Yanmar 1GM10 User manual

EPA Certified Engine
It meets the low emission standards set by the EPA
MARINE DIESEL ENGINE
OPERATION MANUAL
California
Proposition 65 Warning
Diesel engine exhaust and some of
its constituents are recognized by
the State of California to cause
cancer, birth defects, and other
reproductive harm.
MODEL :ޓ1GM10(C)
002522-00E
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Contents
2
CONTENTS
INTRODUCTION ................................................. 3
1. FOR YOUR SAFETY ...................................... 4
1.1 WARNING SYMBOLS ............................. 4
1.2 SAFETY PRECAUTIONS ........................ 4
1.3 WARNING LABELS ................................. 7
2. PRODUCT EXPLANATION ............................ 8
2.1 USE, DRIVING SYSTEM, ETC. .............. 8
2.2 Engine Specifications .............................. 9
2.2.1 Direct Seawater Cooling Type,
GM series...................................... 9
2.2.2 Direct Seawater Cooling Type,
GMC series ................................. 10
2.2.3 Direct Seawater Cooling Type,
GMV series ................................. 11
2.3 Names of Parts ...................................... 12
2.4 Major Servicing Parts ............................. 13
2.5 Control Equipment ................................. 14
2.5.1 Control Panel .............................. 14
2.5.2 Single Lever Remote Control Handle
(Morse Type) - Optional. ............. 16
2.5.3 Stopping Equipment.................... 16
2.5.4 Decompression Equipment ........ 16
3. OPERATION ................................................. 17
3.1 Fuel Oil, and Lube Oil ............................ 17
3.1.1 Fuel Oil........................................ 17
3.1.2 Lube Oil....................................... 18
3.2 Before Initial Operation .......................... 19
3.2.1 Supply Fuel Oil............................ 19
3.2.2 Supply Engine Lube Oil............... 19
3.2.3 Supply Clutch Lube Oil................ 19
3.2.4 Cranking...................................... 20
3.2.5 Check and Resupply Lube Oil..... 20
3.3 Operating your engine ........................... 21
3.3.1 Inspection Before Starting........... 21
3.3.2 How to Start the Engine .............. 22
3.3.3 Operation .................................... 24
3.3.4 Cautions During Operation.......... 24
3.3.5 Stopping the Engine.................... 25
3.4 Long Term Storage ................................ 26
4. MAINTENANCE & INSPECTION ..................27
4.1 General Inspection Rules .......................27
4.2 List of Periodic Inspection Items .............28
4.3 Periodic Inspection Items .......................30
4.3.1 Inspection on Initial 50 Hrs. of Opera-
tion (or after 1 Month) .................. 30
4.3.2 Inspection Every 50 Hours
(or Monthly).................................. 30
4.3.3 Inspection Every 150 hours. ........ 32
4.3.4 Inspection Every 300 Hrs............. 32
4.3.5 Inspection Every 600 Hrs............. 33
4.4 EPA Requirements .................................34
4.4.1 EPA and ARB Certification Plate . 34
4.4.2 Conditions to Insure Compliance with
Emission Standards ..................... 35
4.4.3 Inspection and Maintenance........ 36
4.4.4 Emission System Warranty
Statement..................................... 36
5. TROUBLE AND TROUBLESHOOTING ........37
6. PIPING DIAGRAMS ......................................40
7. WIRING DIAGRAMS .....................................41
7.1 For the A-type instrument panel .............41
7.2 For the B-type instrument panel .............42
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Introduction
3
This Operation Manual describes the operation, maintenance and inspection of the
1GM10(C) Yanmar Marine Diesel Engines.
Read this Operation Manual carefully before operating the engine to ensure that it is
used correctly and that it stays in the best possible condition.
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 dealer or
distributor.
Make sure this manual is transfered to subsequent owners. It should be considered as a
permanent part of the engine and remain so.
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 this, please contact your Yanmar dealer or distributor.
The marine gear described in this manual is Yanmar Model KM Series.
