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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. We reserve
are
the right to make any change at any time without notice. Yanmar and
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 Marine International.
2007 Yanmar Marine International
1207
ii
TABLE OF
CONTENTS
Page
Introduction .............................................................. 1
Record of Ownership .............................................. 2
Safety ....................................................................... 3
Safety Precautions .................................................
General Information .........................................
Before You Operate .........................................
During Operation and Maintenance .....................
4
4
4
4
iii
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 .................... 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 .................. 29
Checking 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
iv
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 ............................. 45
Periodic Maintenance Schedule ............................... 46
Inspection and Maintenance of EPA EmissionRelated 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 ........................................... 61
Long-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 ......................... 71
System 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
vi
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:
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.:
Date Purchased:
Dealer:
Dealer Phone:
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 engines safety
decals. Keep the decals 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 decal attached to it, make
sure you order the new part and decal 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 engine, personal property
and / or the environment or cause the
equipment to operate improperly.
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. Read and understand
all of the safety precautions before operation
or performing repairs or maintenance.
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.
Exposure Hazard
ALWAYS wear personal
protective equipment
including appropriate
clothing, gloves, work shoes,
eye and hearing protection as
required for the task at hand.
Entanglement Hazard
NEVER leave the key in the
key switch when you are
servicing the engine.
Someone may accidentally
start the engine and not realize
you are servicing it.
NEVER operate the engine while wearing a
headset to listen to music or radio because
it will be difficult to hear the warning signals.
Stop the engine before you begin to service
it.
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.
Burn Hazard
Some of the engine surfaces
become very hot during
operation and shortly after
shutdown. Keep hands and
other body parts away from
hot engine surfaces.
Exhaust Hazard
NEVER block windows, vents
or other means of ventilation if
the engine is operating in an
enclosed area. All internal
combustion engines create
carbon monoxide gas during operation and
special precautions are required to avoid
carbon monoxide poisoning.
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. At high altitudes the
engine will lose power, run rough and
produce exhaust gases that exceed the
design specifications.
ALWAYS be environmentally
responsible.
Follow the guidelines of the EPA or other
governmental agencies for the proper
disposal of hazardous materials such as
engine oil, diesel fuel and engine coolant.
Consult the local authorities or reclamation
facility.
NEVER dispose of hazardous materials by
dumping them into a sewer, on the ground
or into ground water or waterways.
If a Yanmar Marine Engine is installed at an
angle that exceeds the specifications stated
in the Yanmar Marine Installation manuals,
engine oil may enter the combustion
chamber causing excessive engine speed,
white exhaust smoke and serious engine
damage. This applies to engines that run
SAFETY
WARNING
128296-07350
0005961
Figure 1
1 Part Number: 12829607350
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.
These engines are designed for pleasure
craft use.
It is recommended that new vessels be
propped so the engines can operate at
100 to 200 rpm above the Maximum Rated
Power Output rpm (3700 to 3800) to allow
for some added weight and hull resistance.
The engine must be able to reach the
Maximum Rated Power Output (3600 rpm)
under full load at all times.
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.
A new Yanmar diesel engine must be
operated at suitable speeds and power
settings during the break-in period to allow
bearing surfaces and other friction-related
components, such as piston rings and valve
guides, to wear in properly in order to
stabilize engine lubrication and combustion.
During the break-in period, the engine
coolant temperature gauge should be
monitored closely. The temperature should
remain between 71 and 87C (160 and
190F).
During the first 10 hours of operation, the
engine should be operated at maximum rpm
minus 400 to 500 rpm (approximately 60 to
70% 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.
10
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.
(1)
(2)
(3)
(16)
(15)
(4)
(5)
(6)
(7)
(8)
(14)
(13)
(9)
(12)
(11)
1
2
3
4
5
6
7
8
Nameplate
Thermostat Cover
Fuel Injection Pump
Idle Adjuster
Oil Filler Cap
Fuel Injection Limiter
Engine Stop Lever
Crankshaft V-Pulley
(10)
0005850
Figure 1
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
11
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
PRODUCT OVERVIEW
LOCATION OF
NAMEPLATES
Emission-Control Labels
Model
Gear Model
Continuous power kW
min-1
min-1
Speed of prop,shaf t
min-1
ENG.No.
