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SERVICE MANUAL MARINE DIESEL ENGINE 2GMFY, 3GMFY

1. 2 30 SM 2GMFY 3GMFY mm in Wear limit 71 85 2 8287 0 20 0 0079 2 Precautions 1 Before inserting check whether the piston pin is in the connecting rod 2 Coat the piston pin with oil to facilitate insertion 3 Check that the connecting rod and piston move freely 4 Insert the pin quickly before the piston cools Chapter 2 Basic Engine 4 Piston 4 3 Piston pin and piston pin bushing 4 3 1 Piston pin Measure the dimensions of the piston pin and replace the pin if it is worn past the wear limit or severely scored Maintenance standard Piston pin outside diameter Piston pin hole and piston pin tightening allowance 0 005 0 017 0 0002 0 0007 4 3 2 Piston pin bushing A copper alloy wound bushing is pressed onto the piston pin Since a metallic sound will be produced if the piston pin and piston pin bushing wear is excessive replace the bushing when the wear limit is exceeded The piston pin bushing can be easily removed and installed with a press However when installing the bushing be careful that it is not tilted Cylinder gauge A045052 JB06 220 9 0 7870 0 7874 2 31 SM 2GMFY 3GMFY Piston pin center Maximum wear measured in a b direc tions at central position marked mm in Wear limit 219 98 0 7866 mm in Maintenance Wear Standard limit Piston pin bushing 220 0 220 1 Inside 0 7874
2. SM 2GMFY 3GMFY 6 Remove the No 1 plunger spring upper retainer using 15 Remove the control rack your fingers or tweezers 7 Remove the No 1 control sleeve O O 8 Remove the No 1 delivery valve holder be careful not NOTES 1 Line up the plunger valve and the plunger and to damage the O ring put them in order 9 Remove the No 1 delivery valve spring 2 Immerse the delivery valve plunger etc in 10 Remove the No 1 delivery valve delivery vaive seat and clean oil packing 3 Do not loosen or remove the injection control plate etc 2 5 Inspecting injection pump parts 2 5 1 Rinse each component part in clean light oll before inspecting it NOTE Do not touch the sliding surface of the plunger and the delivery valve with your fingers during handling 2 5 2 Tappet Inspect the cam sliding surface of the tappet roller for wear scoring and peeling replace the tappet and rolier assembly when the total tappet and roller play exceeds 0 3mm 2 5 3 Control rack and pinion 1 Check control rack teeth and sliding surface for damage and abnormalities If found replace NOTE When replacing control rack adjust fuel discharge amount with a fuel injection pump tester and stamp 11 Remove the No 1 plunger barrel be careful not to a rack mark damage the face that matches the delivery valve seat 12 Remove the No 1 plunger barrel packing 13 For No 2 cylinder repeat the above steps 2 through 1 14 The above it
3. 1 Inspect the rubber impeller for fractures cracks and other damage and replace if faulty A0A5052 JB06 6 6 Chapter 6 Cooling System 2 Water Pump 2 Rubber impeller side wear Impeller Packing Main body wel VAS ves weil ll mal l TE mm in Impeller 19 0 1 width 0 744 0 752 Maintenance 18 9 0 7441 Maximum Clearance allowable standard at assembly Clearance without packing 2 9 0 0 04 92 0 7559 0 0079 0 0157 Housing width with packing A04A5052 JB06 6 7 SM 2GMFY 3GMFY 3 Water pump impeller shaft oil seat section wear mm fin Maintenance standard 10 0 0 3937 If water leakage increases while the engine is running or if the components are found to be defective when disas sembled replace them 4 Inspect the bearing for play and check for seizing at the impeller shaft fitting section Replace the bearing if there is any play Wear limit Oil sea section shaft diameter Chapter 6 Cooling System 2 Water Pump 2 2 Fresh Water Pump Pump construction The fresh water pump is a centrifugal type and is used to move fresh water from the fresh water tank through the cooling passages in the cylinder block and cylinder head and back to the fresh water tank The fresh water pump is composed of a pump body im peller pump shaft bearing unit and seals It is driven by a belt and pulley
4. 3 6 4 Nozzle seat oll tightness check After injecting fuel several times by operating the lever of the nozzle tester wipe the oil off the injection port Then raise the pressure to 20 kgf cr 284 5 Ib in 140 kgf cri 1991 Ib in lower than the prescribed injection pressure The nozzle is faulty if cil drips from the nozzle In this case clean repair or replace the nozzle 3 6 5 Checking the spray condition Adjust the nozzle injection pressure to the prescribed value and check the condition of the spray while operating the tester at 4 6 times sec Judge the condition of the spray by referring to the below figure Normal A0A5052 JB06 3 25 SM 2GMFY 3GMFY Stream Injection pressure low Nozzle seized Nozzie spring broken Dirt on valve seat Spike Injection port damaged or dirty Carbon build up Nozzle end abnormally worn Spray Injection port worn Carbon build up Slanted Uneven seat contact Injection port damaged or worn Carbon build up 3 6 6 Inspecting the nozzle spring Inspect the nozzle spring for fractured coils corrosion and permanent strain and replace the spring when faulty 3 6 7 Inspecting the nozzle spring retainer and inter spindle inspect the nozzie spring retainer and inter spindie for wear and peeling of the contact face and repair or replace the spring if faulty Chapter 3 Fuel System 4 Fuel Filter 4 Fuel Filter 4 1 Construction The
5. Overall efficiency N 26 100 Discharge Q t min Ls Q diagram Water temperature 80 2 C Shalt horse power Ls Ps Discharge Q timin A0A5052 806 6 9 SM 2GMFY 3GMFY Pump disassembly Disassembly of the fresh water pump is difficult and should not be attempted Faulty units should be replaced The pump assembly should not be disassembled from the pump body brackets unless absolutely necessary kgf cm ftit Tighteni come sang tore 40 80 2 89 5 79 Pump bedy bracket inspection and measurement 1 Confirm smooth rotation by rotating the impeller by hand When the rotation is not smooth due to bearing play or friction or abnormal noise is heard replace the entire pump assembly 2 impeller inspection Check impeller for damage corrosion and water Repiace if required 3 Check the holes drilled in the cooling water passage or by pass passage and clean or unblock where necessary Chapter 6 Cooling System 2 Water Pump SM 2GMFY 3GMFY Measuring clearance between impeller and pump body By pass passage MO NC 5 Thickness gauge Measuring clearance between impeller and pump body bracket Na x DN Straightedge By pass passage 4 Where water leakage is heavy due to wear or a damaged mechanical seal and impeller seal replace the pump assembly with a new one 5 Pump body and pump bracket inspection Clean deposits and rust from body and bracket Replace if heavily worn o
6. The injection pump is the most important part of the fuel system This pump feeds the proper amount of fuel to the engine at the proper time in accordance with the engine load This engine uses a Bosch integral type injection pump for two three cylinders It is designed and manufactured by Yanmar and is ideal for the fuel system of this engine Since the injection pump is subjected to extremely high pressures and must be accurate as well as defor mation and wear free stringently selected materials are used and precision finished after undergoing heat treat ment The injection pump must be handled carefully Since the delivery valve and delivery valve holder and the plunger and plunger barrel are lapped they must be changed as a pair A0A5052 J806 3 3 SM 2GMFY 3GMFY The fuel injection pump is constructed from the following main parts 1 Pump parts which compress and deliver the fuel plunger plunger barrel 2 Parts which move the plunger camshaft tappet plunger spring plunger spring retainer 3 Parts which control the injection amount control rack control pinion control sleeve 4 Parts which prevent back flow and dripping during in jection delivery valve Chapter 3 Fuel Systern 2 Injection Pump 2 1 Construction Delivery valve spring holder O ring Delivery valve spring Delivery valve Delivery valve packing Delivery valve holder Plunger barreli Plunger
7. 0 7913 diameter NOTE Piston pin bushing inside diameter is the dimen sion after pressing onto the connecting rod Chapter 2 Basic Engine 4 Piston 4 4 Piston rings 4 4 1 Piston ring configuration First compression ring Barrel face E Second compression ring Taper ring oy ZD Oil ring Coil expander ring 1 The first compression ring is a barrel face ring that effec tively prevents abnormal wear caused by engine loading and combustion gas blowby at initial run in The sliding surface is hard chromium plated This part is first hard chromium plated thickness 0 1mm 0 0039in or more then tin plated 2 The second compression ring is a taper ring having a sliding face taper of 30 1 30 Since the cylinder liner is straight and the contact area at initial operation is small it is easily seated to the cylinder liner Moreover the bottom of the sliding face is sharp and oil splash is excellent and air tightness is superb 1 1230 A0A5052 JB06 SM 2GMFY 3GMFY 3 The oil ring is a chrome plated coil expander having a small contacting face and exerts high pressure against the cylinder liner wall Oil splash at the bottom of the sliding face is excellent and its oil control effect is high This part is hard chromium plated Thickness is 0 1mm 0 0039in or more Coil Coil Oil slot 4 4 2 Inspection 1 Piston ring contact Inspect th
8. 9 3 2 Inspecting the gear tooth surface Check the tooth surface for damage caused by pitching and check tooth contact Repair if the damage is light Also inspect the gears for cracking and corrosion When gear noise becomes high because of wear or damage replace the gears as a set Pitching 9 3 3 Inspecting the gear boss Check for play between each gear and the gear shaft burn ing caused by play key damage and for cracking at the edge of the key groove Replace the gears when faulty A0A5052 J B06 2 62 ADA5052 JB06 CHAPTER 3 FUEL SYSTEM 1 Fuel Injection System Aa 3 1 2 Injection Pump 0 a 3 3 3 Injection Nozzle 6 cee ne tee eens 3 22 4 Fuel Fllter 2 44 00 decar xe mee ese NA 3 26 5 Fuel Feed Pump 000 06 cc cence 3 27 Chapter 3 Fuel System 1 Constructi 1 Fuel Injection System 87mm 213mm Rubber hose Q7mm eg 13mm Rubber hose Fuel high a ressure pipe Fuel injection pump d Bo A0A5052 JB06 3 1 Chapter 3 Fuel System 1 Construction 1 1 Construction The fuel system consists mainly of an injection pump in jection pipe and an injection nozzle plus a fuel tank feed pump fuel filter and other associated parts The injection pump is driven by a fuel cam mounted on the camshaft and is controlled by a governor Fuel stored in the fuel tank is fed to the fuel filter through the feed pump The feed pump is indispensable when the fuel tank is install
9. Eng revs for Forward Reverse clutch switching Forward Reverse Lever control force cooling water temp Oil cooler cooling water q ty Dry weight A0A5052 J806 21 PS 3400 rpm 500 3800 rpm Counterclockwise Clockwise on forwarding 3 48 2 96 2 55 9 5 10 5 kg cm 1 5 3 0 kg cm SAE 30 or equivalent 1 58 0 32 Below 1000 rpm Below 1000 rpm Below 30 kg cm Below 45 C inlet side 750 1500 g h 28 kg excluding 0 9 kg engine side joint amp 1 3 kg coupling 7 13 SM 2GMFY 3GMFY 2 03 90GN C909YOV Oil cooler Damper disc Drive gear Input shaft FIL Output gear Support shaft Pinion Driven gear PT 1 8 Hydraulic main pressure detection port M12 x 1 25 Reverse hydraulic pressure detection port Strainer inside the cover Lube oil pressure detection port PT 1 8 Forward hydrau lic pressure detection port PT 1 8 suoyvaifisads jodidu nig 4021 Suissaaay puv uoyonpay 4 4aj dpyD AAWOE AAWOCIWS Chapter 7 Reduction and Reversing Gear 4 Outline SM 2GMFY 3GMFY 4 Outline The YX 6 houses the reduction gears and hydraulic multi disc clutch for forwarding and reversing and reduces the diesel engine revolutions for transmission to the propeller shaft Changeover between reverse and neutral is easy by clutch operation There is no need to install a bearing to receive the propeller s thrusting force becaus
10. aag 10U12109 I 40u42a0r p 43 ADY AAWIE ANNIE WS Chapter 4 Governor 1 Governor 1 Regulator lever 2 Regulator spring sub 3 Regulator spring main 4 Crankshaft gear 5 Governor weight 6 Governor sleeve 7 Crankshaft 8 Governor lever 2 9 Fuel control lever 10 Fuel injection limiter ADA5052 JB06 11 Locking screw 12 Engine stop cam 13 Regulator handle 14 Engine stop lever 15 Engine stop spring 16 Governor lever shaft 17 Governor lever shaft support 18 Start spring 19 No load maximum speed limiter 20 Fuel injection pump 4 3 SM 2GMFY 3GMFY 21 Fuel control rack 22 Camshaft gear 23 Lubricating oil pump 24 Governor tever 1 25 Thrust needle bearing 26 Thrust collar Chapter 4 Governor 1 Governor ens SM 2GM FY 3GMFY 1 2 Operation The position of the two governor weights open and closed is regulated by the speed of the engine The centrifugal force of the governor weights pivots around the governor weight pin and is changed to axial force that acts on the sleeve This force is transmitted to governor lever 2 through governor lever 1 and lever 1 shifts the fuel control rack to increase or decrease the fuel supply The governor lever is Regulator lever Regulator handle Pivot point ale idle adjuster No load maximum speed limiter Regulator spring Fuel control lever Fuel injection limiter 1 3 Performance No load maximum speed No load minimum
11. towards the front Refer to 2 57 3 Tightening torque of nut Gamshatt gear Crankshaft gear Chapter 2 Basic Engine 9 Timing Gear kgf m ft lb Camshaft end nut 70 80 506 579 Crankshaft nut 8 0 10 0 579 72 3 NOTE When tightening or loosening the crankshaft nut take care that the spanner does not touch the gover nor weight or weight support Special tool SM 2GMFY 3GMFY 9 3 Inspection 9 3 1 Backlash Unsuitable backlash will cause excessive wear or damage at the tooth top and abnorma noise during operation Moreover in extreme cases the valve and fuel injection timing will deviate and the engine will not run smoothly When the backtash exceeds the wear limit repair or relace the gears as a set Crankshaft gear and camshaft gear backlash Crankshaft gear and lubricating oil pump driven gear backlash 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 tooth surface A0A5052 JB06 Wear limit 03 0 0118 0 3 0 0118 Maintenance standard 0 05 0 13 0 0020 0 0051 0 05 0 13 0 0020 0 0051 mm In Chapter 2 Basic Engine angat SM 2GMFY 3GMFY 2 Insert a piece of quality sotder between the gears to be measured and turn the gears The backlash can be measured by measuring the thickness of the crushed part of the solder Solder wire
12. 0 015 0 050 Rotor shaft hole g14 1 4 inside diameter 0 5512 Chapter 5 Lubrication System 8 Oil Filter 3 Oil Filter 3 1 Construction The oil filter removes the dirt and metal particles from the lubricating oil to minimize wear of moving parts The con struction of the oil filter is shown below The lubricating oil from the oil pump is passed through the filter paper and distributed to each part as shown by arrow Ain the figure After extended use the filter paper will become clogged and its filter performance will drop When the pressure loss caused by the filter paper exceeds 1 kgf cr 14 22 Ib in the bypass vaive inside the filter opens and the lubricating oil is sent to each part automatically as an emergency Oil filter Oll filter ADA5052 JB06 5 9 SM 2GMFY 3GMFY measure without passing through the filter as shown by arrow B The oil filter is located at the fitted position of the oil pressure regulator valve on the side surface of the gear case together with the oil pressure valve The oil pressure regulator valve is installed separately on the end surface of the cylinder in the gear case Chapter 5 Lubrication System 3 Oil Filter SM 2GMFY 3GMFY Qil pressure regulator valva Bearing Filter element 3 2 Replacement When the oil filter has been used for an extended period the filter paper will become clogged unfiltered lubricating oil wili be sent directly to each
13. 1 and 2 2 Tightening torque of hexagonal bolts for affixing the top and bottom of the intermediate main bearing housing kgf m ft lb 3 0 3 5 Tightening torque 21 7 25 3 A0A5052 JB06 SM 2GMFY 3GMFY 3 Set up vertically the cylinder block suspend the crankshaft and match the positions of the cylinder block oil hole and the intermediate main bearing housing set bolts to the intermediate main bearing housing 4 Attaching the intermediate main bearing housing set bolts 1 First temporarily screw the set bolt in the intermediate main bearing housing on the timing gear housing side and with the prescribed tightening torque start tighten ing from the intermediate main bearing housing on the flywheel side After tightening the bolts confirm that the crankshaft rotates smoothly Each set bolt hole can be adjusted vertically kgf m ft ib Tightening torque 45 50 of the set bolt 32 5 362 5 Reassembly of the main bearing housing 1 Enclose a small amount of oil inside the oi seal and assemble after coating the bearing with oil Chapter 2 Basic Engine 6 Crankshaft SM 2GMFY 3GMFY 2 Be sure to place the down mark on the main bearing 6 5 2 Inspecting the crank bearing housing side in the downward direction 1 Check the crank bearing metal for scaling deposited kgf m feb metal and seizure Also check the condition of the con Main bosing housing 25 18 1 tact surface If defects
14. 2 Measure the clearance between the crankshaft and the inside of the sleeve check the contact between the governor weight SM 2GMFY 3GMFY SCI Governor weight contact mm fin Maintenance standard Clearance Maximum allowable Wear limit Crankshaft outside diameter 225 0007 0 9831 0 9840 Governor sleeve inside diameter 70083 B25 10983 0 9863 0 9875 when assembled clearance 0 06 0 111 0 0024 0 0044 0 2 0 0079 Governor sleeve overall length f 15 20 1 0 5866 0 5945 1 5 3 Thrust collar Check the contact between the governor lever 1 and replace the collar when wear exceeds the wear limit mmn Maintenance standard Wear limit Thrust collar thickness 3 0 1181 0 1 0 0394 1 5 4 Thrust needie bearing Replace the bearing when wear exceeds the specified limit 148 0 5827 1 5 5 Governor weight 1 Check contact with the sleeve and for wear Support NM e Pin Governor sleeve contact Calk Support Pin Governor weight Governor weight Fuel control lever 1 5 6 Governor lever shaft Distance piece A0A5052 JB06 Taper pin Governor lever shaft support Governor lever 1 4 6 Chapter 4 Governor 1 Governor ER a es 1 Replace the governor lever shaft if there is play between the shaft and needle bearing play when the lever is mov ed or if the shaft does not
15. If faulty replace them as a set 2 Check for O ring damage Replace if faulty 3 Inspect the spring for coil damage and corrosion and replace if fauity 4 Inspect the contact between the governor lever 2 and the dam repiace the cam if it is too damaged A0A5052 JB06 4 11 SM 2GMFY 3GMFY A04A5052 806 CHAPTER 5 LUBRICATION SYSTEM 1 Lubrication System ce ee eee 5 1 2 Oil Pump 2 5 ea cle ede VES RC HERE Ea a RUE 5 5 KNoe li M nennen ar 5 9 4 Oit Pressure Regulator Valve eee 5 12 5 Oil Pressure Measurement eee eee ees 5 14 Chapter 5 Lubrication System 1 Lubrication System 1 Lubrication System Engine parts are lubricated by a trochoid pump forced lubrication system To keep the engine exterior uncluttered and to eliminate vibration damage to piping exterior piping has been minimized by transporting the lubricating oil through passages drilled in the cylinders and timing gear case ADA5052 JB06 5 1 SM 2GMFY 3GMFY Chapter 5 Lubrication System 1 Lubrication System 1 2 Lubrication oi passage of model 2GMF Y The lubricating oil supplied from the oil filter in the rocker arm cover is collected in the oil pan at the bottom of the cylinder block through the tappet holes The lubricating oil is drawn back up through the lubricating oil suction pipe by the trochoid pump and fed to the oil filter where impurities are filtered out Then it is adjusted to the pr
16. If it sinks quickly and stops at the position where the suck back collar closes the valve seat hole the delivery valve may be considered normal If this is not the case replace the delivery valve as a set Z0 Chapter 3 Fuel System 2 Injection Pump 3 Place your finger over the hole in the bottom of the valve seat and insert the valve into the valve body If the valve returns to its original position when you remove your finger the valve is okay If some defect is found replace with a new valve 4 If the valve closes completely by its own weight when you remove your finger from the hole on the bottom of the valve seat the valve is okay If it doesn t close perfectly replace with a new valve NOTE When using a brand new set wash off the rustproof oil with clean oil or gasoline Then wash once more with clean oil and follow the steps outlined above 2 5 6 Plunger spring and delivery valve spring Inspect the plunger spring and delivery valve spring for fractured coils rust inclination and permanent strain Replace the spring when faulty Ye Ey N N amp NN E x x E E Ej N IL SA INIT LLLI Free length Set length 35 5mm 295mm 1 3976in 1 1614in 21mm 17 25mm 0 679tin 0 8268in 1159 21 1 kg 23 13 27 98 Ib 24 0 24 kg 4 76 582 ib Delivery valve spring A0A5052 JB06 2 5 7 Plunger guide Check the tappet roller In
17. Use new O rings p Attention direction 2 M6 x 75 A0A5052 JB06 Chapter 7 Reduction and Reversing Gear 9 Disassembly and Reassembl SM 2GMFY 3GMFY LL m O ring TA G65 8 L O Cooler 1 Clean the cooling core completely 2 Use new O rings 3 Apply THREEBOND 1215 to the joint surface of the L O cooler and case Bolt with collar M8 x 25 2 Torque 210 206g cm S Rock washer B AG aa Gasket G Clutch case 5 Se Q Nga Os AOA 5052 JB06 7 25 Chapter 7 Reduction and Reversing Gear 9 Disassembly and Reassembly 9 3 Reassembly SM 2GMFY 3GMFY Friction plate Damper disc Stop plate Stop ring Steel plate 5 LU A NI Pipi Square ring Emergency bolt f N Pe Hydraulic cylinder Oil seal Square ring Spline Cap 1 Clean all part and take care not to let dust and metal chips get inside during reassembly Reassemble in the reverse order of disassembly according to the following instructions a Replace parts with oil leaks and other faults fore disassembly b Check for discoloration and abnormal wear to the bearing listening for abnormal sounds If faulty replace the bearing c Replace parts which exceed the wear limit d Check the alignment marks for reassembly Be sure to install the hydraulic pump in the correct direction Observe the A mark on the external drawing e For rubber parts such as O rings either clean in cleaning oil or
18. Water Pump ok cece ee aaa 6 3 3 Principal Construction 0 0 eee ee ees 1 5 3 Heat Exchanger aaa 6 11 4 Performance Curves La 1 6 4 Filler Cap and Subtank aa 6 15 5 Piping Layout aaa 1 8 5 Thermostat veresre aaa aaa waaa 6 17 6 Cylinder Number ua aaa 1 10 6 Coolling Water Temperature Switch 6 20 71 Precautions 2 2a 6 21 CHAPTER 2 BASIC ENGINE 8 Kingston Cock Optional aaa 6 23 1 Cylinder Block mana 2 1 9 Bilge Pump and Bilge Strainer Optinal 6 24 2 Cylinder Liner ccc ccc cece ete eee eee anaes 2 7 3 Cylinder Head co eei Ene 2 10 CHAPTER 7 REDUCTION AND REVERSING GEAR 4 Piston 4 02 040 sor ra ore Dev eer vns a 2 29 For engine model 2GMF Y and 3GMF Y 5 Connecting Rod saaan 2 35 1 Model Y 5M Sectional View 7 1 6 Crankshaft sinri edi e eee n eens 2 39 2 Model Y X 6 1 Clotch Sectional View 7 11 7 Flywheel and Housing ianc 2 50 3 Principal Specibications 0 0005 7 14 B Camshaft ur essen nos sah bY 2 53 4 Outlin zer ere alas rua woes aves 7 16 9 Timing Gear 2a 2 59 5 Str clirg c looo ll veto Snag ANG AG 7 16 6 Handling 2 0 0 ccc cece eee eee ees 7 17 CHAPTER 3 FUEL SYSTEM 7 Service Standard oo aaa 7 20 1 Fuel Injection System eee eee ees 3 1 8 Troubleshooting a n aaa 7 21 2 Injection Pump iiis
19. fill with proper rust inhibitor and then top off cooling system with fresh water Fresh water tank 7 5 Idling the engine when stopping Always idle the engine for ten minutes immediately after starting and prior to stopping Be sure to idle the engine adequately especially before stopping Stop the engine on ly after its temperature has dropped sufficiently If the engine is stopped while hot the hot fresh water will cause the temperature of the water in the heat exchanger pipe to rise causing a build up of calcium deposits in the pipe and a drop in the cooling affect 7 6 Cleaning the heat exchanger tube If the heat exchanger tube through which the fresh water flows becomes extremely dirty the cooling effect will deteriorate If the C W warning lamp lights periodically when the engine is run at the rated output clean the tube in the fresh water tank with a cleaning agent and then flush the ac cumulated scale produced by cooling the fresh water from the tube A0A5052 B06 Rust inhibitor SM 2GMFY 3GMFY Chapter 6 Cooling System 8 Kingston Cock Optional use 8 Kingston Cock Optional 8 1 Construction The Kingston cock installed on the bottom of the huli con trols the intake of cooling water into the boat The Kingston cock serves to filter the water so that mud sand and other foreign matter in the water does not enter the water pump Numerous holes are drilled in the water side of the Kingston
20. passage leading out of the storage position which is in tegrated with the water cooled exhaust manifold Chapter 6 Cooling System 3 Heat Exchanger SM 2GMFY 3GMFY The filter cap on the top of the heat exchanger is equipped On the other hand when cooling system pressure with a pressure relief valve When pressure exceeds the becomes negative in retationship to the atmospheric specified limit this valve opens to release pressure through pressure air enters from the overfiow pipe the overflow pipe Fresh water inlet Sea water outlet Filler cap with pressure relief valve Cooling pipe Baffle plate ee Side cover Pe ze DAN a peri CU JN Sea water inlet Exhaust manifold Fresh water outlet Fresh water reservoir ADA 5052 JB06 6 12 Overflow pipe Chapter 6 Cooling System 3 Heat Exchanger 3 2 Water flow in water cooling tube Fresh water enters the cooling tube from a hole drilled at one end of the cooling tube It is then fed to the water storage through a hole at the other end after passing through the flow passage formed by the baffle plates and the tube cover Sea water inlet Side cover 3 3 Specifications Model of engine Output DIN 6270 B rating Pipe dia X pieces Radiation area Radiation area HP 0 0072 tevin 29070 34 207 5 Fresh water capacity A045052 JB06 SM 2GMFY 3GMFY Sea water outlet Side cover Packing Fresh water outle
21. 1 When disassembling lay the cylinder down with the main bearing housing side on top so that the crankshaft will be vertical for easy operation Remove the crank gear and flywheel beforehand 2 Remove the main bearing housing 3 Attach a rope to the crankshaft gradually lifting it with chain block etc and remove the two set bolts of the in termediate main bearing housing If the crankshaft is lifted too much or not enough the set bolts will be dif ficult to release 4 Lift and remove the crankshaft with the intermediate main bearing housing 5 Remove each intermediate main bearing housing from the crankshaft Arrow marks Primary main bearing A045052 JB06 2 44 Chapter 2 Basic Engine 6 Crankshaft 6 4 2 Reassembly 1 Clean each part before reassembly 2 Attach the intermediate main bearing housing to the crankshaft and confirm that the crankshaft rotates smoothly 1 Assembling position and direction of the intermediate main bearing housing The F mark on the intermediate main bearing hous ing indicates the direction of assembly on the crankshaft flywheel FT mark Arrow marks Align the arrow marks pointing up and down on the side of the intermediate main bearing housing and assemble it so that the F mark is in the direction of the flywheel e Assemble integrated with thrust bearing the in termediate main bearing on the flywheel side between cylinder No
22. 2 18 Install the crankshaft V pulley 1 Install the crankshaft key 2 Coat the crankshaft V pulley and the inside of the oil seal with oil 3 Insert and tighten the V pulley making sure that the lip of the oil seal is not distorted Tightening torque 10 kgf m 723 ft tb Chapter 8 Disassembly and Reassembly 2 Reassembly of Fresh Water Cooled Engine SM 2GMFY 3GMFY 2 19 Install the water pump 3 Insert the pump by looking through the gear case side Install the V belt to the crankshaft V pulley and instal the cover and align the governor No 2 lever and rack con water pump necting part Sea water pump Sea water pump drive pulley 1 V belt tension 547mm 0 1969 0 2756 in 10kg 22 ib 4 Tighten the fuel pump Tightening torque 25 kgf m 18 ft ib 5 Install the gear case side cover Crank shaftpulley 2 20 Install the cylinder head 1 Install the gasket packing V belt tension 5 7mm Pushed with a force of 10kg 22 Ib 0 1969 0 2756 in 2 Tightening torque Tightening torque 25 kgf m 18 ft Ib CAUTION Take particular notice of the surfaces to be fitted Keep the TOP mark on the cylinder head side A0A5052 B06 8 16 Chapter 8 Disassernbly and Reassembly 2 Reassembly of Fresh Water Cooled Engine SM 2GMFY 3GMFY 2 Insert the cylinder head being careful not to damage 2 Coat the inside of valve spring retainer with oil the threads of the tightenin
