Yanmar 1GM10 User manual

MARINE ENGINES
OPERATION MANUAL
en
English
1GM10
1GM10C
1GM10V

Disclaimers:
All information, illustrations and specifications in this manual are based on the latest
information available at the time of publishing. The illustrations used in this manual
are intended as representative reference views only. Moreover, because of our
continuous product improvement policy, we may modify information, illustrations
and/or specifications to explain and/or exemplify a product, service or maintenance
improvement. We reserve the right to make any change at any time without notice.
Yanmar and are registered trademarks of YANMAR CO., LTD. in
Japan, the United States and/or other countries.
All Rights Reserved:
No part of this publication may be reproduced or used in any form by any means -
graphic, electronic, or mechanical, including photocopying, recording, taping, or
information storage and retrieval systems - without the written permission of
YANMAR CO., LTD.
MODEL
OPERATION MANUAL CODE
All Rights Reserved, Copyright
1GM10, 1GM10C, 1GM10V
0AGMM-G00101

GM Series Operation Manual i
TABLE OF
CONTENTS
Page
INTRODUCTION .............................................................. 1
RECORD OF OWNERSHIP ...................................... 2
SAFETY ........................................................................... 3
SAFETY PRECAUTIONS .......................................... 4
General Information............................................. 4
Before You Operate............................................. 4
During Operation and Maintenance..................... 4
LOCATION OF SAFETY DECALS ............................ 8
PRODUCT OVERVIEW ................................................... 9
YANMAR GM FEATURES AND APPLICATIONS ..... 9
New Engine Break-In......................................... 10
COMPONENT IDENTIFICATION ............................ 11
Service Side - 1GM10 with KM2P ..................... 11
Non-Service Side - 1GM10 with KM2P.............. 12
LOCATION OF NAMEPLATES................................ 13
MAJOR COMPONENTS AND FUNCTIONS ........... 14
CONTROL EQUIPMENT ......................................... 15
Instrument Panel (Optional)............................... 15
Single-Lever Throttle and Shift Console
(Optional) ........................................................... 22
BEFORE YOU OPERATE ............................................. 25
INTRODUCTION...................................................... 25
SAFETY PRECAUTIONS ........................................ 25
DIESEL FUEL .......................................................... 26
Diesel Fuel Specifications ................................. 26
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TABLE OF CONTENTS
ii GM Series Operation Manual
ENGINE OIL ............................................................. 29
Engine Oil Specifications .................................. 29
Engine Oil Viscosity ........................................... 30
Checking the Engine Oil..................................... 30
Adding Engine Oil .............................................. 31
MARINE GEAR OR SAIL-DRIVE OIL ...................... 31
Marine Gear Oil Specifications........................... 31
Sail-Drive Oil Specifications - SD20................... 31
Checking Marine Gear Oil.................................. 32
Adding Marine Gear Oil...................................... 32
Checking and Adding Sail-Drive Oil ................... 32
CRANKING THE ENGINE MANUALLY ................... 33
CRANKING THE ENGINE ELECTRICALLY ............ 34
Recheck the Engine Oil...................................... 34
DAILY CHECKS ....................................................... 35
Visual Checks .................................................... 35
Checking Diesel Fuel and Engine Oil................. 35
Checking and Refilling Marine Gear Oil ............. 35
Checking the Battery Electrolyte Level .............. 35
Checking the Alternator Belt ............................. 36
Checking the Throttle and Shift Console............ 36
Checking the Warning Indicators ....................... 36
Preparing Fuel, Oil and Coolant in Reserve....... 36
ENGINE OPERATION .................................................... 37
INTRODUCTION ...................................................... 37
SAFETY PRECAUTIONS......................................... 37
STARTING THE ENGINE ELECTRICALLY............. 39
Starting the Engine Manually ............................. 40
Restarting After Starting Failure......................... 40
Starting at Low Temperatures............................ 41
After the Engine Has Started ............................. 41
THROTTLE AND SHIFT LEVER OPERATION........ 42
