Yanmar 1GM10 service manual/Руководство по техническому обслуживанию Yanmar 1GM10

Издание на английском языке
This service manual has been compiled for engineers engaged in sales, service, inspection and maintenance. Accordingly, descriptions of the construction and functions of the engine are emphasized in this manual while items which should already be common knowledge are omitted.
One characteristic of a marine diesel engine is that its performance in a vessel is governed by its applicability to the vessel’s hull construction and its steering system.
Engine installation, fitting out and propeller selection have a substantial effect on the performance of the engine and the vessel. Moreover, when the engine runs unevenly or when trouble occurs, it is essential to check a wide range of operating conditions—such as installation on the hull and suitability of the ship’s piping and propeller—and not just the engine itself. To get maximum performance from this engine, you should completely understand its functions, construction and capabilities, as well as proper use and servicing.
Use this manual as a handy reference in daily inspection and maintenance, and as a text for engineering guidance.

Contents
Contents
Engine Model Name
Engine Model Name Plate and Clutch Model Name Plate
Item descriptions on the model name plates and information to be forwarded to us
Location of engine model name plate and clutch model name plate
Cylinder Number
Location of stamped engine serial number
General
Specifications
Principal Construction
Performance Curves
Features
Engine Cross-Sections
Dimensions
Piping Diagrams
Basic Engine
Cylinder Block Construction
Cylinder of model 1GM10(C) engine
Cylinder of model 2GM20(F)(C) engine
Cylinder of model 3GM30(F)(C) engine
Cylinder of model 3HM35(F)(C) engine
Cylinder block inspection
Inspecting each part for cracks
Inspecting the water jacket of the cylinder for corrosion
Cylinder bore measurement
Oil and water passages
Color check flaw detection procedure
Boring the cylinder
Measurement of distortion on the upper surface of the cylinder
Purpose of cup plug
How to drive in the cup plug
Cylinder Head Construction
Cylinder head of model 1GM10(C) engine
Cylinder head of model 2GM20(F)(C) engine
Cylinder head of models 3GM30(F)(C) and 3HM35(F)(C)
Cylinder head inspection and measurement
Measurement of carbon build-up at combustion surface and intake and exhaust ports
Deposit build-up in water passages
Inspection of corrosion in water passages and anti-corrosion zinc
Measuring valve sinkage
Dismounting and remounting the cylinder head
Rocker arm support positioning pin
Cylinder head assembly sequence
Tightening the cylinder head bolts and nuts
Cylinder head nut loosening sequence
Intake and exhaust valves, valve guide and valve spring
Inspecting and measuring the intake and exhaust valves
Inspecting and measuring valve guides
Valve spring
Precombustion chamber and top clearance
Valve stem seal
Spring retainer and spring cotter pin
Intake and exhaust valve rocker arm
Insulation packing
Components of valve rocker arm
Measuring the valve rocker arm shaft and bushing clearance
Valve rocker arm and valve top retainer contact and wear
Valve clearance adjusting screw
Classification of the intake and exhaust valve rocker arms
Adjusting intake and exhaust valve head clearance
Decompression mechanism
Adjusting without a feeler gauge
Disassembling and reassembling cylinder head
Piston assembly construction
Piston inspection
Replacing a piston
Piston pin
Piston pin bushing
Piston ring configuration
Piston rings inspection
Connecting rod ass'y construction
Connecting rod inspection
Crank pin bushing
Crank pin and bushing clearance (oil clearance)
Tightening the connecting rod bolts
Connecting rod side clearance
Crank pin bushing replacement precautions
