worn beyond the wear limit. .. part should any defect be found.
(3)Measurethe amount of wear on the tapered contact
surface of the drive cone, and replacethe cone when the
Input shaft foqad gs wear exceedsthe sDecifiedlimit.
and outDut shafl foruild
Input shaft Hre 0.06 0.12

- 0.0044
0.0024 tu
Internedhte 9s and 0.06a 0.12
outpul shaft rffi gear p.0024 tu 0.0047)
(The same dimensiore appty to both KM2p and KM3p
)
3.4 Forward and reyerse large gears

(1) Contact surtace with drive con€.
Visually inspect the tapered surface of the lorward and
reverse targe gears where they make contact with the
drive cone to check if any abnormal condition or sign ol
overheating exists.
lf any defect is lound,
replace the gear.
Taoeredsurface
I'ti^t.d i^ Jopan I'tiated ia Japoa

0 0 0 0 A0 A l 3 6 l 0 0 0 0 A0 4 1 3 6 r
Chopler I0 Reduclion and Rcvcrsing Geur

Chaplo I0 Reduclion and Reversing Geu
3. Inspection and Servicing sM/GM(F)(CIHM(F)(C)
3. Ircpeclion and Servicing
sM/GM(F)(c).HM(F)(C)
3-11 Intermediateshaft
(1) Visually inspect the sliding surface of thrust collar A or 38 Oil seal of output shaft
B to check forsigns ol overheating, scoring, or cracks. Visually inspect the oil seal of the output shafl to check il
Replacelhe collarif any abnormalcondition is found. there is any damage or oil leakage; replace the seal when
(2) Measure the thickness of thrust collar A or B, and any abnormalcondition is found.
reDlace il when the dimension exceeds the specified
limit. 3-9 Inout shaft
Sliding s udac e
Thrust collar A
mm (in.)
Standard Limil
66.9 - 67.0
D1 (2 . 5 5 9 1 )
(2.6338 - 2.6378)
1 1 .966 - 1r -984 1 1-95
02
Stepped ws Limit for us 10.4711- 0.4718) (0.4705)
0.050.m20) '12.o- 12.014 't2.o5

Thrust@lla. A, t, Shift lever shaIt.
(1) Needle bearingdimensions,staining. Shi{ter insert hole lo-4724- 0.47311 to.47441

Check the surlace of the roller to see whether the
needle bearing sticks or is damaged. Replace if
3-7 Cup spiing and 3pring retainer necessary.
(l)Check for cracks and damage to the cup spring and 3-122 shift lever shaft and loetion pin
spring retainer.Replacethe part if defective. (1)Check the shift lever shaft and location pin for damag€
(2)Measurethe free length of the cup spring and the thick- (1) Spline part. or distortion, and replacedefectiveparts. l{ the lo€tion
nessof the spring retainer. lf the length or the thickness Whenever uneven wear and/or scratches are tound, pin must be replrced. replace it together with the shift
deviatesfrom the standardsize,replacethe part. replace with a new part. 3-12 Shifting device levershaft.
(2) Surface of oil seal. (2)Measurethe diameter of the shift lever shaft and the
3-12.1 Shifier
lf the sealing surface of the oil seal is wom orscratched, shifter insertionhole. Replae the part if the size
replace. deviatesfrom the standardvalue.
Cup spring
ll t
trn 3-10 Output shaft
tl
Jt_
il
tltl
+-. {in.)
St anda r d Limit
mm (an.)
2 8 - 3.1
Cup spring, T Standard Limit
(0 .11 0 2- 0.1220) 10.1024)
27.959- 27.94 27 SO
2.92- 3.Oa 28 (1)Visually inspect the spline and the helical involute o'l
Spring retainer.T spline, and repait or replace a part when any abnormal (1 , 1 0 0 1- 1 . 1 0 1 6 ) {1.0984)
{0 .11 5 0- O.1213) { 0.1102)
condition is found on its surface. ( 1) Vi s ual l y i ns pec t the s u rf a c e i n c o n t a c t w i t h t h e d ri v e 12-o- 12.018 12.O5
0.1 02
Spring retainer,t cone, and replacethe shifter when signsof overheating. .o.4724- O.47311 l'o.47441
t0.00401
damageor wear are found. Side cover, 2a.o - 28.021 28.08
(2)Measurethe shaft diameter of the shifter. Replacethe ( 1 . 1o 5 5 t
Shift insert hole 1 1 . 1 0 2-4 1 . 1 0 3 2 1
shaft if the sizedeviatesfrom the standard.
10&
Printed in JoPn I'tinted i^ Jryn
0 0 0 0 A0 A1 3 6 1 00004041361
-
I Chapler I0 Reduclion and Reversing Ceu

SM/GM(FXCIHM(F)(C)
Chaplcr I 0 Reduclion and Rcyersing Gear
SM/GM(FXC}HM(F)(C)
t
(1)Shim thickness (Tt ) measurement of inout shaft
3-12.3 Shifter spring
-,.l
(1)Checkthe springfor scratchesor corroston. (a)Measure the bearing insertion hole depth (A) of the T3 n Clutch case
4i.- /
mounting flange,and the bearing insertion hole depth
{2)Measurethe free length of the sprng.
rj. rli'lttrrr
l fI )tI
(A') of the clutch case.
,l [-r r '-
(b)Measure the length (B) between the bearing outer El
Shifrer sprang Standard Limit races of the input shaft assembly. /ffi' t
I Free len gth
Spring constant
L en gth whe n at t ac hed

22.6 mm (0.890in.)
0.854k9l/mm(1.88 tbs/0.04in.)
14.35 mm (0.5650 in.)

t9.8 mm {O.78Oin.}
(c)Obtain the {Tr) thickness by the following formula:
T 1 =A+A'- B (Tt : C l e a ra n c e t 0 . 0 5 mm)

i l 2 t T-
ll
\W r
l,-]
rl
out'Ur
'r - i - - - r l r l
i-
shart lJl,
'i i.-
R
iq,#\
,=1
i
| \
l'l
)l i-r
I
--l ))
Lo ad whe n ar t ac hed 7.046 kg (15.54 tbs) 6.08 ks (l3 4t tbs) Mounting flange
3-13Dampe.disc { c )Me a s u ret h e { F) a n d (E ) l e n g t h f ro m t h e o u t e r ra c e

3-12.4 Stopperbolr end of the clutch casebearingincluded in the output
I
Check the stopperbolt. lf it is worn or stepped,replace. shaft assembly.
NOTE.Before masuilng the (F) and (E) tength, pres the
forward large gear and the rever* large gear to the
drive cone until there is no clearance among them.
I
(d )O b t a i n t h e (T2 ) a n d (T: ) t h i c k n e s sb y t h e f o l l o w i n g
f o rm u l a s :
T2 = c + c ' - D - T3 (C t e a ra n c e1 3 . 1 --)
T3 (K M2 P ) = C ' - 4 8 . 3 -i - - r l C t e a ra n c 1
e 0 . 0 5 mm)
I (1)Spline part.
Pin Spring
Wh€never uneven wear and/or scralches are found.

T3 (KM3P) = C' - 41 .3 ** - f (Ctearance
10.05mm)
replace with a new part.
I 3-12.5 Side cover and oil seal

(l )Check the neutral, foruard and reverseposition grooves-
Replaceif the groovesare worn.
(2)Measure the insertion hole of the shift lever shaft.
(2) Spring.
Whenever uneven wear and/or scratches are tound.
(3) Pin wear.
t
Whenever uneven wear andlor scratches are found,
Replaceif the sizedeviatesfrom the standardvalue.
(3)Checkthe oil sealand the O-ringfor damage.
(4) Whenever a crack or damage to the spring slot is tound
Replaceif the part is defective.
. replace thedefective part with a new one.
I 3-14 Shim adiustment for output and input shafts

Check the thicknessof shims for both input and output
shafts. When the component parts are not replacedafter
KM3P.....47.3 mm
dismantling,the sameshimscan be reused.When the clutch
I + Neuiral
case and flange or any one of the following parts is
replaced the thickress of shim must be determined in the
following manner.
For input shaft parts: input shaft. bearing.

(2)Shim thickness{T2, T3) measurementof output shaft
(a)Measurethe bearing insertion hole depth (C) of the
KM2P......48.3mm
Output shaft ass'y
t For output ahafl parts: output shaft, thrust collar A, mounting flange,and the bearinginsertionhole depth
thrust collar B, gear,bearing. (C') of rhe clutch case.
(blMeasure rhe length (D) betwen the bearing outer

races.
NOTE:Tighten the mounting flange nut of the output
I shaft asembly with the sp&ified torque. pre$-fit

the inner rrce of the clutch cas roller bearing to
the large gear side.
I Printed in J6pon
00004041361
I'ti n kl n Jo p u
0 0 0 0 A0 A 1 3 6 l
10-66
Geat
Chapler I0 Reduclion and Reversing
Chaptu I0 Reduabn and ReversingGear 4. DisasemblY sM/GM(F)(CIHM(FXC)
3. Inspectionand Scwicing SM/GM(FXCIHM(F)(C)
(3)Standard size of Parts 4. DisassemblY

a c+c D centerposrlon 4-1Dlsmantlhg tho cluic{| (4) R€motreth€ end nut and outpui shaft coupling'
123.40- 123.75 122.20- 123.10 12910- 130.1 5 128.07- 129.53 20 .50- 2 l .l o 53.59- 9.41 fll Flemoveihe romoteconttol cable'
mount'
KM2P
4As83 - 4.87201 48t ro - 434651 5.1102- 5.12401 5.0421- 5.0996) 1.8071- 0.83071 2.1W - 2.11211 (1.90161
bi n"tot" the clutch assemblyfrom the engine
r 4l.O0 23.54- 24.10 57.83 - 58.65 ing tlange.
r3230 - 132.75 1 3 1 .2 0- 1 32.10 141.20- 141.55 139.56-
KM3P 5.5512) )s252 - 0.94a81 2.276a - 2.3@11 .a6221
5.2126- 522il1 5.1654- 5.2008) 5.ss91 - 5.57281 5.4945-
NATE:Compare YNr measuHnents with the above

standard size. lf your meavrements largely differ
from the standard sizes,masrements may not be
correct. Chek ild magtre again.
(4) Adiusting shim set
Part No. Thickn*..mm(in.) of ahims
o.5 (oo197l I
Input rh.fl 7?G802350 o.4 (oot57l I
0.3 (0.0118)
1.O(003941 I
0.5 (0.01971 t
Ostput shafi 17708802300
0.3 (o.0t181
o.r (0.0039)
(3) Drainth€ lub(bating oil.

Orain th€ lubrlcating oll by loos€ning the plug at the
bottom of the clutch caso.
NOTE:Takecaieasnhasa teft-hanN thr@d'

{5)Remove the oil dip.tick and Gring.
(6)Remove th€ fixing bolts on the side @r€r. and als
remove the shift lewr shaft, shift lever and shifter.
D,.in Plug
Ptint.d ir Jap6 Pri.ted ia Jw

0 0 0 0 A0 At3 6 1 0000A04 l36l
C:hapler I0 Reduction md Revtsing Ceu ('hapler 10 Reduclion and Reversin1 Gcor

4. Disassembly 4- Disasemhly
sM/GM(F)(CtHM(F)(C) SM/GM(FXCTHM(F)(C)
(7) Remove lhe bolts which secure the mounting flange to (10) Remove the oil seal of the output shafl from th€ case (12) Remove the oil seat of the input shaft from the
the case body, give light taps to the teft and right with a body. mounting flange.
plastic headed hammer white supporting thd clutch (13) Remove the outer bearing race trom the mounting
case with your hand, then remove the mounting flange. flange in the same way as with the cas€ body.
Inlcfrldht6 rhrlt
(14) Remove each adjusting plate from the input or output
shatt.
NOTE: The same adiusting plates can be rcused when the
follawing parts are not replaced. When any part is
replaced however, re-adjustment is necessarv.
Oil seal
4-2 Removal ol the oulput shaft

(1)Take out the reverselarge gear, thrust collar A, cup
spring,springretainerand inner bearingrace.
(9) Take out the intemediate shaft and input shaft. When The reverselargegear must be withdrawn usinga pulley
taking oul the intermediale shaft, place a bolt or extracter,by fixing the nut at the foruard end in a vice.
spacer on the shaft hole of the case, and drive the
shaft out by lapping it lightly. (11) Remove the ouler bea.ing r:rce trom the case body by
using the special tool.
MountinOflange headed
goll or
sp a ce l
(8)Withdrarr/
the outputshattassembly. /'Y\\
(2)Loosenthe calkingof th€ forwardnut and removeihe
Remove the nut by using a torque wrench alter selting

the outpul shafl coupling and fixing the coupling bolt in
a vice.
Calking chisel
oeann9 race
tuint.d in Jopon Ptinted in Jdpa,
00004041361 0000A0A1361
Chapter I0 Reduaion and Revasing Geor

Chaptu I0 Reduclion and ReversingGear 4. Disuxmbly
SMlGM(F)(C'HM(FXC)
4. Disarenily
sM/GM(F)(cIHM(F)(c)
44 Dismantling the shifting device
(4lwhile gripping the drive cone, tap the €nd of the shaft (4)Remove th€ shift lev€r to the anti{hift lever side.
(l )Take out the shifter and shifter spring
with a plastic headedhammer, and withdrm the thrust
ollar B and inner needle bearing rac€. A pulley
extractor mav be used.
(3)Place the pullsy extractor against the end surface of the

fward large gear, and withdril the foMard large gear,
thrust collar A, cup spring, spring retainer and inner
besring race. (5)Removethe oilseal md O*ing.
(2)Remove the stopper bolt of the shifter and shim'
Fon{d la.o€
+3 Romomlof tho hrorm€dltto shafi

(1)Refilovethe 'O' rlng. (3lLoosen the bolt of the rhift lever and remove the shift
e) Remolrethe thrust wastFr. lever from the shift lever sh8ft.
(3)Removetheintermediategearand needlebearing.
lntem€diate shaft
\)
NOTE: TatG carc as lhe nut has lelt-handed thrcad.
1(}71 Pildet in J@
Ptid.l ir JW
00mA0Att6l
00004041361
Chapler I0 Reduclion and Rclcrsing Gear Choplcr I0 Reduclion and Reversing (ieor
5. Reassembly 5. Reassembly
SM/GM(F)(CIHM(FXC) sM/GM(FXCITTM@)(C)
5. Reassembly 5-2 Reasemblyof the clutch

{1)Fit the oil seal. bearing outer races and shim(output
shaft side) in the clutch case.
5-1Reassemblyof oulput shaft (2)lnsertthe input shaft into the clutch case.
(1) Fit the forward side lhrusl collar I onto the shaft. {3)Drivethe intermediateshaft into the clutch €se.
(2) Drive in the forward end inner needle bearing race using
a jiu.
Intermediale shalt
/lnpul shalt
Inseilrn9 tool
Inner needle bearing
(7) Insert the drive cone while keeping the output shaft set
for reverse.
NOrES: tJ lt the output shaft is not tilted into the clutch
case betore driving-in the intermediate shalt, it
NOTE: I JDrive in with a plastic headed hammer. Do not
cannot be assembled.
hit it hard.
2) Note the assembly direction ot the thrust
2)When fitting the thrust collar A, note the fitting
ln' dirrction. Fit it keping

toward the roller bearing side.
the stepped wrface
D d ve co n e washer.
(4) Insert the output shaft into the clutch case.
{3) Assemble the needle bearing and forward large gear. 3)Note that the oin cannot be fitted after the inner
NOTE: Check that the torwarct larye geat rotates smoothly. bearing rae has been driven in.
(4)Fit the cup spring. spring retainer, thrust collar A and 4JChEk that the foward large gear rotates
pin, and drive in the inner bearingraceusinga ffioothly,
iig.
Steppedsurlace (5) Assemble the collar and pin so that the pin is in the
Inlermdiate
groove of the collar. shaft
(6) Set and tighten the lorward end nut. Ins€rt the bott into
the coupling, and fix it in a vice, keeping the spline part (8)Applyprocedures1 through4 to the forwardend.
upward.
Insert the shaft into the spline of lhe coupling, fit the Stepped surlace
Thrusl collar A
spacer, and tighten the nut with a torque wrench.
Thrust coller A
output shalt
Tightening tofque 1011.5k gf.m NOTE: l) Fit thrust collar A s that the stepped ilr'face
( 61.5- 83.2r t- r b)
frces the roller bearing side.
(Thesme torqueapplieslo both modelsKMzP and KM3p)
2) ChEk that the rever& large gear rotates
NOIES: t,l Take care as it is a lefthanded thread. woothly.
2) Use the reverse side nut used belore dis-
mantling as the lorward end nut. fhis is so as
nol lo match the calked oorlion to the same
Doint.
I'tiilad in Japoa Pti a r cd i a Jq o

00004041361 0 0 0 0 A0 4 l36l
.-
Chapler I0 Redu<lion and I?eversing Gear

Chapru I0 Reduction and Reversing Geor 5. Reassembll'
5. Reossembly sM/GIvI(F)(CIHM(FXC)
SM/GM(FXCTHM(F)(C)
5-3 Reas*mbly of the shifting device
{5) Fit the adiusting plate lo the mounling flange, and {8) lnsert the input shaft and output shaft into the shaft {1) F i t the oi l s ealand O-ri n gt o t h e s i d ec o v e r
drive in the outer bearing race. holes of the mounting flange, assemblethe mounting
NOTE: The outer bearing race can be easily driven in by flange on the case body, and tighten the bolt. A maft
(K M2 P }
heating the mounting tlange to about 100oC,or by
cooling the outer race with liquid hydrogen.
(6) Apply non-drying liquid packing around lhe outer
surface of the oil seal, and insert lhe oil seal into the
mounting flange while keeping the spring part ot the
oit seal facing the inside of the case.
(7) Apply non-drying liquid packing to the matching
surfaces of the mounting llange and the case body.
O u l D U l s h a tl
(2)lnsert the shift lever shait to the sidecover
NOTE:Appty non'drying liquid packing to either the (4)lnsert the shifter spring and shifter to th€ shift lever
mounting llange ot the case bodY shaft.
(5) F it the side cover assemblyto the clutch €se.
€) Assemble the output shaft coupling on the output
shaft, and lit the O-ring. NOTE: 1) Check the direction of the $ifter (Top and
(10) Tighten the end nut by using a torque wrench, lhen bottom side).
calk it. 2) The shitt lever may not tum snoothly if the
clutch caF is not filled with lubricating oil'
(6) Fit the shim and stopper bolt to the shift levershaft.
NOTE: Apply non4rying liguid p*king or eal'tape to

the thread of the stoqPer bolt-
(3) Fit the shi{t leverto the shift levershaft. smm (0.196ain.)
NOTE: Chuk the direction of the shift lever Lmark. Oo not apply
liquid packing
oa seal tar to
thrs aaea.
{7)Fit the cableconnector to the shift levet
NOTE: fake care as it is a lelt'handed thread.

101'1.5kgf'm
lorque
Tightenang (61.5 - 83.2fr-lb)
(The sme torque applies to both models KM2P and KM3P )
I'tintcd i^ Jqpe
Pr i n r e d r a Jo p o n
00004041361
0 0 0 0 A0 A 1 3 6 l
CHAPTER11
REMOTECONTROLSYSTEM
t.@.ldr uctir n...., .................i t- l
2 Cker tnd Sp6d F€guLtorRdnoigContd ..,......... fl a3
3 EngkEStopRg m otoC onr ol .........,................. n- 7
Prj.Ll h to'trr
00000Al$r
Chapter I I Remole Control System

I. Construction
sM/GM(FXclHM(FXC)
1. Construction
This engineis designedprimarilyfor remotecontrolopera-
lion. A remote control cable bracket can be installed by
merelyaddinga remotecontrolleverandlink to the engine. Top mounted
Engine stop control 8nd deco.npression remote @ntrol
may also be installed,in additionto one-handleremote
control,which permitsenginespeedadiustmenland one-
handleforuard-astemswitching.
Fd this engine, two.h€r|db eontrol cannot be used to
replaceone-handb control.
1-1 Model 1GM10,2GM20(F)and 3cM30(F) Clutch regutalo. remote control stand

M06€ one-haodle MT2
ModelKM2-Creductionandreversinggearis usedin model
1GM10and2GM20(F),3GM3O(F)(C) engines,therefore
the
toruardand reveGeleverlson the leftwhenvi€wedfromthe
stern.The constructionfor models1GMl0 and 2GM20(F)
3GM30(F)is the sameex@pt for the shapeand mounting
positionof the bracket.
Cabl6 (Push-p!ll) No. lXl-C
dqrnrnd.atolc$b
ffiui
qnoô^t36l
Chapler I I Remole Conlrol Sysiem Chapler I I Remole Control System

I. Conslruclion 2. Clulch and Speed Regulalor Remote Control
sM/GM(F)(CIHM(F)(c) SM/GM(F)(C).HM(F)(C)
1-2 Model 3HM35(F)

Model 3HM35(F) is built the same except for the shape and
2. ClutchAnd SpeedRegulatorRemoteControl
mounting position of the bracket.
The reduction and reversing gear for engine model
2.1Construction
3HM35(F)is model KBW10E,therefore,the clutch leveris on Bolhmodelsof MT2andMV morseone handleremote
the right when viewed trom the stern. controlcan be used.Theyareoptionallyavailable.
2-1.1MT2lype 2.2.2MVtyo€
NewlyexpandedMV seriescontrolsincluderight and lefl
handmodelsdesignedtor easierinstallationand servicing.
The MV controlcan b€ preassembled and installedwithout
removingsidepanels.
Pull-outbutton disengagesclutch lor full throtile rangein
neutralforsafestarlingandwarm-up.
one handle MT2 lype MV controls have forward, neulral and reversedetents;
built-infrictionlo preventthrottlecreep-
Remote conl@l cable (push-pull)

No. 33C
slop aemote cootrol
2.2One.handle
remotecontrolcomposition
(l) Controlcable (2)Clamp

MorseType"3il.G"push.putl YANMARcablechmps arestandardparts,andaretitted
controlcables. to lhe bracketson the engineandclutch.
Use only Super.Responsive Morse Control Cables. They

are designed specifically for use with Morse control
heads. This engineered system of Morse cables, control
head and engine connection kits ensures dependable,
smooth operation with an absolute minimum ol
backlash. The thread size on cable ends is 10-32. Travel
is up to 3". The core is a solid wire, with a 3BZ diameter.
1 l -3
000040A1361 0000A0A1361
Chaplet II Remole Conlrol Syslem

Chaplq I I Remote Control SYilem
2. Clulch and Speed Regulalor Remote Control
2. Clulch and Speed Regulalor Remole Conlrol
sM/GM(F)(cIHM(F)(c) sM/GM(F)(CrHM(F)(C)
2-3.2 Movement of lever for models 2GM20(FXC), 2-4.1 For models 1GM10,2GMm(F) and SGIAF)
(3) Spring ioint
3GM30(n(c), and 3Hil35(D(c)
The cone clutch is titted to engine models 1GM10,
2GM20(F) and 3GM30(F).The spring joint is fitted to the
clutch lever, and is also connected to the control cable.
Remote conlaol
M5 lhread
Spring joinl
Operation
Operalion
(4) Clevis levet shaft
The YANMAR clevis is attached to the clutch lever on

model 3HM35(F).
Cable securing screw. NOTE:Whenthe push-pull cableis titted, it must be titted
at thespdngside.
!2as22.)
2-&1Movemdt ol lererlor modeliGM10(C)
Cabl€ lecudno scaew
On modd 3GM$(D (KM3A),A mark is
slg afd.m the opposatBside ol the
shift 16r.
2-3 Englne slde Installation tloP levet
The same govemor lelsr is us€d In all 4 eogine models,

trowever,lls operationangle is ditterent depending on the
model.
Theconnectlngmetalwhichfits with the dampingspringis
at the tip of lhe got€mor lever,and the cablehasonly to be
screwedinto this fittino.
2-4 Setting the reduction and revelslng gear side
Model KM2C reduction and reversing gear is used forengine
models lGMl0 and 2GM20(F),and model KM3A lor engine
model 3Gl#qF).
On these reduction and reverslng gears, lhe spring loint is
litted to the control lever, and the remote conirol cable is
connected to this loint.
Reduction and reversing gear model KBWlOE is used on
engine model 3HM35(F). On these reduction and reversing
gears, lheclevis is attached to the clutch operating lever, and
the remote control cable is connected to the clevis.
Engine stop level
I l-4
000040A1361 0000A0A136t
Chapla I I Remote Conlrol System Chapler I I R emote Conlrol S),slem

2. Clulch otd SpeedRegulalot Remote Control 3. Engine Stop Remote Control
sM/GM(FXCTHM(F)(c) sM/GM(g(crHM@)(C)
2-{.2 For model 3HM35(F)

3. EngineStopRemoteControl
Foaward
For model1cM10(C)
'f-1
Maximum aaoge
Englnsstop leYel
tst
;-6'o
Motrtffi@tdfitting
YANMAR made otsmn (0.05006In., op{on Th€ metal connEtor fittno h$ r
Cable dia. 61.5 e o2.5mm (0.08006e O.Og8itln.l hol€ ol 2.5mm (r.0984 In.) di& to
rcmrcdato thq c!b16. md cable
ol 1.5 tu 2.5mm @.(}5006 ry O.O98.rIn.)
di!. cs bc ulad In th€ cffn&tor.
+? !g, models 2GM20(FXC),3cffiq$(c) and

3HM35(FXC)
0000A0A1361
00o0A0Al36l
CHAPTER12
SYSTEM
ELECTRICAL
Pr&rcd ir Jqc
0IA0A$5r
Choptr I 2 E leclrLol Sy stem

I. Electdcal Syslan
SM/CM(F)(CTHM(FXC)
1. ElectricalSystem
1.1Systemdiagramol electdcparts
CoOling wate. temperatUre switch
Fuse bor (3OA)
F6 Cltrdar:
Batlery s*itch (ogtional) ttY. tlAH { nigh.i
ForModol3HM S€ri€s.
t:4/, lmAH o. hiohet
Tachometef
sensol Extssion Wi.ehmess
Wir€lu,mst. instruog.t panel
l.tD. l.tfifi,tt p-c$ itpel
Rubber saled l.m9 (gail.drive)

Watg lehperature wtrnino lahp
Waler lempcratu,a wa.ning lamp
Oil prgS3grg ryr6;69 lqrt
Oil preEsuc s&nino lamp
Push button switctl
Alafr buzra
Pdlirl nr Jp
0(mA0Al35r
Chapter 12 Electrical System