Acceleration and Deceleration ........................... 42
Shifting the Engine ............................................. 42
CAUTIONS DURING OPERATION.......................... 43
SHUTTING DOWN THE ENGINE............................ 45
CHECKING THE ENGINE AFTER OPERATION..... 46
PERIODIC MAINTENANCE ........................................... 47
INTRODUCTION ...................................................... 47
SAFETY PRECAUTIONS......................................... 47
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TABLE OF CONTENTS
GM Series Operation Manual iii
12/05
PRECAUTIONS ....................................................... 49
The Importance of Periodic Maintenance.......... 49
Performing Periodic Maintenance ..................... 49
The Importance of Daily Checks ....................... 49
Keep a Log of Engine Hours and Daily Checks 49
Yanmar Replacement Parts .............................. 49
Tools Required .................................................. 49
Ask Your Authorized Yanmar Marine Dealer or
Distributor for Help............................................. 49
Tightening Fasteners......................................... 50
PERIODIC MAINTENANCE SCHEDULE ................ 51
PERIODIC MAINTENANCE PROCEDURES .......... 53
After Initial 50 Hours of Operation ..................... 53
Every 50 Hours of Operation ............................. 57
Every 150 Hours of Operation ........................... 58
Every 250 Hours of Operation ........................... 59
Every 1000 Hours of Operation ......................... 63
TROUBLESHOOTING ................................................... 65
SAFETY PRECAUTIONS ........................................ 65
TROUBLESHOOTING AFTER STARTING ............. 65
TROUBLESHOOTING INFORMATION................... 66
TROUBLESHOOTING CHART................................ 67
LONG-TERM STORAGE ............................................... 71
PREPARE ENGINE FOR LONG-TERM STORAGE 71
DRAIN SEAWATER COOLING SYSTEM ............... 72
RETURNING THE ENGINE TO SERVICE .............. 72
SPECIFICATIONS ......................................................... 73
PRINCIPAL ENGINE SPECIFICATIONS ................ 73
1GM10 Engine................................................... 74
1GM10C Engine ................................................ 75
1GM10V Engine ................................................ 76
SYSTEM DIAGRAMS .................................................... 77
PIPING DIAGRAMS................................................. 77
WIRING DIAGRAMS................................................ 80
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TABLE OF CONTENTS
iv GM Series Operation Manual
This Page Intentionally Left Blank
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GM Series Operation Manual 1
GM Series Operation Manual
INTRODUCTION
Welcome to the world of Yanmar Marine!
Yanmar Marine offers engines, drive
systems and accessories for all types of
boats, from runabouts to sailboats, and
from cruisers to mega yachts. In marine
leisure boating, the worldwide reputation of
Yanmar Marine is second to none. We
design our engines to respect nature. This
means quieter engines, with minimal
vibrations, cleaner than ever. All of our
engines meet applicable regulations,
including emissions, at the time of
manufacture.
To help you enjoy your Yanmar GM series
engine for many years to come, please
follow these recommendations:
• Read and understand this Operation
Manual before you operate the engine to
ensure that you follow safe operating
practices and maintenance procedures.
• Keep this Operation Manual in a
convenient place for easy access.
•IfthisOperation Manual is lost or
damaged, order a new one from your
authorized Yanmar Marine dealer or
distributor.
• Make sure this manual is transferred to
subsequent owners. This manual should
be considered a permanent part of the
engine and remain with it.
• Constant efforts are made to improve the
quality and performance of Yanmar
products, so some details included in
this Operation Manual may differ slightly
from your engine. If you have any
questions about these differences,
please contact your authorized Yanmar
Marine dealer or distributor.
• The specifications and components
(instrument panel, fuel tank, etc.)
described in this manual may differ from
ones installed on your vessel. Please
refer to the manual provided by the
manufacturer of these components.
• Refer to the Yanmar Limited Warranty
Handbook for a complete warranty
description.
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INTRODUCTION
2GM Series Operation Manual
RECORD OF OWNERSHIP
Take a few moments to record the information you need when you contact Yanmar for
service, parts or literature.