With regard to the sail drive, this manual describes lube oil selection and specification
only. Please read the Sail Drive Operation Manual, which is supplied with the Sail Drive
Unit, for further information.
Tank you for purchasing a YANMAR Marine Diesel Engine.
Operation Manual
(Marine Engine)
Models 1GM10(C)
Code. No. 42221-556060
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1. For your safety
4
1. FOR Y OUR SAFETY
1.1 WARNING SYMBOLS
Most operation, maintenance and inspection problems arise due to users' failure to
comply with the rules and precautions for safe operation described in this operation
manual. Often, users do not understand or recognize the signs of approaching
problems. Improper handling can cause burns and other injuries and can result in death.
Be sure to read this operation manual carefully before operating the engine and observe
all of the instructions and precautions described in this manual.
Below follow the warning signs used in this manual. Pay special attention to parts
containing these words and signs.
DANGER indicates an imminently hazardous
situation which, if not avoided, WILL result in
death or serious injury.
WARNING indicates a potentially hazardous
situation which, if not avoided, COULD result in
death or serious injury.
CAUTION indicates a potentially hazardous
situation which, if not avoided, may result in minor
or moderate injury.
This sign is also be used to alert against unsafe
practices.
The descriptions captioned by are particularly important cautions for
handling. If you ignore them, the performance of your machine may deteriorate leading
to problems.
1.2 SAFETY PRECAUTIONS
(Observe these instructions for your own safety!)
Precautions for Operation
Filler Cap of Fresh Water Tank
Never open the cap of the fresh water tank while the engine is still hot.
Steam and hot water will spurt out and burn you seriously. Wait until
the temperature of the fresh water tank has dropped, wrap a cloth
around the filler cap and loosen the cap slowly. After inspection,
refasten the cap firmly.
002523-00E
002524-00E
002525-00E
002526-00E
002527-00E
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1. For your safety
5
Battery
Never smoke or permit sparks near the battery, because it may emit
explosive hydrogen gas. Place the battery in a well-ventilated place.
Fuel
Use only diesel oil. Never use other fuels, including gasoline,
kerosene, etc., because they could cause a fire. The wrong fuel could
also cause the fuel injection pump and injector to fail due to lack of
proper lubrication. Be sure to check that you have selected the correct
diesel fuel before filling the fuel tank.
Fire Prevention
Be sure to stop the engine and confirm that there are no open flames
in the vicinity before supplying fuel. If you do spill fuel, wipe such
spillage carefully and dispose of the wiping materials properly. Wash
your hands thorougly with soap and water.
Never place oil or other flammable material in the engine room.
Install a fire extinguisher near the engine room, and familiarize
yourself with its use.
Exhaust Gas
Exhaust gas contains poisonous carbon monoxide and should not be
inhaled.
Be sure to install ventilation ports or ventilators in the engine room and
ensure good ventilation during engine operation.
Moving Parts
Do not touch or let your clothing get caught in the moving parts of the
engine, such as the front drive shaft, V-belt or propeller shaft, during
engine operation. You will be injured.
Never operate the engine without the covers on the moving parts.
Burns
The whole engine is hot during operation and immediately after
stopping. The exhaust manifold, exhaust pipe and high pressure fuel
pipe are very hot. Never touch these parts with your body or clothing.
002528-00E
002529-00E
002530-00E
002531-00E
002532-00E
002533-00E
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1. For your safety
6
Alcohol
Never operate the engine while you are under the influence of alcohol.
Never operate the engine when you are ill or feeling unwell.
SAFETY PRECAUTIONS FOR INSPECTION
Battery Fluid
Battery fluid is dilute sulfuric acid. It can blind you if it gets in your
eyes, or burn your skin. Keep the fluid away from your body. If you
touch it, wash it off immediately with a large quantity or fresh water
and call your doctor for treatment.
Fire by Electric Short-Circuits
Always turn off the battery switch before inspecting the electrical
system.
Failure to do so could cause short-circuiting and fires.
Stop the engine before servicing
Stop the engine before you service it.
