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-