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.

1. Seawater pump
2. Seawater strainer
3. Kingston cock
1. W.L.
2. Waterlock
3. Above seawater
line
1. W.L.
2. Waterlock
3. Vacuum valve

I3-6.] Remote control
1) Control cable Use only the single lever remote control device with 1GM 2GM, 3GM and
3HM engines.
Note
The dual lever remote control device cannot be used.
Recommended
Cable Control Cable Cable Clamp Connecting metal fittings
Speed Control Morse 33-C Yanmar Standard Yanmar Standard
Clutch Control Morse 33-C Yanmar Standard Yanmar Standard
Engine Stop (option) Yanmar made
Morse
2) Speed control
2-a) A spring is attached to the connector to absorb shock when operating the speed control
lever. Make the wiring so that the spring works when the throttle is "idling" as illustrated.
1. Spring
2. Speed Control Lever
3. Connector
4. Idle adjusting bolt

Note
1) Fix the wire to the cable clamp of the F.O. filter side.
2) Cable connector has M5 thread.
2-b)
After completing of wiring, check the following
points:
2-b)-1.
That the remote control lever and speed control lever
can be moved smoothly through the whole stroke.
2-b)-2
That the idle speed adjuster regulates the speed to
850-900 rpm, after all preparations for starting the
engine have been completed.
1. Cable clamp
3) Clutch Control
3-a)
Cone Clutch (for 1GM, 2GM, 3GMD)
3-a)-1.
Remove the spring joint from the operation lever.
3-a)-2.
With the spring joint disconnected from the operation lever,
move the operation lever forward and reverse, to make sure
that the strokes from the neutral position are the same.
3-a)-3.
Attach the spring joint to the operation lever 60mm from the shaft lever center.
The stroke from the neutral position moves through a distance of 24.4 to 35.Ohm. When the
spring joint is attached to the hole 52mm from the center of the shift lever, these strokes must
be 21.1-30.Ohm.
Note
The operation lever may not move smoothly when there is no lubrication oil in the clutch
case.

1. Remote Control Cable
2. M5 Thread
3. Operation Lever
4. Shaft
5. Clutch Case side cover
6. Spring joint
3-a)-4
Move the remote control lever to the forward
position, and make sure that the M5 thread of the
spring joint reaches to the inside of the joint.
In this position, the output shaft (propeller shaft) of
the clutch should rotate clockwise as viewed from
the stern.
3-a)-5.
Move the remote control lever to the reverse position,
and make sure that the M5 thread of the spring joint
reaches the outside of the joint. In this position, the
output shaft (propeller shaft) of the clutch should rotate
counter-clockwise as viewed from the stern.
3-a)-6.
Adjust the M5 thread depth so that the value of A, and 16 are nearly the same.

3-a)-7.
Make sure that the angle made between the spring joint
and the clutch control lever forms 90 degrees.
3-b)
Kanzaki-Hurth clutch (for 3GMD and 3HM)
To connect the cable, the operating cable must
be positioned at right angles to the shift lever
when the shift lever is in the neutral position.
The shift play, measured at the pivot point of
the shift lever, must be at least 35mm to each
side (reverse and forward) from the neutral
position. A greater shift play has no adverse
effect on the marine gearbox. After connecting
the linkage, confirm that the remote control
and the shift lever on the marine gearbox work
properly. A typical linkage arrangement is
illustrated in the figure below. 1. Astern 4. Propeller side
2. Neutral 5. Engine Side
3. Ahead
Note
Since the cable stroke may be insufficient, two holes are
drilled in the shift lever.
When the cable is attached to the hole 60mm from the
center of the rotation of the shift lever, the strokes from
the center to the forward and reverse sides must be
35mm. When the cable is attached to the hole 52mm
from the rotation of the shift lever, these strokes must be
30mm.
4) Engine stop remote control Connect the engine stop
remote control cable as in the illustration, after
completing the wiring check that the engine stop lever
can be moved smoothly through the whole stroke.