Turn the battery switch off. If you must inspect while the engine is in
operation, never touch moving parts. Keep your body and clothing well
clear of all moving parts.
Scalds
If extracting oil from the engine while it is still hot, don't let the oil
splash on you.
Wait until the temperature has dropped before extracting cooling
water
from the engine. Don't let it splash on you.
Forbidden Modifications
Never release the limiting devices such as the engine speed limit, fuel
injection limit, etc.
Modification will impair the safety and performance of the product and
shorten product life.
Also note that any troubles arising from modification are not covered
by our warranty.
Precautions for Treating Waste
Never dispose of waste oil or other fluid in a field, sewer, river, or the
sea. Treat waste matters safely observing regulations or laws.
Ask a waste recovery company to collect it.
002534-00E
002535-00E
002536-00E
002532-00E
002533-00E
002537-00E
002537-00E
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1. For your safety
7
SAFETY PRECAUTIONS FOR INSPECTION
1.3 WARNING LABELS
To insure safe operation, warning device
labels have been attached. Their location
is shown below and they should always
be visible. Please replace if damaged or
lost.
1GM10
Part Code No.
128296-07350
128296-07350
WARNING
Warning Label
002539-00E
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2. Product explanation
8
2. PRODUC T EXPLAN ATION
2.1 USE, DRIVING SYSTEM, ETC.
The engine is equipped with marine gear, connect the marine gear output shaft to the
propeller shaft.
In order to obtain full performance from your engine, it is imperative that you check the
size and structure of the hull and use a propeller of the appropriate size.
The engine must be installed correctly with safe cooling water and exhaust piping and
electrical wiring. The PTO work should be easy to use for onboard equipment.
To hand l e t h e d rive eq u i p m e nt, dr i v e n systems (including the propeller) and other
onboard equipment,be sure to observe the instructions and cautions given in the
operation manuals supplied by the shipyard and equipment manufacturers.
The laws of some countries may require hull and engine inspections, depending on the
use, size and cruising area of the boat.
The installation, fitting and surveying of this engine all require specialized knowledge
and engineering skills. Consult Yanmar's local subsidiary in your region or your
distributor or dealer.
Never modify this product or release the limit devices (which limit engine speed,
fuel injection quantity, etc.). Modification will impair the safety and performance of
the product and functions and shorten the product life.
Please note that any troubles arising from modification of the product will not be
covered by our warranty.
DETAIL OF NAME PLATE
002540-00E
MODEL KM
GEARRATIO
OIL SAE20/30HD
OIL QTY. LTR.
NO.
KANZAKI
OSAKA JAPAN
The name plate shown below is attached
to the engine. Check the engine's model,
output, rpm and serial number on the
name plate.
The name plate shown below is
described in the marine gear. Check the
marine gear's model, gear ratio, oil used,
oil quantity and serial number.
YANMAR DIESEL ENGINE
YANMAR CO., LTD.
MADE IN JAPAN
MODEL
CONT. RATING kW rpm
MAX. OUT PUT kW rpm
ENGINE NO.
002541-00E
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2. Product explanation
9
2.2 Engine Specifications
2.2.1 Direct Seawater Cooling Type, GM series
(Note) 1. Rating condition: ISO 3046-1 and ISO 8665. 2. 1hp=0.7355 kW.
Engine Model 1GM10
Type Vertical 4-cycle water cooled diesel engine
Combustion system Swirl pre-combustion chamber
Number of cylinders 1
Bore × stroke mm (in.) 75 × 72 (2.95 × 2.83)
Displacement l (cu.in.) 0.318 (19.40)
Continuous
rating output
Output/crankshaft
speed
kW/rpm
(HP/rpm)
5.9/3400
(8.02/3400)
Brake mean
effective pressure
kg/cm2
(lb./in.2)
6.66
(94.71)
Piston speed m/sec.
(ft./sec.)