23. 2 Reassembly and precautions Reassemble in the reverse order of disassembly paying special attention to the folowing items 1 Check the governor weight movement 2 Check for the movement of the governor sleeve sliding on the crankshaft 3 Since a common taper pin hole is drilled in the governor lever shaft and governor levers 1 and 2 they must be replaced as an ass y 4 Since the movement and play of the governor lever have a direct effect on the governor s performance they must be carefully checked A0A5052 B06 1 5 Parts inspection and replacement 1 5 1 Regulator spring 1 Inspect the spring for coil damage corrosion and hook deformation and replace if faulty 2 Measure the spring s dimensions and spring constant Since the spring constant determines the governor s performance it must be carefully checked Spring specifications 1 Regulator spring main SE 2GMF Y 3GMFY 2 3mm b f F 218 3mm Coil outside diameter 0 7205in Number of coils 75 0922 kgimm Spring constant 0516 ib in 20mm 0 7874in 78mm 3 0709in Free length 2 Regulator spring sub L poe 2 mM 2GMFY 3GMFY Wire diameter Goo Coil outside diameter oa Number of coils 7 Spring constant a hn 10mm 0 3937in Free length 23mm Chapter 4 Governor I Governor 1 5 2 Sieeve 1 Slide the sleeve on the crankshaft to check that it slides smoothly
24. 3 Crank bearing installation precautions Lubrication hole Rounded corner part Cylinder side 9 For Main bearing metal housing For gear case 6 6 2 Oil seal insertion precautions 1 Clean the inside of the housing hole ascertaining that the hole was not dented when the sea was removed 2 Be sure that the insertion direction of the oil seal is cor rect Insert so that the main lip mounting the spring is on the inside oil side Assembly direction 3 Since the direction of rotation of the shaft is specified on a spiral oil seal be sure that the rotating direction is correct Direction of rotation c oi seal thickness irection of rotation A0A5052 B06 7 seal inside diameter A zi PAN seal outside diameter 1 Pay careful attention to the crank bearing insertion direction Insert the bearing so that the side with the outside fillet is on the outside 2 Align the oit hole of the crank bearing with the oil holes of the cylinder block and bearing housing 3 After inserting the crank bearing check that the crankshaft rotates easily with the thrust metal and bear ing housing installed 4 Be careful that the bearing is not tilted during insertion 6 6 Crankshaft oil seal 6 6 1 Oil seal type and size Spiral oi seals are employed at both ends of the crankshaft This type of oi seal is pulled toward the oil pan by pump action while the engine is running so that there i
25. 3 and a groove which connects the lead to the plunger head The plunger has an intake hole 4 through which the fuel passes and is force fed by the plunger Then the fuel opens the delivery valve 5 goes through the fuel injection tube and is injected into the spiral vortex type pre combustion chamber from the injection valve The plunger is fitted with the fuel control gear 6 and its flange 7 fits into the groove which is longitudinally cut into the inner surface of the lower end of the control gear The fuel control gear is in mesh with the fuel contro rack the motion of which rotates the plunger to constantly vary the amount of fuel in jected from zero to maximum ADA5052 JB06 3 8 SM 2GMFY 3GMFY delivery valve 5 intake hole 4 1 plunger 3 obliquely cut lead 2 plunger barrel Fuel injection volume increases Fuel injection volume decreas 8 fuel control 6 fuel control gear 7 ange Chapter 3 Fuel System 2 Injection Pump 2 3 1 Fuelcontrol When the plunger 1 is at bottom dead center the oil which comes in through the oil hole fills the delivery chamber 3 to above the plunger the oil pressure then builds up as the plunger rises and closes the oil hole and by opening the delivery valve is force fed toward the fuel injection tube As the plunger pushed by the plunger guide rises further the pressure of the oil between the delivery chamber and the nozzle also inc
26. 8 11 Chapter 8 Disassembly and Reassembly 2 Reassembly of Fresh Water Cooled Engine 2 5 Tighten the set boit of the intermediate main bearing There are two intermediate main bearings viz No 1 and No 2 for model IGMFY cei 2GMFY 3GMFY 45 5 0 Tighten torque 325 362 2 6 Install the main bearing housing 1 Coat the oil seal section with oil 2 Insert the main bearing housing and tighten Tightening torque 2 5 kgf m 18 ft Ib 3 Check that the crankshaft rotates smoothly A0A5052 J B06 8 12 SM 2GMFY 3GMFY 4 Measure the crankshaft side gap and adjust it to the prescribed value by the thickness of the packing Dial gauge oe Crankshaft 0 09 0 18mm 0 035 0 0071in Crankshaft side gap 2 7 Assemble the piston and connecting rod assembly 1 Coat the crankpin section with oil and position so that the insertion side crank is at the top 2 Coat the piston and crankpin bearing with oil 3 Position the piston rings so that the gaps are 120 apart make sure that there is no gap at the side pressure section 1st compression ring 2nd compression ring Oil ring 2nd Direction of piston pin Oil Chapter 8 Disassembly and Reassembly 2 Reassernbly of Fresh Water Cooled Engine SM 2GMFY 3GMFY 4 Insert the piston connecting rod assembly so that the 2 8 Install the lubricating oil intake pipe side of the connecting rod large end with the Coat th
27. Cooling water pump shaft he LP SPAS ronan cae iba N X Leer EA Wii Cooling water pump shaft Collar Bali bearing Bearing cover Water seal ring Oil seal Cam Packing tmpeller pm nanaun t Chapter 6 Cooling System 2 Water Pump Disassembly 1 2 3 4 5 6 7 8 9 Impeller SE amp IS Impeller shaft SQ After removing the V belt by loosening the mounting bolts of the cooling water pump bracket remove the cooling water pump assembly Remove the cooling water pump bracket Remove the V pulley mounting bolt and V pulley Remove the cooling water pump cover fixing screws and then remove the cooling water pump cover and packing Pull the water pump impeller Remove the set screw and remove the offset plate Remove the bearing snap ring and remove the impeller shaft and bearing ass y while tapping the impeller side of the impeller shaft lightly At the sarne time the bearing cover and seal ring can be removed together with the impeller shaft Pull the oil seal from the pump body Pull the ball bearing and spacer from the impeller shaft Ball bearing Ball bearing cover Water seal ring U Circlip Collar A0A5052 JB06 6 5 SM 2GMFY 3GMFY Chapter 6 Cooling System 2 Water Pump SM 2GMFY 3GMFY Reassembly precautions 3 Adjust the V belt tension 1 Before inserting the rubber impelier into the casing If th
28. Engine 3 Cylinder Head 3 7 Adjusting intake and exhaust valve head clearance Adjustment of the intake and exhaust valve head clearance governs the performance of the engine and must be performed accurately The intake and exhaust valve head clearance must always be checked and readjusted as re quired when the engine is disassembled and reassembled and after every 300 hours of operation Adjust the valve head clearance as described below 3 7 1 Adjustment Make this adjustment when the engine is cold 1 Remove the valve rocker arm cover 2 Crank the engine and set the piston to top dead center TDC on the compression stroke The matching mark is made at the setting hole of the starter motor on all models Matching mark NOTE Set to the position at which the valve rocker arm shaft does not move even when the crankshaft is turned to the left and right centered around the matching mark A0A5052 B06 SM 2GMFY 3GMFY 3 Check and adjust the intake and exhaust valve head clearances of the No 1 piston Loosen the valve clearance adjusting screw lock nut ad just the clearance to the maintenance standard with a feeler gauge and retighten the lock nut eA CJ fete Adjusting screw O Feeler gauge Lock nut j RA KS S JA S RN I z AKA OI b NGG 1G 0 2mm 0 0079in Clearance intake and exhaust valve head clearance 0 2mm 0 0079in in the case of 2GMF Y adjust the va
29. Water Cooled Engine 8 1 2 Reassembly of Fresh Water Cooled Engine 8 11 8 Accessarles NA ANAND re eR Una 8 18 A0A5052 806 Chapter 8 Disassembly and Reassembly 1 Disassembly of Fresh Water Cooled Engine SM 2GMFY 3GMFY 1 Disassembly of Fresh Water Cooled Engine in general the disassembly sequence for a fresh water cooled engine is the same as that for a sea water cooled engine except that the sequence for parts related to the 1 1 Draining the cooling water 1 Drain the sea water from the heat exchanger The sea water drain cock is installed on the side cover of the heat exchanger at the rear Heat exchanger Sea water drain cock 2 Drain the fresh water from the heat exchanger Loosen the fresh water drain plug installed at the bottom of the heat exchanger Fresh water drain plug 3 Drain the fresh water from the cylinder block Loosen the cylinder block water drain plug and drain the fresh water The water drain plug is installed on the block wall surface at the exhaust side in a model 2GMFY engine and on the block wall surface at the intake side in models 3GMFY engines A0A5052 B06 cooling water system are slightly different Refer to the disassembly section of the sea water cooled engine manual for the latter steps X ape ORL Cylinder block IN water drain plug IN m Cylinder block water drain plug 4 Draining sea water from the CSW pump Loos
30. and exhaust valves 1 Press the valve guide into the cylinder head 2 Install the valve stem seal Always replace the valve stem seal with a new seal 3 Install the valve in the cylinder head 4 Install the valve spring and valve spring seat 5 Install the split collar Using the special tool Using a wrench 2 Installing the valve arm ass y 1 Install the intake and exhaust rocker arms on the rocker I arm support Precombustion chamber Xi _ 2 install both the rocker arm supports and rocker arm re tainers on the cylinder head then tighten them with 3 ws nuts o 3 installing the precombustion chamber C9 CL 1 Install the front precombustion chamber and packing NI 2 Install the rear precombustion chamber and packing Always replace the insulation packing 1 Set the special tool at the intake and exhaust valve ass y and depress the valve spring by turning the lever 2 When the special tool is not available depress the valve spring with a wrench 3 Remove the spring cotter pin 4 Tum the lever of the special tool in the loosening direc tion release the valve spring retainer and remove the valve spring retainer and valve spring 5 Pull the valve from the cylinder head 6 Remove the valve stem seal 7 Remove the valve guide A0A5052 JB06 2 28 Chapter 2 Basic Engine 4 Piston 4 Piston 4 1 Piston assembly construction The pistons are made of LO EX AC8A T6 for lightness and are des
31. and the end of the plunger barrel using a dial gauge mm in Plunger top clearance 1 0 0 05 0 0374 0 0398 2 Using the plunger top clearance measuring jig 1 Instalt a dial gauge on the measuring jig 2 Stand the measuring jig on a stool and set the dial gauge pointer to O 3 Remove the pump delivery valve and install the measur ing jig 4 Turn the camshaft to set the plunger to top dead center and read the dia gauge The value given is the plunger top clearance Top clearance Fuel injection pump body Plunger barrel Chapter 3 Fuel System 2 Injection Pump 3 When the plunger top clearance is larger than the prescribed value remove the plunger guide and insert plunger shims between the plunger spring lower re tainer and the plunger guide Adjust each pump in the same manner 0 1mm 0 004in 0 3mm 0 012in 4 After rechecking adjustment install the delivery valve 174307 51710 174307 51720 174307 51730 Plunger shim thickness Delivery valve holder 40 45 kgf m tightening torque b 29 32 6 Ib ft 2 8 4 Checking the cylinder injection interval 1 Align the control rack punch mark with the pump reference face Fuel control rack 2 Turn the pump by hand to check the No 1 cylinder injec tion timing 3 Turn the pump in the prescribed direction and check the No 2 3 cylinder injection timing 4 Using the plunger shims adjust each cyl
32. any abnormalities or the danger of any abnor malities occurring make a color check 1 2 2 Cylinder head stud bolts Check for loose cylinder head bolts and for cracking caus ed by abnormal tightening either by visual inspection or by a color check Replace the cylinder block if cracked 2GMFY M12 0 4724in 96mm 3 7795in 82mm 3 2283in x3 40 45 kg m 28 9 32 5 ft lb Tightening torque A0A5052 B06 2 3 SM 2GMFY 3GMFY Chapter 2 Basic Engine 1 Cylinder Block SM 2GMFY 3GMFY 1 2 4Color check flaw detection procedure 1 Clean the inspection point thoroughly 2 Procure the dye penetration flaw detection age M12 0 4724in 96mm 3 7795in x2 82mm 32283in X6 40 45kgf m 289 325 ft lb Cylinder head bolt Length Square Cylinder body i 1 2 3 Oil and water passages Check the oil and water passages for clogging and build up of foreign matter A0A5052 JB06 2 4 agent comes in spray cans and consists of a penetrant and developer in one set CLEANER 9 2 3 Pretreat the inspection surface with the cleaner Spray the cleaner directly onto the inspection surface or wipe the inspection surface with a cloth moistened with the cleaner 4 Spray the red penetration liquid onto the inspection surface After cleaning the inspection surface spray the red penetrant dye penetration flaw detection agent on to it and allow t
33. at the same height as the fresh water tank 2 Ensure that the iength of the overflow pipe is no more than 1m 39 37 in and that it does not break NOTE if a subtank is not used be careful not to immerse overfiow pipe in the bilge since this can cause bilge water to be siphoned into the cooling system 4 6 Maintenance during use 1 Check that when the cooling water is cold the level is within the specified range 2 Check that the overflow pipe is not broken and also that the holes are not blocked up 6 16 Chapter 6 Cooling System 5 Thermostat 5 Thermostat 5 1 Operation Cylinder head outlet connection connected to heat exchanger Fresh water pump mounting bracket By pass passage To suction side of frash water pump Cylinder head When valve is closed by pass passage is opened The thermostat opens and closes the by pass valve and thermostat valve according to the temperature changes in the fresh water in the engine adjusts the flow of fresh water to the heat exchanger and keeps the fresh water temperature in the engine at the correct degree The thermostat in the fresh water cooled engine is a bottom by pass type as shown in the figure and is in stalied Inside the fresh water pump bracket which com bines with the cylinder head cooling water outlet passage The thermostat valve is closed while the fresh water ADA5052 JB06 Thermostat Thermostat valve By pass valve 6 17
34. attached to the cylinder block and bearing housing with a press a force of approximately 1 0 1 5 tons 2200 3300 tbs is required to remove them Moreover since the crankshaft will not rotate smoothly and other trouble may occur if the bearing is distorted it must always be installed with the special tool 1 Removal 2 Insertion extraction bolt Insertion guide Crank bearing ADA5052 3B06 Maintenance standard 244 0 1 7323 244 0 1 7323 25 009 0 9776 0 9807 SM 2GMFY 3GMFY diameter When the flange wears away the side gap of the crankshaft increases Wear limit 244 12 1 7370 244 12 1 7370 24 63 0 9697 0 17 Assemble the spacer and plate A as shown in the figure place the puller extractor against the bearing from the opposite end and pull the bearing by tightening the nut of the special tool Remove the oil seal before pulling the bearing pressed to the bearing housing 2 Installation Coat the outside of the bearing with oil and align the positions of the bearing oil holes Then press in plate B Plate B Insertion guide Crank bearing 2 48 Chapter 2 Basic Engine 6 Crankshaft ces SM 2GMFY 3GMFY until it touches the cylinder block or bearing housing using the puller extractor as a guide as shown in the figure After inserting the bearing measure its outside diameter If the bearing is distorted remove it again and replace it with a new bearing
35. barrel packing Body Fuel controt rack Injection timing adjust shim Fuel control pinion Plunger spring retainer Plunger spring Piunger spring lower retainer Plunger position shim e i d Plunger guide a Pa Plunger guide roller pin FZ A045052 806 SM 2GMFY 3GMFY Pin Fuel injection volume adjusting plate Eccentric screw Set screw Plunger barrel stopper Plunger guide stopper Plunger guide stopper pin NOTE The same construction parts are used for the fuel injection pump of the 2GMFY and 3GMFY Only the fuel injection pump body itself plunger spring upper retainer plunger guide stopper pin and fuel control rack are different and it may be understood that the injection pump of the 3GMFY is the same as that of the 2GMFY with the addition of one more cylinder the same except for the fuel injection pump body plunger and plunger barrel However care must be taken as the basic surface of the fuel volume adjusting rack is different Genuine parts for the delivery valve and plunger consist of the delivery valve and delivery valve holder and plunger and plunger barrel respective ly Plunger guide rotler outer Plunger guide roller inner Chapter 3 Fuel System 2 Injection Pump SM 2GMFY 3GMFY 2GMFY Reference face 1 O ring 2 Injection timing shim 3 Fuel control pinion 4 Plunger spring 5 Plunger guide stopper 6 Plunger guide stopper pin 7 Plunge
36. by the crankshaft gear The tubricating oi is drawn in and discharged through drill ed holes in the cylinder body A0A5052 JB06 5 5 Chapter 5 Lubrication System 2 Oil Pump cnn SM 2GMFY 3GMFY Outer rotor Camshaft Gear Inner rotor Rotor shaft Crankshaft Snap pin 2 7879 3mm 0 1094 0 1106in Shaped hole on pump cover er RR Cylinder Specifications of lubrication oil pump Engine speed Pump speed Discharge volume 12 5 t min 760 th 35 0 5 kgf cri 42 67 56 89 Iblin Discharge pressure A0A5052 JB06 5 6 Chapter 5 Lubrication System or PE SM 2GMFY 3GMFY 2 2 Disassembly 1 Remove the timing gear case 2 Remove the lubricating oi pump driving gear and pump assembly NOTE Do not separate the lubricating pump gear from the rotor shaft if removed it cannot be used again When any part is unusable replace it as a complete assembly A045052 JB06 5 7 Chapter 5 Lubrication System 2 Oil Pum E SM 2GMFY 3GMFY 2 3 Inspection When the discharge pressure of the oil pump is extremely low check the oil level If it is within the prescribed range Giairanca the oil pump must be inspected 1 Outer rotor and pump body clearance Measure the clearance by inserting a feeler gauge between the outside of the outer rotor and the pump body casing If the clearance exceeds the wear limit replace the outer rotor and pump body as a set Outer
37. cause a compression pressure leakage gas leakage or water leakage as a clearance is formed around the cylinder head even though the cylinder head is thoroughly secured 1 How to measure distortion on the upper surface of the cylinder The amount of distortion is measured by placing a straight scale on the upper surface of the cylinder and inserting a thickness gauge between the upper surface of the cylinder and the straight scale Straight scale Thickness gauge A0A5052 J806 2 5 SM 2GMFY 3GMFY Measurement is to be carried out on the 4 sides and 2 diagonal lines as shown in the figure and the largest value of clearance for each Measurement is to be taken as the amount of distortion mm fin Allowable limit of distortion 0 07 0 0028 0 07 0 0028 1 4 Cup plug 1 4 1 Purpose of cup plug In order to minimize the danger of cylinder block breakage caused by the cooling water freezing a cup plug is provid ed at the side of the cylinder block to prevent damage by frost in the event that freezing cooling water has caused the cup plug to come out repair in the following way In cold weather it is necessary to drain the cooling water completely from the inside of the cylinder block through the cooling water drain pipe No of plugs used 105311 01090 Chapter 2 Basic Engine 1 Cylinder Block SM 2GMFY 3GMFY 1 4 2 How to drive in the cup plug 1 Clean and remove grease from the hole into
38. clutch case Set key in thrust shaft Install thrust shaft j Insert bearing RAMA S ERR e 2 dier gear Use new O ring on idler gear shaft e Install idler gear shaft assembly tighten mounting nuts A0A5052 JB06 7 9 Chapter 7 Reduction and Reversing Gear 1 Model Y 5M Sectional View SM 2GMFY 8GMFY Procedure lustration 3 Thurst shaft Use new lockwasher coupling Poy Tighten mounting nut Distinguish between inside and outside faces Install rear cover of thrust shaft Install thrust shaft key Install coupling After assembly is completed check for case of rotation of shafts A0A5052 JB06 7 10 RST 7808 VOY t 2 Model Y X 6 1 Clutch Sectional View ay eS 3 OR A ls KY a Pa PN m na 7 P NW b rr p N x KA MATA puooog YIMID I 9 XYA PPOW 409r Buisiaaag pup uogonpoy 2 AdO AAWDE A AWDE WS Chapter 7 Reduction and Reversi 2 Model YX 6 1 Clutch Sectional View SM 2GMFY 3GMFY Chapter 7 Reduction and Reversing Gear 3 Principal Specifications 3 Principal Specifications YX 6 Reduction Reverse Gear Clutch capacity Input shaft allowable rev speed Rev direction Input shaft viewed from stern Output shaft Reduction ratio for both forward amp reverse Hydraulic oil pressure at rated engine speed Lube oil pressure at rated engine speed Lube oil Max lube oil capacity effective Neutral
39. components blow compressed air against them and inspect Replace any defective components 2 Replace the packings etc with new ones 3 When mounting the valves be careful not to mix up the inlet and outlet valves Also don t forget the valve packing Outlet valve A0A5052 JB06 3 28 SM 2GMFY 3GMFY 4 Make sure the diaphragm mounting hole is in the cor rect position and gently attach the diaphragm to the pump body 5 Line up the matching marks on the pump body and clamp on the pump body evenly j 30 10 kef cm Tightening torque of screw 145 2 80 ft lb 5 3 Inspecting and adjusting the fuel feed pump 5 3 1 Checking the pump for fuel oil leaks After removal immerse the pump in kerosene stop its outlet port with a finger and by operating the rocker arm check for bubbies If any bubbles are present this indicates a defective point which should be replaced 5 3 2 Checking the pump for engine oil leaks Check pump mounting bolts for looseness and the pump packing for breaks Retighten any loose bolts and repiace defective packing 3 3 Measuring the sucking power Attach a piece of vinyl hose to the inlet port keep the pump at a specified height head above the fuel oil level and operate the rocker arm by hand If the fuel oil spurts out from the outlet port the pump is all right A simpler method of testing pump power is as follows cover the inlet port with a finger and by operatin
40. cylinder head cover and replace the zinc when it has worn over the wear limit Anticorrosion zinc wear limit Volumetric ratio with new zinc 1 2 3 2 4 Cracking of combustion surface The combustion surface is exposed to high temperature high pressure gas and low temperature air and is repeated ty flexed during operation Moreover it is used under ex tremely severe conditions such as the high temperature difference between the combustion surface and cooling water passages Inspect the combustion surface for cracking by the color check and replace the cylinder head if any cracking is detected At the same time check for signs of overloading and check the cooling water flow 3 2 5 Cylinder head distortion Distortion of the cylinder head causes gasket packing damage compression leakage change in compression etc Measure the distortion as described below and replace the cylinder head when the wear limit is exceeded Since A0A5052 JB06 SM 2GMFY 3GMFY distortion of the cylinder head is caused by irregular tightening forces faulty repair of the mounting face and gasket packing damage these must also be checked Cylinder head distortion mm in Wear limit 0 07 0 0028 0 07 0 0028 1 Clean the cylinder head tightening surface 2 Place a straightedge across two symmetrical points at the four sides of the cylinder head as shown in the figure 3 Insert feeler gauges between the str
41. fuel filter is installed between the feed pump and injec tion pump and serves to remove dirt and impurities from the oil fed from the fuel tank through the feed pump The fuel fiiter incorporates a replaceable filter paper ele ment Fuel from the fuel tank enters the outside of the ele ment and passes through the element under its own pressure As it passes through the dirt and impurities in the fuel are filtered out allowing only clean fuel to enter the interior of the element The fuel exits from the outlet at the top center of the filter and is sent to the injection pump A cross headed hexagonal bolt is fitted to the fuel filter body Loosen the boit with a cross headed screw driver before starting or after dismantling and reassembly to bleed the air in the fuel system to the fuel oil filter Air bteeding bolt Fuel filter body Packing Fuel filter cover co Retaining ring A0A5052 B06 SM 2GMFY 3GMFY 4 2 Specification Common to Models 2GMFY 3GMFY Filtering Area 333cm 203in Material of element Cotton fiber Filter mesh 10 154 4 3 Inspection The fuel filter must be periodically inspected if there is water and sediment in the filter remove ali dirt rust etc by washing the filter with clean fuel The normal replacement interval for the element is 250 hours but the element should be replaced whenever it is dirty or damaged even if the 250 hour replacement period has not elapsed Fu
42. m ft ib Tightening torque 2 14 5 Moreover the nozzle holder must be installed with the notch side on the nozzle side Nozzle hoider Injection nozzie 3 6 Injection nozzle inspection and adjustment 3 6 1 Carbon and corrosion on the nozzle body Inspect the end and sides of the nozzle body for carbon build up and corrosion if there is considerable carbon build up check the properties of the fuel used etc Replace the body if heavily corroded 3 6 2 Checking nozzle action Wash the nozzle in clean fuel oil and hold the nozzle body upright then lift the nozzle about 1 3 of its length with one hand The nozzle is in good condition if it drops smoothly by its own weight when released If the nozzle slides stiffly repair or replace it Chapter 3 Fuel System 3 Injection Nozzle 3 6 3 Adjusting the nozzle injection pressure Install the injection nozzle to the high pressure pipe of a nozzle tester and slowly operate the lever of the tester Read the pressure the instant injection from the nozzle begins If the injection pressure is lower than the prescribed pressure remove the nozzle spring holder and adjust the pressure by adding nozzle spring shims The injection pressure increases about 10 kgi cr 1422 Ib in when a 0 1mm 0 004in shim is added Nozzle tester BRA l t 0 tmm 0 0039in 0 2mm 0 0079in 0 3mm 0 0118in 0 5mm 0 0197in Injection pressure 170 mi cri 2347 2 Ib in
43. move smoothly 2 Repair or replace the shaft if there is play between lever 1 lever 2 fuel control lever or support and the shaft or if the taper pin is loose 3 Inspect the contact between the governor lever 1 and the governor sieeve replace it if it is too damaged 1 5 7 Regulator lever and handle O ring Circhip Regulator lever Le Regulator handle Hook 1 Check for play in the regulator lever and regulator han dle if fauity replace them as a set 2 Check for O ring damage Replace if faulty A0A5052 JB06 4 7 Chapter 4 Governor 2 Injection Limiter 2 Injection Limiter 2 1 Construction Since surplus power is required from the standpoints of sudden overloads and durability the engine is equipped with an injection control shaft that limits the amount of fuel injected into the precombustion chamber to a fixed amount Moreover since the injection control spring tor que spring affects engine performance by adjusting engine torque Yanmar selected the best position for operating conditions Lock nut Cap nut Seat washer 2 2 Inspection 1 Hold the end of the spindle and check it for smooth movement 2 Replace the spring if it is damaged corroded or per manently strained 2 3 Adjustment Rack mark Fuel control rack ADA5052 JB06 Reference face SM 2GMFY 3GMFY Pay close attention when handling the sealed wire If the engine does not accelerate