Piston bushing and piston pin
Replacing the piston pin bushing
Crankshaft ass'y and bearing construction
Constructions of models 2GM20(F)(C), 3GM30(F)(C) and 3HM35(F)
(C) crankshaft assembly
Crank journal and crank pin
Crankshaft side gap
Disassembly of the crankshaft
Side gap maintenance standard and wear limit
Main bearing construction
Inspecting the crank bearing
Inspecting the thrust metal
Inspecting the intermediate main bearing
Replacing the crank bearing
Crankshaft oil seal
Oil seal insertion precautions
Oil seal type and size
Flywheel and Housing
Specifications of flywheel
Dimensions of flywheel and flywheel housing
Ring Gear
Position of top dead center
Construction of the camshaft
Camshaft of engine model 1Gm10(C)
Camshaft of engine model 2GM20(F)(C)
Camshaft of engine models 3GM30(F)(C) and 3HM35(F)(C)
Valve timing diagram
Camshaft inspection
Camshaft height
Journals of camshaft
Camshaft ball bearing
Tappets
Camshaft deflection
Push rods
Fuel cam check
Fuel cam assembly precautions
Timing gear train construction
Timing gear of model 1GM10(C)
Timing gear of models 2GM20(F)(C), 3GM30(F)(C) and 3HM35(F) (C)
Disassembly and reassembly of the timing gear
Backlash inspection
Inspecting the gear tooth surface
Inspecting the gear boss
Fuel System
Fuel Injection System
Fuel Injection System Construction
Fuel injection system specifications
Injection Pump Construction
Specifications and performance of fuel injection pump
Injection volume characteristics of fuel injection pump
Operation of fuel injection pump
Fuel control
Action of the delivery valve and the sucking-back of fuel
Disassembly of fuel injection pump
Dismantling of fuel pump of model 2GM20(F)(C), 3GM30(F)(C) and 3HM35(F)(C)
Inspecting injection pump parts
Plunger
Delivery valve
Assembling the fuel injection pump
Plunger spring and delivery valve spring
Plunger guide
Inspection after reassembly
Control rack resistance test
Fuel injection timing
Injection pump adjustment
Setting pump on tester
Measuring the sliding resistance of the fuel control rack
Adjusting the plunger top clearance
Checking the cylinder injection interval
Delivery valve oil-tight test
Plunger pressure test
Measuring the fuel injection volume
Adjustment of injection volume for each cylinder
Injection Nozzle Construction
Specifications for nozzle valve
Yanmar throttle nozzle
Nozzle operation
Injection Nozzle Disassembly and reassembly
Injection nozzle inspection and adjustment
Carbon and corrosion on the nozzle body
Checking nozzle action
Adjusting the nozzle injection pressure
Nozzle seat oil tightness check
Checking the spray condition
Inspecting the nozzle spring
Fuel Filter Construction
Fuel Filter Specifications
Fuel Filter Inspection
Fuel Feed Pump Construction
Fuel Feed Pump Specifications
Fuel Feed Pump Disassembly and reassembly
Inspecting and adjusting the fuel feed pump
Checking the pump for fuel oil leaks
Checking the pump for engine oil leaks
Aging, breakdown and cracking of the diaphragm
The contact area and mounting condition of valve
Diaphragm spring and rocker arm spring
Fuel Tank (Option)
Fuel Tank Dimension
Governor
Governor Construction
Governor Operation
Governor Performance
Governor Disassembly
Governor Parts inspection and replacement
Regulator spring
Sleeve
Thrust collar
Thrust needle bearing
Governor weight
Regulator lever and handle
Injection Limiter Construction
Injection Limiter Inspection
Injection Limiter Adjustment
No-Load Maximum Speed Limiter Construction
No-Load Maximum Speed Limiter Handling precautions
Idling Adjuster
Engine Stop Lever Construction
Engine Stop Lever Inspection
Intake And Exhaust System
Intake And Exhaust System of model 1GM10(C)
Intake And Exhaust System of model 2GM20(F)(C)
Intake And Exhaust System of models 3GM30(F)(C) and 3HM35(F) (C)
Intake Silencer Construction
Inspection of the intake silencer