Engine Model: __________________________________________________________
Engine Serial No.: _______________________________________________________
Date Purchased: ________________________________________________________
Dealer: ________________________________________________________________
Dealer Phone: __________________________________________________________
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GM Series Operation Manual 3
SAFETY
Yanmar considers safety of great
importance and recommends that anyone
that comes into close contact with its
products, such as those who install,
operate, maintain or service Yanmar
products, exercise care, common sense
and comply with the safety information in
this manual and on the machine’s safety
decals. Keep the labels from becoming
dirty or torn and replace them if they are
lost or damaged. Also, if you need to
replace a part that has a label attached to
it, make sure you order the new part and
label at the same time.
DANGER
Indicates a hazardous situation which,
if not avoided, will result in death or
serious injury.
WARNING
Indicates a hazardous situation which,
if not avoided, could result in death or
serious injury.
CAUTION
Indicates a hazardous situation which,
if not avoided, could result in minor or
moderate injury.
NOTICE
Indicates a situation which can cause
damage to the machine, personal property
and / or the environment, or cause the
equipment to operate improperly.
A
This safety alert symbol
appears with most safety
statements. It means
attention, become alert,
your safety is involved!
Please read and abide by
the message that follows
the safety alert symbol.
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SAFETY
4GM Series Operation Manual
SAFETY PRECAUTIONS
General Information
There is no substitute for common sense
and careful practices. Improper practices
or carelessness can cause burns, cuts,
mutilation, asphyxiation, other bodily injury
or death. This information contains general
safety precautions and guidelines that
must be followed to reduce risk to personal
safety. Special safety precautions are
listed in specific procedures. Read and
understand all of the safety precautions
before operation or performing repairs or
maintenance.
Before You Operate
DANGER
The safety messages that follow have
DANGER level hazards.
Never permit anyone to
install or operate the engine
without proper training.
Read and understand this
Operation Manual before you
operate or service the engine to ensure
that you follow safe operating practices
and maintenance procedures.
• Safety signs and labels are additional
reminders for safe operating and
maintenance techniques.
•Consult authorized Yanmar Marine
dealer or distributor for additional
training.
During Operation and
Maintenance
WARNING
The safety messages that follow have
WARNING level hazards.
Explosion Hazard
While the engine is running
or the battery is charging,
hydrogen gas is being
produced and can be easily
ignited. Keep the area
around the battery
well-ventilated and keep sparks, open
flames and any other form of ignition
out of the area.
Fire and Explosion Hazard
Diesel fuel is flammable and explosive
under certain conditions.
Never use a shop rag to catch the fuel.
Wipe up all spills immediately.
Never refuel with the engine running.
Fire Hazard
Undersized wiring systems
can cause an electrical fire.
Store any containers containing fuel or
other flammable products in a
well-ventilated area, away from any
combustibles or source of ignition.
Store any equipment in a designated
area away from moving parts.
Never use the engine compartment for
storage.
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SAFETY
GM Series Operation Manual 5
12/05
WARNING
Sever Hazard
Rotating parts can cause
severe injury or death.
Never wear jewelry,
unbuttoned cuffs, ties or
loose-fitting clothing and
always tie long hair back when working
near moving / rotating parts such as the
flywheel or PTO shaft. Keep hands, feet
and tools away from all moving parts.
Alcohol and Drug Hazard
Never operate the engine
while under the influence of
alcohol or drugs, or when
feeling ill.
Exposure Hazard
Always wear personal
protective equipment
including appropriate
clothing, gloves, work
shoes, and eye and hearing protection
as required by the task at hand.
Sudden Movement Hazard
Never operate the engine while wearing
a headset to listen to music or radio
because it will be difficult to hear the
warning signals.
Burn Hazard
Some of the engine
surfaces become very hot
during operation and
shortly after shutdown.
Keep hands and other
body parts away from hot
engine surfaces.
Exhaust Hazard
Never block windows, vents
or other means of
ventilation if the engine is
operating in an enclosed
area. All internal
combustion engines create carbon
monoxide gas during operation and
special precautions are required to
avoid carbon monoxide poisoning.
