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.
TABLE OF CONTENTS Page Introduction .............................................................. 1 Record of Ownership .............................................. 2 Safety ....................................................................... 3 Safety Precautions ................................................. General Information ......................................... Before You Operate ......................................... During Operation and Maintenance .....................
TABLE OF CONTENTS 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 ...................
TABLE OF CONTENTS 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 ...............
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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.
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.
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.
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.
SAFETY Sever Hazard ! 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.
SAFETY ! WARNING ! CAUTION Piercing Hazard Avoid skin contact with highpressure diesel fuel spray caused by a fuel system leak such as a broken fuel injection line. High-pressure fuel can penetrate your skin and result in serious injury. If you are exposed to high-pressure fuel spray, obtain prompt medical treatment. NEVER check for a fuel leak with your hands. ALWAYS use a piece of wood or cardboard. Have your authorized Yanmar Marine dealer or distributor repair the damage.
SAFETY 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. See your authorized Yanmar Marine dealer or distributor if you need to operate the engine at high altitudes.
SAFETY LOCATION OF SAFETY DECALS Figure 1 shows the location of safety decals on Yanmar GM series marine engines.
PRODUCT OVERVIEW YANMAR GM FEATURES AND APPLICATIONS The GM series engines are four-stroke direct injection diesels equipped with direct seawater coolant 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.
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.
PRODUCT OVERVIEW 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.
PRODUCT OVERVIEW Non-Service Side - 1GM10 with KM2P (1) (2) (3) (4) (5) (10) (6) (7) (9) (8) 1– 2– 3– 4– 5– 12 Decompression Lever Fuel Injection Valve Intake Silencer (Air Cleaner) Tachometer Sensor Marine Gear Dipstick Figure 2 0005849 6 – Marine Gearbox 7 – Output Shaft Coupling 8 – Shift Lever 9 – Starter Motor 10 – Alternator GM Series Operation Manual © 2007 Yanmar Marine International
PRODUCT OVERVIEW LOCATION OF NAMEPLATES Emission-Control Labels The nameplate of the Yanmar GM series engine is shown in Figure 3. Check the engine’s model, output, rpm and serial number on the nameplate. Replace it if it is damaged or lost. To ensure safe operation, emission-control labels have been attached to the engine. Their location is shown in Figure 6. They should always be visible. Replace labels if damaged or lost.
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.
PRODUCT OVERVIEW 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.
PRODUCT OVERVIEW Gauges Instrument Function Tachometer Shows the engine rotation speed Hour Meter Shows the number of operating hours; can be used as a guide for periodic maintenance checks. The hour meter is located at the bottom of the tachometer. Instrument Panel Lights When turning the key switch to ON, the gauges will illuminate for easier viewing. Key Switch Engine Decompression Lever When the key is in the OFF position (Figure 8, (1)) the electric current is off.
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. The alarm is located on the back of the panel. Under normal operating conditions, the indicators are off. Figure 10 Battery Low Charge Indicator (Figure 10) - When the alternator output is too low, the indicator will light. When charging begins, the indicator will turn off.
PRODUCT OVERVIEW Alarms Check that indicators and alarms are working normally when the key is turned to ON. Key Switch OFF ⇒ ON START ⇒ ON Engine Before start Running Alarm Sound No sound Battery Low Charge Indicator ON OFF Water Temperature Indicator OFF OFF Engine Oil Low Pressure Indicator ON OFF Water In Sail-Drive Indicator OFF OFF Indicators Note: All warning indications will continue until the engine starts or the key switch is in the OFF position.
BEFORE YOU OPERATE This section of the Operation Manual describes diesel fuel and engine oil, and how to replenish them. It also describes the daily engine checks. Before performing any operations within this section, review the Safety section on page 3. DIESEL FUEL Diesel Fuel Specifications NOTICE: Only use diesel fuels recommended by Yanmar for the best engine performance, to prevent engine damage and to comply with EPA warranty requirements. Only use clean diesel fuel.
BEFORE YOU OPERATE Additional Technical Fuel Requirements Handling Diesel Fuel • The fuel cetane number should be 45 or higher. • The sulfur content must not exceed 0.5% by volume. Less than 0.05% is preferred. • NEVER mix kerosene, used engine oil or residual fuels with the diesel fuel. • Water and sediment in the fuel should not exceed 0.05% by volume. • Keep the fuel tank and fuel-handling equipment clean at all times. • Ash content not to exceed 0.01% by volume.