0005987
Figure 5
EPA & ARB label
0004574
Figure 3
The engine nameplate is attached to the
engine rocker arm cover.
The marine gear nameplate (Figure 4) is
attached to the marine gear. Check the
marine gears model, gear ratio, oil used, oil
quantity and serial number.
MODE L
GEAR R ATIO
OIL
OIL QT Y.
NO.
0005988
Figure 6
KM
SAE
20 / 30 HD
LTR.
0004529
Figure 4
13
PRODUCT OVERVIEW
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.
Pumps fuel from the tank to the fuel injection system. Pumping the priming lever
up and down supplies fuel to the engine when the fuel system needs to be primed.
Filters fine metal fragments and carbon from the engine oil. Filtered engine oil is
distributed to the engines moving parts. The filter is a spin-on type and the element
should be replaced periodically. See Replacing the Engine Oil Filter Element on
page 50.
Cooling System
Seawater Pump
Pumps seawater from outside the vessel and through the engine. The seawater
pump has a replaceable rubber impeller.
Zinc Anode
The metal surfaces of the seawater cooling system are prone to corrosion. The
zinc anode is installed in the cylinder block to prevent this. The surface of the zinc
anode erodes so it needs to be replaced at fixed intervals in order to fully protect
the seawater cooling system of the engine.
The intake silencer guards against dirt entering the engine induction system and
reduces the noise of air intake.
Nameplates
Nameplates are provided on the engine and the marine gear and contain the
model, 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.
14
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.
The instrument panel is located at the helm and is available in two options. The following
controls and indicators enable you to start, stop and monitor the condition of the engine during
operation.
Instrument Panel Options and Components
(2) (3)
(4)
(5)
(5)
(4)
(2) (3)
(9)
(1)
(8)
(7)
(7)
(12)
(6)
(10)
(6)
(8)
(11)
0005848
Figure 7
1 Option A Instrument Panel
2 Seawater in Marine Gear Warning Lamp
3 Water Temperature Warning Lamp
4 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
15
PRODUCT OVERVIEW
Gauges
Instrument
Function
Tachometer
Hour Meter
When turning the key switch to ON, the gauges will illuminate for
easier viewing.
Key Switch
(1)
(3)
(2)
(1)
OFF ON
0005838
Figure 9
0005847
Figure 8
1 OFF Position
2 ON Position
The ON position (Figure 8, (2)) allows
electrical current to the controls and
equipment and allows the engine to keep
running. To stop the engine, keep the key
switch in the ON position and pull the engine
stop knob. After stopping the engine, turn
the key to the OFF position.
16
1 RUN Position
2 Decompression Position
3 Decompression Lever
Raising the decompression lever to the
decompression position (Figure 9, (2))
opens the exhaust valve and makes hand
cranking of the engine possible. Returning
the lever to its RUN position (DOWN)
(Figure 9, (1)) closes the exhaust valve and
normal engine operation can resume.
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.
No alarm will sound for low battery charge.
Figure 13
Water in Sail-Drive Seal Indicator and Alarm
(Figure 13) - When seawater is detected
between the seals of the sail-drive, the
indicator will light and the alarm will sound.
(2)
Figure 11
Water Temperature Indicator and Alarm
(Figure 11) - When water temperature
reaches the maximum allowable
temperature (95C [203F] or higher), the
indicator will light and the alarm will sound.
Continuing operation at temperatures
exceeding the maximum limit will result in
damage and seizure. Check the load and
troubleshoot the cooling system.
(3)
0005842
Figure 14
1 Engine Stop Knob
2 Bulkhead
3 Engine Stop Cable
Figure 12
Engine Oil Low Pressure Indicator and
Alarm (Figure 12) - When the engine oil
pressure falls below normal, the oil pressure
sensor will send a signal to the indicator
causing it to light and the alarm to sound.