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SAFETY
6GM Series Operation Manual
CAUTION
The safety messages that follow have
CAUTION level hazards.
Poor Lighting Hazard
Ensure that the work area is adequately
illuminated. Always install wire cages
on portable safety lamps.
To o l H a z a rd
Always use tools appropriate for the
task at hand and use the correct size
tool for loosening or tightening
machine parts.
Flying Object Hazard
Always wear eye protection when
servicing the engine or when using
compressed air or high-pressure water.
Dust, flying debris, compressed air,
pressurized water or steam may injure
your eyes.
Coolant Hazard
Wear eye protection and
rubber gloves when you
handle engine coolant. If
contact with the eyes or skin should
occur, flush eyes and wash immediately
with clean water.
NOTICE
The safety messages that follow have
NOTICE level hazards.
It is important to perform daily checks as
listed in the Operation Manual. Periodic
maintenance prevents unexpected
downtime, reduces the number of
accidents due to poor engine performance
and helps extend the life of the engine.
Consult authorized Yanmar Marine dealer
or distributor if you need to operate the
engine at high altitudes. At high altitudes
the engine will lose power, run rough and
produce exhaust gases that exceed the
design specifications.
Always be environmentally
responsible.
Follow the guidelines of your
country’s governmental
agencies for the proper disposal of
hazardous materials such as engine oil,
diesel fuel and engine coolant. Consult the
local authorities or reclamation facility.
Never dispose of hazardous materials by
dumping them into a sewer, on the ground,
or into ground water or waterways.
If a Yanmar Marine Engine is installed at
an angle that exceeds the specifications
stated in the Yanmar Marine Installation
Manuals, engine oil may enter the
combustion chamber causing excessive
engine speed, white exhaust smoke and
serious engine damage. This applies to
engines that run continuously or those that
run for short periods of time.
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SAFETY
GM Series Operation Manual 7
12/05
NOTICE
If you have an installation with two or three
engines and only one engine is operating,
the water pickup (thru-hull) of the
non-running engine(s) should be closed.
This will prevent water from being forced
past the seawater pump and eventually
finding its way into the engine. The result
of water entering the engine could cause
seizure or other serious problems.
If you have an installation with two or three
engines, and only one engine is operating,
please note that if the propeller shaft
thru-hull (stuffing box) is lubricated by
engine water pressure and the engines are
interconnected, care must be taken that
water from the running engine does not
enter the exhaust of the non-running
engine(s). This water could cause seizure
of the non-running engine(s). Consult
authorized Yanmar Marine dealer or
distributor for a complete explanation of
this condition.
If you have an installation with two or three
engines, and only one engine is operating,
it is important to limit the amount of throttle
applied to the running engine. If you
observe black smoke or movement of the
throttle does not increase engine speed,
you are overloading the engine that is
running. Immediately throttle back to
approximately 2/3 throttle or to a setting
where the engine performs normally.
Failure to do so may cause the running
engine to overheat or cause excess
carbon buildup which may shorten the
engine’s life.
Never turn off the battery switch (if
equipped) or short the battery cables
during operation. Damage to the electrical
system will result.
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SAFETY
8GM Series Operation Manual
LOCATION OF SAFETY DECALS
Figure 1 show the location of safety decals on Yanmar GM series marine engines.
GM Engines
Figure 1
1–Part Number: 128296-07350
128296-07350
WARNING
1
0005961
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GM Series Operation Manual 9
GM Series Operation Manual
PRODUCT OVERVIEW
YANMAR GM FEATURES
AND APPLICATIONS
The GM series are four-stroke swirl
pre-combustion chamber diesel engines
equipped with direct seawater cooling
systems.
The 1GM10 is a naturally aspirated
1-cylinder engine equipped with a KM2P
marine gear.
The 1GM10C is a naturally aspirated
1-cylinder engine equipped with an SD20
sail-drive.
The 1GM10V is a naturally aspirated
1-cylinder engine equipped with a KM3V
marine gear.
