Engine Yan

8/20/2019 Engine Yan

1/92

GM series

OPERATION MANUAL1GM10

1GM10C1GM10V

P/N: 0AGMM-G00100

MARINEENGINES


2/92

Disclaimers:

All information, illustrations and specifications in this manual are based on the latestinformation available at the time of publishing. The illustrations used in this manual areintended as representative reference views only. Moreover, because of our continuousproduct improvement policy, we may modify information, illustrations and / or specifications

to explain and / or exemplify a product, service or maintenance improvement. We reservethe right to make any change at any time without notice. Yanmar and areregistered trademarks of Yanmar Co., Ltd. in Japan, the United States and / or othercountries.

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 storageand retrieval systems - without the written permission of Yanmar Marine International.

© 2007 Yanmar Marine International

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TABLE OF

CONTENTS

Page

Introduction .............................................................. 1

Record of Ownership . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Safety ....................................................................... 3

Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Before You Operate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

During Operation and Maintenance . . . . . . . . . . . . . . . . . . . . . 4

Location of Safety Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Product Overview ...................................................... 9

Yanmar GM Features and Applications . . . . . . . . . . . . . . . . .. . .. . . 9

New Engine Break-In . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Component Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Service Side - 1GM10 with KM2P . . . . . . . . . . . . . . . . . . . . . . 11

Non-Service Side - 1GM10 with KM2P . . . . . . . . . .. . . . . . 12

Location of Nameplates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Emission-Control Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Major Components and Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Control Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Instrument Panel (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Optional Single-Lever Throttle and Shift

Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Before You Operate .................................................. 19

Diesel Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Diesel Fuel Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Filling the Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Engine Oil Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Engine Oil Viscosity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

GM Series Operation Manual iii



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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 . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . 25Adding Marine Gear Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Checking and Adding Sail-Drive Oil . . . . . . . . . . . . . . . . . . . . 26

Cranking the Engine Manually . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Cranking the Engine Electrically . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Recheck the Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Daily Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Visual Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Checking Diesel Fuel and Engine Oil . . . . . . . . . . . . . . . . . . 29Checking and Refilling Marine Gear Oil . . . . . . . . . . . . . . . 29

Checking the Battery Electrolyte Level . . . . . . . . . . . . . . . . 29

Checking the Alternator Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Checking the Throttle and Shift Console . . . . . . . . . . . . . . 29

Checking the Warning Indicators . . . . . . . . . . . . . . . . . . . . . . . 29

Preparing Fuel, Oil and Coolant in Reserve . . . . . . . . . . 29

Engine Operation ...................................................... 31

Starting the Engine Electrically . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Starting the Engine Manually . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Restarting After Starting Failure . . . . . . . . . . . . . . . . . . . . . . . . . 34

Starting at Low Temperatures . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

After the Engine Has Started . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Throttle and Shift Lever Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Acceleration and Deceleration . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Shifting the Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Precautions During Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Shutting Down the Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . 38

Checking the Engine After Operation . . . . . . . . . . . . . . .. . . . . . . . . . 39

Periodic Maintenance ................................................ 41

Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

The Importance of Periodic Maintenance . . . . . . . . . . . . . 43

Performing Periodic Maintenance . . . . . . . . . . . . . . . . . . . . . . 43

The Importance of Daily Checks . . . . . . . . . . . . . . . . . . . . . . . . 43

Keep a Log of Engine Hours and Daily Checks . . . . . 43

Yanmar Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Tools Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

TABLE OF CONTENTS

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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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45Conditions to Ensure Compliance with EPA

Emission Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

Inspection and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

Periodic Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Inspection and Maintenance of EPA Emission-

Related Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

Periodic Maintenance Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

After Initial 50 Hours of Operation . . . . . . . . . . . . . . . . . . . . . . 49

Every 50 Hours of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

Every 150 Hours of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

Every 250 Hours of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

Every 1000 Hours of Operation . . . . . . . . . . . . . . . . . . . . . . . . . 58

Troubleshooting ....................................................... 59

Troubleshooting After Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

Troubleshooting Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61Long-Term Storage ................................................... 65

Prepare Engine for Long-Term Storage . . . . . . . . . . . . . . . . . . . . . . 65

Draining the Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

Specifications .......................................................... 67

Principal Engine Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

1GM10 Engine Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

1GM10C Engine Specifications . . . . . . . . . . . . . . . . . . . . . . . . . 69

1GM10V Engine Specifications . . . . . . . . . . . . . . . . . . . . . . . . . 71System Diagrams ..................................................... 73

Piping Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

Emission System Warranty ........................................ 81

Non-Road Emission System Warranty . . . . . .. . . . . . . . . . . . . . . . . 81

Yanmar Co., Ltd. Limited Emission Control

System Warranty - USA Only . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

Maintenance Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84

TABLE OF CONTENTS

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TABLE OF CONTENTS

vi GM Series Operation Manual



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INTRODUCTION

Welcome to the world of Yanmar Marine!Yanmar Marine offers engines, drivesystems and accessories for all types ofboats, from runabouts to sailboats, and fromcruisers to mega yachts. In marine leisure

boating, the worldwide reputation of YanmarMarine is second to none. We design ourengines to respect nature. This meansquieter engines, with minimal vibrations,cleaner than ever. All of our engines meetapplicable regulations, including emissions,at the time of manufacture.

To help you enjoy your Yanmar GM seriesengine for many years to come, please

follow these recommendations:

• Read and understand this OperationManual before you operate the engine toensure that you follow safe operatingpractices 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 yourauthorized Yanmar Marine dealer ordistributor.

• Make sure this manual is transferred tosubsequent owners. This manual shouldbe considered a permanent part of theengine and remain with it.

• Constant efforts are made to improve thequality and performance of Yanmarproducts, so some details included in thisOperation Manual may differ slightly fromyour engine. If you have any questionsabout these differences, please contactyour authorized Yanmar Marine dealer ordistributor.

• The specifications and components(instrument panel, fuel tank, etc.)described in this manual may differ fromones installed on your vessel. Please referto the manual provided by themanufacturer of these components.

• Refer to the Yanmar Limited WarrantyHandbook for a complete warrantydescription.

GM Series Operation Manual 1



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RECORD OF OWNERSHIP

Take a few moments to record the information you need when you contact Yanmar forservice, parts or literature.

Engine Model:

Engine Serial No.:

Date Purchased:

Dealer:

Dealer Phone:

INTRODUCTION

2 GM Series Operation Manual



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SAFETY

Yanmar considers safety of greatimportance and recommends that anyonewho comes in close contact with itsproducts, such as those who install,operate, maintain or service Yanmar

products, exercise care, common senseand comply with the safety information inthis manual and on the engine’s safetydecals. Keep the decals from becomingdirty or torn and replace them if they are lostor damaged. Also, if you need to replace apart that has a decal attached to it, makesure you order the new part and decal at thesame time.

!

This safety alert symbol appearswith most safety statements. Itmeans attention, become alert,your safety is involved! Pleaseread and abide by the messagethat follows the safety alertsymbol.

! DANGER

Indicates a hazardous situation which, if

not avoided, will result in death or

serious injury.

! WARNING


not avoided, could result in death or

serious injury.

! CAUTION


not avoided, could result in minor ormoderate injury.

NOTICE

Indicates a situation which can causedamage to the engine, personal propertyand / or the environment or cause theequipment to operate improperly.




10/92

SAFETY PRECAUTIONS

General Information

There is no substitute for common senseand careful practices. Improper practices or

carelessness can cause burns, cuts,mutilation, asphyxiation, other bodily injuryor death. This information contains generalsafety precautions and guidelines that mustbe followed to reduce risk to personal safety.Special safety precautions are listed inspecific procedures. Read and understandall of the safety precautions before operationor performing repairs or maintenance.

