OPERATION MANUAL MARINE ENGINES 1GM10 1GM10C 1GM10V en English
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.
GM_OM.book i ページ ２０１３年６月１０日 月曜日 午後２時２６分 TABLE OF CONTENTS Page INTRODUCTION .............................................................. 1 RECORD OF OWNERSHIP ...................................... 2 SAFETY ........................................................................... 3 SAFETY PRECAUTIONS .......................................... General Information ............................................. Before You Operate.............................................
GM_OM.book ii ページ ２０１３年６月１０日 月曜日 午後２時２６分 TABLE OF CONTENTS ENGINE OIL ............................................................. Engine Oil Specifications .................................. Engine Oil Viscosity ........................................... Checking the Engine Oil..................................... Adding Engine Oil .............................................. 29 29 30 30 31 MARINE GEAR OR SAIL-DRIVE OIL ...................... Marine Gear Oil Specifications.......................
GM_OM.book iii ページ ２０１３年６月１０日 月曜日 午後２時２６分 TABLE OF CONTENTS 12/05 PRECAUTIONS ....................................................... The Importance of Periodic Maintenance .......... Performing Periodic Maintenance ..................... The Importance of Daily Checks ....................... Keep a Log of Engine Hours and Daily Checks Yanmar Replacement Parts .............................. Tools Required ..................................................
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GM_OM.book 1 ページ ２０１３年６月１０日 月曜日 午後２時２６分 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.
GM_OM.book 2 ページ ２０１３年６月１０日 月曜日 午後２時２６分 INTRODUCTION 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.
GM_OM.book 3 ページ ２０１３年６月１０日 月曜日 午後２時２６分 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.
GM_OM.book 4 ページ ２０１３年６月１０日 月曜日 午後２時２６分 SAFETY 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.
GM_OM.book 5 ページ ２０１３年６月１０日 月曜日 午後２時２６分 SAFETY 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. Exhaust Hazard Never block windows, vents or other means of ventilation if the engine is operating in an enclosed area.
GM_OM.book 6 ページ ２０１３年６月１０日 月曜日 午後２時２６分 SAFETY 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. Tool Hazard 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.
GM_OM.book 7 ページ ２０１３年６月１０日 月曜日 午後２時２６分 SAFETY 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.
GM_OM.book 8 ページ ２０１３年６月１０日 月曜日 午後２時２６分 SAFETY LOCATION OF SAFETY DECALS Figure 1 show the location of safety decals on Yanmar GM series marine engines.
GM_OM.book 9 ページ ２０１３年６月１０日 月曜日 午後２時２６分 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.
GM_OM.book 10 ページ ２０１３年６月１０日 月曜日 午後２時２６分 PRODUCT OVERVIEW 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.
GM_OM.book 11 ページ ２０１３年６月１０日 月曜日 午後２時２６分 PRODUCT OVERVIEW 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.
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GM_OM.book 13 ページ ２０１３年６月１０日 月曜日 午後２時２６分 PRODUCT OVERVIEW 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. The sail drive nameplate (Figure 5) is attached to the sail drive. Check the sail drive model and serial number.
GM_OM.book 14 ページ ２０１３年６月１０日 月曜日 午後２時２６分 PRODUCT OVERVIEW 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.
GM_OM.book 15 ページ ２０１３年６月１０日 月曜日 午後２時２６分 PRODUCT OVERVIEW 12/05 CONTROL EQUIPMENT The control equipment at the helm makes remote control operation possible. It consists of the instrument panel, which is connected to the engine by a wire harness, and the throttle and shift console, which is connected by control cables to the engine control lever and marine gear. Instrument Panel (Optional) Equipment and Functions The instrument panel is located at the helm and is available in two options.
GM_OM.book 16 ページ ２０１３年６月１０日 月曜日 午後２時２６分 PRODUCT OVERVIEW Key Switch When the key is in the OFF position (Figure 7, (1)) the electric current is off. The key can be inserted or removed in this position. Figure 6 (1) OFF (2) ON 0005847 Figure 7 1–OFF Position 2–ON Position The ON position (Figure 7, (2)) allows electrical current to the controls and equipment and allows the engine to keep running. To stop the engine, keep the key switch in the ON position and pull the engine stop knob.