8.16
(26.77)
One hour
rating output
Output/crankshaft
speed
kW/rpm
(HP/rpm)
6.7/3600
(9.1/3600)
Brake mean
effective pressure
kg/cm2
(lb./in.2)
7.07
(100.54)
Piston speed m/sec.
(ft./sec.)
8.64
(28.35)
Compression ratio 23.0
Fuel injection timing (b.T.D.C.) ° 15 ± 1
Fuel injection pressure kg/cm2
(lb./in.2)
170 ± 5
(2347 - 2489)
Main power take off at Flywheel side
Front power take off at Crankshaft V-pulley side
Direction of
rotation
Crankshaft Counter-clockwise viewed from stern
Propeller shaft (Ahead) Clockwise viewed from stern
Cooling system Direct seawater cooling (rubber impeller water pump)
Lubrication system Complete enclosed forced lubrication
Starting
system
Type Electric and manual
Starting motor DC 12V, 1.0kW
AC generator 12V, 35A
Marine gear
system
Model KM2P
Type Mechanical cone clutch with single stage
for both ahead and astern
Reduction
ratio
Forward 2.21 2.62 3.22
Reverse 3.06 3.06 3.06
Propeller
speed
Forward rpm 1540 1298 1055
Reverse rpm 1113 1113 1113
Lubricating oil capacity l (cu.in.) 0.3 (18.31)
Weight kg (lb.) 10.3 (22.71)
Dimensions
Overall length mm (in.) 554 (21.81)
Overall width mm (in.) 410 (16.14)
Overall height mm (in.) 485 (19.09)
Lubricating oil
capacity
(rake angle 8°)
Tota l l (cu.in.) 1.3 (79.33)
Effective l (cu.in.) 0.6 (36.61)
Engine weight with marine gear kg (lb.) 76 (167)
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2. Product explanation
10
2.2.2 Direct Seawater Cooling Type, GMC series
(Note) 1. Rating condition: ISO 3046-1 and ISO 8665. 2. 1hp=0.7355 kW.
(Note) Sail drive unit will be coupled with the engine in the market.
Engine Model 1GM10C
Type Vertical 4-cycle water cooled diesel engine
Combustion system Swirl pre-combustion chamber
Number of cylinders 1
Bore × stroke mm (in.) 75 × 72 (2.95 × 2.83)
Displacement l (cu.in.) 0.318 (19.40)
Continuous
rating output
Output/crankshaft
speed
kW/rpm
(HP/rpm)
5.9/3400
(8.02/3400)
Brake mean
effective pressure
kg/cm2
(lb./in.2)
6.66
(94.71)
Piston speed m/sec.
(ft./sec.)
8.16
(26.77)
One hour
rating output
Output/crankshaft
speed
kW/rpm
(HP/rpm)
6.7/3600
(9.1/2600)
Brake mean
effective pressure
kg/cm2
(lb./in.2)
7.07
(100.54)
Piston speed m/sec.
(ft./sec.)
8.64
(28.35)
Compression ratio 23.0
Fuel injection timing (b.T.D.C.) ° 15 ± 1
Fuel injection pressure kg/cm2
(lb./in.2)
170 ± 5
(2347 - 2489)
Main power take off at Flywheel side
Front power take off at Crankshaft V-pulley side
Direction of
rotation
Crankshaft Counter-clockwise viewed from stern
Propeller shaft (Ahead) Clockwise viewed from stern
Cooling system Direct seawater cooling (rubber impeller water pump)
Lubrication system Complete enclosed forced lubrication
Starting
system
Type Electric and manual
Starting motor DC 12V, 1.0kW
AC generator 12V, 35A
Marine gear
system
Model SD20
Type Sail drive unit- Dog type clutch, spiral bevel gear type
Reduction
ratio
Forward 2.64
Reverse 2.64
Propeller
speed
Forward rpm 1290
Reverse rpm 1290
Dimensions
Overall length mm (in.) 412 (16.22)
Overall width mm (in.) 410 (16.14)
Overall height mm (in.) 485 (19.09)
Lubricating oil
capacity
(rake angle 8°)
Tota l l (cu.in.) 1.3 (79.33)
Effective l (cu.in.) 0.6 (36.61)
Engine weight with sail driver kg (lb.) 104 (229)
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2. Product explanation
11
2.2.3 Direct Seawater Cooling Type, GMV series
(Note) 1. Rating condition: ISO 3046-1 and ISO 8665. 2. 1hp=0.7355 kW.