44. of rotation RR at Crankshaft V pulley side Counter clockwise viewed from stern Clockwise viewed from stern Cooling system Fresh water cooling Lubrication sysiem Complete enclosed forced lubrication Starting system EA Electric and or manual Electric Model Y 5M YX 6 Type Hydraulic multidisc clutch FR Reduction ratio Ahead Astern 2 10 1 80 3 04 248 2 10 3 04 2 03 2 55 2 96 3 48 Propeller speed DINA rating Ahead Asterm rom 1521 1051 t521 1051 1577 1254 1081 920 umamoremeiy 1 95 cos E Tom ws 5 KC mw mas DE Dimensions CO w m Owalegm m 96 606 rake angle 8 Etfective ok 2 6 Engine weight with clutch dry ow w 155 A0A5052 JB06 1 4 Chapter 1 General 3 Principal Construction 3 Principal Construction Engine model Group Engine block Intake and exhaust systems and valve mechanism Main moving elements Lubrication system Cooling system Fuel system Governor Starting system Electrical system Reduction reversing Clutch system AGA5052 B 06 SM 2GMFY 3GMFY Oil sump intake and exhaust valves Part Exhaust manifold Exhaust silencer Valve machanism Intake silencer Crankshaft Piston Piston pin Piston rings SN a up n Construction integrally cast water jacket and crankcase E Sleeveless Metal housing type Oil pan integrated type cylinders Poppet ty
45. oil pressure builds up to 155 to 165 kg cm the nozzle opens and the fuel oil is injected into the spiral vortex type combustion chamber However if the plunger keeps rising and the lead groove 4 lines up with the oil hole 2 the oil under high pressure in the delivery chamber passes the lead from the longitudinal groove up the lead and is driven back into the suction chamber from the oil hole At the same time force feeding of the fuel is suspended Full injection Effective st vent the backward dripping of the nozzle valve When the notch lead of the plunger comes up to the oil hole of the plunger barrel the feeding pressure acting on the fue oil drops and the delivery valve falls due to the force of the spring After the sucking back collar 1 has first shut off the fuel injection tube and the delivery chamber the delivery valve drops further until it comes into contact with the seat surface 2 corresponding to the amount of fall i e increase in volume the fuel oil pressure within the in jection tube drops speeding up the closure of the nozzle valve and sucking up the fuel before it drips back This enhances the durability of the nozzle and improves fuel oil combustion Delivery valve Return colar Retraction Delivery valve holder 3 Amount of fuel retraction na di 23 5mm stroke 0 0014in st Chapter 3 Fuel System 2 Injection Pump SM 2GMFY 3GMFY 2 4 Disassembly of fuel injection pump
46. part from the bypass circuit and wear of moving parts will be accelerated Therefore it is important that the filter be periodically replaced Because this oil filter is a cartridge type it is replaced as a complete unit n 4 i Every 300 hours of engine Oil filter replacement period operation A0A5052 JB06 5 10 Chapter 5 Lubrication System 3 2 1 Replacing the oil filter 1 Clean the oil filter mounting face on the cylinder block 2 Before installing the new filter coat the rubber packing with a thin coat of lubricating oil 3 Turn the filter gently until it contacts the rubber packing of the seal surface then tighten another 2 3 turn 4 After installation run the engine and check the packing face for oil leakage 3 2 2 In case of oli leakage If there is oil leakage remove the oil filter and replace the packing At the same time inspect the cylinder block mounting face and repair the face with an oil stone if it is scored ADA5052 JB06 5 11 Chapter 5 Lubrication System 4 Oil Pressure Regulator Valve 4 Oil Pressure Regulator Valve 4 1 Construction The oii pressure regulator valve serves to adjust the pressure of the lubricating oil to the prescribed pressure during operation When the pressure of the lubricating oil from the oil filter exceeds the force of the spring the metal ball is pushed away from the valve seat and the lubricating oil flows to the oil pan through the gap between the ball and
47. rotor Body Feeler gauge mm in 0 050 0 105 0 00197 0 00413 0 15 0 00591 Maintenance standard Wear limit 2 Outer rotor and inner rotor clearance Fit one of the teeth of the inner rotor to one of the grooves of the outer rotor and measure the clearance at the point where the teeth of both rotors are aligned Replace the inner rotor and outer rotor ass y if the wear limit is exceeded Inner rotor Outer rotor Feeler gauge A0A5052 B06 5 8 Inner rotor Outer rotor mm in Maintenance standard 000197 s Gi 3 Wear limit 0 00591 3 Pump body and inner rotor outer rotor side clearance Install the inner rotor and outer rotor into the pump body casing so that they fit snugly Check the clearance by piacing a ruler against the end of the body and inserting a feeler gauge between the ruler and the end of the rotor Replace as a set if the wear limit is exceeded Straight scale Body Feeler gauge mm in 2GMFY 3GMFY Maintenance 0 03 0 07 standard 0 0012 0 0031 Wear limit Pym 4 Rotor shaft and body clearance Measure the outside diameter of the rotor shaft and the inside diameter of the body shaft hole and replace the rotor shaft and body as an ass y if the clearance exceeds the wear limit mm in i Maximum Maintenance Clearance allowable when assembled clearance Rotor shaft 214 outside diameter 0 5512
48. seal lip while reassembling the input shaft cou pling Bolt with collar M10 Torque 500 90kg om 4 Hydraulic Pump Switch Valve 1 Clean oil holes and joint surface completely Use new packings and O rings 2 Install the hydraulic pump in the direction as shown in the sketch Filling up grease e Circlip 4 Spring Steel bati 5 16 NS Kk Spring gin N Q Y Bolt with collar ma Parallel pin N Ierque 210 20k Pa Cover for Control valve Control valve ASAE 4 flange AS Cntrol lever Lock nut M16 Torque 5005 50 kg cm Hydraulic pump Assy 2 M8 bolts sre not open M Washer ma NGA Bolt with collar M8 x 95 Washer ES Torque 2107 T cm Bolt with collar M8 x 5 Sosa Torque 2105 kg om A0A5052 JB06 7 23 Chapter 7 Reduction and Reversing Gear 9 Disassembly and Reassembly SM 2GMFY 3GMFY 5 Primary Pressure Control Valve Slow Engaging Valve 1 Clean oil holes and disassembled parts completely 2 Visually check for rust flaws and cracks of the pressure control valve and spring 3 Check if or not the pressure control valve moves smoothly 4 Use new packings and O rings O ring tA P22 Cover for regulator valve 6 Secondary Pressure Controt Valve nd regulating valve Valve seat for 2nd regulating valve Spring Retainer for Spring 7 Slow Moving Valve 1 Clean oi holes and joint surface com pietely 2
49. seat The spring s force is adjusted with a shim The regulator valve is located in the mounting position of the lubricating oil filter at the timing gear case SM 2GMFY 3GMFY Mounting position for mode 2GMF Y Oil filter A0A5052 JB06 5 12 Chapter 5 Lubrication System 4 Oil Pressure Regulator Valve Shim N Steel ball f Body Spring retainer Spring Nut Bearing When the pressure is lower that the regulated pessure Bearing When the pressure is higher that the regulated pressure A0A5052 JB06 5 13 SM 2GMFY 3GMFY Speclfications 35 405 kgf ch Standard pressure 4267 56 89 Ib in As the lubricating oil pressure requlator valve has been calked during manufacture so that it cannot be dismantled replace it as a unit if any replacement becomes necessary Chapter 5 Lubrication System 5 Oil Pressure Measurement 5 Oil Pressure Measurement The lubricating oil pressure is monitored by a pilot lamp but it must also be measured using a pressure gauge Con nect the oil pressure gauge to the pilot lamp unit for primary pressure and to the lubricating oi pipe connector for secondary pressure as shown in figure Secondary oil pressure is especially important Idle the engine at medium speed when measuring the oi pressure Also check whether the oil pressure rises smoothly and to the standard value Pressure gauge Secondary pressure standard value If the oil pressure is lowe
50. smoothly i e the speed is not well controlled turn the limiter slightly counter clockwise NOTE If it is turned back too much it will produce exhaust smoke S Injection control shaft Spindle Spring Spring retainer Seal washer 1 Set the governor lever to the free position and remove the injection pump adjustment cover 2 Remove the injection control shaft cap nut loosen the hexagonal lock nut and loosen the injection control shaft so that the spring inside the injection control shaft is disabled 3 Move governor lever 2 slowly to the left until the rack and injection contro shaft contact lightly 4 Set the governor lever to the free position and push the rack by slowly turning the injection control shaft clockwise 5 Align the center mark of the rack with the reference face 6 Lock the injection control shaft with the hexagonal nut and cap nut Reference face Fuel control rack Reference face G Rack mark Chapter 4 Governor 3 No Load Maximum Speed Limiter 3 No Load Maximum Speed Limiter 3 1 Construction A stopper is instalied on the regulator lever so that the engine speed at no load does not exceed a fixed speed The fuel control rack is stopped when the regulator lever contacts the stopper No load maximum speed limiter Regulator handie Regulator lever 3 2 Handling precautions The no load maximum speed is adjusted during bench testing at the factory a
51. tester Increase pressure and if pressure remains constant for six seconds the cap is normal If pressure does not in crease or does not remain constant for six seconds check for defects Repair or replace as required 4 4 Subtank function When cooling system pressure rises above 0 9kgf c l 12 80 Ib in the pressure valve opens and vapor is releas ed reducing the amount of water in the cooling system The subtank collects this vapor where it condenses Then when cooling system pressure falls below atmospheric pressure the water in the subtank is siphoned back to the main tank Use of a subtank is highly recommended since this allows the engine to be run for longer periods between water replenishment and the need to open the filler cap is eliminated removing one possible cause of accidents Chapter 6 Cooling System 4 Filler Cap and Subtank Filler cap 30 1 18 29 0 35 70 2 76 55 0 98 35 1 38 Over all capacit Subtank ki capacity 4 5 Installation of subtank Subtank T A0A5052 JB06 Full scale position Low scale position 120445 44530 3 3 EJ 5 2 wm amp la NM E 61 2 40 2120 4 72 t cu in 1 25 76 28 about 0 8 48 82 about 0 2 12 20 Overfiow pipe Filler cap SM 2GMFY 3GMF Y Subtank mounting plate attached to subtank MB bolt 0 315in 89mm hole 0 354in 44mm 1 732in 1 Mount the subtank
52. the delivery side 3 Bleed the air from the injection pump Measuring pipe Air bleeding bolt 4 Set the control rack to the middle fuel injection position Pull the lever when setting the accelerator lever 5 Turn the crankshaft slowly by hand and read the timing mark TD on the flywheei the instant fuel appears at the measuring pipe or pipe joint nipple FID Fuel injection from delivery valve Chapter 3 Fuel System 2 Injection Pump Timing mark 6 If the injection timing is off add plunger shims when the timing is slow and remove shims when the timing is fast Adjust the timing of every pump in the same man ner Refer to item Plunger head gap adjustment 7 After the injection timing of every pump has been mat ched recheck the injection timing as described in item 5 above If the injection timing is not properly set ad just it with the timing shims bTOC18 FID Fuel injection timing 0 2mm 2 shims 124950 Fuel 0 008in 01931 121450 01931 injection timing en 5 1 shim 0 3mm 0 012in 121450 01951 A0A5052 JB06 3 18 SM 2GMFY 3GMFY The thickness of the plunger location adjusting shim and the injection timing adjusting plate is 0 1 mm and by this the injection timing can be changed by approx imately 1 on the crankshaft Fuel injection timing shim 8 Finally tum the crankshaft slowly and confirm that it turns easily
53. 0 C 50 F Valve opening temperature 71 1 5 C 157 1 162 5 F bu water temperature C Fully opened lift checking temperature 85 C 185 F Chapter 6 Cooling System VEL ast SM 2GMFY 3GMFY 5 3 Inspection 3 In general inspect the thermostat after every 500 hours of operation However always inspect it when the cool ing water temperature has risen abnormally and when white smoke is emitted for a long period of time after the engine starts 4 Replace the thermostat when it has been in use for a year or after every 2000 hours of operation 1 Remove the cooling water outlet connection at the top of the fresh water pump mounting bracket and take out the thermostat Remove all deposits and rust check functioning and in spect parts Replace if performance has deteriorated or if the spring or other parts are excessively corroded deformed or otherwise unsuitable Part No code of thermostat 121750 49800 Cooling water outlet connection Thermostat Fresh water pump Fresh water pump mounting bracket 2 Testing the thermostat Place the thermostat in a container filled with water Heat the container with an electric heater If the ther mostat valve begins to open when the water temper ature reaches about 71 C and becomes fully open at 85 C the thermostat may be considered all right If its behaviour differs much from the above or if it is found to be broken replace it AOA5052 B06 6 19 Ch
54. 15 Remove the starter motor Remove the CFW pump by loosening the hose clamp on the CFW hose between the CFW pump and cylinder block at the cylinder block end Fresh water pump 1 13 Remove the air intake silencer Remove the intake silencer clip and the filter element Then remove the set screw and the cover 1 17 Remove the CSW pump Loosen the water pump mounting bolts remove the V belt by sliding it toward the crankshaft side and remove the sea 1 14 Hari fuel high pressure pipe and fuel water pump LY y f oi mm IC CC Pal C Sea water pump Sea water pump drive pulley A0A5052 JB06 8 5 Chapter 8 Disassembly and Reassembly Di Engi 1 Disassembly of Fresh Water Cooled Engine SM 2GMFY 3GMFY 1 18 Remove the rocker arm chamber 1 Remove the breather pipe at the side of the intake pipe intake manifold for model 3GMF Y 2 Remove the rocker arm chamber After this step disassembly is carried out in the same se The details are given in Section 4 3 14 Remove the rocker quence as for the sea water cooled engine arms P12 23 of the sea water cooled engine manual For reference 1 19 Remove the rocker arms 1 Remove the mounting nut and remove the rocker arm 2 Pull the push rods shaft assembly 3 Remove the cotter pins of the intake and exhaust valve springs NOTE Arrange the parts by cylinder no intake and ex haust AOA 5052 B 06 8 6 Chapte
55. 2 50 Chapter 2 Basic Engine 7 Flywheel and Housi Fe eee ANE NOB Si JSGMPYSGMEY 7 2 Dimensions of flywheel and mounting flange 7 2 1 For models 2GMFY 3GMFY 8 M8threaded holes Depth 15 20 6 M10threaded holes Depth 14 20 equally spaced ADA5052 JB06 2 51 Chapter 2 Basic Engine 7 Flywheel and Housing SUBEMEYSCHFY 7 3 Ring gear When replacing the ring gear due to excessive wear or damaged teeth heat the ring gear evenly at its cir cumference and after it has expanded drive it gradually off the flywheel by tapping it with a hammer a copper bar or something similar around the whole circumference Fiywheel mm in interference of 0 188 0 348 ring gear 0 0074 0 0137 Ring gear Wooden stand Stamped letter indicating T D C 7 4 Position of top dead center 1 Marking Stamped marking line Stamped marking line 1T 2T 3T Stamped letter Angle a of Stamped lines Both surfaces Both surfaces Stamped surfaced 2 Matching mark The matching mark is made at the setting hole of the starter motor on all models Matching mark A0A5052 JB06 2 52 Chapter 2 Basic Engine 8 Camshaft 8 Camshaft 8 1 Construction of the camshaft The camshaft an integral camshaft with intake and ex haust cams is driven by the camshaft gear and may be timed individually On top of the intake and exhaust cams a tappet is mounted guided by the cylinder block The tappet move
56. 5052 B06 3 29 A0A5052 JB06 CHAPTER 4 GOVERNOR 1 Governor een ae RA wed 4 1 2 Injection Limiter naaa naii ie RI 4 8 3 No Load Maximum Speed Limiter 0 4 9 4 Idling Adjuster RI 4 10 5 Engine Stop Lever eee 4 11 Chapter 4 Governor 1 Governor 1 Governor The governor serves to keep engine speed constant by automatically adjusting the amount of fue supplied to the engine according to changes in the load This protects the engine against sudden changes in the load such as sud den disengagement of the clutch the propeller leaving the water in rough weather or other cases where the engine is suddenly accelerated A0A5052 JB06 4 1 SM 2GMFY 3GMFY This engine employs an ali speed governor in which the centrifugal force of the governor weight produced by rota tion of the crankshaft and the load of the regulator spring are balanced The governor is remotely controlled by a wire Refer to the Control System chapter for details bh D ra a Na c 3 A Y Regulator handle 1 Idle adjuster bracket No load maximum speed limiter T gt No Gear case side cover Locking screw Engine stop lever Engine stop spring Cam KN av Fuel injection me flo Regulator lever Fuel control lever Governor lever 2 Start spring Governor lever 1 Crankshaft Governor weight Governor sleeve uonanasuoj L L p G5ZQZ9 Z ie 9 r
57. A0A5052 SERVICE MANUAL MARINE DIESEL ENGINE 2GMFY 3GMFY 2000 3 10 YANMAR SERVICE MANUAL MARINE DIESEL ENGINE MODELS 2GMF Y 3GMF Y FOREWORD 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 dieset 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 mainte nance and as a text for engineering guidance Models 2GMFY 3GMFY CHAPTER 1 GENERAL CHAPTER 6 COOLING SYSTEM 1 Outlitie u ri KAWI PLANG 11 1 Coolling System aaa aaa 6 1 2 Specifications aaa 1 4 2
58. As a rule the injection pump should not be disassembled but when disassembly is unavoidable proceed as describ ed below Open Seat surface Close Retraction of fuel A0A5052 B06 3 10 Chapter 3 Fuel System 2 Injection P nn SM 2GMFY 3GMFY Dismantling of fuel pump 1 Remove the plunger guide stopper pin with needle nose pliers The cylinders are classified as No 1 No 2 and No 3 from the left when facing the name plate which is fitted on the upper part of the fuel injection pump When dismantling it is necessary to prepare pans or vessels in which to keep the dismantled parts from each cylinder each part must be placed in the corresponding pan or vessel for each cy linder namely No 1 No 2 and No 3 cylinder If a part is placed in the wrong pan or vessel reassembly becomes im possible without a pump tester The following explanation applies to the pump of the 2 cylinder type engine model 2GMF Y but it equally applies to that of the 3 cylinder type engine model 3GMF Y which merely has an additional set 2 Remove the No 1 plunger guide stopper The stopper can be removed by pushing the plunger guide down with the palm of your hand 3 Remove the No 1 plunger guide 4 Remove the No 1 plunger and plunger spring lower re tainer and plunger shim be careful not to damage the plunger 5 Remove the No 1 plunger spring A0A5052 JB06 3 11 Chapter 3 Fuel System 2 Injection Pump
59. Chapter 2 Basic Engine 8 Camshatt SM 2GMFY 3GMFY Camshaft gear Fuel cam Camshaft AOA 5052 JB06 2 68 Chapter 2 Basic Engine 9 Timing Gear 9 Timing Gear 9 1 Timing gear train construction The camshaft which is the basic component of the valve opening and closing mechanism and the fue cam which determines the fuel injction timing are driven by the timing gear The timing gear consists of the crankshaft gear and the camshaft gear Camshaft gear Camshaft gear Crankshaft gear Lubricating oil pump gear A0A5052 JB06 i0 Funden e 30 Faraon 35 9 wem SM 2GMFY 3GMFY The crankshaft gear also drives the governor weight and the lubricating oil pump by meshing with the lubricating oil pump gear Forthe timing gears helical gears are used The timing gear case which covers these gears is fitted to the cylinder body with bolts Camshaft gear Center distance 999mm 3 8976 3 8995in 65 98 8 46mm 2 5976 2 5995in Chapter 2 Basic Engine 9 Timing Gear 9 2 Disassembly and reassembly of the timing gear 9 2 1 Disassembly 1 Remove the alternator 2 Remove the rubber hose by loosening the hose clip on the cooling water pump NOTE The cooling water pumpt does not need to be removed Difficult to connect it with the rotor shaft of the lubricating oil pump if the gear case has not been praviously assembled 3 Remove the
60. If it is stiff or does not rotate the plunger head gap is too small Chapter 3 Fuel System 2 Injection Pump 2 8 injection pump adjustment The injection pump is adjusted with an injection pump tester after reassembly 2 8 1 Setting pump on tester 1 After the injection pump has been disassembled and reassembled install it on a pump tester cam lift 7mm 0 276in 2 Confirm that the control rack stides smoothly If it does not inspect the injection pump and repair it so that the rack slides smoothly control rack full stroke 15mm 0 5905in 3 Run the pump tester at low speed loosen the air bleeder screw and bleed the air from the injection pump 2 8 2 Measuring the sliding resistance of the fuel control rack Measure the sliding resistance of the fuel control rack with a spring scale balance 1 Number of pump rotations sliding resistance Orpm less than 60 g 0 132 Ib ADA5052 JB06 3 19 SM 2GMFY 3GMFY NOTE If the sliding resistance is unsatisfactory disassem ble inspect and repair the fuel control rack 2 8 3 Adjusting the plunger top clearance 1 Set the pump installation dimension end of plunger bar rel when the rofier is on the cam base cycle at 76 0 05mm 2 9902 2 9941in remove the delivery valve holder and delivery valve and set the plunger to top dead center by turning the camshaft Measure the dif ference in height head gap between the end of the plunger
61. MB 0 3150in A0A5052 806 2 17 25 kgf m 18 1 ft Ib Gear side Tightening torque 10 kgf m 72 3 ft lb 25kgf m 18 1 ft lb 2 First tighten the nuts sequentially to 1 3 of the prescribed torque 3 Second tighten the nuts sequentially to 2 3 of the prescribed torque 4 Third tighten the nuts to the prescribed torque 5 Recheck that all the nuts have been properly tightened NOTE After tightening valve clearance must be adjusted 3 3 3 Cylinder head nut loosening sequence When loosening the cylinder head nuts reverse the tightening sequence The cylinder head nut loosening se quence is shown in the figure Chapter 2 Basic Engine 3 Cylinder Head 3 4 Intake and exhaust valves valve guide and valve spring Valve top retainer intake and exhaust valve spring coltar Intake and exhaust valve spring seat Intake and exhaust valve Valve stem seal Valve spring 3 4 1 Inspecting and measuring the intake and exhaust valves 1 Valve seat wear and contact width Inspect valve seats for carbon build up and heavy wear Also check if each valve seat contact width is suitable If the valve seat contact width is narrower than the valve seat width the seat angle must be checked and cor rected Maintenance standard Valve stem outside diameter SM 2GMFY 3GMFY Valve stem diameter Valve seat width Valve thickness Valve diameter Seat angle mm in Intake valve diame
62. MFY 3GMFY ADA5052 JB06 2 39 Chapter 2 Basic Engine 6 Crankshaft 6 1 2 Construction of crankshaft assembly The following figure shows the crankshaft assembly the intermediate bearing at the gear case end is not fitted Fiywheel Oil seal Ri Metal housing Ing gear NG O ring Crank metal E X Crankshaft Intermediate bearing metal at gear case end Set bolt Case end Crankshaft gear Governor weight Hexagonal nut 8 10kgf m width across flats 36mm Governor sleeve Thrust bearing Bali bearing Oil seal V pulley Hexagonai nut 10kgf m width across flats 27mm A0A5052 B06 2 40 SM 2GMFY 3GMFY Crank metal at gear Chapter 2 Basic Engine 6 Crankshaft SM 2GMFY 3GMFY 6 2 inspection 6 2 1 Crank journal and crank pin 1 Cracking 2 Crank pin and crank journal outside diameter measure If cracking of the crank journal or crank pin is suspected ment thoroughly clean the crankshaft and perform a cotor When the difference between the maximum wear and check on the shaft or run a candle flame over the minimum wear of each bearing section exceeds the crankshaft and took for oil seepage from cracks If any wear limit replace the crankshaft Aiso check each bear cracks are detected replace the crankshaft ing section for scoring If the scoring is light repair it with emery cloth mm in Maintenance standard Wear limit SR
63. Oil Yanmar Marine Super Oil SAE30 2 Oil Replacement Interval 1 st time 50 hours after initial operation 2 nd time 250 hours after initial operation 3 rd time amp thereafter Every 1000 hours of operation 1 Black oil may be noted at the initial oil exchange but this is not a problem 2 If cooling water has entered the marine gear disassemble it completely and clean the inside Replace all of the oil and check that there is no emulsification in the oil A0A5052 JB06 7 16 Chapter 7 Reduction and Reversing Gear 6 Handling rr SMIBGMFYI3GMFY 6 2 Preparations before Starting amp Starting 1 Preparations a Check the entire marine gear and confirm that there are no loose bolts and nuts b Check the oil level Check the oil level before starting the engine or 15 minutes after stopping Fully insert the oil dipstick to check Resupply oil up to the upper limit of the dipstick c Shift the handle to neutral 2 Starting a Operate the engine at low speed and check for oil leakage abnormal sounds and temp rise b Raise the engine speed gradually and check the clutch oil pressure and lube oil pressure The clutch oil pressure should normally be 8 11 kg cm in neutral c Operate the engine at idling speed for about 10 minutes after starting to warm it up 6 3 Operation amp Stopping 1 Shovein the clutch and check that the clutch oil pressure reaches the specified level The oil pressure levelfalls durin
64. SM 2GMFY 3GMFY To heat exchanger Thermostat valve Cylinder head When valve is opened by pass passage is closed temperature is low and fresh water is fed to the fresh water pump inlet through the drilled hole in the by pass passage and circulated inside the engine When the fresh water temperature rises over the valve opening temperature the thermostat valve opens and fresh water is fed to the heat exchanger and where fresh water is cooled and then it is fed to the fresh water pump With the thermostat valve opening the by pass passage is throttled The by pass passage is completely closed as the tamperature rises Chapter 6 Cooling System 5 Thermostat 5 2 Construction A wax pellet type thermostat is used for this engine The wax pellet type is the description given to a quantity of wax in the shape of a small pellet When the temperature of mm in 228 1 102 Wax 41 5 1 634 6 0 236 N When valve is closed Thermostat operating temperature NG F 71 159 8 Opening temperature Full open temperature Temperature corresponding to 8mm or more valve lift 85 185 A0A5052 B06 Synthetic rubber E qM passage SM 2GMFY 3GMFY the cooling water rises the wax melts and its volume ex pands The valve is opened or closed by this variation of volume When valve is opened Characteristic of Thermostat mm Valve lift 6 18 0 1
65. Screw driver or saw blade which the cup plug is to be driven eThinner Remove scale and sealing material previously applied Remove foreign materials with screw driver or saw blade 2 Remove grease from the cup plug Visually check the nick around Thinner the plug 3 Apply Threebond No 4 to the seat surface Apply over the whole outside of Threebond No 4 where the plug is to be driven in the plug 4 Insert the plug into the hole Insert the plug so that it seats correctly 5 Place a driving tool on the cup plug and drive it Drive in the plug parallel to the Driving too in using a hammer seating surface Hammer A Er ing Er Ele os E 3 i Ss 2 3mm 0 0787 0 1181in Bp ak un 3mm 0 1181in 100mm 3 9370in Using the special tool drive the cup plug to a depth where the edge of the plug is 2mm 0 0787in below the cylinder surface A0A5052 B06 2 6 Chapter 2 Basic Engine 1 Cylinder Liner 2 Cylinder Liner 2 1 Construction The cylinder liner is the thin wall type of liner thickness 2mm 0 0787in made of special cast iron which is highly wear resistant and its inside surface is finished by honing It has non chrome plated inside The part of the liner fitting against the cylinder is ground to a precise finished and clearance between the liner and cylinder is greater towards the top of the cylinder in order to prevent any abn