GM_OM.book 17 ページ ２０１３年６月１０日 月曜日 午後２時２６分 PRODUCT OVERVIEW 12/05 B20-Type Figure 7Instrument Panel Options and Components 1 2 3 4 5 6 7 8 9 042563-00X01 Figure 8 1–“B20” instrument panel 2–Tachometer 3–Engine oil low pressure alarm lamp 4–Cooling water temperature alarm lamp 5–Seawater in sail drive alarm lamp (Optional) 6–Battery low charge alarm lamp 7–LCD (Hour meter) 8–Start switch 9–Power switch Control panel switches All switches are push-buttons.
GM_OM.book 18 ページ ２０１３年６月１０日 月曜日 午後２時２６分 PRODUCT OVERVIEW Indicators and Alarms (Optional) When a sensor detects a problem during operation, the indicator on the instrument panel will light and an alarm will sound. Indicators are located on the instrument panel and the alarms are located on the back of the panel. Under normal operating conditions, the indicators are off. Battery low charge indicator When the alternator output is too low, the indicator will light.
GM_OM.book 19 ページ ２０１３年６月１０日 月曜日 午後２時２６分 PRODUCT OVERVIEW 12/05 Alarms Checking the Warning Devices Before and after engine start, make sure that the instruments and warning devices operate correctly. If the engine runs out of coolant or lubricating oil and the instruments and warning devices fail, they can not give you warning to prevent accidents. This can also lead to incorrect operation and cause further malfunctions of the engine. Before Engine Start 1. Turn on the battery switch. 2.
GM_OM.book 20 ページ ２０１３年６月１０日 月曜日 午後２時２６分 PRODUCT OVERVIEW Accessory power output The harness attached to the panel has a terminal where the signal that is synchronized to the panel power supply can be taken off. (Figure 9) (Refer to the See Wiring Diagrams on page 80.) The maximum current of this output terminal is 3A. Do not use a current higher than 3A. For the content of the output terminal, refer to the Wiring Diagrams on 82.
GM_OM.book 21 ページ ２０１３年６月１０日 月曜日 午後２時２６分 PRODUCT OVERVIEW 12/05 LCD control (hourmeter, coolant temperature, display brightness, oil pressure, battery voltage) Figure 9 You can switch (scroll) between displays by pressing the buttons on the bottom. Ɣ 6ZLWFKLQJ VFUHHQV E\ SUHVVLQJ WKH ULJKW EXWWRQ 3UHVVLQJ WKH OHIW EXWWRQ VZLWFKHV WKH VFUHHQV LQ WKH RSSRVLWH GLUHFWLRQ Scroll (QJLQH KRXU ! PLQ-1 Press the power switch. $IWHU VHFRQGV WKH /&' VKRZV WKH hourmeter.
GM_OM.book 22 ページ ２０１３年６月１０日 月曜日 午後２時２６分 PRODUCT OVERVIEW Engine Stop Control The engine is stopped by pulling out the engine stop knob (Figure 10, (1)). This cable is connected to the engine stop lever and cuts off the fuel supply to the engine. (1) (2) Raising the decompression lever to the decompression position (Figure 11, (2)) opens the exhaust valve and makes hand cranking of the engine possible.
GM_OM.book 23 ページ ２０１３年６月１０日 月曜日 午後２時２６分 PRODUCT OVERVIEW 12/05 With the lever in the NEUTRAL position, pull the lever out from the console (Figure 12, (4)) to disengage the clutch. The lever controls the direction of the vessel (ahead or astern) and acts as an accelerator, increasing the engine speed as it is pushed further in the FWD or REV direction. When the lever is pulled out, engine speed can be controlled without moving the vessel.
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GM_OM.book 25 ページ ２０１３年６月１０日 月曜日 午後２時２６分 BEFORE YOU OPERATE INTRODUCTION SAFETY PRECAUTIONS This section of the Operation Manual describes the diesel fuel, engine oil and engine coolant specifications and how to replenish them. Before performing any operations within this section, review the Safety section on page 3.