BEFORE YOU OPERATE Fuel Tank (Optional) Fuel System NOTICE: Water and / or dust in the fuel may cause engine failure. When fuel is stored, check that the inside of the storage container is clean and dry, and that the fuel is stored away from dirt or rain. Install the fuel line from the fuel tank to the fuel injection pump as shown in Figure 2. The recommended fuel / water separator (Figure 2, (3)) (optional) is installed at the center section of that line.
BEFORE YOU OPERATE Filling the Fuel Tank Before filling the fuel tank for the first time: Rinse the fuel tank with kerosene or diesel fuel. Dispose of waste properly. To fill the fuel tank: If filling the tank from a storage container (Figure 3), 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.
BEFORE YOU OPERATE ENGINE OIL Handling Engine Oil Engine Oil Specifications NOTICE: Only use the engine oil specified. Other engine oils may affect warranty coverage, cause internal engine components to seize and / or shorten engine life. NEVER mix different types of engine oil. This may adversely affect the lubricating properties of the engine oil. Use an engine oil that meets or exceeds the following guidelines and classifications: • API Service Categories: CD or higher TBN value: 9 or more 1. 2. 3.
BEFORE YOU OPERATE Checking the Engine Oil Adding Engine Oil 1. 1. 2. Make sure the engine is off. It is recommended that the engine be as level as possible before checking the oil. Remove the dipstick (Figure 5, (2)) and wipe with a clean cloth. NOTICE: Prevent dirt and debris from contaminating the engine oil. Carefully clean the dipstick and the surrounding area before you remove the cap. 2. NOTICE: Prevent dirt and debris from contaminating the engine oil.
BEFORE YOU OPERATE MARINE GEAR OR SAILDRIVE OIL Checking Marine Gear Oil 1. Marine Gear Oil Specifications Use marine gear oil that meets or exceeds the following guidelines and classifications: 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, (4)).
BEFORE YOU OPERATE Adding Marine Gear Oil 1. 2. 3. 4. 5. Make sure the engine is as level as possible. Remove the filler cap / dipstick (Figure 6, (1)) at the top of the housing. Fill with oil to the upper limit on the dipstick (Figure 6, (2)). NOTICE: NEVER overfill the marine gear with oil. Fully reinsert the dipstick. Hand-tighten the filler port cap.
BEFORE YOU OPERATE 5. Slide the starter handle (Figure 8, (2)) on the starter shaft (Figure 8, (1)), align the groove and pin, and turn the engine over about 10 times. CRANKING THE ENGINE ELECTRICALLY NOTICE: 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.
BEFORE YOU OPERATE NOTICE: If the engine stop knob is released (pushed in) during the cranking procedure, the engine will start. NEVER start the engine in this mode. Recheck the Engine Oil When the oil is distributed throughout the internal components, start the engine and run at no load for about 5 minutes. This will ensure that all oil galleys, oil filters and oil tubes are full of oil. Shut the engine down and recheck the engine oil level. See Checking the Engine Oil on page 24.
BEFORE YOU OPERATE 8. Check the fuel filter / water separator for water and contaminants. If you find any water or contaminants, drain the fuel filter / water separator. See Draining the Fuel Filter / Water Separator on page 52. If you have to drain the fuel filter / water separator frequently, drain the fuel tank and check for water in your fuel supply. See Draining the Fuel Tank on page 49.
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ENGINE OPERATION This section of the Operation Manual describes the procedures for starting the engine, checking engine performance during operation and shutting down the engine. Before performing any operations within this section, read the following safety information and review the Safety section on page 3. ! WARNING Fire and Explosion Hazard NEVER jump-start the engine. Sparks caused by shorting the battery to the starter terminals may cause a fire or explosion.
ENGINE OPERATION 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. If the alarm indicator lamps and audible alarm fail to display or sound when the ignition switch is in the ON position, see your authorized Yanmar Marine dealer or distributor for service before operating the engine.
ENGINE OPERATION 5. Turn the key switch to the ON position (Figure 2, (2)). Ensure that the instrument panel indicators light and the alarm sounds. This indicates that the indicators and the alarm are working correctly. Note: The water temperature alarm indicator and water in SailDrive indicator should not come on during start-up. Starting the Engine Manually 1. 2. 3. Open the seacock (if equipped). Open the fuel cock. Put the remote control shift lever in the NEUTRAL position (Figure 3, (1)).
