YANMAR 1GM10 Diesel Marine Engine Full Service & Repair Manual

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

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

GM Series Operation Manual i TABLE OF CONTENTS Page INTRODUCTION .............................................................. 1 RECORD OF OWNERSHIP ...................................... 2 SAFETY ........................................................................... 3 SAFETY PRECAUTIONS .......................................... 4 General Information ............................................. 4 Before You Operate............................................. 4 During Operation and Maintenance..................... 4 LOCATION OF SAFETY DECALS ............................ 8 PRODUCT OVERVIEW ................................................... 9 YANMAR GM FEATURES AND APPLICATIONS ..... 9 New Engine Break-In......................................... 10 COMPONENT IDENTIFICATION ............................ 11 Service Side - 1GM10 with KM2P ..................... 11 Non-Service Side - 1GM10 with KM2P.............. 12 LOCATION OF NAMEPLATES................................ 13 MAJOR COMPONENTS AND FUNCTIONS ........... 14 CONTROL EQUIPMENT ......................................... 15 Instrument Panel (Optional) ............................... 15 Single-Lever Throttle and Shift Console (Optional) ........................................................... 22 BEFORE YOU OPERATE ............................................. 25 INTRODUCTION...................................................... 25 SAFETY PRECAUTIONS ........................................ 25 DIESEL FUEL .......................................................... 26 Diesel Fuel Specifications ................................. 26

TABLE OF CONTENTS ii GM Series Operation Manual ENGINE OIL ............................................................. 29 Engine Oil Specifications .................................. 29 Engine Oil Viscosity ........................................... 30 Checking the Engine Oil..................................... 30 Adding Engine Oil .............................................. 31 MARINE GEAR OR SAIL-DRIVE OIL ...................... 31 Marine Gear Oil Specifications........................... 31 Sail-Drive Oil Specifications - SD20 ................... 31 Checking Marine Gear Oil .................................. 32 Adding Marine Gear Oil ...................................... 32 Checking and Adding Sail-Drive Oil ................... 32 CRANKING THE ENGINE MANUALLY ................... 33 CRANKING THE ENGINE ELECTRICALLY ............ 34 Recheck the Engine Oil ...................................... 34 DAILY CHECKS ....................................................... 35 Visual Checks .................................................... 35 Checking Diesel Fuel and Engine Oil ................. 35 Checking and Refilling Marine Gear Oil ............. 35 Checking the Battery Electrolyte Level .............. 35 Checking the Alternator Belt ............................. 36 Checking the Throttle and Shift Console............ 36 Checking the Warning Indicators ....................... 36 Preparing Fuel, Oil and Coolant in Reserve....... 36 ENGINE OPERATION .................................................... 37 INTRODUCTION ...................................................... 37 SAFETY PRECAUTIONS......................................... 37 STARTING THE ENGINE ELECTRICALLY ............. 39 Starting the Engine Manually ............................. 40 Restarting After Starting Failure ......................... 40 Starting at Low Temperatures ............................ 41 After the Engine Has Started ............................. 41 THROTTLE AND SHIFT LEVER OPERATION........ 42 Acceleration and Deceleration ........................... 42 Shifting the Engine ............................................. 42 CAUTIONS DURING OPERATION.......................... 43 SHUTTING DOWN THE ENGINE ............................ 45 CHECKING THE ENGINE AFTER OPERATION..... 46 PERIODIC MAINTENANCE ........................................... 47 INTRODUCTION ...................................................... 47 SAFETY PRECAUTIONS......................................... 47

TABLE OF CONTENTS GM Series Operation Manual iii 12/05 PRECAUTIONS ....................................................... 49 The Importance of Periodic Maintenance .......... 49 Performing Periodic Maintenance ..................... 49 The Importance of Daily Checks ....................... 49 Keep a Log of Engine Hours and Daily Checks 49 Yanmar Replacement Parts .............................. 49 Tools Required .................................................. 49 Ask Your Authorized Yanmar Marine Dealer or Distributor for Help............................................. 49 Tightening Fasteners ......................................... 50 PERIODIC MAINTENANCE SCHEDULE ................ 51 PERIODIC MAINTENANCE PROCEDURES .......... 53 After Initial 50 Hours of Operation ..................... 53 Every 50 Hours of Operation ............................. 57 Every 150 Hours of Operation ........................... 58 Every 250 Hours of Operation ........................... 59 Every 1000 Hours of Operation ......................... 63 TROUBLESHOOTING ................................................... 65 SAFETY PRECAUTIONS ........................................ 65 TROUBLESHOOTING AFTER STARTING ............. 65 TROUBLESHOOTING INFORMATION ................... 66 TROUBLESHOOTING CHART................................ 67 LONG-TERM STORAGE ............................................... 71 PREPARE ENGINE FOR LONG-TERM STORAGE 71 DRAIN SEAWATER COOLING SYSTEM ............... 72 RETURNING THE ENGINE TO SERVICE .............. 72 SPECIFICATIONS ......................................................... 73 PRINCIPAL ENGINE SPECIFICATIONS ................ 73 1GM10 Engine................................................... 74 1GM10C Engine ................................................ 75 1GM10V Engine ................................................ 76 SYSTEM DIAGRAMS .................................................... 77 PIPING DIAGRAMS ................................................. 77 WIRING DIAGRAMS................................................ 80