04-Before You Operate.fm 26 ページ ２０１３年６月２７日 木曜日 午前９時５６分 BEFORE YOU OPERATE DIESEL FUEL B7 diesel fuels must meet certain specifications. Diesel Fuel Specifications The biodiesel fuels must meet the minimum specifications for the country in which they are used: WARNING Fire and Explosion Hazard. Diesel fuel is flammable and explosive under certain conditions. Only use diesel fuels recommended by Yanmar for the best engine performance, to prevent engine damage. Only use clean diesel fuel.
04-Before You Operate.fm 27 ページ ２０１３年６月２７日 木曜日 午前９時５６分 BEFORE YOU OPERATE 12/05 • Even biodiesel fuels that comply with a suitable standard as delivered will require additional care and attention to maintain the quality of the fuel in the equipment or other fuel tanks. It is important to maintain a supply of clean, fresh fuel. Regular flushing of the fuel system, and / or fuel storage containers, may be necessary.
GM_OM.book 28 ページ ２０１３年６月１０日 月曜日 午後２時２６分 BEFORE YOU OPERATE 2. Keep the fuel container stationary for several hours to allow any dirt or water to settle to the bottom of the container. Use a pump to extract the clear, filtered fuel from the top of the container. Fuel Tank (Optional) Fuel System Install the fuel line from the fuel tank to the fuel injection pump as shown in Figure 3. The recommended fuel / water separator (Figure 3, (3)) (optional) is installed at the center section of that line.
GM_OM.book 29 ページ ２０１３年６月１０日 月曜日 午後２時２６分 BEFORE YOU OPERATE 12/05 To fill the fuel tank: WARNING Fire and Explosion Hazard. Operate bilge ventilation (blowers) for a minimum of 5 minutes to purge fumes from engine compartment after refueling. Never operate bilge blower while refueling. Doing so can pump explosive fumes into the engine compartment and result in an explosion. ENGINE OIL Engine Oil Specifications NOTICE Only use the engine oil specified.
GM_OM.book 30 ページ ２０１３年６月１０日 月曜日 午後２時２６分 BEFORE YOU OPERATE NOTICE • Select the oil viscosity based on the ambient temperature where the engine is being operated. See the SAE Service Grade Viscosity Chart (Figure 4). • Yanmar does not recommend the use of engine oil “additives.” Handling Engine Oil 1. When handling and storing engine oil, be careful not to allow dust and water to contaminate the oil. Clean around the filler port before filling. 2. Do not mix oils of different types or brands.
GM_OM.book 31 ページ ２０１３年６月１０日 月曜日 午後２時２６分 BEFORE YOU OPERATE 12/05 3 – Upper Limit 4 – Lower Limit 3. Fully reinsert the dipstick. MARINE GEAR OR SAIL-DRIVE OIL 4. Remove the dipstick. The oil level should be between the upper (Figure 5, (3)) and lower (Figure 5, (4)) lines on the dipstick. Marine Gear Oil Specifications 5. Add oil if necessary. See Adding Engine Oil on page 31. KM2P-1 (S), (G) or (GG): 6. Fully reinsert the dipstick.
04-Before You Operate.fm 32 ページ ２０１３年６月２７日 木曜日 午後５時５０分 BEFORE YOU OPERATE Checking Marine Gear Oil Adding Marine Gear Oil 1. Turn the engine off. Make sure the engine is as level as possible and wipe area clean around the marine gear filler port (Figure 6, (2)). 1. Make sure the engine is as level as possible. Figure 4 2. Remove the filler cap / dipstick (Figure 6, (1)) at the top of the housing. 3. Fill with oil to the upper limit on the dipstick (Figure 6, (3)).
GM_OM.book 33 ページ ２０１３年６月１０日 月曜日 午後２時２６分 BEFORE YOU OPERATE 12/05 CRANKING THE ENGINE MANUALLY NOTICE 5. Slide the starter handle (Figure 8, (1)) on the starter shaft (Figure 8, (1)), align the groove and pin, and turn the engine over about 10 times. Figure 6 When performing engine break-in or if the engine has not been used for a long period of time, engine oil will not be distributed to all the operating parts. Using the engine in this condition will lead to seizure.
GM_OM.book 34 ページ ２０１３年６月１０日 月曜日 午後２時２６分 BEFORE YOU OPERATE CRANKING THE ENGINE ELECTRICALLY 5. With the key in the ON position, push the start button and the engine will begin cranking. NOTICE 6. Continue cranking for about 5 seconds and listen for any unusual noises. When performing engine break-in or if the engine has not been used for a long period of time, engine oil will not be distributed to all of the operating parts. Using the engine in this condition will lead to seizure.