Engine Model 1GM10V
Type Vertical 4-cycle water cooled diesel engine
Combustion system Swirl pre-combustion chamber
Number of cylinders 1
Bore × stroke mm (in.) 75 × 72 (2.95 × 2.83)
Displacement l (cu.in.) 0.318 (19.40)
Continuous
rating output
(DIN 6270A)
Output/crankshaft
speed
kW/rpm
(HP/rpm)
5.9/3400
(8.02/3400)
Brake mean
effective pressure
kg/cm2
(lb./in.2)
6.66
(94.71)
Piston speed m/sec.
(ft./sec.)
8.16
(26.77)
One hour
rating output
(DIN 6270B)
Output/crankshaft
speed
kW/rpm
(HP/rpm)
6.7/3600
(9.1/3600)
Brake mean
effective pressure
kg/cm2
(lb./in.2)
7.07
(100.54)
Piston speed m/sec.
(ft./sec.)
8.64
(28.35)
Compression ratio 23.0
Fuel injection timing (b.T.D.C.) ° 15 ± 1
Fuel injection pressure kg/cm2
(lb./in.2)
170 ± 5
(2347 - 2489)
Main power take off at Flywheel side
Front power take off at Crankshaft V-pulley side
Direction of
rotation
Crankshaft Clockwise viewed from stern
Propeller shaft (Ahead) Clockwise viewed from stern
Cooling system Direct seawater cooling (rubber impeller water pump)
Lubrication system Complete enclosed forced lubrication
Starting
system
Type Electric and manual
Starting motor DC 12V, 1.0kW
AC generator 12V, 35A
Marine gear
system
Model KM3V
Type V-drive, mechanical cone clutch with single stage
for both ahead and astern (Angle 15 degree)
Reduction
ratio
Forward 2.36
Reverse 3.16
Propeller
speed DIN
6270A rating
Forward rpm 1441
Reverse rpm 1076
Lubricating oil capacity l (cu.in.) 0.8 (48.92)
Weight kg (lb.) 19.5 (43.0)
Dimensions
Overall length mm (in.) 680 (26.77)
Overall width mm (in.) 450 (17.71)
Overall height mm (in.) 554 (21.81)
Lubricating oil
capacity
(rake angle 8°)
Tota l l (cu.in.) 1.3 (79.33)
Effective l (cu.in.) 0.6 (36.61)
Engine weight with marine gear kg (lb.) 90 (198)
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2. Product explanation
12
2.3 Names of Parts
Non Operation Side
1GM10 with KM2P
Operation Side
Decompression lever Fuel injection valve
Intake silencer
Tachometer sensor
Dipstick
Marine gearbox
Output shaft
coupling
Shift lever
Starter motor
Alternator
Name plate
Thermostat cover
Fuel injection pump
Idle adjuster
Oil filler cap
Fuel injection limiter
Engine stop lever
Crankshaft V-pulley
Cooling seawater pump
Lubricating oil filter
Regulator handle
Fuel oil filter
Mixing elbow
Mounting flange
Dipstick
Fuel feed pump
002542-00E
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2. Product explanation
13
2.4 Major Servicing Parts
Name of part Function
Decompression lever Opens the exhaust valve and releases the pressure for manual starting.
Fuel filter Removes dust and water from fuel. Drain the filter periodically. The internal
element (filter) should be changed periodically.
Fuel feed pump,
Priming lever
Feed fuel to the fuel injection pump. Moving the priming lever up and down
feeds the fuel. When there is no fuel, the priming lever is used to bleed air
from the fuel system.
Filler port (engine) Filler port for engine lube oil.