66. aightedge and the cylinder head combustion face Measurement procedure Straig htedge Feeler gauge 4 The thickness of the largest feeler gauge that can be in serted is the amount of distortion 3 2 6 Cylinder head valve seat The valve seats become wider with use If the seats become wider than the maintenance standard carbon built up at the seats wili cause compression leakage On the other hand if the seats are too narrow they will wear quickly and heat transmission efficiency will deteriorate Clean the carbon and other foreign matter from the valve seats and check that the seats are not scored or dented Chapter 2 Basic Engine 3 Cylinder Head Measure the seat width with vernier calipers and repair or replace the seat when the wear limit is exceeded When the valves have been lapped and or ground measure the amount of valve recess and replace the valve when the wear limit is exceeded i Common to 4 models mm in Maintenance standard Wear limit 1 77 0 06969 1 Lapping the valve seat When scoring and pitting of the valve seat is slight coat the seat with valve compound mixed oit and lap the seat with a lapping tool At this time be sure that the compound does not flow into the valve stem and valve guide Seat width Seat angie Lapping tool 2 Correcting valve seat width When the valve seat is heavily pitted and when the seat width must be corrected repair w
67. ain bearing inside diameter 260 0 2 3622 Crankshaft journal outside diameter Oil clearance Fiywheel side 0 036 0 095 0 0014 0 0037 Main bearing inside diameter 244 0 1 7323 Crankshaft journal outside diameter 244 0 1 7323 0 036 0 092 0 0014 0 0036 Opposite side of ly had 243 90 1 7283 Cil clearance 6 5 3 Inspecting the intermediate main bearing 1 Caution when inspecting The intermediate main bearing is divided into two semi circles Therefore always measure after tightening the intermediate main bearing with the standard tightening torque Measure at four places as in the main bearing and replace it if it exceeds the wear timit kgf m ft lb Tightening torque of the intermediate main bearing eu Ps m housing tightening bolt A0A5052 B06 2 47 Chapter 2 Basic Engine 6 Crankshaft 2 Intermediate main bearing The intermediate main bearing on the flywheel side is the primary main bearing Because this is a flange type bearing measure the flange width as wel as the inside Intermediate Basic bearing bearing PLAKA SELB SME Gear case side intermediate bearing inside diameter 0 Flywheel side intermediate bearing inside diameter D Width of intermediate bearing Flywheel side Ww NOTE Only at the flywheel end for model 1GM 6 5 4 Replacing the crank bearing Since the crank bearings at both ends of the crankshaft are
68. air the trouble For re use of the emergency bolt turn the bolt in the reverse direction until it stops Before tightening the emergency bolts supply lube oil up to the center of the support shaft 7 Service Standard 7 1 Periodic Inspection Check the marine gear periodically using to the following list Inspection interval Procedure Every day Insert oil dipstick fully before starting the engine On ail exchange Clean Buang 5000 hours Clean inside the cooling pipe amp cooler 7 2 Wear Limit of Major Parts Part Measuring position Wear Simit Procedure Spline meshing backlash Friction plate Pinion 0 5 Replace Bush in pinion Clearance to shaft 0 2 Replace Unit mm Steel ptate Drive driven gear 1 Replace 7 3 Periodic Parts Replacement Ball bearings at4 years periodic inspection Packings Replace ali when disassembled Rubber packings O rings square rings Replace all when disassembled Rubber biock Damper disc at4 years periodic inspection A0A5052 JB06 7 19 Chapter 7 Reduction and Reversing Gear 8 Troubleshooting SM 2GMFY 3GMFY 8 Troubleshooting Clutch Slips due to Abnormal Drop in Clutch Hydraulic Pressure Check that there is no phase deviation of the remote control device 2i is the oil level as high as specified 3 i Is there abnormal wear in the gear pump 4 Is there oil strainer clogged Are the switch valve and clutch hydraulic pressure contro valve assembled correctly Refer to the par
69. ake and exhaust valves Large diameter intake valves and smoothly shaped intake and exhaust ports provide high intake efficiency and superior combustion performance Specia consideration has also been given to the shape of the cooling water passages so that the combustion surface A0A5052 B06 2 10 SM 2GMFY 3GMFY and precombustion chamber are uniformly cooled by an ample water flow The thermostat is installed on the side surface of the cylinder at the timing gear case side On models 2GMF Y 3GMF Y it is integrated with the alternator bracket Chapter 2 Basic Engine 3 Cylinder Head KK mm SM 2GMFY 3GMFY 3 14 Cylinder head of model 2GMF Y engine Valve rocker arm support Nut SS II Nalve top retai gt alve top retainer x M Washer ai Cotter Fuel valve retainer amp Circlip d Pa Valve spring retainer S mg um d Valve clearance LY f9 valve spring Fuel valve E CI adjust screw G e NAA KI Heat resistant packing G Si Valve rocker arm In OS KY e g EX R V R9 Valve stem seal ri U 5 Nd gt Ss 3 Cal m 2 Pre combustion chamber uA IGOS e li alve guide C na 7 Ns bd O IQ 3 y 7 Packing N a Q Rocker arm mounting bolt Side cover Thermostat housing Cylinder head No 1 Exhaust valve e No 1 Intake valve No 2 Intake valve No 2 Exhaust valve A0A 5052 JB06 2 11 Chapter 2 Basic Engine 3 Cylinder Head SM 2GMFY 3GMFY 3 1 2 Cy
70. and Reversing Gear I Model Y 5M Sectional View Procedure Install ahead gear Place shifting shaft assembly in housing A Install ahead and astern friction plate assemblies Refit link arms and insert clevis pins Insert locating pins and springs in friction retainer plate install housing B Install ball bearing Install lock washer and lock nut Use new lock washer After bending tabs on lock washer check to be sure that rotation of ball bearing is not interfered with Install shifter and nut insert cotter pin Use new cotter pin After assembly is completed check for ease of rotation of ahead and astern gears Disassembly of clutch speed reduction unit ltem Procedure 1 Thrust shaft Remove thrust shaft coupling coupling Remove key Remove rear cover of thrust shaft Take care not to damage oil seal Remove mounting nut and lockwasher ANA 5052 806 7 8 SM 2GMFY 3GMFY Hlustration Illustration Chapter 7 Reduction and Reversing Gear 1 Model Y 5M Sectional View SM 2GMFY 3GMFY Procedure lilustration 2 Idler gear Remove mounting nut and washer e Withdraw idler gear together with shaft 3 Thrust shaft Remove thrust shaft s Remove final reduction gear Do not misplace the key Reassembly of clutch speed reduction unit tem Procedure Illustration 1 Thrust shaft e Install final reduction gear in
71. apter 6 Cooling System 6 Cooling Water Ternperature Switch 6 Cooling Water Temperature Switch The cooling water temperature switch is identical to that for the sea water cooled engine in shape and dimension but care must be taken when parts are replaced as the operating temperature is different This can be checked by the seat color SM 2GMFY 3GMFY 56mm 2 2in Brown for fresh water cooled engine Yellow for sea water cooled engine PT 3 8 Operating temperature Current cit Response time ee We 96 C 204 8 F or higher DC 12V 1A Within 60 sec Indication color Parts code ON 106 3 C 217 4 228 2 F 127610 91360 ADA5052 JBO06 6 20 Chapter 6 Cooling System 7 Precautions 7 Precautions 7 1 Ventilator The surface temperature of fresh water cooled engines is higher than sea water cooled engines Therefore if the engine room is not well ventilated engine room temper ature can rise to a point where it will adversely influence engine performance 7 2 Cooling water 1 Fresh water Use clean soft water as cooling water Hard water will cause calcium build up poor heat transmission and a drop in the cooling affect resulting in overheating 2 Fresh water tank capacity cu in 2 9 177 0 34 207 5 Remove the cap from the fresh water cooler and check the water level If the water level is below the top of the cooling pipe add clean soft water up to the
72. are directly related to the valve riming and have an effect on engine performance they must be carefully serviced 3 6 1 Components of valve rocker arm 1 Model 2G MF Y The intake and exhaust valve rocker arms for two cyinders are fitted to a valve rocker arm shaft at both sides of the spring The same part is used for both in take and exhaust valve rocker arms Valve rocker arm shaft rocker arm Spring No 1 intake valve rocker arm Pin Nut Washer Bush No 2 intake valve rocker arm Washer li Valve clearance 2 5 adjust screw Screw ey Washer Valve rocker arm support en No 2 exhaust valve rocker arm 2 Models 3G MF Y The intake and exhaust valve rocker arms for three cylinders are fitted to a valve rocker arm shaft at both sides of the spring The same intake and exhaust valve shaft sprin rocker arms valve rocker arm support spring and valve rocker arm clearance adjusting screw are used S posite valve Circlip Valve rocker arm shaft Washer No 2 exhaust valve rocker arm Valve rocker arm support gt ta 12mm 0 4724in 10mm 0 3937in Nut NO Washer L f Q pe N Bush NA IN x RO ILE No 3 intake valve rocker arm A SS No 3 exhaust valve rocker arm Valve clearance adjusting screw Exhaust valve intake valve rocker arm rocker arm A0A5052 JB06 2 23 No 1 exhaust valve No 1 intake valve No 2 intake valve rocker arm Chapter 2 Basic Engine 3 Cylind
73. are found replace ghtening torque If the bearing metal contact is too unsymmetrical carefully check all related component parts which might be responsible and take proper measures 6 5 Main bearing 2 Determine the oil clearance by measuring the inside 6 5 1 Construction diameter of the crankshaft bearing and the outside For the intermediate main bearing on the flywheel side a diameter of the crankshaft flange type bearing integrated with the thrust bearing is us ed Because this is the primary main bearing those without the thrust bearing on the sides of the flywheel and timing gear housing are whole circle bearings while the in termediate main bearing on the timing gear housing side is the divided circle type Primary main bearing Flanged type Intermediate bearing at flywheel end basic bearing Intermediate bearing at gear case end A0A5052 JB06 2 46 Chapter 2 Basic Engine 6 Crankshaft SM 2GMFY 3GMFY NOTES 1 Measure the crank bearing at the four points shown in the figure and replace the bearing if the wear limit is exceeded at any of these points 2 When measuring the inner diameter of the crank bearing the crank bearing should be in Stalled on the bearing housing and or cylinder block Cylinder gauge Crank metal A B Y tt Q Main bearing housing A B Y mm in Wear limit 260 12 2 3669 259 90 2 3583 0 15 0 0059 244 12 1 7370 Maintenance standard M
74. arrangement at the end of the pump shaft The packed bearing unit supports the shaft by roller bear ings It cannot be disassembled The impelter is equipped with multiple blades and is mounted on the pump shaft The mechanical seal prevents water from entering from around the pump shaft The impeller seal is fixed to the impeller side with spring pressure applied from the pump body side Mechanical seal Pulley flange V puiley To heat exchanger From heat exchanger To cylinder block A0A5052 JB06 SM 2GMFY 3GMFY Cooling fresh water outlet connection Thermostat Cooling water temperature switch Plug for water heater PT 3 8 Qutiet Body bracket Impeller Pump body Applicable Engine Model amp Ei LOMEY a E 09727 after 3JGMFY Ehe 05548 after impeller Impeller seal Bearing unit By pass passage TU Body bracket Mechanical seal Pump body 6 8 Chapter 6 Cooling System 2 Water Pump Pump capacity and characteristic li 2GMFY 3GMFY Crank shaft speed Pulley ratio Crank shaft Pump shaft Pump shaft speed Delivery capacity Total head PC2127 PC2103 40001 3m 9 84ft NOTE The same type of fresh water pump is used for models 2GMF Y 3GMF Y Water temperature 8022 C H Q diagram pem Overall lift H mm Aq Discharge Q Umin n G diagram Water temperature 802 2 C
75. ates are assembled by turns When the pressurized oil pushes against the hydraulic cylinder clutch piston the steel plates and friction plates are pressed together to transmit power When the pressurized oil is drained the hydraulic cylinder is pushed back to disengage the clutch automatically 5 4 Switch Valve and Clutch Oil Pressure Control Valve The switch valve distributes the pressurized oil from the gear pump to the forward or reverse clutch by switching the oil passages in the valve The clutch oil pressure control valve controls the oil pressure of the clutch When the switch valve is operated the hydraulic oil in the clutch flows through the groove of the switch valve and oil gallery groove or drilled hole to press on the hydraulic cylinder When the switch lever is returned to neutral the pressurized oil pressing on the hydraulic cylinder is drained instantly and the clutch is disengaged The remaining oil not fed to the clutch oil pressure control valve flows to the lube oil control valve where the pressure is regulated to lubricate each part 6 Handling 6 1 Type of Cil 1 The oil must be stable against temperature changes It should also possess high acid and water resisting characteristics to give no adverse effect on the oil seals O rings nitrile based rubber gear faces friction plates paper based etc Use API CC grade or higher grade oil with an SAE viscosity index or 30 or the equivalent viscosity Recommended
76. bly and Reassembly 3 Accessaries SM 2GMFY 3GMFY 2 10 Assemble the cooling water pipe 2 12 Install the remote control cables 1 CFW hose heat exchanger CFW pump 2 13 Connect the interior piping A0A5052 JB06 8 20 YANMAR DIESEL ENGINE CO LTOD 1 32 CHAYAMACHI KITA KU OSAKA 530 JAPAN TEL 06 376 6211 TELEX63436 Y ANMAR J FA X 06 372 2455 Printed in Japan 0000 ADA 5052 9206 YANMAR DIESEL ENGINE CO LTD 1 32 CHAYAMACHI KITA KU OSAKA 530 JAPAN TEL 06 376 6211 TELEX 63436 YANMARJ FAX 06 372 2455 Printed in Japan 0000 AD A 5052 9206
77. change When load is suddenly changed from rated load to low load Speed ni ns nr Time ni instant maximum speed rpm ns Stabilized speed rpm nr Rated speed rpm ts Stabilization time sec Chapter 4 Governor I Governor 1 4 Disassembly 1 4 1 Disassembly 1 Remove the injection limiter and no load maximum speed limiter from the gear case 2 Remove the idle adjuster and adjuster bracket 3 Remove the cover at the gear case end move the governor lever 2 to match the control rack to the pulled out position of the fuel injection pump indicated by a slot in the gear case to show the position then take out the fuel injecton pump 4 Remove the gear case from the cylinder block 6 Pull the thrust collar the thrust needle bearing and the governor sleeve from the crankshaft 6 Loosen the end nut of crankshaft and remove the governor weight assembly 7 Remove the regulator spring main sub from the regulator lever 2 and fuel control lever 8 Remove the circlip of the regulator lever and remove the regulator lever and handle 9 Remove the governor lever shaft support bolt from the rear of the gear case and take out the governor lever shaft assembly 10 Loosen the nut of engine stop lever and pull the cam 11 Draw out the locking screw from the rear of the gear case and remove the taper pin for setting the return spring 12 Remove the engine stop lever and the spring 1 4
78. ck 2 Fuel pump 2 13 Install the lubricating oll pump Install the tubricating oil pump and driving gear assembly Lube pump body mounting boit 0 9 kgf m 65 ft Ib 2 14 Assembie the camshaft gear and fuel cam 1 Coat the shaft hole of the camshaft gear with oil and in sert the gear A0A5052 JB06 8 14 SM 2GMFY 3GMFY Chapter 8 Disassembly and Reassembly 2 Reassembly of Fresh Water Cooled Engine 2 Coat the fuel cam with oil and insert the cam by aligning the 0 mark opposite the camshaft gear 3 Tighten the camshaft end nut Tightening torque 7 8 kgf m 506 579 ft ib 2 15 Assemble the crankshaft gears 1 Coat the crankshaft section and the inside of the gear with oil 2 Align the matching marks of the camshaft gear and the crankshaft gear and insert the crankshaft gear 3 After inserting the crankshaft gear check the backlash Backlash 0 05 0 13mm 4 Install the governor weight assembly and tighten the crankshaft end nut Tightening torque 8 10 kgf m 67 9 72 3 ft Ib 2 16 Install the governor sleeve install the governor sleeve thrust needle bearing and thrust collar A0A5052 JB06 0 0020 0 0051in SM 2GMFY 3GMFY 2 17 Install the timing gear case 1 Coat both sides of the new packing with Three Bond 388 005 and install 2 Install the timing gear case p if EN ua un b J ____ Tightening torque 2 5 kef m 18 ft lb
79. cock and a scoop strainer is installed to prevent the sucking in of vinyl etc Sunction pipe Hull Kingston cock cover 8 2 Handling precautions Caution the user to always close the Kingston cock after each day of use and to confirm that it is open before begin ning operation If the Kingston cock is left open water will flow in reverse and the vessel will sink if trouble occurs with the water pump Moreover if the engine is operated with the Kingston cock closed cooling water will not be able to get in resulting in engine and pump trouble 8 3 Inspection When the cooling water volume has dropped and the pump is normal remove the vessel from the water and check for clogging of the Kingston cock Moreover when water leaks from the cock disassemble the cock and inspect it for wear and repair or replace it A0A5052 JB06 6 23 Chapter 6 Cooling System 9 Bilge Pump and Bilge Strainer Optional SM 2GMFY 2GMFY 9 Bilge Pump and Bilge Strainer Optional Cable connector 48 1 8898 bi 3 045 0 1772 Holes AY THEO Cable connecter 57 2 2440 N 90 3 5433 4 055 2 1654 Holes 50 1 9685 217 5 0 6890 Cooling water outlet Cooling water inlet 9 1 Bilge pump 9 2 Bilge strainer 1 Specifications 120345 46010 with strainer E mm in Model No BP190 10 E else S 7 a Output 3 0kg 6 6 Ib 2 Performance of pump in pure wat
80. crankshaft V pulley 4 Remove the fuel injection pump NOTE Remove the cap at the timing gear case end and remove the fuel injection pump by moving the governor second lever while observing through the hole 5 Loosen the hexagonal bolt with the hole and remove the straight pin from the manual starting handle 6 Remove the gear case 7 Remove the governor sleeve and needie bearing collar 8 Loosen the hexagonal nut and remove the governor weight support 9 Remove the camshaft nut and take out the fuel cam 10 Remove the camshaft gear crankshaft gear and lubricating oil pump A0A5052 B06 SM 2GMFY 3GMFY 9 2 2 Disassembly and reassembly precautions Reassembie in the reverse order of disassembly Pay attention to the foilowing points when assembling 1 Timing mark A timing mark is provided on the crankshaft gear and camshaft gear to adjust the timing between opening and closing of the intake and exhaust valves and fuel injec tion when the piston is operated Always check that these timing marks are aligned when disassembling and reassembling the timing gear First fit the crankshaft gear to the crankshaft by mat ching the key and slot Next by rotating the camshaft fit the camshaft gear in the position where the marks on the camshaft gear and the crankshaft gear align Slee I 17 Camshaft 2 Fuelcam When the fuel cam is fitted to the camshaft assemble it keeping the surface marked O
81. d contact surfaces for high wear resistance The center of the cam surface width and the center of the tappet are offset to prevent eccentric wear of the contact surface A0A5052 JB06 2 56 SM 2GMFY 3GMFY 8 5 1 Tappet disassembly precautions The cylinder number and intake and exhaust must be clear ly indicated when disassembling the camshaft and tappets 8 5 2 Tappet stem wear and contact Measure the outside diameter of the tappet stem and replace the tappet when the wear limit is exceeded or con tact is uneven mm in Maintenance lei standard Wear limit Tappet stem outside diameter Tappet stem and 0 010 0 040 Han raan 0 0004 0 0016 10 0039 Abnormal contact Normal contact Chapter 2 Basic Engine 8 Camshaft Www el Since the tappet and cam are offset the tappet rotates in an up and down movement during operation so there is no uneven contact Since eccentric wear will occur if cam tappet contact is poor replace the tappet if there is any uneven contact or deformation Contact surface conditions are shown in the following a 2 3 4 1 2 Traces when the tappet is rotating normally 3 4 Traces when the tappet does not rotate and the con tact surface remains still and only the point of con tact wears away excessively Discover the reason for the lack or rotation and replace the tappet Cracks Pitting Also there may be perforated pitting
82. e Since the oil clearance affects both the durability of the bushing and lubricating oil pressure it must always be the prescribed value Replace the bushing when the oil clearance exceeds the wear limit 1 Measurement 1 Thoroughly clean the inside surface and crank pin sec tion of the crank pin bushing 2 Install the connecting rod on the crank pin section of the crankshaft and simultaneously fit a Plasti gauge on the inside surface of the crank pin bearing A0A5052 JB06 SM 2GMFY 3GMFY 3 Tighten the connecting rod bolt to the prescribed tightening torque Connecting rod 25 kgf tightening torque 18 1 ft ib Hexagon width 12mm 0 4724in 4 Loosen the connecting rod bolt and slowly remove the connecting rod big end cap then measure the crushed Plasti gauge with a gauge NOTE Never adjust by shims or machine the crank pin bushing Always replace the crank pin bushing with a new one Chapter 2 Basic Engine 5 Connecting Rod 5 The crank pin and bushing clearance oil clearance may also be measured with a micrometer in addition to measurement with a Plasti gauge With this method the outside diameter of the crankshaft crank pin sec tion and the inside diameter of the connecting rod s big end bushing when the connecting rod bolt has been tightened to the prescribed torque are measured and the difference between the large end bushing inside diameter and crank pin outside diameter is se
83. e diameter Valve guide orotrusion mm in Valve guide protrusion 7 0 2756 Intake Stem outside diameter ane guide inside diameter after assem Exhaust Y Stem outside diameter A0A5052 JB06 Clearance at assembly ap SU 0 040 0 065 0 0016 0 0026 2 19 0 045 0 070 0 0018 0 0028 SM 2GMFY 3GMFY 2 Measuring the valve guide inside diameter Measure the valve guide inside diameter and clearance and replace the guide when wear exceeds the wear limit mm in Wear limit 0 15 0 0059 0 15 0 0059 Chapter 2 Basic Engine 3 Cylinder Head SM 2GMFY 3GMFY 3 Replacing the intake exhaust valve guide 1 Using a special tool for extracting and inserting the 2 Using the above tool drive the valve guide into position valve guide extract the valve guide by starting from the valve spring side and finish the in side diameter with a reamer Tool Valve guide Cylinder head mm in 2GMFY 3GMFY 0 018 0 047 0 0007 0 0019 Amount of interference of valve guide Fit the intake and exhaust valve guides until the bottom of the groove around the outside of the valve guide is flush with the end of the cylinder head Square gauge Relationship between valve guide fitting groove and head surtace Surface plate mm in 3 4 3 Valve spring Maintenance standard 1 Valve spring inclination Valve spring f
84. e CFW hose between the cylinder head and heat exchanger The hose clamp at the heat exchanger side or the cooling water outlet con nection side only need be loosened Cooling water zx Outlet connection Fuel filter A0A5052 JB06 8 3 Chapter 8 Disassembly and Reassembly 1 Disassembly of Fresh Water Cooled Engine 1 7 Removing the fuel filter The fuel filter can be removed as assembled to the heat ex changer However to make removal of the heat exchanger easier the filter should be removed separately Fuel filter 1 8 Remove the fuel feed pump In cases of model 3GMFY the heat exchanger drain plug may jam against the fuel feed pump pipe con necter The fuel feed pump should be removed before removing the heat exchanger in cases of models 2GMFY the heat exchanger can be removed without removing the fuel feed pump Fuel feed pump 1 9 Remove the remote control bracket The heat exchanger fixing nut cannot be removed without first removing the remote control bracket Remote contro bracket ADA5052 JB06 8 4 SM 2GMFY 3GMFY 1 10 Remove the heat exchanger Heat exchanger 1 11 Remove the alternator 1 Loosen the adjusting bolt and remove the V belt 2 Remove the alternator Alternator Fresh water pump drive pulley Crank shaft pulley Chapter 8 Disassembly and Reassembly 1 Disassernbly of Fresh Water Cooled Engine SM 2GMFY 8GMFY 1 12 Remove the CFW pump 1
85. e V belt tension is slack the discharge of the cool coat the sliding face pump shaft and impeller fitting ing water will diminish if it is too tight the play of the section with grease or Monton X pump bearings and the wear of the wear plate will be ac celerated Adjust the tension to the specified value Check the deflection of the V belt by pressing it in the center with your fingers Coat these parts with grease 2 Be sure that the direction of curving of the impeller is correct The impeller is curved in the direction opposite the direction of rotation Direction of rotation To be 5 7mm 0 1964 0 2756in deflection when pushed with the thumb with a force of 10kg 22 0 Ib V belt tension Type of V belt V belt part No 104511 78780 NOTE Mount the belt in the direction of pump rotation 4 If the sliding surface of the V belt is cracked or worn or is stained with oil etc replace it with a new one 5 Check after assembly After assembly attach the belt and run the engine to ascertain whether or not it provides the specified discharge Handling precautions 1 Never operate the water pump dry as this will damage the rubber impeller 2 Always turn the engine in the correct direction of rota tion as turning the engine in the opposite direction will damage the rubber impeller 3 Inspect the pump after every 1 500 hours of operation and replace if faulty Inspection
86. e a bearing is already housed inside 5 Structure 5 1 Power Transmission Route Ii 4 Revolutions in Neutral Input shaft coupling 1 Input shaft 2 Drive Gear 5 Driven Gear 9 Revolutions in Forward Input shaft coupling 1 Input shaft 2 Forwarding clutch 4 Forwarding pinion 3 Output gear 6 Output shaft coupling 10 Revolutions in Reverse Input shaft coupling 1 Input shaft 2 Drive gear 5 Driven gear 9 Reversing clutch 8 Reversing pinion 7 Output gear 6 Output shaft coupling 1 0 A0A5052 JB06 745 Chapter 7 Reduction and Reversing Gear 6 Mandin SM 2GMFY 3GMFY 5 2 Hydraulic System The lube oil in the oil pan is sucked up by the pump through the strainer and sent to the clutch hydraulic pressure control valve where the pressure is regulated The oil is then sent to each clutch by the forward reverse switch valve The pressure of the remaining oil not supplied to the clutch is regulated by the lube oil pressure control valve for use in lubricating the clutch bush and some of the ball bearings Splash lubrication is provided for the gears and bali bearings 5 3 Clutch in the hydraulic wet type multi disc clutch the spline of the forward and reverse pinion meshes with the friction plate which has the spline on its inner circumference The outside circumference of the steel plate meshes with the drive gear and driven gear The steel plates and friction pl
87. e and the starting characteristic of the engine it must be checked periodically 4 RS 4 PL Top ciearance S K UNG Nozzle nut Z Precombustion chamber Gasket packing Piston 1 Top clearance measurement 1 Check the cylinder head mounting bolts and tightening torque 2 Remove the fue injection valve and precombustion chamber Fuse wire A0A5052 JB06 2 22 SM 2GMFY 3GMFY 3 Lower the piston at the side to be measured 4 Insert quality fuse wire 61 2mm 0 472in through the nozzle holder hole Be careful that the wire does not enter the intake and exhaust valve and the groove in the combustion surface 5 Crush the fuse wire by moving the piston to top dead center by slowly cranking the engine by hand 6 Lower the piston by hand cranking the engine and remove the crushed fuse wire being careful not to drop it 7 Measure the thickness of the crushed part of the fuse wire with vernier calipers or a micrometer 2 Top clearance value mm in 0 7 0 0276 Top clearance When the top clearance value is not within the above range check for damaged gasket packing distortion of the cylinder head combustion surface or other abnor mal conditions Chapter 2 Basic Engine Cyli Head 3 Cylinder Head SM 2GMFY 3GMFY 3 6 Intake and exhaust valve rocker arm Since the intake and exhaust valve rocker arm shaft and bushing clearance and valve head and push rod contact wear