Chapter I 2 Electrical SYstem
I. Electrical Syslem
I. Eleclrical SYstem SM/GM(FXCTHM(FXC) SM/CM(FXCTHM(FXC)
1-2.2 Fot the A-type (smalll instrument board
1-2. Wiring diagram
1-2"1For ihc B'tyfn (larg€l iGtmml boatd
At't'ifrs€L
#'
E-
€ cp
r 9i
ss:
5ai
Ige
3 !$
+a i
ls€
*Eq
33s
BI::
:;E
t3d
5i€g
sg*E
* a\i
t;
tl a; $
I oo
lE s E =
?F
.9EE
\$
4t.
!, !l
E
! E
I
6
' EE 6E o
o 5 .e c€€8 c
3
, RE
( l*
B
U @ 3 I
cl
\I FI 3I @ .98
o
-'14E
ve9 :1
o
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o@ z
++
oo
++
oo
d
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o
2
3E c \{3' u'l
iR 3t
a s-. ol
-E
o c=E d zl
12-2 | ,,,,,0,, r.,""

00004041361
0000404136r
I
Chapler 12 Eleclrical SYstem

Chapla 12 Eledrical SYstem 2. BallerY
SMlGM(FXCIHM(FXC) SM/GM(FXC}HM(FXC)
2. BdllqY
2.32 Checking ihe electrolyte (50%). lf the specific Aravity is below 1.200'
2. BatterY {1) ElectrolYte level

G@d Low
rechargethe battery.
4) lf the differencein the specificgravityamongthe
2-1 Construction
Wire lhinner than sPsilied
Vv|re longer than sp6ilied

<F>
ll, lr
<F>
il r l
cellsof the batteryis 10.01,the batteryis OK.
5) Measurethe temperatureof the electrolyte'
Since the specific gravity changes with the
temperature,20oC is used as the reference
temperature.
/.
Fille( cap Readingthe specificgravityat 2OoC
High wiring teslstance s," = sr+0.0007(t-20)
Check the electrolytelevel every 7 to 10 days. The S.: Specificgravityat the standardtemperatureof
electrolytemust alwaysbe 10 20mm over the tops 20"c
-
Low currenl
ol the Dlates. St: Specificgravityof the electrolyteat toC
--T- 0.0007:Speciticgravitychangeper 1oC
+
Faulty sttrling
NOTES:1) The "LEVEL"line on a tmnsparentplasticbat-
tery case indicates the height ol the elec-
t: Temperature of electrolYte
trolyte. 2-3.3Voltagptest
2) Always usedistilled watet to bilng up the elec- Using a battery tester,the amount of dischargecan be
trolyte level. determinedby measuringthe voltagedroP which occurs
3) Whenthe electrolyte hasleakedout, add dilute whilethe batteryis beingdischargedwith a largecunent.
sulturic acid with the same specllic gravity as
the electrolyte,
(2) Measuringthe specificgravityof the electrolyte

1) Draw some of the electrolyte up into a hy-
The battery utilizeschemicalaction to convert chemical drometer.
to it*ttl"tt energy.This engine uses a lead acid
power that can be
LttJv wfrictr stores a fixed amount ot
"n"tu
The overall lengths of the wiring between the
battery (+) ter'
be
useO'wnen required. After use, the battery can .ifur tn" iurter(B)terminal,andbetweenthebattery
recha€ed and usedagain' "^J shouldb€based
,nestarter(E)terminal on
ls st&n in rtretigure'a nonconductive containeris filled ili'ilrtt"i ""0
positive the followlng table.
*ittr Oitrt" sut{uricacid electrolyte'Lead dioxide
glass
of"t"" *A f""O dioxidenegativeplatesseparatedby Allilable Conductq a+b+c
li,.ii in the electrolyte'Thepositive Voltage winr€ q6s-
allilable
"r" "t*t "d "ltemately
plates are connecled to their respective rcltaqe setim lmgth
and negative system
drop M
teminals. 20mm'
load
Poner is removedfrom the battery by connecting the O.O311in.') in.)
(1) Connectthe testerto the battery.
acrossthese two terminals. lAl {Omm' Up to 5m 12Vbatterytester
flows
Wn"n ttt batteryis discharging,an electriccunent 0.@ir') (196.87 in.)
Adiustthe cuffent(A).
the
irom the positiveptatesto the negativeplates'When (2) Conn€ct the (+) lead ol the tester to the (+) battery
electriccunent is passedthrough keY switch circuit
U"tt"ty t"-U.ing ,VOfEi Excessive resistance in the terminal, and the (-) tester lead to the (-) battery
it O"tt".y in ihe oppositedirectionby an externalpower
"h"tged, batteryand start (S) terminals)can cause
" @etween
'irprop", pinion engagement' To prevent this' terminal.
souroe. (3) Push the TEST button, wait 5 seconds, and then read
foitow thewiringdiagnm exactl[' the m€ter.
2.2 Battery capacity and battery cables . Repeat the test twice to make sure that the meter
2.3 Insp€ction 4 Takethe specific gavity reading at the topof the
2-Zl Batt€rycaPaclty pertormance indicationremainsthe same.
Sincethe batteryhasa minimumcapacityof 12V'70AH'it ine oualitvot ttreuatterygof'emsthe startiog scale of the hydrometer.
can be used for 100- 150AH. rhereloreine oatterymust be routinelvin' Rubber bulb
2-3.4Washlngth€ battery
i*liJ t6 otrr" thatit functionsperfectlvat all times'
"i'iti-""tii*.
(1)Wash the outside ot the battery with a brush while
Glass tube runningcold or warm water over the battery.(Make
2-3.1VisualinsPection Read lop of sale
surethat no watergetsinto the battery)
6il;;;i the'case for cracks,damageand electrolvte (2) When the lerminals or other melal parts are conoded
leakage. dueto exposureto etectrolyteleakage,washoff all the
conosion'ano
Fut-ararsedsP€ifi csa"ity fZfi""Gt the batteryholderfor tightness' Float acid.
damage. (3) Checkthe ventholesof the capsand cleanif clogged'
terminalslor rusting and conosion' and
2-z2BallerY c*le
tsli;;li'ttre (4) After washingthe battery,dry it with compressedair'
checkthe cablesfor darnage' connectthe batterycable,and coat lhe terminalswith
wirinornu"i Uup.rformedwith the speciliedelectricwire' *p" for cracling, electrolvteleakageand
Thicklshort wiring shouldbe used lo connectthe battery or i"ip."iiG 3) The battery is fully charged if the specilic Aravity grease.Since the greaseacts as an insulator,do not
cloooedventholes'
io'the starter,(softautomotivelow-voltagewireIAVwire])' ilil"Lnv conditionsfound Cleanol( rusted is 1.260 at an eleclrolyte temperature of 20oC. The coatthe terminalsbeforeconnectingthe cables'
fol'
iilng *i* other than that specified may cause the i"-*in"f *itt"ono,tal brushbeforereconnecting
the bat- battery is discharged it the specific gravity is 1.200
lowingtroubles: "
tery cable. " "ire
i
124 I
00004041361
I
I 0000A0Ar36r
Chapler I2 Electricol Syslem

Chapter 12 Ekclrical System
3. Slarler Motor
2. Ballery
SM/GM(F)(CIHM(F)(C]
SM/GM(F)(C'HM(F)(C)
2-4 Charging
2-4.1Charglngmethods 1.29
3.StarterMotor
Thereare two methodsof charginga battery:normaland 1.28 The starter motor is installedon the flywheel housing.
rapid. When the starting button is pushed, the starter motor .g
Rapidchargingshouldonlybe usedin emergencies. 1.27
pinionflies out and engagesthe ring gearol ihe flywheel. E
. Normal charging...Should Specific
be conductedat a currentof g.avity 1.26 Then the main conlact is closed,cunent flows, and the 12
1/10or less of the indicatedbattery engineis started.
capacity (10A or less lor a .t00AH 1.25 Alter the enginestarts,the pinionautomaticailyreturnslo
battery). its initialpositionwhen lhe startingbutton is released.
. Rapid charging-..Rapid 1.24
chargingis doneovera short Once the engine starls,the startingbutton should be
p€riodof time at a current of 1/5 tu 1.8 releasedimmediately. Otherwise,the startermotormaybe
1/2 the indicated battery capacity damagedor burnedout.
(204 tu 5OA for a 100AH bartery).
Eleclrolyte temperatu.e (oC)
However, since rapid charging 3.1 Specificalions'and Performance.
Electrolyte temperature and specilic 0ravity
causes the electrolytetemperature
to rise too hlgh, special care must 2-5 Ballery slorage prccauiions lGM1O(C)
be exercised. Engine Model 2GM20(FXC) 3HM35(FXC) o 2oo tf,**, 8oo
The life of a batterydependsconsiderablyon how it is 3Gli80(R(c) ffi
2-42 Charglngprocedure handled-Generallyspeaking,however,atter about two Model s11+303 s'12-77A
(1) Check the speclficgravityand adiust the electrolyte yearslts performancewill deteriorate,starting will become S12-ZA Ferformne cures
Rating (s) 30 30
level. difficult,and the batterywill not fulty recoverits originat
(21 Disconnectthe batterycables. chargeevenafterrecharging. Thenit mustbe replaced.
Odprrt (kW) t.0 1.8 3-2Constructioo
(3) Connectlhe red clip of the chargerto the (+) battery (1)Since the batterywill self-dischargeabout 0.5%/day Direction of rotation Thestartermotordescribedin thissectionis a conventional
O@kwig Cl6kwis
evenwhennot in use,it mustbe charged1 or 2 timesa
(viewed trcm pinion side) pre-engaged 4-brush4-polestartermotorwith ascrewroller
terminalandconnectthe blackclip to the (-, terminal.
monthwhenit is beingstored. Weight kg (lb) 4.4 (9.7) 9.3 (20.5) driveclutch.
Clutch system o\€mnning Ovetrunning
The starter molor is composed of three maior parts, as
Engagemst system follows:
Magnetic shift shitl
(l) Magneticswitch
No. ol pinio teeth o 15 Moves plungerto engageand disengagepinion, and
Pinion fiydt rcltag€ (V) I or le$ I or le$ throughthe engagemenllever,opensand closes main
Selt.discharge/
day (%) 3 TermiEl
12
contact(movingcontact)to stop the startermotor.
voltaoe (V) (2)Motor
Current(A) @ or less 90 or le$ A continuouscurrentseriesmotorwhichgeneratesrota-
Speed(rpm) 7m0 or greaer 40(n or gr@ter tional drivepower.
Tmiml (3)Pinion
voltagp (V) 6.3 Transfergdrlving powerfrom motor to ring gear.An over-
L@ded
cha€cter- Curent (A) 460 or ls 4n speed clutch is employed to preventdamage if the
istics engineshouldrun too fast-
(a lf charging by the engine allemator is insufficient Torque 0.9 (6.51) 1.3s(9.76)
k9f-m(tr-lb) or gr€Iea or grearer
becauseof frequentstarls and slops, the battery will
rapidlylosepower.
(4) Sel the cunent to i/10 tu 1/5of th€ capacityindicated Chargeth€ battery as soon as possibleafter it is used ab E t
on th€ outsideof lhe battery- undertheseconditions. Jrs D500412-B
(5) Poriodically rneasure the specific gravity during (3) An easy-to-use battery charger that permits home Batlery:N702/4charged-tooc
charging to make sure that the speclfic gravity charging is availablefrom Yanmar-Takepropercare of
rernainsat a high fixed value. Also check whether the battery by uslng the charger as a sel wlth a 't.2l
P l 2000
gas ls being generated. hydrometer. I
2-43 Ct|erglngptecautbns
When the specificgravityhas droppedto about 1.16 ' of0@0
andthe enginewill not start,chargethe baneryup to a orf8000
(11 Remove the battery caps to vent the gas during sp€cificAravityof 1.26(24hours).
charging.
(2) While charging, ventilate the room and prohibit
(4) Before putting the battery in storage for tong
periods, charge it for about I hours to prevent rapid
"uf6@0
oof(mo
srnoking,wolding,etc.
aging.
(3) The el€ctrolyte temperatureshould not exceed 4S6C
duringcharging. "rf2000
(4) Since an altemator is used on this engine, when
chargingwttha charger,alwaysdisconnectthe batterv
(+)cableto preventdestructionof the diodes.
(Beforedisconnectingthe (+)batterycabte,disconnect 5114.303 Perfmnce curyes
the(-) balterycable[groundsidel.)
000040A1361
000040A1361
Chapter 12 Eleclrical SYdem Chapter 12 Electrical Syslem

3. Slarte Molor 3. Stailq Molor
SM/GM(FXC}HM(FXC) SM/GM(F)(C'HM(FXC)
To preventthe motor receivlnga shockwhich will occuras
&*
3-4 Adiustmenl and perfomance test
lhe engine starts and over-runs,this starter motor is in- 3.4.1L.sizemeasu.ement(gapbelweenpinion and pinion
stalledwith anover-runningclutch- stoppe.)
When the pinion is at the pojected position, measure
Over-runningclutch
betweenpinionand pinion stopper.This checkshould be
made with the pinion pressedback lightly to take up any
Clutch outer
playin theengagementlinkage.
Ierminal cover cover Roll!, mm{in.l
Rott., sp.ing
Startermotor /dimeGion
S11.1.303 0.3 - 2.5

(0.0118- 0.0984)
Pressing the pinion

Shitl lever
Dusl cov6r 3-3Operataon
Current fbffi h serigs @ll md shmt @il
When pinbn flies ot rcffrElly with ring gq
Measu.ing of I dimension
Gear ese Pinionand ring gs rct engaged
3-42 Pinionmovem€nt
After complete assemblyof the starter motor, connecl up
Contetsof min cont*t clo6e the motorasin Fig.
J|d curst tlows
Conlstsof min mtmt clced

and dnenl tbre
Pinlon ad ririg gpa, sepaatq

dnim engages ring gw,
and ring gea rclal6
Afts engire stntq stating switch opens
Pinkm Gturns to digiml positim thrwgh shift les

by tcim spring ild mtets tre simultilsudy opened
12-9
m00A0Al36l 0000A0A136r
Chapler 12 Elcctrical Syslem Chopter 12 Electrical System

3. Slartet Molor 3. Slarter Motor
3-4.3 Plunger movemenl 3-4.4 Pinion lock lorque measuremenl 3-52 Rea.cover 3-5.4Yoke
Adiustment made by adjusting stroke of magnetic plunger (1) Removedust cover. (1) Removeyoke. Pull it oul slowly so that it does not
to the prescribed Yalue. strike againstother parts.
{1) Shim adjusting type (S114-303)
Adiust the l-dimension installing shim (Adjusting plate)
at the magnetic switch attach section.
There are two kind of shim [Thickness 0.5mm (0.0197in.),
0.8mm (0.0315in.)l
Dust cover
3-55Armature
3"4.5 Mesh clearance (1) Slide pinion stopperto pinion side.
Mesh cl€arance is the distance between the llywheel ring (2) RemoveE-ring,and removethrust washer (be careful
gear and starter motor pinion in the rest position. This not to lose the washerand shim).
clearance should be between 3mm (0.1181in.)to 5mm (3) Removeth€ two through bolts holding the rearcover
(0.1969in.). and the two screwsholdingthe brush holder.
(4) Bemove rear cover.
(2) Adiusting screw typ€ (S12-774)

Adiust the t-dimension by adjusting screw and nut
(2) Removethe pinion slopperclip.

Adiustin0 sc.ew
and nul
3.5.6Pinlon
(1) Slide the pinion stopperto the pinion side.
(2) Removeihe pinionstopperctip.
3-5Disassembly (3) Removethe pinion from the annarure.
3.5.1Magneticswltch 3.5.3Brush hold€r
(1) Disconnect magentic switch wiring. 0) Float (-)brush from the commutator.
(2) Remove through bolt mounling magnetic switch. (2) Remove(+)brushfrom the brushholder
=:_:_-/ (3) Remove magnetic switch. (3) Removebrush holder.
m00A0Al36l 0000A0A136r
Chapter 12 Eleclrical Syslem Chopter 12 Eleclrictl Syslem

3. Starler Motor 3. Starter Motor
SM/CM(FXC}HM(F)(C) SM/GM(FXC}HM(FXC)
3.6 lnspectaon Checkingarmaturewindingsfor insulationfaults. (2) Short test

3-6.1Armsturc Checkfor continuitybetweenth€ yoke and any fietd
(l) Commulator coil terminal. Continuity indicates that the coil is
Inspeclthe surfaceof the commutator.lf corrodedor shortedandthat it mustbe replaced.
pitled, sand with #500 d #600 sandpaper.tf the (3) Cleaningthe insideof theyoke
commutatoris severelypitted, grind it to within a lf any carbon powderor rust has collectedon lhe
surface roughnessof at least0.4 by turning it on a inside of the yoke, blow the yoke out with dry
lathe. Replace the commutator if damage is comoressedair.
irreparable. 'Do not removethe tieldcoil from the yoke.
/-
(4)Armatureshefl outside diameter

mm {in.) Measurethe outsid€ diameter of the annature shaft at
S11,1-303 s12-77A four locations:front, center,end, and plnion. Replace
Mainlrcstardard lntrearlimit Mainte@@ stand{d \rJear limit
the armaturelf the shaftls excessivelywom.
Check the bend of the shaft: reolacethe armaturelf the 3-6.3Brush
Comutatq outsue diarettr o3B (129q o9.(1.N1 o4r (1.693) 640 (1.575) Thebrushesarequicklywomdown by the motor.Whenthe
bendexceedsO.@mm(O.m31in.)
Cmmutatq run-oot Within0O3O.mla 02 p.m79 Within0.030.0012 02 p.0079) brushesaredefective,theoutputof the motorwilldrop.
Diffffi botween rEximum Repair limlt Repairmuacy Repairlimit Repairecurrcy
diamttr and minknm dkurEts 0.4 o.015n 0.050.004 0.40.015n 0.05 0.002)
(2) Micaundercut (3)Armaturecoilgroundtest

Check the mica undercut,conect with a hacksaw Using a tester, check for continuity between the
bladewhenthe underculis ioo shallow. commutator and the shaft (or armature core).
Continuityindicatesthat these points are grounded
Bad c@d
andlhat thearmaturemustbe reolaced.
1) Shorttest...exisience
of brokenor disconnectedcoil. 3.62 Fieldcoil
2) Insulaliontest..-betweencommutatorand armature (1)Opentest
coreordistortionshaft. Check for continuity between the terminals con-
nectingthe fieldcoil brushes.continuity indicatesthat
Checkingcommutatortor insulationdefects. the coil is openandthat the coll must be replaced.
cmmutato, F""il0o.s * (1) Brushdimensions
seorent mi€ o.e
-. Replacebrusheswhich have been wom beyondthe
N/Z specifiedwearlimii.
ffi
Repla@ the brush lf lt is
wom up to lh€ bottom of
the Hitachi trademaft
(apprcxlmately oo€-hall ils
,original length)
Standard
height
Wear limit
t
12-13
0000404t361 0000A0Ar36r
Chryle 12 Ekclrical System Chapter 12 Eleclrical Syslem

3. Starter Mobr 3. Slarler Motor
SM/GM(FXC}HM(F)(C) SM/GM(FXC}HM(FXC)
(4 Brushappearance andmovementin brushholder 3-6.4 Magnetic swilch (3) Contactorcontacttest (2)Mountingthe magenticswitch
lf th€ outsideof the brushis damaged,replaceit. It the (1) Shunt coil continuity test Push the plunger with your finger and check for Attach the shift leverto the pinion; assemblethe gear
movemeni of the brushes in the brush holder is Check for conlinuity between the S terminal and the conlinuity between the M terminal and B terminal. caseas shown below.
hampered because the holder is rusted, repair or magnetic swilch body (metal paro. Continuity Continuityindicatesthat the contactis faultyand that Do not forget to install the dust cover before assembling
replacethe holder. indicates that the coil is open and that the switch musl the contactormust be replaced. the gearcas€.
(3) Brushspring be replaced. After reassembly,check by conductingno-loadopera-
Since the brush springpusheslhe brush againstthe tion.
co.nmutatorwhile lhe motor is running,a weak or
defective spring will cause excessivebrush wear,
resulling in sparking between the brush and the
commutatdr during operation. Measure the spring
force with a springbalance;replacethe spring when
the differencebetweenthe standardvalue and the
measurcdvalueexceedsi0.2kg-
Wd llmit rO.2k0
(3) Lubrication
Lubricate each bearlng and spline (polnts indicated in
the tigure belorvl with high quality "Hitachi Electrical
&65 Pinb{l EqulpmentGreaseA".
(M6uring brush rpring to.ce) (1) Inspect the plnlon te€th and replaceth€ pinion lf the The following lubdcants rnayb€ used In place of Hltachi
teeth ar€ excesslvelywom ordaanaged. El€ctricalEqulpm€ntGr€aseA
(2) Checklf the pinlonslidessmoothl),;reptacethe pinion
Sta.tdadspdnglod | 1.6lig€5z/b) | 085ks(1s737tb) lffaulty. ,
(2)S€riescoil continuitytest
(3) Inspect the springs and repleceif faulty.
Check for c-o{rlinuitybetween the S terminal and M (4) Replacethe clutch lf lt stipsorseizes.
{4) Brushholdergroondtest termlnal.ContlnuityIndicatesthal the coil ls oDenand
Check for continuity between the Insulated brush lhat it must be replaced.
3-7 Roassembly precautlons
holder and the base ot the brush holder assembly. Reassemble the starter rnotor In the reverse order of
Continuity indicates that these two points are disassembly,paylng particularattentlon to the following:
groundd and tt|at the holder must be replaced. (1)Torsionspringandshift lever
Hook the torslon spring Into the hole In the magnetic
switch and Insert the shift leverInlo the notch in the
plunger of the magnetic switch through the lorston
spring.
ToGion sp.ing
I S114.m I S12_77A
| 0.32ila
Resisla@value(at20oc) | 02674
12-14 t2-15
Prin .d,n Jwn
m00A0Ar35r 0000404t361
Chapler 12 Eleclrical Syslem Chapter 12 Eleclrical System

3. Slortu Molor 3. Starler Motor
SM/GM(F)(C}HM(FXC) sM/GM(F)(CIHM(FXC)
3-8TeslirE (2)Coinect the negativeterminalot the batteryto the 3.10 Various problems and their remedies
3-8.1No loed lesl bodyof the starler- (1)Pinion lails lo advancewhen the startir€ switch is closed
Test procedure (3)Connectthe positivesideof the voltmeter(V)to the B Problem Cause CdrcliYe actls
(1) Connect the positiveside of the ammeter(A) to the terminalof lhe starter,and connectthe negativeside Wiring Open d loo* battery q switch tmiml Repairs retighten
positive terminal of lhe battery, and connect the of thevoltmetertothe bodyofthe starler. Threadedpart cmneted to pinion stion of ilmture shaft
Sttrting switch Repair coniacts,
negativeside of the ammeterto the B terminalof the (4)Attachthe tachometer. is dmaged, ild the pinio d@s not roe s rsle sitch
slarter. (5)Connectthe B terminalof the starterto the S terminal Threadedpart @nneted to pinion wtim of aruture shaft
of the magneticswitch- Startermts Replrcb.
is damaged,md the pinion d@s rct mde
. The magneticswitch should begin operating,
and the Magnetic switch Plunger of rognetic switch rolfunctiqing or coil
speed,current,and voltageshould be the prescribed shorted Repairor replace
vatues.
. A fullychargedbatterymustbe used.
. Sincea largecunentflowswhenthe starteris operated, (2)Pinionis engagedand molor rotates,but rotationis not transmiltedto lhe engine
close the protection circuit switch betore initiai
operation,then op€n the switch and measurethe
cunent after lhe starter reachesa constant soe€d.
(3) Molor rotates at tull power before pinion engagesring gear
3-9Malnlenance
standard
(4) Pinion engagesdng gear, bul slarter motor tails to .otale
Problem Cause Conective rctim
Wires mn*ting battery and magretic switch op€n
Wking or wire mffiting grunq magretic sitch ad mttr Repair,rerighlm,
q repl@ wiE
tminals bos
Pinim Jd ring gpar engagemt fillty Reple
Motd rEunting lelty Rernornt
Brush m tr cmteting brush sfiirE faulty @le
Starler mts
Cornmutatd dirty Repair
Annature, tield cdl laulty Repair or replee
Field coil and b.ush mrctim loo$ Retighltr
Coot&ld contact fillly Feple€
Magretic sritdl
Contactq mteis oitted
(5) Motor lalls to stop when sta.ting switch ls opened after
13950 tu
000rlA0Al
361 00@A0Al36l
Chopler 12 Electrical System Chapler 12 Electrical Syslem

1. Allerrmlor Stondail, I2V/55A 4. Allemalor Stonfurd, I2V/55A
SM/GM(FXC}HM(FXC) SM/GM(FXC}HM(F)(C)
4.4 Conslruction
4. Alternator Shndard,l2vtssA This is a standardrotatinglield typethree.phasealternator.
It consistsof six marorparts: the pulley,fan, front cover,
The alternator serves to keeo the battery constanily charg. 4.2 Specifications rotor, statorand rearcover.The lC regulatoris an integral
ed. lt is installedon the cylinderblock by a bracket,and is oartof the altemator.
drivenfrom the V-pulleyat the end of the crankshaftby a V. Model of alttrnatq LF155.20(HtTACHt)
belt. Model of lC
The type of altematorussGin this engineis idealtor high 8altery rcltage l2v
sp€edengineswith a wide rangeof enginespeeds.lt con-
Nominaloutput
tains diodes that convert AC to DC, and an lC regulator
that ke€psthe generatedvoltageconstanteven when the
enginespeedchanges. Dirmtion of rotatis
(viewedfrom pulley end) Clockwis
4-1 Featu.es Weight 4.3ks(9.51b)

Thealternatorcontainsa regulatorusingan lC,and hasthe 5000 rpm
following featu.es- 1000 tu 9000
(1)The lC regulatorls sell-contained,and has no moving Speedfs 135V l00O tr le$
parts finechanical contact point). lt theretore has curtrt at 20oC
superlor features such as fre€dom trom vibration, no
tluctuation of voltag€ during use, and no need for read-
Capacltor 6sembly
,ustment.
Also, lt ls of the over-heating compensation type and
can automatically adjust the voltage to the most
suitableleveldependingon the operailngtemperature.
(2)The r€gubtor is Integratedwithin the altemator to Brush holder
slmplifyexlemalwiring.
(3)Th€alte.natoris designedfor compactness,lightnessof
weight,.nd high output.
(4)A newly developed.;qlEg=!-9!9qg is used ro provide
Increaseo retiaDitity and easier checking and
malntenance.
6) As the altemator ls to b€ instalt€d on board. the foltow-
Ing measuresare taken to provide saltproofing. Reaacover assemblv
1) The faontand rearcov€rsaresalt-proofed.
4 Salt-proofpaintis eppliedto the diode.
3) The termlnal, wh€re the Inboard harness is connected
to the altemator,is nlckel phted.
4.3 Characlerlstlcs
Fronl covef Rotor ssembly
100
I Regulatcd v
Bearing .otainet
8.ush assembty
lC regulator assehbly
80 Ball b€a.lng Through boll