ENGINE OPERATION 5. 6. 7. 8. Raise the decompression lever up. See Cranking the Engine Manually on page 26. Slide the starter handle (Figure 3, (2)) on the starter shaft (Figure 3, (1)), align the groove and pin, and turn by hand. Turn the handle vigorously. When engine rotation is rapid, return the decompression handle to the RUN position. Remove the starter handle from the starter shaft after the engine starts.
ENGINE OPERATION 3. 4. 5. Check that the exhaust color, engine vibration and sound are normal. When there are no problems, keep the engine at low speed with the boat still stopped to distribute engine oil to all parts of the engine. Check that water is being discharged from the seawater outlet pipe. Operation with inadequate seawater discharge will damage the impeller of the seawater pump. If seawater discharge is too low, stop the engine immediately. Identify the cause and repair.
ENGINE OPERATION THROTTLE AND SHIFT LEVER OPERATION Acceleration and Deceleration Note: Direction of travel will vary depending on installation location. Use the throttle handle to control acceleration and deceleration. Move the handle slowly. Shifting the Engine NOTICE: Shifting the marine gear while operating at high speed or not pushing the handle fully into position (partial engagement) will result in damage to marine gear parts and abnormal wear. 1. 2.
ENGINE OPERATION PRECAUTIONS DURING OPERATION 6. Always check for problems during engine operation. 7. 1. 2. 3. 4. 5. Is sufficient seawater being discharged from the seawater outlet? If the discharge is too little, stop the engine immediately and correct the problem. Is the exhaust color normal? The continuous emission of black smoke indicates engine overloading. This shortens engine life and should be avoided. Be aware of any abnormal vibration and unusual engine noises.
ENGINE OPERATION SHUTTING DOWN THE ENGINE (1) 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. 2. 3. 4. 38 Reduce the engine speed to low idle and put the shift control lever in NEUTRAL.
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 22. • 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. See Draining the Cooling System on page 66.
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PERIODIC MAINTENANCE This section of the Operation Manual describes the procedures for proper care and maintenance of the engine. SAFETY PRECAUTIONS ! WARNING Before performing any maintenance procedures within this section, read the following safety information and review the Safety section on page 3. Crush Hazard If you need to transport an engine for repair, have a helper assist you attach it to a hoist and load it on a truck.
PERIODIC MAINTENANCE NOTICE ! WARNING 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. • Connect the weld clamp to the component to be welded and as close as possible to the welding point. • NEVER connect the weld clamp to the engine or in a manner which would allow current to pass through a mounting bracket.
PERIODIC MAINTENANCE 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 engine performance and helps extend the life of the engine.
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.
PERIODIC MAINTENANCE EPA MAINTENANCE REQUIREMENTS Perform the inspections as outlined in Periodic Maintenance Procedures on page 49 and keep a record of the results. To maintain optimum engine performance and compliance with the Environmental Protection Agency (EPA) Regulations for Engines, it is essential that you follow the Periodic Maintenance Schedule on page 46 and the Periodic Maintenance Procedures on page 49.
PERIODIC MAINTENANCE 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, and are hard to establish definitively. The following should be treated only as a general guideline.
PERIODIC MAINTENANCE ◯: Check or Clean ◊: Replace ●: Contact your authorized Yanmar Marine dealer or distributor Periodic Maintenance Interval Before Every Every Starting Initial 50 Every Every 250 System Item 1000 See Daily Hours Hours 50 150 or Checks on Hours Hours or 1 Hours page 28.
PERIODIC MAINTENANCE Inspection and Maintenance of EPA Emission-Related Parts • Marine diesel engines less than 37 kW (50 hp metric) are certified as EPA non-road engines • Marine diesel engines greater than 37 kW (50 hp metric) are certified as EPA CI marine engines Inspection and Maintenance of EPA Emission-Related Parts for Non-Road Marine Engines Parts Interval Clean fuel injection nozzle 1500 hours Check fuel injection nozzle pressure and spray pattern 3000 hours Check fuel injection pump adjust
PERIODIC MAINTENANCE PERIODIC MAINTENANCE PROCEDURES 1. Put a pan under the drain cock (Figure 1, (2)) to catch the fuel. After Initial 50 Hours of Operation Perform the following maintenance after the initial 50 hours of operation.