Before You Operate! DANGER

The safety messages that follow have

DANGER level hazards.

NEVER permit anyone toinstall or operate theengine without propertraining.

• Read and understand this OperationManual before you operate or service theengine to ensure that you follow safeoperating practices and maintenanceprocedures.

• Safety signs and decals are additionalreminders for safe operating andmaintenance techniques.

• See your authorized Yanmar Marinedealer or distributor for additional training.

During Operation andMaintenance

! DANGER


DANGER level hazards.

Crush Hazard

NEVER stand under a hoistedengine. If the hoist mechanismfails, the engine will fall on you.

Fire Hazard

Ensure that appropriate fire

detection and extinguishingequipment are installed andchecked periodically forproper operation.

SAFETY




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! WARNING


WARNING level hazards.

Explosion Hazard

While the engine is running orthe battery is charging,hydrogen gas is beingproduced and can be easilyignited. Keep the area around

the battery well-ventilated and keep sparks,open flames and any other form of ignitionout of the area.

Fire and Explosion Hazard

Diesel fuel is flammable and explosiveunder certain conditions.

NEVER use a shop rag to catch the fuel.

Wipe up all spills immediately.

NEVER refuel with the engine running.

Store any containers containing fuel in awell-ventilated area, away from anycombustibles or sources of ignition.

Fire Hazard

Undersized wiring systemscan cause an electrical fire.

Sever Hazard

NEVER wear jewelry,unbuttoned cuffs, ties orloose-fitting clothing andALWAYS tie back long hairwhen working near moving /

rotating parts such as the flywheel or PTOshaft. Keep hands, feet and tools away fromall moving parts.

lcohol and Drug Hazard

NEVER operate the enginewhile under the influence ofalcohol or drugs or if you arefeeling ill.

Exposure Hazard

ALWAYS wear personalprotective equipmentincluding appropriateclothing, gloves, work shoes,eye and hearing protection as

required for the task at hand.

Entanglement Hazard

NEVER leave the key in thekey switch when you areservicing the engine.Someone may accidentallystart the engine and not realize

you are servicing it.

NEVER operate the engine while wearing aheadset to listen to music or radio because

it will be difficult to hear the warning signals.

Stop the engine before you begin to serviceit.

SAFETY




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! WARNING

Piercing Hazard

Avoid skin contact with high-pressure diesel fuel spraycaused by a fuel system leaksuch as a broken fuel injectionline. High-pressure fuel can

penetrate your skin and result in seriousinjury. If you are exposed to high-pressurefuel spray, obtain prompt medical treatment.

NEVER check for a fuel leak with yourhands. ALWAYS use a piece of wood orcardboard. Have your authorized Yanmar

Marine dealer or distributor repair thedamage.

Burn Hazard

Some of the engine surfacesbecome very hot duringoperation and shortly aftershutdown. Keep hands andother body parts away fromhot engine surfaces.

Exhaust Hazard

NEVER block windows, ventsor other means of ventilation ifthe engine is operating in anenclosed area. All internalcombustion engines create

carbon monoxide gas during operation andspecial precautions are required to avoid

carbon monoxide poisoning.

! CAUTION


CAUTION level hazards.

Poor Lighting Hazard

Ensure that the work area is adequatelyilluminated. ALWAYS install wire cages onportable safety lamps.

Tool Hazard

ALWAYS use tools appropriate for the taskat hand and use the correct size tool forloosening or tightening engine parts.

Flying Object Hazard

ALWAYS wear eye protection whenservicing the engine or when usingcompressed air or high-pressure water.Dust, flying debris, compressed air,pressurized water or steam may injure youreyes.

SAFETY




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NOTICE


NOTICE level hazards.

It is important to perform daily checks aslisted in the Operation Manual .

Periodic maintenance prevents unexpecteddowntime, reduces the number of accidentsdue to poor engine performance and helpsextend the life of the engine.

See your authorized Yanmar Marine dealeror distributor if you need to operate theengine at high altitudes. At high altitudes theengine will lose power, run rough andproduce exhaust gases that exceed the

design specifications.

ALWAYS be environmentallyresponsible.

Follow the guidelines of the EPA or othergovernmental agencies for the properdisposal of hazardous materials such as

engine oil, diesel fuel and engine coolant.Consult the local authorities or reclamationfacility.NEVER dispose of hazardous materials bydumping them into a sewer, on the groundor into ground water or waterways.

If a Yanmar Marine Engine is installed at anangle that exceeds the specifications statedin the Yanmar Marine Installation manuals,

engine oil may enter the combustionchamber causing excessive engine speed,white exhaust smoke and serious enginedamage. This applies to engines that run

continuously or those that run for shortperiods of time.If you have an installation with two or threeengines 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 theseawater pump and entering the engine.The result of water entering the engine couldcause engine seizure or other seriousproblems.

If you have an installation with two or threeengines, and only one engine is operating,please note that if the propeller shaftthru-hull (stuffing box) is lubricated byengine water pressure and the engines areinterconnected, care must be taken thatwater from the running engine does notenter the exhaust of the non-runningengine(s). This water could cause seizure ofthe non-running engine(s). See yourauthorized Yanmar Marine dealer ordistributor for a complete explanation of thiscondition.

If you have an installation with two or threeengines, and only one engine is operating,it is important to limit the amount of throttleapplied to the running engine. If you observeblack smoke or movement of the throttledoes not increase engine rpm, you areoverloading the engine that is running.Immediately throttle back to approximatelytwo-thirds throttle or to a setting where the

engine performs normally. Failure to do somay cause the running engine to overheator cause excess carbon buildup which mayshorten the engine's life.

SAFETY




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LOCATION OF SAFETY DECALS

Figure 1 shows the location of safety decals on Yanmar GM series marine engines.

GM Engines

128296-07350

WARNING

(1)

0005961

Figure 1

1 – Part Number: 128296–07350

SAFETY




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PRODUCT OVERVIEW

YANMAR GM FEATURESAND APPLICATIONS

The GM series engines are four-stroke

direct injection diesels equipped with directseawater coolant systems.

The 1GM10 is a naturally aspirated1-cylinder engine equipped with a KM2Pmarine gear.

The 1GM10C is a naturally aspirated1-cylinder engine equipped with an SD20sail-drive.

The 1GM10V is a naturally aspirated1-cylinder engine equipped with a KM3Vmarine gear.

The engines are equipped with a marinegear or sail-drive unit.

These engines are designed for pleasurecraft use.

It is recommended that new vessels be

propped so the engines can operate at100 to 200 rpm above the Maximum RatedPower Output rpm (3700 to 3800) to allowfor some added weight and hull resistance.The engine must be able to reach theMaximum Rated Power Output (3600 rpm)under full load at all times.

Failure to do so can lead to reduced vesselperformance and increased smoke levels,

and can cause permanent damage to yourengine, which is not covered by warranty.

The engine must be installed correctly withcoolant lines, exhaust gas lines andelectrical wiring. Any auxiliary equipmentattached to the engine should be easy to useand accessible for service. To handle the

drive equipment, propulsion systems(including the propeller) and other onboardequipment, always observe the instructionsand cautions given in the operation manualssupplied by the shipyard and originalequipment manufacturers.

The GM series engines are designed to beoperated at maximum throttle (3600 rpm) forless than 5% of total engine time (30 minutes

out of every 10 hours) and cruising speed(3400 rpm or less) for less than 90% of totalengine time (9 hours out of every 10 hours).

The laws of some countries may require hulland engine inspections, depending on theuse, size and cruising area of the boat. Thestructural design, vessel application andinstallation of this engine all requirespecialized knowledge and engineering

skills. See Yanmar’s local subsidiary in yourregion or your authorized Yanmar Marinedealer or distributor.