GM_OM.book 35 ページ ２０１３年６月１０日 月曜日 午後２時２６分 BEFORE YOU OPERATE 12/05 DAILY CHECKS Before starting for the day, make sure the Yanmar engine is in good operating condition. CAUTION It is important to perform daily checks as listed in this 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. Make sure you check the following items: Visual Checks 1. Check for engine oil leaks. 2.
GM_OM.book 36 ページ ２０１３年６月１０日 月曜日 午後２時２６分 BEFORE YOU OPERATE Checking the Alternator Belt Check the belt tension before use. See Checking and Adjusting the Alternator V-Belt Tension on page 56. Checking the Throttle and Shift Console Check the operation of the throttle and shift control lever. Make sure it moves smoothly. If it is hard to operate, grease the joints of the control cable and lever bearings. If the lever has excessive play, adjust the control cable connectors and clamps.
GM_OM.book 37 ページ ２０１３年６月１０日 月曜日 午後２時２６分 ENGINE OPERATION INTRODUCTION SAFETY PRECAUTIONS This section of the Operation Manual describes the diesel fuel, engine oil and engine coolant specifications and how to replenish them. It also describes the daily engine checkout. Before performing any operations within this section, review the Safety section on page 3. WARNING Fire and Explosion Hazard Never jump-start the engine.
GM_OM.book 38 ページ ２０１３年６月１０日 月曜日 午後２時２６分 ENGINE OPERATION WARNING To prevent accidental equipment movement, never start the engine in gear. Sever Hazard Keep children and pets away while the engine is operating. NOTICE If any indicator illuminates during engine operation, stop the engine immediately. Determine the cause and repair the problem before you continue to operate the engine.
GM_OM.book 39 ページ ２０１３年６月１０日 月曜日 午後２時２６分 ENGINE OPERATION 12/05 STARTING THE ENGINE ELECTRICALLY NOTICE If the vessel is equipped with a water lift (water lock) muffler, excessive cranking could cause seawater to enter the cylinders and damage the engine. If the engine does not start after cranking for 10 seconds, close the thru-hull water intake valve to avoid filling the muffler with water. Crank for 10 seconds or until the engine starts.
GM_OM.book 40 ページ ２０１３年６月１０日 月曜日 午後２時２６分 ENGINE OPERATION 4. Turn the master battery switch (if equipped) to ON. NOTICE If any indicator fails to illuminate when the key switch is in the ON position, consult authorized Yanmar Marine dealer or distributor for service before operating the engine. Starting the Engine Manually 1. Open the seacock (if equipped). 2. Open the fuel cock. 3. Put the remote control shift lever in the NEUTRAL position (Figure 3, (1)).
GM_OM.book 41 ページ ２０１３年６月１０日 月曜日 午後２時２６分 ENGINE OPERATION 12/05 Air Bleeding from the Fuel System After Starting Failure If the engine does not start after several attempts, there may be air in the fuel system. If air is in the fuel system, fuel cannot reach the fuel injection pump. Bleed the air from the fuel system according to the following steps: 1. Check the fuel tank level. 2. Loosen the air vent bolt at the top of the fuel / water separator.
GM_OM.book 42 ページ ２０１３年６月１０日 月曜日 午後２時２６分 ENGINE OPERATION NOTICE The engine will seize if it is operated when cooling seawater discharge is inadequate or if load is applied without any warm-up operation. • Is the seacock open? • Is the inlet of the seacock on the hull bottom clogged? • Is the seawater suction hose broken or does the hose suck air because of a loose clamp? When operating the engine at low speed for long periods of time, race the engine once every two hours.
GM_OM.book 43 ページ ２０１３年６月１０日 月曜日 午後２時２６分 ENGINE OPERATION 12/05 Figure 4 (1) (4) (2) (3) NOTICE FWD NEUTRAL IPULLI CLUTCH REV 0005846 Figure 4 1 2 3 4 CAUTIONS DURING OPERATION – FORWARD (FWD) – NEUTRAL (N) – REVERSE (REV) – Pull the lever to disengage the clutch.
