Yanmar 1GM, User Manual

Page 1: ...YANMAR DIESEL INBOARD SHOP MANUAL ONE TWO s THREE CYLINDER ENGINES...

Page 2: ...Lubrication Maintenance and Tune up Lay up and fitting Out Single Cylinder Engines r Multlcyllnder Engines Fuel Injection and Governor Systems Cooling System Electrical System Transmlsslon KM Series...

Page 3: ...Fasteners 4 CHAPTER TWO Lubricants 8 RTV gasket sealant 9 Threadlock 9 Basic hand tools 9 Precision measuring tools 13 Mechanic s tips 16 Bearing replacement 18 Seals 23 TROUBLESHOOTING 26 Starting s...

Page 4: ...ve seats 77 Push rods 79 Piston connecting rod assembly 79 Timing gearcase 85 Lubrication system 86 Flywheel 89 Drive disc 91 Crankshaft 91 Main bearings 93 Camshaft 93 Cylinder block 95 CHAPTER SIX M...

Page 5: ...Operation 199 Removal installation 201 Overhaul 202 CHAPTER ELEVEN TRANSMISSION KBW SERIES Operation 216 Removallinstallation 217 Overhaul 217 Seawater pump 170 Freshwater pump 177 Freshwater cooling...

Page 6: ...t 5 4 L iue clearance models 0 2 m 0 008 In 0 2 m 0 008 In 0 2 m 0 008 In 0 2 m 0 008 In 0 2 m 0 008 In 0 2 m 0 008 In 0 2 m 0 008 In 0 2 m 0 008 In 0 2 m 0 008 In 0 2 m 0 008 In 0 2 m 0 008 In 0 2 m...

Page 7: ......

Page 8: ...ations for students Each Yanmar marine diesel can be identified by its indi vidual model number The model numbers for all Yanmar marine diesel engines covered in this manual are listed in Table 1 Some...

Page 9: ...ed tune up procedures eliminating the need to constantly consult other chapters on the various assemblies Subsequent chapters describe specific systems provid ing disassembly repair assembly and adjus...

Page 10: ...oftheprocedures or service specifica tions in this manual may not be accurate if the engine has been modified or if it has been equipped with after market equipment Ifinstalling after market equipment...

Page 11: ...gas ket material with the same approximate thickness 17 Use heavy grease to hold small parts in place if they tend to fall out during assembly However keep grease and oil away from electrical compone...

Page 12: ...hows how to determine bolt diameter NOTE Ifpurchasing a bolt from a dealer or parts store it is important to know how to specify bolt length The correct way to measure holt length is to measure from u...

Page 13: ...h di mension The measurem ent across two flats on the nut in dicates the wrench size 1 0 be used Several type s of bolts screws and nuts incorporate a system that develops an interference between the...

Page 14: ...re 12 shows several types of wash ers Washers are also used in the following functions a As spacers b To prevent galling or damage of the equipment by the fastener c To help distribute fastener load d...

Page 15: ...tely seated in its groove LUBRICANTS Periodic lubrication ensures long life for any type of equipment The type of lubricant used is as important as the lubrication service itself although in an emerge...

Page 16: ...ue and 27 1 red are recommended for many threadlock requirements described in this manual Loctite 242 blue is a medium strength threadlock and component disassembly can be performed with normal hand t...

Page 17: ...can damage the screw head making removal of the screw difficult A screw driver must be selected to conform to the shape of the screw head used Two basic types of screwdrivers are re quired standard fl...

Page 18: ...lade d Phillips screwdriver size 3 tip 6 and 8 in blade 7 Use screwdrivers only for driv ing screws Never usc a screwdriver for prying or chiseling metal Do not try to rc move a Phillips Torx or Allen...

Page 19: ...ad justable wrench only when other wrenches are not avail able Adjustable wrenches come in various sizes Sucket wrenches This type is undoubtedly the fastest safest and most f25 convenient to usc Sock...

Page 20: ...pe oil or grease offthe hammer before using it 4 The head of the hammer should always strike the ob ject squarely Do not use the side of the hammer or the handle to strike an object 5 Always use the c...

Page 21: ...ut limits Select a dial indicator with a continuous dial Fig ure 34 Cylinder Bore Ga uge The cylinder bore gauge is a very specialized precision toot The gauge set shown in Figure 35 is comprised ofa...

Page 22: ...is instrument Figure 38 is required for electrical system troub leshooting Hattery Hydrometer A hydrometer Figure 39 is the used to check a bat tery s state of charge A hydrometer measures the weight...

Page 23: ...hand is important when performing engine work However to prevent the possibility offire store solvent soaked rags in a sealed metal container until they can be washed or dis carded NOTE To avoid abso...

Page 24: ...er type ofthread 17 __ Filed Slotted insert Follow the manufacturer s instructions when in stalling their insert Ifit is necessary to drill and tap a hole refer to Table 4 for metric tap and drill siz...

Page 25: ...earing care should be taken to prevent damage to the new bearing While bearing re placement is described in the individual chapters where applicable the following should be used as a guideline 2 Drill...

Page 26: ...g races with a suitable size wood or aluminum ring Figure 52 Ifonly the outer race is supported pressure ap plied against the bearings and or the inner race will damage them b Always make sure the pre...

Page 27: ...h a file or sandpaper c Fill a suitable pot or beaker with clean mineral oil Place a thennomctcr rated highe r than 1200 C 2480 F in the oil Support the thermome ter so it does not rest on the bottom...

Page 28: ...GENERAL INFORMATION r _ _ _ t Spacer Shaft 21 Bearing Blocks Press arm Shaft Bearing Spacer Press bed...

Page 29: ...eck to see that it is at the proper tempera ture by dropping tiny drops of water on the case if they sizzle and evaporate immediately the tempera ture is correct Heat only one housing at a time CAUTIO...

Page 30: ...uce its outside diameter while the heated bearing housing assembly will be slightly larger due to heat expansion This will make bear ing installation much easier NOTE Always install bearings with the...

Page 31: ...1 64 0 015625 0 39688 33 64 0 515625 13 09687 1 32 0 03125 0 9375 17 32 0 53125 13 49375 3 64 0 046875 1 19062 35 64 0 546875 13 89062 1 16 0 0625 1 58750 9 16 0 5625 14 28750 5 64 0 078125 1 98437 3...

Page 32: ...ottle and would not restart Identify as many symptoms as possible to aid in diagno sis Note whether the engine lost power gradually or all at once what color smoke if any came from the exhaust etc Aft...