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New Engine Break-In

As with all reciprocating engines, the wayyour engine is operated during its first 50hours of operation plays a very significantrole in determining how long it will last and

how well the engine will perform over itslifetime.

A new Yanmar diesel engine must beoperated at suitable speeds and powersettings during the break-in period to allowbearing surfaces and other friction-relatedcomponents, such as piston rings and valveguides, to wear in properly in order tostabilize engine lubrication and combustion.

During the break-in period, the enginecoolant temperature gauge should bemonitored closely. The temperature shouldremain between 71˚ and 87˚C (160˚ and190˚F).

During the first 10 hours of operation, theengine should be operated at maximum rpmminus 400 to 500 rpm (approximately 60 to70% of load) most of the time. This will

ensure the sliding parts break in properly.

NOTICE: During this period, avoid

operating at maximum engine speed

and load to avoid damaging or scoring

sliding parts.

NOTICE: NEVER operate at WOT (wide

open throttle) for more than a minute at

a time during the first 10 hours of

operation.

Do not operate the engine at low idle or atlow speed and light load for more than30 minutes at a time. Since unburned fueland engine oil will adhere to the piston ringswhen operating at low speeds for longperiods, this will interfere with propermovement of the rings and the diesel fuelconsumption may increase. Low idle speed

does not allow break-in of sliding parts.

If operating the engine at low speed and lightload, you must race the engine to clean thecarbon from the cylinders and the fuelinjection valve.

Perform this procedure in open waters:

• With the clutch in NEUTRAL, acceleratefrom the low speed position to the highspeed position briefly.

• Repeat this process five times.

Once past the initial 10 hours until 50 hours,the engine should be used over its fulloperating range, with special emphasis onrunning at relatively high power settings.This is not the time for an extended cruise atidle or low speed. The boat should beoperated at maximum speed minus 400 rpmmost of the time (approximately 70% load),with a 10-minute run at maximum minus 200rpm (approximately 80% load) every30 minutes and a 4 to 5 minute period ofoperation at WOT (wide open throttle) onceevery 30 minutes. During this period, be surenot to operate the engine at low speed and

light load for more than 30 minutes. Ifoperating engine at low speed and light loadis necessary, race the engine after low idleoperation.

To complete engine break-in, perform After Initial 50 Hours maintenance procedures.See After Initial 50 Hours of Operation on

page 49.

PRODUCT OVERVIEW




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COMPONENT IDENTIFICATION

Service Side - 1GM10 with KM2P

Figure 1 and Figure 2 illustrate a typicalversion of a 1GM10 engine. Your engine

may have different equipment from thatillustrated.

(1)(2)

(3)

(4)

(5)

(6)

(7)

(8)

(9)

(10)(11)

(12)

(13)

(14)

(15)

(16)

0005850

Figure 11 – Nameplate

2 – Thermostat Cover

3 – Fuel Injection Pump

4 – Idle Adjuster

5 – Oil Filler Cap

6 – Fuel Injection Limiter

7 – Engine Stop Lever

8 – Crankshaft V-Pulley

9 – Seawater Pump

10 – Engine Oil Filter

11 – Regulator Handle

12 – Fuel Feed Pump

13 – Engine Oil Dipstick

14 – Mounting Flange

15 – Mixing Elbow

16 – Fuel Filter

PRODUCT OVERVIEW



http://-/?-http://-/?-


18/92

Non-Service Side - 1GM10 withKM2P

(1)(2)

(3)

(4)

(5)

(6)(7)

(8)

(9)

(10)

0005849

Figure 2

1 – Decompression Lever2 – Fuel Injection Valve

3 – Intake Silencer (Air Cleaner)

4 – Tachometer Sensor

5 – Marine Gear Dipstick

6 – Marine Gearbox7 – Output Shaft Coupling

8 – Shift Lever

9 – Starter Motor

10 – Alternator

PRODUCT OVERVIEW




19/92

LOCATION OFNAMEPLATES

The nameplate of the Yanmar GM seriesengine is shown in Figure 3. Check the

engine’s model, output, rpm and serialnumber on the nameplate. Replace it if it isdamaged or lost.

/

Gear Model

ENG.No.

/

Model

min-1

min-1

min-1

Continuous power kW

Speed of prop,shaf t

Fuel stop power kW

0004574

Figure 3

The engine nameplate is attached to the

engine rocker arm cover.The marine gear nameplate (Figure 4) isattached to the marine gear. Check themarine gear’s model, gear ratio, oil used, oilquantity and serial number.

MODE L KM

GEAR RATIO

OIL SAE 20/30HD

OIL QTY. LTR.NO.

0004529

Figure 4

Emission-Control Labels

To ensure safe operation, emission-controllabels have been attached to the engine.Their location is shown in Figure 6. Theyshould always be visible. Replace labels if

damaged or lost.

0005987

Figure 5

EPA & ARB label

0005988

Figure 6

PRODUCT OVERVIEW




20/92

MAJOR COMPONENTS AND FUNCTIONS

Name of Component Function

Decompression Lever Opens the exhaust valve and releases cylinder pressure to aid in manual enginestarting

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. Pumping the priming leverup and down supplies fuel to the engine when the fuel system needs to be primed.

Engine Oil Filler Port Filler port for engine oil

Marine Gear Oil Filler Port Filler port for marine gear oil

Engine Oil Filter

Filters fine metal fragments and carbon from the engine oil. Filtered engine oil isdistributed to the engine’s moving parts. The filter is a spin-on type and the elementshould be replaced periodically. See Replacing the Engine Oil Filter Element on

page 50.

Cooling System Direct seawater cooling

Seawater Pump Pumps seawater from outside the vessel and through the engine. The seawaterpump has a replaceable rubber impeller.

Zinc Anode

The metal surfaces of the seawater cooling system are prone to corrosion. Thezinc anode is installed in the cylinder block to prevent this. The surface of the zincanode erodes so it needs to be replaced at fixed intervals in order to fully protectthe seawater cooling system of the engine.

Intake Silencer (AirCleaner)

The intake silencer guards against dirt entering the engine induction system andreduces the noise of air intake.

Nameplates Nameplates are provided on the engine and the marine gear and contain themodel, serial number and other data.

Starter Motor The starter motor cranks the engine and is powered by the battery.Alternator The alternator is belt driven and generates electricity to charge the battery.

Engine Oil Dipstick Gauge stick for checking the engine oil level

PRODUCT OVERVIEW




21/92

CONTROL EQUIPMENT

The control equipment at the helm makes remote control operation possible. It consists ofthe instrument panel, which is connected to the engine by a wire harness, and the throttleand 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. The followingcontrols and indicators enable you to start, stop and monitor the condition of the engine duringoperation.

Instrument Panel Options and Components

(2) (3) (4) (5)

(8) (7) (6) (10)(12) (7)

(9)

(8) (11)(6)

(5)(4)(3)(2)

(1)

0005848

Figure 7

1 – Option “A” Instrument Panel

2 – Seawater in Marine Gear Warning Lamp

3 – Water Temperature Warning Lamp4 – Oil Pressure Warning Lamp

5 – Battery Low Charge Warning Lamp

6 – Key Switch

7 – Warning Buzzer

8 – Start Button

9 – Option “B” Instrument Panel

10 – Engine Tachometer

11 – Instrument Panel Light Switch

12 – Hour Meter

PRODUCT OVERVIEW




22/92

Gauges

Instrument Function

Tachometer Shows the engine rotation speed

Hour MeterShows the number of operating hours; can be used as a guidefor periodic maintenance checks. The hour meter is located atthe bottom of the tachometer.

Instrument Panel Lights When turning the key switch to ON, the gauges will illuminate foreasier viewing.