PERIODIC MAINTENANCE 5. Purge air from the fuel system. See Air Bleeding from the Fuel System After Starting Failure on page 34. Changing the Engine Oil Replacing the Engine Oil Filter Element 1. 2. The engine oil in a new engine becomes contaminated from the initial break-in of internal parts. It is very important that the initial oil replacement is performed as scheduled. This includes the replacement of the oil filter at this time.
PERIODIC MAINTENANCE 4. After approximately 10 minutes, stop the engine and check the oil level. Add oil if the level is too low. Checking and Adjusting the Alternator V-Belt Tension Inadequate V-belt tension will cause reduced electrical power generation and increase the wear on the belt. Too much Vbelt tension can cause damage to the alternator bearing. NOTICE: NEVER get any oil on the belt. Oil on the belt causes slipping and stretching. Replace the belt if it is damaged.
PERIODIC MAINTENANCE Adjusting the Marine Gear Control Cable 1. Check that the control lever moves to the correct position when the remote control cable handle is moved to the NEUTRAL, FORWARD and REVERSE positions. 2. Use the NEUTRAL position as the standard for adjustment. When there is deviation, loosen the bracket for the shift control cable on the marine gear and adjust its position as necessary.
PERIODIC MAINTENANCE Every 150 Hours of Operation Perform the following maintenance every 150 hours of operation. • Changing the Engine Oil • Changing the Marine Gear Oil • Inspecting the Battery Electrolyte Level 4. If the electrolyte level is lower than the minimum fill level (Figure 3, (1)), fill with distilled water (Figure 3, (2)) (available locally) to the upper level (Figure 3, (3)) of the battery. (2) Changing the Engine Oil See Changing the Engine Oil on page 50.
PERIODIC MAINTENANCE 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. Consult your authorized Yanmar Marine dealer or distributor. Every 250 Hours of Operation Perform the following maintenance every 250 hours or 1 year of operation.
PERIODIC MAINTENANCE 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. The fuel system is under pressure and fuel could spray out when you remove any fuel system component.
PERIODIC MAINTENANCE 1. Loosen the cover bolts and remove the pump side cover (Figure 5, (7)). (3) (1) (2) (4) (5) (7) (6) 0005887 Figure 5 1– 2– 3– 4– 5– 6– 7– 2. Cam Inlet Outlet Seawater Pump Body Impeller Gasket Side Cover NOTICE: During normal operation, the pump impeller rotates in a counterclockwise direction (Figure 6, (1)). Use caution when installing the impeller to ensure that all the blades of the impeller are set in the proper direction.
PERIODIC MAINTENANCE Inspecting the Zinc Anode The inspection intervals and replacement schedule for the zinc anode are determined by seawater characteristics and your operating environment. Inspect the zinc anode a minimum of every 300 hours of operation, but shorten this interval if your operating conditions show a higher corrosion rate. Replace the zinc anode when its surface area has been reduced to less than half of its original size.
PERIODIC MAINTENANCE Every 1000 Hours of Operation Perform the following maintenance every 1000 hours or every 4 years of operation, whichever comes first. • Inspecting the Fuel Injection Timing • Inspecting the Seawater Pump Impeller • Checking and Adjusting the Alternator V-Belt Tension • Tightening All Major Nuts and Bolts • Adjusting the Propeller Shaft Alignment Inspecting the Fuel Injection Timing See your authorized Yanmar Marine dealer or distributor.
TROUBLESHOOTING Before performing any troubleshooting procedures within this section, review the Safety section on page 3. TROUBLESHOOTING AFTER STARTING If a problem occurs, stop the engine immediately. Refer to the SYMPTOM column in the Troubleshooting Chart to identify the problem. Just after the engine has started, check the following items at a low engine speed: Is sufficient water being discharged from the seawater outlet pipe? If the discharge is low, stop the engine immediately.
TROUBLESHOOTING Are there abnormal vibrations or noise? Depending on the hull structure, engine and hull resonance may suddenly increase at certain engine speed ranges, causing heavy vibrations. Avoid operation in this speed range. If any abnormal sounds are heard, stop the engine and inspect for the cause. Alarm sounds during operation. If the alarm sounds during operation, lower the engine speed immediately, check the warning lamps and stop the engine for repairs.
TROUBLESHOOTING 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 see your authorized Yanmar Marine dealer or distributor. • Engine oil low pressure alarm indicator lights Engine oil level is low.
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. 62 No fuel Add fuel. Bleed fuel system. Ensure that fuel shut-off valve is open. See Filling the Fuel Tank on page 22. Fuel filter is clogged. Replace filter element. See Replacing the Fuel Filter Element on page 55. Improper fuel Replace with recommended fuel.