GM_OM.book 44 ページ ２０１３年６月１０日 月曜日 午後２時２６分 ENGINE OPERATION • Are there abnormal vibrations or noise? NOTICE Excessive vibration may cause damage to the engine, marine gear, hull and onboard equipment. In addition, it causes able passenger and crew discomfort. Depending on the hull structure, engine and hull resonance may suddenly become great at a certain engine speed range, causing heavy vibrations. Avoid operation in this speed range. If you hear any abnormal sounds, stop the engine and inspect.
GM_OM.book 45 ページ ２０１３年６月１０日 月曜日 午後２時２６分 ENGINE OPERATION 12/05 SHUTTING DOWN THE ENGINE Figure 5 (1) (2) NOTICE Never stop the engine abruptly during operation. Yanmar recommends that when shutting the engine down, allow the engine to run, without load, for 5 minutes. This will allow the engine components that operate at high temperatures, such as the exhaust system, to cool slightly before the engine itself is shut down. 1.
GM_OM.book 46 ページ ２０１３年６月１０日 月曜日 午後２時２６分 ENGINE OPERATION CHECKING THE ENGINE AFTER OPERATION • Check that the key switch is in the OFF position and master battery switch (if equipped) is turned to OFF. • Fill the fuel tank. See Filling the Fuel Tank on page 28. • Close the seacock (if equipped). NOTICE Be sure to close the seacock. Neglecting to close the seacock could allow water to leak into the boat and may cause it to sink. • If there is a risk of freezing, drain the seawater system.
GM_OM.book 47 ページ ２０１３年６月１０日 月曜日 午後２時２６分 PERIODIC MAINTENANCE INTRODUCTION SAFETY PRECAUTIONS This section of the Operation Manual describes the procedures for proper care and maintenance of the engine. Before performing any maintenance procedures within this section, read the following safety information and review the Safety section on page 3. WARNING Crush Hazard If the engine needs to be transported for repair, have a helper assist you attach it to a hoist and load it on a truck.
GM_OM.book 48 ページ ２０１３年６月１０日 月曜日 午後２時２６分 PERIODIC MAINTENANCE WARNING Never use undersized wiring for the electrical system. Welding Hazard • Always turn off the battery switch (if equipped) or disconnect the negative battery cable and the leads to the alternator when welding on the equipment. • Remove the engine control unit multi-pin connector. Connect the weld clamp to the component to be welded and as close as possible to the welding point.
GM_OM.book 49 ページ ２０１３年６月１０日 月曜日 午後２時２６分 PERIODIC MAINTENANCE 12/05 PRECAUTIONS The Importance of Periodic Maintenance Engine deterioration and wear occur in proportion to the length of time the engine has been in service and the conditions the engine is subjected to during operation. Periodic maintenance prevents unexpected downtime, reduces the number of accidents due to poor machine performance and helps extend the life of the engine. Performing Periodic Maintenance WARNING Exhaust Hazard.
GM_OM.book 50 ページ ２０１３年６月１０日 月曜日 午後２時２６分 PERIODIC MAINTENANCE Tightening Fasteners Use the correct amount of torque when you tighten fasteners on the engine. Applying excessive torque may damage the fastener or component and not enough torque may cause a leak or component failure. When working on critical components that require calibrated tools, special procedures and specific tightening sequences, consult with your Yanmar distributor or dealer.
GM_OM.book 51 ページ ２０１３年６月１０日 月曜日 午後２時２６分 PERIODIC MAINTENANCE 12/05 PERIODIC MAINTENANCE SCHEDULE Daily and periodic maintenance is important to keep the engine in good operating condition. The following is a summary of maintenance items by periodic maintenance intervals. Periodic maintenance intervals vary depending on engine application, loads, diesel fuel and engine oil used and are hard to establish definitively. The following should be treated only as a general guideline.
GM_OM.book 52 ページ ２０１３年６月１０日 月曜日 午後２時２６分 PERIODIC MAINTENANCE : Check or Clean ✧: Replace ●: Contact your authorized Yanmar Marine dealer or distributor Periodic Maintenance Interval System Whole Before Starting See Daily Checks on page 35.