Key Switch

When the key is in the OFF position(Figure 8, (1)) the electric current is off. Thekey can be inserted or removed in thisposition.

OFFON

(2)

(1)

0005847

Figure 8

1 – OFF Position

2 – ON Position

The ON position (Figure 8, (2)) allowselectrical current to the controls and

equipment and allows the engine to keeprunning. To stop the engine, keep the keyswitch in the ON position and pull the enginestop knob. After stopping the engine, turnthe key to the OFF position.

Engine Decompression Lever

The engine decompression lever(Figure 9, (3)) releases cylinder pressureto aid in manual starting.

(3)(2)

(1)

0005838

Figure 9

1 – RUN Position

2 – Decompression Position

3 – Decompression Lever

Raising the decompression lever to thedecompression position (Figure 9, (2))opens the exhaust valve and makes handcranking of the engine possible. Returning

the lever to its RUN position (DOWN)(Figure 9, (1)) closes the exhaust valve andnormal engine operation can resume.

PRODUCT OVERVIEW




23/92

Indicators and Alarms (Optional)

When a sensor detects a problem duringoperation, the indicator on the instrumentpanel will light and an alarm will sound.Indicators are located on the instrumentpanel. The alarm is located on the back ofthe panel. Under normal operatingconditions, the indicators are off.

Figure 10

Battery Low Charge Indicator(Figure 10) - When the alternator output istoo low, the indicator will light. When

charging begins, the indicator will turn off.No alarm will sound for low battery charge.

Figure 11

Water Temperature Indicator and Alarm(Figure 11) - When water temperaturereaches the maximum allowable

temperature (95˚C [203˚F] or higher), theindicator will light and the alarm will sound.Continuing operation at temperaturesexceeding the maximum limit will result indamage and seizure. Check the load andtroubleshoot the cooling system.

Figure 12

Engine Oil Low Pressure Indicator andAlarm (Figure 12) - When the engine oilpressure falls below normal, the oil pressuresensor will send a signal to the indicatorcausing it to light and the alarm to sound.Stop operation immediately to avoiddamage to the engine. Check the oil leveland troubleshoot the lubrication system.

Figure 13

Water in Sail-Drive Seal Indicator and Alarm(Figure 13) - When seawater is detected

between the seals of the sail-drive, theindicator will light and the alarm will sound.

Engine Stop Control

The engine is stopped by pulling out theengine stop knob (Figure 14, (1)). Thiscable is connected to the engine stop leverand cuts off the fuel supply to the engine.

(3)

(1) (2)

0005842

Figure 14

1 – Engine Stop Knob

2 – Bulkhead

3 – Engine Stop Cable

PRODUCT OVERVIEW




24/92

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

Indicators

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

Note: All warning indications will continue until the engine starts or the key switch is in theOFF position.

Optional Single-Lever Throttle

and Shift ConsoleThis console (Morse Type) uses a singlelever to operate the throttle and the shiftingmechanism.

FORWARD (FWD) (Figure 15, (1)) - Thedrive shaft is engaged and the enginepropels the vessel forward.

FWD

REV

NEUTR L

IPULLI

LUT H

(1)(2)

(3)

(4)

0005846

Figure 15

1 – FORWARD (FWD)

2 – NEUTRAL (N)

3 – REVERSE (REV)

4 – Pull out the lever to disengage theclutch.

NEUTRAL (N) (Figure 15, (2)) - The drive

shaft is disengaged from the propeller andthe engine idles.

REVERSE (REV) (Figure 15, (3)) - Thedrive shaft is engaged and the enginepropels the vessel aft.

With the lever in the NEUTRAL position, pullthe lever out from the console(Figure 15, (4)) to disengage the clutch.

The lever controls the direction of the vessel(ahead or astern) and acts as anaccelerator, increasing the engine speed(rpm) as it is pushed further in the FWD orREV direction. When the lever is pulled out,engine speed can be controlled withoutmoving the vessel. The clutch is disengagedand the vessel is in NEUTRAL (no-loadposition).

Note: Yanmar recommends the use of asingle-lever type console for the remotecontrol system. If only a two-lever type isavailable in the market, reduce enginespeed to 1000 rpm or less before engagingand disengaging the marine gear clutch.

PRODUCT OVERVIEW




25/92

BEFORE YOU OPERATE

This section of the Operation Manual describes diesel fuel and engine oil, andhow to replenish them. It also describes thedaily engine checks.

Before performing any operations within thissection, review the Safety section onpage 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.

Diesel fuel should comply with the followingspecifications. The table lists severalworldwide specifications for diesel fuels.

DIESEL FUELSPECIFICATION LOCATION

ASTM D975 No. 2-D, No.1-D,

USA

EN590:96 European Union

ISO 8217 DMX International

BS 2869-A1 or A2 United Kingdom

JIS K2204 Grade No. 2 Japan




26/92

Additional Technical FuelRequirements

• The fuel cetane number should be 45 orhigher.

• The sulfur content must not exceed 0.5%

by volume. Less than 0.05% is preferred.• NEVER mix kerosene, used engine oil orresidual fuels with the diesel fuel.

• Water and sediment in the fuel should notexceed 0.05% by volume.

• Keep the fuel tank and fuel-handlingequipment clean at all times.

• Ash content not to exceed 0.01% byvolume.

• Carbon residue content not to exceed0.35% by volume. Less than 0.1% ispreferred.

• Total aromatics content should notexceed 35% by volume. Less than 30% ispreferred.

• PAH (polycyclic aromatic hydrocarbons)content should be below 10% by volume.

• Do not use Biocide.

• Do not use kerosene or residual fuels.

Handling Diesel Fuel

! DANGER

Only use diesel fuel in the fuel tank. Fillingthe fuel tank with gasoline may result in a fireand will damage the engine. NEVER refuelwith the engine running. Wipe up all spillsimmediately. Keep sparks, open flames orany other form of ignition (match, cigarette,static electric source) well away whenrefueling.

ALWAYS store any containers containingfuel in a well-ventilated area, away from anycombustibles or sources of ignition.

ALWAYS put the diesel fuel container on theground when transferring the diesel fuelfrom the pump to the container. Hold thehose nozzle firmly against the side of thecontainer while filling it. This prevents staticelectricity buildup which could cause sparksand ignite fuel vapors.

BEFORE YOU OPERATE




27/92

Fuel Tank (Optional)

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 a drain cock (Figure 1, (2)) at thebottom of the fuel tank to remove water andcontaminants from the sediment bowl(Figure 1, (1)).

0004542

(3)

(1) (2)

Figure 11 – Sediment Bowl

2 – Drain Cock

3 – Fuel Line to Engine

The fuel outlet should be positioned20 to 30 mm (0.75 to 1.125 in.) above thebottom of the tank (Figure 2, (4)) so thatonly clean fuel is distributed to the engine.

Fuel System

Install the fuel line from the fuel tank to thefuel injection pump as shown in Figure 2.The recommended fuel / water separator(Figure 2, (3)) (optional) is installed at thecenter section of that line.

(1)

(2)(3)

(8)

(10)

(4)

(6)

(7)

(9)

(5)

0004788

Figure 2

1 – Fuel Filter

2 – Fuel Feed Pump (Priming Lever)

3 – Fuel / Water Separator (Optional)

4 – Approximately 20 - 30 mm

(0.75 - 1.125 in.)5 – Within 500 mm (20 in.)

6 – Drain Cock

7 – Fuel Cock

8 – Fuel Return Line

9 – To Fuel Injection Pump

10 – Fuel Tank

BEFORE YOU OPERATE




28/92

Filling the Fuel Tank

Before filling the fuel tank for the firsttime:

Rinse the fuel tank with kerosene or dieselfuel. Dispose of waste properly.