Page 33: ...must have one thing in common to be successful a logical system atic approach Troubleshooting diagrams for individual systems are provided within this chapter A master troubleshooting chart Table 1 i...

Page 34: ...connections or a low charge Clean and tighten the connections as required Recharge the battery if neces sary 2 If starter running speed does not sound normal clean and tighten all starter solenoid co...

Page 35: ...hours of opera tion NOTE A low battery or loose or corroded battery connections can also cause the starter to re main engaged with the flywheel ring gear Low voltage at the starter can cause the conta...

Page 36: ...30 CHARGING SYSTEM TYPICAL CHAPTER TWO...

Page 37: ...y Ifthe engine starts remove and test the warning lamp bulb If the problem persists the alternator brushes may not be making contact Perform the System Circuitry Test in this chapter 31 3 Charging sys...

Page 38: ...in the stop position 7 Tum on all accessories and crank the engine for 15 20 seconds to remove any surface charge from the battery 8 Tum off all accessories 9 Connect a tachometer to the engine Connec...

Page 39: ...ected in Chapter Seven 2 Engine slops suddenly Chcck for an empty fuel tank incorrect fuel or watcr in the fuel Bleed the fuel systcm as directed in Chapter Seven to be sure that fuel is routed to the...

Page 40: ...ssure only slight loosening is required If the engine runs worse the injector is operat ing satisfactorily Ifthe engine runs the same the injector or the fuel injection pump is not operating properly...

Page 41: ...ms soot when burned Either excess fuel or insufficient air can cause black smoke Some possible causes are a de fective fuel injection pump poor injector spray pattern low injection opening pressure cl...

Page 42: ...termine ifthe engine rotates freely Refer to Chapter Three to check governor adjustment or to CHAPTER TWO Chapter Seven to repair the governor If a fuel system problem is suspected refer to troublesho...

Page 43: ...STEM 1GM AND 1GM10 MODELS Valve rocker arm support Camshaft LUbricating oil suction pipe To oil pan Oil pressure regulator valve To oil pan Lubricating oil pump Tappet Push rod Camshaft Crankshaft gea...

Page 44: ...ND 2GM20 MODELS CHAPTER TWO Valve rocker arm shaft Valve rocker arm r1O l Push rod Tappet Camshaft gear Crankshaft gear Oil pressure regulator valve Oil pressure switch Filter Valve spring Piston Lubr...

Page 45: ...TROUBLESHOOTING 39 LUBRICATION SYSTEM 3GM 3GM30 3HM AND 3HM35 MODELS 3HM AND 3HM35 MODELS Valve rocker arm uli Push rod Tappet Camshaft gear Filter Piston...

Page 46: ...aulty or w charge Faulty starter motor Incorrect engine 011 viscosity Discharged battery Corroded battery terminals loose connection In starting ci rcuit Defective starting switch Starting motor brush...

Page 47: ...on Repair governor Inspect and repair Locate cause for overload and rectify Inspect and unclog or replace Bleed air in fuel system Remove water Adjust governor Repair damaged components determine caus...

Page 48: ...e ifmodel 3GM is called out in a procedure the procedure also applies to 3GMD and 3GMF FUEL REQUIREMENTS The recommended fuel is number 2 2 D diesel fuel Be sure the fuel is clean and free ofwater NOT...

Page 49: ...to start the engine CAUTION Do not operate the starterfor more than I5 seconds or the starter motor may be dam aged due to overheating 6 Start the engine by pushing the start button The alarm lights...

Page 50: ...ir intake A flat plate is desirable if it will adequately cover the opening A rag may also be used but do not al low the rag to enter the engine POST OPERATlO AL CHECKS Perform the following maintenan...

Page 51: ...ly five minutes for the oil in the upper end to drain back into the crankcase oil pan 1 With the boat at rest in the water and the engine off pull out the dipstick See Figure 1 for the typical locatio...

Page 52: ...th a paper towel 9 Coat the neoprene gasket on the new filter with a thin coat of clean engine oii 10 Screw the new filter onto the engine by hand until the gasket just touches the engine block At thi...

Page 53: ...ove dirt from the fuel before it enters the fuel injection pump After every 50 hours ofoperation or more frequently if necessary remove and disassemble the fuel filter and clean the inside of the fuel...

Page 54: ...clean and undamaged Use the following procedure to remove and clean the filter clement I Unsnap the filter canister retaining clip B Figure 10 and remove the canister and filter element 2 Separate the...

Page 55: ...alternator drive bell tension loosen the alter nator retaining nuts 8 Fil ure 12 then reposition the al ternator Retighten the retaining bolts and recheck belt tension Alternator drive belt adjU ilme...

Page 56: ...Adjust belt tension as previously described Crankcase Breather The crankcase breather assembly vents crankcase pressure into the intake port or manifold This produces a negative pressure in the crankc...

Page 57: ...ases to the intake manifold Anticorrosion Iai ntenance The engines are equipped with sacrificial anodes that provide protection against galvanic corrosion Sacrificial anodes are relatively inexpensive...

Page 58: ...eplace the anode if dimensions are less than 50 percent oforiginal size 5 Install a new gasket on the anode Figure 23 I Drain the cooling system 2 Unscrew the sacrificial anodes in the cylinder head F...

Page 59: ...with a closed cooling system both pumps must be supplied with cooling water The following procedure provides steps to flush the cooling system ofengines equipped with a seawater cool ing system as we...

Page 60: ...Check the level of fluid in the system It should be level with the iron plate at the bottom ofthe filler neck NOTE Excess coolant above proper level will be expelled when coolant reaches operating tem...

Page 61: ...nous and in gesting even a very small amount may cause illness Observe warning labels on anti freeze containers Make sure to discard used antifreeze in a safe and suitable manner and wipe up any spill...

Page 62: ...ccumulation of scale is apparent on the interior ofthe cooling system use an automotive cool ing system cleaner Be sure to thoroughly flush out the cooling system with freshwater afterward 5 Close the...

Page 63: ...the following 1 Compression test 2 Valve adjustment 3 Idle speed adjustment Careful and accurate adjustment is crucial to a success ful engine tune up Each procedure in this section must be performed...

Page 64: ...ad jacent cylinders on a multicylindereng ine read Iow an both tests the head gasket may be leaking between the cylinders Excessively high compression readi ngs indicate carbon buildup in the cylinder...

Page 65: ...ver 3 Rotate the crankshaft with a wrench on the crankshaft pulley retaining nut Figure 32 j l Idle speed screw NOTE When thepiston is on its compression stroke and at top dead center both valves will...

