Yanmar 1GM10 User manual

GM
series
OPERATION MANUAL
1GM10
1GM10C
1GM10V
P/N: 0AGMM-G00100
MARINE
ENGINES

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 Marine International.
© 2007 Yanmar Marine International
1207
ii GM Series Operation Manual
© 2007 Yanmar Marine International

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
Emission-Control Labels .................................. 13
Major Components and Functions ............................ 14
Control Equipment ................................................ 15
Instrument Panel (Optional) .............................. 15
Optional Single-Lever Throttle and Shift
Console ....................................................... 18
Before You Operate .................................................. 19
Diesel Fuel .......................................................... 19
Diesel Fuel Specifications ................................ 19
Filling the Fuel Tank ........................................ 22
Engine Oil ........................................................... 23
Engine Oil Specifications ................................. 23
Engine Oil Viscosity ........................................ 23
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© 2007 Yanmar Marine International

Checking the Engine Oil .................................. 24
Adding Engine Oil .......................................... 24
Marine Gear or Sail-Drive Oil ................................... 25
Marine Gear Oil Specifications .......................... 25
Sail-Drive Oil Specifications - SD20 .................... 25
Checking Marine Gear Oil ................................ 25
Adding Marine Gear Oil ................................... 26
Checking and Adding Sail-Drive Oil .................... 26
Cranking the Engine Manually ................................. 26
Cranking the Engine Electrically ............................... 27
Recheck the Engine Oil ................................... 28
Daily Checks ....................................................... 28
Visual Checks ............................................... 28
Checking Diesel Fuel and Engine Oil .................. 29
Checking and Refilling Marine Gear Oil ............... 29
Checking the Battery Electrolyte Level ................ 29
Checking the Alternator Belt ............................ 29
Checking the Throttle and Shift Console .............. 29
Checking the Warning Indicators ....................... 29
Preparing Fuel, Oil and Coolant in Reserve .......... 29
Engine Operation ...................................................... 31
Starting the Engine Electrically ................................. 32
Starting the Engine Manually ............................ 33
Restarting After Starting Failure ......................... 34
Starting at Low Temperatures ........................... 34
After the Engine Has Started ............................. 34
Throttle and Shift Lever Operation ............................ 36
Acceleration and Deceleration .......................... 36
Shifting the Engine ......................................... 36
Precautions During Operation .................................. 37
Shutting Down the Engine ....................................... 38
Checking the Engine After Operation ......................... 39
Periodic Maintenance ................................................ 41
Safety Precautions ................................................ 41
Precautions ......................................................... 43
The Importance of Periodic Maintenance ............. 43
Performing Periodic Maintenance ...................... 43
The Importance of Daily Checks ........................ 43
Keep a Log of Engine Hours and Daily Checks ..... 43
Yanmar Replacement Parts .............................. 43
Tools Required .............................................. 43
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iv GM Series Operation Manual
© 2007 Yanmar Marine International

Ask Your Authorized Yanmar Marine Dealer or
Distributor For Help ........................................ 43
Tightening Fasteners ...................................... 44
EPA Maintenance Requirements .............................. 45
EPA Requirements for USA and Other Applicable
Countries ..................................................... 45
Conditions to Ensure Compliance with EPA
Emission Standards ........................................ 45
Inspection and Maintenance ............................. 45
Periodic Maintenance Schedule ............................... 46
Inspection and Maintenance of EPA Emission-
Related Parts ................................................ 48
Periodic Maintenance Procedures ............................ 49
After Initial 50 Hours of Operation ...................... 49
Every 50 Hours of Operation ............................. 52
Every 150 Hours of Operation ........................... 53
Every 250 Hours of Operation ........................... 54
Every 1000 Hours of Operation ......................... 58
Troubleshooting ....................................................... 59
Troubleshooting After Starting ................................. 59
Troubleshooting Information .................................... 60
Troubleshooting Chart ........................................... 61
Long-Term Storage ................................................... 65
Prepare Engine for Long-Term Storage ...................... 65
Draining the Cooling System ................................... 66
Specifications .......................................................... 67
Principal Engine Specifications ................................ 67
1GM10 Engine Specifications ........................... 67
1GM10C Engine Specifications ......................... 69
1GM10V Engine Specifications ......................... 71
System Diagrams ..................................................... 73
Piping Diagrams ................................................... 73
Wiring Diagrams ................................................... 76
Emission System Warranty ........................................ 81
Non-Road Emission System Warranty ....................... 81
Yanmar Co., Ltd. Limited Emission Control
System Warranty - USA Only ............................ 81
Maintenance Log ........................................... 84
TABLE OF CONTENTS
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© 2007 Yanmar Marine International

This Page Intentionally Left Blank
TABLE OF CONTENTS
vi GM Series Operation Manual
© 2007 Yanmar Marine International

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.
• If this Operation 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.
GM Series Operation Manual 1
© 2007 Yanmar Marine International

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:
INTRODUCTION
2GM Series Operation Manual
© 2007 Yanmar Marine International

SAFETY
Yanmar considers safety of great
importance and recommends that anyone
who comes in 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 engine’s safety
decals. Keep the decals 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 decal attached to it, make
sure you order the new part and decal at the
same time.
!
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.
!
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 engine, personal property
and / or the environment or cause the
equipment to operate improperly.
GM Series Operation Manual 3
© 2007 Yanmar Marine International

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 decals are additional
reminders for safe operating and
maintenance techniques.
• See your authorized Yanmar Marine
dealer or distributor for additional training.
During Operation and
Maintenance
!
DANGER
The safety messages that follow have
DANGER level hazards.
Crush Hazard
NEVER stand under a hoisted
engine. If the hoist mechanism
fails, the engine will fall on you.
Fire Hazard
Ensure that appropriate fire
detection and extinguishing
equipment are installed and
checked periodically for
proper operation.
SAFETY
4GM Series Operation Manual
© 2007 Yanmar Marine International