GM_OM.book 53 ページ ２０１３年６月１０日 月曜日 午後２時２６分 PERIODIC MAINTENANCE 12/05 PERIODIC MAINTENANCE PROCEDURES After Initial 50 Hours of Operation Perform the following maintenance after the initial 50 hours of operation. • Draining the Fuel Tank • Draining the Fuel Filter / Water Separator Draining the Fuel Tank WARNING When you are draining the fuel tank to perform maintenance, put an approved container under the opening to catch the fuel. Never use a shop rag to catch the fuel.
GM_OM.book 54 ページ ２０１３年６月１０日 月曜日 午後２時２６分 PERIODIC MAINTENANCE Draining the Fuel Filter / Water Separator WARNING When removing any fuel system component to perform maintenance (such as changing the fuel filter), put an approved container under the opening to catch the fuel. Never use a shop rag to catch the fuel. Vapors from the rag are flammable and explosive. Wipe up any spills immediately. Wear eye protection.
GM_OM.book 55 ページ ２０１３年６月１０日 月曜日 午後２時２６分 PERIODIC MAINTENANCE 12/05 5. Approximately 10 minutes after stopping the engine, remove the oil dipstick and check the oil level. Add oil as necessary. Replacing the Engine Oil Filter Element 1. Turn the engine off. 2. Turn the engine oil filter (Figure 2) counterclockwise with a wrench. Changing the Marine Gear Oil Note: Refer to the Operation Manual supplied with your marine gear or sail-drive unit for service and maintenance details.
GM_OM.book 56 ページ ２０１３年６月１０日 月曜日 午後２時２６分 PERIODIC MAINTENANCE Checking and Adjusting the Alternator V-Belt Tension Inspecting and Adjusting the Intake / Exhaust Valve Clearances Inadequate V-belt tension will cause reduced electrical power generation and increase the wear on the belt. Too much V-belt tension can cause damage to the alternator bearing. Proper adjustment is necessary to maintain the correct timing for opening and closing the valves.
GM_OM.book 57 ページ ２０１３年６月１０日 月曜日 午後２時２６分 PERIODIC MAINTENANCE 12/05 4. Verify that the governor control lever on the engine is in contact with the low speed stop bolt. If adjustment is needed, loosen the bracket that holds the control cable and adjust its position as necessary. Adjust the high speed position first and then the low speed position. NOTICE The high speed stop bolt on the engine governor is set at the factory. Do not adjust. Adjustments to this bolt will void the engine warranty.
GM_OM.book 58 ページ ２０１３年６月１０日 月曜日 午後２時２６分 PERIODIC MAINTENANCE Every 150 Hours of Operation Perform the following maintenance every 150 hours of operation. 2. Turn the master battery switch to OFF (if equipped) or disconnect the negative (-) battery cable. 3. Remove the plugs and check the electrolyte level in all cells. NOTICE • Changing the Engine Oil • Changing the Marine Gear Oil Never attempt to remove the covers or fill a maintenance-free battery.
GM_OM.book 59 ページ ２０１３年６月１０日 月曜日 午後２時２６分 PERIODIC MAINTENANCE 12/05 If charging the battery does not raise the specific gravity, replace the battery. Note: The maximum fill level is approximately 10 to 15 mm (3/8 to 9/16 in.) above the plates. NOTICE The standard alternator with the recommended battery is designed to produce electrical power for regular engine operations only. If power is being used for onboard lights and other systems, the charging system may be inadequate.
GM_OM.book 60 ページ ２０１３年６月１０日 月曜日 午後２時２６分 PERIODIC MAINTENANCE Draining the Fuel Tank Figure 4 See Draining the Fuel Tank on page 53. Replacing the Fuel Filter Element WARNING When you remove any fuel system component to perform maintenance (such as changing the fuel filter), put an approved container under the opening to catch the fuel. Never use a shop rag to catch the fuel. Vapors from the rag are flammable and explosive. Wipe up any spills immediately. Wear eye protection.
GM_OM.book 61 ページ ２０１３年６月１０日 月曜日 午後２時２６分 PERIODIC MAINTENANCE 12/05 Replacing the Engine Oil Filter Element 2. Inspect the internal components of the pump. See Replacing the Engine Oil Filter Element on page 55. • Inspect the impeller blades (Figure 5, (5)). Look for nicks, cracks and any evidence of damage. This includes excessive scratches and marring of the surface of the impeller blades.