Brush set
Pulley nut 6sem6ty

z Ball b€a.ing
le
;6 0
=
o
o
:6 E40
o Rear corea
G
20 InsulatlngbushinO
I Pulley assembty
0
{68 14 x t0, Scr€w (M5 x 0.8 x .t4)
Speed of allerMtor (rpml
12-19
00004041361 0000A0A1361
Clwpla 12 Ekctrical Syilem Chapter 12 Eleclricol System

1. Altenutor Slandar4 I2V/55A 4. A kemaru Standard I 2 V/ SSA
SM/GM(FXC}HM(FXC) sM/GM(F)(clHM(F)(c)
tl-5 Alternatorlunctioning 4.6 Handling precaulions 4.7Disassembling the alternator
(l) lC regulalot (1)Be carefulof the battery'spolarity(+, - terminals),and (1)Remove the through-bolt,andseparate
the frontas- (4)Removethe nut, the brush.holder,and diode fixing nut
The lC tegulatorls th€ transistor{Tr,}which is series- do not connect the wrong lerminals to the wrong semblyfromtherearassembly. at the BAT, and the teminal screws of the rear cover.
connected wlth the rotor. The lC regulator controls the cables or the baltpry will be short-circuitedby the Separatethe rear cover from the stator (wlth the diode
output voltageof the generatorby breakingor conduc- generatordiode. and brushholder).
ting the rolorcoil (exciling)cunent. In this casetoo much cunentwill flow, the lC regulaior
When the output voltageof the generatoris within the and diodesburnout, andthe wire harnesswill burn.
b f f i @wu*
standad yelue,th€ transistor(T() tums on. When the (2)Makesureof the conect connectionof eachterminal.
voltage exceedsthe standardvalue, the Zener diode (3)When quick-charging,etc., disconnecteither the bat-
goeson and the transistor(Tr,)tums off. tery terminalon the AC generatoror the terminalon the
With the repeatedturning on and olf of the transistor. battery.
the output voltage is kept at the standardvalue. (Refer (4)Do not short-circuitthe terminals.
to the circuitdiagrambelow.)
€) Chargelamp
(5)Do nol conductany tests usinghigh tensioninsulation
/ --Y1]
When th€ transistor (Tr,) is on, lhe charge lamp key
switch ls lumed to ON, and cun€nt flows to R,. & and _t|0
to Tr, to light the lamp.When the enginestarts to run _10
and orjtput voltage is generated in the stator coil, the H)
cunont slops flowing to this clrcuit, turning off the (5)Disconnect the solde{€d lolnt of the stator lead wlre,
chargo hrnp. and remove the diode and brush regulator assemblles
(3) Ckcuit dkrgram (2)Removethe pulley nut, and pull out the rotor from the fromthe statoratth€ sametime.
front cover.
qhtraaK
f{-XV9,'
'*b \qBA)c'Ar
, ,wrcfu
Batt€ryswitch
#@@ (6)Separatingthe r€gulator
1) To s€parate the reguhtor, emove the 63.0mm dvet
(3)Remove lhe osmm screw from the front cover. and which keeps th€ diode ass€mbly and the brushless
then remo/ethe ball bearing. regulalor In place, and the soldered loint of the L.
terminal.
@A y,e\l9so
BAT: Gen@tor output tminal O,-O.: . Output comoutation dlode

D,.: lC p@isting diodo R,-R.: Resisto.
L: Ch{ge lamp teminal D,-Or: Cha.ging lamp swltchlng diode
ZO. Ze6 diode F: To gupply curent to roto. coil
E: Eaflh Rn: fhemistor
T.,, Trt: (Temp66tu.o O€dient aGlstance)
Transistoa
12-m 12-21
0000A0Al36t rrc00A0Al36t
Chapler 12 Electriul Syslem

1. Alldndlor Standar4 I2V/55A Chapt* 12 Electfical System
4. Ailerndor Stanford, I2V/55A
SM/GM(F)(CTHM(FXC) SM/GM(FXC}HM(FXC)
i 2) To replacethe lC regulator,disconnectthe soldered After repeatingthe abovetest, if any diode is found to 3) Rotorcoil insulationtest 2) Statorcoil insulationtest
,olnt of the lC regulatorand pull out the two bolts. Do be defective,replacethe diodeassembly-Sincethereis Check the continuity betweenthe slip ring and the
not remotelhesetwo bolts exceptwhen replacingthe Check the continuity betweenthe terminalsand the
no terminalon the auxiliarydiode,checklhe continuily rotor core,or the shaft.lf thereis continuity,insulation stator core. lf there is continuity, insulationof the
lC regulalor. betweenboth endsot the diode. Inskle the rolor is defective,causing a short-circuit stator coil is defective.This will causea short-circuit
with the earthcircuit.Reolacethe rotorcoil. with the earthcore.Replacethe statorcoil.
F?--*
R
\:"-'-t
sru
h=3 1tr
4.EInspoctionandadjustment
{1}Diod€ 4) Check the rear slde ball bearing.lf the rotation of the
BAT(+ sljediode)
bearing,ls heavy, or prcduc€s abnormal sounds,
CAUTION:Do not use high tensiteinsulation/eslstance replace the ball bearlng. (4)Brush
such as meggerc,etc. tot testing.Otherwise, Thebrushis hardand wearsslowly,but when it is worn
the diode may bum out. beyondth€ allowablelimit, replaceit. When replacing
the brush also check the strengthof the brushspring.
(2)Botor To checb push the spring down to 2mm from the end
Inspeclthe slip dng $rface, rotor coil continuityand surface of the brush holder,and readthe gauge.
insulation.
1) tnsp€ctingthe slip ring surface
Check lf the surface of the slip ring is sufficienfly
smooth.lf lhe surlaceis rough,grind the surfacewitir
No. 500-600 sand paper. lf it is contaminated with
oil, etc.,wipethe surfacecleanwith alcohol.
2) Rotorcoil continuitytest (3) Stator

1) Statorcoll contlnullytest
, Checkthe continuityin the slip ring with the tester.ll
' there is no continuity,there is a wire break.Reolace Check the continulty betweeneach terminal of the
lhe rotorcoil. slator coil. lf there is no continulty,there is a wire
breakin the statorcoil.Replacethe statorcoil.
Cur6t dirrction (0.s6 76rb.)
U.V.W.i teminat trom the gtator coil
(5)Brushwear
Checkthe brushlength.
Thebrushwearsvery little,but replacethe brushif worn
Cunent fbws only In one direction in the diode as overthewearlimitlineDrintedon thebrush.
shorrrnln Flg. 181.Accordingly,when ther€ is continui.
ty betweeneach terminal (e.g. BATand U), the diode is
In nomal cordition (photo).When there is no continui-
ty, lhe diode is defective.
When the tester ls connected in the reyers€of above.
th€{€ should be no continuity.lf lhere is, the diode is
defective.
Approx. 3.34e
Wear lahil line brushl
''-'--"-- '_'-- | l-oh6e resislarce
12-22
Prh.cA ir Jw
000040A136r 00rxlA0Ar36r
Chaplcr 12 Dleclrical Syslem Chapler 12 Eleclrical Syslem

4. Allcrnalor Slandard, I2V/55A 4. Allernator Standard, I2Y/SSA
SM/GM(FXC}HM(F)(C) SM/GM(F)(C}HM(FXC)
(6) lC regulator Wind the wire 1.5 times (3)Assemblingthe rearcover (1) Measuring devices
Connect lhe variableresistance,two 12V bafleries, around the leminal groove. Insertpins from the outsideof the rearcover.Installthe
brush on the brush holde( then attach the rear cover. 0- tsv d 0-30v, 05 ctass, 1pc.
resistor,andvoltmeleras shownin lhe diagram.
After assembly,pull out the pins. 0-10OA, 1.0Class, 'lpc.
1) Usethe followingmeasuringdevices.
Resislor(R,) 100a,2W,1pc.
Variableresistor(Rv) 0-3004, 12W,1pc.
Battery@AT,,BAT,) 12V,2pcs.
DCvoltmeter 0-30V, 0.5classI pc. (2)Measuringthe regulatingvoltage
(to measureat 3 points)
1) When measuring devices are connected in lhe
2) Checkthe regulatorin the followingsequence,accor. Mount lhe insulationtube performancetesi circuil as shown above,the charge
on lhe leminal surlace.
ding to the diagram. lamp lights.
a)Check V, (BAl + BAT,voltage).lf the voltage is NOfESi t. Usenon.acidtype paste.
2. The soldering iron tempenture is gOO * 2) Close SW, while keepingSW open and run the AC
20-26V, both BAT,and BAT,arenormal. generator.When the revolutionsof the generatorare
b)While measurinsV, (F-Eterminalvoltage),move Rv 3500c.
graduallyraised,the-chargelampgoesotf.
graduallyfrom the o-position.Check if there is a 2) Mount the lC regulatoron the brush holder as il- 3) Raisethe revolutionsof lhe AC generato(and readthe
point where the Vr voltage rises sharply lrom below lustrated,and press in the M5 bolt. Oo not forget to voltmeter gauge when the revolutions reach about
2.0V to over 2.0V. lf there is no such point, the assemblethe bushingand the connectingplateat the
5,000rpms.
regulatoris defective.Replacethe regulator.lf there sametime.
ls a sharpvoltag€rise when testing,returnthe Rv to (lf the bushingis left out, the output termlnalwill be ,volEs.' t. Make sure that the ammetet indication at this
the o-position,and connectthe voltmeterto the V, earthedandthe batteryshort.circuited). lrme is /ess than 5A. f the indication is over
position. 54, connectthe 0.259 reslstor.Thevoltmeter
clWhile measuringV, (voltagebetweenL-E termlnats), indication at this time must be within the
moveRy graduallyfrom the o-posit'on.Thereshould prescibed regulating voltage value.
be a point wherethe voltageof V, rises sharplyby 2. Raise the AC generctot revolutions high to
2-6V. Measurethe voltage of V lust before this make sure the regulating valtage does not
sharp voltagerise.This ls the regulatingvoltag€of lluctuate along with changesin the rcvolution
the regulator.It this voltageof V, ls within the stan- speed.
dard limit, the regulatoris normal. tf the voltage (3)Precautionslor measuringthe regulatingvoltage
deviatestrom the limit, the regulatoris defective. 1) When measuringthe voltage, measure the voltage
Replacethe regulator. betweenthe AC generatorBATterminal,or Battery +
terminal,and ACgeneratorE.terminal.
2) Usea fully chargedbattery.
NOTES:l.lnsertion pressureis 100k9en.s bs.) 3) Measurethe voltagequickly.
2. lnsert vertically. 4) Keep SW open for measurement.
(4)Tighteningtorques
(2)Connectingthe brushregulatorassemblyanddiode
Tightening brqu€
1).Checkthe rlvets Fo6ltlons
kgf{m(ft-lb)
Placethe rivetsas shown in the figure,and then calk (2.31tu 2.8s)
32-40
lhem usingthe calkingtool. 32-40 (2.31tu 2.89)
32-40 (2.31tu 2.89)
Calking torque (1102lbs) 4m-600 (28.93tu 43.40)
32-a0 e31 tu 2.89)
2) Connectthe brushto the diode. 4-10turlorilF"Lrc
<_ Insert the brushside terminalinto the diodeterminal, Conduct a perfomance test on the reassembled AC
calk it, and then solderInto Dlace. generaloras follows. The following is the circuit for ihe
perfomancetest.
3.0 mm (0.1181in.l dia. rivet.

1.9 R.6..ebflq tl eilsnelor
Reassomblyls done In the reverseorder ol diassembly.
For reassembly,be caretulof the following points.(Retet
to 4-7 disassembling altemator).
(1)Assemblingthe brushregulator
1) Solderthe brushes.
Positionthe brushas shownin the dfawingand solder
It. Be carefulnot to let the solderdrip into the pig tail
(leadwlre).
5o0kg (1102
12-24 12-25
m00A0Ar36r 000040A136r
Chqta12 EleotfiulSytem
1. A &anwtu Slattud, I 2 V/ SSA Chapler 12 Eleclrical System
1. Ailanabr Slanfurd, I2V/55A
SM/GM(FXC}HM(FXC) SM/GM(FXC'HM(F)(C)
rl-lt Trorbleshoofiq
(11GtEOlng falluG
(2)Overcharging
006 the chage hrnp g|ooft

rho.r the toy swilch b tunod
(aftr 6gh. ststkroD?
Altc rtopphg th.dE&r, tm n tft.lcy,r{dt.
(3)Charge lamp failure
Ctl$k lhe wkim.

octld(.LcMcat wttlo !d (bf€cilw Ropleclraoohtrrp.
lilcalu|l tho voltrOg bct*st BAT
|gmfigl rd F.L couoler tflnhC- ffifldttts$;.ttdn
och.d( thc fsy swftch nd li'!o
derecrhc
co.trhutry
of1h3
mr
8,{I, &L terrrkpt
Voiltgo:0- l2V
Atts twnho on tha fry tilr[dl
6fter cnglno drfhgD,.tud( f Cfidg€ larnp b o|( f fr !06 off.
lnsst R.L cc^9lr to gitrdor. ttr€ clla !€ hrrp 9006 o{f.
Tum dr the l(€y swltdl torrtelrr€ sfdhor
'M€8JJ|! tt|s vottro8 bdwql

gs|€retor 8AT. and L tsrmtEt
'E^ffi#mffi'ffi.
on a- ol defcc$yc oontkxritv o{
L-tilnhd, ct!d( or rFb dfrdo.
|llld.rdrdtr-
Llght the nloftt bftp. MGUI!

thc 8AT tsmlrd Ki(4e ol Cl|€d( cbctdc.d rfhg ta nlghl
Osnealoc 03-2V b mmd-
12-?f
PdJ.A h Jq. P'jt.litt6 12-27
0o00Ao^t36i mooAoAr$r
Chapter 12 Eleclrical System Chapter 12 Electrical System

4A. Allenalor Opliot, I2V/35A 4A. Allernalor Option, I2Y/35A
SM/GM(FXC/HM(F)(C) SM/GM(FXC}HM(FXC)
4A-4.Construction
4A. Afternator, Optioh, 1 2V /35A rExcep,icMlo(c)l Thisis a standardrotatingfield typethree.phasealtemator.
It conslstsof six maiorparts: the pulley,fan, front cover, Te.minal
The aliemalor serves to kebp the battery constanily charg. 4A-3. Charactedstics rotor,stator and rearcover.The lC regulatoris an integral
ed. lt is installed on the cylinder block by a bracket, and is partot the alternator.
driven from the V-pulleyat the end of the crankshaftby a V.
belt. I
The type ol altemator used in this engine is ideal for high ^l

>I
speed engines having a wide range of engine speeds. lt
contains diodes that convert AC to DC, and an lC regulator
PI ;
that keep the generated voltage constant even when the 9r s f i
Dlo
engine speed changes. e14t ?
4A-l.Features 316
Thealtematorcontainsa regulatorusingan lC,andhas the ] I
followingfeatures.
(1)The lC regulator,which is selt.contained,hasno moving
part(mechanical contactpoinl),theretoreit hassuperior
leaturessuchas,freedomfrom vibration,no fluctuation
ot voltageduringuse,andno needforreadiustment.
Also, it is of ihe over-heatingcompensalingtype and
can autornaticallyadiust the voltage to lhe most
suitableleveldependingon the operatingtemperature.
(2)The regulator is integrated wiihin the attematorto
simplifyextemal wiring.
{3)lt is an allemalor designed for compactness,light
weight,andhighoutput.
(4)A newlydevelopedU.shap€ddiode is used to provide
increased reliability and easier checking and
maintenance.
(5)As the altematoris to be instailedon board,the follow-
ing countermeasures aretakenlo providesalt-proofing.
1) Thefrontandrearcoversaresalt-proofed.
2) Salt-proofpaintis appliedto the diode.
3) The terminal,wherethe hamessinboardis connected
to the altemator,is nickelplated.
12-28
0000404t36r
000040A1361
Chapler 12 Eleclrical Sydem

Chapler 12 Eleclrical Syslem
1A. Alternator Optioa I2V/35A
SM/CM(FXC}HM(FXC) 4A. Alternalor Option, l2V/35A
sM/cM(FXctHM(F)(C)
4A-5.Wirlng 44-6.2Principleof lC regulalorfunclion (2)Whendisassemblingthe front sidepulteyand fan, front (5)Removethe nut at the threadedpartof the BATterminat
(l) Wiringdiagram The lC regulatorcontrols the output vottageof the alter- .co/er and rotor,clamp the rotor in a vice within copper on the rearcove( the fixing nut of the diode,and the bolt
natorby switchingthe rotorcunent(excitingcunent)on or platesand loosenthe pulleynut,as shownin the figure. of E terminal.
Battery switch
otf by meansof the transistorTr, which is connectedin
.--'O----r serieswiththerotorcoil.
After removingthe L terminal assembly,separatethe
alternatorinto rearcoverand stator(withattacheddiode
When lhe oulput voltageof the alternatoris within the andbrushholder).
regulatedvalues,transistorTr, is ,,ON" but when lhe
voltageis outsidethe regulatedvalue,the ZenerdiodeZD
comes"ON",and regulatesthe outputvoltageriseby turn-
ing transistorTr,
"OFF".
The output voltageis kept within lhe regulatedvaluesby
repeatingthe "ON"-"OFF" operation.
(2)Terminalconnections
The alternatorhas the following lerminals. Connecl
th€seterminalsas indicatedbelow. 4A-7. Altemalor handling precautions
(1)Payattentionto the potarityof the battery;be caretulnot
to connecl lt In revers€polarity.lf the batteryis con-
nectedin reversepobrity,the batterywill be shortedby
the diodeof the allernator,an overcurentwill result.the
diodes and transistorreguhtorwill be destroyed,and (6)Unsolderthe leadwireconnectionand removethe diode
the wiringhamesswill be bumed. (3)When the fan and pulleyhavebeenremoved,the rotor assemblytogetherwith the regulatorassembly.
(2)Connecttheterminatsconecily. can be pulledfromthe frontcoverby hand.
(3)Whenchargingthe batteryfromoutside,suchas during
tlA-6. Clrcult diagram rapid charging,disconnectthe altematorB terminalor
fA{.1 Clr€ultdhgram the batleryterminals.
(4)Do not shortthe terminals.
(5)Nevertesllhe altematorwitha highvoltagemeter.
4A-8. Altemator disassembly

Oisassembbthealtematoras follows.
The maior points of disassemblyare the removalol the
cover,the separationof the frontand rearsides,anddetaif
ed disassembly.
(l) Removethecoverattachedto the rearcover,removethe O)Separaiethe diode assemblyand the brush regulator
throughbolts,anddisassemble into frontand rearsides. (4) Next, removethe bearlngattachedto the t|ont cover. assemblyby removingthe 3mm dia rivet which con-
Loosen the bearlng proteclor mounllng bolts (M4) and nects thesetwo parts and then unsolderthe L terminal
pull the bearingby applylng pressureto the bearing connection.
from the front cover.
BAT:
L:
E:
galt.ry output teminal
Chs.ge tamp tdminal
Errth
D, D.: Diod€3 lor r@ilfying the ootDut cu,rent
O, r- Dr: Oiod€s fq lwitching thc chargo lamp
Oiod6 lor p.ot$tinq the tC -
bffi
'/ ---x,| ffi%
96=
D-:
ZO: Z.nddlode
T.,, Tr,: TanriltoB
R, a R,: Resistoc _n0
F: Rotorcurcnt
Rn: Thcmislor (resisto.s with cureot, -il
lcmptralurc 9.adient)
t2-31
000040A1361 0000A0Alt6r
Chopta 12 Electricol System Chapter 12 Elechicol Systent

1A. Altonalor Optio4 I2V/35A 4A. Altanator Optb4 I2V/lSA
SM/CM(FXC}HM(F)(C) SM/GM(FXC}HM(F)(C)
(8)When replacingthe lC regulator,it can be removedbv Electriccunenttlows only in one directionin the diodeas (2)Statorcoilgroundtest
unsolderingthe regulator'slerminalsand removinglwo shown on the previouspage- By testing the continuitv
bolls- Neverremovethese two bolts except when the Check lhe continuity betweenone of the stalor coil
betweenterminals(e.9. BAT and U) with the continuifv leadsandthe statorcore-
regulatoris replaced. tester,(asshownin lhe picture),the diodeis determinedas Thestatorcoil is good if the resistanceis infinite.lf the
usabiewhen lhe conlinuityis ,,yes",but is taultywhen it statorcore is grounded,indicatedby continuity,il must
.-^q "No".
Connectthe testerin the reverseway,and thenlhe diodeis
usablewhencontinuityis "No", but faultywhen,,yes".lf a
be reolaced.
&*.*
w\:.br faullydiodeis foundin this test,replaceit with a comDlete

uzg.; newdiodeassembly.
t'l As the auxiliarydiodedoes not havea terminal,checkthe
h3
L_jl
\.a/
continuitybetweenits ends.
(at2O"Cl
R6ifrnewtuo I Apprcx.3,1O I LRt3S-tOs
(4)Rotorcoil groundtest
(9) When (1)-(8) above are compteted, the alternator Ch€ck the rotof coll lor grounding wlth a tester, or by
is checking th€ conlinuitybetweenone slip ring and the
completely disassembled.
rotorcoreorshaft.
Usabb if the conlinuityls ..No',.
nJ1 lf "Yes",rephc€it as the rotorcollls grounded.
[6Wffi
$qJ
^ [J
4A-9.4Brush
(1)Brushwear
Checklhebrushlength.
@b #F*S-te
Oiodgshorttest
Thebrushwearsvery little,but replacethe brushif wom
overthewearlimlt lineprintedon the brush.
CAUTION: lf a high voltage neter rb used, a high voltage
--W n
@@
€6lt\
wiil be applied to the diode and ,he diode iill
be destrcyed. Theretorc, never test the diodes
w with a high voltage meten etc.
{A-9.2 Rotor
tlA-9. Inspecton and adjustnent 44-9.3Stalor coil
(l) Slip ring wear
Becausethe slip rings wearvery lilile, the diameterof (1)Slatorcoil shorttest
aA-9.1 Dlodc.
the ringsmustbe measuredwith a micrometer.Replace Checkthe continultybetwe€nlhe terminalsof the stator
Woar limlt linr OGh)
the rings (rotor assembly)when wear exceeds the coil. Measue the resistance between the oulput ter-
maintenance standard by I mm. (0.0393in.) minalswiih a tester.The reslstanceshould be nearthe mm lln I
mm(in.l prescribedvalue. I Malntemce staridard I Weartimit
YGa limit lf the statorcoil is open,Indicatedby infiniteresistance, 8rushrengrh | 16p.6299) | 9p3S43)
it must b€ replaced.
Slip ring @tsile dhmts o30.6 (2)Brushspringpressuremeasuremenl
fl204A Measureth€ pressur€with the brush protruding2mm
from the brush holde( as shown in the figure.The spr_
(2)Slip ringroughness ing is normalif the measuredvaluels over1S0gr.
The slip ringshouldbe smoothwith no surlaceoil. etc. Confirmthat the brushmovessmoothlyin lhe holder.
It the surtaceof the rings ls rough,potishwith #500 tu
#6@ sandpaper, and if the surfaceis soiled.cleanwith
a clothdippedin alcohol.
(3)Rotorcoilshorttest
Checkthecontinuitybetweenthe rotorcoit andslip ring
with a tester-Theresistanceshouldbe nearthe orescrib-
ed value.
lf the resistanceis extremelylow, there is a layershort
at the rotorcoil; if the resistance is infinite,the coil is
open.ln eithercase,replacethe roror.
12-32 12-33
000040A1361 0000A0A136r
Chopler 12 Electrical System Chapter I2 Eleclrical Syslem

1A. Allernator Optioa I2Y/35A 4A. Alternator option, I2V/35A
SM/GM(F)(C/HM(FXC) SM/GM(FXCTHM(FXC)
4A-10 Reassembly precaulions 4A-11.3 Perfomance test

