Yanmar 1GM10 Install guide

YANMAR
DIESEL INBOARD SHOP MANUAL
ONE, TWO 8. THREE CYLINDER ENGINES

General Information
Troubleshooting
Operation, Lubrication, Maintenance and Tune
- up
Lay
- up and Fitting Out
Single
- Cylinder Engines
' Multicyiinder Engines
Fuel Injectionand GovernorSystems
Cooling System
Eiectricai System
Transmission-KM Series
Transmission-KBWSeries
Index
Wiring Diagrams

Contents
QUICKREFERENCEDATA .............................................. IX
CHAPTER ONE
GENEMLINFORMAflON ............................................... 1
Manual organization ......................... 1 Lubricants ................................. 8
Notes. cautions and warnings
.................. 2 RTV gasket sealant .......................... 9
Safety first ................................. 2 Threadlock ................................ 9
Service hints ............................... 3 Basic hand tools ............................ 9
Parts replacement ........................... 4 Precision measuring tools ..................... 13
Torque specifications
........................ 4 Mechanic's tips ............................. 16
Fasteners
.................................. 4 Bearing replacement ......................... 18
Seals
..................................... 23
CHAPTER TWO
TROUBLLSHO<YI1NG .................................................. 26
Starting system ............................. 27 Engine exhaust smoke
....................... 35
Charging system
............................ 31 Engine noises .............................. 35
Charging system tests
........................ 3 1 Engine troubleshooting ....................... 36
Fuel system
................................ 32 Cooling system ............................. 36
............................. Cooling system 34 Lubrication system .......................... 36

CHAPTER THREE
OPERATION. LUBRICATION. MAINTENANCE AND TUNE
- UP ................... 42
Fuel requirements ...... : .................... 42 Engine maintenanceand lubrication
............. 44
Preoperational checks
........................ 42 Cooling system
............................. 52
Starting checklist
............................ 43 Battery
.................................... 56
......................... Stopping the engine 44 Engine tune - up ............................. 57
Emergency engine stopping
................... 44 Transmission
............................... 60
Post
- operational checks ...................... 44
CHAPTER FOUR
LAY.UPANDFITT1NGOUT ............................................. 63
Lay - up .................................... 63 Fittingout
................................. 66
Cooling system draining
...................... 64
CHAPTER FIVE
SINGLE.CYLINDERENGINES ............................................ GS
Diesel engine fundamentals ................... 68 Pushrods
.................................. 79
Engine serial number and code
................. 70 Pistoniconnecting rod assembly
................ 79
Replacement parts
........................... 70 Timing gearcase 85
............................
Engine removal precautions ................... 70 Lubrication system
.......................... 86
Valvecover
................................ 71 Flywheel
.................................. 89
. .
Breather assembly ........................... 71 Drlvedisc
................................. 91
Decompression mechanism
................... 73 Crankshaft
................................. 91
Cylinder head
.............................. 73 Mainbearings
.............................. 93
Rocker shaft assembly
....................... 76 Camshaft 93
..................................
Valves and valve seats ........................ 77 Cylinder block
.............................. 95
CHAPTER SIX
MULTICYLINDER ENGINES
............................................. 99
Engine serial number and code ................. 99 Push rods
.................................. 113
................
Replacement parts ........................... 100 Pistoniconnecting rod assembly 113
Engine
.................................... 100 Timing gearcase
............................ 118
..........................
Valve cover ................................ 10 1 Lubrication system 120
Breather assembly
........................... 10 1
Flywheel ................................ 122
Decompression mechanism
................... 102 Drivedisc
................................. 123
Exhaust manifold
........................... 103 Crankshaft
................................. 123
Cylinderhead
.............................. 105 Mainbearings
.............................. 126
Rocker shaft assembly
....................... 109 Camshaft
................................. 127
Valves and valve seats
........................ 110 Cylinder block
.............................. 128
CHAPTER SEVEN
FUEL INJECTIONAND GOVERNOR SYSTEMS
............................... 138
Fuel injection fundamentals ................... 138 Fuel injection pump
......................... 149
Fuel injection system bleeding
................. 142 Fuel transfer pump
.......................... 150
Fuel injection timing
......................... 144 Fuellines .................................. 151
Fuel injector
............................... 146 Governor system
............................ 152