To fill the fuel tank:

NOTICE: 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.

1. Clean the area around the fuel cap.2. Remove the fuel cap from the fuel tank.

3. Fill the tank with clean fuel free of oil anddirt. WARNING! Hold the hosenozzle firmly against the filler port

while filling. This prevents static

electricity buildup which could

cause sparks and ignite fuel vapors.

4. Stop fueling when the gauge shows thefuel tank is full. CAUTION! NEVER overfill the fuel tank.

5. Replace the fuel cap and hand-tighten.Over-tightening the fuel cap willdamage it.

If filling the tank from a storage container(Figure 3), keep the fuel containerstationary for several hours to allow any dirtor water to settle to the bottom of thecontainer. Use a pump to extract the clear,filtered fuel from the top of the container.

0004512

Figure 3

BEFORE YOU OPERATE




29/92

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. Thi s may adversely

affect the lubricating properties of the

engine oil.

Use an engine oil that meets or exceeds thefollowing guidelines and classifications:

• API Service Categories: CD or higherTBN value: 9 or more

The oil must be changed when the TotalBase Number (TBN) has been reduced to2.0.

TBN (mgKOH/g) test method: JISK-2501–5.2–2(HCI), ASTM D4739(HCI)

• Recommended SAE Viscosity: 10W30,15W40. Engine oil 10W30 and 15W40can be used throughout the year.

• NEVER use API Service Category CG-4or CH-4 oils.

NOTICE:

1. Be sure the engine oil, engine oil

storage containers and engine oil

filling equipment are free of

sediment or water.

2. Change the engine oil after the first

50 hours of operation and then at

every 150 hours thereafter. See

Changing the Engine Oil on page

50.

3. Select the oil viscosity based on the

ambient temperature where the

engine is being operated. See the

SAE Service Grade Viscosity Chart

(Figure 4).

4. Yanmar d oes not recommend theuse of engine oil “additives.”

Handling Engine Oil

1. When handling and storing engine oil,be careful not to allow dust and water tocontaminate the oil. Clean around thefiller port before filling.

2. Do not mix oils of different types orbrands. Mixing may cause the chemicalcharacteristics of the oil to change andlubricating performance to decrease,reducing the engine’s life.

3. Engine oil should be replaced at thespecified intervals, regardless of theengine’s operation history. SeePeriodic Maintenance Schedule on

page 46 .

Engine Oil Viscosity

-4°F 14°F 32°F 50°F 68°F 86°F 104°F

(-20°C) (-10°C) (0°C) (10°C) (20°C) (30°C) (40°C)

SAE 10W-30

SAE 15W-40

0000005

Figure 4

Select the appropriate engine oil viscositybased on the ambient temperature shown inthe SAE Service Grade Viscosity Chart inFigure 4.

NOTICE: If you intend to operate your

equipment at temperatures outside the

limits shown, you must consult your

authorized Yanmar Marine dealer or

distributor for special lubricants or

starting aids.

BEFORE YOU OPERATE




30/92

Checking the Engine Oil

1. Make sure the engine is off. It isrecommended that the engine be aslevel as possible before checking theoil.

2. 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.

(1) (2)

(4)

(3)

0005852

Figure 5

1 – Filler Port

2 – Dipstick

3 – Upper Limit

4 – Lower Limit

3. Fully reinsert the dipstick.

4. Remove the dipstick. The oil levelshould be between the upper(Figure 5, (3)) and lower(Figure 5, (4)) lines on the dipstick.

5. Add oil if necessary. See AddingEngine Oil on page 24.


Adding Engine Oil

1. NOTICE: Prevent dirt and debris fromcontaminating the engine oil.

Carefully clean the dipstick and the

surrounding area before you remove

the cap. Remove the yellow oil filler portcap from filler port (Figure 5, (1)) on therocker arm cover and fill with engine oil.

2. Fill with engine oil to the upper limit(Figure 5, (3)) on the dipstick(Figure 5, (2)). NOTICE: NEVER overfill the engine with engine oil.

Engine Oil Capacity

1GM10 (V) (C) Full: 1.5 L (1.5 qt)

3. Insert the dipstick fully to check the level.NOTICE: ALWAYS keep the oil level between upper and low er lines on the

oil cap / dipstick.

4. Hand-tighten the filler port cap securely.

BEFORE YOU OPERATE




31/92

MARINE GEAR OR SAIL-DRIVE OIL

Marine Gear Oil Specifications

Use marine gear oil that meets or exceeds

the following guidelines and classifications:

KM2P-1 (S), (G) or (GG):

• API Service Categories: CD or higher

• SAE Viscosity: #20 or #30

Sail-Drive Oil Specifications -SD20

Refer to the Sail-Drive Operation Manual for

the procedure to fill or replace the drive oil.SD20:

• API Service Category: GL4.5

• SAE Viscosity: 90 or 80W90

• QuickSilver® 1 High Performance GearLube

Checking Marine Gear Oil

1. Turn the engine off. Make sure the engineis as level as possible and wipe area cleanaround the marine gear filler port(Figure 6, (4)).

(1)

(3)

(4)

(2)

0005851

Figure 6

1 – Dipstick

2 – Upper Limit

3 – Lower Limit

4 – Marine Gear Filler Port

Marine Gear Oil Capacity

KM2P 0.3 L (0.63 pt)

2. Remove the filler cap at the top of thehousing.

3. Remove the dipstick (Figure 6, (1)) andwipe with a clean cloth.


5. Remove the dipstick. The oil level shouldbe between the upper (Figure 6, (2)) andlower (Figure 6, (3)) lines on the dipstick.


1 QuickSilver is a registered trademark of Brunswick Corporation.

BEFORE YOU OPERATE




32/92

Adding Marine Gear Oil

1. Make sure the engine is as level aspossible.

2. Remove the filler cap / dipstick(Figure 6, (1)) at the top of the housing.

3. Fill with oil to the upper limit on thedipstick (Figure 6, (2)). NOTICE:NEVER overfill the marine gear with

oil.


5. Hand-tighten the filler port cap.

Checking and Adding Sail-DriveOil

Refer to the Sail-Drive Operation Manual forthe procedure for checking and filling thesail-drive oil.

CRANKING THE ENGINEMANUALLY

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 the

operating parts. Using the engine in this

condition will lead to seizure.

After a long period of non-use, distributeengine oil to each part by cranking theengine. Perform the following procedurebefore beginning operation:

1. Open the seacock.

2. Open the fuel cock.

3. Put the remote control shift lever in theNEUTRAL position.

4. Raise the decompression lever(Figure 7, (3)) up.

(3)(2)

(1)

0005838

Figure 7

1 – RUN Position

2 – Decompression Position

3 – Decompression Lever

BEFORE YOU OPERATE




33/92

5. Slide the starter handle(Figure 8, (2)) on the starter shaft(Figure 8, (1)), align the groove andpin, and turn the engine over about 10times.

(1)

(2)

0005888

Figure 81 – Starter Shaft

2 – Starter Handle

6. Listen for any abnormal noises whilecranking the engine.

7. Remove the starter handle.

8. Place the decompression lever in theRUN position.

CRANKING THE ENGINEELECTRICALLY

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.

After a long period of non-use, distributeengine oil to each part by cranking theengine. Perform the following procedurebefore beginning operation:

1. Open the seacock.

2. Open the fuel cock.Note: If the engine has not beenoperated for a long period of time,check that the key can be moved from the OFF to the ON positionsmoothly.

3. Put the remote control shift lever in theNEUTRAL position.

4. Pull the engine stop knob

(Figure 9, (1)) out and holdcontinuously while cranking.