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GM Series Operation Manual 1 GM Series Operation Manual INTRODUCTION Welcome to the world of Yanmar Marine! Yanmar Marine offers engines, drive systems and accessories for all types of boats, from runabouts to sailboats, and from cruisers to mega yachts. In marine leisure boating, the worldwide reputation of Yanmar Marine is second to none. We design our engines to respect nature. This means quieter engines, with minimal vibrations, cleaner than ever. All of our engines meet applicable regulations, including emissions, at the time of manufacture. To help you enjoy your Yanmar GM series engine for many years to come, please follow these recommendations: • Read and understand this Operation Manual before you operate the engine to ensure that you follow safe operating practices and maintenance procedures. • Keep this Operation Manual in a convenient place for easy access. • If this Operation Manual is lost or damaged, order a new one from your authorized Yanmar Marine dealer or distributor. • Make sure this manual is transferred to subsequent owners. This manual should be considered a permanent part of the engine and remain with it. • Constant efforts are made to improve the quality and performance of Yanmar products, so some details included in this Operation Manual may differ slightly from your engine. If you have any questions about these differences, please contact your authorized Yanmar Marine dealer or distributor. • The specifications and components (instrument panel, fuel tank, etc.) described in this manual may differ from ones installed on your vessel. Please refer to the manual provided by the manufacturer of these components. • Refer to the Yanmar Limited Warranty Handbook for a complete warranty description.

INTRODUCTION 2 GM Series Operation Manual RECORD OF OWNERSHIP Take a few moments to record the information you need when you contact Yanmar for service, parts or literature. Engine Model: __________________________________________________________ Engine Serial No.: _______________________________________________________ Date Purchased: ________________________________________________________ Dealer: ________________________________________________________________ Dealer Phone: __________________________________________________________

GM Series Operation Manual 3 SAFETY Yanmar considers safety of great importance and recommends that anyone that comes into close contact with its products, such as those who install, operate, maintain or service Yanmar products, exercise care, common sense and comply with the safety information in this manual and on the machine’s safety decals. Keep the labels from becoming dirty or torn and replace them if they are lost or damaged. Also, if you need to replace a part that has a label attached to it, make sure you order the new part and label at the same time. DANGER Indicates a hazardous situation which, if not avoided, will result in death or serious injury. WARNING Indicates a hazardous situation which, if not avoided, could result in death or serious injury. CAUTION Indicates a hazardous situation which, if not avoided, could result in minor or moderate injury. NOTICE Indicates a situation which can cause damage to the machine, personal property and / or the environment, or cause the equipment to operate improperly. A This safety alert symbol appears with most safety statements. It means attention, become alert, your safety is involved! Please read and abide by the message that follows the safety alert symbol.

SAFETY 4 GM Series Operation Manual SAFETY PRECAUTIONS General Information There is no substitute for common sense and careful practices. Improper practices or carelessness can cause burns, cuts, mutilation, asphyxiation, other bodily injury or death. This information contains general safety precautions and guidelines that must be followed to reduce risk to personal safety. Special safety precautions are listed in specific procedures. Read and understand all of the safety precautions before operation or performing repairs or maintenance. Before You Operate DANGER The safety messages that follow have DANGER level hazards. Never permit anyone to install or operate the engine without proper training. Read and understand this Operation Manual before you operate or service the engine to ensure that you follow safe operating practices and maintenance procedures. • Safety signs and labels are additional reminders for safe operating and maintenance techniques. • Consult authorized Yanmar Marine dealer or distributor for additional training. During Operation and Maintenance WARNING The safety messages that follow have WARNING level hazards. Explosion Hazard While the engine is running or the battery is charging, hydrogen gas is being produced and can be easily ignited. Keep the area around the battery well-ventilated and keep sparks, open flames and any other form of ignition out of the area. Fire and Explosion Hazard Diesel fuel is flammable and explosive under certain conditions. Never use a shop rag to catch the fuel. Wipe up all spills immediately. Never refuel with the engine running. Fire Hazard Undersized wiring systems can cause an electrical fire. Store any containers containing fuel or other flammable products in a well-ventilated area, away from any combustibles or source of ignition. Store any equipment in a designated area away from moving parts. Never use the engine compartment for storage.

YANMAR 1GM10 Diesel Marine Engine Full Service & Repair Manual

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