88. e is running or while the engine is still hot after it has been stopped A0A 5052 JB06 SM 2GMFY 3GMFY steam will escape and may cause serious injury If removal of the filler cap is unavoidable place a piece of cloth over the cap and turn the cap slowly making sure you are in a safe position even if steam escapes 7 3 Antifreeze 1 Use permanent type antifreeze in the winter Freezing of the fresh water will damage the heat exchanger cylinder head and water jacket 2 Antifreeze use 1 Before adding antifreeze clean cooling system and check for leaks 2 Select mixing ratio according to the following table 1 cu in 0 NOTE The temperature selected in the above table should be 5 C lower than the lowest expected temperature in the area NOTE Check mixing ratio carefully especially when using premixed coolant 3 Tighten drain cock and fill cooling system Then run engine for approx 5 to 30 minutes to make sure the solution is well mixed Antifreeze NOTE Some antifreeze solutions will corrode aluminum Check carefully before use NOTE When antifreeze protection is no longer necessary drain water flush cooling system and refill with fresh water 6 21 Chapter 6 Cooling System 7 Precautions 7 4 Rust inhibitor When the fresh water is changed a rust inhibitor must be added to the new water to prevent rusting Rust inhibitor Fresh water 1 10 Flush cooling system with fresh water
89. e piston ring contact and replace the ring when contact is faulty Since the oil ring side contact is closely related to oil consumption it must be checked with particular care 2 Measuring the piston ring gap Insert the piston into the cylinder or cylinder liner by pushing the piston ring at the head of the piston as shown in the figure and measure the piston ring gap with a feeler gauge Measure the gap at a point about 100mm 3 9370in from the top of the cylinder Measure by inserting a thickness gauge Connecting rod Cylinder liner cylinder for model 1GM Piston 3 9370in Approx 100mm Piston ring 2 32 Chapter 2 Basic Engine 4 Piston SM 2GMFY 3GMFY Gap Thickness mm fin Wear limit Maintenance standard 2 903 Width 0 0776 0 0783 3 220 10 I 47001 Width 0 1563 0 1181 2 82020 0 20 0 40 0 0079 0 0157 0 20 0 40 0 0079 0 0157 Piston ring 1 2 Oil ring 15 0 0591 15 0 0591 Piston ring gap 1 2 Oil ring gap 3 Piston ring replacement precautions 1 Clean the ring grooves carefully when replacing the rings 2 When installing the rings assemble the rings so that the manufacturer s mark near the gap is facing the top of the piston Manufacturer s mark 1st compression ring 2nd compression ring oil ring 3 After assembly check that the rings move freely in the grooves 4 The rings must be ins
90. e stem seal Valve guide Cylinder head 3 4 5 Spring retainer and spring cotter pin Inspect the inside face of the spring retainer and the out side surface of the spring cotter pin and the contact area of the spring cotter pin inside surface and the notch in the head of the valve stem Replace the spring retainer and spr ing cotter pin when the contact area is less than 7096 or when the spring cotter pin has been recessed because of wear No recess 3 5 Precombustion chamber and top clearance 3 5 1 Precombustion chamber Remove the packing and insulation packing at the precom bustion chamber s front and rear chambers and inspect Check for burning at the front end of the precombustion chamber front chamber acid corrosion at the precombus tion chamber rear chamber and for burned packing Replace if faulty Heat insulator Precombustion chamber rear Packing Pin Precombustion chamber front Packing Chapter 2 Basic Engine 3 Cylinder Head 3 5 2 Insulation packing The insulation packing prevents transmission of heat from the precombustion chamber to the nozzle valve and serves to improve the nozzle s durability Always put in new insulation packing when it has been disassembled 3 5 3 Top clearance Top clearance is the size of the gap between the cylinder head combustion surface and the top of the piston at top dead center Since top clearance has considerable effect on the com bustion performanc
91. e threads with Screw Lock Super 203M screw the identification number is on the exhaust side Install the piston rings with a piston ring inserter 8 10mm about 6 turns Screw in distance 0 3149 0 3937in 5 After the connecting rod large end contacts the crankpin push the piston crown down slowly to turn the 2 8 install the engine bottom cover oil pan crankshaft to bottom dead center 1 Change the packing 6 Align the connecting rod cap and connecting rod large 2 Install the bottom cover end matching mark and tighten the connecting rod Tightening torque 09 kgf m 6 5 ft lb 2 10 Install the mounting flange 1 Set the engine upright 2 Align the positioning pins and tighten the flange CAUTION 1 Be careful to tighten the connecting rod bolts evenly 2 Coat the boit threads and washer face with oil kgt m ft Ib 2GMF Y 3GMF Y Tightening torque 25 18 1 7 Measure the side clearance Side clearance 0 0079 QUI 8 Check that the crankshaft rotates smoothly Tightening torque 4 5 kgf m 325 ft Ib A0A5052 JB06 8 13 Chapter 8 Disassembly and Reassembly 2 Reassernbly of Fresh Water Cooled Engine 2 11 Install the flywheel 1 Align the reference pins 2 Install the flywheel mn Tightening torque e3 ka AG d NOTE After tightening check the end run out 2 12 Install the engine feet and set the engine in position 1 Dipstick flange and dipsti
92. ed Engine SM 2GMFY 3GMFY 2 Reassembly in general the reassembly of the fresh water cooled engine For details of the first half of the reassembly sequence is the same as that for a sea water cooled engine except refer to the sea water cooled engine manual Sections 5 for cooling system components such as the heat ex 3 1 P12 35 to 5 3 24 P12 41 changer fresh water pump cooling water pipe and related parts For reference 2 1 Assemble the cylinder liners 2 3 Insert the camshaft 1 Remove any rust from the cylinder block where it 1 Coat the camshaft bearing section with oil and insert contacts the cylinder liners the camshaft into the cylinder block by tapping the shaft 2 Coat the outside periphery of the liners with waterproof end with a plastic hammer ing paint 3 Insert the liners into the cylinder block making sure that the cylinder liner protrusion is correct 2 2 Insert the tappets NOTE Be careful not to damage the groove in the end of 1 Tum the cylinder block over or turn it upside down the shaft 2 Coat the tappets with oil and insert into the tappet 2 After inserting the camshaft check that it rotates holes smoothly before tightening the camshaft bearing set screw Tightening torque 2 kgf m 14 5 ft lb 2 4 Install the crankshaft NOTE Assemble the tappets in their original positions paying careful attention to the cylinder numbers and intake and exhaust groupings A04A5052 JB06
93. ed lower than the injection pump Dirt and other impurities in the fuel are removed by the filter and the clean fuel is sent to the injection pump which applies the necessary pressure for injection to the fuel and atomizes the fuel by passing it through the injection nozzle The injection pump also controls the amount of fuel in jected and the injection timing according to the engine toad and speed by means of a governor The injection pump feeds the fuel to the injection nozzle 1 2 Fuel injection system specifications 2GMFY YPFR 0707 2 YDN OSDYD Throttle 170 kgf crf 2418 Ib in 26mm 0 2362in x 7mm 0 2756in 23 5mm st 0 0014in st 0 1 kg cm 1 4224 Iblin Type of injection pump Type of injection nozzle Injection pressure Piunger diameter x stroke Delivery valve suction capacity Fuel feed pressure A0A5052 JB806 3 2 SM 2GMFY 3GMFY through a high pressure pipe The pressurized fuel is atomized and injected by the injection nozzle into the precombustion chamber Fuel that overflows the injection nozzle is returned to the fuel tank through the fuel return pipe The quality of the equipment and parts comprising the fuel injection system directly affects combustion performance and has a con siderable effect on engine performance Therefore this system must be inspected and serviced regularly to ensure top performance 3GMFY YPFR 0707 Chapter 3 Fuel System 2 Injection Pump 2 Injection Pump
94. el feed pump cam No 1 intake valve cam No 2 intake valve cam Ball bearing No 2 exhaust valve cam Set screw 3 Ball bearing retainer Camshaft gear Hexagonal nut No 1 intake valve cam Fuel feed pump cam Key No 1 exhaust 8 1 2 Camshaft of engine models 3G MF Y valve cam Journal Pin No 2 intake valve cam No 2 exhaust valve cam Camshaft gear Ball bearing Journal No 3 intake valve cam P dd No 3 exhaust vaive cam Set screw Ball bearing The cam profile is common to models 2GMF Y and retalning screw 3GMFY The camshaft has drilled holes for lubricating the intake and exhaust valve cams A0A5052 B06 2 54 Chapter 2 Basic Engine 8 Camshaft 8 2 Valve timing diagram TDC Intake valve open Exhaust valve close Intake valve close Exhaust valve open 8 3 Inspection Visually check for steps or wear on the cam surface and replace if excessive Since the cam surface is tempered and ground there is almost no wear However measure the height of the intake and exhaust cams and replace the camshaft when the measured value exceeds the wear limit 8 3 1 Camshaft height 8 3 2 Journals of camshaft Measure the amount of wear and eccentricity of the cam shaft journal Measurements must be carried out in at least two directions for each position Replace the camshaft with a new one if the value exceeds the allowable limit Maintenance standard Fly
95. el filter Filter cleaning First time 50 hours Filter element replacement Every 250 hours Chapter 3 Fuel System 5 Fuel Feed Pump 5 Fuel Feed Pump 5 1 Construction The tuel pump feeds the fuel from the fuel tank to the injec tion pump through the fuel filter When the fuel tank is in stalled at a higher position than the fuel filter and injection pump the fuel will be fed by its head pressure but if the fuel tank is lower than the filter and Injection pump a fuel pump is required The fuel pump of this engine is a diaphragm type and is in stalied on the exhaust side of the cylinder body The diaphragm is operated by the movement of a lever by the fuel feed pump cam at the cam shaft Fuel feed pump Camshaft 2GMFY 3GMFY ADA5052 JB06 SM 2GMF Y 3GMFY Specifications Part No Suction head Capacity 121256 52020 Max 0 8m 3 15in 0 3 timin at 1000 rpm 0 1 kgf cm 1422 Ib in at koo 1800 rpm 60 mmHg at 600 rpm Feed pressure Suction pressure Chapter 3 Fuel System 5 Fuel Feed Pump 5 2 Disassembly and reassembly 5 2 1 Disassembly Clean the outside of the pump scribe a matching mark on the upper body and lower body of the pump disassemble and put the components in order Component parts of fuel feed pump 5 2 2 Reassembly Assemble the pump by reversing the disassembling pro cedures Pay close attention to the following 1 Clean the
96. elity When the measured value ex ceeds the wear limit replace the connecting rod Twisting and poor parallelity will cause uneven contact of the piston and bushing and shifting of the piston rings resulting in compression leakage Connecting rod twist and paralielity mm in Maintenance standard a O0 489 937 ET 0 08 100 Limit 0 00315 3 937 Measuring twist and parallelity 5 3 Crank pin bushing Since the crank pin bushing slides while receiving the load from the piston an easy to replace kelmet bushing with a wear resistant overlay is used Overlay Keimet bushing Backing metal 5 3 1 Crank pin bushing Inside diameter Tighten the large end of the connecting rod to the prescrib ed torque with the connecting rod bolts and measure the inside diameter of the crank pin bushing Replace the bushing if the inside diameter exceeds the wear limit or the clearance at the crank pin part exceeds the wear limit Chapter 2 Basic Engine 5 Connecting Rod Maintenance standard Crank pin bushing 240 10 inside 15787 diameter Crank pin and bushing oil clearance Connecting rod bolt M7 x P1 0 Thread 0 2755 x 0 0393 diameter Connecting rod boit 25kgf m tightening 18 1 ft Ib torque NOTE The crank pin bushing inside diameter must always be measured with the connecting rod bolts tighten ed to the prescribed torque 5 3 2 Crank pin and bushing clearance oil clearanc
97. em also applies to No 3 cylinder for the 3 cylinder type engine A0A5052 JB06 3 12 Chapter 3 Fuel System 2 Injection Pump 2 Replace pinion if teeth are damaged or worn unevenly 3 If the control rack does not move smoothly when a force of within 60g is applied replace the rack and pinion assembly 2 5 4 Plunger 1 Inspect the plunger for wear scoring and discoloration around the lead If any problems are found conduct a pressure test and replace the piunger and plunger barrel assembly Lead 2 Inspect the outside sliding surface of the plunger with a magnifying glass Lap or replace the plunger and plunger barrel assembly when corrosion hairline cracks staining and or scoring are detected 3 Check the clearance between the plunger collar and control sleeve groove Replace these parts when wear exceeds the specified limit ADA5052 JB06 SM 2GMFY 3GMFY 4 After cleaning the plunger tilt it approximately 60 as shown in the figure and slowly slide it down Repeat this several times while rotating the plunger The plunger should slide slowly and smoothly If it slides too quickly or binds along the way repair or replace it 2 5 5 Delivery valve 1 Replace the delivery valve if the return collar and seat are scored dented or worn Seat ues d REC Return collar 2 Raise the delivery valve and put a finger over the hole on the valve seat bottom Let go of the delivery valve
98. embly W Cooled Engi 1 Disassembly of Fresh Water Cooled Engine SM 2GMFY 3GMFY 1 30 Remove the governor weight assembly 1 34 Remove the oil pan and the oll intake pipe Special tool Remove the crankshaft end nut and remove the governor weight assembly 1 31 Remove the lubricating oi pump and driving gear assembly A E 1 35 Remove the mounting bolt of the intermediate main bearing LE r N 2 ir There are two intermediate main bearings viz No 1 and No 2 for engine model 3GMFY 1 36 Puli the crankshaft 1 33 Tum the engine onto its side 1 Remove the engine feet of the crankshaft side 2 Turn the cylinder block over so that the crankshaft side is on the bottom A0A5052 JB06 8 9 Chapter 8 Disassembly and Reassernbly 1 Disassembly of Fresh Water Cooled Engine SM 2GMFY 3GMFY 1 37 Remove the camshaft NOTE Arrange the removed tappets by cylinder no and 1 Remove the camshaft bearing set screw intake and exhaust groups 1 39 Remove the liners Set the engine upright and pull the liners with a liner puller 2 Place the cylinder block upside down or raise the cylinder block by inserting a plate beneath it in order to prevent contact between the tappet and the cam 3 Check that all the tappets are separated from the cam and pull the camshaft out 1 38 Remove the tappets ADA5052 JB06 8 10 Chapter 8 Disassembly and Reassembly 2 Reassembly of Fresh Water Cool
99. embly also check for abnormal sounds from each bearing by turning the input shaft manually 1 Remove of Case Plate a Remove piping remote control wires etc b Extract the output shaft coupling from the output shaft c Remove the hydraulic pump d Remove the starter with bolts e Remove all the case plate fixing bolts Note that the knock pin is fitted to the case and case plate Take care not to damage the shaft s seal ring 2 Disassembly of Rotational Parts a Disassembly of Input Shaft and Support Shaft Ass y Remove the bearing and bearing mount engine side from the shaft The pinion assembly can be removed by removing the stop ring The stop ring is fitted inside the bearing mount Do not pull out the pinion before removing this stop ring To disassemble the clutch remove the stop rings of the drive gear and driven gear engine side Now the friction plates and steel plates can be removed The spring and hydraulic cylinder are removed by removing the stop ring at the middle of the shaft b The out put shaft is easily disassembly by disassembling the case Note The drive gear and driven gear are shrink fitted to each shaft Do not disassemble these gears c Use the puller to remove the ball bearing from the case Warm the case in hot oil or water to facilitate removal YX6 Series Disassembly Procedures 1 Remove all the pipings 2 Place the clutch on the input shaft side on a work table Set the drive sha
100. en the CSW pump cover fixing screws and drain the sea water from the CSW pump and COW hose CSW pump cover sea water NOTE CSW Cooling Sea Water Chapter 8 Disassembly and Reassembly Di F led Engi 1 Disassembly of Fresh Water Cooled Engine SM 2GMFY 3GMFY 1 2 Drain the lubricating oil 1 3 Disconnect the remote control cables 1 Clutch remote control cable 1 Engine side Turn to engine side of the cock and pump out the 2 Speed remote control cable oil with a waste oi pump with cylinder 3 Engine stop remote control cable 4 Decompression remote control cable 2 Clutch side Turn to marine gear side to the cock and pump out the oil with a waste oi pump 1 4 Disconnect the electrical wiring 1 Alternator wiring 2 Starter motor wiring 3 Water temperature switch wiring 4 Oil pressure switch wiring 5 Tachometer sender wiring Cooling water temperature switch Alternator A0A5052 JB06 8 2 Chapter 8 Disassembly and Reassernbly 1 Disassembly of Fresh Water Cooled Engine SM 2GMF 83GMFY 1 5 Remove the CSW hose 1 6 Disconnect the fuel piping 1 Remove the CSW hose between the CSW pump and 1 Fuel tank to feed pump heat exchanger 2 Feed pump to fuel filter 3 Fuel filter to fuel injection pump Fuel filter Fuel oil pipe 2 Remove the CFW hose between the heat exchanger and CFW pump NOTE CFW Cooling Fresh Water 3 Loosen the hose clamp on th
101. er 124 4 8819 BEN 12m 947 4 sec Self suction performance Pumping lif 8A performance Total lift im 328 ft Lifting volume of water 17 timin A0A5052 JB06 6 24 A0A5052 JB06 CHAPTER 7 REDUCTION AND REVERSING GEAR For engine model 2GMFY and 3GMFY 1 Model Y 5M Sectional View cc een 7 1 2 Model Y X 6 1 Clutch Sectional View 7 11 3 Principal Specifications a 7 13 4 Outline AAP APA Ee e ah 7 15 5 Str ct re iiie soi re ever pi rre s eene a 7 15 GC Handlifig 2 2 nn en sane ADIPIS 7 16 7 Service Standard suus sese 7 19 8 Troupleshooting a 7 20 9 Disassembly and Reassembly 7 21 Chapter 7 Reduction and Reversing Gear 1 Model Y 5M Sectional View 1 Model Y 5M Sectional View A0A5052 J806 i SM 2GMFY 3GMFY Chapter 7 Reduction and Reversing Gear 1 Model Y 5M Sectional Vi Model Era aen EE VM GCM EY GMEY 1 1 Clutch Housing Y 5M A0A5052 JB06 72 Chapter 7 Reduction and Reversing Gear 1 Model Y ti l Vi 1 Model Y 5M Sectional Vtew ot 2GMFY 3GMFY 1 2 Friction Disk Housing Y 5M A04A5052 B06 7 3 Chapter 7 Reduction and Reversing Gear 1 Model Y 5M Sectional View SM 2GMFY 3GMFY 1 3 Output Shaft Y 5M 74 A045052 JB06 Chapter 7 Reduction and Reversing Gear 1 Model Y 5M Sectional View SM 2GMFY 3GMFY 1 4 Disassembly and Reassembly of Maj
102. er Head SM 2GMFY 3GMFY 3 6 2 Measuring the valve rocker arm shaft and bushing clearance Measure the outside diameter of the vaive rocker arm shaft and the inside diameter of the bushing and replace the rocker arm or bushing if the measured value exceeds the wear limit Replace a loose valve rocker arm shaft bushing with a new bushing However when there is no tightening allowance replace the valve rocker arm Valve rocker arm shaft Valve rocker arm Wear limit Intake and exhaust valve rocker A arm shaft outside diameter 0 016 0 052 2GMFY p 0 15 0 0059 intake and exhaust valve rockeram g 0 0006 0 0020 00 0059 bushing inside diameter assembled 0 5551 Intake and exhaust valve rocker A arm shaft outside diameter 0 016 0 052 3GMFY Intake and exhaust valve rocker am p 0 0006 0 0020 bushing inside diameter assembled 3 6 3 Valve rocker arm and valve top retainer contact and 3 6 5 Classification of the intake and exhaust valve rocker wear arms Check the valve rocker arm and valve top retainer contact Since the intake and exhaust valve rocker arms have dif and replace when there is any abnormal wear or peeling ferent shapes care must be exercised in service and assembly 3 6 4 Valve clearance adjusting screw inspect the valve clearance adjusting screw and push rod contact and replace when there is any abnormal wear or peeling A0A5052 JB06 2 24 Chapter 2 Basic
103. es that may have high humidity or hot air 2 Cautions for Storing Bare Unit include inboard unit with anti rust treatment a Apply anti rust oil inside the marine gear every 6 months Feed anti rust oil to the specified amount Turn the input shaft ten times in its normal turning direction Turn the output shaft clockwise and counterclockwise ten times each Then drain the anti rust oil b When the unit is left unused for over a year overhaul it 3 Storage Onboard with hydraulic oil a When the marine gear is left onboard operate the unit at least once in 3 months to send oil to each part b When the unit is teft onboard for more than a year overhaul it 4 Storage of Parts Be sure to store the parts indoors a Handle bearing gears and other parts which may rust with care Do not touch these parts directly with your hand If they have to be touched or oil must be wiped off them be sure to re apply anti rust oil b Be sure to put electrical equipment and other parts which may be damaged by moisture into a vinyl bag and storeiton a dry shelf Put O rings oil seals and other rubber parts which may degenerate into a vinyl bag for storage Do not use O rings oil seals and other rubber parts which have been left unused for more than 2 years from the date recorded on the inspection list in the vinyl bag A0A5052 JB06 7 28 Chapter 7 Reduction and Reversing Gear 9 Disassembly and Reassembly SM 2GMFY 3GMFY 2 Parts t
104. escribed pressure by the oil pressure regulating valve and sent to the main bearing The lubricating oil sent to the gear side main bearing flows in two paths one from the main bearing to lubricate the crank pin through the hole drilled through the crankshaft The lubricating oil sent to the flywheel side main bearing also flows in two paths one from the main bearing to lubricate the crank pin through the hole drilled through the crankshaft and the other to the rocker arm shaft through Valve rocker arm shaft Camshaft gear Crankshaft gear Oi pressure regulator valve To oil pan Oii pressure switch Filter A0A5052 JB06 SM 2GMFY 3GMFY the hole drilled through the cylinders and cylinder head From the rocker arm shaft the lubricating oil flows through the small hole in the rocker arm to lubricate the push rods and part of the valve head The oil that has dropped to the push rod chamber from the rocker arm chamber lubricates the tappets cam and cam bearing and returns to the oil pan The pistons piston pins and contact faces of the cylinder liners are splash lubricated by the oil that has lubricated the crank pin Moreover an oil pressure switch is provided in the lubricating system to monitor normal circulation and pressure of the lubricating oil When the lubricating oil pressure drops 0 5kgf cm 7 114 Ib in the oil pressure switch illuminates the oil pressure lamp on the instrument panel to notify the operat
105. essure adjusting nozzle spring and contacts the valve seat of the nozzle body Under high pressure fuel from the fuel pump passes through the hole drilled in the nozzle holder enters the cir cular groove at the end of the nozzie body and then enters the pressure chamber at the bottom of the nozzie body When the force acting in the axial direction on the differen tial area of tne nozzle at the pressure chamber overcomes the force of the spring the nozzle is pushed up and the fuel is injected into the precombustion chamber through the throttle hole The nozzle is closed again when the pressure in the nozzle body s pressure chamber drops below the force of the spring This cycle is repeated at each opening and ciosing of the injection pump delivery valve A0A5052 JB06 SM 2GMFY 3GMFY 3 5 Disassembly and reassembly 3 5 1Disassembly sequence 1 Remove the carbon from the nozzle end 2 Loosen the nozzle spring holder 3 Remove the nozzle holder body from the nozzle moun ting nut 4 Remove the nozzle body and nozzle ass y from the nozzle mounting nut 5 Remove the nozzle spring retainer from the nozzle holder body and remove the nozzle spring retainer inter spindle etc Reassemble in the reverse order of disassembly paying special attention to the following items 3 5 2 Disassembly and reassembly precautions 1 The disassembied parts must be washed in fuel oil and carbon must be completely removed fro
106. f its volume approx 1500 cc 2 Apply lithium grease to the damper disc spline and oil seal A0A5052 JB06 7 26 Chapter 7 Reduction and Reversing Gear 9 Disassembly and Reassembly SM 2GMFY 3GMFY 9 4 List of Tightening Torques Tightening Positions Tightening position Output shaft coupling fixing bolts Emergency bolt Hydraulic pump fixing bolts SUS bolts below the case Switch valve lever fixing bolt PT plug Hexagon head plug Tightening torque N m kgf m Remarks A M14x1 5 196 9 20 41 ee 4 9 1 0 5 0 1 Apply 1215 to the threads M8X 1 25 20 641 2 140 1 M8x1 25 25 5 1 2 6 0 1 PT1 8 9 8 1 0 1 040 1 M12x 1 25 29 4 2 0 3 0 0 2 M16x1 5 53 944 9 5 50 5 Standard Tightening Torque 7T bolt Tightening torque N m kgf m A0A5052 JB06 Bolt dia x pitch Tightened material 8 841 0 0 940 1 20 642 2 1 0 2 aluminum EE or steel e 28 522 2 620 2 EC or eteel 10 83 1 0 1 10 1 25 542 2 6 0 2 M10x1 5 39 2 2 0 4 0 0 2 49 0 4 9 5 0 0 5 M6x1 0 M8x 1 25 7 27 Chapter 7 Reduction and Reversing Gear 9 Disassembly and Reassembly SMI2GMFY 3GMFY Deine nn aao a mc c A APPENDIX 1 Storage Standard 1 Place for Storing the Bare Unit a Store the unit on the an indoor concrete floor b The storage place should be free from dust c Do not store the unit near places that may be damp d Do not store the unit near plac
107. f the side gap is too large contact with pistons will be uneven the clutch disengagement position will change and other troubles will occur If it is too small the crankshaft sliding resistance will increase and cranking will become stiff The vaiue of the side gap is the difference between the width of the basic bearing meta and the width of the journal The basic bearing for mode 2GMF Y is the intermediate bearing and for models 3GMFY it is the intermediate bearing at the flywheel end Intermediate bearing metal housing Basic bearing metal AOA5052 806 SM 2GMFY 3GMFY 6 3 2 Measuring side gap Set a dial indicator against the end of the crankshaft or end of the flywheel and measure the amount of movement of the crankshaft in the axial direction If the measured value exceeds the wear limit replace the crankshaft thrust washer Main bearing housing packing of the prescribed thickness must be used Dial indicator Crankshaft Chapter 2 Basic Engine 6 Crankshaft SM 2GMFY 3GMFY Dial indicator Fiywheel 6 3 3 Side gap maintenance standard and wear limit mm fin Maintenance standard Wear limit 0 09 0 19 0 0035 0 0075 6 4 Disassembly of the crankshaft For model 1GM see the chapter on disassembly and reassembly Because there are points over which care must be taken disassembly and reassembly procedures are explained below Crank shaft side gap 6 4 1 Disassembly
108. ft free 3 Remove the switch valve and hydraulic pump assemblies Disassembly of Hydraulic Pump Ass y Hold the pump cover and lightly knock on the pump body with a copper or nylon hammer to disassemble Take care notto damage the joint surface corners of the pump cover and case base Disassembly of Switch Valve Ass y Remove the main unit cover fastening bolts and remove the switch valve The spring and ball will fly out Take care not to lose them 4 Remove the forward reverse shaft rear cover Remove the forward reverse shaft seal ring Remove the output shaft rear cover and the case cover Remove the large gear assembly Remove the forward reverse shaft assembly Forward Reverse Shaft Remove the inner race and thrust collar of the engine side bearing Remove the stop ring and then the pinion ass y can be removed Note To reassemble follow to the disassembly procedures in reverse order Clean all parts completely before reassembly Take care not to catch metal chips and not to damage the seat surface of the aluminum alloy case during reassembly NOW ADA 5052 B06 7 21 Chapter 7 Reduction and Reversing Gear 9 Disassemblyand Reassembly SM 2GMFY 3GMFY 9 2 Disassembly 4 Reassembly Procedures by Model 1 Clutch Case 1 Apply THREEBOND 1215 to the joint surface of the case and flange and tha threads of the emergency bolt before reassembly 2 Apply lithium grease to the oil seal O ring square