Page 66: ...T I tANSM ISSIO Transmission Oil Transmission moaet K U1A KJU2C KJflp Kllf1 A and Ki fJP The recommended transmission oil is an engine oil that meets APIclassification cc The recommended viscosity is...

Page 67: ...ery 1500 hours Every 2000 hours Annually Ambient Temperature Below 50 F 10 C 50 68 F W 20 C 68 95 F 20 35 C Above 95 F 35 C Model 1GM 1GM10 2GM 2GM20 3GM 3GM30 3HM 3HM35 Table 1 MAINTENANCE SCHEDULE C...

Page 68: ...850 3750 25 BTDC 0 2 m 0 008 in 2GM20 850 3825 15 BTDC 0 2 m 0 008 ln 2GM20F 850 3825 15 BTDC 0 2 m 0 008 ln 3GM 850 3750 28 BTDC 0 2 m 0 008 in 3GMF 850 3750 28 BTDC 0 2 m 0 008 in 3GMD 850 3750 28 B...

Page 69: ...er cooling pump NOTE Except where specified F and D series en gines are included when a basic model num her is specified For example ifmodel3GM is called out in a procedure the procedure also applies...

Page 70: ...battery from the boat Tape the vent holes closed and clean the battery case with a baking soda solu tion to remove any traces ofcorrosion and acid then rinse with cold water Check the electrolyte leve...

Page 71: ...e tnat fotlows Be fore returning the hoat to service drain the seawatercooling system as described in this chapter I Refer to Chapter Eight to remove the thermostat and gasket Discard the gasket 2 Mak...

Page 72: ...ormed before returning the engine to service 1 Remove all covers placed over engine openings during lay up 2 If the seawater cooling system is filled with an anti freeze solution drain the antifreeze...

Page 73: ...es for deterioration and clamps for tightness 13 Check all through hull fittings 14 Make sure water is available to the cooling system 67 15 Operate all engine controls to be sure they operate properl...

Page 74: ...es The intake compression ignition ex pansion and exhaust cycle occur in the same sequence for compression ignition engines as for spark ignition en gines The major differences are how the fuel is int...

Page 75: ...the piston moves upward compressing the air c Injector i Exhaustvalve o As the piston almost reaches the top of its travel the injector sprays fuel into the combustion chamber The fuel Is ignited by t...

Page 76: ...om bustion efficiency which produces greater power with re duced emmissions Combustion first occurs in the precombustion chamber when hot compressed air enters the precombustion chamber just as fuel i...

Page 77: ...noid that will interfere with engine re moval 8 Detach the exhaust system 9 Detach the driveshaft from the transmission output 5 flange 10 Remove the engine retaining bolts II Remove the engi ne and t...

Page 78: ...1 Bolt 2 Washer 3 Breather cover 4 Gasket S Screw 6 Washer 7 Valve stop 8 Breather valve reed 9 Pin 10 Nut 11 Washer 2 Valve cover 13 Gasket 14 O ring 15 Decompression shaft 16 Spring 17 Pin 18 Decom...

Page 79: ...d of the spring must sit behind the lug on the valve cover Position the hooked spring end on top of the lever b The shaft and lever must be properly assembled or the taper pin and tapered holes in the...

Page 80: ...ater temperature sender Figure 12 9 Remove the air cleaner and the air cleaner base Fig ure 13 10 Remove the fuel injector and precombustion chamber as described in Chapter Seve n 11 Remove the valve...

Page 81: ...n the ports 5 Clean all carbon off the piston top 6 Cheek the cylinder head studs for damage and replace them ifnecessary Ifa stud is loose tighten it using the fol lowing procedure a Install two nuts...

Page 82: ...l lows a Attach the water hose A Figure II to the exhaust elbow and thermostat housing then tighten the hose clamps b Attach the exhaust hose to the exhaust elbow e Connect the negative battery cable...

Page 83: ...rform all disassem bly except valve removal and take the head to a dealer or machine shop for inspection and service Since the cost is low relative to the required effort and equipment this is usually...

Page 84: ...s have been ground See Figure 25 Any valve with a margin less than 0 75 mm 0 030 in should be dis carded 3 Remove all carbon and varnish from the valve guides with a stiff spiral wire brush NOTE The n...

Page 85: ...29 8 Check each spring on a flat surface with a steel square See Figure 27 Slowly revolve the spring 3600 and note the space between the top of the coil and the square If it exceeds 1 4 mm 0 055 in a...

Page 86: ...ge Figure 30 Ifthe clearance exceeds specifications Table 1 replace the connecting rod during reassembly 7 Remove the connecting rod bolts Lift off the cap along with the lower bearing insert 8 Use a...

Page 87: ...th a hair dryer Separate the piston from the connecting rod Piston Cylinder Bore Check Unless precision measuring equipment is available have this procedure done by a machine shop 1 Measure the piston...

Page 88: ...der bore is acceptable install a new piston NOTE Provide the machine shop with the new pis ton so the cylinder can be bored to the cor rect dimension CHAPTER FIVE t Piston Ring Fit Installation 1 Chec...

Page 89: ...em as required 4 Use a ring expander tool Ftaure 41 to carefully in stall the oil control ring then the compression rings The oil ring consists oftwo pieces the oute r ring and the inner expansion spr...

Page 90: ...e Plastigagc is in place 4 Remove the connecting rod cap To determine bea ring clearance compare the width of the llattcncd Plasugagc to the markings on the envelope Fi u n 45 If the clear ance is exc...

Page 91: ...s the camshaft and crankshaft gears and the oil pump Figure 48 The timing gcarcasc also contains the governor mechanism and serves as the mounting location for the fuel injection pump A ball bearing i...

Page 92: ...or press out the bearing Figure 54 Force the bearing toward the inside of the gearcase d Clean the seal and bearing recesses in the cover with solvent and blow them dry with compressed air e Drive or...

Page 93: ...nkshaft nut A Figure 58 4 Remove the governor flyweight assembly B Figure 58 NOTE Early model engines may be equipped with a nut on the oil pump shaft 5 Early models Unscrew the oil pump nut To preven...

Page 94: ...pump body Reinstall the outer rotor in the pump body 6 Measure the clearance between the inner rotor tip and outer rotor tip Figure 63 Compare the measurement with the specification in Table 1 7 Measu...

Page 95: ...re relief valve The valve is scaled and it must be replaced as a unit assembly Oi pickup The oil pickup A Figure 67 is located in the oil pan B The pickup includes a strainer to prevent foreign mat te...