CHAPTER EIGHT
COOLINGSYIZM ................................................... 159
Cooling systems ............................ 159 Seawater pump ............................. 170
Thermostat
................................ 165 Freshwater pump
............................ 177
Hose replacement
........................... 168 Freshwater cooling system maintenance ......... 177
Drivebelts
................................. 169 Seawater cooling system maintenance ........... 181
CHAPTER NINE
ELECTRICALSYSTEM
................................................ 183
Battery ................................... 183 Senders
................................... 195
Electrical protection
......................... 188 Warning lamps
............................. 197
Charging system
............................ 189 Alarm buzzer
.... .I. ......................... 197
Starting system
............................. 190 Tachometer ................................ 197
Switches
.................................. 195
CHAPTER TEN
TRANSMISSION--KM SERIES .......................................... 199
Operation ................................. 199 Reassembly
................................ 208
Removal/installation ......................... 20 1
Bearing adjustment .......................... 211
Overhaul
.................................. 202 Drivedisc
................................. 213
CHAPTER ELEVEN
......................................... TRANSMISSION--KBWSERIES 216
Operation ................................. 216 Bearing adjustment
.......................... 224
Removal/installation ......................... 217 Drivedisc
................................. 225
Overhaul
.................................. 217
INDEX ........................................................... 227
WIRING DIAGRAMS ................................................. 231

Chapter One
This shop manual covers the GM Yanmar ma
-
rine diesel engine series identified in Table 1.
Troubleshooting, tune - up, maintenance and repair are
not difficult, if you know what tools and equipment to use
and what to do. Step
- by - step instructions guide you
through jobs ranging from simple maintenance to com
-
plete engine overhaul.
This manual can be used by anyone from a first
- time
do
- it - yourselfer to a professional mechanic. Detailed
drawings and clear photographs provide all the informa
-
tion needed to do the work right.
Some oftheprocedures in this manual require the useof
special tools. The resourceful mechanic can, in many
cases, think of acceptable substitutes for special tools.
However,using a substitutefor aspecial tool is not recom
-
mended, as it can be dangerous and may damage the part.
If a tool can be designed and safely made, but will require
some type of machine work, contact a local community
college or high school that has a machine shop curricu
-
lum. Shop teachers sometimes welcome outside workthat
can be used as practical shop applications 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.
Someengine model numbersend with the letters F or D,
such as 2GMF or 3GMD.Suffix letter F indicates the en
-
gine is equipped with a freshwater (closed) cooling sys -
tem.Suffix letter D indicates the engine is equipped with a
Kanzaki
KBW 1 OD transmission.
Except where specified, F and D series engines are in
-
cluded when a basic model number is specified. For ex -
ample, if model 3GM is called out in a procedure, the
procedure also applies to 3GMD and 3GMF.
NOTE
Engine models ending with the letters
C
(sail drive) or V (V - drive transmission) are
not covered in this manual.
Metric and U.S. standards are used throughout this
manual. U.S. to metric conversions are in
Table 2.
Critical torque specifications are provided at the end of
each chapter (as required). Use the general torque specifi
-
cations listed in Table 3 if a torque specification is not
listed for a specific component or assembly.
Metric drill tap sizes are in
Table 4.
Tables 1 - 4 are located at the end of the chapter.
MANUAL ORGANIZATION
This chapter provides general information useful to en -
gine owners and mechanics. In addition, this chapter dis-