After inspection and seryicing, reassemble the Darls in the (l) Speed measurementat 13.5V.
reverse order of disassembly, paying careful attention to 3.0 mm (0.1t8l in.) dra 1) Run the allernalor up to a speed of approx. 1500 rpm
lhe following ilems: with SW and SW, ooen.
(1) Brush regulatorassembly Then reduce speed gradually and measure lhe rpm
1) Soldering the brush when lhe voltage reaches13.5V.
Solder the brush atter setting it as shown in the figure. 2) This value is called the "rpm at 13V" and is acceptable
Take care thal solder does not llow into the pig.tail (ead if '1000rpm or below.
wire). (The alternatorspeed at which the lamp goes on or otf
is 1500 rpm, or 1000 rpm or below, respectively,and
Wind the wke one
aod half lurns
there are different conditions for each of the two
a@!nd the teminal cases.)
stot. (2) Voltage measurement. Acceptable within lhe range of
102lbs) 14.3 t1.3V and when the generator rpm is 5000, SW is
Brush spring strength O562 9.761
-
* brush) open and SW is closed, the temperalure is 20oC and
using lwo batteries.
4A-9.5 Checking lC regulator unlt (3)Assemblingrearcover (Confirm that the arnmeler is 5A or below. lf over 5A,
Connect the wiring as shown in th€ diagram below using a Assemblethe rearcoverafler insertingthe pin fromout' connect the 0.25Qresistor.)
variable register, two 12V batteries, register and ammeter. Phce Insulatlng
taOe on th€ teminal
sideandlitting the brushinto the brushholder. (3) Measurement of output cunent
{1} Prepare the following measuringdevices suatac6 (4)Tighteningtorqueof eachPart 1) In the circuit shown in figure, set the variable resistor at
1 I Resistor{Rt } l00a 2W - I the minimum value, close SW and SW, and run the
2) Variableresistor(Rvl 0-300a l2W - 1 32 r 40 €31 ! 239) allernator.
3l Battery (BAT,, BAT.I t2V - 2 NOTES:1) Usenon-acidllux lor soldering. 2) While keeping the voltage at 13.5V by adiusting the
4l DC voltmeter 0 - 30V 0.5 class - 1 2) Thetemperctureof the sotcteringbit is to be JOO variabte resistor, increase the alternator speed, and
16 tu 20 (1.16tu 1.45)
{to measureat 3 points} tosfioc. measure the currenl at 2500 rpm and 5OO0rpm.
(21 Ch€ck the regulator in the foltowing sequence.
32 ryaop31 2as)
1l Ctck V, (total voltage of BAt plus BA! ). -
Wh€n the value is betreen 20V and 26V, BAT. and a Assemblyof lC regulator
Placethe lC regulatoron the brushhotderas shownin
BATI are normal.
the figure,andinsertthe M5bolt. (4) Remarks on performance test
2! When measuringV, (Voltage between F - E terminals), 4A-11 Altemalor performance test
After lnsertingthe bolt, solderthe brush holderto the a) Forthe test leads, use cable with a cross-sectional area
shift ttte variable resistor gradually from the ,,0,, oosi_ 4A-11.1Testequlpmeht
lC regulator. of Smmr or more and with a length not exceeding 2.5m
tion. Check ifthe V, voltagechangessharplyfrom below
2.0V to over 2.0V. between the allemator B terminal and the positive ter-
lf there is no sharp voltage change, the regulator is minal of the battery, and between the S terminal and
faulty and must be replaced. the negative terminal of lhe battery.
When there is sharp voltage change, stop the variable b) Switches with low contacl resistance are io be used in
regislor at that point. the circuit.
3) MeasureV1 (voltage between L - E terminals).
The V1 voltage is the regulated voltage of the regulator 4A-12 Standards of adiuslment
...Confirm that the value is within the standardrange.
Adi0stod wltrge
'14.3
i0.3V
(at 20"C,with 2 batterie.)
4A-11.2 Perlormance lesl clrcuit
When the circuit is connected lhe charge lamp will lighl
Staodarddimension of shaft
at fronl end
/VOrE.s' t, lnsertion pressure is tÔ kg (W.S tbs) Pari No. of ball bearing
2) lnsertvertlcaily. LR135-105 Variable resislol
Standard dimension of shafi
at rar end
(2) Connecting the brush regulatorassembly lo the diode. R6istanc of rotor coil (al 20ocf
1) Fixing with rivet
Insert a 3mm dia. rivel as shown in the figure, and fix it
by using the appropriale tool 0.25Qregistor SiardardO.D.of slip rino
This is connected
when the Mtteries Limit of reduced size (diametd
are discharged.
00004041361 000040A1361
Chapter 12 Eleclrical Syslem Chopter 12 Eleclrical System

1A. Altunalor Optio4 I2Y/35A 5. Instrunenl Ponel
SM/GM(F)(CTHM(F.)(C) sM/GM(FXC\HM(FXC)
4A-13. Altemator troubleshooting and repalr

Failure lo
5. Instrument
Panel
Problom Cause Corslivo aclion
Wiring, curst Open, shorted, tr disconneted R€pair or replace 5.1B'type(aqe) Insirumentpane&
Open,gounded, d shortedcoil Rephce
Alttrnator Teminal insulatormissino Repair
Diode faulty Replae
Tansistor regulator Tansistorregulatorfaulty Feplace
S-rt'!,J,,D
(21Batlerychargeinsuflicienland
8@
Add distilled water
Rubber seated tamp (sait-drive)

Wals lodpe.ature uming tahp
(4) Cunont charg€ unstable
5.2A.lyp€(small)instrumentpanel
156 aO.2(6.13 tu 6.t5)

Rubb€r sealed lamo {sil.drivel
Waler lefrp€rature warning lamp
UANMAB -6.
OOOO ,-s---*"
;. ,,{- /A\ Push butlon switch
\/\ v
/ n\ t ' t : \ \ {{i ( @ ) ) ) )
Key switch
mooAoAl36l
0000A0Al36r
Chapta 12 Electilcol Sydem Chapkr 12 Electrbol System

5. Instrumenl Panel 5. Instrument Pancl
WalertemDerature
switch 5.6.2Buzzerto.A.typeinslrumentpanel
(1)Construction
Direct Sea Water

Operating temperature
Current @pacity Response time lndication color Parts code
N OFF
65t?C (154- 148pF) 58'C (1il0pF) or more DC12V1A Within 60 w White 12427'913/,0
Fresh Water
Operatlng fmperaltls
Raspon$ tlm Parb @de
ON GF
95pC(202*r93pF) 8AC(187"R qhigher DC 12V 1A Wthln60s. GM 12761G91350
Pnolbmp:lAr,3.,1W
The parls ol the alarmcircuit which must be checkedare the cord-lhe pilot lamp is normal if the pitot lamp if
the open pilot bulb,fuse,and wiring.To check,disconnect luminates.Moreover,be sure the check the color ot the
the wiring at the watertemperatureunit side and ground codeafterreplacing.
(2) Specilications (3)Wiringdhgram
5-6 Alam buzzer
The alarm buzzersounds when the engine oil pressure,
coolingwatertemperature, or chargingbecornesabnormal.
The lrouble sourceis indicatedby illuminationof the ap-
propriatealarmlampsimultaneouslywith the soundingof
the buzzer.
5.6.1Buzzerfor B.typeinstrumentboad
(l) Conslruction
0 = 0 r4 5 o 7 0 d B t rb e b w
To key swltch
lmp€aatue pr€ssure
sensol Senst
To each sensor
5.6.3
Normaloperationis as follows:
To oach sensor
3 {0.8268) Main swiich ON, engine running

(2)Specifications (3)Wiringdiagram
'The condition of the lamp can be checked by using the
checkswitch.
1241
m00A0Al36l 0000A0A1361
Chaplu 12 Electilcol System Chopler 12 Electrical System

5. Instrument Panel 6. Tachomets
SM/GM(FXC/HM(F)(C)
SM/GM(FXC}HM(FXC)
5-7
Faull
6. Tachometer
Oiagnosis Remedy
ao""*' 6.1 Construction of tachomeler
.Ch€ck if there is a bGe or open.circuil mnntrtion al the Make god
ffi'no'"to dphsg mnnetor between the inslrument panel and the relay
the connmtion.
The tachometerindicateslhe numberof revolutionsper
minute by meansof an electricalinput signal which is
generatedas a pulsesignalfromthe magneticpickupsen-
der(MPUsender).
The functionof the senderis to convertthe rotarymotion
Ring gear
Take out the tamp from p box 6e and chek if it is Replace the lamo. intoanelectrical signalby meansol countingbythenumber
un$ryrcabte (G-1mp r2V&4W) of teethof the ringgearfittedto theflywheelhousing,
lNo
It must be m open-circuit onnstion in the haress. Replace

theharress.
B@sdoes rct wnd. Check il there is a bos q open-circuit mrction al the Make good the @nHtion.
connmtq betwen the Instrurent paret and the rehy
F*t_{rjgg
Chek if the buzzer is seruic€ble.

Replae the hrzs.
(Fis) 6.2 Specifications and dimensions of tachomeler
I Yes
It must be m open-cimit mneclion in tfp twns. DC t2v 3HM3s(FXC)
Replae the harns.
Oths switctB ard Ch*k lf ttHe is a bos tr @nrircuit conmtion ai the Rated voltage DC 12V
Itms do rct oDemte @uptingconHtor betwen the instrumentpaneland the Ehy Make good the mmtion.
ntrnN- '10- 15v
lllumination 3.1Wt1At (4)Dimensionsandshapeof tachometer

lNo
Chek the.mtinuity ot the individuatswitch when the switch b Ring gear

cbg Dy the tesler. Sepla@ ttp detective itm
rt No.
ot tachometq 128670-9t100
toK
Part No.
of snder unit 12817tr91160
It mGl be m open-circuitmmlion in tfE hare$. Replace the harre$.
(2)Sensitivitylimit of senderunit
Ring gea. speed

(m/s*)
Formodeb'lGM10(C),
2GM20(F
)(c), For model3HM35(F)(C)
3Gr,m(F)(C)
,A
///E''" ;a\\\
w4","3)))
\\\ rton* ///
Y
| .0 | .5 2.0 2.5
Sender unit and dng gear clearance C (mm)
0000A0A136r
00004041361
Clupla 12 Eleclrical Sydem

6. Taclumetq Chqter 12 Ekctriul SYstem
SM/GM(FXCTHM(FXC) 6. Tachomew
SM/GM(FXC'HM(FXC)
6-3 Measuremenl of sensor unil characle.istics
(1)Measurement
ofoutput voltage Chsk i{ t]€ snds b l@ly fitted. Ys Fix the srider ecurely
ninseearl
No. ot tech/
lV or higher
AC100V
'Check the ouiput wave pa[ent and numberof oulses
Measudngconditlons whencarryingout theoutputvoltagemeasurement.
Numberofteethof (2)Measurement
of inlemalresistance
ring gear: 97,114
Gap betweenthe ring gear Iteasurlng corditions
and sender: 'l.3mm(0.0511in.)
8e€lstance: Measudngtemperature:20oC
20k9 Measurlnginstrument: Digitaltester
Speedof ring gear: 500rpm (approx.8O0Hz)
Measudagtemperature: a)oc Digltat tester
Measuringinstrument: Synchroscope
M€surB the htsrEl Eistance ol the s€rder.
CIo be 16 l,.ll@ at 20oq
MsnG the oFut rcltao€ of lhe sends.

(To b€ lV or hiohs at 20oq
Ch€ck_f ttse b an opeccircuit cabls conEtbn at the

Gar_oJthe nEts, a lGe or dis@ffEled tennin€t, o( bad
srnuny dG to ffoslrn
Dis,conn€ctat the instrurHt tminds, aald|lleeG the

vortage betK the cabte tmimts. Oa be 10 tu l6V)
1244
1245
0000404136t 0000A0At36!
CHAPTER13
NG INSTRUCTI
OPERATI ONS
r. Fu d o i t rd L u b d c d n go i | . . . . . . . . . ' . . . . . . . . . . . . ...... 13.1
2 E n g | mO p o n t n g I t E f i td i o G . . . . . . . . . . . . . . . . . . . . . ' . . ' . 1 3 {
gd R€p.ir .......................
3 . Tru b l a s h o o t i nrt ...
"1913
Pr&.rd i J.pi
o00 0Ar$r
Chapler 13 Operating Instrucliorc
I. Fuel Oil and Lubricating Oil
sM/GM(F)(CIHM(F)(c)
1. FuelOil andLubricating
Oil
Seleclionot and properattentionto tuel and lubricatingoils delay is shown in the figure below. Firing delay
has a substantialeftecton engineperformance,and these becomessmallerandstartingcharacteristicsbetieras
arevitalfactorsgoverningenginelife. thecelanevaluebecomeshigher,
The use of low quality,uel and lubricatingoils will leadto
variousenginetroubles.Yanmar dieselengineswilldisplay
satisfactoryperformanceand ample reliabilityil the fuel
Inlake air temperalure19oC{66.2oF)
and lubricatingoil recommendedby Yanmarare usedcor-
rectly.For the engine to havelong-termhigh perfom-
ance,sullicientknowledge of theproperties of thefueland
lubricatingoilsandlheirselection, management andusage
I
are necessary.
1-1Fuel I
1.1.1Properliesof fuel
Numerouskinds of fuelsareusedwith dieselengines,and ':
the propertiesand composilionof each differ somewhat
accordingto the manufacturer.
Moreover,ihe various national standards are introduced
herefor teferencepurposes.
tuels
1.12Recommended Relationship between celane value and tiring delay
B€nd|rffi
Callex
Shell Shell Dieslire q bcal suivalenl
Mobil Mobil Di*l Oil
1.1.3Fuelselectionprecaulions
Paycarefulattention to the followingwhen selectingthe E
fuel.
(1) Musthavea suitablespecificgravity
Cetane value
Fnel havlrlg a specific ora/ity of 0.88 0.94at 15oCis Cetane value and startino characteristic
suitableas dieselenginefuel. Specific - gravity
has no
relalionto spontaneouscombustibility,but does give The use of a fuel wiih an unsuitable cetane value will cause
an ideaof viscosityand combustibilityor mixingof im- the followingtroubles:
purities. 1) Difficultstarting.
Generally,the higher the specific gravity,the higher 2) Pooroperation.
the viscosityand the poorerthe combustibility. 3) High combustionpressureand dieselknock.
(4 Musthavea suitableviscosity 4) Lower outpul and engine damage becauseof
When the viscosity is too high, the fuel flow will be ovefieatingcausedby knocking.
poor,operationof the pumpand nozzlewill be inferior, 5) Stickingof nozzlesandexhaustvalves-
atomizaiionwill be faultyand fuel combustionwill be 6) Severe smoking, carbon build-up inside the
. incomplete. engine,andoil contamination.
lf the viscosityis too low,the plunger,nozzle,etc. will 7) Deterioriationof the oil and excessivewearin the
wear rapidly because of insufficient lubrication. pistonrings,ringgrooves,and cylinderliner.
Generally,however,the higherthe viscosity,the lower (4)Thelevelot impuritiesmust be low
the qualityof the fuel. 1) Sulfur
(3)Cetanevaluemust be high. With propercombustionsulfur in the tuel turnsto
The most importantindicatorof fuet's combustibility nitrousacidgas(SO,)and sulfuricanhydride(SO,).
is its cetanevalue(alsorepresented by cetaneindexor When combustion is imperfect, it becomes
diesel index), The celane value is particularly im- sulfuric acid containingwater that conodesand
portantfor fuels usedin high-speedengines.The rela- wears the cylinderliners, pistons,exhaustvalve
tionshipamongthe cetanevalue,startabitityand firing and exhaustpipe.
tJ- |
0000A0A1361
Chaptu 13 Operaling Inslrucliorc
Chapter I3 Operuting Instructions
I. Fuel Oil and Lubicaling Oil
sM/cM(F)(c).HM(F)(C)
sM/GM(FXCTHM@)(C)
Properlies and compositiofls of tuel of various nalional standards
a Watercontent (5) lf crackedby mixingwith an equalarnountof sulfuric
A high watercontentcausessludge,resultingin acid in a glasstube,numerousbtackparticlesand im-
,,,**;K'""
JapanJIS-K-2m4.1965 u.s.A.AsTM.D975.74 loweroutput,impertectcombustionancttroubli in puritieswill appear.Thesearemainlycarbonandresin.
u.K. 85-2689,70
the tuel iniectionsystem. (6) Discolorationof litmus test paper indicates the
3) Carbonconlent presenceof acids.
Clss No-1 Class No.2 No.2D lf the carboncontentia high,carbonwiil remainin-
lightoil Class A1 Cl6s M side the combustion chamber, causing ac_
light oil Dieseloil 1-1.5Troubtescausedby badtuel
celeratedcylinderlinerand pistonwearand iono- (1) Cloggingof exhaustvalve
sion of the pistonsandexhaustvalves. In additionto faultycompression,incompletecombus-
Speilic gravily l5/40c
4) Residualcarbon(cokecontenl) tion, and high fuel consumption,a cloggedexhaust
Coke becomesa carbidethat sticks lo the end of valve will cause fuel to be mixed in ihe exhaust,
the nozzle,causingfaultyiniection.In addition. leadingto corrosionof the exhaustvalveseat.
unburnedcarbonwill build up on the pistonsand (2)Cloggingof pistonringgrooves
30oCcst liners,causingpistonringwearandsticking.
(86"F cst) 2.7q rcrc 2.5 or more ( ' 5.2) (- 7.5) (- 7.5) Clogged piston ring grooves will cause acceleraled
cylinder liner and piston wear due to sticking rings,
1.1.4Simplemethodsof identiryingtuel properties fuel gas blowbacKfaultylubrication.incomoleiecom-
37.8oC (1@oF (1) Fuel that is extremelyodorousand smokycontainsa bustion, high fuel consumption, contaminated
(2.3droe) (22q wel 2.O\4.3 '1.6 6.0 1.6 tu 6.0
cst - largeamountof volatilecomponentsand impurities. lubricatingoil,andcombustiongas blowback
(2) Fuel that emits little smokewhenused in a tamp is of (3) Cloggedorconoded in,ection vatvehole
goodquality. Thlswill causeinco.npletecombustionandpistonand
R6rclim Natral Ndtral
(3) Fuel that emits a cracklingsound when soaked into liner wear, tuel Ini€ction mechanism wear, coroslori,
paperand ignitedcontainsa highwatercontent. and groovewearand carrosion.
(4) lf a transparentfilm of dieseloil is squeezedbetween (4) Sedimentinsidecftmkcase
two piecesol glass,the watercontentand imourities Since sedim€ntin the crankcaseis often mistakenlv
Flash poinl 50 d more 50qMe 51.7or mre 55 q rcre 55 or mre
fD (12 or morcl can be determined-
(1?2srcrc} (125d rc.e) (131 or more) (131orMe) ,udgedas coming trom the lubricatingoil, care must
be takenin determiningits true origin.
1.1.6 Relationshlp bdtw€on fu€l prcperties .nd engin€ pertormance
Flow polnl -5 q less -10 o( less -12 or less
eF) (23 q le$) (14d les) (10.4d less)
Fu€l Slarllng Fuel Clogglng of
Lubrletlm Smoke Exhausl Oulpul coBUmp.
proporly charac16rlstic characlsisllc combuslitr
genanllm odc lim
(10% residual (10% residual chamb€r
Fesidual crrbon o/o d0
trGight oi0 0.35 d less 0.2 q le$ 0.2 q less
0..15tr less DiEtly
0.15tr less Directry r6ht€d- Dir€clly chted- Clo6€ly related- €lded- Related-
Flring StatirE char*- tubrietion Smoke ircreas Doc@sod Deqeesed by
C€tane tsistlc kmproE lmproE as as etane €[€
Moisture Volure % Yalue by lrseas- lrelevant Relal€d redudno cettrE
0.05 q ls 0.05 d less €s cetare EIG €taFnlre dsrcas6 lng cetan€
lrcr6eg raf.r
ris Yatr
Volalility Belated- Dir6tly related- Related-

Ash !',/eigil on 90% end No ds 8@anes poor lrcrffias No diEt
0.01d less 0.01 d le$ 0.01 q l6s rehtimship wtEn rclatillty lrelemt lre|emt lrct€6€s
polnl wlatility reldimship rcldility
is poor oerws d6Bs6
Ssne Glatkm-
Sultur Vlreighto/" 'l.2qls '12 tr lss 0.5 s less 0.5 q less 1.0 q le$ ship- Rebted-
No
Viscoslty No dee lrc|%ess Felated-
Bmrc poor lrdeperdenl lreb€nt lreb\€nl
relatimship viscity Increcm with
when visco€lty relatkmship
incBes vlsco8lty
Incr€s€s
Cet!n€ v!|re 50dr ue {5trffie ilod|rc 50 tr mtre 45droe
Rehted- DiEtly
Specllic No relat€d- Felaled- Rslated-
lrelsant lf,dffil
rrcr€&s6 Dependson
0raylty spsific g@ity i.deperxlenl Asshled
Sludge relationship withw-fic with elo- properties ol
trcrses er€im
d sedi 0.05 q less 0.01sls 0.01tr le$ yalue rilic E|r,e
Oislillallqr 10 Related- Selated-

prop€rlios, residual No
350 d below 350 tr belw ?B,221 357 tr below 357 or below lreleHt lrelemt lmprcas D€creas s
lrxbpendent lrelemt
640 - -W
662 q below) lrelemt
lemperalu(os at fF) @2 q below) 640) (675or belowl G75 o. below) 6160n r6ldual erbon
relatiof,ship cldual c{bon
90% disllllalion d,ecrS (g6es
Sultur No
Independent
rehlknship
Flash No
polnt independent
relati6ship
13-2
13-3
0000404r36r 0000A0A1361
Chapter 13 Operaling Inslructions
Chapter 13 Operuling Inslruclions I. Fuel Oil and Lubricaling Oil SM/GM(F)(CTHM(F)(C)
I. Fucl Oil and Lubricating Oil
sM/GM(FXC).HM(F)(C)
since only 98.9oc viscosity is stipulated for s.A.E. No. 20 -
1.1.7Fuelhandlingprecaullons 1.22 Required lubricating oil condilions S0 oil in the table, and only -17.8oC viscosity is stipulated
guaranteed at
(1) Fill the tuel tankafterwork to preventcondensationof (1) Must be of suitable viscosity for S.A.E. No. 5W - 20W oil, they are not
waterin the tank. lf the viscosity as too low, the oil film will be too thin other temperatures. On the olher hand, S.A.E. No.10W
(2) Always use a tank inlet strainer.Water mixed in the and the lubricatingaction insuflicient. lf the viscosity viscosity is stipulated. Oil having viscosity equal to that of
fuel can be removedby removingthe strainerquickly. is too high, the friction resistance will be increased S.A.E.No.3Oeven at 98.9'C is called S.A.E. No.10W-30' or
(3) Removethe plug at the bottom of the fuel tank and and starting will become especially difficult. multigradeoil. Muttigrade oil comprises S.A.E.No.5W-20'
drainout lhe waterand sedimentafterevery.100 hours (2) Viscosity change with temperature must be small. 1OW-30, and 20W-40. In arctic regions, oil lrom S.A.E.
of operation,andwhenservicingthe pumpandnozzle. While the lube oil temperature goes from low at No.2OWto 10W-30 can be used
(4) Do not use fuel in the botlom of the fuel tankbecause starting to high during operation, the viscosity index
it containslargeamountsof dirt andwater. should be high at all temperatures.
1.2.4SAE service classification and API service
(3) Must have good lubricating capability
classification
1-2 Lubricating oil That is. it must coat metal surtaces as a thin film. In
Selectionof the lubricatingoil is extremelyimportantwith other words, the lubricating oil must coai lhe metal
a diesel engine.The use of unsuitablelubricatingoil will surfaces so that metal-to-metal conlacl caused by
cause sticking of the pislon rings,acceleratedwear and breakingof the oil lilm at the top dead center and bot-
seizingol the piston and cylinderliner,rapid wear of the tom deadcenterpistonpositiondoes notoccur, andthat
bearingsand other moving Parts,and reduced engine the oil film is not broken by collision, even at the
durability.Sincethis enginels a high-speedengine,always bearings.
lollow the lubricatingoil replacementinterval. (4) Mixability with water must be low (l) DGgrade:Usedwhen depositsand enginewearmust
Since water can mix with the oil b€cause of the be controlledwhen the engineis normallyoperatedat
1.21 Action ot lh€ lubdcatingoil presence of cooling water in the engine, emulsification alightloadusinglow sullurfuel.
(l) Lubdcatingaction:Buildsa film ol oil on eachmoving of water and oil, which causes the oil to lose its (2)DM grade:Usedwhen the generationof depositsand
part reduceswearandits accompanying damage. lubricating properties, must be prevented. wear caus€d by sulfur in the fuel is possibleunder
(2) Cooling action: Removesheat generated at moving (5) Must be neutral and difficult to oxidize severeconditions.
partsby carryinglt awaywlth the lubricatingoil llow. Since acids and alkalis corode tnetal, the lubricating (3) DSgrade:Usedunderextemelysevereoperatingcon-
(3) Sealing action: Maintainsthe air tightness of the oil must be neutral. Moreover, since even a neutral oil ditionsor whenexcessivewearor depositsarecaused
pistonsandcylindersby the oll film on the pistonrings. will be oxidized easily by contact with the combustion by the fuel.
{4} Oeaning action: Canies away carbon ptoduced at the gas, the oil must be stable with few oxidizing
cylindersas wellas dust that hasenteredfromthe out- elements.
(6) Must withsland high temperature and must evaporate operatbndieselengimservi€ withhigh'erfmejrel'
Uigf,fOutyOi"*l unginewice: Mil4 modeGte and
sida. and5OsThisoil is
(5) Rustprootingaction: Preventscorrosion by coating orcombust with difficulty riJ s;;tr-1! t"gld *Ue rne oit&silnea ioi ttriss6e.ms minly usedin the194Os pret/€ntim
t*-fiigt purfo;-ce fEl u* mC ia Oeatng corosim ard high tmp€rdure deposit
metalsurlaceswith a thin film of oil. Oil must have a high llash point. It it is evaporated by
heat or is not burned completely, ca6on will be prc operatkn diesl engire seflice using low perfq-rnnce lrel
Variousadditivesareaddedto the lubricatingoil to ensure duced. This carbon is toxic. @e
,"q"iri"g b"";i'g @r*,-im and high tmpe.tur€ deposii p(eventlon ct,ractsistic lrcludes mi6-gas6ire
that adequateperformanceis assured under the high' ftiels and
C/) Must not contain any water or dirt and must have a low ,fri* &*i&. 5iLO""igneO fq ttrii *rui& ms introiuced- in t9+9.tte-oil ls used with high s{,lfur
speed, high-loadand other severeoperatingconditions sulfurand coke content
met by moderndieselengines.Whiletheseadditivesdiffer
with each manufacturer,commonly used additives in' Mod"*te drry die*l *rylce md Oelim ffgire seryi@: ApFlicable to bw superchatged di€sel
engin€s ld moderateto"tSit€
sege duty.
clude: €quipntent'
Td oit designed lc this se.wicewas intoduced in 1961and b widely used In trucks atld agdcultural lil $pe(-
1) Flowpointreductionadditive consirucfioi renirery, farm trctorsr etc itE oil fatures hlgh depodt
pr'€ntid ct€ractsistic in
additive sludg@prs€ntls cheetsistics in gasolin€
2) Viscosityindeximprovement ini.d.O-a"*f urghli aO rust, corciion ed tow tmperature
3) Oxldationpreventionadditive
engim
4) CleaningdisPersent ilorty Gs"t sgire ssoica: Applicable to high'speed, high'outpul high $percfsged diesel
5) Lubricationadditive wnicn are iuoicrea to msiderabte Ga ild depo.sits This-dl-E:1"111*d- |I'^1T::l*"i::9,f:YS
msirei ti als l€s beafingconcim andhishtmpe€lure deposit
6) Anticonosionadditive ;.dil:#ffilii"-t'i-diiilrpi.tnrs"d
7) Bubbleeliminationaddiiive prmntim charcteristi6
8! Alkalineutralizer
1.25 Lubrlcationgoil
SAEnew classificationCB gradeor CC gradefuel having
1.2.3Classlt'rationby Yiscoslty suitableviscosityfor the atmospherictemperaturemust be
usedin ihis engine.
17.8oC(60F) $.9oc(210oF) Appli€ble tmpeBture Bnge
SAENo. Sayboltunire€l (@tside temperature)
Dy|micvi$Gily Saybolt uniwl Dymmicvimsity
vismity(s) (cs0 visccity (s) (cst)
5W Unds4,000 Under 869 20oC s le$
10f'/ 6,0@ 12,m0 1,303 2,606 (68oF q less)
20r 12,0m- {8,0m 2,606a- 10,423
-
n 45- 58 5.73 9.62 20oC 35'C
30 58- 70 9.62- (68'F - 95"F)
-12.93 -
4 70- 85 12.93 16.2 35oC( gr€ter
50 85 110 16.77-N2'8 (95oFd gr€teo
-
13-4 0000A0A1361
0000A04136t
Chapla 13 Operaling lrebuctiore Chapler 13 Operaling lrclruclions
I. Fnd OiI and Lubricating Oil
I
sM/GM(F)(crHM(F)(c) I SM/GM(FXC).HM(F)(C)
1.2.6Rscommond€dftrbrlcatingoils
I (1) Removethe clutch case clutch and herd cover tiller
II plug (engine),and filt with specifiedtubricatingott up
1-23 Oil capaclty
Lubricatingoil capacityat an enginemountingangle(rake)
SAE No. to the top markson the respectivedipsticks.(Oil levels
Sspplad Brand Name of 80 is givenbelow.
Eolor 10oC l0tumoc 20tu35oC Ovo.35oC mustnot dropbelowthe lowermarkson thedipsticks.)
(8alow 50.F) (50tu680F) (68a9soF) (over gsoF)
She[ Rotelhoil to|!.nffr{{ 6txw s 50
10
SHELL Shell TalonaOil O
10l/ n ,10 50
SfEll Rimula Oil ?0.tat't at2cM 30