(3)

(1) (2)

0005842

Figure 9


2 – Bulkhead

3 – Engine Stop Cable

5. With the key in the ON position, pushthe start button and the engine will

begin cranking.6. Continue cranking for about 5 secondsand listen for any unusual noises.

BEFORE YOU OPERATE




34/92

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 OilWhen the oil is distributed throughout theinternal components, start the engine andrun at no load for about 5 minutes. This willensure that all oil galleys, oil filters and oiltubes are full of oil. Shut the engine downand recheck the engine oil level. SeeChecking the Engine Oil on page 24. Add oilto the proper level, if necessary.

DAILY CHECKS

Before starting for the day, make sure theYanmar engine is in good operatingcondition. CAUTION! It is important to

perform daily checks as listed in thisOperation 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 thefollowing items:

Visual Checks

1. Check for engine oil leaks.2. Check for fuel leaks.WARNING! Avoid

skin contact with the high-pressure

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.

3. Check for engine seawater leaks.

4. Check for damaged or missing parts.

5. Check for loose, missing or damagedfasteners.

6. Check the electrical harnesses forcracks, abrasions, and damaged orcorroded connectors.

7. Check hoses for cracks, abrasions, anddamaged, loose or corroded clamps.

BEFORE YOU OPERATE



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35/92

8. Check the fuel filter / water separator forwater and contaminants. If you find anywater or contaminants, drain the fuelfilter / water separator. See Draining theFuel Filter / Water Separator on page52 . If you have to drain the fuel filter /

water separator frequently, drain thefuel tank and check for water in your fuelsupply. See Draining the Fuel Tank on

page 49.

CAUTION! If any problem is noted

during the visual check, the necessary

corrective action should be taken before

you operate the engine.

Checking Diesel Fuel and EngineOil

Follow the procedures in Filling the Fuel Tank on page 22 and Checking the EngineOil on page 24 to check these levels.

Checking and Refilling MarineGear Oil

See Checking Mari ne Gear Oil on page 25 .

Checking the Battery ElectrolyteLevel

Check the battery electrolyte level beforeuse. See Inspecting the Battery Electroly teLevel (Serviceable Batteries Only) on page53.

Checking the Alternator Belt

Check the belt tension before use.See Checking and Adjusting the Alternator V-Belt Tension on page 51.

Checking the Throttle and ShiftConsoleCheck the operation of the throttle and shiftcontrol lever. Make sure it moves smoothly.If it is hard to operate, grease the joints of thecontrol cable and lever bearings. If the leverhas excessive play, adjust the control cableconnectors and clamps. See Inspecting and

Adjusting the Throttle and Shift Control Cables on page 51.

Checking the Warning Indicators

Check to ensure the engine instruments andwarning indicators are functioning properly.See Alarms on page 18. Check them oftenduring operation.

Preparing Fuel, Oil and Coolant inReserve

Prepare sufficient diesel fuel for the day’s

operation. Always store engine oil andcoolant in reserve (for at least one refill)onboard, to be ready for emergencies.

BEFORE YOU OPERATE



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36/92


BEFORE YOU OPERATE




37/92

ENGINE OPERATION

This section of the Operation Manual describes the procedures for starting theengine, checking engine performanceduring operation and shutting down theengine.

Before performing any operations within thissection, read the following safetyinformation and review the Safety section onpage 3.

! WARNING

Fire and Explosion Hazard

NEVER jump-start the engine.Sparks caused by shorting the

battery to the starter terminalsmay cause a fire or explosion.ONLY use the key switch to

start the engine.

Sudden Movement Hazard

Be sure the boat is in open water away fromother boats, docks or other obstructionsbefore increasing rpm. Avoid unexpected

equipment movement. Shift the marine gearinto the NEUTRAL position any time theengine is at idle.

To prevent accidental equipmentmovement, NEVER start the engine in gear.

Sever Hazard

Keep children and pets awaywhile the engine is operating.

Exhaust Hazard

NEVER block windows, ventsor other means of ventilation ifthe engine is operating in anenclosed area. All internalcombustion engines create

carbon monoxide gas during operation andspecial precautions are required to avoidcarbon monoxide poisoning.




38/92

NOTICE

If any indicator illuminates during engineoperation, stop the engine immediately.Determine the cause and repair the problembefore you continue to operate the engine.

If the alarm indicator lamps and audiblealarm fail to display or sound when theignition switch is in the ON position, see yourauthorized Yanmar Marine dealer ordistributor for service before operating theengine.

Observe the following environmentaloperating conditions to maintain engine

performance and avoid premature enginewear:

• Avoid operating in extremely dustyconditions.

• Avoid operating in the presence ofchemical gases or fumes.

• NEVER run the engine if the ambienttemperature is above +40˚C (+104˚F) orbelow -16˚C (+5˚F).

• If the ambient temperature exceeds+40˚C (+104˚F), the engine may overheatand cause the engine oil to break down.

• If the ambient temperature is below -16˚C(+5˚F), rubber components such asgaskets and seals will harden causingpremature engine wear and damage.

• Contact your authorized Yanmar Marineengine dealer or distributor if the engine

will be operated outside of this standardtemperature range.

NEVER engage the starter motor while theengine is running. Damage to the startermotor pinion and / or ring gear will result.

STARTING THE ENGINEELECTRICALLY

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. When the engine does

start, stop the engine immediately and

turn the switch to the OFF position.

1. Open the seacock (if equipped).2. Open the fuel cock.

3. Put the remote control shift lever in theNEUTRAL position (Figure 1, (1)).

Note: Safety equipment should make it impossible to start theengine in any position other thanNEUTRAL.

(1)

0005890

Figure 1

1 – NEUTRAL (N)

4. Turn the master battery switch (ifequipped) to ON.

ENGINE OPERATION




39/92

5. Turn the key switch to the ON position(Figure 2, (2)). Ensure that theinstrument panel indicators light andthe alarm sounds. This indicates thatthe indicators and the alarm areworking correctly.

Note: The water temperaturealarm indicator and water in Sail-Drive indicator should not come onduring start-up.

OFFON

(2)

(1)

0005847

Figure 2

1 – OFF position

2 – ON position

6. Push the start button. Release the startbutton when the engine has started.NOTICE: NEVER hold the start

button for longer than 15 seconds

or the starter motor will overheat.

7. The alarm should stop and the indicatorlamps should go out. NOTICE: If any indicator fails to illuminate when the

key switch is in the ON position, see

your 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 theNEUTRAL position (Figure 3, (1)).

Note: Safety equipment should make it impossible to start theengine in any position other thanNEUTRAL.

(1)

(2)

0005888

Figure 3

1 – Starting Shaft

2 – Starting Handle

4. Turn the master battery switch (ifequipped) to ON.

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5. Raise the decompression lever up. SeeCranking the Engine Manually on page

26 .

6. Slide the starter handle(Figure 3, (2)) on the starter shaft(Figure 3, (1)), align the groove andpin, and turn by hand.

7. Turn the handle vigorously. Whenengine rotation is rapid, return thedecompression handle to the RUNposition.

8. Remove the starter handle from thestarter shaft after the engine starts.

Restarting After Starting Failure

Before pushing the start button again, besure the engine has stopped completely.NEVER attempt to restart the engine whilethe engine is running. The pinion gear on thestarter motor will be damaged.NOTICE: NEVER hold the start button for

longer than 15 seconds or the starter

motor will overheat.

NOTICE: NEVER attempt to restart the

engine if the engine has not stopped completely. Pinion gear and starter

motor damage will occur.

Air Bleeding from the Fuel SystemAfter Starting Failure

If the engine does not start after severalattempts, there may be air in the fuel system.If air is in the fuel system, fuel cannot reachthe fuel injection pump. Bleed the air from

the fuel system according to the followingsteps:

1. Check the fuel tank level.

2. Loosen the air vent bolt at the top of thefuel / water separator. When fuel is freeof bubbles, retighten the air vent bolt.