Filler port (marine gear) Filler port for marine gear lube oil.
Lube oil filter Filters fine metal fragments and carbon from the lube oil.
Filtered lube oil is distributed to the engine’s moving parts.
Cooling Water System Direct seawater cooling.
Seawater cooling The seawater pump feeds seawater. The flow is controlled automatically by a
thermostat which measures the temperature during operation.
Anticorrosion zinc The metal area of the seawater cooling system is prone to electrical corrosion.
The anticorrosion zinc is installed in the cylinder block and/or cylinder head to
prevent this. The anticorrosion zinc is itself reduced over time by electrical
corrosion, so it must be replaced at fixed intervals before it is completely
consumed in order to ensure that the metal area of the seawater cooling
system remains fully protected.
Intake air silencer This is the air intake silencer. The silencer guards against dirt in the air and
reduces the noise of air intake.
Name plate Name plates are provided on the engine and the marine gear and have the
model, serial number and other data.
Starter Starter motor for the engine. Powered by the battery.
Alternator Rotates by belt drive, generates electricity and charges the battery.
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2. Product explanation
14
2.5 Control Equipment
The equipment in the control room, making remote control possible, consists of: the
instrument panel, which is connected by wire harness; the remote control handle, which
is hooked up by remote control cable to each of the engine control levers, and the
stopping equipment.
2.5.1 Control Panel
Electric Operation
There are two control panel options. The controls and alarm lamps included are shown
below.
(A) (B)
ԘWater Proof (sail drive)
ԙHigh temp. cooling water
ԚLow lube oil pressure
ԛCharge
ԜKey switch
ԝBuzzer
ԞStart switch
ԟTachometre
ԠIllumination switch 002543-00E
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2. Product explanation
15
(1) Controls and Equipment
Note: The mark indicates equipment for type B control panel only.
(2) Alarm Equipment (lamps and buzzer)
Controls and Equipment Mechanism
Key Switch
Rotary switch with 2 positions.
In the OFF position, the switch key can be inserted or removed.
In OFF, all electric current is cut off.
In ON (1 position to the right), the engine is turned on.
In ON, electric current to the controls and equipment is turned on.
The engine cannot be stopped with the key switch.
Alarm Lamps Lamps come on when there is a problem. See Section 2 for the types of lamps
and the way they work.
Alarm Buzzer Buzzer goes off when there is a problem.
Illumination Switch The switch turns on the control panel lamps.
Tachometre The engine’s rotation speed is indicated by the needle.
Hour Metre (optional) The number of hours of operation is indicated, and can be used as a guide for
periodic maintenance checks. The hour meter is at the bottom of the tachometre.
B
OFF ON
002546-00E
B
B
B
Mechanism
When the sensor detects a problem
during operation, the lamps come on and
the buzzer goes off.
Control Panel (TypeA)
There are 4 separate alarm monitors on
the upper left side of the control panel.
Control Panel (TypeB)
Alarm monitors are located on the upper
right side of the control panel. Under
normal conditions, the monitors are off.
When there is a problem, the monitors
light up.
(3) Alarm Devices
Check that the pilot lamps on the
instrument panel are as shown below
when the starter key is turned on:
NOTE:
All these signals will continue until the
engine starts up or the key is turned off.
Pilot
lamps
Low L.O. pressure alarm lamp Lit
Charge lamp Lit
Cooling water temp. alarm lamp Off
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2. Product explanation
16
2.5.2 Single Lever Remote Control
Handle (Morse Type) - Optional.
This remote control system uses a single
handle to operate marinegear-clutch-
(neutral, forward, reverse) and to control
the engine speed.
NEUTRAL: Power to the propeller shaft is
cut off and the engine idles.
FWD (FORWARD)
REV (REVERSE)
The handle controls the course of the boat
(ahead or astern) and, at the same time,
acts as an accelerator increasing the
engine speed as it is pushed further in the
FWD or REV direction. If the handle is
pulled out, engine speed can be
controlled without engaging the clutch
(clutch remains in the NEUTRAL, no load
position).