&
RPMDeloMaineoil r0\/ n 30 . C_hectlhecrankcaseoil levelby completelyinserting
CALTEX 40 50 the
dipstick Checkthe clutchcaseoil levelwithoutscre-wino
RPMDetoMutusqviceoil nf8i't,1wt n 30 m in the cap.
De|veSpedal 101/ n 30 The oil levelsmustbe betweenthe upperand lowerlimit
Delve20\ /-4) 20VV-/() markson bothdipsticks.
N,t't-4
XOBIL Delse l1@Ssl6s lOtN,?ol?olil 2'.r2gtnt c)
4 50
DdEl&Serbs l0rl'l,?o8lrl nEgiN s 50
rl0
EstorHD t o/ n s
4
ESSO Esso Lube HD $
n {0 50
StadadDi*elOil t or n o
4 50
(8dtbrl B.P. Emrgd ICMB

B.P. Ersg|ol DS€ 8N ztfl q 50
P.troLuaro
f '27 Engha of, lrplacfi|€ tt.nd h.offng

1-2.8Addingoll
0) Necessltyof rcplac€ment The crankcaseand clutch caseare not connected.For the
Sinco tf|e €nglne oil ls expos€d to hlgh temperatures crankcase, add one of the lubrlcating oits descdH in
du.lng us6 and ls mlxed {rlth alr 8t hlgh tempera- chapter 126. Fof th€ c.ftrtcttcase, add th€ lubflcaflon oll
turcg lt wlll oxldile aftt lts properties wifl graduaily doocfbod bdolfl. 86 sure not to mix up the olls.
change In eddition, lts tubrtcatingcapabititi; wifl be
lost 0rough contanlnation and dilution bv water.
lmpt/rltl€si and the tuel. Emulslfication and studge
ar€ pfoduc€d by h€at ard mlxing when the lubrlcat_
Ing oll contalns water and lmpurftieq causing lts vis-
coslty to lrrcr€ase.Moreo/er, lf the carbon dthe cyl_
lrdefs entere the crankcase, the oil witt tum pure
blacft ard th€ change In lts properties can be seen
at e glanoe. The continued use of deteriorated oil
wlll not only oaus€ wear and conosion of moving
palq b|rt wlll ulflrnately cause the bearings and cyl: (a Since it takes sometime for the oil to flow completely
Inders to selze. Therefore, deteriorated oit must 6e into the clutch case and oil pan,wait for 2 tu 3 mlnutes
replecod. after filling betore checking the oil levels. Mo.eover.
el @hcomontp€riod ch€ck the oil whlte the boat ls afloat.
Although the ongine oll changeIntenraldiffers with the
onglno operatlng conditions and the quality ol the
lubrlcetlng oll and tuel used, the oll change Interval
should be as follows when Cg grade oil iJused In a
n€i , engln€:
1st tlmo . . . . . . . . Aflerapproxirnately20 hours of use
2nd tirne. . . . . . . . Afterapproxlmatety30 hours of use
Fro.n 3rd lkne . . . Aftaret€ry l{phours of use
Oraintha old oll completely ard reptaceit with new olt
whllethe€nglneis stiil warm.
CAUTION:Nwe( mix diltercnt b6,ds ot tubrication ott.
13-6 1:f'7
mooAoAl3sr
00004041
361
Chapler I 3 Operating Inslructiotts
2. Enginc Operoling Inslrucliorc Chapler B Operaling Instrucliore
sM/GM(F)(crHM(F)(c) 2. Engine Opualing Irclruclions
2. EngineOperating
Instructions Loosenthe nippleon lhe fuel injectionvalveside,set
the regulatorhandleto the operatingpositionand the
2-2 Slarling and warm.up
2-2.1Slarling
decompressionleverto the decompressionposition, (1) Startingprocedure
2.1Preparationsbeforestarting and crankthe engine.Whenno more bubblesappear
2-1,1Fuelingup 1) Setthe clutchhandleto the "NEUTML" position.
in the fuel flowing from the end of the injectionpipe, 2) Setthe govemorlevertothe "MEDluMsPEEo"-
(1) Check the fuel level in the fuel tank and add fuel if
retightenlhe nipple. 3) Keep the decompressionlever In the "OPERA-
necessary. (5) Checkinjection.
(2) Bemovewaterand dirt collectedin the bottom of the TION" oosition.
After bleedingthe air, set the regulatorhandleto the 4) S€tthe mainswitchto the ON position.
tank usingthe fuel lankdraincock.
op€ratingposition,set the decompressionleverto the Thealarmbuzzerwill
(3) Add cleanfuel to lhe tank. sound.
decompressionposition,and crankihe engine.When 5) Pushihe startingbuttonto startthe engine.
Since dirt and waler sink to the bottom of the fuel fuel is beinginjectedfromthe iniectionvalve,an iniec-
drum,do not lurn the drum upsidedown and do not Releasethe start button after the engine has
tion soundwill be heardandyou can teel resistanceif started.
pumplhe fuel fromthe bottomof the drum.
you placeyour handon the fuel intectionpipe.This
6) Whenthe enginehas started,the alarmlampsand
check must not be oerformedmorethan lwo or three buzzerwillgo off.
2.12 Addinglubricalingoll times since overcheckingwill flood ihe combustion
(1) Check the oil level with the dipstick,and add oit, if lf the lampsor buzzerstay on, immediatelystop
chamberwithfuel,and faultycombustionwill occurat the engineandcheckfortrouble.
necessary,to bring the levelup to the tull mark of the
starting.
dipstick.
Tho levelmustbe neithertoo tow nor too high. A type
2.1-6Chedd€ fo3abnomalsoundsbycranklng
(2) The crankcaseand clutch case requiredifferent oil. (1) Set the regulatorhandleto the STOPposition,release Rubber sealed lamp (Sail-dtivel
Check both and add oil separately,being caretul not to {3} Bleed the airfrom the fuel retum pipe. the compressionof the engineby setting the decom.
mix the oils. Loosen the connnector bolt of the luel retum pipe in- pressionlever,and crankthe engineabout 10times to
(3) Since the crankcase oil flows into the crankcase stalled on the fuel injection valve, and bleed the air by check lor abnormalsounds.
throughthe camshaftand t€lve chambers,wait 2 tu 3 operating the manual handle of the fuel pump. (A Crankthe enginewith the startinghandle
minulesbeforecheckingits level. Bleed the air in the No.l cylinder (timing gear case (Alwaystum the enginein the properdirectionof rota-
side) and No2 cylinder (clutch side), in that order. tion.)
2-13 Luffiating eachpart
(l) Lubricateeachpin of the remotecontrollever.
2-1.7Ched&g the cooling system Push boltom
(1) Opentt€ Kingstoncock
2.1.4Cfi€ckingfu€l pdmlng and injection
(a Check for bending and cross-sectionaldeformation ot
(1) Operatethe primingleverofthe fuel pump.
(2) Set the regulatorhandleto the full speedpositionand the coolingwaterinletpipe.
(3) Set all waterdrain cocks to the CLOSEDposition.
check tor iniectionsound by tuming the engine over
severaltimes.
2.13 ChecLhg fhe remole conl]ol syslem
(3) lf therels no luel iniectlonsound,bleed th€ air from : (1) Checkthat the remotecontrol handleoperatesconect-
the fuel system.
ly.
(2) Check that the engine stop remote control operates
2.15 Bl€€dinglho lrlel sysl€m
Since tfle presenceof air in the tuel system anywhere smoothly.
betweenthe fuel tank and the Iniectionvalve will cause
taulty fuel injection,alwaysbleedthe air fro{n the syslem 2.19 Checklngttle electrlcalsystem
(1) Check the baltery electrolytelevel and add distilled
whenthe fuel systemis disassembled andreassembled.
waterif low.
(2) Checkthatthe wiringls connectedcorectly. Bubb€r 9€aled lamp (Sail.drive)
Bleedingthe tuel system (Especiallyf or polarity.) Waler tempeature wahing lamp
(1) Openthe fuel tankcock (4) Bleed the airfrom the fuel injection pipe (3)Tum the batteryswitchon, set the main switch to the
P) Bleedthe air tromthe fuel filter. ON position,and check if the oil pressurelamp and
Loosenthe air bleedingplug at the top of the fuel filter charge lamp are illuminatedand if the alarm buzzer
bodyand operatethe manualhandteof the fuel pump soundswhenthe engineis stopped.
Charge lamp
until no more bubblesappearin the tuel flowing from

Fhe chargelamp should be on while the engine is
the filter. stoppedandshouldbe off whilethe engineis running.)
Theninstallandtightenthe airbleedingptug.
2.1.10Ch€ckingappearanceand exiedo.
(1) Checkfor looseor missingboltsand nuts-
(2) Checkfor looseordisconnectedpipingand hoses.
(3) Check lhat there are no tools or other articles near
rotatingpartsoron the englne.
Lamp switch for tehorcter

Push boltom switch
0000404t361 0000.{0A136r
Chaplu I3 Operaling Instruclions Chapler 13 Operoting Inslruclions
2, Engine Operating Inslruclions 2. Engine Operating Inslrucliore
sM/GM(F)(CIHM(F)(c) sM/GM(F)(CIHM(F)(c)
(2) Starting precautions (21Startingin cold weather (2) Checking after starting haustvalves,pistonrings,cylinderliners,and iniection
'1) Oon't continue to push the starting button overts 'l) Pull the neutralknob,and set the controlleverlo Check the lollowing with lhe clutch in the NEUTBAL nozle will be shortened-Do not run the engin€lor
seconos. the HIGHSPEED oosition. Position: longperiodswhenexhausiis this colour.
lf the engine doesn't start, wait 30 seconds or 1) Meters and lamps on lhe instrument panel (8) Abnormalsounds,abnotmalheating
more. . Check that all alarm lamps are otf When abnonnal sounds or abnormalhealing occur
2) When restarting the engine, always confirm the (1,000rpm or higher). during operation,immediatelystop the engine and
tlywheel is stopped. . Alarm buzzer must be off. checkfor trouble-
lf you re-start the engine while the flywheel is 2) Cooling water discharge
rotating, the pinion gear of the starter motor and (Check that the cooling water temperature 2.3.2Operatingpr€cautions
the ring gear of the flywheet will be damaged. reaches 45 tu 55oC before beginning operation.) (1) Alwaysset the batteryswitchand main switch to lhe
3) When starting is difficult in cotd weather tift the Check forabnormal sounds and heating. ON positionduringoperation.
decompression lever lo decompress the engine, 4) Check for oil and water leakagetrom piping. Since lhe diodes o( the altematorwill be damaged,
and lurn the starting motor. Once the engine has Check the state of lubrication of the valve arms. don'tset the switchesOFFposition.
reached a certain speed, retum the decompres- (2) Do not touch lhe starting button during operation.
sion lever to the "OPERAT|ON" position. In this 2.3 Operation Operationof lhe startermotorpinion will damagethe
way, starling is made easier while current com- 2) Set the decompressionhandle to the DECOM- It warm-up operation is nomal, engage the clutch and gears.
sumption is reduced. PRESSION position. begin normal operation. Check the following during opera- (3) Since the boat will resonateand vibrateat a certain
3) Set the main switch to the ON oositionand start tion and stop the engine and lake suitable coreclive action speed,dependingon the struclureof the hull, do not
the engineby pushingthe startingbutton,at the if there are any abnormalities. operateit at that speed.
sametime puttingthe decompression leverto the (4)Alwaysset the clutch in the neuiralpositionand wait
2.2.2 Starling with one.handle remole control (option)
COMPRESSION positlon. After the engine has 2-3.1 Checks duttng oP€ration for the propellerto stop rotating before raising the pre
(1) Starting procedure started,retum the control leverto the MEDIUM (1) Oil pressure pellershaft (if hoisting lype stem gparsare installed).
1) Pull the neutral knob and set the conlrol lever to SPEED posilion. Check that the lubricating oil pressure and operating (5) Do not suddenlyapply a lull load to the engine or
the "MEOIUMSPEED" oosition. 'When the control leveris set in the H|GH SPEEO oil pressure lamps are off. operateit at full loadfor long periods.
position,iniectiontiming is automatiiattydelayedto Lubrication oil pressure during operation: 2.5 3.5
-
facilitatestarting. kgf/cm I 2-4 Siopping
CAUTION: When the engine ls started with the contrcl (2) Cooling water 2-4.1Sfoppingprocedte
leverin the HIGH SPEEDposition,the starting Periodically check whether water is being discharged (1) Beforestopping,put ttle clutch in NEUTRALand run
button must be rcleased lmmediatelyand the from the cooling water outlet pipe. the engine at approximately 1,000 rpm for about 5
control lever must be rcturned to the idling tf the iooling water is being discharged intermittently minutes.
positionafter the engine has started. or if only a small amount of water is being discharged (a Before stopping, temporatily raise the speed to the
lf the starting button is not rcleased,the starter during high speed operation, immediately stop the rated speedto blow out residueIn the cylinders.Then
motor will oveffun,causingit to be damagedor engine and checjKif air is being sucked into the cooling stop the engine by trJlling the engine stop lerrerto cul
bumt out, system, the impeller of the water pump is abnormal, or the fuel.
the water plpes and Kingston cock are clogged.
2-2.3Atler starling Cooling water temperature during operation: 45 ru 2-42 Slopplng p(ectl,uons
(1)Warm-upop€ration 550C. (1) Donot stopthe enginewith thedecotnpression lever.
Theenginemust not be suddentyoperatedat full load Check that the watertemperature alarm lamp is oft. It tt|e engineis stoppedwlth the decompression lever,
immedialelyafter stariing. Warm up the engine for (3) Fuel fuel will remainin the combustionchamberandabnor'
about5 minutesatterstartingby runningthe engineat Check the fuel level in the fuel tank and add fuel belore mal combustionwill occurwhenthe engineis started
about half speed,and begin fult toad operationonty the tank becomes too low. lf the fuel level is low, air again,p€rhapsdamaginglhe engine.
after the temperatureol each part has ris€n to a will enter the fuel iniection system and the engine will (4 lf the engine is stopped immediatelyafter full-load
uniformvalue.Neglectingto warm up the enginewill stoP. operation,the temperatureof each part will rise sud-
resultin: (4) Charging denly,leadingto trouble.
1) Seizingof the pistonand linerdue to suddenheat Check that the charge lamp is ofl.
expansionof the piston. It the charge lamP is still on even when the engine is 2-4.3Inspec'tionand p.ocedur€satter stopping
4 Euming of piston fings and seizing o{ bear. run ai 1,000 rpm or above, the charging system is taulty (l) Alwaysclose the Kingstoncock atter the engine is
ings/bushingsbecauseof insuff icientlubrication. and the battery is not b€ing charged. stopped.
3) Faulty intake and exhaust valve seat contact and (5) Temperaiure of each part Watermayenterbecauseof a faultywaterpump,etc.
shorteningof the life of each part due to sudden At full power operation, the surface temperature of (2) ln cold weather, the cooling water should always be
Medium speed
heating. each engine part is about 50 tu moc and hot to the drainedafter engine use to prevenl freezing.Thereare
Warm-uptlme (no-loadoperation) touch. lf engine temperature is too high, the oil will be water drain cocks on the cy'indersand the exhaust
1,000tu 1200 rpm 3 minutes used up, the propeller shaft will noi be centered, or manifold.(Drainthe wateraftertheenginehascooled-)
1,600tu 1,800rpm2 minutes othertroubles may occur. (3) Check for oil leakageand water leakage,and repairas
CAUTION:Do not run the engineat tull Speedlor fi hours (6) Leakage and abnormalities required.
atter installationto assureproperbreak-in. Check for water leakage, oil leakage, gas leakage, (4) Checkfor loosebollsandnuts,and repairas tequired.
loose bolts, abnormal sounds, abnormal heating, and
vibration.
O) Exhaust color
2:, Set the main switch io the ,.ON" position, and Black exhaust smoke indicates that the engine is be-
push the starting bufion to start the engine. ing ovedoaded and that the lives of the intake and ex-
Ptinted ia Jaoon
0000404r361 00004041361
()nplu 13 Opraling Inslmclions Chapter 13 Operaling Instruclions
2. Enginc Operating Inslruclions 3. Troubleshooling and Repair
sM/GM(F)(CrHM(F)(c) sM/GM(FXC).HM(F)(c)
2.5 Storage when moored for an exlended pedod
(1) Securely close engine room windows and doors so
lhat rain and snow cannoi enler.
3.Troubleshooting
andRepair
Also plug the exhaust outlet since water that enters lf trouble @curs in the engine,lhe engine must be im.
the cylinder from the exhaust pipe will be comoressed mediatelystoppedor run at low speeduntil the causeof
when lhe engine is started, causing serious trouble. theiroubleis located.
(2) The boai may also sink because of water leakage at lf evenextremelysmall lraublesare not detectedand cor.
lhe slern tube stuffing box packing. This can be pre_ recled early,they can lead to serioustroubte and even
vented by tightening the packing. disaster.Delectingand conecting troublesquickly is ex.
(3) Change the lubricating oil before cranking the engine. tremelyimportant.
(4) Wipe off each part and coat with oil to prevenl rustino
ot the engine exterior. 3.1 Troubles and corrective aclion at starting
(5) Coal the regulator handle stand and each link with a
thin tilm of lube oil orgrease. T.ouble Cause Coreclive acliafl
(6) Run the engine once a week to lubricate each part.This (1)Balterynot charged 'l) Rechargebatlery
will prevent rusting of the bearings, pistons, and
Flywheel tails (a Startermotor faulty 2) Oisassembleandrepairslartermotor
cylinderliners.
to rotale correctly (3)Movingparts seized 3) Inspectand repair
2-OEme.gency slop (4)Lubricatingoil viscosity 4) Replacewith lubricatingoil ofsultable
(1) toosen the fuelvalvehigh-pressure pipeto releasethe too high viscosity
fuel.
(4 Pull the decompressionlever(decompression 1) Prirneand bleedair from fuel lines
mech.
anism)so that compressionis not apptiedto the com- 4 Iniect tuel through iniection valve and replace
bustionchamber. needlelf required
(3) Blockthe air intakeport so that air does not enterthe 3) Cleanfuel filter
combustionchamber. (1) Fuel not lnjected, or 4) Checkoperationof fuel pump, plunge( ptunger
iniection faulty spring,and deliveryvalve,and replace
if required
5) The remote control system or govemor is
faulty,so check if fuel is cut off, and adiust
if reouired
Starter motor rotates, (4 Fueliniectiontiming 1) Conect the fuel injection timing
but enginefalls to starl inconect a Check if alignment mark of timlng gear is aligned
1) Lapvalveswhen air tightnessof intakeand
exhaustvalvels poor
4 Replacecylinderheadpackingit gas is leaking
(3)Compressionpressurelow 3) Cleanor replacepiston rings when
stickingoccurs
4) Readiusttiming when intakeand exhaustvalve
closingis veryslow.
1) Replacepiston pin bearingand crankpin
(4) Drop in compression ratio bealing if wom
2) Replacepistoniings if wom
13-12 '13-13
0000A0Ar361
m00A0Al36r
Chapler I3 Operoting Inslruclions Chapler I3 Operating Inslruclions
3. Troubleshooting and Repair 3. Troublcshooling and Repair
sM/GM(FXC).HM(F)(C) SM/GM(FXCTHM(F)(C)
3.2 Troubles and conective aclion during operalion

Trouble Cause Cotrective aclion Trouble Cause Conective aclion
(1)Fuel iniectioncul oft due to (1) Bearing clearance too large 1) Inspect, and repair or replace parts
(2) Connecting rod bolt loose 2) Check and retighten
troublein the governoror 1) Inspect, and repair or replace
governOrsystem (3) Flywheel bolt, coupling bolt
3) Check and retighten or replace bolt as required
Enginestops suddenty (2)Air in fuettank loose
2) Add luel Engine knocks
(3)Air in tuetsystem (4) Injection timing faulty 4) Check and adjust
3) Bleed air
(4)Piston,b€aring,or other (5) Too much fuel injected
5) Check fuel injection pump and injection nozzle
movingpartsseized 4) Inspect and repair or replace the parts because of faulty fuel pump
and replace if required
or iniection nozzle
(1)Governor maladjusted 1) Adjus t
1) Check engine interior and exterior piping,
2) Lighten the load (check propeller system and (1) Lubricating oil leakage
(2) Overload replenish oil
power take-ofl system)
(2) Bearing, crankpin bearing
(3) Piston seized 3) Stop the engine, and repair or replace 2) Check clearance, and replace b€aring if necessary
clearance too large
(4) Bearing seized 4) Stop the engine, and repair or replace (3) Oil filter clogged 3) Check and replace filter element
(5) Fuel filter clogged 5) Clean lhe tuel filler
Speed decreases (4) Oil regulator valve loos€. 4) Check and readiust oil pressure
(6) Fuel injection pump or Engine oil pressure low
unexpectedly (5) Oil temperature high;
injection valve sticking
6) Stop the engine, and repair or reDlace cooling water flow 5) Check oil pump, and replace if necessary
Dirt in fuel pump delivery
insuflicient
valve
(6) Lubricating oil viscosity low 6) Replace with oil having a high viscosity index
C/)Air in fuel system 7) Prime and bleed air
f/) Excessive gas leaking into 7) Check pistons, piston ring, and cylinder liners and
(8) Water in fuel 8) Drain the fuel tank and tuel filter
cranKcase replace if necessary
Add fuel if insufficient
(1)Coolingwaterflow
(1)Loadunsuitable 1) Adjust the load (check propeiler system and 1) Checkwaterpump
insufficient
power take-off system) Lubricating
oil
(2)Fuel iniectiontiming off (2)Excessivegas leakingin to
2) Adjust iniection timing lemperaturetoo high 2) Check piston rings and cylinderliners
(3)Fuel unsuitable. cftrnkcrse
3) Change the fuel type
(4)Iniectionvalvefaulty (3) Overload 3) Lightenthe load
4) Test iniection and replace valve if reauired
(5)Intakeand exhausivalve (1)Air suckedin with cooling
adjustmentfaulty 5) Adjust valve head clearance t 1) Checkwater pump inlet side pip€ connections
Exhaust color is bad water
{6)Intakeand exhaustvalves Coolingwater temperalure (2)Coolingwaler llow
leaking. 6) Lap or grind valves 2) Checkwaterpump
hi gh insufficient
7) Check the fuel iniection pump and injection vatve (3)Coolingsystemdirty 3) Flushcooling systemwith cleaner
f/) Output of cylindersuneven
and replace if necessary (4)Thermostatfaulty 4) Replacethermostat
(8)Injectionpressuretoo low 8) Sel iniection pressure with shrms
(1)Neukal positionadiustment
€) Precombustionchamber 9) Replace the precombustion chamber...perform Propellershaft rotates 1) Resetneutralpositionadiustingboll
melted faulty
item (1) above evenwhen clutch is in
(2)Frictionplateseized 2) Checkand repair
Full load operation (1) Fuel filter clogged 1) Check and replace filter element neutralposition
(3) Steel plate waryed 3) Repairor replace
impossible (4 Fuel pump ptunger wom 2) Replace plunger and barrel as a ser
(1)Clutch face s€ized 1) Beplace
(1) Air in fuel pump or fuel line 1) Prime and bleed air from the fuel pump and luel (2)Movingparts, leversystem
Ahead, neutral, astern 2) Readiust
lines malfunctioning
(2) Water in fuel switching taulty
2) Orain the fuel tank and fuel filter and add fuel (3)Remotecontrolsystem
(3) Fuel injection yolume uneven 3) Check and adjust inlection volume 3) Repairor replace
malfunctioning
Outp'utof cylinders (4) Fuel iniection timing uneven 4) Check and ad.iust injection timing
uneven (5) Intake and exhausl valves (1)Clutch slippingbecauseof
1) Reduce load
5) Disassemble and clean overload operation
sticking
6) lf nozzle is clogged, clean; replace nozzle if
Abnormal heating (2) Bearing damaged 2) Replace
(6) Injection valve fautty necessary (3) Excessaveoil 3) Check oil level and adjust to prescribed level
lf the needle is sticking, inspect and reolace (4)Oil deteriorated 4) Replace oil
(1)Gearnoise causedby
1) Avoid high speeds
Abnormatsound torsionalvibration
i (2)Gearbacklashexcessive 2) Replace
I
13-14 I
I 0000A0Ar361
1 3 -1 5
00004041361
DTsASSEilIE
AND REASSEMBLY
(DirectSea-Water
GoolingEngine)
000oArlA
I 36I
Chapter I 4 D isuscmbly and Ras*mbly
I. Diwnbly ond Rooinbly Pruuions
sM/GM(FXcrHM@)(c)
DISASSEMBLYAND REASSEMBLY
This chapter covers the most efficient method of disassemblingand
reassemblirg the engine. Sorne parts may not have to be renrOved,
clependingon the maintenance and inspection objective. In this case,
removalis unnecessaryand disassemblingin accordancewith thtssec_
lim is not required.
Ho|/E|/er, if ],ou follo\,\,the disassernuy and reassemblyprocedures, ao_
justrnent melhods, and precautions described in this chapter, you
should be able to prevent sLbsequent troubles and a loss in engine
pertormanceafter reassembly.The enginemust be tesl-runto coniirm
Iturl lhe engin€ is furrctioningproperly and delilering Ml pericffnance.
Sjincelhis chapter does rbt co/er detaileddisassenbly ard reassefibly
procedures for each part, refer lo pertkEnt chaptefs tor details.
1. Disassemblyand Reassembly
Prccautions
0) Reco(dlhe parts that r€qulrsr€plmm€nt, ar|d Eplace
mem wlth new parls durlng reassembly.
8€ caruful not to rrr33.mbtc wltft tfto old paits.
(21Do not forgct rdhc3lvcs rrd peklng ao€nt8tor seanng
dudnof€$en6ly.
Facklng of th€ qt dfr.d $nllty atd pacldng a0€nts
mrlctEd to thcpdng mat ftl mrlt b€ rjscd.
o &r'|cc tho dlsarr.fitLd p..tr lnto group!, arc-t|es irts
dlvldud cyilnd6r!, Intlkord od|a,s! ctc.
Cyllnder No. b lfiflcat€d No. l, No. 2 andlq No. 3
q/krl€rtrcm Ftyu,tEel.ldo.
(41Th. p.€Gcrtbod $dnenhg to(que must be obeerved
wt|qr tlghtonlrrg bolts rd nuts" Mor€o€r, sinca the
.t]lr€th of tho bolts rd nuts depondson th€lr.mt€riat,
be ano to use thoodr€cl boll3r|d ruts 8t thelr prcper
places.
Sp€clalbolts, nuts. . . . Hed co|€r, rod boltg flytrt|e€t, €tc.
Stong bolb. . . . . . . . . Eottt markrd(7)Gil&Zfi
Co.t|.nonbolt3, nufs . . Urrned<cC(J|S.{D
In rddition, ch€d( tho(rrs.ss€mblys|d |r6sembly pr€cau-
r()ns lofoach englne nodel,
PriJ.d tr J6
oo0 0Al!51
Chapter 14 Disasembly and Reassembly
Chopla 14 Disassemblyand Rasscmbly 2. Disossemblyand Reassemb$'Toob
2. Discsembly and ReossemhlyTools SM/GM(FXCIHM(F)(C)
sM/GM(F)(CIHM(F)(c)
Name of lool lllustration Remarks
2. Disassembly Tools
and Reassembly
The followingtools arenecessarywhendisassemblingand
reassemblingthe engine.Thesetools must be usedaccor- Stsl hamru Local supply
ding to disassemblyprocessandlocalion.
2-1. General handtools
Nams ol lool llluslration Remarks