1. Clamp
2. Engine Stop lever
3. Engine stop remote control cable
[3-7.] Recommended battery capacity
Use sufficient capacity of battery.
1GM, 2GM, 3GMD -12V - 70AH (Mini)
3HM -12V - 100AH (Mini)

IV. After launching
1) Check for water or air intake around the gland part of the stern tube and the kingston cock
fitting.
2) Make sure that the engine installation bolts and shaft joints are firmly secured.
3) Release compression with the decompression lever and slowly run the engine with the
engine starting handle. Relative compression can be determined by comparing the weight (re-
sistance when turning) of the clutch handle when placed in the neutral, ahead, and astern
positions. When there is little weight difference among the three positions, decompression is
complete. If the clutch is heavier when engaged than when disengaged, this indicates that the
shaft is not in the correct position. If the engine is operated under this condition, a broken
propeller shaft may result. Check the alignment of the propeller shaft and the engine.

V. Fuel and lubricating oil
[5-1.] Selection and handling of fuel oil
1) Choice of fuel oil Fuel oils available in countries other than those listed above
which are to equipment specification may be used. Use the chart at below to
determine correct grade of fuel.
United States ASTM/D975 No.1-D or No.2-D diesel oil
United Kingdom BS2869 Class A 1 or Class A 2
Air temperature Diesel/fuel (ASTM/D975)
Below 5°C (40°F) 1-D
Above 5°C (40°F) 2-D
1-a)
As further insurance of satisfactory operation, use fuel having less than 0.5% sulphur.
1-b)
For maximum filter life, sediment and water should not exceed 0.1 %.
1-c)
To maintain proper fuel delivery during cold weather operation, use grade No.1-D diesel fuel
as defined in ASTM Designation D975 with a pour point at least 5.6°C (10°F) below the
lowest outside air temperature.
1-d)
The cetane number should be 40 minimum.
Low atmospheric temperature, as well as high altitude operation, may require use of a fuel
with a higher cetane number.
2) Storing fuel Proper fuel storage is vitally important. Keep all dirt, water and other con-
taminants out of fuel. Avoid storing fuel over long periods of time. Store fuel in a convenient
place away from buildings.
Important
Presence of water or dust in the fuel may cause failure of the engine and
early wear of the fuel injection equipment. Water and dust in the fuel
tank should be removed and clean fuel used.
3) After each day's operation.
Fill fuel tank at the end of each day's operation. This prevents condensation in fuel tank as moist
air cools.

[5-2.] Selection of lubricating oil
1) Choice of lube oil
The selection of lube oil is very important to a diesel engine. If an unsuitable oil is used, or oil
change is neglected, it may result in damage, and a shorter engine life.
When selecting the lube oil, it must be one of the following.
2) Kinds of lube oil
Choose a lube oil with a rating higher than SAE class CC.
3) Lube oil viscosity
Theviscosityofthelubeoilgreatlyinfluencesenginestartingandrunningperformance.Thelube
oil weight number chosen should vary with the season and temperature.
4) Recommended brands of lube oil for crankcase:
SAE NO. SAE NO. SAE NO.
SUPPLIER BRAND TEMP. TEMP. TEMP. TEMP.
Below 10C 10-20C 20-35C Over 35C
Shell Rotella 10W,20(W) 20(W) 30, 40 50
Talona 10W 20 30, 40 50
Rimula 20(W) 20(W) 30, 40 -
Caltex Marine 10W 20 30,40 50
Multi-
purpose 20(W), 10(W) 20 30 50
Mobile Delvac
Special 10W 20 30 -
Delvac
20W-40 20W-40 20W-40 - -
Delvac 1100
Series 10W, 20(W) 20(W) 30, 40 50
Delvac 1200
Series 10W, 20(W) 20(W) 30, 40 50
Esso Estor HD 10W 20 30, 40 50
Lube HD -20 30, 40 50
Standard 10W 20 30, 40 50
BP Energol 20W 20W 40 50

V1. Starting the new engine for the first time
Important !
Before starting the engine for the first time check carefully the following
preparations.
[6-1.] Supply of fuel oil
1) Fill fuel into the fuel tank. When you feed fuel from storage tank, put the inlet of the syphon
at the middle of the storage tank. Take care not to draw unwanted materials floating on the fuel
surface or depositing in the bottom.
2) Draining the fuel tank. Be sure to equip the fuel tank with a precipitation tank, as shown in the
figure, and install a drain cock to remove any dirt and water that accumulate. Before starting the
engine. open the drain cock to remove any precipitation and dirt.
1. Precipitation Tank
2. Drain Cock
[6-2.] Supply of lubricating oil
1) Lube oil to the crankcase
1-a)
Remove the lube oil supply port (yellow cap) and supply approved lube oil.
FOR 1GM
1. Oil Supply Port