GM_OM.book 62 ページ ２０１３年６月１０日 月曜日 午後２時２６分 PERIODIC MAINTENANCE Cleaning the Intake Silencer (Air Cleaner) Figure 6 (2) 1. Open the clamps that secure the air cleaner cover. (1) 2. Remove the air filter element. 3. Wash the air filter element with a mild neutral detergent and water. 4. Allow the element to dry completely. 5. Remove any debris from the filter housing and cover. 6. Reinstall the filter element and secure the cover with the clamps.
GM_OM.book 63 ページ ２０１３年６月１０日 月曜日 午後２時２６分 PERIODIC MAINTENANCE 12/05 Checking the Wiring Connectors Consult authorized Yanmar Marine dealer or distributor. Inspecting and Adjusting the Intake / Exhaust Valve Clearances See Inspecting and Adjusting the Intake / Exhaust Valve Clearances on page 56. Consult authorized Yanmar Marine dealer or distributor. Inspecting and Adjusting the Throttle and Shift Control Cables See Inspecting and Adjusting the Throttle and Shift Control Cables on page 56.
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GM_OM.book 65 ページ ２０１３年６月１０日 月曜日 午後２時２６分 TROUBLESHOOTING SAFETY PRECAUTIONS Before performing any troubleshooting procedures within this section, review the Safety section on page 3. If a problem occurs, stop the engine immediately. Refer to the Symptom column in the Troubleshooting Chart to identify the problem.
GM_OM.book 66 ページ ２０１３年６月１０日 月曜日 午後２時２６分 TROUBLESHOOTING Is there water, oil or fuel leakage? Are there any loose bolts or connections? TROUBLESHOOTING INFORMATION Check the engine room daily for any leaks or loose connections. If the engine does not operate properly, refer to the Troubleshooting Chart on page 67 or consult authorized Yanmar Marine dealer or distributor. Is there sufficient fuel in the fuel tank? Refill fuel in advance to avoid running out of fuel.
GM_OM.book 67 ページ ２０１３年６月１０日 月曜日 午後２時２６分 TROUBLESHOOTING 12/05 TROUBLESHOOTING CHART Symptom Probable Cause Measure Reference Indicators light on the instrument panel and alarm sounds during operation. Shift to low speed operation immediately, and check which indicator has come on. Stop the engine and inspect. If no abnormality is identified and there is no problem with operation, return to port at lowest speed and consult authorized Yanmar Marine dealer or distributor.
GM_OM.book 68 ページ ２０１３年６月１０日 月曜日 午後２時２６分 TROUBLESHOOTING Symptom Probable Cause Measure Reference Starting Failures: Starter turns but engine does not start. Starter does not turn or turns slowly (engine can be turned manually). Engine cannot be turned manually. 68 No fuel Add fuel. Bleed fuel system. Ensure that fuel shut-off valve is open. See Filling the Fuel Tank on page 28. Fuel filter is clogged. Replace filter element. See Replacing the Fuel Filter Element on page 60.
GM_OM.book 69 ページ ２０１３年６月１０日 月曜日 午後２時２６分 TROUBLESHOOTING 12/05 Symptom Probable Cause Measure Reference Abnormal Exhaust Color: • • Engine is overloaded. Consult authorized Yanmar Marine dealer or distributor. — Improper propeller matching Consult authorized Yanmar Marine dealer or distributor. — Dirty intake silencer (air cleaner) Clean element. See Cleaning the Intake Silencer (Air Cleaner) on page 62. Improper fuel Replace with recommended fuel.
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GM_OM.book 71 ページ ２０１３年６月１０日 月曜日 午後２時２６分 LONG-TERM STORAGE If the engine will not be used for an extended period of time, special measures should be taken to protect the cooling system, fuel system and combustion chamber from corrosion and the exterior from rusting. The engine can normally stand idle for up to 6 months. If it remains unused for longer than this, please contact your authorized Yanmar Marine dealer or distributor.