Stop operation immediately to avoid
damage to the engine. Check the oil level
and troubleshoot the lubrication system.
17
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
ON
OFF
OFF
OFF
ON
OFF
OFF
OFF
Indicators
Note: All warning indications will continue until the engine starts or the key switch is in the
OFF position.
(1)
(4)
(2)
(3)
FWD
NEUTRAL
IPULLI
CLUTCH
REV
0005846
Figure 15
1
2
3
4
18
FORWARD (FWD)
NEUTRAL (N)
REVERSE (REV)
Pull out the lever to disengage the
clutch.
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 following
specifications. The table lists several
worldwide specifications for diesel fuels.
DIESEL FUEL
SPECIFICATION
LOCATION
USA
EN590:96
European Union
International
BS 2869-A1 or A2
United Kingdom
Japan
19
20
! DANGER
Only use diesel fuel in the fuel tank. Filling
the fuel tank with gasoline may result in a fire
and will damage the engine. NEVER refuel
with the engine running. Wipe up all spills
immediately. Keep sparks, open flames or
any other form of ignition (match, cigarette,
static electric source) well away when
refueling.
ALWAYS store any containers containing
fuel in a well-ventilated area, away from any
combustibles or sources of ignition.
ALWAYS put the diesel fuel container on the
ground when transferring the diesel fuel
from the pump to the container. Hold the
hose nozzle firmly against the side of the
container while filling it. This prevents static
electricity buildup which could cause sparks
and ignite fuel vapors.
Fuel System
(1)
(8)
(2)
(9)
(3)
(10)
(5)
(7)
(4)
(6)
0004788
Figure 2
(3)
(1)
(2)
0004542
Figure 1
1 Sediment Bowl
2 Drain Cock
3 Fuel Line to Engine
The fuel outlet should be positioned
20 to 30 mm (0.75 to 1.125 in.) above the
bottom of the tank (Figure 2, (4)) so that
only clean fuel is distributed to the engine.
1
2
3
4
Fuel Filter
Fuel Feed Pump (Priming Lever)
Fuel / Water Separator (Optional)
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
21
4.
5.
22
0004512
Figure 3
ENGINE OIL
1.
2.
3.
SAE 10W-30
SAE 15W-40
Figure 4
Select the appropriate engine oil viscosity
based on the ambient temperature shown in
the SAE Service Grade Viscosity Chart in
Figure 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.
23
1.
1.
2.
2.
(2)
(1)
3.
(3)
4.
(4)
0005852
Figure 5
1
2
3
4
3.
4.
5.
6.
24
Filler Port
Dipstick
Upper Limit
Lower Limit
(2)
(3)
(4)
0005851
Figure 6
SD20:
1
2
3
4
Dipstick
Upper Limit
Lower Limit
Marine Gear Filler Port
Marine Gear Oil Capacity
KM2P
2.
3.
4.
5.
6.
25
4.
5.
1.
2.
3.
4.
(3)
(1)
0005838
Figure 7
1 RUN Position
2 Decompression Position
3 Decompression Lever
26
(1)
1.
2.
3.
4.
(2)
(2)
0005888
Figure 8
(3)
1 Starter Shaft
2 Starter Handle
6.
7.
8.
0005842
Figure 9
27
DAILY CHECKS
Before starting for the day, make sure the
Yanmar engine is in good operating
condition. CAUTION! It is important to
perform daily checks as listed in this
Operation Manual. Periodic
maintenance prevents unexpected
downtime, reduces the number of
accidents due to poor engine
performance and helps extend the life of
the engine. Make sure you check the
following items:
Visual Checks
1.
2.
3.
4.
5.
6.
7.
28
29
30
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.
ONLY use the key switch to
start the engine.