3. Loosen the air vent bolts of the fuel filterand fuel injection pump.

4. Pump fuel with the fuel feed pump by

moving the lever on the left side of thefuel feed pump up and down.

5. Allow the fuel containing air bubbles toflow out of the air vent bolt holes.

6. When the fuel no longer contains airbubbles, tighten the air vent bolts.

7. Try starting the engine again.

Starting at Low TemperaturesComply with local environmentalrequirements. Do not use starting aids.NOTICE: NEVER use an engine starting

aid such as ether. Engine damage will

result. Using a starting aid may void thewarranty.

To limit white smoke, run the engine at lowspeed and under moderate load until theengine reaches normal operatingtemperature. A light load on a cold engineprovides better combustion and fasterengine warm-up than no-load.

Avoid running the engine at idling speed anylonger than necessary.

After the Engine Has Started

After the engine has started, check the

following items at a low engine rpm.

1. Check that the gauges, indicators andalarm are normal.

2. Check for any water, fuel, enginecoolant or engine oil leaks. If any leaksare found, shut down the engine andperform the necessary repairs.WARNING! NEVER check for a fuel

leak with your hands. ALWAYS use

a piece of wood or cardboard. Have


dealer or distributor repair the

damage. Avoid skin contact with the

high-pressure 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-pressurefuel spray, obtain prompt medical

treatment.

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3. Check that the exhaust color, enginevibration and sound are normal.

4. When there are no problems, keep theengine at low speed with the boat stillstopped to distribute engine oil to allparts of the engine.

5. Check that water is being dischargedfrom the seawater outlet pipe.Operation with inadequate seawaterdischarge will damage the impeller ofthe seawater pump. If seawaterdischarge is too low, stop the engineimmediately. Identify the cause andrepair. NOTICE: The engine will seizeif it is operated when cooling

seawater discharge is inadequateor if load is applied without any

warm-up operation.

• Is the seacock open?

• Is the inlet of the seacock on the hullbottom clogged?

• Is the seawater suction hose brokenor does the hose suck air because ofa loose clamp?

When operating the engine at low speed forlong periods of time, race the engine onceevery two hours. Race the engine with theclutch in NEUTRAL, accelerate from the lowspeed position to the high speed positionand repeat this process about five times.

This cleans out carbon from the cylindersand the fuel injection valves.NOTICE: Neglecting to race the engine

will result in poor exhaust color and

reduce engine performance.

Periodically operate the engine nearmaximum speed while underway. This willgenerate higher exhaust temperatures,which will help clean out hard carbon

deposits, maintain engine performance andprolong the life of the engine.

For troubleshooting assistance, seeTroubleshooting After Starting on page59 or Troubleshooting Chart on page61.

If necessary, see your authorized YanmarMarine dealer or distributor.

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THROTTLE AND SHIFTLEVER OPERATION

Acceleration and Deceleration

Note: Direction of travel will vary depending

on installation location.

Use the throttle handle to controlacceleration and deceleration. Move thehandle 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 tomarine gear parts and abnormal wear.

1. Before using the marine gear, be sureto move the throttle handle to a low idleposition (less than 1000 rpm). Move thethrottle handle slowly to a higher speedposition after completing clutchengagement.

2. NOTICE: NEVER shift the marine gear at high engine speed. During

normal operation, the marine gear

should only be shifted with the

engine at idle. When moving thehandle between FORWARD(Figure 4, (1)) and REVERSE(Figure 4, (3)), bring the clutch toNEUTRAL (Figure 4, (2)) and pausebefore slowly shifting to the desiredposition. Do not shift abruptly fromFORWARD to REVERSE or vise versa.

FWD

REV

NEUTR L

IPULLI

LUT H

(1)(2)

(3)

(4)

0005846

Figure 4

1 – FORWARD (FWD)

2 – NEUTRAL (N)

3 – REVERSE (REV)

4 – Pull the lever to disengage theclutch.

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PRECAUTIONS DURINGOPERATION

Always check for problems during engineoperation.

1. Is sufficient seawater being dischargedfrom the seawater outlet?If the discharge is too little, stop theengine immediately and correct theproblem.

2. Is the exhaust color normal?The continuous emission of blacksmoke indicates engine overloading.This shortens engine life and should be

avoided.3. Be aware of any abnormal vibration and

unusual engine noises. NEVERoperate at speeds that produce violentvibrations. Depending on the hullstructure, engine and hull resonancemay become great at a certain speedrange. Avoid operating in this range.Stop the engine and inspect anyunusual engine noise.

4. Ensure that there are no warningindicators active. If an indicatoractivates during operation, lower theengine speed immediately, check theindicator and stop the engine forrepairs.

5. Check for any water, oil or fuel leaks.Check the engine room periodically.WARNING! NEVER check for a fuel

leak with your hands. ALWAYS usea piece of wood or cardboard. Have


dealer or distributor repair the

damage. Avoid skin contact with the

high-pressure 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-pressurefuel spray, obtain prompt medical

treatment.

6. Is there sufficient fuel in the tank?Replenish fuel in advance to avoidrunning out of fuel during operation.

7. When operating the engine at lowspeed for long periods of time, race theengine once every two hours. Race theengine with the clutch in NEUTRAL,accelerate from the low speed positionto the high speed position and repeatthis process about five times. Thiscleans out carbon from the cylindersand the fuel injection valves.

NOTICE: Never turn OFF the battery

switch or spark the battery during

operation. Damage to electrical parts

will result.

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SHUTTING DOWN THEENGINE

NOTICE: NEVER stop the engine

abruptly during operation. Yanmar

recommends that when shutting theengine 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. Reduce the engine speed to low idleand put the shift control lever in

NEUTRAL.2. Accelerate from low speed to high

speed and repeat five times. This willclean out the carbon from the cylindersand the fuel injection nozzles.

3. Allow the engine to run at low speed(approximately 1000 rpm) without loadfor five minutes.

4. With the key in the ON position, pull andhold the engine stop knob(Figure 5, (1)) until the engine hascome to a complete stop. After theengine has stopped, turn the key switchto OFF.

Note: Continue to hold the enginestop knob until the engine iscompletely stopped. If the knob isreleased before the engine hascompletely stopped, it may restart.

(3)

(1) (2)

0005842

Figure 5


2 – Bulkhead

3 – Control Cable

5. Turn off the master battery switch (ifequipped).

6. Remove the key.

7. Close the fuel cock.

8. 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.

Note: The engine may be stopped by raisingthe decompression lever, but avoid doing soexcept in times of emergency. Thedecompression lever releases compression

pressure in the cylinder which causes theengine to stop. However, fuel injection doesnot stop and fuel continues to be pumped into the cylinder. This can lead to abnormal combustion when the engine is restarted

and is not desirable.

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CHECKING THE ENGINEAFTER OPERATION

• Check that the key switch is in the OFFposition 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 theCooling System on page 66 .

• At temperatures below 0˚C (32˚F), drainseawater system and connect the engineheater (if equipped).

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PERIODIC MAINTENANCE

This section of the Operation Manual describes the procedures for proper careand maintenance of the engine.

Before performing any maintenance

procedures within this section, read thefollowing safety information and review theSafety section on page 3.

SAFETY PRECAUTIONS

! WARNING

Crush Hazard

If you need to transport anengine for repair, have ahelper assist you attach itto a hoist and load it on atruck.

The engine lifting eyes are engineered to liftthe weight of the marine engine only.ALWAYS use the engine lifting eyes when

lifting the engine.