Page 96: ...6 Thrust bearing 7 Thrust sleeve 8 Nut 9 Governor flyweight assy 10 PIn 11 Gear 12 Thrust washer 13 Thrust bearing 14 Main bearing 15 Thrust bearing 16 Key 17 Crankshaft 18 Plug 19 Pin 20 Main bearing...

Page 97: ...IVE DISC Refer to Chapter Ten for drive disc procedures Figure 68 CRANKSHAFT Rem oval and Installation Refer to Figure 70 1 Remove the flywheel as previously described 2 Remove the bellhousing A Figur...

Page 98: ...front thrust bearing so the oi l grooves A Figure 77 are toward the outside ofthe crankcase and the tab B fits onto the pin in the crankcase f Install the thrust washer Figure 73 so the beveled side o...

Page 99: ...e main bearing carrier Thrust bearings located at the front ofthe crankshaft control cran kshaft end play Refer to Figure 70 Remove the crankshaft as described in the previous sec tion for access to t...

Page 100: ...ications Replace the valve lifter if the lifter face is scored galled excessively worn or otherwise damaged CHAPTER FIVE Fuel transfer pump lobe Intake valve lo be Exhau st valve lobe 11 Replace the b...

Page 101: ...ny discoloration appears in the treated area the block is cracked and should be replaced 3 Check the flatness of the cylinder block deck or top surface Place an accurate straightedge on the block If t...

Page 102: ...ore plugs into the engine cast ing It will he impossible to retrieve them and they can restrict coolant circulation re suIting in serious engine damage Sealing edge beforeinstallation l c o ce p g lns...

Page 103: ...ring width Top second ring Oil control ring Crankshaft main journal diameter Timing gear end Flywheel end Journal out of round max Crankshaft end play Crankshaft runout max Main bearing clearance Timi...

Page 104: ...1417 In 22 000 mm 0 8661 in 20 000 mm 0 7874 In 0 02 mm max 0 0008 in max 0 05 0 13 mm 0 002 0 005 in 0 3 mm 0 012 In 0 03 mm 0 0012 In Mechanical 10 000 mm 0 3937 ln 9 95 mm 0 3917 in 0 025 0 060 mm...

Page 105: ...inder engines the camshaft is equipped with two additional bearings In addition to operating the valves the camshaft operates the fuel transfer pump and has an actuating lobe for the injection pump at...

Page 106: ...er 3 Be sure the hoist is designed to lift engines and has enough load capacity for the engine 4 Be sure the hoist is securely attached to safe lifting points on the engine 5 The engine should not be...

Page 107: ...d Refill the freshwater cooling system ifso equipped as described in Chapter Eight VALVE COVER Refer to Figure 3 and Figure 4 for an exploded view of the valve cover assembly To remove the valve cove...

Page 108: ...e upper plate 18 DECOMPRESSION MECHANISM The decompression mechanism on the valve cover forces the exhaust valves open to reduce compression pressure in the cylinders Reducing compression pressure ena...

Page 109: ...of the freshwater closed cooling system Removal and Installation 2GMmodeis Refer to Figure 5 1 Detach the exhaust hose from the exhaust elbow 2 Loosen the hose clamps and remove the water hose from t...

Page 110: ...n 7 Heat exchanger 8 Cap 9 Filler neck 10 Gasket 11 Exhaust manlfloldlreservolr 12 End cap 13 Elbow 14 Stud 15 Hose 16 Gasket 17 Elbow 18 Drain valve 19 Remote reservoir 20 Gasket 21 Drain fitting 22...

Page 111: ...he engine removal procedure Refer to Figure 8 for an exploded view of the cylinder head assembly To remove the cylinder head proceed as follows 1 Disconnect the negative battery cable from the nega ti...

Page 112: ...106 CHAPTER SIX...

Page 113: ...guide 21 Intake valve guide 22 Plug 23 Thermostat housing 24 Gasket 25 Cylinder head 26 Gasket 27 End cap 28 Washer 29 Sacrificial anode 30 Exhaust valve 31 Intake valve CYLINDER HEAD 4 Without remov...

Page 114: ...h rods in their original position uo C oD o 0 o Installation I Make sure the cylinder head and block gasket surfaces are clean 2 Recheck all visible oil and water passages for cleanli ness 3 Apply Thr...

Page 115: ...ling system as described in Chapter Four c Connect the negative battery cable to the negative battery terminal Each valve is actuated by a rocker arm that rides on a shaft Figure 8 Each rocker arm is...

Page 116: ...Adjust the valve clearance as described in Chapter Three VALVES AND VALVE SEATS Servicing the valves guides and valve seats must be done by a dealer or machine shop as special knowledge and expensive...

Page 117: ...l Discard any cracked warped or burned valves 2 Measure the valve stems at the top center and bottom for wear A machine shop can do this when the valves are ground NOTE Check the thickness of the valv...

Page 118: ...ure 23 Slowly revolve the spring 3600 and note the space between the top of the coil and the square If it exceeds 1 4 mm 0 055 in at any point replace the spring 9 Check the valve guides for wear and...

Page 119: ...then reinstall the drain plug 3 Remove the cylinder head as described in this chapter 4 Remove the oil pan 5 On 2GM 2GM20 3GMand 3GM30 models Loosen the oil pickup jam nut Figure 26 and remove the oi...

Page 120: ...or combination of these 2 Remove the clip from each side of the piston pin bore Figure 30 with a small screwdriver or scribe Hold a thumb over one edge of the clip when removing it to pre vent the cli...

Page 121: ...ore the cylinder bore and install a new piston If the piston is worn but the cylinder bore is good install a new piston P 41n 1 A 44 B NOTE Obtain the new piston and have it available so the machine s...

Page 122: ...trol ring then the compression rings The oil ring consists oftwo pieces the outer ring and the inner expansion spring Assemble the oil ring on the piston so the expansion spring gap is on the opposite...

Page 123: ...ing halfon the connecting rod journal 2 Cut a piece ofPlastigage the width ofthe bearing Fig ure 40 Place the Plastigage on the journal then install the rod cap and bearing Be sure to install the cap...

Page 124: ...he cran kpin Lightly lubricate the connecting rod bolt threads with engine oil 8 Install the connecting rod cap Make sure the rod and cap are properly aligned Install the cap bolts finger t ight 9 Tig...

Page 125: ...al recess in the cover with solvent and blow it dry with compressed air c Apply gasket sealer to the periphery of the seal d Position a new seal in the cover recess with its open end facing the inside...

Page 126: ...iming gea r side of the cylinder block Figure 45 Removal and installation I Remove the timing gearcase as previously described 2 Remove the governor thrust washer Figure 50 thrust bearing and thrust s...