109. g bolts and tighten the nuts 3 Install the rocker arm shaft assembly and tighten the in the tightening sequence nut ryi N YE SS FI SSS PO I WI d 4 PES 1 pay BAY UU Flywheei end Gear side Tightening torque 37 kgf m 27 ft Ib Flywheel end Gear side CAUTION 1 Loosen the valve head clearance adjusting screw in advance 2 Check that the arm moves smoothly k gf m ft lb 4 Adjust the intake and exhaust valve head clearance and Main 100723 lock with the nut Tightening torque Sub 25 18 1 Intake and exhaust vaive 0 2mm 0 008in head clearance engine cold 3 Install the water pipe EN 2 22 Install the rocker arm cover from the thermostat cover to the cylinder inlet joint 1 Install the rocker arm cover 2 21 Install the rocker arms 1 Install the push rods on the tappets 2 Install the breather pipe to the air intake pipe intake rnanifotd 3GMF Y AOA5052 JB06 8 17 Chapter 8 Disassembly and Reassembly CA i ee SM 2GMFY 3GMFY 3 Accessaries The following sequence is different from that of a 3 4 Install the intake silencer sea water cooled engine 1 Install the intake silencer cover to the air intake pipe 3 1 Install the starter motor lintake manifold 3GMF Y 2 Install the intake silencer and tighten it with the clip 3 5 Assembie the CFW pump Mount the CFW pump and replace the CFW hose between the CFW pump and cylinder block by connecting at the CFW pump and at t
110. g low speed operation but this is not a problem 2 Shove in the clutch when the engine speed is below 1000 rpm for neutral forward or reverse and also for forward reverse 3 During service operation the oil temp normally stabilizes at 50 80 C However the temp is higher when clutch operation is frequent 4 Check for oil leakage and the oil level from time to time 5 Check for the abnormal sounds and excessive tamp rise When trouble is suspected stop the engine and locate the cause 6 Shift the clutch to neutral before stopping the engine 6 4 Cautions for Single Unit Operation of Twin Eng Twin prop Unit and Towing When the vessel is towed for a long time the output shaft is rotated by the force of the propeller causing the marine gear to be operated without lubrication This can lead to trouble if the vessel is towed for more than one hour or if single unit operation of the twin eng twin prop unit is necessary fasten the propeller shaft to prevent it from turning li this can t be done itis necessary to disassemble and check each part clutch bearing etc after the vessel has been towed to the port 6 5 Cautions during Operation Avoid the use of the clutch for long hours in the range where damper sounds or gear sounds are heard A0A5052 JB06 7 17 Chapter 7 Reduction and Reversing Gear 6 Handling SMIZGMFYI3GMFY 6 6 Emergency Clutch Repair Should there be any trouble in the clutch immediately stop
111. g the rocker arm by hand estimate the pump s sucking power by judging the suction on the finger Although this is not an exact method it can at least confirm that the diaphragm vaives etc are operating Chapter 3 Fuel System 5 Fuel Feed Pump SM 2GMFY 3GMFY 5 3 5 The contact area and mounting condition of valve Test the valve seat as follows Remove the valve and blow into the valve seat from the direction in which the valve spr ing is mounted If air leaks replace the seat with a new one If fuel oil leaks as a result of dust foreign objects etc caught in the valve seat rinse it and clean it by blowing air into it 5 3 6 Diaphragm spring and rocker arm spring Check the diaphragm spring and rocker arm spring for per manent deformation and the rocker arm and rocker pin for wear If any of these components are defective replace them with new ones NOTE When it becomes necessary to replace any of these parts the entire fuel feed pump assembly should be replaced Limit of suction head Fuel oit 5 3 4 Aging breakdown and cracking of the diaphragm Since the diaphragm is constantly in motion the cloth on its flexible parts becomes thin cracked and sometimes breaks down after long periods of use A broken diaphragm causes fuel oil leakage and often fragments of the diaphragm get into the engine oil either seriously hamper ing fuel oil discharge or blocking it altogether Diaphragm AOA
112. he cylinder block Fresh water pump mounting bracket Fresh water pump 2 htening torque for NG C W pump fixing boit 2 25 kgf m 14 8 18 ft Ib 3 6 Install the alternator 3 3 Assemble the high pressure fuel pipe and fuel netah the alternato return pipe 1 Install the alternator to the bracket A0A5052 J806 8 18 Chapter 8 Disassembly and Reassembly 3 Accessaries 2 Install the V belt and tighten the adjusting bolt while ad justing the V belt tension Fresh water pump drive pultey Adjusting bolt V belt tension C W Pump pulley 10kg 22 Ib INN lt Approx 10mm AR Approx 0 3937 in Alternator pulley Crank shaft pulley V belt tension Approx 10mm Pushed with a force of 10kg 22 Ib Approx 0 3937 in ADA5052 JB06 SM 2GMFY 3GMFY 3 7 Assemble the heat exchanger Mount the heat exchanger and replace the CFW hose at the thermostat cover side by connecting the hose to the heat exchanger Tighten the hose clamp after the heat ex changer is assembled Heat exchanger Tightening torque for heat 2 25 kgf m exchanger fixing bolt 14 5 18 ft lb 3 8 Assemble the fuel feed pump 3GMF Y For model 3GMF Y engine assemble the fuel feed pump after the heat exchanger is assembled Fuel feed pump 3 9 Assemble the fuel oil pipe 1 Fuel feed pump fuel filter 2 Fuel filter fuet injection pump Remote control bracket Chapter 8 Disassem
113. he liquid to penetrate for 5 10 minutes If the penetrant fails to penetrate the inspection surface because of the ambient temperature or other condi tions allow it to dry and respray the inspection surface 5 Spray the developer onto the inspection surface After penetration processing remove the residual penetrant from the inspection surface with the cleaner and then spray the developer onto the inspection surface If the inspection surface is flawed red dots or lines will ap pear on the surface within several minutes When spray ing the developer onto the inspection surface hold the can about 30 40cm from the surface and sweep the can slowly back and forth to obtain a uniform film 6 Reclean the inspection surface with the cleaner NOTE Before using the dye penetration flaw detection agent read its usage instructions thoroughly Chapter 2 Basic Engine 1 Cylinder Block 1 3 Measurement of distortion on the upper surface of the cylinder As the cylinder is subjected to thermal expansion and high pressure repeatedly 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 materia differences of the cylinder but may arise from the cylinder head bolts being tightened in the wrong order or an uneven tightening torque of the bolts when assembl ing If there is any distortion at the upper surface of the cylinder it will
114. high precision is required Both are made of quality alloy steel that has been specially heat treated and lapped so they must always be handled as a pair Common parts are used for the fuel valve of models 2GMF Y and 3GMF Y Nozzie spring nut Nozzle spring adjustment shim Packing Nozzle spring Nozzle holder body Nozzle spring seat Inter spindle Nozzle valve Nozzle body Nozzle nut DEDNAUAON ea YDN OSDYD1 Throttle 170 5 kgf cri 2347 2489 Ib in 160 45 kgf cnt 2205 2347 Ib in 21mm 0 0394in 5 10 30 0mm 1 1811in 28 7 mm 1 1299in 14 14 kg 31 17 Ib 0 2mm 0 0079in 0 1mm 0 0039in 0 3mm 0 0118in 0 5mm 0 0197in 3 22 Chapter 3 Fuel System 3 Injection Nozzle 3 3 Yanmar throttle nozzle The semi throttle nozzles used in this engine are designed and manufactured by Yanmar A semi throttle nozzle resembles a pintle nozzte except that with the former the nozzle hole at the end of nozzle and nozzle body are longer and the end of the nozzle is tapered This nozzle features a throttling effect relatively less fuel is injected into the precombustion chamber at the initial stage of injection and the volume is increased as the nozzle rises This type of throttle nozzle ideal for small high speed engines YANMAR semi throttle nozzle Pintle nozzle 3 4 Nozzle operation The nozzle is pushed down to its lowest position by the pr
115. ides with the hole on the small end of the connecting rod 2 After forcing the piston pin bushing into position finish the inner surface of the bushing by using a pin honing machine or reamer so that it fits the piston pin to be used NOTE Attach the bushing to the piston pin so that a pin coated with engine oil can be pushed into position with your thumb 2 38 Chapter 2 Basic Engine 6 Crankshaft 6 Crankshaft 6 1 Crankshaft ass y and bearing construction The crankshaft is stamp forged and the crank pin and jour nal sections are high frequency induction hardened and ground and polished to a high precision finish Therefore the contact surface with the bushing is excellent and durability is superb The crankshaft is a balance weight integral type Engine un 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 case and the governor weight support is fixed with a hexagonal nut together with the crankshaft gear It is so designed that the governor sieeve and the thrust bearing can be slid onto the crankshaft to get the gear side end of the crankshaft to perform as the governor shaft The V pulley is fitted outside the timing gear case and it drives the alternator and cooling water pump SM 2G
116. if corroded broken or otherwise damaged 2 Check joints at sea water inlet and outlet ports and fresh water inlet and outlet ports Retighten any loose screws and clean pipes as required 3 Check drain cock for clogging If clogged clean or repair as required Retighten screws if necessary 4 For inspection of fitler cap anticorrosion zinc and ther mostat see below Leakage test 1 Test with compressed air and test tank Seal fresh and sea water ports with rubber caps and immerse tank in a test tank filled with water Inject compressed air through the overflow pipe and check for air bubbles NOTE Air pressure should be 0 5 20kgf cm 7 11 28 45 Ib in Pressure auge Air hose O gaug ty TI a ET Filler cap o Compressor Overflow pipe Test tank Leakage test using compressed air and test tank 2 Test using pressure tester Seal fresh and sea water ports with rubber caps and fill tank compietely with water Replace the filter cap with a Pressure tester and pressurize the tank If a leak is present the tank cannot be pressurized or it will only be able to retain pressure for a short time Pressure tester Pressure gauge Rubber cap Rubber cap Leakage test using a pressure tester Chapter 6 Cooling System 4 Filler Cap and Subtank 4 Filler Cap and Subtank 4 1 Filler cap construction The filler cap is placed on the fresh water inlet port and is equipped with a pressure control va
117. igned for reduced vibration The outside of the piston is machined to a special oval shape During opera tion thermal expansion is small the optimum clearance between the piston and cylinder liner is maintained and a stable supply of lubricating oil is assured First compression ring Second compression ring Oi ring A Sen Circlip Piston KK Piston pin Circlip A complete set of piston rings consists of two compres sion rings and one oil ring To improve the rigidity of the piston skirt no ring is installed on the skirt itself so that the piston seldom becomes deformed and retains stable contact The piston pin is of the floating type Both its ends are fastened with circlips Grooves called a heat dam are cut round the top section of the piston These grooves help to dissipate heat and pre vent scuffing 4 2 Piston 4 2 1 Inspection 1 Measuring important dimensions Measure each important dimension and replace the piston when the wear limit is exceeded First compression ring groove width Second compression ring groove width Oil ring groove width Piston pin hole inside diameter Piston outside diameter 0 3543in 9mm A0A5052 JB06 2 29 Detail of A heat dam SM 2GMFY 3GMFY ri 5 0 26mm E 5 0 0102in og 1 0mm 0 039din Measuring piston outside diamter 2 Measure the clearance between the piston ring or oil ring and the ri
118. inder distortion In such an event a special tool must be used to withdraw the liner Withdrawl of liner by hand Withdrawl of liner amp using the special tool Cylinder liner puller 2 52 Inserting the cylinder liner Insert the liner by hand after applying oil to the whole of the outside of the liner Tapping with a wooden hammer or something may distort it 2 5 3 Notes on replacing cylinder liner During assembly at the manufacturing plant the inner diameter of the cylinder and the outer diameter of the liner are measured and classified into three categories so that they can be matched and fitted For replacement parts service part the liner with dimensions listed in Notation B in the following table is to be used Chapter 2 Basic Engine 2 Cylinder Liner 1 Classification of outer diameter of cylinder liner mm fin Dimension D 7642010 2 9921 2 9925 785010 2 9917 2 9921 76 9010 00 2 9913 2 9917 Notation ADA5052 JB06 E E amp n t o e To be marked A B or C on outside of liner in major axis direction 2 9 SM 2GMFY 3GMFY Chapter 2 Basic Engine 3 Cylinder Head 3 Cylinder Head 3 1 Construction The cylinder head is an integral two three cylinder type which is bolted to the block The unique Yanmar swirl type precombustion chambers are at an angle in the cylinder head and form the combustion chambers together with the int
119. inder injection timing interval For crankshaft angle 180 540 1 2 1 240 240 240 iv3n2 N1 For camshaft angle 90 270 120 120 120 1321 2 8 5 Delivery valve oil tight test 1 Install a 1 000 kgf cni 14 223 Ib in pressure gauge on the delivery valve holder 2 Drive the fuel pump to apply a pressure of approximately 120 kgf cni 1 707 ib in and measure the time required for the pressure to drop from 100 kgf cm 1 422 Ib in to 90 kgf cm 1280 ib in 20 sec or more 5 sec or less Pressure drop standard Pressure drop limit A0A5052 J806 SM 2GMFY 3GMFY 3 If both the plunger and the delivery valve fail the test replace them 2 8 6 Plunger pressure test 1 Install a 1 000 kgf cm 14 223 Ib in pressure gauge on the delivery valve holder 2 Check that there is no oil leaking from the delivery valve holder and high pressure pipe mountings and that the pressure does not drop suddenly when raised to 500 kgf cm 7 112 Ib in or higher Pressure gauge AVT 1 2 x 150 x 1 000 kgf cm 2 8 7 Measuring the fuel injection volume Chapter 3 Fuel Systern 2 Injection Pump 1 Set the fuel pump camshaft speed By loosening the set bolt and turning the eccentric bolt 2 Check the injection nozzle clockwise the position of the pin moves to the leftside to increase the injection volume and by turning the ec centric bolt counterclockwise the pin mo
120. inder liner diameter 272 2 8345 0 057 0 117 0 0022 0 a nu al O046 Piston outside diameter 272 2 8346 Oylinder liner roundness 0 02 0 0008 2GMFY 3GMFY 271 85 2 8287 0 04 0 0016 A0A5052 JB06 2 7 Chapter 2 Basic Engine 2 Cylinder Liner 2 4 Measuring cylinder liner projection The flange of the cylinder liner projects slightly from the end surface of the cylinder This projection will bed into the gasket packing so as to prevent compression pressure leakage or gas leakage However if the projection is ex cessive compression pressure or gas leakage may occur because the gasket packing is damaged On the otherhand if the projection is insufficient the cylinder liner can not be securely fixed Excessive cylinder liner projection is frequently caused by incomplete removal of the rust at the ledge part A of figure of the cylinder block Cylinder gauge mm fin 0 005 0 075 Cylinder liner projection 0 0002 0 0030 2 5 Cylinder liner replacement 2 5 1 Withdrawl of cylinder liner As the liner used in these engines is especially fitted to the cylinder to ensure constant clearance when assembled it fits closely to the cylinder while running to enable good heat conduction and can be easily withdrawn when the engine is cool However it may prove difficult to withdraw A0A5052 JB06 2 8 SM 2GMFY 3GMFY the liner when there is reduced clearance due to cyl
121. ing elbow from the heat ex changer and is discharged with the exhaust gas Chapter 6 Cooling System 2 Water Pump 2 Water Pump Construclion and operation The water pump is a rubber impeller type pump The rubber impeller which has ample elasticity is deformed by the off set plate inside the casing causing the water to be discharged This pump is ideal for small high speed engines SM 2GMFY 3GMFY ADA5052 JB06 6 3 Chapter 6 Cooling System 2 Water Pump 2 1 Sea Water Pump The sea water pump used for the fresh water cooled engine is the rubber impeller pump it is the same type as used for the sea water cooled engine The same sea water pumps are used for models 2GMF 3GMF and 3HMF these are also the same type as used for the model 3HM sea water cooled engine However in the model 3HMF the pulley ratio is changed to increase the discharge volume 2GMFY 3GMFY Engine speed Max Pulley ratio Crank shaft Pump shaft Pump shaft speed Suction head Total head Delivery capacity 1m 3 28ft 4m 13 12ft Water seal ring Circlip Circlip Ball bearing Collar V pulley Direction of rotation Viewed from pulley side NOTE For details on the disassembly and reassembly handling precautions and inspection refer to Service Manual ADA5052 JB06 SM 2GMFY 3GMFY Cooling water pump cover Oil seal Cooling water pump body Ball bearing
122. iron plate at the bottom of the filler If water is added up to the mouth of the fresh water tank about 50cc of water will overflow from the filler im mediately after the engine is started This is normal and is caused by the increase in the volume of the water as its temperature rises tf the water filler cap is removed after the engine has been stopped and allowed to cool the water level wil be 2 3cm from the top of the filler This is also normal and is caused by the overflow of the unnecessary water as the temperature of the water rises 3 Cooling water fresh water level check Check the level of the cooling water fresh water before daily operation A low cooling water level can cause in sufficient pump discharge and the accumulation of scale in the heat exchanger 4 Cooling water leakage check during operation Although checking for 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 every 500 hours Always use an anti rust agent To drain the water open the cooling water drain cock and remove the water filler cap If the filler cap is not removed a vacuum will be created in the water jacket and all the water will not be drained 6 Removing the filler cap Do not attempt to remove the water filler cap at the top of the fresh water tank while the engin
123. ith a seat grinder 1 Repair pitting of the seat face with a 45 grinder 2 Since the valve seat is larger than the initial value cor rect the seat width to the maintenance standard by grin ding the inside face of the seat with a 70 grinder 3 Grind the outside face of the valve seat with a 15 grinder and finish the seat width to the standard value A0A5052 JB06 SM 2GMFY 3GMFY 4 Mix the compound with oil and lap the valve 5 Finally lap with oil Specified seat width Seat width Before correction After correction A Grind with a 45 grinder B Grind with a 15 grinder C Grind with a 65 v75 grinder NOTE When the valve seat has been corrected with a seat grinder insert an adjusting shim between the valve spring and cylinder head 3 2 7 Measuring valve sinkage When the valve has been lapped many times the valve will be recessed and will adversely affect combustion per formance Therefore measure the valve sinkage and replace the valve and cylinder head when the wear limit is exceeded Depth gauge Chapter 2 Basic Engine A80 UENO end SM 2GMFY 3GMFY Valve seat width Sinkage mm in 2GMFY 3GMFY Maintenance standard Wear limit Valve sinkage 0 95 0 0374 1 25 0 0492 3 2 8 Rocker arm Suppor positioning pin for mode 1GM Check if the guide pin is damaged or if the hole is clogged and replace the pin if faulty 3 3 Dismounting and remo
124. journal outside r Be NA 528 Crank pin outside diameter D Peng BA 18709 Crank journal pin eccentric wear 0 0004 E Crank UT and bushing QUO S 019036 0 0089 Crank pin and crank pin bearing oil clearance our Ag DOG ka 0 0081 Measurement must be taken in at least 2 positions in the direction of crankshaft center line for each journal and in each measurement maximum and minimum wear direc tions must be measured From these results eccentric wear and maximum wear can be determined sis A0A5052 JB06 2 41 Chapter 2 Basic Engine PE Aba SM 2GMFY 3GMFY iate journal 2GMF Y Crahkpin Intermedia e jour N Crank journal Flywheet end Gear case end Crank pin 3GMF Y Crank pin Crank pin Gear case end Crank pin Intermediate journal 3 Measuring the crankshaft bend Measure on a surface plate Place the journal parts of both ends of the crankshaft on a V block and measure with a dial gauge while moving the crankshaft in an axial direction If the deflection of the middle of the crankshaft exceeds the limit replace the crankshaft Journal A0A5052 JB06 2 42 Chapter 2 Basic Engine 6 Crankshaft Dial gauge V btock V block Deflection mm in Maintenance standard Less than 0 015 0 0006 Crankshaft bend 6 3 Crankshaft side gap 6 3 1 Side gap The clearance in the axial direction after the crankshaft has been assembled is called the side gap I
125. linder head of models 3GMF Y Fuel valve retainer S NS e Fuel valve Q O O ring Bush Valve rocker arm support 1 Circli A Heat resistant packing ef cating LI Pre combustion chamber Valve top retainer Washer C3 5 Cotter t T gt Valve spring retainer 7 Valve spring CNS tun ka RA en S amp Valve stem seal E SN A Valve guide o a GA N T PA Side cover ay Exhaust valve A0A5052 JB06 2 12 Chapter 2 Basic Engine 3 Cylinder Head 3 2 Cylinder head inspection and measurement 3 21 Measurement of carbon bulld up at combustion surface and intake and exhaust ports Visually check for carbon build up around the combustion surface and the port near the intake and exhaust valve seats and remove any build up When a large amount of carbon has built up check the top of the chamber combustion for oit flow at the intake and ex haust valve guides and take suitable corrective action 3 2 2 Deposit build up in water passages Check for build up deposit in the water passages and remove any deposit with a deposit remover When a large amount of deposit has built up check each part of the cool ing system 3 2 3 Inspection of corrosion in water passages and anti corrosion zinc inspect the state of corrosion of the water passages and replace the cylinder head when corrosion is severe Corrosion pitting limit 2mm 0 0787in Inspect the anticorrosion zinc on the
126. lve To attach place the rocking tab extension on the attach ment section on the flyneck cam Then turn and tighten The top seal touches the flyneck tap seat while the pres sure valve touches the lower seat Lower seat Overflow pipe Top seat 4 2 Filler cap pressure control Pressure valve spring SS Pressure vaive Rubber seal Pressure valve operation Vacuum valve spring Vacuum valve Vacuum valve operation A0A5052 B06 SM 2GMFY 3GMFY When cooling system pressure is within the specified range 0 9kgf er 12 80 Ib in the pressure valve and vacuum valve are tightly closed on their valve seats When pressure rises the pressure valve opens and vapor is discharged from the overflow pipe When water becomes cool and pressure in the system is lower than the at mospheric pressure the vacuum valve opens and air enters the system through the overflow pipe To prevent the pressure valve from opening and the resulting water loss the cooling ystem can be equipped with a subtank described below Action of Pressure control Valve Opens at 0 9 kgf cnt G 12 80 Ib in Opens at 0 05 kgf cnt G 0 71 Ib in or below Pressure Valve Vacuum Valve 4 3 Filler cap inspection 1 Remove all deposits and rust check for damage and wear on the seat contacting surfaces and check spring for proper functioning Repair or replace as required 2 Tester inspection Attach adaptor and filler cap to
127. lve head clearance of the No 2 cylinder in the same manner after turning the crankshaft 180 In the case of 3GMF Y adjust the valve head clearance on the No 3 cylinder in the same manner after turning the crankshaft 240 and then adjust the No 2 cylinder after turning the crankshaft another 240 NOTE If you adjust the valve head clearance of the No 2 cylinder first turn the crankshaft 540 Adjust the clearance of the No 1 cylinder in the same manner on a 2 cylinder engine Chapter 2 Basic Engine 3 Cylinder Head pA 3 7 2 Adjusting without a feeler gauge Set the head clearance to zero by tightening the adjusting screw being careful not to tighten the screw too tight Then adjust the valve clearance to the maintenance stan dard by backing off the adjusting screw by the angle given below Lock nut Adjusting screw mm in Valve clearance adjusting screw MB x 1 25 0 3149 x 0 0492 Adjusting screw backoff angle Approx 58 NOTE Calculating the backoff angle calculate the 0 2mm advance angle from 1 25mm advance at one turn 360 0 2 1 25 x 360 58 One side 60 of the hexagonal nut should be used to measure 3 8 Decompression mechanism The decompression mechanism is used when the starter motor fails to rotate sufficiently because the battery is weak and to facilitate starting in cold weather When the decompression lever is operated the valve is pushed down the engine is decompressed the engi
128. m O Replace 9 Replace whenever disassembled even within 2 years X Replace depending on the condition of parts Replace bearing at fixed term inspections A0A5052 JB06 7 29 Chapter 7 Reduction and Reversing Gear 9 Disassembly and Reassembly SMI2GMFY 3GMFY 3 Recommended Marine Gear Oil The marine gear oil is used as both the clutch hydraulic oil and lubrication oil The oil Should be stable against temp changes superior in acid and water resisting characteristics and should have no adverse effect on gears friction plates and other materials Recommended Oil Brands Idemitsu Kosan Daphne Marine Oil SX30 Esso Standard Oil Tromer SD30 Caltex R P M DELO Marine Oil 30 Kyodo Oil K yoseki Marine D13 Showa Shell Oil Merina S Oil 30 General Bussan Gemico Marine DX103 Mitsubishi Oil Diamond Marine T 103 Mobile Oil Mobile Guard 312 Nihon Oil MDL Oit U X30 Nichimo Oil Kignas Marine D X30 Cosmo Oil Cosmo Marine 3005 A0A5052 JB06 7 30 Chapter 7 Reduction and Reversing Gear 9 Disassembly and Reassembl M 2GMFY 3GMFY 4 Reduction Reversing Gear Hydraulic Oil Diagram YX 6 Reverse clutch To lubrication of E each part Y el I T4 EN Forward clutch Reverse Forward Q Ya Cs t Ez L O press control valve 7 I c Paan Clutch oil press control valve ZN P Oil pump EN pre ADA5052 JB06 7 31 CHAPTER 8 DISASSEMBLY AND REASSEMBLY 1 Disassembly of Fresh
129. m the end of the nozzle body the nozzle body and the nozzle mounting nut fitting section If reassembled with any carbon remaining the nozzle will not tighten evenly causing faulty injection Boome Doll Chapter 3 Fuel System 3 Injection Nozzle 2 Parts for No 1 cylinder and No 2 cylinder must be kept separate The nozzle body and nozzle must always be handled as a pair 3 Precautions when using a new nozzle First immerse the new nozzle in rust preventive oil and then seal it on the outside with seal peel After removing the seal peel immerse the nozzle in diesel oil and remove the rust preventive oil from both the inside and outside of the nozzle Stand the nozzle holder upright lift the nozzle about 1 3 of its length it shoutd drop smoothly by it own weight when released 4 The nozzle must be assembled to the nozzle holder with the nozzle spring retainer loosened If the nozzle is installed with the nozzie spring tighten ed the nozzle mounting nut will be tightened unevenly and oil will leak from between the end of the nozzle holder body and the end of the nozzle mounting nut causing faulty injection kgf m ft Ib 10 72 36 Nozzle nut Noz2le tightening torque Nozzle spring nut 6055 S789 A0A5052 JB06 SM 2GMFY 3GMFY 5 When instaliing the injection nozzle on the cylinder head tighten the nozzle hoider nuts alternately being careful to tighten them evenly kgf
130. mmn 3 3 9 Disassembly nd Reassmbly 7 22 3 Injection Nozzle l aa 3 22 ACE UCI Filter ci ioca ice eii e ENTIS A Da 3 26 CHAPTER 8 DISASSEMBLY AND REASSEMBLY 5 Fuel Feed Pump non cc 3 27 1 Disassembly of Fresh Water Cooled Engine 8 1 2 Reassembly of Fresh Water Cooled Engine 8 11 CHAPTER 4 GOVERNOR 3 Accessaries nenn AL RL e esas 8 18 1 Governor cessisse ii e eaa d mis enger 4 1 2 Injection Limiter 0 0 cece cece eens 4 8 3 No Load Maximum Speed Limiter 4 9 4 Idling Adjuster aaa 4 10 5 Engine Stop Lever 0 ccc ccc cece ee eee 4 11 CHAPTER 5 LUBRICATION SYSTEM 1 Lubrication System 0 0 00 5 1 2 OIL P mp Ara rro kaha Ng LANG sr ai Sn NAG US 5 5 3 Oll Filter ioo etna es RE RR IER 5 9 4 Oil Pressure Regulator Valve 5 12 5 Oil Pressure Measurement ocean 5 14 A0A5052 JB06 CHAPTER 1 GENERAL 1 Outline ei Shoe mA ETHER RECO SERM v 11 2 Specifications 0 0 ce eee 1 4 3 Principal Construction ee ees 1 5 4 Performance Curves c cece cee eee 1 6 5 Piping Layout 2 cee cece ees 1 8 6 Cylinder Number eene 1 10 Chapter 1 General 1 Outline SM 2GMFY 3GMFY 1 Outline 1 1 Model 2GMFY 2GMFYS Y 5M U asi pipe Sea water inlet 813 4 14 5 hole ipe ael overflow F Petail of Propeller ahoft 482 Alternator 600W o