Washing the intake silencer element
Exhaust System
Exhaust manifold and mixing elbow
U type mixing elbow
Exhaust manifold inspection
Mixing elbow inspection
Construction of breather
Breather for model 1GM10(C)
Breather for models 2GM20(F)(C) and 3GM30(F)(C)
Breather for model 3HM35(F)(C)
Lubrication System
Lubricating oil passage of model 1GM10(C)
Lubrication oil passage of model 2GM20(F)(C)
Lubrication oil passage of model 3GM30(F)(C) and 3HM35(F)(C)
Table of capacity for lubricating oil system
Oil Pump Construction
Lubricating oil pump on model 1Gm10(C)
Lubricating oil pump on models 2GM20(F)(C), 3GM30(F)(C) and
3HM35(F)(C)
Specifications of lubrication oil pump
Oil Pump Disassembly
Oil Pump Inspection
Outer rotor and pump body clearance
Outer rotor and inner rotor clearance
Pump body and inner rotor, outer rotor side clearance
Oil Filter Construction
Oil Filter Replacement
Replacing the oil filter
In case of oil leakage
Oil Pressure Regulator Valve Construction
Oil Pressure Regulator Valve Specifications
Oil Pressure Measurement
Direct Sea-Water Cooling System
Cooling system composition
Cooling water route
Piping
Cooling water passage of engine model 1GM10(C)
Cooling water passage of engine model 2GM20(C)
Cooling water passage of engine models 3GM30(C) and 3HM35(C)
Water Pump Construction and operation
Cooling water pump of engine model 1GM10(C)
Cooling water pump of engine models 2GM20(C) and 3GM30(C)
Cooling water pump of engine model 3HM35(C)
Water Pump Disassembly
Water Pump Specifications
Water Pump Reassembly precautions
Water Pump Handling precautions
Water Pump Inspection
Thermostat Construction and operation
Thermostat Inspection
Care must be taken when assembling the thermostat
Anticorrosion Zinc Principles
Anticorrosion Zinc Inspection
Kingston Cock Construction
Kingston Cock Handling precautions
Kingston Cock Inspection
Bilge Strainer
Bilge Pump Specifications
Bilge Pump Performance
Fresh Water Cooling System
Cooling System Diagrams
Cooling System Configuration
Sea Water Pump
Fresh Water Pump construction
Pump capacity and characteristic
Pump disassembly
Pump Inspection and measurement Heat Exchanger Construction
Water flow in water cooling tube
Heat Exchanger Specifications Heat Exchanger Disassembly
Heat Exchanger Inspection and cleaning Cooling pipe
Heat exchanger body
Filler cap construction
Filler cap pressure control
Filler cap inspection
Subtank function
Installation of subtank
Maintenance during use
Thermostat Operation
Thermostat Construction
Cooling Water Temperature Switch Precautions
Ventilator
Cooling water
Antifreeze
Rust inhibitor
Idling the engine when stopping Cleaning the heat exchanger tube
Modifying The Cooling System
Direct sea water-cooled engine and fresh water-cooled engine
Modification method
Testing a modified engine
Kit for modification into a fresh water-cooled engine
Disassembly of sea water-cooled engine
Drain the cooling sea water
Remove the cooling water pipe
Remove the fuel oil pipe
Remove the fuel filter
Remove the remote control bracket
Remove the mixing elbow
Remove the exhaust manifold
Remove the thermostat cover
Remove the thermostat bracket
Remove the cooling water by-pass connection
Remove the CSW pump
Remove the intake silencer
Remove the fuel high pressure pipe
Remove the lifting hook at the front of the engine
Remove the lifting hook at the rear or the engine together with the rear cylinder head cover
Assembling modified parts to the fresh water-cooled engine
Assemble the rear cylinder head cover together with the rear lifting hook
Assemble the front lifting hook
Assemble the fuel injection tube
Assemble the CFW joint to the cylinder block
Assemble the CFW pump assembly
Assemble the CFW hose
Assemble the CSW pump
Assemble the heat exchanger
Assemble the fuel filter
Assemble the fuel oil pipe
Assemble the mixing elbow