Page 127: ...replaced as a unit as sembly ifany parts are damaged 5 Reinstall the inner rotor in the pump body Reinstall the outer rotor in the pump body 6 Measure the clearance between the inner rotor tip and out...

Page 128: ...in the oil pan The pickup in cludes a strainer to prevent foreign matter from entering the lubrication system To remove the oil pickup remove the oil pan and un screw the jam nut Figure 58 Removal ln...

Page 129: ...nnecting rod as previously described 4 Remove the oil pum p as previously described 5 Remove the crankshaft gear 6 Install a dial indicator as shown in Figure 63 and mea sure crankshaft end play Compa...

Page 130: ...leeve 8 NUl 9 Pin 10 Governor flyweight assy 11 Gear 12 Main bea ring 13 Crank shaft 14 Key 15 Bolt 16 Lower main bearing holder 17 Main bearing Insert 18 Upper main bearing holder 19 Bolts 20 Lower m...

Page 131: ...with its open end facing the inside of the bearing housing Drive the seal into place with a suitably sized seal driver 13 Refer to the Main Bearings section for information concerning service to the...

Page 132: ...s nicks or other sharp edges that might dam age a seal during installation NOTE Unless precision measuring equipment is available have a machine shop perform Step 3 3 Check all journals against specif...

Page 133: ...ediate main bearing housing on the crankshaft Install the bearing housing on the crankshaft so the F mark B Figure 69 on the housing faces toward the flywheel end ofthe crankshaft 8 Tighten the bearin...

Page 134: ...Check gear backlash by installing a dial indicator as she n in Figure 67 or by rotating the gear teeth with soft solder between the gear teeth Compare the measurement with the specification in Tables...

Page 135: ...1 and 311 Incl uding F and D Series Iodds Have cylinder liners replacement performed by a deal ership or diesel engine shop The liner is available in dif ferent outside diameters so a precise fit bet...

Page 136: ...protrusion above the cylinder block Figure SO and compare the result with the specification in Tab les 1 3 a Excess protrusion may damage the head gasket Ex cess protrusion may becaused by improper se...

Page 137: ...bottom edge of the core plug with a hammer and drift Use several sharp blows to push the bottom of the plug inward tilting the top out Figure 81 2 Grip the top ofthe plug firmly with pliers Pull the p...

Page 138: ...r Runout 72 mm 2 83 In 75 mm 2 95 In 72 mm 2 83 In 586 cc 35 7 cu In 636 cc 38 8 cu In 2 1 2 72 000 mm 2 8346 In 0 005 0 075 mm 0 0002 0 0030 in 75 000 75 030 mm 2 9528 2 9540 ln 0 02 mm 0 0008 In 0 0...

Page 139: ...3937 In 9 95 mm 0 3917 In 0 010 0 040 mm 0 0004 0 0016 In 0 10 mm 0 004 In 45 45 0 75 1 15 mm 0 030 0 045 In 1 n mm 0 070 In 1 25 mm 0 049 In 0 040 0 065 mm 0 0016 0 0026 In 0 045 0 070 mm 0 0018 0 00...

Page 140: ...0 3917 in 0 010 0 040 mm 0 0004 0 0016In 0 10 mm 0 004 In 45 45 continUed 30 000 mm 1 1811 ln 41 500 mm 1 6339 In 0 02 mm max 0 0008 In max 0 05 0 13 mm 0 002 0 005 In 0 3 mm 0 012 In 0 03 mm 0 0012 i...

Page 141: ...16 16 kg at 29 2 mm 35 63 lb at 1 15 In 0 016 0 052 mm 0 0006 0 0020 In 0 15 mm 0 006 In 14 10 mm 0 555 In 13 90 mm 0 547 in 0 050 0 105 mm 0 0020 0 0041 In 0 15 mm 0 006 In 0 050 0 105 mm 0 0020 0 00...

Page 142: ...d exh Valve depth max Valve stem clearance Intake Exhaust 0 020 0 055 mm 0 0008 0 0022 In 0 25 0 45 mm 0 010 0 018 In 0 20 0 40 mm 0 008 0 016 In 0 25 0 45 mm 0 010 0 018 In 22 991 23 000 mm 0 9052 0...

Page 143: ...2717 In 0 03 mm 0 0012 In 7 000 mm 0 2756 In 7 080 mm 0 2878 In 7 0 mm 0 276 In 38 5 mm 1 52 In 37 mm 1 46 In 30 2 mm 1 19 In 14 43 kg at 30 2 mm 31 81 lb at 1 19 In 0 016 0 052 mm 0 0006 0 0020 In 0...

Page 144: ...e The major components ofthe diesel fuel system are the fuel tank fuel filters injection pump and injection noz zle s Figure 1 A feed transfer pump moves fuel from the fuel tank through the filters to...

Page 145: ...FUEL INJECTION AND GOVERNOR SYSTEMS FUEL IN JECTION SYSTEM Fuel return hose 139 Fuel return pipe Fuel InJection pump J...

Page 146: ...gine s cylinder The fuel must be broken into very small particles so that the fuel will quickly absorb heat from the compressed hot air change to a vapor then ignite The design ofthe nozzle tip affect...

Page 147: ...15 16 17 19 18 20 11 1 Delivery valve holder 2 a ring 3 Spring 4 Delivery valve 5 Gasket 6 Delivery valve seat 7 Barrel 8 Gasket 9 Pump body 10 Control rack 11 Shims 12 Plunger 13 Control sleeve 14 W...

Page 148: ...tion or stoppage Bleeding purges air from the system Bleed the system anytime fuel line connections are disconnected or fuel components are removed To ensu re all air is re moved perform the complete...

Page 149: ...FUEL INJECTION AND GOVERNOR SYSTEMS 143 Throttle pintle I L Nozzle nut FUEL INJECTOR c p Gasket Shims I Nezzle s p g Spring seat j PUShrOd Nau volvo d NOU 7 Nozzle holder...

Page 150: ...on a gasoline engine the fuel must be injected at the proper time to obtain optimum combustion Injection timing is determined by the relationship be tween the injection pump plunger and the injection...

Page 151: ...essure fuel line Figure 18 3A On IGM and IGMIO models Unscrew the fuel in jcction line retaining nut Figure 16 and disconnect the fuel line from the pump Adjust Fucl lnjcction Timing NOTE Always rotat...

Page 152: ...Injection timing retarded If injection timing is re tarded decrease the shim thickness to advance injection timing Decreasing shim thickness D I mm will advance injection timing one degree 11 B Inject...