Copperhammer L@d supply
YANMARstandad
Wrmch Code m; 28110-100130
Size:l0 x 13
YANMARsiandard
Wrencfl Codeno.:2811G1201/O
Size;12x 14
=<=\-.-_-----r Local sJpply
YANMARstandard
Nippec
-ra -\----
Wr€nch Codeno.:2811G170190
Size:17x 19
PlieF Lcd $pply
YANMARstandard
Wrencfr Coderc.; 2811G2202i()
Sizei2.x24
Local $pply 1 sel
a
YANMARstardtrd
/ Code rc.: 1(X2@-92350
Local supdy 1 sl
0000A0A1361
00004041361
Choltlu 11 Diswmily and Ras*mbly
Chqta I 1 Discsemfu and R anlrllnbly
2. Dirrenbly and Rcaalaittily T&
2. DiwnMy otd Rwnfiy T&
sM/GM(FXCTHMF)G)
sM/GM(FXCIHM(FXC)
ilrltcdlool lfluslratlon . 2.2 Spedal handtools
Rcmrlc
il.m€ of tool
Scr?e.
l-ocal supply
f-.*nu,
@"n,""
L6d rcd
o
tocal supply F4.spwcrrnoer lr$ftbn
rxketbo bo|l
S-,n*n"nou,a,ns Rdc A
pifi"'l**''*
MaLt borhg |rpls.
Locd $pply t Dt $--*
Rod+rrrfor
Itqmrod€f Locrla$ply
hdErH 8&&ilnp.15EtrJ
&nmOtShJ
|l/bbnhool No 2
llls crr-rurDs
qxn^0Al3Sr 0000A0Ar361
Chaplcr 14 Disaxmbly and Reasembly Chapler I1 Disassemblyand Reasembly
2- Diswmbly and Rawnbly Tools 2. Disassemblyand ReassemblyToob
sM/GM(qG|HM@XC) SM/GM(FXC'HM(FXC)
Name of lool Shape and size Name ol lool Shape and she Appllca$on
Applacalion
--.---_-t.-(fu
f-j /
-=->pa-L<du-l
Pbts pin insrtbn/

extretbn tol o (f$t\--gl
Pistm pin extractd
(),/
f#J
\\i/----
f1
f-(
!L/' /
Pistm ring
cqnpcsof
ffi
Model I Code No.
ffi Pisiln In$rtion ouide
trilodel d o No.
o\M)-_-_,-.-
Criretlon ot pistm pin
// l:-,4)-
V7I/HH. t-*=S
Valve hpplng handh
(#./
lGMlO //r/ uh II
(c) /-ut { Y-'l tl
2Gtvt20
(FXC} 09.510.1 Q.m6
3GM3O (037m -7815)
(D(c)
3HM35
{).3780)
012
rroxi:
Qn 80
g7 124oas
13.8189 4m
q9,-v'il
s' i - i
ValYehpping po^d€(
v All models
@L'PPinot@l
LF.--rr."t-E
Code no.; 2821G000070
(FXC) (o.17241 (0.8661) 3.1496i 0\
Insertlon ot dstm pin
CdrEthg rod !|mll lrodel d D Feel€r gia4e

-2
Y
w
dd bGhlng hsliqr, IGMlO O.2mm €
erlreRm fol (c) (0.m79)
2GMzO ozol:3 onX:8 m 't24085
(FXC) (0.74{lo (0.8268 io.7a74 q2270
3Gt\rco --o.zs6) -.83$)
IFXC) All models
cfd€tlo;812-N7fi
3HM35 ool:3 rrul:3 3.0 128670
(FXC} (0.8819 (0s606 1.1811142270
-{r.8937} -47211
\d
Ml. r 1.5p.551
lntake sd od|aat
YdElnstixt
extractbn tool ffi Frel hlectbn Elw
reptacer
l
All models
Co(b m.: 12408S2250 W Code mj 1011o4-el€x)
P.inted ir Jw 0000A0Ar36r
00004041361
Chaplo 14 Dircsembly ond Reossembly Chopler 14 Disossemblyand Reassembly
2. Discsembly and ReassemblyToob 2. Disassemblyand ReassemblyTools
sM/GM(F)(clHM(F)(c) sM/GM(ryGrHM@)(c)
Name of lool Namo of lool Shape and size Application
rrTt
TT
------------J
tl.l-
>1,...J:5\ll llnl
ExtGctor tol for the
beiling outer ra@ (for d-:.+'| H_Y]
models lGMlo, fcjn J.llol
2GM20(F), 3GM3O(F)
[T ITJ+,-,
\/ll\/,lf""""oo.,
jruffifABearinsoure-ace
Remving the coupling
I - ',
e mm (in.) Code rc; 1r/@49160 ExtEcting ihe beaing outer ra@ from the hflsing.
iz
; \so
hexagonal hole Output shaft nut

wrench for
3HM35(F)
/@v
Code no.; 124@S92m ffi
- eSFrr B.'o*'r
I ln.r"1n| 't*'*'o
Otrt"nrr^"*@
Outputshaftnul wen^*>
Outpulrhafl couptingt@kzt '
Orivhg t@l ld bearing

lnn€r re fitr models
oulput shaft coupling
1GM10,2GM20(F), lockfor3HM35(F)
3GM3O(F)
Ftr rorwing and tightening th€ outpot shatt
e I e I codeNo.
@nzo
The bearing inrer |@ of the drive outDut shaft

A, , 4
/hcl
Puller cradle fof

3HM3s(F)
-@
-ffi
H&H':,1'*'"
Purre'Purrer
W
Fo( refising the etput shaft whs using a
Adiustingthe opeEtion lever Code noj 1r/09649170 pulley pulls.
0000404136r 0000A0Ar361
Chapto 14 Disassemblyand Russembly Chapter 14 Disassemblyand Reassembly
2. Disurcnhly and Reascmbly Tools 2. Discsembly and ReassemblyToob
sM/GM(rycrHMF)rc) sM/cM(F)(clHM(FXC)
il.m€ of tool Shape and slze Applicalio.l Name of lool
€7
--4
, p!--f{ na..e,
/-j'rffi
\T:t(
-- outpulshall
Pullingsupport for ldi
3HM35(F) ru1 (1.77171
,*i.
o1s
@) "u"'no"'ooon
t-l
aarerorsornoetde
ij-l,J
Insertingt@l for f,r
-
Itr*rllng t@l
Il
3HM35(F)
Fq |ming the needle beiling inH |re, D.lYlne glNte
thcl 6llar and lhrust beding of the dtpui
Code m; lft@{SA, shaft (fwdd ostr side). plate
Lll \Fwad
Pr6r0rc
lr.ge Cq
K-
GN&., For hsfalling the 3ps

krH |u o{ tlF q.rtil
rd .r€€dle bedng
,ffi"*""0,,"n
6haft (r€v€Ge smdl
gs sld€I
Plate fo.sp.ku le
tais tor 3tlM35(F)
t fr ( f,' \"n",,0
' >1, \pi"r" ro,,p,,ng.",.,n",
\u,""
Ftr ffi|ovlng sd instdling the phte spring,

rctaiH ar|dlcircllp of the |aIgE qe€F (fward
Codenoi 1fro95.@ru
il **"
l]_**.
lk-.
Insertinglml fq
3HM35(F) Reve L.qo Cw
shttt
@
Affibly sperfor
3Hi/|l}s(R Forvsd lsg€ gg
l tN
\Assmb,ylpacer For hsta{llng tt€ tnFf bedne dd thrust
o[dfBrqss hge gEr 3idel
Fd detmlnlng th€ thickGs of the

Codem; l7t@@10 adjustim plate.
0000404t361 000040A1361
Chapler I4 Disassemblyand Reassembly Chapler 14 Disassembly and Reassembly
2. Disassemblyand Reasembly Tools
3. Olhers
sM/GM(F)(CIHM(F)(C) sM/cM(F)(crHM(F)(c)
2.3 Measudng inslrumenls
Nomenclalure Accuracy and range

3. Others
Supplemenlarypacking agent
Bond 388.005"
-\ l*
'Thre White. Since "Th@ Bond 388S5" is a
elvflt, it do€s rct penotrale asbesloo shets
Verniercalirers 1/20mm, prircipally o. complet€ly of sbestos. Alwrys use il with
0tu150mm gey Gbestos stEt psking for mplete oil tightrpss.
VY WtH "Three Bqrd 388405" is difficult lo obtain, u$
silicm non$kmt type "The Bond No. 50."
"ThreeBmd No.50" Grey. Silicm MelHl type liquid ptrkinq.
type peking agmt @ted on mting fa@s to p|egt oil
and gs leakage.Does not penetrate dbestos shet ard
6sur6 cmplele oil tightness.
"Thre Eond No. 1" Reddish brofln. Paste typ€ ret vis@s liquid peking.
1/100mm, ldeal ld mting fffi which ile resbred but reiNtalled.
0tu25m m , Particuhdy used to prrent mter leal€ge md to prffint
Micrometer
25 tu 50 mm, of bolts and nuts.
50 tu 75 mm,
75tul m m m ,
The surface to be coated must be thoroughlycleaned Products ofThrs Bond Co., Ltd
with thinner or tienzeneand completelydry. Moreover,
coatingmust be thin and uniform.
1/1m m m ,
Cylindergauge 18 tu 35 mm, Painl Painl
35 tu 60 mm, C)
50 tu 100 mm, TyP€
g cobrso(ay Whitepaint
(Mixedoil paint)
| "'"') Metalttc E6te sits b Ged
trtreVmthisensine.
k--\1l Us.ge polnl
N__-/l Cylinder lin€r
0.05 tu 2mm insertion hole
Thicknessgauge
(0.m20 ry 0.0787 in.l @,
Us
Wipe off the surface to be painted with lhinner or
benzene,shake the spray can well, push the hjttofl at Palnt parts that mtd t]€ cylln&r body wtFn
instif,O ths 6/linder linef to pffit rustlng s|d
the top of the can and spray the paint onto the surface waierleak4s
trom a dislance of 30 tu .O cm.
Torquewrench 0 - 13kgf-m
(0 - 94ft-rb)
Yanmar cleane. (Ref) NE I LOCK SUPER 2o3M:alockingag€nttdffi(R€f.)
Nozzletester 0 - 500kgf-cm'
(0 - 7111.7
l b/i n.'!)
Cooling passage cleaner is made by adding one part For coatlng on screws and bolts to prevent loosening,
"Unicon 1rt6" to about tG parts water (specific gravity rusting,and l€aking.To use,wip€ off all oil and waterofl the
ratio). To use, draln th€ water from the cooling system, th@adsof studs, coat the threads with screw locK tighten
lill the systemwith cleaner,allowingit to stand oi/emlght the stud bolt ard allow to stand until the screw lock
(10 r 15 hours). Then drain out the cleane( lill the hardens.Us€ screw lock on the oil intake pipe threads' oil
syslem with water, and operate lhe engine for at least pressureswitch threads,fuel in ection timlng shim taces'
one hour. and front axle bracketmounting bolts.
t4- 12
1 4 -1 3
00004041361 m00A0Al36l
Chopler 14 Disassemblyond Reossembly
1. Disrscmbly Chapter 14 Disosvmbly and Reassembly
SM/GM(F)(CTHM(FXC) 4. Discsembly
SM/GM(FXCIHM(F)(C)
4. Disassembly 4.26 Remove lheaklntake sllencel 4-29 Removolhe altemator

(1)Loosenthe adjustingbolt and removethe V-belt
Remove lhe intake silencerclip and the filter element. Then
4.1.GeneralPrecautions (2)Clutchside remove the set screw and the cover. (2)Removethealtematorandbracket
Malnteflanceand Inspectlon Bhouldbe done as effectively Pump out the oil from the filler/dipstickhole using a
as poGslble,arciding unnecessarydisassembling except wasteoil pumpor removethe drainplug at the botiom
for genoraloverttauls. stemsideof theclutchcaseanddrainthe oil.
At the time of disassembly,recod the presence ol parts
which require repair or rephcernent, and make ar-
rangemenls b€forehandfor procurementof such parts so
that problems will not occur during the reassembling
operation.
+2 Dlsmantling engine model iGMlo(C)

4.21 Op€nlhe cooling wate. draln cock and drain th€
coollng waler
4.27 Dbconn€d t|e tuel pbittg 4.210 Removethe wator pump

(1)Fueltanktofeed pump (1)Disconnectthe hoseb€tweenthe waterpumpand cool-
(2)Feedpump to fuel tiltet ing watercylinderInletloinl
(3)Fuelfilterto fuel iniectionpump
(4)Fuelhighpr€ssurcpipe
(5)Fuelretumpipe
{-23 Dlsconnectlhe remotocontrol cables
(1)Clutch remotecontrol cable and bracket
(2)Speedremotecontrol cableand bracket
(3) Enginestop remotecontrol cable and bracket
(4)Decompressionremotecontrol cable
4.22 Drdn lh6 lub.lca$ng oil
(1)Engln€slde 4-24 Dbconn€ct the el€clrlcal wiring
Insort a suctbn tube Into the dipstick hole and pump (1)Altematorwiring
out the oll wlth a wasteoll pump(option). (2)Startermotorwiring
Altemativelyremovethe plug of oil pan and oil intake (3)Watertemperature switchwiring
pipe,and drainthe oil. (4)Oil pressureswitchwiring
(5)Tachometersenderwlring
(a Loosenthe waterpump mountingbolts and removethe
{-23 Remousthe sl,artermolor waterpump-
,1.21I Rea|oUofft6 oll till€r .nd bGct6t
(1) Remov€th6 oll filter uslng the remover.
t2) Loos€nthe lolnt bolts at|d removethe oil plpes.
(3)Removettle oil filter breket.
4.25 Obconnecl lh€ coofing water Inlet pipe

NOTE: Always close the Kingston cock. --)
14 -1 5
000040Ar361
0000A0Ar361
Chaptu 14 Discsembly and Reossembly
4. Disassemblv Chapler 14 Disassemblyand Reassembly
4. DisossemblY
SM/GM(FXC'HM(F)(C) sM/GM(F)(CIHM(F)(C)
4.212 Removelhe rockeram chamb€r
(2)Pullthe pushrods 4.220 Remove tho llywheel
(3)Removethe cotter pins of the intakeand exhaustvalve (1) Remove the clutch disk
springs.
NOTE:Anange partsby intakeand exhaust.
4.2.15 Removethe cy'inder head

(1)Disconnectthe lubricating oil pipe located at
lhe
cylinderblockandlhe cylinderhead.
(2)Removethe cylinderheadnuts in the prescribedorder.
and removethe cylinderhead.
4-Zl3 Romovothe mlxlngelbow

(1)Disconnectthe coolingwaterbypasshose
(4 Remorrethe mixingelbow CAUTION: Notethe numbetand total thicknessof the tim-
ing adiustmentshims- (2) Remo\re the flywheel
Screw-ln the two bolts for securing the clutch disc
4.218 Remov€th€ timlng g€arcase (slightly to the left and right sides of the flywheel) and
{1}Removethe starting shaft cove( loosen the bolt with remove it by pulling on the bolts.
the hexagonalsocket head,and withdraw the pin for
..-..->< handlefitting.
(3! Removethe gasketpacking

NOTE:Cleady identily the trcnt and back ot the gasket
packing.
Mixlng elbow
4-216 Removelho crankshaftpu[6y
Remove the crankshaft pultey end nut and remove the
V-pulleyandkey.
(l) Removethe rockerarmass,y

(3)Removethe thrust collar, thrust ne€dle bearing,and
govemorsleeve.
4-219Remofe th€ clutch assombly 4.ZZl Removeth€ llyrrvheelhouslng

Loosenthe mounting fhngp bolts and remove the clutch
assembly.
4-217 Rfi|ove lhe lniectbn pump

('l) Removethe fixingnut of the fuetinjectionpump
(2)Openthe oil supplyhole,movethegovemorlever
2, and /-
iakeou.t theluel in ection pumpby rnatchingthe control
rackwith the cut-offpartof the gearcase.
t4- 16
0000A0A1361
Chapler I1 Disassembly and Reusemhly Chapler 14 Disasrembly and Reusembly
4. Disassembly 4. Disassembly
SM/GM(FXCIHM(FXC) SM/GM(FXCIHM(FXC)
4.2-22 Remove the feed pump 4-226 R-emove the crankshattgearard lhe lubrbating 4.227Tumlhe englnoonto lts sHe (2)Set the piston to lop dead center,tuming the crankshatt
oil pump so that the connecting rod does not separatefrom the
(1)Removethe enginefeetof the camshaftside
(1)Removethe crankshaftgear (2)Tumthe cylinderblock overso that the camshaftside is crank pin. Pull out the piston connectingrod assembly
e@ plmp (2)Removethe lubricatingoil pumpandgearassembly on the bottom. by pushingthe largeendof the rodwith a pusher.
a)
i.
I
4.2?3 Removelh€ lubdcaiingoll dipstick
4-e24 Remoyethe govemorwelght ess€mbly
(3)Removethe thrustmetaland the thrustwasherfromthe
crankshaft-
4.228 Remove the ofl pan and lh€ oll lnfake pho
I
Removethe crankshaftend nut and removethe govemor
weightassembly.
4.2il) Rernoye the main beadng hoqslng
Remove the main bearing housing bolt and rcmo/e the I
I
4.229 Remoyelh€ plston connecting rod assembly
(4) Remove the lubricaling oll pressure control valve. (1)Set the pislon to bottom dead center and removethe
connectingrod bolts. 4-231 Pull lh€ crankshafl
(1) Removethe camshaft end nut and remove lhe fuel cam (1)Pullthe crankshaft
(2) Bemovethe camshaftgear (2)Removethe thrustmetal
Camshatt
l 4 -1 9
0000A04r361 0000A0A136r
Chapler 14 Disassemhlyond Reassembly Chopter14 Disasemltly and Reassembly
1. Disusembly 4, Disassembly
sM/GM(F)(CIHM(F)(c) SM/GM(FXCIHM(F)(C)
4-232 RemoYethe camshatt 4.3Dismantlingenginemodels2GM20(C)and (2)clutch side (1)Altematorwiring
(1)Remo/ethe camshaftb€aringsel screw 3GM30(C) Pumpout the oil from the filler/dipstickhole using a (2)Starter motor wiring
(2)Check lhat all the tappetsare separatedfrom lhe cam, For the model 3HM35 engine, refer to the model 3GM30(C)
wasteoil pump or removethe drainplug at the bottom (4)Watertemperatureswitch wiring
and pull the camshaftout- instructions as the procedure is almost the same tor both
stemsideot the clutchcaseanddrainthe oil. (4)Oil pressureswftchwiring
engine models. (5)Tachometersenderwiring
4.3.1 Open the cooling waterdrain cocks and drain the 4.3.5Dbconn€ct lhe cooling water Inl€t pire and bllge plp€
cooling watea
I jz-7J"1
(1) Cylinder body waterdrain cock
/a1^ tn \i
'/q,)l:"/)
4,"!),
@
Camshaft 4.3.3Disconnectthe remote control cabhs
4.Zgl Romovelhe tappels NOTE:Alwaysclose the Klngslonc@k

NOTE:Amnge thercmoved tappetsby lntakeand exhaust.
tl-3-6Rernorethe.h h*c alencer
(2)Exhaustpipewaterdraincocklonlylor model3GM30(C)] Removethe Intakesilencerclip and the filter elernenLThen
removethe s€t screlvand the co\r€r.
4.32 Dralnth€ lubrhrllng oll
(1)Engineside
Insert a suction tube into the dipstick hole and pump
o|lt the oilwith awasteoil pump(option).
{1)Clutchremotecontrolcableand bEcket
(2)Speedremote control cable and bracket
(3)Englnestop remote control cableand bracket
(4)Decompressionremotecontrol cable
+3.4 Dbconn€ct th€ 6bctrbal wthg
00004041361
;ill
Chapler 14 Disassemblyand Reassembly Chapter 14 Disassemblyand Reassembly
4. Disassemblv 4. Disassembly
sM/GM(F)(C).HM(F)(C) SM/GM(F)(CTHM(FXC)
4.3.7Dbconnecl the tuel pbing 4-3.9 Remove lh€ altemator 4.3.12 Remov€ the rockerarm chamber (2)Pullthe pushrods.
( l) Loosen the adjusting bolt and remove the V-belt (1) Remove the breather pipe at the side of the intake pipe
(2) Remove the aliemalorand bracket [intake manifold tor model 3cM30(C)1.
(2) Remove the rockerarm chamber
(3) Removethe cotter pins of the intake and exhaustvalve

springs.
4.3.10 Romore lhe oll filtel NOTE:Arange the parts by cylinder no., intake aN ex-
+3.13 Remoreth€ exhausl menifoH
haust.
lonly lo] model3cM3O(C)landlhe mlxlngelbow
(1)Disconnectthe coollng waterbypasshose at the ther- tl.3.l5 Remow th€ cyllnd€r h€d
mostatcoverside.
(1)Disconnectthe lubrlcatingoil pipe.
€) Removethe mixingelbow[2GM20(C)]. (2)Renove the cylinder head nuls in the prescribedorder,
(3)Removethe exhaust rnanifoldtogether with the fuel
and remove the cylinder head.
filter and mixingelbow[3GM3O(C)}
(3) Remove the gasket packing
o\
si
6) s ,
(l) Fueltankto feedpump
(2)Feedpump to fuel filter
(3)Fuelfilterto fuel injectlonpump
(4)Fuelhlgh pressurepipe
(5) Fuel r€tum plpe 4.3.11Removothewalerpump
(1)Disconnectthe hosebetweenthe walerpumpand cool-
4.33 R€moIe lhe starleamotor ing watercylinderInletioint.
4.3.14Remorelh€ rockerarms
(1)Removethe mounting nut and removethe rocker NOTE:Clearly identity the lront and back ot the gasket
shaftassembly. packing.
(2)Loosenthe waterpump mountingbolts, removethe V-

belt by slidingit towardthe crankshaftside,and remove
the waterpump.
I
J
14-22 14-23
0000404t361 000040A136r
qile 11 Disosembly and Reassembly Chapler 14 Disassemblyand Reassembly
Disosembly 4. Disusembly
sM/GM(F)(C|HM@)(c) SM/GM(F)(C}HM(FXC)
' 116 Rornovethe crankshatl pulley 4.3.18 Remove lh€ timing gearcase 4.3.rc Removelhe f lywheel 4.3.22 Remoye lhe lubrtcating oil dipslick
move the crankshaft pulley end nut and remove the (1) Remove the starting shaft coveq loosen the bolt with (1)Removethe damperdisk 4-3.?3 Remolre lh€ leed pump
the hexagonal socket head, and withdraw lhe oin to.
handlefitting.
0)
Gu,
.etl Remorelhe InFclbn pump

l) R€fi|otrethe Inlectlon pump nut.
"(aG$, (2)Removethe f lywheel
Screw-inthe two bolts to securethe clutchdisk (slightly
1 Rgrnovethe gear case side cover, move the goyernor to the left and right sides of the flywheel)and removeit 4.3.24 Remove lhe luel cam
(2)Removethegearcase
brer 2, take out the fuel Inlection pump by matching the by pullingon the bolts. Remove the camshaft end nut and remove the fuel carn
Dofltrolrack with the cut-off part of the gearcase.
ii
4.325 Remow lh€ goremor welgftt assembly
(3) Remove lhe thrust collar, thrust needle bearing, and
gol/erK)r s|eeve.
4-3.19 Remove lhe clulch assembly

4-3.fi Removoth€ llnrheel houslng
Loosen the mounting thnge bolts and remove the ctutch
assembly.
l| Removethe Inlectiontimingadiustmentshims.
lflo{: Notethe numbetand totat thicknessto the tim-
lng acliustmentshims. Removethe crankshaft end nut and remove the govemor
weightassembly.
14-25
0000A0Ar36r 0000A0Ar36r
Chapler 14 Disasembly and Reassembly Chapler 14 Disassemblyand Reassembly
4. Disassembly 4. Disossembly
SM/GM(DGTHM(FXC) SM/GM(FXCIHM(FXC)
4-326 R6ove th€ lubricatingoll pump and d.tving g€ar 4-3.30Removelhe pislon connectfoqrcd assembly 4.3.32Remo-volt|€ mountlng boll of lhe Intermediate
(1)Sel the piston to bottom dead centerand removethe
connectingrodbolls-
', / -1-\1
tt I
l yihT;
iyt-
"^l).
tt
4.3.27 Remove lhe camshaft gearand the crankshatt gear
Two intemediate main bearings,viz No.1 and No.2,for

