Yanmar 1GM10 | 2GM20 | 3GM30 | 3HM35 Service Workshop Manual

Workshop Service and Repair Manual for the Yanmar 1GM, 2GM, 3GM & 3HM engines, an absolute gem for any Yanmar owner. This full workshop manual covers every component, service and repair procedure in full Yanmar factory specification with clear step by step photographs and technical drawings for the 1,2 & 3 cylinder Yanmar units with torque setting values throughout each chapter, this is the most comprehensive service manual available as used by boatyards and independent marine engineers the world over.

Models Covered Within This Manual

1GM10(C)
2GM20(F)(C)
3GM30(F)(C)
3HM35(F)(C)

A. Engine Model Name
B. Engine Model Name Plate
and Clutch Model Name Plate
C. Cylinder Number

CHAPTER O FOR SAFETY
1. For safe servicing
2. Precaution for safe servicing

CHAPTER 1 GENERAL
1. Specifications
2. Principal Construction
3. Performance Curves
4. Features
5. Engine Cross Sections
6. Dimensions
7 Piping Diagrams

CHAPTER 2 BASIC ENGINE
1. Cylinder Block
2. Cylinder Head
3. Piston
4. Connecting Rod
5. Crankshaft
6. Flywheel and Housing
7. Camshaft
8. Timing Gear

CHAPTER 3 FUEL SYSTEM
1. Fuel injection System
2. injection Pump
3. Injection Nozzle
4. Fuel Filter
5. Fuel Feed Pump
6. Fuel Tank (Option)

CHAPTER 4 GOVERNOR
1. Governor
2. Injection Limiter
3. No-Load Maximum Speed Limiter
4. Idling Adjuster
5. Engine Stop Lever

CHAPTER 5 INTAKE AND EXHAUST SYSTEM
1. Intake and Exhaust System
2. Intake Silencer
3. Exhaust System
4. Breather

CHAPTER 6 LUBRICATION SYSTEM
1. Lubrication System
2. Oil Pump
3. Oil Filter
4. Oil Pressure Regulator Valve
5. Oil Pressure Measurement

CHAPTER 7 DIRECT SEA-WATER COOLING SYSTEM
1. Cooling System
2. Water Pump
3. Thermostat
4. Anticorrosion Zinc
5. Kingston Cock (Option)
6. Bilge Pump and Bilge Strainer (Option)

CHAPTER 8 FRESHWATER COOLING SYSTEM
1. Cooling System
2. Sea Water Pump
3. Fresh Water Pump
4. Heat Exchanger
5. Filler Cap and Subtank
6. Thermostat
7. Cooling Water Temperature Switch
8. Precautions

CHAPTER 9 MODIFYING THE COOLING SYSTEM
1. General
2. Disassembly of Sea Water-Cooled Engine
3. Assembling modified parts to the Fresh Water-Cooled Engine
4. Cautions When the Engine is Installed Inboard

CHAPTER 10 REDUCTION AND REVERSING GEAR
[AJ For Engine Models 1GM10. 2GM20(F) and 3GM30(F)
1. Construction
2. Shifting Device
3. Inspection and Servicing
4. Disassembly
5. Reassembly
[BJ For Model 3GM35(F)
1. Construction
2. Installation
3. Operation and Maintenance
4. Inspection and Servicing
5. Disassembly
6. Reassembly
Marine Gear Models KM2P. KM3P and KM3V
For Engine Models 1GM10. 2GM20(F) and 3GM30(F)
1. Construction
2. Shifting Device
3. Inspection and Servicing
4. Disassembly
5. Reassembly
V-drive Gear. Model KM3V
1. Construction
2 Specifications
3. Power Transmission System
4. Cooling System (Sea-water Cooling Engine)
5. Piping Diagrams
6. Inspection and Servicing
7. Shim Adjustment for V-drive Gear Shaft.
And Backlash Adjustment for V-drive Gear Shaft and DriveGear
8. Disassembly
9. Reassembly

CHAPTER 11 REMOTE CONTROL SYSTEM
1. Construction
2. Clutch and Speed Regulator Remote Control
3. Engine Stop Remote Control

CHAPTER 12 ELECTRICAL SYSTEM
1. Electrical System
2. Battery
3. Starter Motor
4. Alternator Standard, 12V/55A
4A. Alternator Option, 12V/35A
5. Instrument Panel
6. Tachometer

CHAPTER 13 OPERATING INSTRUCTIONS
1. Fuel Oil and Lubricating
2. Engine Operating Instructions
3. Troubleshooting and Repair

CHAPTER 14 DISASSEMBLY AND REASSEMBLY
(Direct Sea-Water Cooling Engine)
1. Disassembly and Reassembly Precautions
2. Disassembly and Reassembly Toots
3. Others
4. Disassembly
5. Reassembly

CHAPTER 15 DISASSEMBLY AND REASSEMBLY
(Fresh Water Cooling Engine)
1. Disassembly of Fresh Water-Cooled Engine
2. Reassembly of Fresh Water-Cooled Engine
3. Tightening Torque
4. Packing Supplement and Adhesive Application Point