GM_OM.book 72 ページ ２０１３年６月１０日 月曜日 午後２時２６分 LONG-TERM STORAGE DRAIN SEAWATER COOLING SYSTEM RETURNING THE ENGINE TO SERVICE In cold temperatures or before long-term storage, be sure to drain the seawater from the cooling system. 1. Replace the oil and the oil filter before running the engine. 1. Put a pan under the seawater drain cocks. 2. Loosen the drain cock at the side of the thermostat cover and drain the water from the inside. 3.
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GM_OM.book 74 ページ ２０１３年６月１０日 月曜日 午後２時２６分 SPECIFICATIONS 1GM10 Engine Type Vertical 4-cycle water-cooled diesel engine Combustion System Swirl pre-combustion chamber Number of Cylinders 1 Bore and Stroke 75 mm x 72 mm (2.95 in. x 2.83 in.) Displacement 0.318 L (19.4 cu. in.) Continuous Rating Output Output at Crankshaft / Engine Speed 5.9 kW (8 hp metric) / 3400 min-1* Maximum Rating Output Output at Crankshaft / Engine Speed 6.7 kW (9.1 hp metric) / 3600 min-1* 6.55 kW (8.
GM_OM.book 75 ページ ２０１３年６月１０日 月曜日 午後２時２６分 SPECIFICATIONS 12/05 1GM10C Engine Type Vertical 4-cycle water-cooled diesel engine Combustion System Swirl pre-combustion chamber Number of Cylinders 1 Bore and Stroke 75 mm x 72 mm (2.95 in. x 2.83 in.) Displacement 0.318 L (19.4 cu. in.) Continuous Rating Output Output at Crankshaft / Engine Speed 5.9 kW (8 hp metric) / 3400 min-1* Maximum Rating Output Output at Crankshaft / Engine Speed 6.7 kW (9.1 hp metric) / 3600 min-1* 6.55 kW (8.
GM_OM.book 76 ページ ２０１３年６月１０日 月曜日 午後２時２６分 SPECIFICATIONS 1GM10V Engine Type Vertical 4-cycle water-cooled diesel engine Combustion System Swirl pre-combustion chamber Number of Cylinders 1 Bore and Stroke 75 mm x 72 mm (2.95 in. x 2.83 in.) Displacement 0.318 L (19.4 cu. in.) Continuous Rating Output Output at Crankshaft / Engine Speed 5.9 kW (8 hp metric) / 3400 min-1* Maximum Rating Output Output at Crankshaft / Engine Speed 9.7 kW (9.1 hp metric) / 3600 min-1* 6.55 kW (8.
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1 3 4 5 6 Front SW2 8 7 9 11 10 13 15 12 14 Resistance B B 19 20 + O S - Figure 3 GM Series Operation Manual 35 R W L 21 A A 34 YW VW WL LB O B YG B-B 30 WL 3L 3W 25 3L G 26 24 B 12V 32 R RB - 27 Power SW Glow SW Stop SW Start SW *Self-holding * Stop Starter relay relay 33 29 043967-00X00 Output Panel power Glow ACC power relay Input Output status table RB LB O YG 28 B L 23 LB E 5B + YW WL WG B A-A 2R 31 3R 3W YW WB YB 3W 22 月曜日 V 16 17
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GM_OM.book 85 ページ ２０１３年６月１０日 月曜日 午後２時２６分 Declaration of Conformity for Recreational Craft Propulsion Engine with the Exhaust emission requirements of Directive 94/25/EC as amended by 2003/44/EC (To be completed by manufacturer of inboard engines without integral exhaust) Name of engine manufacturer: Yanmar Co., Ltd. Street: 1-9 Town: Tsuruno-cho, Kitaku, Osaka-City Post Code: 530-8311 Country: Japan Name of Authorised Representative: Yanmar Co., Ltd.
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ڦMarine Operations Division Quality Assurance Dept. 5-3-1, Tsukaguchi-honmachi, Amagasaki Hyogo, 661-0001, Japan Phone: +81-6-6428-3251 Fax: +81-6-6421-5549 Overseas Office ڦYanmar Europe B.V. (YEU) Brugplein 11, 1332 BS Almere-de Vaart, Netherlands Phone: +31-36-5493200 Fax: +31-36-5493209 ڦYanmar Asia (Singapore) Corporation Pte Ltd.
MARINE ENGINES http://yanmar.