Page 153: ...to Figure 23 for an exploded view ofthe fuel in jector and precombustion chamber assembly I Thoroughly clean the fuel injector and the area around the injector to make sure debris will not fall into...

Page 154: ...chamber Clean the heat shield 12 Discard the gaskets and install new gaskets Thor oughly remove any gasket residue in the top of the heat shield 13 Install the bottom copper gasket in the injector bor...

Page 155: ...ting have a Yanmar dealership or diesel fuel injection shop perform any unnecessary service Removal and Installation WARNING Serious fire hazards always exist around diesel fuel Do not allow any smoki...

Page 156: ...pump diaphragm to pump the fuel Fuel pump pressure is approximately 9 7 kPa 1 4 psi The transfer pump outpu t port on lGM and IGM IOen gines is on the left side with the pump mounted on the en gme On...

Page 157: ...urchase the formed steel fuel lines from a Yanmar dealership If nee essary a diesel fuel injection shop can fabricate fuel lines All lines must be secured by brackets to prevent fractures or splitting...

Page 158: ...to the governor le ver which is connected to the fuel injection pump fuel control rack The governor spring tension forces the speed control lever against the governor lever which forces the injection...

Page 159: ...ver 2 Governor weight Governor sleeve Pivot point Fuel control rack Fuel control lever Governor spring It P vol 0 Idle adjuster No load maximum speed limiter Governor lever 1 Fuel injection limiter GO...

Page 160: ...d service techni cians Refer to Chapter Three for the idle speed procedure Other adjustments such as no load maximum governed speed and fuel limiter screw setting are set by the manufacturer Incorrect...

Page 161: ...ded view ofthe governor mechanism 1 Remove the timing gearcase as described in Chapter Five or Six NOTE Do not distort or damage the governor spring 22 Roll pin 23 Shaft 24 Start spring 25 Needle bear...

Page 162: ...overnor spring 14 se onda orSpring 15 Main g v 16 Snap ring 17 Washer 18 Control lever 19 Spring post 20 Govern r lever 21 Taper pln 22 Roll Pin 23 Shaft 4 Start spring 2 Needle bearing 25 26 Roll pin...

Page 163: ...place or repair any worn parts 8 Inspect the governor springs for damage and distor tion Measure the length ofthe main and secondary gover nor springs as shown in Figure 49 Replace either spring if it...

Page 164: ...0 71 in 26mm 1 02 in 5mm 0 20 in 78mm 3 07 ln 20mm 0 79 in 23mm 0 90 in 10mm 0 39 in 78mm 3 07 In 20mm 0 79 In 23mm 0 90 in 10mm 0 39 ln Table 3 GOVERNOR SLEEVE AND CRANKSHAFT SPECIFICATIONS Governor...

Page 165: ...3GM is called out in a procedure the procedure also applies 10 3GMD and 3GMF COOLl G SYSTEMS Seawater Sta ndard Cooling Syste m All engines arc equipped with a seawater cooling sys tem The water in w...

Page 166: ...160 SEAWATER COOLING SYSTEM 1GM AND 1GM10 Drain plug d liiii Seacock except 1GM10C CHAPTER EIGHT Cylinder head I _ Cylinder block...

Page 167: ...COOLING SYSTEM SEAWATER COOLING SYSTEM 2GM AND 2GM20 161 U type mixing elbow option Thermostat cover U type mixing elbow Rubber hose Seacock except 2GM20C Cylinder head r Cylinder block...

Page 168: ...NG SYSTEM 3GM AND 3GM30 MODELS 3HM AND 3HM35 Thermostat housing Thermostat switch U type mixing elbow Thermostat Thermostat cover Elbow 1 Drain plug J Antlcorroslon zinc ob Exhaust manifold Cooling wa...

Page 169: ...stem diagram in Figure 5 Typical compo nents are shown in Figure 6 Various configurations ofthe closed cooling system are used but all function essentially the same The seawater system operation is si...

Page 170: ...164 CHAPTER EIGHT CLOSED COOLING SYSTEM TYPICAL u type mixing elbow Rubber JOin w hose Elbow0 Seacock option I To outside of boat Remote tank Cylinder block...

Page 171: ...n the thermostat closes it prevents coolant from entering the heat exchanger rerouting it back to the engine circulating pump Once the thermostat opens it closes offthe passage to the circulating pump...

Page 172: ...insta ll the gasket onto the thermostat cover 9 Install the cove r Note that the inlet and outlet nipples arc stepped Install the cove r so the outermost nipple faces down as shown in Ftgurc 10 Tight...

Page 173: ...the thermostat Ifthe thermostat has not started to open at this temperature replace it 3 Heat the water another 25 F 14 C above the temper ature value stamped on thermostat The thermostat should now b...

Page 174: ...e mark starts to melt the thermostat is stuck open and should be replaced IIUSE REPLACEMENT Replace any hoses that are cracked brittle or very soft and spongy If a hose is in doubtful condition replac...

Page 175: ...far more in time and money Drive belts should be properly tensioned at all times If loose the belts will not permit the driven components to operate at maximum efficiency The belts will also wear rapi...

Page 176: ...he end of the oil pump drives haft All other engines use a belt driven seawater pump A rubber impeller inside the pump moves water through the pump The pump draws water into the intake port as the imp...

Page 177: ...system and engine that drains back down to the water pump This water will lubricate the water pump for a short period oftime perhaps a cou ple of minutes but the pump will be damaged as soon as the h...

Page 178: ...to Table 1 for the tightening torque of the pump mounting bolts Adjust the belt tension as described in Chapter Three 3HMand 3HM35 1 Ifthe boat is in water make sure the seacock is closed 2 Drain the...

Page 179: ...ess Force each bearing away from the locating snap ring 13 Figure 24 9 Extract or push out the seals 9 and 10 Figure 24 10 Clean all metal components with solvent then dry them with compressed air 11...

Page 180: ...tal components in solvent then dry them with compressed air 13 Thoroughly clean all gasket material from all mating surfaces 14 Inspect the pump shaft for grooves in the seal contact area 15 Inspect t...

Page 181: ...d the gasket 3 Extract the impeller 16 Figure 28 from the pump body and remove the drive key 8 4 Rotate the pump shaft to check the bearings for rough ness excessive wear or other damage Do not remove...

Page 182: ...seal 11 Figure 28 so the lip is to ward the impeller side ofthe pump body 16 If removed install the snap ring 6 Figure 28 into the groove in the impeller shaft 11 Seal 12 Pump body 13 Fitting 14 Cam...