Sudden Movement Hazard
Be sure the boat is in open water away from
other boats, docks or other obstructions
before increasing rpm. Avoid unexpected
equipment movement. Shift the marine gear
into the NEUTRAL position any time the
engine is at idle.
To prevent accidental equipment
movement, NEVER start the engine in gear.
Sever Hazard
Keep children and pets away
while the engine is operating.
Exhaust Hazard
NEVER block windows, vents
or other means of ventilation if
the engine is operating in an
enclosed area. All internal
combustion engines create
carbon monoxide gas during operation and
special precautions are required to avoid
carbon monoxide poisoning.
31
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.
Observe the following environmental
operating conditions to maintain engine
performance and avoid premature engine
wear:
Avoid operating in extremely dusty
conditions.
Avoid operating in the presence of
chemical gases or fumes.
NEVER run the engine if the ambient
temperature is above +40C (+104F) or
below -16C (+5F).
If the ambient temperature exceeds
+40C (+104F), the engine may overheat
and cause the engine oil to break down.
If the ambient temperature is below -16C
(+5F), rubber components such as
gaskets and seals will harden causing
premature engine wear and damage.
Contact your authorized Yanmar Marine
engine dealer or distributor if the engine
will be operated outside of this standard
temperature range.
0005890
Figure 1
1 NEUTRAL (N)
4.
32
ENGINE OPERATION
5.
(1)
(2)
OFF ON
(1)
0005847
Figure 2
1 OFF position
2 ON position
6.
7.
(2)
0005888
Figure 3
1 Starting Shaft
2 Starting Handle
4.
33
ENGINE OPERATION
5.
6.
7.
8.
34
5.
6.
7.
ENGINE OPERATION
3.
4.
5.
35
ENGINE OPERATION
2.
(2)
(1)
(3)
FWD
NEUTRAL
IPULLI
CLUTCH
REV
0005846
Figure 4
1
2
3
4
36
FORWARD (FWD)
NEUTRAL (N)
REVERSE (REV)
Pull the lever to disengage the
clutch.
ENGINE OPERATION
PRECAUTIONS DURING
OPERATION
6.
7.
1.
2.
3.
4.
5.
37
ENGINE OPERATION
(1)
3.
4.
38
(2)
(3)
0005842
Figure 5
1 Engine Stop Knob
2 Bulkhead
3 Control Cable
5.
6.
7.
8.
ENGINE OPERATION
39
ENGINE OPERATION
40
PERIODIC MAINTENANCE
This section of the Operation Manual
describes the procedures for proper care
and maintenance of the engine.
SAFETY PRECAUTIONS
! WARNING
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.
The engine lifting eyes are engineered to lift
the weight of the marine engine only.
ALWAYS use the engine lifting eyes when
lifting the engine.
Additional equipment is necessary to lift the
marine engine and marine gear together.
ALWAYS use lifting equipment with
sufficient capacity to lift the marine engine.
41
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.
When welding is completed, reconnect
the leads to the alternator prior to
reconnecting the batteries.
Exhaust Hazard
ALWAYS ensure that all
connections are tightened to
specifications after repair is
made to the exhaust system.
All internal combustion
engines create carbon monoxide gas during
operation and special precautions are
required to avoid carbon monoxide
poisoning.
Shock Hazard
equipment.
42
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.
Performing Periodic
Maintenance
WARNING! NEVER block windows,
vents or other means of ventilation if the
engine is operating in an enclosed area.
All internal combustion engines create
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.
Tools Required
Before you start any periodic maintenance
procedure, make sure you have the tools
you need to perform all of the required tasks.
43
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.
Bolt diameter x pitch
(mm)
Tightening
Torque
44
M6x1.0
M8x1.25
M10x1.5
M12x1.75
M14x1.5
M16x1.5
Nm
11.0 1.0
26.0 3.0
50.0 5.0
90.0 10.0
140.0 10.0
230.0 10.0
kgfm
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
PERIODIC MAINTENANCE
EPA MAINTENANCE
REQUIREMENTS
Conditions to Ensure
Compliance with EPA Emission
Standards
The 1GM10, 1GM10C and 1GM10V are
EPA-certified engines.