131. n Opening pressure of delivery valve Approx 16 3 kgf cnf 231 8 ibfin Free length 21 0mm 0 8268in Delivery valve spring 124550 51320 commonly used Spring constant 0 64 kgf cm 9 1 Ib in Approx 15mm 0 5906in Rack stroke A0A5052 JB06 3 6 Chapter 3 Fuel System 2 Injection Pump SM 2GMFY 3GMFY 2 2 2 Injection volume characteristics of fuel injection pump 1 Model 2GMF Y Injection volume mm st 0 UI 1 3 5 7 9 11 13 15 Moving distance of the rack trom the pump body reference face mm 8 6 4 2 0 2 4 6 8 Moving distance of the rack pin from the center of the pump body mm 2 Model 3GMF Y o Ww a z o 25 0 oO E m 10 2 85 5 53 60 2 2 3 50 P f NIN 5 E H 5 i BENE 3 g 2 2 gt E wo S a AZ Rack stop AA 10 1 11 13 15 Moving distance of the rack from the pump body reference face mm 4 6 8 10 12 14 16 18 20 Moving distance of the rack pin from the center of the pump body mm A0A5052 JB06 3 7 Chapter 3 Fuel Systern 2 Injection Pump 2 3 Operation of fuel injection pump The fuel injection pump force feeds the fuel by means of the plunger 1 which operates at a constant stroke Since the plunger is lap fitted into the plunger barrel 2 for super precison it can be replaced only as a set The cylindrical surface of the plunger has an obliquely cut lead
132. nd is locked with wire and sealed with lead Care must be taken to keep the seal from being accidentally broken A0A5052 JB06 4 9 SM 2GMFY 3GMFY Chapter 4 Governor 4 Idling Adjuster 4 Idling Adjuster When controlling the speed with the push pull remote con trol the idling adjustor operates so that the regulator han dle does not move beyond the idling position in order to keep the engine running SM 2GMFY 3GMFY E p dedi Regulator handie m Adjuster bracket 1 When the control lever is in the neutral position set the push pull cable so that clearance C is 1 to Imm 0 0397 0 1181in 2 Take care not to fit the joint in the wrong direction ADA5052 JB06 4 10 Chapter 4 Governor 5 Engine Stop Lever 5 Engine Stop Lever 5 1 Construction With this device governor lever 2 is moved by the cam of the engine stop lever shaft regardless of the position of the regulator lever so as to adjust the fuel control rack and reduce the supply of fuel This device can be remote controlled Taper pin not provided on model 1GM Set bolt Locking screw not provided on model 1GM Lock nut Pulled by remote contro device Cam Spring washer washer Nut Engine stop lever O ring Return spring Fuel control rack Taper pin Governor lever 2 Locking screw Return spring 5 2 Inspection 1 Check for play in the Cam or Taper pin and the engine stop lever
133. nd the big end cap and tighten the bolts until these two marks are aligned 5 5 Connecting rod side clearance After installing the connecting rod on the crankshaft push the rod to one side and measure the side clearance by in serting a feeler gauge into the gap produced at the other side Chapter 2 Basic Engine 5 Connecting Rod The connecting rod boits must also be tightened to the prescribed tightening torque in this case mm in Connecting rod side 0 2 v04 clearance 0 0079 0 0157 5 6 Piston bushing and piston pin The piston bushing is a round copper alloy bushing driven onto the small end of the connecting rod During use the piston pin bushing and piston pin will wear If this wear becomes excessive a metallic sound will be produced and the engine wil become noisy Piston pin bushing Piston pin 3900000090099009900090 20000 RODE Piston pin bushing inside diameter Piston pin outside diameter mm in Maintenance standard Piston pin bushing 2200 220 10 inside 0 7874 0 7913 diameter ando 00250047 on bushing 0 0043 clearance 0 0019 A0A5052 JB06 SM 2GMFY 3GMFY Replacing the piston pin bushing 1 When the bushing for the connecting rod piston pin is either worn out or damaged replace it by using the piston pin extracting tool installed on a press NOTE Force the piston pin bushing into position so that its oil hole coinc
134. ne turns over easily and the flywheet inertia increases thus making starting easy Valve rocker arm Decompression shaft Decompression lever A0A5052 B06 2 26 SM 2GMFY 3GMFY Chapter 2 Basic Engine 3 Cylinder Head SM 2GMFY 3GMFY Ba Decompression shaft Decompression lever 2 e Washer Spring Nut Stee ball C With this engine there is no need to adjust the decompres Pi Nana aaja mao sion lift 3 9 Disassembling and reassembling the cylinder 3 Remove the rocker arm retainer and pull the rocker arm head from the rocker arm support 3 9 1 Disassembling the cylinder head When disassembling the cylinder head group the parts separately according to cylinder intake or exhaust to avoid confusion 1 Disassembling the rocker arm ass y 1 Remove the rocker arm ass y mounting nuts 2 Remove the rocker arm ass y Valve rocker arm support Valve rocker arm A0A5052 806 2 27 Chapter 2 Basic Engine 3 Cylinder Head SM 2GMFY 3GMFY 2 Removing the precombustion chamber 3 9 2 Reassembling the cylinder head 1 Remove the rear precombustion chamber and packing Before reassembling the cylinder head wash all the parts 2 Remove the front precombustion chamber and pack inspect and measure the dimensions of each part and ing repair or replace any parts that are abnormal Be careful not to confuse the parts grouped by cylinder number and in take or exhaust 1 Assembling the intake
135. ng groove with a thickness gauge Feeler gauge Ring to groove clearance Chapter 2 Basic Engine 4 Piston Aa HA Rj jt aaa Maintenance standard Piston outside diameter At right angles to the piston 72 D pin at a point 9 0mm 0 3543in 2 8312 2 8324 from the bottom Piston pin hole inside diameter First compression piston 0 06 0 10 ring to groove clearance Second compression piston ring to groove clearance Oil ring to groove clearance 3 Piston pin outside contact and ring groove carbon build up check if the piston ring grooves are clogged with car bon if the rings move freely and for abnormal contact around the outside of the piston Repair or replace the piston if faulty 4 2 2 Replacing a piston If the dimension of any part is worn past the wear limit or outside of the piston is scored replace the piston 1 Replacement 1 Install the piston pin circlip at one side only 2 Immerse the piston in 80 C oil for 10 15 minutes Piston 3 Remove the piston from the hot oil and place it on a bench with the piston head at the bottom 4 Insert the small end of the connecting rod into the piston insert the piston pin with a rotating motion and install the other piston pin circlip Use wooden hammer if necessary A0A5052 JB06 008 220 0 0 7872 0 7877 0 0024 0 0039 0 035 0 07 0 0014 0 0028 0 02 0 055 0 0008 0 0022
136. o be Replaced Periodically 1 The Maritime Safety Law requires inspection of the following Intermediate Inspection gear face and main thrust bearings Fixed Term Inspection overall disassembly and inspection 2 Rubber parts packings bend washers etc must be replaced after disassembly 3 Replace all parts which are expected to be damaged due to fatigue by the time of the next fixed term inspection In order to prevent trouble we have prepared the following list based on our past experience of repair and parts replacement The list however is only to be used as a standard reference for parts replacement it may also be necessary to replace parts not included in the list depending on the results of the inspection We prepared parts lists with parts numbers by model and are ready to deliver the parts necessary for the intermediate and fixed term inspections immediately upon being advised of the manufacturing number of your marine gear Replacement interval Remarks Item 2 Years 4 Years Square ring Hydraulic cylinder Seal ring Input amp support shafts Packing O ring Oil seal Input amp output shafts Copper packing Damper disc Stop ring Hydraulic cylinder Spring Hydraulic cylinder Friction plate O Forward only Steel plate O Forward only Bush metal Pinion gear Needle bearing Hydraulic oil pump Orudum joint Pump dry sleeve amp pin Hydraulic oil pump Hydraulic oil pump ass y Hydraulic oil pump dmm J
137. oint SIP i Steel pipe RH Rubber hose Lube oil drain pump Exhaust gas pipe Fuel injection valve t Fuel oil return x pa ng cR ires elem Je SS SS SS SS SSS 2 wi Me ie ae gal p Vio Main beding fh RT u bp 4 76x0 zl to Rocker arm 38kSRH L PA Lu NETO exfi Cur Fuel oil filter Fuel oil feed pump Fuel oil inlet Ma ieee AIWOZ LS jnoAe Buidig q w ss n a t RS MMns Lube oil pressure switch Lube oi filter Lube oil pressure Lube oil stainer M Lube oil pump fuel injection pump Cooling water thermostat Cooling fresh water pump Kingston cock t 20058 ngn Sa a Sea water X Cooling sea water pump wuma4bvip Buidig c6 posauay sa dDY AAW DE KAWDE WS HEL Z50S VOW 6 1 Marks of piping paan Lube oil pipe Sea water pipe HE mer oo fesse rien Rubber joint am Rum m Lube oil drain pump p di 4L PAT 2 an YI pir a j Exhaust gas pipe Heb ad l Fuel oil return amp m p13x3TRH Cooling sea water pump v r Fresh water cooler e d a 9 Fuel oil filter KG jnofivT c AAWDE c8 pauar I tajdny Fuel injection valve Lube oil pressure switch Lube oil filter Lube oil p
138. ole of the bolted to the cylinder block flywheel housing the rotary position of the crankshaft can On the crankshaft side of the flywheel is the fitting surface be ascertained in order to adjust tappet clearance or fuel in for the damper disc through which the rotation of the jection timing crankshaft is transmitted to the input shaft of the reduction and reversing gear The reduction and reversing gear is fit ted to the mounting flange The flywheels imbalanced force on the shaft center must be kept below the specified value for the crankshaft as the flywheel rotates with the crankshaft at high speed To achieve this the balanced amount is adjusted by drilling holes in the side of the flywheel and the unbalanced mo ment is adjusted by drilling holes in the circumference 7 1 Specifications of flywheel 2GMFY 3GMFY Outside diameter of flywheel 2252 2 Width of flywheel 53 70 Weight of flywhee Circumferential speed m s 47 5 3600 rpm Speed fluctuation rate EI 3600 rpm 3600 p Allowable amount of imbalance gem 5 30 Allowable moment of imbalance 244 x20 363 20 Pitch circle 150 Fixing part of diameter of bolts damper disc No of bolts x bolt diameter MANIKA eps Pitch circle 41 diameter of bolts Fixing part ot Fit joint diameter 260M7 Model of reduction and reversing gear YX 6 Mounting flange No SAE No 6 in metric unit Center diameter mm 246 38 Ring gear No of teeth Z 97 ADA5052 JB06
139. ooling system diagram Filler cap Mixing elbow ZZ Sea water 1 3 Cooling system configuration With fresh water cooled engines fresh water from the heat exchanger is circulated around the cylinder block and cylinder head The fresh water itse f is cooled by sea water The fresh water pump forces the fresh water through the cylinder block and cylinder head cooling passages and back to the heat exchanger The fresh water is kept in con stant circulation The thermostat is installed at the cylinder head cooling water outlet fresh water pump mounting bracket As the thermostat is closed while the fresh water temperature is low directly after starting engine or when engine load is light fresh water flows through the by pass passage to the suction side of the fresh water pump and circulates A0A5052 JB06 6 2 Heat exchanger SM 2GMFY 3GMFY Cylinder head Fresh water pump Cytinder block Fresh water line inside the engine without passing through the heat exchanger As the fresh water temperature rises the thermostat is opened and fresh water flows into the heat exchanger The fresh water is cooled in the heat exchanger by sea water in the tube So that the fresh water temperature is always kept at the proper degree by the thermostat Sea water is delivered by the sea water pump and fed through tubes located inside the cooling pipe to cool the fresh water Sea water flows into the mix
140. or Suction pipe Chapter 5 Lubrication System 1 Lubrication System SM 2GMFY 3GMFY 1 3 Lubrication oll passage of model 3GMF Y Piston Camshaft gear Crankshaft gear Pressure regulator valve N Suction pipe AN3 Lubricating oil pump drive gear Oil pressure switch Lubricating oil pump Filter ADA5052 JB06 5 3 Chapter 5 Lubrication System 1 dies Lubrication System SM 2GMFY 3GMFY 1 4 Table of capacity for lubricating oil system Pump spend I wm am timin 12 5 Lubricating oil pump Discharge volume 760 kgf cdi 35 05 Discharge pressure Ib in 4267 56 89 Filter capacity bare Lubricating oil filter haa a Discharge pressure m 1 1422 kgf cni 35 05 NEN uibus Standard pressure biin 42 67 56 89 re ri Ol ve durs eie Full open pressure kgf cal 4 Max ib in 56 89 Lubricating oil pressure kgf cnl 02 20 1 alarm switch Ib in 1 422 4 266 Crankcase oil capacity 20 27 A0A5052 B06 5 4 Chapter 5 Lubrication System eee SM 2GMFY 3GMFY 2 Oil Pump 2 1 Construction The oit pump is a compact low pressure variation trochoid pump comprising a trochoid curve inner rotor and outer rotor Pumping pressure is provided by the change in volume between the two rotors caused by rotation of the rotor shaft Outer rotor Niner rotor The lubricating oil pump is installed on the cylinder body at the timing gear case end and its rotor shaft gear is driven
141. or Components Disassembly of reduction reverse gear Procedure illustration I Clutch assembly e Note the numbers stamped on mating surfaces e Remove cotter pin nut and shifter e Note semi circular key ADA5052 JB06 7 5 Chapter 7 Reduction and Reversing Gear 1 Model Y 5M Sectional View SM 2GMFY 8GMFY Procedure Illustration e Straighten lock washer and remove locknut e Remove ball bearing e Remove housing B ncluding locating pin and springs Remove the two clevis pins and swing clevis arms outward Remove ahead and astern friction plate assemblies Remove shifting shaft assenbly et a 1 N OO Mit A0A5052 B06 7 6 Chapter 7 Reduction and Reversing Gear 1 Model Y 5M Sectional View SM 2GMFY 3GMFY Procedure Hlustration e Remove ahead gear 18090 in Remove ahead shaft friction plate assembly and retainer friction disc e Check friction plates and retainer friction disc for damage UKE OGO MA Remove ahead and astern friction plate assemblies Reassembly of clutch ass y Install ahead friction plates and astern friction plates on ahead shaft and astern Cutch assembly gear e Be sure that safety wire pulls in direction in which bolts are tightened e Place friction retainer plate between ahead shaft friction plate assembly and astern gear friction plate assembly ADAS052 JB06 7 7 Chapter 7 Reduction
142. ormal deformation which will occur with thermal expansion Clearance is always kept to within 104 to 304 when assembling by selecting the appropriate liner from the 3 kinds with different dimensions by measurng the inside diameter of the cylinder and the outside diameter of the liner 2 2 Inspection Since the piston and piston rings constantly slide against the cylinder liner while the engine is in operation and side pressure is applied to the cylinder liner by the movement of the crankshaft eccentric wear occurs easily Moreover if lubrication and cooling are insufficient the in ner surface will be damaged or rusted inspect the inner surface and replace the cylinder liner if the surface is noticeably damaged or rusted 2 3 Cylinder liner bore diameter measurement Measure the bore diameter of the cylinder liner with a cylinder gauge at the positions shown in the figure Replace the cylinder liner when the measured value ex ceeds the wear limit Measurements are to be taken in at least 3 positions as shown in the figure namely top middle and bottom posi tions in both directions of crankshaft rotation and crankshaft center line Direction of crankshaft center line Direction of crankshaft rotation AA NG Maintenance standard Clearance at assembly SM 2GMFY 3GMFY Cylinder gauge Position of top ring at T D C Position of cil ring at B D C 2GMF Y 3GMFY mm in 272 10 2 8386 Cyl
143. pe seat angle 90 Dry sieeve type Overhead vaive push rod rocker arm system Round polyurethane sound absorbing type Stamped forging Attached to crankshaft by flange with ring gear Oval type Floating type 2 compression rings 1 oil ring Oil pump Oil filter Oil level gauge Water pump Thermostat Fuel injection pump YPFR 0707 2 Fuel injection valve Fuel strainer Trochoid pump Full flow cartridge type paper element Dipstick Rubber impeller type A Wax pellet type YPFR 0707 590 semi throttle valve Filter paper Centrifuga all speed mechanical type Pinion ring gear type starter motor Camshaft starting Alternator with built in 1C regulator 1 5 Chapter 1 General 4 Performance Curves SM 2GMFY 3GMFY 4 Performance Curves 4 1 2GMFY SPECIFIC FUEL CONSUMPTION AT FLYWHEEL OUTPUT DIN6270B rating 5 1200 1600 2000 2400 2800 3200 3600 pm THE ENGINE FLYWHEEL OUTPUT IS APPROX 3 HIGHER AO0A5052 JB06 Chapter 1 General 4 Performance Curves SM 2GMFY 3GMFY 4 2 3GMFY SPECIFIC FUEL CONSUMPTION AT FLYWHEEL OUTPUT DIN6270B rating OUTPUT MEASURED AT THE PROPELLER SHAFT 4 1200 1600 2000 2400 2800 3200 3600 rpm THE ENGINE FLYWHEEL OUTPUT IS APPROX 3 HIGHER ADA5052 JB06 1 7 Marks of piping Fuel oil pipe Lube oil pipe rer E Sea water pipe Fresh water pipe Drilled hole HES CS0S VOY TIRE o Rubber j
144. pted in which the cooling water does not come into derect contact with the external surface of the liner SM 2GMFY 3GMFY Dry liner type Liner Cylinder body Water jacket The cylinder block is a high quality cast iron casting with integral cylinders and deep skirt crankcase construction As a result of stress analyses the shape and thickness of each part has been optimized and special ribs employed which not only increase the strength and rigidity of the block but also reduce noise ADA 5052 JB06 2 1 Chapter 2 Basic Engine 1 Cylinder Block SM 2GMFY 3GMFY 1 1 1 Cylinder of model 2GMFY engine Cylinder liner Non chrome plated Drilied hole for cooling water ae NM A O CU Cylinder body Camshaft hole Cup plug Screwed hole tor cooling water joint Gear case side Crankshaft hole Cast hole for lubricating oil 1 1 2 Cylinder of model 3GMFY engine Cylinder liner Non chrome plated wi Drilled hole for cooling water PL Cytinder body Camshaft hole Screwed hole for cooling water joint Gear case side Crankshaft hole Cast hole for tubricating oil ADA 5052 JB06 2 2 Chapter 2 Basic Engine 1 Cylinder Block p UU e c DjmDQ V E O EE nint a 1 2 Cylinder block inspection 1 2 1 inspecting each part for cracks If the engine has been frozen or dropped visually inspect it for cracks and other abnormalities before disassembling If there are
145. ption A0A5052 JB06 1 1 908 cS05 VOV ci Exhaust bend Neutral Ahead Asien N Y Fail oil inlet pipe nk 283 2173 Sea water inlet pipe 2113 Petail of B NS A SAJWOE AdINDE ISPOIN Z L aunng I josauay I 13 ADYQ KAWDE AAWIE WS HEL 7505 VOY Petaii of Propeller ahoft 495 Alternator 600W option 1 Fuel oil inlet pipe 283 _ Sea water Sea water inlet pipe BI Installation plate Petail of B 9 XA SAAWDE AdWOE IePOIN L QR M I M n aumno I 1042uar I Aajdoy AAWIEAAWIE WS Chapter 1 General 2 Specifications SM 2GMFY 3GMFY 2 Specifications Model 2GMFY 3GMFY Type Vertical 4 cycle water cooted diesel engine Combustion chamber Swirl pre combustion chamber Number of cylinders EXC EDAD 3 Bore x stroke mm 72x72 Displacement He 0 586 0879 OutputiCrankshaft speed 18 3200 neers Brake mean effective pressure 5 76 Piston speed 7 68 Output crankshaft speed 21 3400 Coie ot DING2 06 Brake maan effective pressure 6 32 Piston speed misec 8 16 Compression ratio d i 23 0 Fuel injection timing FID degree bTDC15 1 bTDC18 t Fuel injection pressure 18045 Main power take off RS at Flywheel side Front power take off Crankshaft Propeller shaft A head Direction
146. r 8 Disassembly and Reassembly l 1 Disassembly of Fresh Water Cooled Engine SM 2GMFY 3GMFY 1 22 Remove the injection pump 1 Disconnect the lubricating oil pipe 1 Remove the injection pump nut 2 Remove the cylinder head nuts in the prescribed order 2 Remove the gear case side cover move the governor and remove the cylinder head lever 2 take out the fuel injection pump by matching the 3 Remove the gasket packing control rack with the cut off part of the gear case 1 20 Remove the cylinder head NOTE Clearly identify the front and back of the gasket packing 1 21 Remove the crankshaft pulley Remove the crankshaft pulley end nut and remove the V pulley and key 3 Remove the injection timing adjustment shims CAUTION Note the number and total thickness of the timing adjustment shims 1 23 Remove the timing gear case 1 Remove the gear case 2 Remove the thrust collar thrust needle bearing and governor sleeve A0A5052 JB06 8 7 Chapter 8 Disassembly and Reassembly 1 Disassembly of Fresh Water Cooled Engine SM 2GMFY 3GMFY 1 25 Remove the flywheel 1 27 Remove the lubricating oil dipstick Screw in the two boits to secure the clutch disk slightly 1 28 Remove the feed pump to the left and right sides of the flywheel and remove it by pulling on the bolts 1 29 Remove the fuel cam Remove the camshaft end nut and remove the fuel cam A0A5052 JB06 8 8 Chapter 8 Disassembly and Reass
147. r corroded 6 Impeller clearances Thickness gauge mm in Maintenance standard 0 3 1 1 0 0118 0 0433 Clearance between impelier and body Clearance between impeller and bracket 0 5 0 0197 To measure clearance between impeller and body in sert thickness gauge between the two parts at an oblique angle To measure clearance between impeller and bracket place a straightedge on the pump body surface and insert a thickness gauge between the straightedge and impeller A0A5052 JB06 6 10 Chapter 6 Cooling System 3 Heat Exchanger 3 Heat Exchanger 3 1 Construction Filler cap with pressure relief valve Heat exchanger body X Cooling tube cover N Fresh water outlet to fresh water pump Sea water inlet from sea water pump The heat exchanger cools the fresh water which has reach ed a high temperature circulated in the cylinder block by sea water The heat exchanger is a cooling tube which consists of 24 slender tubes and baffle plates and a cooling tube cover Sea water passes through the slender tubes and fresh A0A5052 JB06 SM 2GMFY 3GMFY Sea water outlet to mixing elbow Fresh water inlet from cylinder head Drain cock water passes through the flow path formed outside of the tubes and baffle plates inside the cooling tube cover The lower part of the heat exchanger stores the fresh water acting as a fresh water tank There is an exhaust gas
148. r position shim 8 Delivery valve spring holder 9 Delivery valve spring 10 Delivery valve 11 Delivery vaive holder 12 Delivery valve packing 13 Body 14 Plunger barrel 15 Plunger barrel packing 16 Fuel control rack 17 Plunger spring retainer 18 Plunger 19 Plunger spring lower retainer 20 Plunger guide 21 Plunger guide roller outer 22 Plunger guide roller inner 23 Plunger guide roller pin A0A5052 B06 3 5 Chapter 3 Fuel System 2 Injection Pump SM 2GMFY 3GMFY 2 2 Specifications and performance of fuel injection pump 2 2 1 Specifications of fuel injection pump 2GMFY 3GMFY 6mm 0 2362in 7mm 0 2756in 2 5mm 0 0984in at starting 3 2mm 0 1260in Piunger diameter Standard plunger stroke Static mechanical lift at injection Sliding resistance of fuel volume adjusting rack when pump stops Top clearance of plunger at the set dimension of 76 0 05mm Thickness of plunger position adjusting shim Free length Spring constant At upper limit At lower limit 609 0 002 Ib or less 1 0mm 0 0394in 0 1mm 0 0039in 0 2mm 0 0079in 0 3mm 0 0118in 35 5mm 1 3976in 1 93 kgf cm 10 8 Ib in 25 1 kg 5533 Ib 11 6 kg 25 6 Ib Plunger spring 124950 51190 commonly used Load At static injection 16 4 kg 36 2 Ib Suction volume of delivery valve 23 5mm 0 0014i
149. r than the standard value probable causes are 1 Clearance of lubricated bearings in the lubricating oil cir cuit is too large Shaft or bearing is worn 2 Excessive oil escaping from rocker arm support Therefore inspection and repair of the bearings and rocker arm support are required A0A5052 JB06 5 14 SM 2GMFY 3GMFY CHAPTER 6 COOLING SYSTEM t Coolling System cece ala 6 1 2 Water Pump ea den 6 3 3 Heat Exchanger cece eee eee nnne 6 11 4 Filler Cap and Subtank aaa 6 15 5 Thermostat 2 2 nna NG eed exe nere ente 6 17 6 Coolling Water Temperature Switch 6 20 T PRECAUTIONS u roO pa eee Le CH EIE 6 21 8 Kingston Cock Optional 0 cee ee eee 6 23 9 Bilge Pump and Bilge Strainer Optional 6 24 A0A5052 JB06 Chapter 6 Cooling System 1 i 1 Cooling system 1 1 Cooling System Models 2GMFY 3GMFY are constructed from different parts but use the same water flow The illustrationbelow is of model 3GMFY Filler cap with pressure control valve Gh Overflow pipe cx NE 4 UN ng Heat exchanger db NG Sub tank no d 2 Q SEC oa cylinder By pass flow a Fresh water pump NG Cylinder block f y SZ Ga e To cylinder block Kingston cock option N 4m Fresh water C Sea water ct Inlet and outlet for water heater A0A5052 JB06 6 1 Chapter 6 Cooling System 1 Cooling System 1 2 C
150. reases When this No injection Asa result of the above action the plunger is rotated by the fuel control rack and the angle of this rotation changes the effective stroke of the plunger and controls the discharge of the pump Also when the fuel control rack iines up the longitudinal groove on the plunger with the oil hole the oil hole does not close despite the rise of the plunger but rather the fuel is driven back to the suction chamber As a result the fuel is not force fed but the amount of injection is reduced to zero At this time the fuel control rack is at the cylinder side end when it reaches the opposite side end the maximum amount of fuel is injected Before the maxi mum injection level is reached the fue injection controi shaft regulates the amount of fuel injected to the normal operation level NOTE The plunger is an integral part of the plunger barrel and takes in and compresses fuel by reciprocating inside the plunger barrel The plunger and plunger barrel are precisely machined and because the plunger is driven in an extremely small space the two should be used together and should not be changed with other cylinders 2 3 2 Action of the delivery valve and the sucking back of ue The delivery valve on top of the plunger prevents the fuel within the injection tube from flowing backward toward the plunger side and also serves to suck back the fuel to pre A0A5052 JB06 Half injection 3 9 SM 2GMFY 3GMFY
151. ree length A 38 5 1 5157 Since inclination of the valve spring is a direct cause of Allowable tilt value B A is less than 0 035 eccentric contact of the valve stem always check it at disassembly 2 Valve spring free length Stand the valve upright on a stool and check if the entire Measure the free length of the valve spring and replace spring contacts the gauge when a square gauge is plac the spring when the wear limit is exceeded ed against the outside diameter of the valve spring If there is a gap between the gauge and spring measure the gap with a feeler gauge When the vaive spring inclination exceeds the wear limit replace the spring A0A5052 JB06 2 20 Chapter 2 Basic Engine 3 Cylinder Head Also measure the tension ot the spring with a spring tester If the tension is below the prescribed limit replace the spring KA pd 37mm 1 4567in 1 5157in 29 2mm 1 1496in 16 16kg 35 631b attached 137kg applied 30 201b attached 3 4 4 Valve stem seal A0A5052 JB06 SM 2GMFY 3GMFY A valve stem seal is assembled at the top of the valve guide and the valve stem chamber oil is sucked into the combus tion chamber through the valve guide oil down to prevent an increase in oi consumption The vaive stem seal must always be replaced whenever it has been removed When assembling coat the valve stem with engine oil before inserting Valv
152. ressure regulating valve Lube oil stainer w N x Lube oil pump Fuel injection pump Cooling water thermostat Cooling fresh water pump 276x07STP Kingston cock m Exhaust manifold Msn Sea water d Fuel oil feed pump fuel oil inlet AAW DE KAWDE WS Chapter 1 General 6 Cylinder Number 6 Cylinder Number The cylinder numbers of the 2 cylinder engine 2GMFY and 3 cylinder engine 3GMF Y described in this manual are designad as follows Flywheel 1 The sequence of cylinder numbers is given as No 1 No 2 and No 3 starting from the flywheel side 2 These cylinder numbers are consistently used for devices and parts connected with the cylinder head and valve moving mechanism However please note that items related to the fuel injection pump do not correspond to the numbering of the cylinders A0A5052 JB06 1 10 SM 2GMFY 3GMFY A0A5052 JB06 CHAPTER 2 BASIC ENGINE 1 Cylinder Block cles ne 2 1 2 Cylinder Linar s secre rec IR 2 7 3 Cylinder Head acrana 2 0 die ad 2 10 4 PISIOn an anne ana 2 29 5 Connecting Rod aaa 2 35 6 Grankshaft AA 2 39 7 Flywheel and Housing aa 2 50 8 Camshaft ix ise beet vibe a e ry b HERES T 2 53 9 Timing Gear 22cm ea ede NAG Ba Eee eee ng 2 59 Chapter 2 Basic Engine 1 Cylinder Block 1 Cylinder Block 14 Construction For models GM Series engine the dry liner construction is ado