Additional equipment is necessary to lift themarine engine and marine gear together.ALWAYS use lifting equipment withsufficient capacity to lift the marine engine.




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! WARNING

Welding Hazard

• ALWAYS turn off the battery switch (ifequipped) or disconnect the negativebattery cable and the leads to the

alternator when welding on theequipment.

• Connect the weld clamp to thecomponent to be welded and as close aspossible to the welding point.

• NEVER connect the weld clamp to theengine or in a manner which would allowcurrent to pass through a mountingbracket.

• When welding is completed, reconnectthe leads to the alternator prior toreconnecting the batteries.

Exhaust Hazard

ALWAYS ensure that allconnections are tightened tospecifications after repair ismade to the exhaust system.

All internal combustionengines create carbon monoxide gas duringoperation and special precautions arerequired to avoid carbon monoxidepoisoning.

Shock Hazard

ALWAYS turn off thebattery switch (ifequipped) or disconnectthe negative battery cablebefore servicing the

equipment.

ALWAYS keep the electrical connectorsand terminals clean. Check the electricalharnesses for cracks, abrasions, anddamaged or corroded connectors.

NOTICE

Any part which is found defective as a resultof inspection, or any part whose measuredvalue does not satisfy the standard or limit,must be replaced.

Modifications may impair the engine’ssafety and performance characteristics andshorten the engine’s life. Any alterations tothis engine may void its warranty. Be sure touse Yanmar genuine replacement parts.





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PRECAUTIONS

The Importance of PeriodicMaintenance

Engine deterioration and wear occur in

proportion to the length of time the enginehas been in service and the conditions theengine is subjected to during operation.Periodic maintenance prevents unexpecteddowntime, reduces the number of accidentsdue to poor engine performance and helpsextend the life of the engine.

Performing PeriodicMaintenance

WARNING! NEVER block windows,vents or other means of ventilation if the

engine is oper ati ng in an enclosed area.

All internal combustion engines cr eate

carbon monoxide gas during operation.

Accumulation of this gas within an

enclosure could cause illness or even

death. Make sure that all connections

are tightened to specifications after any

repair is made to the exhaust system.

Failure to comply could result in death

or serious injury.

The Importance of Daily Checks

The Periodic Maintenance Scheduleassumes that the daily checks areperformed on a regular basis. Make a habitof performing daily checks before the startof each operating day. See Daily Checks on

page 28.

Keep a Log of Engine Hours andDaily Checks

Keep a log of the number of hours the engineis operated each day and a log of the dailychecks performed. Also note the date, type

of repair (e.g., replaced alternator), andparts used for any service needed betweenthe periodic maintenance intervals. Periodicmaintenance intervals are every 50, 150,300 and 600 engine hours. Failure toperform periodic maintenance will shortenthe life of the engine.

Yanmar Replacement Parts

Yanmar recommends that you use genuine

Yanmar parts when replacement parts areneeded. Genuine replacement parts helpensure long engine life.

Tools Required

Before you start any periodic maintenanceprocedure, make sure you have the toolsyou need to perform all of the required tasks.

Ask Your Authorized Yanmar

Marine Dealer or Distributor ForHelp

Our professional service technicians havethe expertise and skills to help you with anymaintenance or service-related procedures.





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Tightening Fasteners

Use the correct amount of torque when youtighten fasteners on the engine. Applyingexcessive torque may damage the fasteneror component and not enough torque may

cause a leak or component failure. Whenworking on critical components that requirecalibrated tools, special procedures andspecific tightening sequences, consult withyour Yanmar distributor or dealer.

NOTICE: The tightening torque in the

Standard Torque Chart

should be applied only to

the bolts with a “7” head

(JIS strength classification:

7T). Apply 60% torque to

bolts that are not listed. Apply 80%torque when tightened to aluminum

alloy.

Bolt diameter x pitch(mm)

M6x1.0 M8x1.25 M10x1.5 M12x1.75 M14x1.5 M16x1.5

Tightening

Torque

N·m 11.0 ± 1.0 26.0 ± 3.0 50.0 ± 5.0 90.0 ± 10.0 140.0 ± 10.0 230.0 ± 10.0

kgf·m 1.1 ± 0.1 2.7 ± 0.3 5.1 ± 0.5 9.2 ± 1.0 14.3 ± 1.0 23.5 ± 1.0

lb-ft 8.0 ± 0.7 19.0 ± 2.1 37 ± 3.6 66.0 ± 7.2 103 ± 7.2 170 ± 7.2

lb-in — — — — — —





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EPA MAINTENANCEREQUIREMENTS

To maintain optimum engine performanceand compliance with the Environmental

Protection Agency (EPA) Regulations forEngines, it is essential that you follow thePeriodic Maintenance Schedule on page46 and the Periodic MaintenanceProcedures on page 49.

EPA Requirements for USA andOther Applicable Countries

The following are the requirements for theEPA. Unless these requirements are met,

the exhaust gas emissions will not be withinthe limits specified by the EPA.

The EPA emission regulation is applicableonly in the USA and other countries thathave adapted the EPA requirements in partor in whole. Determine and follow theemission regulations in the country whereyour engine will be operating.

Conditions to EnsureCompliance with EPA EmissionStandards

The 1GM10, 1GM10C and 1GM10V areEPA-certified engines.

The following are the conditions that must bemet in order to ensure that the emissionsduring operation meet the EPA standards:

• Ambient temperature: -20˚ to +40˚C(-4˚ to +104˚F)

• Relative humidity: 80% or lower

The diesel fuel should be:

• ASTM D975 No. 1-D or No. 2-D, orequivalent (minimum of cetane No. 45)

The lubricating oil should be:

• Type API, Class CD or higher

Perform the inspections as outlined inPeriodic Maintenance Procedures on page49 and keep a record of the results.

Pay particular attention to these importantpoints:

• Replacing the engine oil

• Replacing the engine oil filter

• Replacing the fuel filter

• Cleaning the intake silencer (air cleaner)

Note: Inspections are divided into twosections in accordance with who isresponsible for performing the inspection:the user or the manufacturer.

Inspection and MaintenanceSee Inspection and Maintenance of EPAEmission-Related Parts on page 48 for theEPA emission-related parts. Inspection andmaintenance procedures not shown in theInspection and Maintenance of EPAEmission-Related Parts on page 48section are covered in PeriodicMaintenance Schedule on page 46 .

This maintenance must be performed tokeep the emission values of your engine inthe standard values during the warrantyperiod. The warranty period is determinedby the age of the engine or the number ofhours of operation.





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PERIODIC MAINTENANCESCHEDULE

Daily and periodic maintenance is importantto keep the engine in good operating

condition. The following is a summary ofmaintenance items by periodicmaintenance intervals. Periodicmaintenance intervals vary depending onengine application, loads, diesel fuel andengine oil, and are hard to establishdefinitively. The following should be treatedonly as a general guideline. CAUTION!Establish a periodic maintenance plan

according to the engine application and

make sure you perform the required periodic maintenance at the intervals

indicated. Failure to follow these

guidelines will impair the engine’s

safety and performance characteristics,

shorten the engine’s life and may affect

the warranty coverage on your engine.

See your authorized Yanmar Marine

dealer or distributor for assistance

when checking items marked with a ●.





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: Check or Clean : Replace ●: Contact your authorized Yanmar Marine dealer or distributor

System Item

Periodic Maintenance Interval

BeforeStarting

See Daily Checks on page 28.

Initial 50Hours

Every50

Hours

Every150

Hours

Every250

Hoursor 1

Year

Every1000

Hours or4 Years

Whole Visually inspecting the engineexterior ◯

Fuel System*

Inspecting the fuel level ◯ Draining the fuel tank ◯ ◯ Draining the fuel filter / waterseparator

◯

Engine Yan

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