(2)Set the piston to top dead center,tuming the crankshaft enginemodel3GM3o(C). (3)Check that all the tappets are separatedtrom the carn,
so that the connecting rod does not separatefrom the andpull the camshaftout
crank pin. Pullout the pistonconnectingrod ass€mbly 4-3.3i1Pu[ lhe crankshatt
by pushingthe largeendof the rodwith a pusher. 4-3.35Removethe lappets
xljY;=>lll I
;!l \t.->'"-:
-,-nt
4-3.34Removothe camshaft
tl-3.28Tum lho onglneonto lts sld€ (1) Removethe camshattb€aringset screw.
(1) Removett|€ enginefeet of the crankshaftsjde
e) Tum the cylind€r block or/erso that the crankshaft side
ls on the bottom.
4.3.29Remove
th€ oll panard th6oll Intakeplpe NOTE:Atnnge the removed tappets W cyllnder no. and
4.3.31Removeth€ maln bearlnghousing intake aN exhaustgroups.
Remove the maln bearing housing bolt and remove the 4-3.36Removetho lan€rs
mainbearinghousing.
Set the engin€ uprlght and pull the lin€rs with a line,
(2)Phce the cylinder block upside down or ralse the

cylinderblock by insertinga platebeneathit in orderto
preventconiact betweenth€ tappet and the cam.
'rs'uffi
14-27
0000A0A136r
00004041361
Chaplu I4 Disasxtnbly and Reossembly Chapler 14 Disossembly and Reassembly
5. Reassembly 5. Reassembly
sM/GM(F)(c).HM(F)(c) SM/GM(F)(CTHM(FXC)
5. Reassembly (2) lnsert the crankshall 5.25 Assembb the plslon and cfl(|ecting rod as.rembly
(1)Coat the crankpin section wlth oil and posltion so that
the crankis at the top.
5.1 General Precaulions NOTE:Be carctul not to damage the groove in the end ol e) Goatthe piston and crankpinbearingwith oil.
Warpedwashersand packingsmust necessarilybe replac- the shaft. (3) Positionthe piston rings so that the gaps are 1200apart,
ed wllh newones. (2)After inserting the camshaft, check that it rotates being sure that there is no gap at the side pressures€c-
In assembling,sealingmust be appliedto att designated smoothly before tightenlngthe camshaftbearingset tion.
parts. Omissionmay cause serioustrouble during a trial Gap posltion ol No. 2
runningof lhe engineafter completionof reassembly.Ad- compcssion aing
a:
Justmenlsshouldbe performedin accordancewith t'hein-
structionsgiven- 5 zo
; I :s
Afler compleiionof engine reassembly,recheckanv defi-
ciencieswhich might haveappeared<turingmaintenance
and inspection,conducta trial runningof the engineand
then submltit lo the user.
*E{ gg
3F
o 06
ot 6lde pc$uae
5.2 Reassembly of engine model 1GM10(C)
posittoo ot oil rlng
5.Zl Insorl the l.app€ts 5.24Insbn ft€ mah b€arlnghoushg
(1)Tumthecylinderbklckoverortumlt upsidedown. (1)Coatthe oil seals€ctionwith oil (4) Ins€rt the piston conn€cting rcd assembly so that the
(a Coat the tappets with oil and Insert into the tappet (a lnsertthe mainb€aringhouslngandtighten. side of th€ connectim rod blg end wlth the ldentific4
)r-*\
holes. ^ t-.-t^
I \%y-.
5 \=J
tion numberls on the camshaftslde.
Install the piston rlngs wllh a piston ring inserter.
$2.3 lnsta[ th€ crankshaft

(l) Coalthe camgearsldethrustmetalrvlthoil and install.
(slAfter the connecting rod hrge end contacts the

-tb) crankpin,push the plston cro{rn dd^rn slolvly to tum th€
(3)Check that the crankshaftrotatessmoothly cankshaft to bottom ded center.
NOTE:Assembb thc bppets at thelr oilgtnat positions, (4)Measure th€ crankshaft slde gBp, and adiust lt io the
paylng cercful attenilon to lntake dn<lexhaust. prescribedvalueby the thicknessof the packing.
5.22 lns.rt lho camshalt
CAUTAN: //,s/€ll so that the thrust metal oit groove is at

the c'ankc€.se slde, being @rctu! not to
ctamagethe tab.
CBnksttsft side gap 0.06o 0.19mm

p-0024 tu 0.m75in)
1+28
0000A0Al36t 0000A0Ar36r
Chalttet Il Dimtsembly and Reassembly Chopter 14 Disassemblyand Reassembly
5. Remsembly 5. Reasscmbly
sM/GM(F)(CrHM(F)(c) s M/ Ght(t,')(('I r rw (t)( q
€) Align lhe conn€cting rod cap and connecting rod large (2)Align the disk and input shaft spline,and insiall the $2l3lnstall the lub.balingoll pumpande.|r raaambly
end rnatching mark and tighten the connecting rod clutch assemblyon the mounlingflange.
bolts.
CAUTION: t. Be caretul to tighten the connecting rcd botts 5.2.8lnstalllhe mounthgtlange
evenly. (1)Setthe engineuprighl.
z.Coat the bolt thrcads ancl washer tace with (2)Alignlhe positioningpinsandtaghtenthe flange.
\
I
oil.
I
oi k rt""(oi fi l b)
t
@
5-214 Assemblelhe crankshefl g6ars

T'rOhtening
(1)Coat the crankshaft section and lhe Inslde of lh€ geat
with oil.
5.21 I Install th€ €nglne te€t ard sel the englne ln posnbn (2) Insert the crankshaftgear
O) Measurelhe sideclearance.
Siledeerc 02 0.4mm
Olx)79-tu 0.0157hJ
ksf-m(U.5
(1)Dipstick
e) Fuel teed pump $215 Assembb lhe c.msheft g€rrrrd luel csm
I
G) Check that the crankshaftrotatessmoothly.
$2.6Intall lhe lubdcaliu oil lnt ke plp€ to lhe oil pan
5.23 Inslall lhe llywf|eol
(1)Alignthe referencepins
(a Installthe tlywheel
I
I
I
5.27 Instrfl tf|€ englnebottom cover(oll pan)
s-Zl2Ass€mbl€lh€ lhrusl melalandthrustwashor
(1)Coat the shaft hole of the carnshaft gear wlth oll, and
align the matching rnarks of the camshatt gear and lhe
ctankshaft gearand ins€rt the camshaftgear.
(2)Coat the fuel cam wlth oil and Insert ttte cam by aligning
the'O" mafi opposlte the carnshaftgear.
I
I
(1)Clla lg€ th€ packing. 6.5 - 7.0ksf-m (31Tightenthe camshattend nut
Tightenhg lorq€ (47 - 60.6fr-tb)
(2)Install lh€ bottom cover.
NOTE:After tlghtening,check the end run-out
(4) Check the backhsh
5.210 Instail lhe clulc-hrssembly
(1)Installthe clutchdiscon the flywheel
I
I
14-30
I
14-31
m00A0Ar36l
Choptcr I 4 D isassembls,
ond R eossembly
5. Reassemhly
Chapter 14 Disassemblyand Reossembly
SM/GM(F)(CIHM(F)(C) 5. Reossembly
SM/GM(FXCIHM(F)(C)
1).9ksf-m(6.5f r_tb) (2)Insert the pump by lookingthrough the oil filler and (3)Installthe waterpipe
(3) lnsert the pin for fitting the (fromthe thermostatcovertothe cylinderinletioint)
handteinto the camshaftand
fix it by means of the bott with
the hexagon"f .""f,"i 5.224Inslalllhe rocke.arms
head, then fit the starting shafl
cover. (1)Installthe pushrodson the tappets
5-2.19Installtheoil ,ilterandbracket (2)Coalthe insideof valvespringretainerwithoil.
(3)Install the rocker arm shaft assemblyand tighten the
(1)Install the oil filter bracket
on rhe gear side oi the
cytinderblock.
(2)Instatltheoit pipes.
(3)Instailthe oil fitter.
R@kea am supporl
8 - r0ksr-m(07.9t2- frJb)
-
5.217 Installlh€ governorgleeve (3)Tlghtenthe fuel pump
kgl lb)
Oil liltet / 5-223 Install lh€ cy'inder head

(1)Installthe gasketpacking
s.Zm Installth€ waterpump CAUTION: Takeparticular note ot the litting surfaces.Fit
(1)Installthe waterpump the side wlth tte rccessedpart ot the cooling
water passageto thecytinder block side.
(2)Insert the cyllnder head,belngcareful not to damage the valve head clearancc adiustlng
CNtTnN:l.Loosen
the threadsof th€ tightenlngbolts,and tightenthe nuts screw tn aclvancz.
\) Inthe tighteningsequence. 2. Checkthat the atm movessmoothly.
{4}Adiust the intafie and exhaust valve head clearanceand
lockwith the nut.
lntake ard exh&sl Elve 02m P.ofriinJ

had clearre (englne cob):
CoolinO water pump
5-225 lnslafi lhe rocker trm oover
5.218lmirlt the flmlnggearcase
(1)
9sYt Ootnsides of the new packingwith ,,ThreeBond
388.005,'andInstail.
(2)Instel the flmlnggearcase R@ker aam covea
(2)Installthewaterpipe(pump
to cytinderlnletioint)
5.221InstaflthecnnftshafiV.pulley
(1)Installthe crankshaftkev
et crankshafrV_iutreyano rhe inside
1tg
!_gt with
seal of rhe oil
olt.
(3)Insertand tightenthe V.Duilev
makinssure that rh€ rip
or rneol seaiis noi;;J"[*:r' Flywheel slde Geaa slde
t0 ksf-m(72.3ft-tb)
5-2.22lnstalt the fuel lniectbn pump

(1) Remove grease from both
sides of the fuel injection
Ing.adiustment shims with thinner, tim.
and coat the shims
with ,.Screw Lock Super203M.-
kgf-m(5i1,
14-32
t4-33
0000A0Ar361 0000A0A1361
Chopler 14 Disasxmbly and Reassembly Chapler 14 Dbassembly and Reassembly
5. Russembly 5. Reossembly
SM/GM(FXCTHM@)(C) SM/GM(FXC).HM(FXC)
$2.26Installlh6 mlxlngelboru 5.229 Insl,af,the Intakesilencer 5.3 Reassemblyof engine models 2clut20(C)and 5.33 lnseri th6 cansftaft
(1)Installthe mixingelbow (1)Installthe intakesilencercoverlothe Intakeporl. 3GM3o(C) (1)Coat the camshaft bearing section with oil and Insert
(2)Installthe intakesilencerandtightenit with the clip Referto the model 3GM30(C'instructions,6 the models lh€ camslBft into th€ cylinder block by tapping the shafl
3HM35(C)and 3GM30(C)arealmostthe same. endwith a pbstic hammer.
5.3.1Assemblelhe cylinderliners
(1)Removeany rusl from the cylinder block where it
contactsthe cylinderliners.
(2)Coatthe outsideperipheryof th€ linerswith waterproof-
ingpaint.
(3)Insertthe linersinto the cylinderblock,makingsurelo
checkthat the cylinderlinerprotrusionis conect.
Miring elbow
5.230 Inslall lhe altemator

(1)Installthe altematortothe bracket.
e) Install the cooling waterbypasshos€
(from the mixing elbowto the thermostatcover)
$Z27lnslail lh€ tu€l plpe NOTE:Be @rctul not to.tamage the grcove In the eN ot
the shatt.
(aAfter inserting th€ camshaft check that it .otates
smoothly before tightening the camshaft beerlng set
sc]ew.
5-32 Inserl lhe lappels
(1)Tumthe cylinderblockoverortum it upsidedown.
(2)Coat lhe tappels ,fllth oil and insert into the tapp€t
5.3.4lnslail the crrnkshatt
holes.
(1)Installthe le€d pumpto luet filterptpe

€) lnstallth€fuolfilterto fu€tInlectionpumppip€ (2)Installthe V-bettandtightenthe adiustingbottwhitead-
(3! Install th6 fuel hlgh pressur€pipe iustingthe V.belttension.
(4)Installthefuel retumpipe
5-231Connectlhe elGcirlcalwlrhg
$228 lnslrll lho 3Larlefmotor
&&
NOIE: Assemb/e the tappets ln their original posrtions,
paying caretul attention to the cylinder numbers
dnctintakeand exhaustgroupings.
5-232Instatrthe r€motecontrol cabbs

5-2.3:lConnectlhe Intertorphhg
14-34 14-35
0000A0A1361
0000A0Al36l
Chopla 14 Disassemblyand Reossembly
Chapler 14 Dhusembly and Reossembly
S.Rwmbly
5. Reassembly
sM/cM(F)(c).HM(F)(c) SM/GM(FXCTHM(F)(C)
s.3sTlgftlon tho sel boll of lhe krtemedate mah beadng (4)Measurdthe crankshaftside gap, and adiust it to the (4)Insert the piston connectingrod assemblyso that the 5-3.8 Install lhe lubrballng oll Intake plpe
prescribedvalueby thethicknessof thepacking. side of the connectingrod big end with the identifica- Coat the threads with "Screw Lock Suoer203M". screw th€
tion numberis on the exhaustside. pipe in and lock with the nut.
lnstallthe pistonringswith a pistonring inserler.
1- \
i):
l"iV;-
J),
Scwln distare I tu lornm (about 6 lurns)
Th€ two Intermediatemain bearlngs,viz No.1 and No2' for O3149 03SZn.)
Cdrkshaft site Oap 0-@-0.18.nm (5)Alter the connecting rod large end contacts with the -
model 3GM3O(C). P.035& 0.0071in.)
crankpin, push the piston crown down slowly to turn the 5-33 Instafl the engln€ bottom cover(olt pan]
fiM3s(C) crankshaft to bottom dead center. (1) Change lhe packing
$3.7 Assembl€lhe plston and connectingrod assembly (6) Align the connecting rod cap and the connecting rod
Tigtrtstdq@ 7.O- 7.5 (2) Install lh€ bottom cover
(1)Coat the crankpinsectionwith oil and positionso that largeend matching mark and tighten lhe connecting rod
ihe insertionsidecrar* is at the top.
5-35 lnstri lhe mah bcadnghoushg (2)Coatthe pistonandcrankpinbearingwith oil.
(1) Coat the oll s€al sectlon with oil (3)Positionthe pislonringsso that the gapsare120oapart,
(2) Insort th€ maln bearinghouslngand fighten being sure that the.e ls no gap at the side pressuresec-
lion.
'lst cmpcsdon ,ing
2nd compre3sion rlng
Oll ring
Oir@tion of piston pin 5-&10lnstallh€ mounlhg flar|gp

(1)Setthe enginouprlght
(2)Alignthe positionlngplnsandlighlen the flange
CAUTION:
1.Be carcfulto tightentheconnectingrcd botts
evenly.
2.C@t the boft thrcads and washer face with
oll.
kgf-m(fLtb)
_
I zcuzorq,sou6rcr-T_ililGFl-
Tighteningtorque | 2.5(18.t) | 4.5(32.51
O) Measure the slde clearance

(31Ch€ckthat th€ crankshattrotatessmoothtu
Side clearare 02
P.m79-O.4m
tu 0.0157n)
(8)Checkthat the crankshaftrotatessmoothtv
r4-36
t4-37
0lxnA0Al 36t 0000A0A1
361
Chapler 14 Disasscmbly and Reassembly
Choplo 11 Discscmbly and Reassembly 5, ReassemblY
5. Reassembly SM/GM(F)(C}HM(F)(C)
SM/GM(FXC}HM(F)(C)
(2) Coat the luel cam wilh oil and insert the cam by aligning 5.3.18 Install th€ liming geafcase
(2) Align the disc and input shaft spline, and inslall the '
5.3.1'l Install lhe flyu,tFol the "0" mark opposite lhe camshafl gear. (1) Coat both sides of the new packing with "Three Bond
(1) Align lhe reference pins clutch assembly on the mounting flange. 388-005" and install.
(a Install theflywheel (2) Installthe timing gearcase
#',{Gi
'i t'tlM
,N
(3) Tighten the camshaftend nut.
6-57.9ft-rb)
5.3.16Assembleth€ crankshaflgea.s 18ft-tb)

5-3.13 Installtt|€ engineteel and sel the englneIn position
(1)Oipstickflangeanddipstick (3)Insertthe pin {or fitting the handleinto the camshaftand
6.6- 7.0kgf-m
Tlghtdtq torqG (47 - 60.6fr-rb) (2)Fuelpump fix lt by meansof the bolt with the hexagonalsockel
head,thenfit the startingshaftcover.
NOTE:Altertightenlng, check the end run-out tt|e lubdcatingoil pump
0)
5-3.14Install
Installthe lubricatingoil pumpanddrivinggearassembly.
5.3.12 Instr! lhe cludr lsseBtly
(1)Installtheclutch disc on the fbruheel
a-",^ rll(
e'i,',q
(1)Coat the crankshaftsectionand the insideof the gear
withoil- \\
(2)Align the matchingmafts ot the camshaftgearand the
crankshaftgear and insert the crankshaftgear.
{3)After Inserting the crankshaftgear,check the backlash'
0.05-0.13mm
Bekl6sh (0.m20-0.m51in.)
(4)Install the govemorweight ass€mblyand tighten the

crankshaftendnut
.9-72
_ Lubepump body mnting bolt | 0.9 kgf-m(6.5fr-lb)
5.3.17 Install the golemorsle€ve

5-3.15 A$emble thec.mshaltgearand luel cam
Install ihe govemorsleeve, ihrust needle bearing and thrusl
(1) Coat the shaft hole of the camshaft gear with oil and in-
collar.
t9f sert the gear.
14-39
't4-38
0000A0At361
00004041361
ilnpler 11 Diussembly ond Reasrembly
Chaplo 11 Diusembly and Reosxmbly
, Renssembly
sM/GM(F)(CIHM(F)(c) 5. Rusxmbly
SM/GM(FXCIHM(FXC)
93.19lnstaillh€ crankshaflV.pulley (2) Inserl lhe pump by looking through the gear case side (2) Insert the cylinder head, belng careful not to damag€ (2)Coatthe insideofvalvespringretainerwithoil
I Inslallthe crankshaftkey covec and align lhe governor No.2 lever and rack con- the threads of the tightening bolts, and tighten the nuts (3)Install the rocker arm shaft assembtyand tighten the
I Coat the crankshaft V.pulley and the inside of the oil necling parl In lhe tightening sequence.
seal with oil.
(3| lnsert and tighten the V-puiley, making sure that the lip
of the oil sealis not distorted
-^--S-:-S
Flywh6l snd Gd !ld6
\-7^
$i120 Instrll the water pump

l0kgl
(1)|nstall the V-belt lo the crankshaftV-puileyand lnstatl

tt|ewaterpump.
5
(3)Tightenthe luel pump
@d )
Flywh@l €nd Gq sido
screwln advancc.
27ft-tb)
CAUTTON:l.Loosen the valve head cleanne adiustlng
2. Checkthat thearm movessmoothly.

r-rb) kgf-m(ft-lb) (41Adiusf fh€ htake ind exharst yalvehead clearanc€and
(4) Install the gearcase side cover lockwlth the nut.
lntakg and exhal3l t/anr€ 02rmO.minJ
5.322 Install the cylinderhead h6d demnco (emk€ c
(l) Install the gasket packing
(3)l nstal l th€w aterpi p€' 5-32i1lnsl,rltlho rocl(or||m cdtf,
0rom th€ th€moGtatcoverto the cyllnder Inletloint) (1)Install the rockeram oov€f
5.32i1lmtall lhe rcckecarms
(1)Install the push rods on the tappels
I fbhten whileadiustlngthe V-belttension
f- 'mtall thervaterplpe(pumptocylinderintetjoint)
CAU|ION: Takeparticulat notice ot the surtaces to be
! 2Ilmtelthetu€lhlectbnpump
titted.
(1)Rsnor/e greas€ from both sides of the fuel iniection Fit it keeping the TOp mark to the cvtinder
llming adlustmenl shims with thinner, and coai the headside.
'lhlms with "Screw Lock Super209M." (2) Install the breather pipe to lhe air intake pipe [intake
manifold . . . 3GM30(C).1
14-41R
0000A041361 mooAoAt36r
Chapler 14 Disassemblyand Reassembly Chapter 14 Disassemblyand Reassembly
5. Reosscmbly 5. Reasscmbly
SM/GM(FXCTHM(FXC) SM/GM(FXCTHM@XC)
5-3.25 Inslall lhe exhaust manifold (only for 3-cylinder 5.328 lnslall lhe oll tiiler 5-3.31 Connecl the electrical wlring
englne) and the mirlng elbow
(1)lnstall the exhaust manifold with mixing elbow [3GM
30(c)l
(2) Installthe mixing elbow.[2GM20(C)].
(3) Install the cooling water bypass hose to the thermostat
cover.
Cylinder head
5.33 Instafl lhe Inlake sllencer

(1) Install the intake silencer cover to ihe air intake pipe.
5-3.32Installthe remolecontrolcables
[intake manifold. .. 3cM30(C]1.
(2) Install the intake silencerand tighten it with the clip
5-326 lnstal the fuel plpo

(1)Installthe feedpumpto fuel filter pipe
fa lnstalllhe fuel filterlo fuel iniectionpumppipe
f3) Installthe fuel highpressurepipe
(4)Installthe tuel retumpipe
5.3.30 Inslall lh€ alternatot

(1) Install the altemator to the bracket
5-3.33Connect th€ Interior plplng
5-327 Instafltho 6larler moio.
ll
(2) Install the V-belt and tighten th€ adiusting bolt white ad-
iusling the V-belt tension.
t4-42
0000404136t 0000A0A1361
CHAPTER15
DISASSEMBLYAND
REASSEMBLY
(FreshWaterGoolingEngine)
1. lxs$mbly of F6h WErer{@lcdEngine......... .... . t$t
2 Relsmuy of Fch Water-Coobd Engam..............1$.11
3 T| g h t mi n gTo | q 6 . . . . . . . . -. . . . . . . . 1 9 2 ' l
a. P.cking Suppbmnt rnd AdtBis Applicariff Point . . -. .1924
00q' 0Ar!61
Chapter 15 Disassemblyand Reusembly

I. Disassemblyof Fresh WaterCooled Engine
sM/GM(F)(CIHM(F)(C)
1, Disassembly
of FreshWater-Cooled
Engine
In general,the disassemblysequencefor a fresh water. coollng water system are slightly different. Refer io th€
cooledengine is the sameas that for a sea water.cooled disass€mbly section of the sea water-cooled engin€
engine,except that the sequencefor parts relatedto ihe manualfor the latter steos.
1-1.Draining the cooling waler

(1)Drainthe sea water from the heai exchanger.The sea
water drain cock is installedon lhe side cover o{ lhe
heatexchangerat the rear.
Sea water
(2) Draln the fresh water from the heat exchanger.L@sen

the fresh waterdrainplug installedat the bottomof the
heatexchanger.
(4)Drainingsea water from the CSWpump

Loosen the CSW pump cover fixing screws, and drain
(3)Drainth€ freshwaterfromthe cylinderblock

Loosenthe cylinderblockwaterdrainplug anddrainthe
fresh water. The waler drain plug is installed on the
blockwallsurfaceattheexhaust sidein a model2GM20F
engine,andon the blockwallsurlaceat the intakesidein
models3GM30Fand3HM35F engines. NOTE'
1 5 -1
Pdnted in Jqe
0000404r36t
Chapter 15 Disusembly and Rmssembly Chapler I5 Disassemblyand Reassembly

I. Disusembly ol Frah lVoter{ooled Engine 1. Dkossembly oJ Fresh Waler4ooled Engine
SM/GM(FXC}HM(F)(C)
SM/GM(FXC}HM(F)(C)
1-2 Dralnthe tubricatingoil 1.5. Removelh€ CSW hose 1.6. Oisconn€ct the luel piping
1.3. Disconnect th€ rcmote control cables
(1)Engineside (1)Removethe CSW hose betweenthe CSW pump and (1)Fueltankto feedpump
(1)Clulchremotecontrolcabte heatexchanger.
Insert a suclion tube Into the dipstick hole and (2)Feedpumpto fuel fitter
(2)Speedremotecontrolcable (3)Fuelfilterto fuel inlectionpump
out th€ oil with a wasteo,l pump(option). (3)Enginestopremotecontrolcable
(4) Decompresslonremotecontrcl cable
(2)Removethe CFW hose betweenthe heatexchangerand

CFWpump.
NOTE:CFW = Cooling Fresh Weter
e) Outcfi sHe 1.4. Disconnect the elecMcal wiring
Pump out the oil from th€ fiflerldipstickhole usino a
w"sto oll pump or removeth€ drain pluS at tne bottim (1)Altemalorwiring
stem 8He of the clutch caseand drain th; oil. (2)Startermotor rt/iring
(31Watertemperatureswilch wiring
(4)Oil pressureswitchwiring Fuel l€ed
(5)Tachometersenderwiring pump
C@ling water
(3)Loosenthe hos€ clamp on the CFW hose between the

Allemator
cylinder head and heat oxchanget The hose clamp at
the heat exchangerside or the cooling water ouilet con-
nectionsideonly ne€dbe loosened.
Starling motor
Fuel f€€d
pump
I
I
l
J
0000AoAr36l
000040A1361
Chapler 15 Disassemblyand Reasembly Chapler 15 Disassemblyand Reassembly
I. Discsettrbly of Fresh llaterlooled Engine I. Disassemblyol Fresh lVolertooled Engine
SM/GM(FXC}HM(F)(C) sM/GM(F)(CrHM(F)(C)
1-7.Removlngthe fuel lilter 1-10. Remove lhe heat exchanger. 1.12 Removethe CFW pump 1-15. Removethe starler motol
The fuel tilter can be removed as assembled on the heat Removethe CFW pump by looseningthe hose clampon
exchanger. However, to make removal ofthe heat exchanger the cFw hosebetweenthe cFW pumpand cylinderblock
easier, the filter should be temoved separately. at the cylinderblockend.
1.16.Removeth€ oll filter
1-11.Removelhe allernalor
l-& Remow the fuel feed pump (1) Loosenthe adiustingbolt and removethe V-belt
In ceses ot anodel3GMF,the heat exchanger (4 Removelhealtemator Frcsh wate,pqmp
draln plug may,am agalnstthe fuel feed pump pipe con-

nect6. The t|,el fe€d pump should be removed before 1.13.Removelhe alr lnlake sllencer
r€m(ndrwth€ heat exchanger. Removethe Intakesllencercllpandthe filter element.Then
In cases of mod€ls 2GMF and 3HMF, ttrc heat exchanger rernovelhe set screwand th€ cover.
can be |€morredwlthout.snoving th€ fuel feed pump.
l€€d pump
1-17.Removethe CSW pmp