2.5.3 Stopping Equipment
Manual Operation
The engine is stopped by pulling out the
engine stop knob, which catches the fuel
ԘFWD(forward)
ԙREV(reverse)
ԚNEUTRAL(boat is stopped)
ԛClutch is disengaged
ԜPull out handle 002547-00E
injection pump stop lever thus cutting off
fuel injection.
2.5.4 Decompression Equipment
The decompression lever is used for
manual starting.
When the decompression lever is pulled,
the exhaust valve opens causing decom-
pression inside the cylinders and making
hand-turning possible. Returning the lever
to the original position closes the exhaust
valve, allowing compression and
operation condition.
Engine stopping by engine stop cable
Engine stop cable
002548-00E
Decomp. lever
Decompression
Drive
002549-00E
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3. Operation
17
3. OPERATION
3.1 Fuel Oil, and Lube Oil
3.1.1 Fuel Oil
When other than the specified
fuel oil is used, the engine will
not perform to full capacity and
parts may be damaged.
(1) Selection of Fuel Oil
Use diesel fuels for best engine
performance.
Cetane fuel number should be 45 or
greater.
(2) Handling of Fuel Oil
1)Water and dust in the fuel cause
engine failure. When fuel is stored, be
sure that the inside of the storage con-
tainer is clean, and that the fuel is
stored away from dirt or rain water.
2)Keep the fuel container stationery for
several hours to allow any dirt or
water to settle to the bottom. Use a
pump to extract the clear, filtered fuel
from the top of the container for use.
002550-00E
Use the clear filtered fuel from the upper
middle section of the container only, leaving any
contaminated fuel at the bottom. 002551-00E
(3) Fuel Tank (optional)
Be sure to attach a drain cock to the fuel
tank to enable dirt and water to settle at
the bottom of the tank to be drained off.
The fuel outlet should be positioned 20-
30mm above the bottom of the tank so
that only clean fuel is used.
(4) Fuel System
Install the fuel pipe from the fuel tank to
the fuel pump in accordance with the
diagram.
The oil/water separator (optional) is
placed at the centre section of the line.
ԛ
Ԛ
Ԙ
ԙ
ԘSediment ԙԚ Drain cock ԛTo engine
002552-00E
Fuel system
ԘFuel filter
ԙFuel feed pump
(priming lever)
ԚOil/Water separator
ԛApprox. 25 mm
ԜWithin 500 mm
ԝDrain cock
ԞFuel cock
ԟFuel returm
ԠTo fuel injection pump
ԡFuel tank
002553-00E
9
1
2
3
8
10
5
7
6
4
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3. Operation
18
3.1.2 Lube Oil
Using other than the specified
lube oil will lead to seizure of
parts, abnormal wear, andshorten
engine life.
(1) Selection of Engine Lube Oil
Use the following lube oil:
• API Classification...............CD
• SAE Viscosity.....................15W40
(2) Selection of Oil for Marine Gear
• SAE Viscosity.....................30
(3) The Sail Drive attached to
• SAE Viscosity.....................30
(4) Handling the Lube Oil
1)When handling and storing lube oil,
be careful not to allow dust and water
to enter the lube oil. Clean around the
filter port before refilling.
2)Do not mix lube oils of different types
or brands. Mixing may cause the
chemical characteristics of the lube oil
to change and lubricating perfor-
mance to drop, reducing the engine’s
life.
Before supplying lube oil to the engine
and marine gear for the first time,
extract all the lube oil already in the
tank. Use new lube oil.
3)Lube oil supplied to the engine will
undergo natural degeneration with
time even when the engine is not
used.
Lube oil should be replaced at the
specified intervals, regardless of
whether the engine is being used or
not.
002550-00E
If you operate your equipment at temperatures
below the limits shown, consult four dealer for
special lubricants and starting aids.