Page 183: ...the circulating pump and detach any hose brackets that interfere with ac cess to the water pump bolts NOTE Note the length ofthe pump retaining bolts during removal and if necessary mark them accordin...

Page 184: ...ce it 6 Inspect the filler neck scat and sealing surface Figure 32 for nicks dents distortion or contamination Wipe the sca ling surface with a clean cloth to remove any rust or dirt Make sure the loc...

Page 185: ...ling system flow diagram Figure 35 and follow the manufacturer s instructions regarding the connection of the pressure flushing device and procedure to be fol lowed Cleaning Flush and clean the freshw...

Page 186: ...iller neck 3 Gasket 4 Overflow tube 5 Exhaust manifold heat exchanger 6 Heat exchanger core 7 Cover 8 O ring 9 Gasket 10 End cap 11 Elbow 12 O ring 13 Stud 14 Washer 15 Nut 16 Drain valve 17 Plug 18 E...

Page 187: ...it 5 Clean all gasket residue from the end caps and heat exchanger sealing surfaces 6 Insert an appropriate size wire brush into each passage in the heat exchanger Work the brush back and forth with a...

Page 188: ...er pump Model All engines Seawater system Freshwater system 9 25 20 25 Table 1 TIGHTENING TORQUES ft lb 18 Table 2 RECOMMENDED THERMOSTAT Opening temperature 1080 F 420 C 1600 F 710 C CHAPTER EIGHT In...

Page 189: ...st likely bum out a new alternator as quickly as it damaged the old one If in doubt always consult an expert This chapter provides service procedures for the bat tery charging system starting system a...

Page 190: ...a physician immediately force the eyes open andflood with cool clean wOlerfor approx imatelyJive minutes Ifelectrolyte is spilled or splashed onto any surface it should be immediately neutralized wit...

Page 191: ...he vent holes in each cap with small pieces of masking tape NOTE Keep cleaning solution out of the battery cells in Step 5 or the electrolyte will be seri ously weakened 5 Scrub the top of the battery...

Page 192: ...tip in a cell and release the ball Figure 8 NOTE Do not attempt to test a battery with a hy drometer immediately after adding water to Electrolyte must be 3 16 in above plates the cells Run the engin...

Page 193: ...input time should equal the battery amp hour rating For example a 45 AH battery will require a 9 amp charging rate for five hours 9 x 5 45 or a 15 amp charging rate for three hours 15 x 3 45 Check ch...

Page 194: ...attery Cables Poor terminal connections will cause excessive resis tance Defective cable insulation can cause partial short circuits Both conditions may result in an abnormal volt age drop in the star...

Page 195: ...ri cal system Before replacing a fuse determine what caused it to blow and correct the problem Always carry several spare fuses of the proper amperage values onboard Never replace a fuse with one of h...

Page 196: ...ivot bolts Figure 14 typical CHAPTE R NINE 4 Swivel the alternator toward the engine and remove the drive belt from the alternator pulley 5 Support the alternator with one hand and remove the adjustin...

Page 197: ...following a Position the antito rque spring on the solenoid plunger so the spring ends fit in the holes in the sole noid f igure 18 b Position the yoke in the solenoid plunger so the notch on the yok...

Page 198: ...shing 5 Dust cover 6 Yoke 7 Spring 8 Shims 9 Solenoid 10 Retaining ring 11 Retainer 12 Drive 13 Center plate 14 Armature 15 Frame assembly 16 Positive lead 17 Brush pos 18 Brush neg 19 Brush spring 20...

Page 199: ...9 Washers 10 Shims 11 Solenoid 12 Pin 13 Stopper washer 14 Circllp 15 Retainer 16 Drive 17 Bushing 30 31 29 32 33 18 Center plate 19 Armature 20 Washer 21 Washer 22 Frame assembly 23 Positive lead 24...

Page 200: ...pull back and hold the brush retain ing clip then remove the brush See Figure 20 typical Repeat this step to remove the remaining brushes 6 Remove the brush holder from the armature shaft 7 Use an ohm...

Page 201: ...f Switch The battery cutoffswitc h is con nected between the pos itive terminal of the battery and the starter solenoid The switch provides a means to cutoffall circuits from the bat tery in case of f...

Page 202: ...d IGM 10 engines the coolant temperature sensor is located on the cylinder head f igure 26 The coolant temperature sensor on two or three cylinder en gines is located on the front or side ofthe thermo...

Page 203: ...ulb All warning lamps use the same type ofbulb 4 If a good bulb does not light check the charging sys tem as described in Chapter Two ALARM BUZZER The alarm buzzer provides an audible warning in addi...

Page 204: ...the sender Tachometer Ga uge To check the tachometer gauge unit proceed as fol lows I Disconnect the rcd bleck and black wire leads from the tachometer With the key switch ON measure the voltage betw...

Page 205: ...oaded detent pin sits on a ramp that OPERATION Basic design is the same for all the transmissions with the exception of the shifting mechanism Transmissions 1 _ with a P suffix are equipped with a shi...

Page 206: ...MODELS CHAPTER TEN 1 Connector 2 Circllp 3 Spring retainer 4 Spring 5 Clrcllp 6 Holder 7 Cotter pin 8 Washer 9 Stud 10 Shift lever 11 Bolt 12 Seal 13 Setscrew 14 Spring 15 Detent pin 16 Body 17 Gasket...

Page 207: ...TION The following procedure addresses units that are acces sible In some cases it may be necessary to remove the en gine and transmission as a unit before removing the transmission from the engine If...

Page 208: ...e output flange retaining nut by rotating the nut clockwise left hand threads 5 Remove the oil dipstick Figure 7 6 Remove the shifter retaining bolts B Figure 5 and remove the shifter assembly 7 Remov...

Page 209: ...crewdriver pry out the oil seal in the transmission mounting flange Be careful not to damage the case or the adjacent bearing race 13 If inspection indicates additional disassembly is nec essary refer...

Page 210: ...ut shaft by reversing the disassem bly procedure while noting the following 1 Remove and discard the Q ring Figure 14 at the end of the shaft 2 Remove the thrust washer gear and roller bearings 3 Insp...

Page 211: ...Shims 2 Nut LH 3 Washer 4 Roller bearing 5 Thrust washer 6 Retainer KM2P and KM3P 7 Spring cup KM2P and KM3P 8 Forward gear 9 Needle bearing 10 Inner bearing race 11 Thrust washer 12 Pin 13 Output sh...