TROUBLESHOOTING Symptom Probable Cause Measure Reference Engine is overloaded. See your authorized Yanmar Marine dealer or distributor. — Improper propeller matching See your authorized Yanmar Marine dealer or distributor. — Dirty intake silencer (air cleaner) Clean element. See Cleaning the Intake Silencer (Air Cleaner) on page 57. Improper fuel Replace with recommended fuel. See Diesel Fuel Specifications on page 19.
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LONG-TERM STORAGE Before performing any storage procedures within this section, review the Safety section on page 3. PREPARE ENGINE FOR 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. NOTICE: NEVER drain closed cooling system for long-term storage. Antifreeze must be used to avoid freezing and damaging of components.
LONG-TERM STORAGE 10. Remove the key from the key switch and cover the key switch with the moisture cap (if equipped). DRAINING THE COOLING SYSTEM In cold temperatures or before long-term storage, be sure to drain the seawater from the cooling system. 1. 2. 3. Put a pan under the seawater drain cocks. Loosen the drain cock at the side of the thermostat cover and drain the water from the inside. Loosen the three bolts holding the side cover (Figure 1, (7)) of the seawater pump.
SPECIFICATIONS PRINCIPAL ENGINE SPECIFICATIONS 1GM10 Engine Specifications 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 Continuous Rating Output Maximum Rating Output 0.318 L (19.4 cu. in.) Output at Crankshaft / Engine Speed 5.9 kW (8 hp metric) / 3400 rpm* Brake Mean Effective Pressure 6.66 kg/cm² (94.73 psi) Piston Speed 8.16 m / sec. (26.77 ft / sec.
SPECIFICATIONS Type Starting System Marine Gear System Starting Motor 12 VDC, 1.0 kW (12 VDC, 1.4 hp metric) AC Generator 12V, 35A Model KM2P Type Mechanical cone clutch with single stage for both ahead and astern Reduction Ratio Lubricating Oil Capacity Dimensions Engine Lubricating Oil Capacity (8° Rake Angle) Electric and manual Forward 2.21 : 1 2.62 : 1 3.22 : 1 Reverse 3.06 : 1 3.06 : 1 3.06 : 1 Forward 1540 rpm 1298 rpm 1055 rpm Reverse 1113 rpm 1113 rpm 1113 rpm 0.
SPECIFICATIONS 1GM10C Engine Specifications 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 Continuous Rating Output Maximum Rating Output 0.318 L (19.4 cu. in.) Output at Crankshaft / Engine Speed 5.9 kW (8 hp metric) / 3400 rpm* Brake Mean Effective Pressure 6.66 kg/cm² (94.73 psi) Piston Speed 8.16 m / sec. (26.77 ft / sec.
SPECIFICATIONS Dimensions Engine Lubricating Oil Capacity (8° Rake Angle) Overall Length 412 mm (16.22 in. ) Overall Width 410 mm (16.14 in.) Overall Height 485 mm (19.09 in.) Total 1.3 L (1.373 qt) Effective 0.6 L (0.634 qt) Engine Weight with Sail-Drive 104 kg (229 lb) Note: Density of fuel: 0.842g/cm3 at 15˚C. Fuel temperature at the inlet of the fuel injection pump. 1 hp metric = 0.
SPECIFICATIONS 1GM10V Engine Specifications 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 Continuous Rating Output Maximum Rating Output 0.318 L (19.4 cu. in.) Output at Crankshaft / Engine Speed 5.9 kW (8 hp metric) / 3400 rpm* Break Mean Effective Pressure 6.66 kg/cm² (94.73 psi) Piston Speed 8.16 m / sec. (26.77 ft / sec.
SPECIFICATIONS Marine Gear System Dimensions Lubricating Oil Capacity (8° Rake Angle) Model KM3V Type V-Drive, Mechanical cone clutch with single stage for both ahead and astern (15°) Reduction Ratio Forward 2.36 : 1 Reverse 3.16 : 1 Propeller Speed DIN 6270A Rating Forward 1441 rpm Reverse 1076 rpm Lubricating Oil Capacity 0.8 L (0.845 qt) Weight 19.5 kg (43.0 lb) Overall Length 680 mm (26.77 in.) Overall Width 450 mm (17.71 in.) Overall Height 554 mm (21.81 in.) Total 1.3 L (1.