GENERAL INFORMATION 7
Common nut Self - lockingnut
Plain Folding
Internal tooth External tooth
Washers
There are two basic types of washers: flat washers and
lockwashers. Flat washers are simple discs with a hole to
fit a screw or bolt. Lockwashers are designed to prevent a
fastener from working loose due to vibration, expansion
and contraction.
Figure 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 during torquing.
d. As seals.
Correct
installation
of cotter pin
Flat washersare often used between a lockwasher and a
fastener to provide a smooth bearing surface. This allows
the fastener to be turned easily with a tool.
NOTE
As much care should be given to the selec
-
tion and purchase of washers as that given
to bolts, nuts and other fasteners. Avoid
washers that are made of thin,weak materi
-
als. These will deform and crush the jrst
time they are torqued, allowing the nut or
bolt to loosen.
Cotter Pins
Cotter pins (Figure 13) are used to secure fasteners in a
special location. The threaded stud or bolt must have a
hole in it. The nut or nut lock piece will have castellations
around its upper edge into which the cotter pin fits to keep
it from loosening. When properly installed, a cotter pin is
a positive locking device.
Purchase a cotter pin that will fit snugly when inserted
through the nut and the mating thread part. The cotter pin
should not be sotight that it hasto be driven in and out, but
it should not be so loose that it can moveorfloat after it is
installed.
Before installing a cotter pin, tighten the nut to the rec
-
ommended torque specification. If the castellations in thc
nut do not line up with the hole in the bolt or stud, tighten
the nut until alignment is achieved. Do not loosen the nut

8 CHAPTER ONE
to makealignment.Insert a new cotterpin through the nut
and hole,then tap the head lightlyto seat it. Bend onearm
over the flat on the nut and the otheragainst the top of the
stud or bolt (Figure 13). cutthe arms to a suitable length
to prevent them from snaggingon clothingor skin. When
thecotterpin is bent and its armscut tolength,it should be
tight.If it can be wiggled, it is improperlyinstalled.
Donot reusecotterpins,astheirendsmay breakand al
-
low the cotter pin to fall out and the fastener to loosen.
Circlips
Circlips can be internal or external design. They are
used to retain items on shafts (external type) or within
tubes (internal type). In some applications, circlips of
varyingthicknessare used to control the end play of parts
assemblies.These are often called selective circlips. Re
-
placecirclipsduring installation,as removal weakensand
deformsthem.
Two basic stylesof circlipsare available:machined and
stampedcirclips.Machinedcirclips(Figure
14) can be in -
stalled in either direction (shaft or housing) because both
faces are machined, thus creating two sharp edges.
Stamped circlips (Figure 15) are manufacturedwith one
sharp edge and one rounded edge. When installing
stampedcirclipsin a thrust situation, the sharp edge must
face away from the part producing the thrust. When in
-
stalling circlips, observe the following:
a. Remove and install circlips with circlip pliers. See
Circlip Pliers in this chapter.
b. Compressor expand circlips only enough to install
them.
c. After the circlip is installed, make sure it is com
-
pletely 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 emergency
the wrong type of lubricant is better than none at all. The
following paragraphs describe the types of lubricants
most often required.Be sure to follow the manufacturer's
recommendationsfor lubricanttypes.
Generally, all liquid lubricantsare calledoil. They may
be mineral
- based (including petroleum bases), natu-
ral - based (vegetable and animal bases), synthetic - based
oremulsions(mixtures).Grease is anoil to which a thick
-
ening base has been added so that theoend product is
semi
- solid.Grease is oftenclassifiedby the type of thick -
ener added; lithium soap is commonly used.
Fullsupport
areas
Roundededges
=sharp edges
Direction of thrust
Engine Oil
Oil for marine and automotive four
- stroke engines is
classifiedby the American Petroleum Institute(API) and
the Society of Automotive Engineers (SAE) in several
categories.Oil containersdisplay these classificationson
the top or label. API oil classificationis indicated by let
-
ters;oils for gasolineenginesare identifiedby an " S " and
oils for diesel engines are identified by a
" C " .
Viscosity is an indication of the oil's thickness. The
SAE usesnumberstoindicateviscosity;thinoilshave low
numberswhile thick oils havehigh numbers.A
" W " after
the number indicatesthat the viscositytestingwas doneat
low temperatureto simulate cold
- weatheroperation. En -
gine oils fall into the 5W - 30and 20W - 50range.
Multi
- gradeoils (for example 10W-40)are lessviscous
(thinner) at low temperaturesand more viscous (thicker)
at high temperatures.This allows the oil to perform efi-
ciently across a wide range of engine operating condi-