Page 212: ...7 15 14 17 18 1 Connector 2 Circlip 3 Spring retainer 4 Spring 5 Circlip 6 Holder 7 Cotter pin 8 Washer 9 Stud 10 Shift lever 11 Bolt 12 Seal 13 Setscrew 14 Spring 15 Detent pin 16 Body 17 Gasket 18...

Page 213: ...the tapered roller bearing g Install the washer so the pin in the output shaft fits in the groove in the washer 4 Remove the setscrew and plug then remove the springs and detent pins 5 Remove the shif...

Page 214: ...n Ta ble 7 13 Reassemble the shifter by reversing the disassembly procedure but do not install the stop bolt until final instal lation of the shifter assembly on the transmission 14 Reassemble the shi...

Page 215: ...LS 14 I 15 13 16 17 1 Shoulder bolt 2 Connector 3 Shift lever 4 Washer 5 Nut 6 Stop bolt 7 Shims 8 Bolt 9 Seal 10 Bolt 11 Shift body 12 O ring 13 Shift shaft 14 Detent pin 15 Pin 16 Spring 17 Shifter...

Page 216: ...OTE Note that the bolt holes in the shifter mount ing flange are sufficiently large to allow movement oftheflange around the bolts a Install the shifter assembly on the transmission and tighten the re...

Page 217: ...flange mating surface to the bottom ofthe bearing race bore for both the input and output shaft bearings 6 Subtract the A measurement from the B measurement for each shaft 7 From the result obtained i...

Page 218: ...ve centerline is 47 3 mm from the mating surface ofthe transmission case NOTE To perform the following bearing adjust ment procedure the output shaft must be out ofthe case and the outer bearing races...

Page 219: ...input shaft engages the splined hub on the drive disc The drive disc incorporates springs that dampen drivelinc shocks between the engine and transmissio n b Subtract measurement C fo igure 34 from su...

Page 220: ...or 2 83 2 14 or 2 83 2 14 or 2 83 Table 2 TIGHTENING TORQUES Fastener Transmission mounting flange Output shaft nut Output flange nut Drive disc KM2A KM2C KM2P KM3A KM3P N m 20 25 85 115 85 115 25 Ta...

Page 221: ...er shaft diameter Standard Wear limit Shift shaft bore Standard Wear limit 2 8 3 1 mm 0 110 0 122 in 2 92 3 08 mm 0 115 0 121 in Table 6 SHIFTER KM2A KM2C AND KM3A 7 80 7 85 mm 0 3071 0 3091 ln 7 7 mm...

Page 222: ...n engages the drive disc attached to the engine flywheel Because this is a con stant mesh transmission engine power is transmitted to all gears Power flows to the output shaft when the clutch engages...

Page 223: ...the output flange 5 Unscrew the output flange retaining nut 6 Remove the oil dipstick 7 Make match marks on the shifter cover and the trans mission case so the shifter can be installed in its original...

Page 224: ...218 CHAPTER ELEVEN...

Page 225: ...25 Shift ring 26 Shims 27 Spacer 28 Inner bearing race 29 Bearing 30 Friction plates 31 Steel plates 32 Snap ring 33 Retainer 34 Belleville washers 35 Reverse gear 36 Thrust washer 37 Bearing 38 Seal...

Page 226: ...r rust and mechanical damage Check the teeth for galling chips cracks missing pieces distortion or discol oration from overheating Ifnecessary replace the gear 5 Reassemble the intermediate shaft Inst...

Page 227: ...th of the steel plates tangs and com pare the result with the specification in Table3 7 Measure the width ofthe grooves in the pressure plates and compare the result with the specification in Table3 T...

Page 228: ...ecification in Table 3 Measure the plate spring shoulder diameter C and compare the result with the specification in Table 3 21 Measure the free width of the Belleville springs and compare it with the...

Page 229: ...re plate over the drive plate Make sure the steel balls remain in position and the slots ofboth plates match 18 Install the pressure plate return springs between the shift ring and the drive plate Att...

Page 230: ...e input shaft oil seal 8 Coat the case mating surface with RTV sealer 9 Install the mounting flange and tighten bolts evenly 10 Place the shift ring in neutral position and install the shift fork thro...

Page 231: ...the bearing bore in the mounting flange then press the bearing outer race into the mounting flange on top of the shims Be sure the race is bottomed DRIVE DISC The drive disc attached to the engine fl...

Page 232: ...ent pin spring free length Plate spring retainer thickness Wear limit Plate spring retainer inner diameter Wear limit Plate spring retainer shoulder diameter Wear limit Belleville spring width Min wid...

Page 233: ...belts 169 170 hose replacement 168 169 maintenance freshwater 177 181 seawater 181 pump freshwater 177 seawater 170 177 thermostat 165 168 troubleshooting 34 35 36 Crankshaft multicylinder 123 126 si...

Page 234: ...gency stopping 44 exhaust smoke troubleshooting 35 maintenance and lubrication 44 52 multicylinder 100 101 breather assembly 10I I 02 camshaft 127 128 crankshaft 123 126 cylinder block 128 131 head 10...

Page 235: ...disc 213 operation 199 201 overhaul 202 208 reassembly 208 211 removal installation 20I Troubleshooting charging system 31 tests 31 32 cooling system 36 engine 36 exhaust smoke 35 noises 35 36 fuel s...

Page 236: ...230 Tune up battery 56 engine tune up 57 60 v Valve and seats multicylinder 110 113 single cylinder 77 79 INDEX cover multicylinder 101 single cylinder 71 w Waming lamps 197 Wiring diagrams 231 234...

Page 237: ...ck W White R Red L Blue o Orange WIB WhlteIBlack WIR White Red WIL WhlteIBlue RIB RedlBlack US BlueIBlack LIR BluelRed YIW YellowlWhlte U I I I 1 Extensl s Thet extensl less Push Key button switch swi...

Page 238: ...Key 1 Connectors Ground Frame ground Connectlon r No connection Push button switch U I E r f 1 Color Code B Blaek W White R R d L Blue o Orange WIB WhltelBlaek WIR WhltlllR d WIl WhltelBlue RIB RBdlBl...

Page 239: ...or Code B Black W White R Red L Blue o Orange WIB WhiteIBlack W R WhitelRed WIL WhlteIBlue RIB RedlBlack US BlueIBlack LIR Blue Red VIW VellowlWhite U I I 1 I I I Extensi s The to extensi less I I Not...

Page 240: ...dard The total length extension must be less than 6m Spare connector Diagram Key Connectors JGround Frame ground teonnectlon No connection Color Code B Black W White R Red L Blue o Orenge WIB WhlteIBl...