Connect the CSW hose between the head exchanger and mixing elbow and tighten the hose clamp
Assemble the CFW pump V-belt pulley
Assemble the alternator
Assemble the remote control bracket
Cautions when the engine is installed inboard
Reduction And Reversing Gear
Construction
Power transmission system
Arrangement of shafts and gears
Reduction ratio
Power transmission routine - Forward
Power transmission routine - Reverse
Drawing
Construction of Shifting Device
Action of the shifting device
Changing from neutral to forward
Engagement from forward to neutral
Clutch shifting force
Adjustment
Inspect for the following points
Inspection and Servicing
Clutch case
Bearing
Gear
Oil seal of output shaft
Input shaft
Output shaft
Intermediate shaft
Notch slot of shift lever shaft
Notch
Notch spring
Spring joint
Damper disc
Disassembly
Dismantling the clutch
Removal of the output shaft
Removal of the intermediate shaft
Dismantling the side cover assembly (Shifting device) Reassembly of output shaft
Reassembly of the clutch
Reassembly of the shifting device
Reduction and Reversing Gear Installation
Remote control unit
Reduction and Reversing Gear Operation and Maintenance
Lube oil
Side cover
Friction plate
Pressure plate
Driving plate
Retainer
Plate spring
Shift ring
Shift fork and shift lever
Reassembling the input shaft
Reassembling the intermediate shaft
Installing the input shaft and output shaft
Reassembling and installing the operating system
Installing the output shaft coupling
Marine Gear Models KM2P, KM3P and KM3V
Forward and reverse clutch operation
Engagement and disengagement of clutch
Adjustment of shifting device
Measurement and adjustment of clearance
Adjustment of the remote control head
Marine gearbox control side
V-drive Gear, Model KM3V
KM3V Sectional View
Shim adjustment for V-drive gear shaft, and backlash adjustment for
V-drive gear shaft and drive gear
Backlash adjustment for V-drive near shaft and drive gear
Dismantling the V-drive assembly
Drain the cooling water from the lube oil cooler
Remote Control System
Clutch And Speed Regulator Remote Control
One-handle remote control composition
Engine side installation
Movement of lever for model 1GM10(C)
Setting the reduction and reversing gear side
Movement of lever for models 2GM20(F)(C), 3GM30(F)(C) and 3HM35(F)(C)
Engine Stop Remote Control
Electrical System
Electrical System diagram of electric parts
Wiring diagram
Battery Construction
Battery capacity and battery cables
Battery Inspection
Checking the electrolyte
Voltage test
Washing the battery
Battery Charging
Battery storage precautions
Battery Charging precautions
Starter Motor Specifications and Performance
Starter Motor Construction
Starter Motor Operation
Starter Motor Adjustment and performance test
L-size measurement (gap between pinion and pinion stopper)
Pinion movement
Starter Motor Disassembly
Plunger movement
Pinion lock torque measurement
Mesh clearance
Starter Motor Rear cover
Starter Motor Brush holder
Starter Motor Yoke
Starter Motor Armature
Starter Motor Inspection
Armature
Field coil
Brush
Starter Motor Reassembly precautions
Starter Motor No load test
Starter Motor Maintenance standard
Various problems and their remedies
Alternator Features
Alternator Specifications
Alternator Characteristics
Alternator Construction
Alternator functioning
Alternator handling precautions
Alternator Disassembling the alternator
Alternator inspection and adjustment
Alternator reassembling the alternator
Alternator performance test
Alternator troubleshooting
Charging failure
Overcharging
Charge lamp failure
Alternator, Option, 12v/35A
Alternator, Option, 12v/35A Wiring
Alternator, Option, 12v/35A Circuit diagram
Alternator, Option, 12v/35A Principle of IC regulator function
Alternator, Option, 12v/35A Inspection and adjustment
Alternator, Option, 12v/35A Diodes