The engines are equipped with a marine
gear or sail-drive unit.
These engines are designed for pleasure
craft use.
It is recommended that new vessels be
propped so the engines can operate at 100
to 200 min-1 above the Maximum Rated
Power Output engine speed (3700 to
3800) to allow for some added weight and
hull resistance. The engine must be able to
reach the Maximum Rated Power Output
(3600 min-1) under full load at all times.
Failure to do so can lead to reduced vessel
performance and increased smoke levels,
and can cause permanent damage to your
engine, which is not covered by warranty.
The engine must be installed correctly with
coolant lines, exhaust gas lines and
electrical wiring. Any auxiliary equipment
attached to the engine should be easy to
use and accessible for service. To handle
the drive equipment, propulsion systems
(including the propeller) and other onboard
equipment, always observe the
instructions and cautions given in the
operation manuals supplied by the
shipyard and original equipment
manufacturers.
The GM series engines are designed to be
operated at maximum throttle (3600 min-1)
for less than 5% of total engine time (30
minutes out of every 10 hours) and
cruising speed (3400 min-1 or less).
The laws of some countries may require
hull and engine inspections, depending on
the use, size and cruising area of the boat.
The structural design, vessel application
and installation of this engine all require
specialized knowledge and engineering
skills. See Yanmar’s local subsidiary in
your region or your authorized Yanmar
Marine dealer or distributor.
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PRODUCT OVERVIEW
10 GM Series Operation Manual
New Engine Break-In
As with all reciprocating engines, the way
your engine is operated during its first 50
hours of operation plays a very significant
role in determining how long it will last and
how well the engine will perform over its
lifetime.
A new Yanmar diesel engine must be
operated at suitable speeds and power
settings during the break-in period to allow
bearing surfaces and other friction-related
components, such as piston rings and
valve guides, to wear in properly in order to
stabilize engine lubrication and
combustion.
During the break-in period, carefully
observe the engine oil pressure and
engine temperature.
During the first 10 hours of operation, the
engine should be operated at maximum
engine speed minus 400 to 500 min-1
(approximately 60 to 70% of load) most of
the time. This will ensure the sliding parts
break in properly.
NOTICE
• During this period, avoid operating at
maximum engine speed and load to
avoid damaging or scoring sliding parts.
• Never operate at WOT (wide open
throttle) for more than a minute at a time
during the first 10 hours of operation.
Do not operate the engine at low idle or at
low speed and light load for more than
30 minutes at a time. Since unburned fuel
and engine oil will adhere to the piston
rings when operating at low speeds for
long periods, this will interfere with proper
movement of the rings and the diesel fuel
consumption may increase. Low idle
speed does not allow break-in of sliding
parts.
If operating the engine at low speed and
light load, you must race the engine to
clean the carbon from the cylinders and
the fuel injection valve.
Perform this procedure in open waters:
• With the clutch in NEUTRAL, accelerate
from the low speed position to the high
speed position briefly.
• Repeat this process five times.
Once past the initial 10 hours until 50
hours, the engine should be used over its
full operating range, with special emphasis
on running at relatively high power
settings. This is not the time for an
extended cruise at idle or low speed. The
boat should be operated at maximum
speed minus 400 min-1 most of the time
(approximately 70% load), with a
10-minute run at maximum minus 200
min-1 (approximately 80% load) every
30 minutes and a 4 to 5 minute period of
operation at WOT (wide open throttle)
once every 30 minutes. During this period,
be sure not to operate the engine at low
speed and light load for more than
30 minutes. If operating engine at low
speed and light load is necessary, race the
engine after low idle operation.
To complete engine break-in, perform
After Initial 50 Hours maintenance
procedures. See After Initial 50 Hours of
Operation on page 53.
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PRODUCT OVERVIEW
GM Series Operation Manual 11
12/05
COMPONENT IDENTIFICATION
Service Side - 1GM10 with KM2P
Figure 1 and Figure 2 illustrate a typical version of a 1GM10 engine. Your engine may
have different equipment from that illustrated.