The following are the conditions that must be
met in order to ensure that the emissions
during operation meet the EPA standards:
45
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. 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 engines
safety and performance characteristics,
shorten the engines 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 .
46
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.
Year 4 Years
Visually inspecting the engine
Whole
exterior
separator
Fuel System*
Engine
Inspecting the oil level Marine
Gear
Engine
Changing the oil
Lubricating
Marine
System
Gear
During
Inspecting the function of the oil
pressure warning lamp
Operation
Replacing the engine oil filter
element
During
Inspecting the seawater outlet
Operation
Cooling
Inspecting the seawater pump
System
impeller
filter)
Cleaning
the
exhaust
/
water
Air Intake and
mixing elbow
Exhaust
System
Electrical
level
System
Checking and adjusting the
bolts
and Block
Adjusting the intake / exhaust
valve clearances
Inspecting and adjusting the
Miscellaneous throttle and shift control cables
Items
Adjusting the propeller shaft
alignment
*
For EPA requirements, see Inspection and Maintenance of EPA Emission-Related Parts on page 48.
Note: These procedures are considered normal maintenance and are performed at the
owners expense.
GM Series Operation Manual
2007 Yanmar Marine International
47
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
Interval
1500 hours
3000 hours
3000 hours
Note: The inspection and maintenance items shown above should be performed at your
Yanmar Marine dealer or distributor.
48
PERIODIC MAINTENANCE
PERIODIC MAINTENANCE
PROCEDURES
1.
(3)
(1)
(2)
0004542
Figure 1
1 Sediment Bowl
2 Drain Cock
3 Fuel Line to Engine
2.
49
PERIODIC MAINTENANCE
5.
3.
4.
1.
2.
5.
3.
4.
5.
0004797
6.
7.
Figure 2
Remove the engine oil filter.
Clean the face of the filter mounting
flange and apply a light coat of oil to the
gasket of the new oil filter.
Install a new filter element and tighten
by hand until the seal touches the
housing.
Turn filter an additional 3/4 turn with a
box wrench. Tighten to 20 to 24 Nm
(14 to 17 lb-ft.).
Perform a trial run and check for oil
leaks.
50
PERIODIC MAINTENANCE
4.
4.
5.
6.
51
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.
52
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.
UPPER
LEVEL
LOWER
LEVEL
(3)
(1)
0004566
Figure 3
1 Lower Level
2 Battery Fluid
3 Upper Level
If the engine cannot be started or the rpm
does not rise to rated output, measure the
specific gravity of the battery with a
hydrometer. The specific gravity of a fully
charged battery is 1.27 or more at 20C
(68F). Specific gravity of 1.24 or lower
requires battery charging.
If charging the battery does not raise the
specific gravity, replace the battery.
Note: The maximum fill level is
approximately 10 to 15 mm
(3/8 to 9/16 in.) above the plates.
53
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.
54
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.
When there is dirt in the fuel, the filter
becomes clogged and the fuel will not flow
easily. Check and replace the element.
1.
2.
3.
4.
5.
6.
7.
(2)
(1)
0004804
Figure 4
1 Fuel Filter Housing
2 Retaining Ring
GM Series Operation Manual
2007 Yanmar Marine International
55
PERIODIC MAINTENANCE
1.
(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
(1)
56
(4)
(3)
0005889
Figure 6
1
2
3
4
Direction of Rotation
Outlet
Impeller
Inlet
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.
If neglected, seawater will begin to react with
the internal surface areas of the engine
cooling system. This will lead to seawater
leaks, internal corrosion and eventual failure
of engine components.
1.
2.
3.
4.
5.
6.
57
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
58
TROUBLESHOOTING
Before performing any troubleshooting
procedures within this section, review the
Safety section on page 3.
TROUBLESHOOTING
AFTER STARTING
59
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.
Is there water, oil or fuel leakage? Are
there any loose bolts or connections?