SYSTEM DIAGRAMS PIPING DIAGRAMS Notation Screw Joint (Union) Spherical Pipe Joint Drilled Hole Cooling Seawater Piping Lubricating Oil Piping Fuel Oil Piping STP Steel Pipe RH Rubber Hose VH Vinyl Pipe GM Series Operation Manual © 2007 Yanmar Marine International 73
SYSTEM DIAGRAMS 20 19 0005993 1GM10 Piping Diagram Figure 1 74 GM Series Operation Manual © 2007 Yanmar Marine International
SYSTEM DIAGRAMS Key Notation Description Fuel Pump 1 Engine Oil Pressure Adjusting Valve Engine Oil Pipe 2 Oil Pressure Switch Cooling Water Pipe 3 Fuel Injection Nozzle Drilled Hole 4 Fuel Return Pipe Spherical Pipe Joint 5 To Main Bearing Screw Joint 6 To Main Bearing Bayonet Joint 7 To Oil Pan Cock 8 To Valve Rocker Arm STP Steel Pipe 9 Cooling Water Drain RH Rubber Hose 10 Exhaust Gas VH Vinyl Pipe 11 Cooling Water 12 Mixing Elbow 13 Fuel Inlet 14 Fuel Feed Pu
SYSTEM DIAGRAMS WIRING DIAGRAMS 0005995 1GM10 Series A-Type Instrument Panel Figure 2 76 GM Series Operation Manual © 2007 Yanmar Marine International
SYSTEM DIAGRAMS Color Coding Key Description R Red 1 Battery W White 2 Battery Switch B Black 3 Starter Motor O Orange 4 Alternator L/B Blue/Black 5 Not Used W/L White/Blue 6 Cooling Water Temperature Switch Y/W Yellow/White 7 Engine Oil Pressure Switch W/R White/Red 8 Tachometer Sender L/R Blue/Red 9 W/B White/Black Sail-Drive Connector (Rubber Seal Switch) R/B Red/Black 10 Tachometer 11 Buzzer 12 Rubber Seal Lamp (Sail-Drive) 13 Engine Oil Pressure Lamp 1
SYSTEM DIAGRAMS 0005994 1GM10 Series B-Type Instrument Panel Figure 3 78 GM Series Operation Manual © 2007 Yanmar Marine International
SYSTEM DIAGRAMS Color Coding Key Description R Red 1 Battery W White 2 Battery Switch B Black 3 Starter Motor O Orange 4 Alternator L/B Blue/Black 5 Not Used W/L White/Blue 6 Cooling Water Temperature Switch Y/W Yellow/White 7 Engine Oil Pressure Switch W/R White/Red 8 Spare Connector L/R Blue/Red 9 Spare Connector W/B White/Black 10 R/B Red/Black Extension Cable 3 m (Standard). The total length extension cable must be less than 6 m.
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EMISSION SYSTEM WARRANTY NON-ROAD EMISSION SYSTEM WARRANTY Your emission control system may include parts such as the fuel injection system and the air induction system. Yanmar Co., Ltd. Limited Emission Control System Warranty - USA Only Where a warrantable condition exists, Yanmar will repair your non-road compression-ignition engine at no charge to you including diagnosis, parts and labor.
EMISSION SYSTEM WARRANTY Warranty Coverage: Warranted Parts: This warranty is transferable to each subsequent purchaser for the duration of the warranty period. Repair or replacement of any warranted part will be performed at an authorized Yanmar Marine engine dealer or distributor. This warranty covers engine components that are a part of the emission control system of the engine as delivered by Yanmar to the original retail purchaser.
EMISSION SYSTEM WARRANTY Owner’s Warranty Responsibilities: Customer Assistance As the engine owner, you are responsible for the performance of the required maintenance listed in your owner’s manual. Yanmar recommends that you retain all documentation, including receipts, covering maintenance on your non-road compression-ignition engine, but Yanmar cannot deny warranty solely for the lack of receipts, or for your failure to ensure the performance of all scheduled maintenance.
Maintenance Log Date 84 Operating Hours Maintenance Performed Dealer Name GM Series Operation Manual © 2007 Yanmar Marine International Stamp or Signature
Date Operating Hours Maintenance Performed GM Series Operation Manual © 2007 Yanmar Marine International Dealer Name Stamp or Signature 85
86 GM Series Operation Manual © 2007 Yanmar Marine International