Figure 1
Figure 1
1–Nameplate
2 – Thermostat Cover
3 – Fuel Injection Pump
4 – Idle Adjuster
5 – Oil Filler Cap
6 – Fuel Injection Limiter
7 – Engine Stop Lever
8 – Crankshaft V-Pulley
9 – Seawater Pump
10 – Engine Oil Filter
11 – Regulator Handle
12 – Fuel Feed Pump
13 – Engine Oil Dipstick
14 – Mounting Flange
15 – Mixing Elbow
16 – Fuel Filter
(1) (2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
(12)
(13)
(14)
(15)
(16)
0005850
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PRODUCT OVERVIEW
12 GM Series Operation Manual
Non-Service Side - 1GM10 with KM2P
Figure 2
Figure 2
1 – Decompression Lever
2 – Fuel Injection Valve
3 – Intake Silencer (Air Cleaner)
4 – Tachometer Sensor
5–MarineGearDipstick
6 – Marine Gearbox
7 – Output Shaft Coupling
8 – Shift Lever
9–StarterMotor
10–Alternator
(1) (2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
0005849
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PRODUCT OVERVIEW
GM Series Operation Manual 13
12/05
LOCATION OF NAMEPLATES
The nameplate of the Yanmar GM series
engine is shown in Figure 3. Check the
engine’s model, output, engine speed and
serial number on the nameplate. Replace it
if it is damaged or lost.
Figure 3
The engine nameplate is attached to the
engine rocker arm cover.
The marine gear nameplate (Figure 4) is
attached to the marine gear. Check the
marine gear’s model, gear ratio, oil used,
and serial number.
Figure 3
Figure 4
The sail drive nameplate (Figure 5) is
attached to the sail drive. Check the sail
drive model and serial number.
Figure 4
Figure 5
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㪜㪥㪞㪠㪥㪜㩷㪥㪦㪅
㩷㩷㩷㩷㫂㪮㩷㩷㩷㩷㩷㩷㩷㩷㩷㩷㩷㩷㩷㩷㫉㫇㫄
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㻻㻵㻸㻌
177524-02903
㻹㻲㻳㻚㻺㼛㻚
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196420-02124
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PRODUCT OVERVIEW
14 GM Series Operation Manual
MAJOR COMPONENTS AND FUNCTIONS
Name of Component Function
Decompression Lever Opens the exhaust valve and releases cylinder pressure to aid in manual engine
starting
Fuel Filter Removes dirt and water from the fuel. Drain the filter periodically. The filter
element (filter) should be replaced periodically.
Fuel Feed Pump
(Priming Lever)
Pumps fuel from the tank to the fuel injection system. Pumping the priming lever
up and down supplies fuel to the engine when the fuel system needs to be primed.
Engine Oil Filler Port Filler port for engine oil
Marine Gear Oil Filler Port Filler port for marine gear oil
Engine Oil Filter Filters fine metal fragments and carbon from the engine oil. Filtered engine oil is
distributed to the engine’s moving parts. The filter is a spin-on type and the
element should be replaced periodically. See Replacing the Engine Oil Filter
Element on page 55.
Cooling System Direct seawater cooling
Seawater Pump Pumps seawater from outside the vessel and through the engine. The seawater
pump has a replaceable rubber impeller.
Zinc Anode The metal surfaces of the seawater cooling system are prone to corrosion. The
zinc anode is installed in the cylinder block to prevent this. The surface of the zinc
anode erodes so it needs to be replaced at fixed intervals in order to fully protect
the seawater cooling system of the engine.
Intake Silencer
(Air Cleaner)
The intake silencer guards against dirt entering the engine induction system and
reduces the noise of air intake.
Nameplates Nameplates are provided on the engine and the marine gear and contain the
model, serial number and other data.
Starter Motor The starter motor cranks the engine and is powered by the battery.
Alternator The alternator is belt driven and generates electricity to charge the battery.
Engine Oil Dipstick Gauge stick for checking the engine oil level
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