1.9.Remoyeth€ lemole contol bracket Loosenthe waterpump mountingbolts, removethe V-bett
Theheatexchang€r fixlngnut cannotberemoved
without 1.14.Remowthe luel hlghgessurcplpeandfuel by sliding it toward the crankshaftslde, and removethe sea
flrstremdingtheremotecontrolbracket. .etum plpe. waterpump.
Seawateapumpdrivepulley
154 15-5
0000A0A136r
00004041361
Chapler 15 Diswembly and Reossemblv
I. D isassembll' o! Fresh llaterCooled'Engine Chapler 15 Disassemblyand Reassembly
I. DisassemblyoJ Fresh llaterCooled Engine
SM/GM(F)(C}HM(F)(C) SM/GM(FXC}HM(FXC)
f-1& Ramoyo the rockera.m chamber
(1)Removethe breatherpipeat the 4-3.15 Removethe cyllnderh€ad 4.3.17Removethe inieclion pump
side of the Intakepipe (1)Removethe iniectionpumpnut.
(1)Disconnectthe lubricatingoll pipe.
.-. [intakemanirotd
tor modet3GM3OF and3HMii4- ''* (2)Removethe gear case side cover, move the govemor
(2) Removethe rockerarmcharnber (2)Removethe cylinderheadnuts in the prescribedorder,
andremovethe cylinderhead. lever2,takeout the fuel iniectionpumpby matchingthe
(3)Removethe gasketPacklng. controlrackwith the cutoff partol the gearcase.
After thls step.dlsassembly

41,
ls caniedout in the safi€ se. Th€ details-are given in Section
quenceas for the sea v/ator€ooled 4.3.14 "Remove the rocker
englne. arms "P1+29 of the sea watertooled - -- NOTE:Cleady identify the lront and back ot the gasket
engine manuat. packing.
For reference 4.3.16R€moveth€ crankshaftpulley

Remove the crankshaft pulley end nut and remove the
4.&14 Refl|oyethe rockorlrms V-pulleyand key. (3)Removethe inlection tlming adiustmentshims.
CAUTION:Note the number and total thlckness ot the
n'm"#Xrilunting nutandremove
therockerarm (a purrhepushrods. timing adiustmentshims.
4.3-18Removett€ lffihg geatcase

(1)Remov€thegearcase
(3) Removethe cotter plns of the intake

and exhaust valve
springs. (2)Remove the thrust collar, thrust needle bearlng, and
NOTg Arnnge the parts by cylinder no., govemorsleeve.
intake anctex_
m00A0At
361 0000A0Ar36r
f:tr;K1?;:;;#ii!,Iffj"tj,L,,^"
Chapler 15 Disassemblyand Reassembty
4.3-19Removeth6 ctutcfi SM/GM(FXCTHM(FXC) I. Disossemblyo! Fresh lTater4ooled Engine
rss€mbty
mountins flange borrs 4.321 Remoyeth€ f,n{rre€l SM/CM(FXCTHM(F)(C)
:3il,i1" and removerhe crutch hot,s&rg
4.325 Removeth€ goremorwelght issembt 4-3,29 Remove tho oil pan and lhe o[ Intake phe
rL*a:#:
51iq
Soecial tool
Bemovethe crankshaftend nut and removelhe govemor
weightassembly.
4-3.26Removethe lubrbatlngoil pumpanddrivinggear

assembly
nle lubdcsfr,g ofl dFb*
4.320 Remov€the llynfteel :=
4.3.U1lentove
Rernovethe f""O .O
(1) Removethe darnper n
disk
There are two lnt€m€diate maln bearlngs,vlz No.l and

No.2,for enginemodet3cM30F.
€l Removeth€ flywlEet.
;:ff,:lT,:,*fJ:1,
4.3.3i1Pull lhe crankshaft
T,ffi
;ffifllH:#,,$l:n tl 4.324 R€moyethe rt,el
cam
Removethe camshaft
end nut and remorrethe
fuel cam.
4-3.28Tumlhe englneonlo lts sue

(1)Removethe enginefeetof the crankshaftside
(2)Tumthe cylinderblock overso that the crankshaftside
is on lhe bottom.
0o00A0Al36t
0000A0A1361
'1
ChaOlcr 15 Disossembly and Reossembly
I. Disawnbly o! Frah lVatertooled "Engine Chapler I5 Disassembly and Rrcsembly
2. Reassembly o! Fresh Waler{ooling Engine
sM/GM(F)(C\HM(F)(C) sM/GM(F)(CIHM(FXC)
l-334 Remo|€ tho camshaft
(1) Removethe camshaftbearing
set screw-
(3)Check that all the tappets
andpullthecamsh"ilffi.
are sepaEtedfrom the
*-
cam, 2. Reassembly
of freshwater-cooled
engine
4"3.35Romoreft€ tappets Ingeneral,the reassembly of the freshwater.cooledengine For details of the reassembly sequence refer to chapter 14,
is the sameas that tor a sea waler{ooled engine,except Page'14-28-1+43 (Reassembly of Direct Sea-Water Cootino
for cooling system components such as the heat ex- Engine)
changer, lresh water pump, cooling waler pipe and
relaled Darts.
For reference
5-3.1Insertthe tappets NOTE:Be carcful not to damage the grcove in the end ot
(1)Tumthecylinderblockoverorlumil uosidedown- the shalt.
(2)Coat lhe tappets with oil and insert into the tappet (2)After inserting the camshaft, check that it rotates
@Plac€,the. cylinder block upslde ctown holes. smoothly b€fore tightenlng the camshaft bearing set
or rais€ the
lll'gld gl inserrins
a prate ben".rn ii init"i,I --- screw.
prerrentcontact betweenthe
tipper and the carn.
NOTE: Amnge the rcmoved
taDt
hhk;",;;;;;;;;.ifff;" o' cYtinctet
no.and 5-3.3lnstall lhe crankshatt
tl
&&
NOTE:Assemble the tappets ln tt@h ottghaf postilons,
paylng @reful ettenilon to the cylinder numbers s-3.4Tlehtenth. scl bofiof lho h€(m€d.te mrln beedng
enctlntakeand exhaustgKtuplngs.
s-3.2lnsertthe clmSuft
(1)Coat the camshaft bearing sectbn with oll and Insert
the camshaft Into the cylinder block by fapptng the shaft
€nd wlth a olastlcharnmer.
There at€ two Intermediate main bearings, vlz No.l and

No.2.tor model3GM30F
kgf-m(ft-lb)
15-10
0000A0Ar36t
{m00A0Al36l
Chapler I 5 Disassembls'and Reassembly
2. Reassemblyol Fresh |I/aterCooling Enginc Chopler 15 Dbassembly and Reossembly
SM/GM(F)(CNilIT(F)(C) 2. ReassemblyoJ Fresh WaterCooling Engine
SM/GM(F)(C}HM(F)(C)
5-3.5lnstr[ lh€ malnb€arlnghouslng
(1)Coatlhe oll sealsectlonwllh oil. lst compresslonrlng CAUTTON: l. Be caretul to tghten th6 connectlng rd bolts 5-3.9 Insta$lhe mosrnlng flange
(2)Inserlthe malnbearinghousingand evenly.
(1)Setihe engineupright.
2nd compaession ring 2.Coat the bolt threacls and washer lace with
(2) Align the posltloning pins and tighten the fhnge.
oil.
Oil ring kgf_m(tt-tb)
, ,
| 2GM20F.3GMSF I SHir3Sr
T i ghr eni ngr or quel 2 . S (t B . t ) 4 . b (3 2 . b )
|
Oireclionot pislon pin C/) Measure lhe side clearance
Side cl€rence 0.2-0-4mm

(0.m79^4.0157in.
)
(8)Checkthat the crankshaftrotatessmoothly.
5-3.7lnstalllhe lubrbailngoll Intak€plpe
Coatthe threadswith "ScrewLockSuper2mM",screwthe
pipein andlockwiththe nut.
(3)Checkthaf th€ crankshaftrotates smoothly. Skgf-m(32.

(4)Insert the plslon connectingrod assemblyso that th€
(4) Measuc the crankshaft side Oap,and adiust it to the side of the crnnecling rcd large end with the
prescribedvalueusingthe thicknessof the packing.
ld€ntificatlonnumberis on the exhauslslde. 5-3.10Insi.ll the lMrhe€l
Installthe pistonringswlth a pistonring inserter. rlo
(1)Alignthe refer€ncaplns.
(2I Install the fl!/wfieel.
Scw.ln distane 8 tu lornm (abqn 6 tur'ls)

ru 03932a)
5-3.8tnstatl the onglne'botton corer(oll pan)

(1) Change the packlng.
Yfr
(2) Install the bottom covsr.
(5)Aftertheconnecting rod largeend makes contact with the

C.ml(shaft sld€ Oap O.G)tu 0.1&nm
p335tuO.@711n.) crankpin, push lhe piston crown down slowly to turn the
crankshaft to bottom dead center.
(6)Align the connectlng rod cap and connecting rod targe
5-3.6Aqrcmblolh€ pbton r.dcoonectng rod ass€mbfy
end matchlngmaft and tighten the connecling rod
(1)Coatthe crankpinsectionwith oil and positionit so that bolts.
the insertionsidecrankis at the top. 0.9kgtm(6.5ft-tb)
e) Coal th€ plston and cratkpin bea.ingwith oit. Tightsing brqG 6.5-7.0ksf-m
(47-50.6ft-tb)
O Posltkrn lhe plston rlngs Bo that th€ gaps are 1200
apdt; make sure that there ls no gap at the side NOTE:Attertlghtenlng, check the end runout.
pr6surg sectlon.
15- 12
1 5 -1 3
0000A041361
r
Chopter 15 DisuwmbQ and Reusembly
T
2. Reassemblyo! Frah lVotertooting'Engine Chapler 15 Disusembly ond Reossembly
2, Reassemblyo! Fresh llalerCooling Engine
SM/GM(F)(CTHM(F)(C) sM/GM(FXCIHM(FXC)
5-3.11lnstall lho clutch lssemHy
$3.13lnstal ths lubrba&qoll pump (3)Insertand tightenthe V-pulley,makingsure that the lip
(1)Installthectutchdisc on lhe flywheel. (3) After inserting the crankshaft gear, check the backlash.
Installthe lubricatingoil pumpanddrivinggearassemblv of the oil seal is not distorled.
0.G5 0.13mm
Bekbsh - 0.0051in.)
(0.0020
- I
I
(4)Install the governorweight assemblyand tighten the
crankshaftend nut.
Or
Tighteningtorque |
$3.16lnslall lhe govemor sleeve

8-lokgf-m(57.9-72.3ft-lb)
Install the governor sleeve, thrust needle bearing and thrust

%a$
,@ ,il)
collar.
Lub€pump body munting bolt
5.3.14Ass€mbh thecrmshaflgerrand,u€lcam 5-3.19Installlhe w'terp|lmP

(1)Coatlhe shatt holeof the camshaft
gearwith oil and in. lnstall the V-belt to the crankshaft V'pulley Itd install the
(aAlign th€ disc and Input shaft spline,and sert lhe gear. waterpump.
install the
clulch assemblyon th€ mountingftange. (2)Coatthe fuel cam with oll and il
rhe'o"mark bvarisnins
opposii;;;;jl,:fJg,:am
fF3.17lnstafllhe llmlngg€arcaso
(l)Coat both sldes of the new packingwith "ThreeBond
388{05" and install.
T6'.ej
(#
(2)Installth€ liminggsar case. .
n-o
-a--7
brq6 | 2.0-2.6kgf-m(t1.b-t8.lfr_tb) (3)Tightenthe camshaftendnut.
(1)V-belttenslon
s'3,l2lnstrl th€ engln€te€t..d o6t lheonglne tn po€ltlon
{1, Dlpstlck thnge and dipstck 5-3.15Assemblethe cnd<shaft gears
e, Fuel pump.
$3.18ln3bn the crankshaftV.pulley thafi pullay

(1)Installthe crankshaftkey.
(2)Coat the crankshaft V-pulley and the inside of the oil
sealwith oit.
(1) Coat the crankshaft section and

the inside of the gear
with oil.
(2) Align the-matching marks of the Vn6ft tffiloo
camshaft gear and the
crankshafl gearand insert the crankshaft ge;r.
' t5- 14
1 5 -1 5
000040A1361 mooAoAl36l
i:ffi :f;:;il:{;ff:;tr#:,;.,^"
Chapler l5 Disossenftly and Reassembll'
2, Reasremblyof Fresh lfolerCooling Engine
sM/GM(F)(CIHM(F)(C)
o'ffilffi?l,Tf r*,*""
(2)Coatthe insideof valvespringretainerwithoil.
(3) Install the rocker arm shafl assembly and tighten the
The following sequence is dilferenl lrom thal of a
sea waler-cooled engine.
#,",';;g;"n"
necting part.
"' '-gt^"'**
tt;s';;;'iil' litr""H "*
ff ;ff 2-1.lnstall the starter motor
NX.-\
\>
'yr \
Ftywhet and
6t /Al 2-2 Install lhe oll filter

Flywhel snd i><s-\_1Y\,
CAUTION:l.Loosenthe valve head cleannce ddiusting
6; 6x (
p. LH
Gg .l d e
screwin advance.
2. Checkthat the am movessmoothly.
ksf-m(ft-tb) (4)Adiust the intake and exhaustvalveheadclearanceand
lockwith the nut
3!&(}5F
@ Instartthegear lntake a.|d exhaust Elre
""" "oG fightening torqG 02mmOr6in)
5{.A h.bl 0ra cfind€rft.rd !3 (e1.0) head detrare (engine coll)
(l) Insratlthe gasket packlng. (3)lnstafllh€ waterpipe

(fro,ntherherm;lli"r,".to 5-3.22lnstalllh€ roc*et"rm iore.
uEcylinderlnlet,olnt). (1)Installthe rockerarm@rrer.
5-3.2rt*t Ith.rcd(.r.rms
O) lnstafl the push rcds on
the tappets.
2.3.Assembl€the hlgh pressureluel pipe and fuel

r€lurn plpe
QlUltON: Take i
ti
Ntilcuhr ,r* , ahesurlaces b be
Kccp lhe TOp mar*
ot, thecylinder head
stde. (2)Install the breatherpipe to the air intake pipe 0ntake
mani tol d...3GM30F).
I
r5-16R I
L
15-17
0000A0AI36r
0000A0A136r
lny::!: !:*,:yu,l ondReassemb[.
z. KeossemblJ, ol Frcsh llalertooling
bngine Chapter 15 Dkassembly and Reassembty
sM/GM(F)(c).HM(F)(c) 2. Reassemblyof Fresh Water4ooling Engine
2-4. Insiall the Intake silencer SM/GM(FXCIHM(FXC)
(1)lnsw_the intakesilencer @
coverlo the air intake f.Tjfll l" y;9"1tandrishtenrhead,usrins
boltwhitead. 2.10.Assemble the cooling water pipe
",ilT'ffi
,r,,Hil
Dioe. ,usring the V-belt
tension. 2-7. Assemble th€ heal exchanger
(1)CFWhose(heatexchanger-CFWpump)
";,"'":y."%1tr.,#jTil;"
";"
Mounl the heat exchanger and replace the CFW hose at the
lhermostat cover side by connecting the hose to the heat
exchanger. Tighten the hose clamp after the heat ex-
changer is assembled.
CFW pump
2-5. Ass€mble tfte CFIIVpump
ff"s:ffi:il#:'"fff,'""Iiffi
lT,"ff
*i;r:ffi: (2)CSw hose(CSWpump-heat exchanger)
torque for 2-2.5kof-m

fixing bolt (r4.5^.18-ft-tb)
2.8.Assemblethe luel teedpump (3GM30D

For model 3GM30F engine assemble the fuel leed pump
after the heat exchanger is assembled.
CSWhose
Fwl fsod Dump
l?llff9*T- r-*r,-***-,"
iP,ii'il'l? C.W Pump puilqy 10*o(2 tb.)
.J 2-11.Connect the eleclrlcal wiring
(1)Installthe altematorlo
the bracket. 2.9. Assemble the fuel oll plpe
(1)Fuelfeedpump-fuelfilter
(2)Fuelfilter-fuel iniectionpump
Crankshaftpultey
I
Approx. lomm-
g!p9l 0.3937in.)
L
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-<--t-
Chopler 15 Disossemblyand Reassembly

r I
2-12 lnstail the rrmote sM/GM(F)(c).HM(Fxc) j. Tighrening Torque
controlcabfes sM/GM(F)(ctHM(FXc)
t
3. TighteningTorque
Thebolts and nuts usedin this engineemployISOgenerat
rnetric threads stipulated in Jls (JapaneseIndust.ial
Standards)- Paycarefulattentionto the threaddimensions
whenreplacingboltsand nuts.
Tightenthe boltsand nuts to the tighleningtorquegiveil in
thetablebelow.
r 3-l Mai n bol t and nut ti ghteni ng torque
L@tlon Eolt/rut t G Ml 0 (C l R€marts

i Thr€d diarets
Mt 0 M1 2 Nut and bolt
I M8 Aux- bolt
Cylindgr head
/t D 8 8 Nut and bolt
trght6nrng
)u6ntity
Aux. bolt
7.5(54.218 r2.0(86.8) r3(94.029)Nut snd bolt
Tightsing brq$ kgf-m(ftlb
3.0(2r.7) 3(21.@9) Aux, bolt
I
I
o
Rcker arm support nut )uantiry

Thread diamets M8
I
M1 0
3
I D
J
= Tiohtsrino brou kof fr (ft-lb 3.7(6.7e'.\
o
Thread di8rets x pitch mm M8x r.25
Exhaust manifold ndts luantity o
Tiohtenino bro@ kof-m(ftlb 1.5(32.549)

2.11 Conn€d the fnteriorpiping
Thr6ad diamets M25
Antiffcion zinc luantity
T -tb 5-6(36.165-43.398)
Thrsd diaret{ x Ditch mm M6 x 1.0 M8 x t.25
Timing g@r €se
mounting bolt
luantity 12
Tight$ing rorqs kgf-m(ftlb 0.s(6.5r0) 2.5(r8.@)
E
o Thr€d diamets x pitch mm M20x 1.5 M1 8x 1 . 5
Camshaft sd nut lu6ntity I
.q Tightsing brqs kgf-m(fclb 7-8(50.631-5./.864)

F
Thr6d diemet{ x pitch mm M26x t.5
Gqsrcr reight $t nut Ouantity I
Tightening torque kgf -m(ttlb 8-10(57.88r-72.Cp)
j
!
;
0000A0AI36l i
0(x)0A0Al36r
T
Chaptu t S.D isosembll, oud
R casscnthll,
J. I ightuing Torgue
Chtplar 15 Disassernbly and Reassentbly
3. Tighlening Torquc
L@tlon
sM/GM(F)(cIHM(F)(c) SM/GM(FXCTHM(F)(C)
Ir'.""0oi".JJilE---- Remarks
L@lion Bolt/nul M35(F)(C
GMr0(c)l2GMm(F )(C)bGM30(F)(C)bH Remarks
M l o x l .s GMr0(c ):
Anti@.rosion zirc Thresd diameter x oitch mm
-s mounting
luantity I 2
E (Cylinder bl@k)
!
Tightsing torque kgf-m(ft-lb) 5-6(36.r66-4i1.498)
Thr€d digmets x oitch mm
C@ling water inlet i)int )u€ntity
8 Tightening torque kgl-m(f t-lb)
Thr€d diametd x oatch mm M6 x 1 . 0 M8 x 1 . 2 5
Ttrreaooiameter-if,,IJlm- Watq pump body bolt luantity
Tightening torque kqf -m(ft-lb) 2.5(18.63)
Thr@d diamet€r x oitch mm M2 0 x1 . 5
Nozzle nut lusntity
Tiohtenins torque kcf -m(f t-lb) 10(72.330)
c
fhr€d diamt6 Mt 8
)elivsy vBlw lplds f,uantity a
f isht$ins brqs kgf-m(fllb) 1.(F,r.5(28.&-32.519)

E
fhr€6d diam€ttr x oitch mm M8 x 1.25
a Fuel ini@tion rczzle
'a flango nut IUAnflty 2x 1= 2 2x 2= 1 2x3=6
f ightening brqs kgf-m(ft-lb) 2(r4.{r)
f hr€d diam€ttr x oitch mm MSxl-25 c2)
6.5-7.0(47.015_5oE Clutch housingnul )uantity I GM-seri
a M18x 1.
Tightming brq€ kgf-m(ftJb) 2.0-2.5(14.{66-18.6) 3Hi&ts(
wl
fhread dirm€ts x pitci mm M8x t.2t
to
Clutch muntino bolt luantity 8
rc)J
l-ight$ing brqrc kgf-m(ft-lb)
x oitch mm
2.0-2.5(14.166-r8.8)
( .2)
G
t f hroad diamettr
lridth 8/c mm(in.) $/31.6(r.r8fi/1.&tA
) (' 3) W
\Jnl
ouFut sh€ft @upling lusntity
tight€ning nut r: 315 (t.55511
f ightsing torquo kgf-m(ft-lb)
rotr.5 b: &! (12596)
(2.331-r0.860) (@.71't) c: 7 f0.27561
Thred diamottr x oitch mm Mt o x t . 6 | Ml 2
luantity 2
Fp
I
Tight$ing torque kgt-m(ft-lb) 4.F5.0 | 7,5-8.0
(4.$9-$.166) F5..21t-51.$a
t.o-t.5(7.2330_tol6t Thread diamets x pitch mm M8x t.25
U
u AC gtrtrator mnting f,uantity J
bolt
f ight€ning torqu€ kgf -m(tt-lb) 2.2-2.7( 15.913-19.5$)
3-2Generalbolt andnut tighteningtorque

kgf-m(tLlb)
t5-22
@0A0Al36l o000A0Al36l
ilr
tl
Choplu. I S D tsassembly
and R6.sserrr',ty
4, Packiry Supplement ond Adlwive
tl Agilication points
SM/GM(F)G}r
lllr 4. fac[ing .Supplement
andAdhesive
Applicationpoints
thisensine
isasbestos
sheet
seated
at
ffrtfflff,f,f.jn
conedsupptemenrinaccordance
with
ffi",ff",";,n:"
Localbn
Pacting agent anOaaner
g1y,"d", r,"roiio"G p*r.ins--
,*jl :3T top and bottm
uyffEer_hed csting sand ho-leplug
Cylinder l|ead
eqrffiff.ffiHffiffitri3;*1l",
ild1Iffi&,ff1ff,ffi.ffiT.H* "Three Bond No. 50"
drRjst trtritold stud bolt lhred "Screw L@k Super 2G3M
rffi(d am support stud bolt -xrew Lock Super
2O3M
@rng Htq outlel lornt tr*
Tlming gsat :tl 5 9l!"'ils.ss csepackil-_-- "Thre Bmd 38{1.@5"

ffiSiffiSgHffiHtshims
wudivs nhdl tclng co*pdirrg
'5cr6r Lock fupq 2(BM,,
"Three Bo.d 388-@5"
ft3ffi,flg"fl,ffiH;
Cootingxras
pipolintru;
'Tir€€ Bdd 3Bg-@5"
lvhite Daint
:lqEdk€ dt suctim ptoe uy€ds "Thr€e Bond No.20"
Pl'at',€ds "Scren tock Suptr 2OOM,,
Cylinder btod( ffiffi,d'eul"d
qr switdt
-pr€ssr€ trds
(ryrrxlg hed bolt atld '"Threetu3AB-@5"
r,lqlntLtg tk|ge bae
rrub dl puno fu
ffiffi{mrffi"ffi,
soth std6of trri:tprnp-#ki6
CrU|kshaft, plstdl
ffit#ffiffi-,bh,"'t"c.-,,o,, "Ihr€e Bard 3AA-@S"
Cooling s'rtsn
ffiffitrffi
ua*terpa"*ure*,ittrilEG
YE|s fah lolnl (cylixler, ed|arsf pape,
'"fhr€ Bond No. A'
'Three Bor|d No 4"
Clutch lyslsn MqnthO fhnoe te

Ctuich housim tac
lr
d:r
l5-24
,
ooooAoAl36r-

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fr https://truckmanualshub.

1710E7-42280 129150-r 1310

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

A- Engine N4odelName o-1

CHAPTER 1 GENERAL CHAPTER 8 FRESH WATER COOLING SYSTEM

CfIAPTER 13 OP€RATING INSTRUCTIONS

Clulch model name olate

Yourclutch gear ratio

model name plal€

Venial 4rycle water c@led diesel engire

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

take off at Flywhel side

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

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

?a5€ar4) 786 ($.94)

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

Lubri@ling oil €pacity

1-2. Fresh Waler Coollng Typ€

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

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

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

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

Lukicaring ol €prcity 5.4(329.5r)

SPECIFICFUEL CONSUI\,'lPTlON(DlN6270B rating) SPECIFIC FUEL CONSUMPTION {DlN6270B rating)

ENGINE TOROUE (DlN6270B rating)

SPEED OF CRANKSHAFT: rpm

SPECIFIC'R EL CONSTJMPTION (D|N6270B rating) 300 2n

1600 m6 2400 2800 3200 3600

OUTPUTIS APPROX3% HIGHER.

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

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

C@stant Gh g@. with dog dulcil

Lubri€taing oil €pacity

Printed in Japan r-3

Watd{@l€d mixing dbw ty(a

O€rh€ai, 6lve 96h rcd, rcks am systm

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

llain mving eleMts Ov.l typo

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

Go€mor ffi ltkFodmc(fiaricdtt"o

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

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

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

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

water inlel d14(d0.55)

ri@lion pump 41. Output shalt coupling

31. Fuel feed pump 41. Foruard laroe gear

F uel overilow o8 3(o0 331

Delall ol cqJplir€ (A) (A)

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

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

waler inlet d13 8(d0 54)

Chapler I General Chapler I Ceneral

6-4 3HM35 6-5 2GM20F

F uel over{low d8 3(d0 33)

tHril ol cddi.|g (A)

FuelrnleloB 3(o0 33)

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

12x 30(047 x 1.18)

€rffi*lipe Exhau$ fipe

7-5 3GM30F and 3HM35F

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

Casl hole lor lubricatingoil

C@nte.-docwi viewed t@ ste(n

Uat^",tr'"ffi lst comp.ession rinO