Alternator, Option, 12v/35A Rotor
Alternator, Option, 12v/35A Stator coil
Alternator, Option, 12v/35A Brush
Alternator, Option, 12v/35A Reassembly precautions
Alternator, Option, 12v/35A Checking IC regulator unit
Alternator, Option, 12v/35A performance test
Alternator, Option, 12v/35A Standards of adjustment
Alternator, Option, 12v/35A troubleshooting and repair
B-type Instrument Panel
A-type Instrument Panel
Key switch
Push button switch
Warning devices
Oil pressure alarm
Cooling water temperature alarm
Alarm buzzer
Buzzer for B-type instrument board
Buzzer for A-type instrument panel
Construction of tachometer
Specifications and dimensions of tachometer
Measurement of sensor unit characteristics
Operating Instructions
Fuel Oil and Lubricating Oil
Properties of fuel
Recommended fuels
Fuel selection precautions
Properties and compositions of fuel of various national standards
Simple methods of identifying fuel properties
Troubles caused by bad fuel
Relationship between fuel properties and engine performance
Fuel handling precautions
Action of the lubricating oil
Required lubricating oil conditions
Classification by viscosity
SAE service classification and API service classification
Recommended lubricating oils
Engine oil replacement and handling
Adding oil
Oil capacity
Engine Operating Instructions
Preparations before starting
Adding lubricating oil
Bleeding the fuel system
Starting and warm-up
Checking for abnormal sounds by cranking
Checking the electrical system
Checking appearance and exterior
Starting with one-handle remote control
After starting
Operation
Stopping
Checks during operation
Operating precautions
Storage when moored for an extended period
Emergency stop
Troubleshooting and Repair
Troubles and corrective action at starting
Troubles and corrective action during operation
Disassembly And Reassembly (Direct Sea-Water Cooling Engine)
Disassembly and Reassembly Precautions
Disassembly and Reassembly Tools
Supplementary packing agent
Paint
Yanmar cleaner
Neji lock super
Disassembly General Precautions
Dismantling engine model 1GM10(C)
Open the cooling water drain cock and drain the cooling water
Drain the lubricating oil
Remove the air intake silencer
Disconnect the fuel piping
Remove the starter motor
Remove the alternator
Remove the rocker arm chamber
Remove the rocker arms
Remove the cylinder head
Remove the crankshaft pulley
Remove the timing gear case
Remove the clutch assembly
Remove the flywheel
Remove the flywheel housing
Remove the feed pump
Remove the governor weight assembly
Remove the camshaft gear
Remove the crankshaft gear and the lubricating oil pump
Turn the engine onto its side
Remove the oil pan and the oil intake pipe
Remove the piston connecting rod assembly
Remove the main bearing housing
Dismantling engine models 2GM20(C) and 3GM30(C)
Remove the camshaft
Remove the tappets
Disconnect the remote control cables
Disconnect the electrical wiring
Disconnect the cooling water inlet pipe and bilge pipe
Remove the oil filter
Install the flywheel
Install the clutch assembly
Install the lubricating oil pump
Assemble the camshaft gear and fuel cam
Assemble the crankshaft gears
Install the governor sleeve
Install the timing gear case
Install the crankshaft V-pulley
Install the water pump
Install the fuel injection pump
Install the cylinder head
Install the rocker arms
Install the rocker arm cover
Install the exhaust manifold and the mixing elbow
Install the fuel pipe
Install the starter motor
Install the intake silencer
Connect the electrical wiring
Install the remote control cables
Disassembly And Reassembly (Fresh Water Cooling Engine)
Disassembly of Fresh Water-Cooled Engine
Draining the cooling water
Reassembly of Fresh Water-Cooled Engine
Main bolt and nut tightening torque
Packing Supplement and Adhesive Application Points