Yanmar 1GM User manual

Yan

Thank you for purchasing the YANMAR Diesel Engine
This manual describes the various engine parts and prescribes simple checks for normal
engine maintenance.
Before starting up your new engine, we recommend that you throughly read this manual to
insure proper handling and use. If any sections are unclear or if you have any problems,
please consult your nearest dealer or sales outlet.
In view of our continuing efforts to improve quality and performance, engine parts may
sometimes be changed. This may result in some discrepancies in the contents of this manual.
This manual is concerned with the 2 cylinder model. Although the 1GM, 3GMD and 3HM
seem to be different on the outside, their handling is the same.
Caution
This safety alert symbol indicates important safety messages in this manual. When you see this symbol, be
alert to
the possibility of personal injury and carefully read the message that follows.
Important
This stop symbol indicates important proper operation messages in this manual. When
you see this symbol, carefully read the message that follows.

In order to deliver correct parts to you, we need accurate data on the engine you purchased.
The information needed is described in the illustrations below. For ready reference, please
record the information in the spaces provided under the illustrations.

I. Name of parts
1 Reduction and reversing gear
2 Output shaft coupling
3 Clutch control lever
4 Installation foot
5 Engine tube oil dipstick
6 Clutch tube oil dipstick/Supply port
7 Cooling water pump
8 Fuel feed pump
9 Exhaust manifold
10 Mixing elbow
11 Air intake silencer
12 Alternator
13 Lube oil filter
14 Starter motor
15 Decompression lever
16 Anticorrosion zinc
17 Fuel injection pump
18 Fuel injection valve
19 Crankshaft V-pulley
20 Speed control lever
21 Cooling water drain cock (Cylinder block/Exhaust manifold)
22 Fuel filter
23 Breather pipe
24 Fuel injection limiter
25 Engine lift plate
26 Lube oil supply port
27 Oil pressure sender
28 Engine stop device

III. Engine installation
[3-1.1 Inspection after unpacking
During unpacking be careful not to break the engine base. Check the following points:
1) Have any nuts or bolts become loose or fallen off?
2) Have any parts become rusty?
3) Is there any water inside the engine?
4) Has any part of the engine been broken, chipped, or crushed?
5) Are any of the accessory parts/ items broken or defective?
[3-2.1 Preparation of the engine foundation plate
The installation angle will differ with the vessel configuration and installation location of the
engine. The most suitable installation angle is 8 degrees and the maximum installation angle is
15 degrees. If it is greater than this, horsepower loss will increase and vessel speed will drop. In
addition, abnormal wear of parts will occur and engine performance will be adversely affected.
[3-3.1 Engine installation
1) For the engine installation, be sure to use the flexible rubber mount.
Yanmar prepared the flexible mounts which match the respective engine characteristics as a
standard accessory.
1. Lock Nut 2. Jack Nut
3. Rubber Mount
4. Indication No. (50, 70, 75, 100)

Note
Avoid splashing the flexible mount with water, oil etc.
Indication # Installation distance (unit: mm)
Engine model Front Rear A B
1GM 70 50 209 370
2GM 100 75 275 370
3GMD 100 75 355 370
3HM 100 100 432 400
It is convenient for installation to make the GUIDE PLATE as illustrated.
2) Be sure the propeller shaft lines up with and matches both shaft joints. If necessary adjust the
height of the engine with a jack nut to line up the propeller shaft and the engine. Fit the propeller
shaft and the intermediate shaft if there is one-to the engine.
With a gap gauge, measure the gap of the connection at the top, bottom, right, and left. The
maximum tolerance should be less than 0.2mm. Lock nut should be as low as possible.
3) Tighten the installation bolts firmly and evenly. Do not force the bolts in if the propeller shaft
does not line up.
Important
After 50 hours operation, check that the propeller shaft lines up again, and re-
adjust if necessary.
View From Top
1 - Rear 2 - Front

1. Gap gauges
[3-4.1 Propeller, propeller shaft
1) Select a propeller which is suitable for the size and shape of the vessel, as well as for its
intended usage. An extremely small or large propeller will reduce the speed of the vessel and
overload the engine, which may lead to engine break down. It is recommended that a
propeller be selected in consultation with a reputable dealer. However, the best way to make
sure the propeller fits the vessel is to conduct a test run after installation.
2) It is effective to use a proper flexible stern tube to reduce vibration.
[3-5.1 Cooling water supply device
1) The engine should be operated only after checking the cooling water piping is completed.
Important
If the Cooling water pump is operated without water, the rubber impeller
inside the pump will be broken.
2) Kingston cock installation. Install the canvas on the outside of the hull, and the
canvas or rubber packing on the inside of the hull; tighten the kingston cock. Installation
directions are given in the figure at the right. Install the kingston cock cover as shown.
3) Piping
For the cooling water pipe, use a rubber hose with an inside diameter of 13mm. Piping should
be kept as straight and short as possible. If the pipe is too long, it will be difficult to draw
water up.
4) Connect the rubber hoses to the kingston cock, cooling water pump inlet, and engine
cooling water outlet, and secure with hose clamps.

Piping Diagram
1. Inside Packing
2. Kingston cock cover
3. Outside Packing
4. Direction of vessel movement
5) Seawater strainer
The seawater pump will be damaged if foreign matter is allowed to get into it. Therefore,
attach a seawater strainer between the seawater pump inlet and the seawater cock when the
sea water cock is not already equipped with a strainer.
6) Exhaust pipe layout
Be sure to use the water-lock. Installation of piping should be done as shown in the following
diagram.
6-a)
In case the water outlet of the engine side (A) is above water line.
6-b)
In case the water outlet of the engine side (A) is below water line.
7) Air ventilation and Intake pipe
If the engine is operated at below normal output, incomplete combustion can occur as a result
of an overheated engine room. Therefore, the engine room should be adequately ventilated.
Important
During piping works be sure to cover the intake opening to prevent the entry
of foreign matter.