Air temperature
Single grade Multi grade
50q
40q
30q
20q
10q
0q
-5q
-10q
-15q
-20q
-25q
-30q
-35q
-40q
-56q
122q
104q
86q
68q
50q
32q
23q
14q
5q
-4q
-13q
-22q
-31q
-40q
-67q
SAE 40
SAE 30
SAE 15W30
SAE 15W40
SAE SW20
SAE 10W20
SAE 20W40
SAE 10W
002554-00E
GM OPERATION.book 18 ページ ２００４年１０月４日 月曜日 午前１１時１１分

3. Operation
19
3.2 Before Initial Operation
Perform the following before using the
engine for the first time:
3.2.1 Supply Fuel Oil
Using gasoline, etc.
may cause a fire.
To avoid mistakes, be
sure to double-check
the kind of fuel before
inserting. Wipe off any
spilled fuel carefully.
1. Before filling with fuel, wash out the
fuel tank and fuel system with clean
kerosene or light oil.
2. Fill the tank with clean fuel oil free of
dirt and water.
3.2.2 Supply Engine Lube Oil
1. Remove the filler port cap (yellow),
and fill with engine oil.
2. Fill with oil to the upper limit on the dip-
stick. Insert the dipstick fully to check
the level. (Check the level without
screwing the dipstick in.)
3. Tighten the filler port cap securely by
hand.
Overfilling will cause oil to be sprayed
out from breather and lead to engine
problems.
Engine Oil Capacity (Oil Pan)
1GM10(V)(C) Full:1.5l/Effective:0.8l
002529-00E
002550-00E
3.2.3 Supply Clutch Lube Oil
1. Remove the filler port cap at the top of
the marine gear, and fill with marine
gear- clutch- lube oil.
2. Fill with oil to the upper limit on the dip-
stick. insert the dipstick fully to check
the level.
3. Tighten the filler port cap securely by
hand.
Marine gear oil capacity
KM2P 0.3l
002555-00E
ԛ
Ԛ
ԙ
Ԙ
ԘFiller portޓޓޓޓޓԚUpper limit
ԙDipstickޓޓޓޓ ޓԛLower Limit
002556-00E
Ԛ
ԙ
Ԙ
ԘOil filler port cap
ԙUpper limit/Lower limit
ԚDipstick
GM OPERATION.book 19 ページ ２００４年１０月４日 月曜日 午前１１時１１分

3. Operation
20
3.2.4 Cranking
When the engine has not been used for a
long period of time, lube oil will not be
distributed to all of the operating parts.
Using the engine in this condition will lead
to seizure.
After a long period of disuse, distribute
lube oil to each part by cranking. Perform
in accordance with the following
procedures
before beginning operation.
1. Open Kingston cock.
2. Open fuel tank cock.
3. Put remote control lever in NEUTRAL.
Manual Operation
4. Pull out decompression lever.
5. Put starting handle on the starting
shaft, and turn about 10 times. Check
for abnormal noise while cranking.
002557-00E
ԘForward ԙNeutral ԚReverse
Ԛ
ԙ
Ԙ
Decomp. lever
Decompression
Drive
002549-00E
Electric Operation
4. Turn on battery switch and insert key
into key switch. Turn the key to the
ON position.
5. Pul the stop knob continuously while
cranking.
6. When the start button is pushed, the
engine will begin cranking. Continue
cranking for about 5 seconds, and
check for abnormal noise during that
time. (If you remove your hand from
the stop knob while cranking, the
engine will start. Pull continuously.)
3.2.5 Check and Resupply Lube Oil
When engine oil or clutch oil is supplied
for the first time or when they must be
replaced, conduct a trial operation of the
engine for about 5 minutes and check the
quantity of lube oil. The trial engine
operation will send the lube oil to the
parts, so the lube oil level will drop.
Check and resupply as necessary.
1. Supplying engine lube oil (See 3.2.2)
2. Supplying marine gear lube oil
(See 3.2.3)
002558-00E
Manual
start
position
GM OPERATION.book 20 ページ ２００４年１０月４日 月曜日 午前１１時１１分