153. ric boit which is integrated with the locking pin of the plunger barrel and changes the position of the plunger barrel When the plunger barret is turned the relative position of the suction hole with respect to the lower lead of the plunger changes the injection volume Eccentric bolt Locking pin of plunger barrel Set bolt Increase Decrease ADA5052 JB06 3 21 Chapter 3 Fuel System 3 Injection Nozzle 3 Injection Nozzle 3 1 Construction The injection nozzle atomizes the fuel sent from the injec tion pump and injects it into the precombustion chamber in the prescribed injection pattern to obtain good combustion through optimum fuel air mixing The main parts of the injection nozzle are the nozzle holder and nozzle body Since both these parts are exposed to hot combustion gas they must be extremely durable Moreover since their operation is extremely sensitive to Nozzle spring nut Packing Nozzle spring adjustment shim Nozzle spring Nozzle spring seat Inter spindle Nozzle hoider body ee Nozzie valve Nozzle body Nozzle nut 3 3 2 Specifications for nozzle valve Type of nozzle valve Vaive opening pressure Type of nozzle vave NOn Valve opening pressure Angle of injection Nozzle spring Mounted toad Mounted load Nozzle spring adjusting plate for adjusting nozzie opening pressure A0A5052 JB06 SM 2GMFY 3GMFY the pressure of the fuel
154. ring and seal ring 3 The three bolts at the bottom of the case are made of stainless steel 2 input Shaft Support Shaft 1 Calk the stopper rings of the input shaft and support shaft 2 pcs for each 2 Adjust Shim Thickness Input shaft 0 05 0 05 Support shaft 0 05 0 05 3 Apply lithium grease to the damper disc spline and end seal Fill the lithium grease in the damper disc cap up to 40 of its space A0A5052 JB06 Bolt with collar M8 Torque 210 2047 cm Rock washer x Measure 30 min later after stop ing Stick full oil lever stick Cover for Lube oil supply Stainless steel bolt M8 x 25 ME Torque 210 20kg cm Straight pin Plug PT 3 4 Packin pne plug Plug PT 1 8 for babe SER lube oil pressure check d Rock washer Rua Bolt with coliar M8 Rear cover Torque 2107 TOng com ackin Rock washer js Bolt with collar M8 amp o Torque 210 Ukg cm ver Plug M12 xa Bolt with collar M8 Torque 2104 10kg cm Cover tor Strainer Pinion with bush Friction disc Steel plate Na Thrust collar B Circtip Urgent bolt Torque 190 10kg om Apply 1215 screw 7 22 Chapter 7 Reduction and Reversing Gear 9 Disassembly and Reassembly SM 2GMFY 3GMFY 3 Output Shaft 1 Calk the finger nut stopper of the input shaft after tightening 2 Adjust Shim Tightening Margin Input shaft O 0 1 3 Take care not to reverse the oil
155. s no oil leakage Since the viscous pump action will be lost if the lip of the seal is coated with grease coat the lip with oil when assembling 4 Insert the oil seal with a press However when unavoidabie the seal may be installed by tapping the en tire periphery of the seal with a hammer using a block In this case be careful that the oil seal is not tilted Never tap the oil seal directly GOOD Block Housing BAD Cz Housing u ba m Chapter 2 Basic Engine 7 Flywheel and Housing SM 2GMFY 3GMFY a 7 Flywheel and Housing The function of the flywheel is through inertia to rotate the The ring gear is shrink fitted onto the circumference of the crankshaft in a uniform and smooth manner by absorbing flywheel and this ring gear serves to start the engine by the turning force created during the combustion stroke of meshing with the starter motor pinion the engine and by compensating for the decrease in turn The stamped letter and line which show top dead center of ing force during the other strokes each cylinder are positioned either on the flywheel at the The flywheet is mounted and secured by 5 bolts on the crankshaft side or at the side of the reduction and reversing crankshaft end at the opposite end to the gear case it is gear and by matching these marks with the arrow mark at covered by the mounting flange flywheel housing which is the setting hole of the starter motor or at the h
156. s or cracks on the con tact surface of the tappet In such cases discover the reason for abnormality and replace the tappet 8 6 Push rods The push rods are sufficiently rigid and strong to prevent bending Place the push rod on a stool or flat surface and measure the clearance between the center of the push rod and the flat surface and replace the push rod if the wear limit is ex ceeded Feeler gauge A0A5052 JB06 2 57 SM 2GMFY 3GMFY Check both ends for wear and peeling and replace the push rod if faulty mm in Push rod bend Push rod length 8 7 Fuelcam 8 7 4 Fuel cam check The fuel cam is separate from the intake and exhaust valve cams and is secured to the camshaft together with the camshaft gear by a key The cam drives the fue pump The fuel cam like the intake and exhaust valve cams is ground finished after being quenched Therefore it is almost free from wear However if step or eccentric wear is found to be excessive replace the cam Fuel cam 26 0 01 Cam height mm in Maintenance standard 1 7717 8 7 2 Fuel cam assembly precautions Install the fuel cam by aligning it with the key of the cam shaft If the installation direction is not correct the fuel in jection timing will be considerably off and the engine will not start When assembling the fuel cam be sure that the O mark side of the cam is opposite the camshaft gear Fuel cam height
157. s up and down with the rotation of the cam and opens and closes the intake and exhaust valves with the pushrod and rocker arm During high speed operation the cam surface is exposed to a strong force of inertia from moving valves and spring load and comes in to contact with the tappet at high surface pressure Therefore to reduce wear the surface is tempered by high frequency hardening as well as a cam form selected to decrease the force of inertia Since the in take and exhaust cam profile of this engine is a parabolic acceleration cam with a buffering curve movement of the valve at high speed is smooth improving the durability of the intake and exhaust valve seats A0A 5052 JB06 2 53 SM 2GMFY 3GMFY The camshaft on models 2GMF Y does not have an intermediate bearing however the camshaft on models 3GMFY is supported by two intermediate bearings in order to avoid deflection of the camshaft The fuel cam is separated from the camshaft in ail engine models and it is inserted into the camshaft together with the camshaft gear by matching the key and slot and is fixed by an end nut The cam for the fuel feed pump is integrated with the cam shaft and it is machine finished The cam is located between the intake and exhaust valve cams of No 1 cylinder at the flywheel end in all engine models Chapter 2 Basic Engine 8 Camshaft res SU 2GM FY 3GMFY No 1 exhaust valve cam 8 1 1 Camshaft of engine model 2GMF Y Pin Fu
158. side and outside and roller pin for damage and uneven wear and replace if required Measure the clearance between the plunger and plunger guide f the clearance exceeds the limit replace mm in Clearance limit 0 3 0 0118 2 6 Assembling the fuel injection pump NOTES 1 After inspection divide the components into two groups i e the components to be replac ed and those that are reusable Rinse the com ponents and store the two groups separately 2 Replace the packing with a new one Chapter 3 Fuel System 2 Injection Pump SM 2GMFY 3GMFY 2GMFY 3GMFY 1 install the No 1 plunger barre packing To ensure that the injection pump is correctly reassembled 2 Insert the No 1 plunger barrel by aligning the groove of the following points must be kept in mind the barrel lock pin The parts for each cylinder must not be mixed together When parts are replaced the parts for each cylinder must always be replaced at the same time When assembling parts must be washed in fuel oil and matching marks and scribe lines must be lined up 3 Install the No 1 delivery valve delivery valve seat and packing NOTE If the delivery valve tip projects noticeably above the top of the main unit of the pump the plunger barrel has been installed incorrectly and must be re attached 4 Insert the No 1 delivery vaive spring A04A5052 JB06 3 15 Chapter 3 Fuel System 2 Injection Pump SM 2GMFY 3GMFY 5b Tigh
159. speed Instant speed regulation Stabilization time Stabilized speed regulation Fluctuation of rotation 1026 or less 10 sec or less 596 or less 40 rpm or less Instant speed regulation di jr x 100 ns nr nr bud Stabilized speed regulation ds ni Instant maximum minimum speed The maximum or minimum engine speed which is momentarily reached immediately after the load has been suddenly changed from the rated load to another load or from an arbitrary load to the rated load ns Stabilized speed The speed which is set according to the lapse of time after the load has been changed from a rated load to another load or from an arbitrary load to the rated load A0A5052 JB06 Decrease Increase Pivot point stabilized at the point at which the force produced by the governor weight is balanced with the load of the regulator spring connecting the regulator lever and fuel control lever When the speed is reduced by application of a load the force of the regulator spring pushes the governor sleeve in the fuel increase direction stabilizing the engine speed by changing the position of the regulator lever Fuel control rack Fuel injection pump Governor lever 2 Em Crankshaft gear Pivot point Centrifugal force Governor lever 1 nr Rated speed ts Stabilization time The time it takes for engine to return to the set speed after a
160. ss y 1 For model 2GMFY Position the cylinder head ass y parallel to the top of the cylinder block and install the ass y on the block being threads of the cylinder head bolts Flywheel end Gear side Cooling water E passage cylinder side P hole is drilled co Keep the surface Pil asc marked TOP upward cylinder head side Cooling water passage cylinder side hole is cast 2 For models 3GMF Y Cooling water passage cylinder side hole is cast Flywheel end Cooling water passage cylinder side hole is drilled Keep the surface marked TOP upward cylinder head side 40A5052 JB06 2 16 careful that the cylinder head ass y does not touch the Chapter 2 Basic Engine 3 Cylinder Head 3 3 2 Tightening the cylinder head bolts and nuts DKinds of cylinder head fixing nuts and bolts tightening torpue tihteining sequence 1 Model 2GMFY Flywheel end Tightening sequence Kinds offing Da SM 2GMFY 3GMFY Gear side Tightening Torque 10 kgf m 72 3 ft Ib Stud bolt fixing nut M12 0 4724in Auxiliary tap bolt M8 0 3150in 2 Models 3GMF Y Flywheel end Tightening sequence 1 2 3 4 5 6 7 8 9 10 11 2 Cylinder head nut tightening sequence 1 Coat the threads of the cylinder head bolts with lubricating oil and screw the cylinder head nuts onto the bolts Stud bolt fixing nut M12 0 4724in Auxiliary tap bolt
161. stem 2 Injection Pump 11 Insert the plunger shim NOTE Insert the same number of shims with the same thickness as those inserted before disassembling the pump After re assembling the pump measure and adjust the top clearance of the plunger 12 Insert the No 1 plunger guide 13 Insert the No 1 plunger guide stopper 14 For the pump of the 2 cylinder type engine repeat the above steps for No 2 cylinder t5 For the pump of the 3 cylinder type engine repeat the above steps for No 3 cylinder 16 install the plunger guide stopper pin 17 After attaching tighten the delivery valve holder with a torque wrench kgf m ft Ib Tightening torque 4 0 45 28 92 32 54 NOTE When the tightening torque of the delivery valve holder exceeds the prescribed torque the plunger will be distorted the sliding resistance of the con trol rack will increase and proper performance will not be obtained Moreover excessive tightening will damage the pump body and delivery valve gasket and cause a variety of other problems 2 7 Inspection after reassembly When the engine doesn t run smoothly and the injection pump is suspected as being the cause or when the pump has been disassembled and parts replaced always con duct the following tests 2 7 1 Control rack resistance test After reassembling the pump wash it in clean fuel move the rack and check resistance as follows 1 This test is performed to determine
162. t to fresh water reservoir Cooling pipe cover Fresh water inlet from cylinder head Sea water enters the side cover at the sea water inlet side passes through 8 tubes guided by the side cover ribs and then enters the side cover at the sea water outlet side Here it passes through another 8 tubes guided by side cover ribs and returns to the side cover at the inlet side At the inlet side it is guided by the remaining 8 tubes as at the outlet side and then flows out to the mixing elbow from the outlet connection via the side cover at the outlet side 2GMFY 3GMFY 15 3600 22 5 3600 26 08 x 24 0 163 Chapter 6 Cooling System 3 Heat Exchanger 3 4 Disassembly 1 Remove the side covers and puli out cooling pipe and rubber packings NOTE After cooling pipe is removed always replace the rubber packings on both side covers 2 Remove filler cap and port 3 Remove lower cover and packing Heat exchanger body Cooling tube ass y Side cover O ring 3 5 Inspection and cleaning Cooling pipe 1 Inspect for dirt and deposits in the tubes Clean as re quired 2 Inspect caulked portions of tubes and flanges for damage Repair or replace as required 3 Inspect the cooling pipe and tubes for leaks Repair as required 4 Check for clogged water passages Clean as required A0A5052 B06 Heat exchanger body 1 Check for dirt and corrosion build up inside body and on side covers Replace
163. t as the oil Clearance 2 Measurement precautions 1 Be careful that the Plasti gauge does not enter the crank pin oil hole 2 Be sure that the crankshaft does not turn when tighten ing the connecting rod boit 5 3 3 Crank pin bushing replacement precautions 1 Thoroughly clean the crank pin bushing and the rear of the crank pin bushing 2 Also clean the big end cap and install the crank pin bushing and check if the bushing contacts the big end cap closely 3 When assembling the connecting rod match the number of the big end section and the big end cap coat the bolts with engine oil and alternately tighten the bolts gradually to the prescribed tightening torque If a torque wrench is not available put matching marks tor que indication lines on the bolt head and big end cap before disassembly and tighten the bolts until these two lines are aligned Alignment mark Punched mark ADA 5052 JB06 2 37 SM 2GMFY 3GMFY Matching mark 4 Check that there is no sand or metal particles in the tubricating oil and that the crankshaft is not pitted Clean the oil holes with particular care 5 4 Tightening the connecting rod bolts When tightening the connecting rod bolts coat the threads of the bolts with engine oil Tighten the two bolts alternately and gradually to the prescribed tightening torque If a torque wrench is not available make matching marks torque indication lines on the head of the bolt a
164. talled so that the gaps are 120 apart At this time be careful that the ring gap is not lin ed up with the piston side pressure part Direction of side pressure Gap position of No t compression ring Gap position of oil ring ADA5052 JB06 2 33 Chapter 2 Basic Engine 4 Piston SM 2GMFY 3GMFY 5 Since the oil ring is equipped with a coil expander at tach it to the piston so that the joint of the ring is opposite the gap of the coil expander TS PA sia Iiia aa oo y gt Q Q Joint of coil expander A0A5052 JB06 2 34 Chapter 2 Basic Engine 5 Connecting Rod 5 Connecting Rod 5 1 Connecting rod ass y construction The connecting rod connects the piston pin and crank pin and transmits the explosive force of the piston to the crankshaft It is a stamp forging designed for extreme lightness and ample strength against bending A kelmet bushing split at right angles is installed to the large end of the rod and a round copper alloy is pressed onto the small end Connecting rod Crank pin bushing Connecting rod bolt 5 2 Inspection 5 2 1 Large and small end twist and parallelity A0A5052 JB06 2 35 SM 2GMFY 3GMFY Pass a test bar through the large end and small end holes of the connecting rod place the bars on a V block on a stool and center the large end test bar Then set the sensor of a dial indicator against the small end test bar and measure twist and parall
165. ten the No 1 delivery valve holder 8 Insert the No 1 plunger spring retainer and attach the plunger spring to the main unit kgf m ft Ib Plunger spring Tightening torque 4 0 4 5 28 92 32 54 Plunger NOTE Tighten the delivery valve holder with a torque spring retainer wrench after attaching the plunger and while check ing the fuel control rack for sliding motion 6 With the matching mark of the fuel control rack directed towards the tower part of the main unit of the pump attach the fuel contro rack to the main unit NOTE Make sure the fuel control rack moves smoothly along its entire stroke 7 By aligning the matching mark on the fuel control pi NOTE The plunger spring retainer should face the under nion with that on the fuel control rack attach the fuel side the pump control pinion to the main unit 9 After aligning the matching mark on the plunger fiange 2GMF Y with that on the fuel control pinion attach the plunger Punched mark to the main unit w IP j Matching marks Red tine Punched mark it 3 Red line Plunger NOTE After attaching the fuel control pinion to the main unit check its meshing by moving the fuel control rack NOTE By inverting and standing the main unit of the pump upright attach the plunger to it carefully 10 instal the No 1 plunger spring lower retainer Make sure that it is not installed backwards ADA5052 JB06 3 16 Chapter 3 Fuel Sy
166. ter 232 1 2598 Exhaust valve diameter 226 1 0236 Valve seat width 3 15 0 1240 Valve seat angle 90 NOTE Note that the intake valve and exhaust valve have a different diameter mm in Maintenance standard Wear lirnit Valve 0 75 1 15 thickness 0 0295 0 0453 2 Valve stem bending and wear Check for valve stem wear and strain and repair when such damage is light Measure the outside diameter and bend and replace the valve when the wear limit is ex ceeded mm in Wear limit 26 9 0 2717 Valve stem bend A0A5052 JB06 0 03 0 0012 Chapter 2 Basic Engine 3 Cylinder Head 3 Valve seat hairline cracks Inspect the valve seat by the color check and replace the seat if cracked 3 4 2 Inspecting and measuring valve guides The same valve guide is used both for intake and exhaust valves in the model 1GM engine t has a gas blow opening cut in the inner face at the bottom The valve guide is different for the intake valve and exhaust valve in that the inner face of the exhaust valve guide has a gas blow opening cut Be sure that the correct one is used when replacing the guides Exhaust valve guide Intake valve guide Valve guide inside diameter Gas cut 1 Floating of the intake and exhaust valve guides Check for intake and exhaust valve guide looseness and floating with a test hammer and replace loose or floating guides with guides having an oversize outsid
167. the engine and provide proper measures as described in the Section on Troubleshooting If the trouble can t be repaired tighten the emergency bolt no emergency bolt for the reverse clutch with the accessory tool to connect to the clutch to enable the vessel to reach a port Steel plate Stop ring Friction plate Stop plate Square ring Emergency bolt Hydraulic cylinder Square ring S SCARE Me xtA AN a FR STH bak Wa v Em 8 EN Ne Remove this plug painted red and insert the wrench for use of the emergency bolt A0A 5052 JB06 7 18 Chapter 7 Reduction and Reversing Gear 7 Service Standard SM 2GMFY 3GMFY Handling of Emergency Bolt 1 Stop the engine and remove the hexagon plug with packing of the case plate 2 Turn the flywheel to the position where the emergency bolt can be seen from the bolt hole 3 Insert the accessory wrench into the hole and tighten the emergency bolts Tighten the two emergency bolts evenly The clutch is moved into forward by tightening the bolts 4 Install the plug which was remove to tighten the emergency bolts 5 After the clutch is connected the vessel will move ahead when the engine is started Be sure to shift the switch valve handle into neutral or forward Operate the vessel with care since no halting or reversing is possible Operate the engine within 3 4 load and be sure to avoid overloading After returning to the port disassemble the marine gear completely and rep
168. the resistance of the control rack When the resistance is large the engine will run irregularly or race suddenly 2 Place the pump on its side hold the control rack up and allow it to slide down by its own weight The rack should slide smoothly over its entire stroke Place the pump on end and perform the above test again check for any ab normalities Resistance below 60g 0 132 Ib 3 Since a high stiding resistance is probably a result of the following disassemble the pump and wash or repair it A0A5052 JB06 SM 2GMFY 3GMFY a Resistance of the rotating and sliding parts of the plunger assembly is too high b Delivery valve holder is too tight plunger barrel distorted c Controi rack or contro pinion teeth and control rack outside circumference are dirty or damaged d Injection pump body control rack hole is damaged e Plunger barrel packing is not installed correctly and the barrel is distorted Since in this case fuel will leak into the crankcase and dilute the lubricating oil special care must be taken 2 7 2 Fuel injection timing Fuel injection timing is adjusted by timing shims inserted between the pump body and gear case pump mounting seat The injection pump must be mounted on the engine and each cylinder injection timing adjusted Adjusting the injection timing 1 Remove the high pressure pipe from the pump 2 Install a measuring pipe if the injection pump does not have a nipple on
169. ts diagram ts the spring clutch hydraulic pressure control valve broken Standard spring length or has it collapsed 50 mm Is there stiffening of the control valve of the clutch oil pressure Clean control valve 8 is the seal ring damaged or worn Clean or replace 9 Are the O rings or square rings damaged or worn Replace mg e e Abnormal Heat Inspection is necessary when the oil temp at the oil cooler inlet exceed 90 C Refer to the section above Lower the oil level to the standard level Disassemble and check replace if necessary Is the bearing damaged Is any part of the gear case abnormally hot is there piston stiffening of the lube oil pressure control valve spring colapse or damage Replace Has the bush in the pinion seized Spring standard length 3 Has the clutch piston return spring collapsed or is it damaged A5 mim Forward and Reverse Changeover Failure Clutch seizure the cause is clutch slip check the details the trouble Replace Is the remote control adjusted properly 3 Has the clutch piston return spring collapsed or is it damaged Refer to the above paragraph 4045052 JB06 7 20 Chapter 7 Reduction and Reversing Gear 9 Disassembly and Reassembly SM 2GMFY 3GMFY 9 Disassembly and Reassembly 9 1 Disassembly Check for oil leakage from all parts before starting disassembly Drain the oil Before starting disass
170. unting the cylinder head When dismounting and remounting the cylinder head the mounting bolts must be removed and installed gradually and in the prescribed sequence to prevent damaging the gasket packing and to prevent distortion of the cylinder head Since the tightening torque and tightening sequence of the mounting bolts when remounting the cylinder head are especially important from the standpoint of engine performance the following items must be strictly observed 3 3 1 Cylinder head assembly sequence 1 Check for loose cylinder head stud bolts and lock any loose bolts with two nuts and then tighten to the prescribed torque The cylinder head is fitted to the engine with 4 stud bolts in model 1GM but in other engine models both stud bolts and auxiliary tap bolts are used 2GMFY 3GMFY M12 0 4724in 40 45 kgf m 28 9 325 ft lb Stud bolt diameter of cylinder head Cylinder head stud bolt tightening torque 2 Checking the gasket packing mounting face Confirm correct alignment of the front and rear of the gasket packing and instal the packing by coating both sides with Three Bond 50 Assemble the gasket packing keeping the flat surface upward cylinder head side Make sure that the gasket hole aligns with the drilled hole in the cooling water passage in the cylinder btock A0A5052 B806 2 15 Chapter 2 Basic Engine 3 Cylinder Head SM 2GMFY 3GMFY 3 Installing the cylinder head a
171. ves to the 2GMFY 3GMFY Pump speed 1800 rpm rightside to decrease the injection volume Plunger diameter 26x7mm After adjusting the injection volume tighten the set bolt x stroke 0 2362 x 0 2756in securely Injection nozzle type YDN OSDYD1 Pressure for 170 kgf cni fuel injection 2418 Ib in Amount of 20cc 0 5cc injection at rack fon postion 1 19 1 25in2 Allowable error between cylinders Stroke 1000 NOTE Mainting the pressure for feeding oil to the injection pump at0 5kgf em 7 1 Iblin 1cc 0 06in or less 2 8 8 Adjustment of injection volume for each cylinder 1 Fluctuation of injection volume The injection volumes of each cylinder must be ad justed to within 396 of each other total volume of all cylinder injection number of cylinders Average injection volume Maximum injection volume average injection volume Difference ngo ngin x100 Average injection volume When the difference exceeds 396 adjust the injection volume by sliding the control sleeve and pinion when the difference exceeds 3 the engine output will drop and or one cylinder will overheat 2 Adjustment of injection volume In order to adjust the fluctuation of injection volume for each cylinder alter the position of the injection volume adjusting plate at the side of the fuel injection of pump body The injection volume adjusting plate is operated by the eccent
172. wheel side A0A5052 J806 Clearance at assembly 0 050 0 100 0 0020 0 0039 241 5 1 6339 0 050 0 100 0 0020 0 0039 SM 2GMFY 3GMFY Intake and exhaust valve head clearance Intake valve open b TDC Intake valve close a BDC Exhaust valve open b BDC Exhaust valve close a TOC 02mm 0 0079in Fuel feed pump cam comin LED We Intake and exhaust cam mm in Intake and exhaust cam mm fin Maximum allowable clearance 0 15 0 0059 2 55 Chapter 2 Basic Engine 8 Camshatt 8 3 3 Camshaft deflection models 3GMF Y Support the camshaft at both ends on V blocks and measure the concentricity of the intermediate journal with a dial gauge If the camshaft is excessively bent replace it NOTE Indicated valve on the dial gauge is the amount of swing and the amount of bend is half the reading given V block Maintenance standard Camshaft deflection 8 4 Camshaft ball bearing The camshaft bearing is a single row deep groove ball bear ing The construction and material of this ball bearing is such that it can withstand the radial load thrust loads in both directions and a combination of both these loads When the ball bearing does not rotate smoothly or when the axial direction play is large replace the bearing Ball bearing type 6205 8 5 Tappets These mushroom type tappets feature a special iron casting with chill hardene
173. wipe off dust Be sure to apply grease before reassembly f Replace all the packings g Tighten the bolts and nuts according to the specified tightening torque h Fasten the whirl stop securely for ali bolts fitted with one i itis recommended that the consumable parts such as O rings square rings oil seals stoppers split pins whirl stop etc be replaced with new ones on every disassembly j Apply liquid packing THREE BOND 1215 to the case and flange joint face k Check for oil leakage during operation soon after reassembly and re tighten the bolts from time to time 2 Reassembly of Clutch Be careful of the following points in clutch reassembly 1 Apply grease to the square rings before assembling them to the hydraulic cylinder and shaft 2 Take special care not to catch the square ring in the clearance when assembling the hydraulic cylinder 3 Assemble the friction plates and steel plates by turns When replacing the friction plate soak the new friction plate in lube oil for more than 24 hours before installing it 4 An extra steel plate is supplied in the friction plate and steel plate sets There should be steel plate at both sides of each set Note that the friction plate has the spline on the inside circumference 3 Coupling with Engine Take care of the following points when coupling the marine gear to the engine 1 Fill the inside of the cap at the tip of the damper disc with lithium grease to 40 96 o

SERVICE MANUAL MARINE DIESEL ENGINE 2GMFY, 3GMFY

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