Check the engine room daily for any leaks
or loose connections.
Is there sufficient fuel in the fuel tank?
Refill the fuel tank in advance to avoid
running out of fuel. If the tank runs out of fuel,
bleed the fuel system.See Air Bleeding from
the Fuel System After Starting Failure on
page 34.
60
TROUBLESHOOTING
INFORMATION
If the engine does not operate properly, refer
to the Troubleshooting Chart on page 61
or see your authorized Yanmar Marine
dealer or distributor.
Supply the authorized Yanmar Marine
dealer or distributor with the following
information:
Model name and serial number of your
engine
Boat model, hull material, size (tons)
Use, type of boating, number of hours run
Total number of operation hours (refer to
hour meter), age of boat
The operating conditions when the
problem occurs:
Engine rpm
Color of exhaust smoke
Type of diesel fuel
Type of engine oil
Any abnormal noises or vibration
Operating environment such as high
altitude or extreme ambient
temperatures
Engine maintenance history and
previous problems
Other factors that contribute to the
problem
TROUBLESHOOTING
TROUBLESHOOTING CHART
Symptom
Probable Cause
Measure
Reference
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.
See Checking
the Engine Oil on
page 24.
See Replacing
the Engine Oil
Filter Element on
page 50.
Coolant High
Temperature Alarm
lights
Do not operate the engine if alarm devices are not repaired. Serious accidents may
result if abnormalities are not identified because of faulty indicators or alarm.
See Checking
and Adjusting the
Alternator V-Belt
Tension on page
51.
Battery is defective.
See Inspecting
the Battery
Electrolyte Level
(Serviceable
Batteries Only)
on page 53.
61
TROUBLESHOOTING
Symptom
Probable Cause
Measure
Reference
Starting Failures:
Starter turns but engine
does not start.
62
No fuel
See Replacing
the Fuel Filter
Element on page
55.
Improper fuel
Replace with
recommended fuel.
See Restarting
After Starting
Failure on page
34.
See Inspecting
the Battery
Electrolyte Level
(Serviceable
Batteries Only)
on page 53.
See Inspecting
the Battery
Electrolyte Level
(Serviceable
Batteries Only)
on page 53.
TROUBLESHOOTING
Symptom
Probable Cause
Measure
Reference
Engine is overloaded.
Clean element.
Improper fuel
Replace with
recommended fuel.
Improper fuel
Replace with
recommended fuel.
White smoke
63
TROUBLESHOOTING
64
LONG-TERM STORAGE
Before performing any storage procedures
within this section, review the Safety section
on page 3.
6.
7.
8.
9.
65
LONG-TERM STORAGE
10. Remove the key from the key switch
and cover the key switch with the
moisture cap (if equipped).
(1)
(2)
(4)
(5)
(7)
(6)
0005887
Figure 1
1
2
3
4
5
6
7
4.
66
Cam
Inlet
Outlet
Seawater Pump Body
Impeller
Gasket
Side Cover
SPECIFICATIONS
PRINCIPAL ENGINE SPECIFICATIONS
1GM10 Engine Specifications
Type
Combustion System
Number of Cylinders
Displacement
Continuous
Rating Output
Maximum
Rating Output
Brake Mean
Effective
Pressure
Piston Speed
Output at
Crankshaft /
Engine Speed
Brake Mean
Effective
Pressure
Piston Speed
Compression Ratio
23.0 : 1
15 1
At flywheel end
Direction of
Rotation
Cooling System
Crankshaft
Propeller Shaft
(Ahead)
Lubrication System
*
**
Rating Condition: Temperature of fuel: 25C at fuel pump inlet; ISO 3046-1
Rating Condition: Temperature of fuel: 40C at fuel pump inlet; ISO 8665
67
SPECIFICATIONS
Type
Starting System
Marine Gear
System
Starting Motor
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)
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
Weight
Overall Length
Overall Width
Overall Height
Total
Effective
76 kg (167 lb)
Note: Density of fuel: 0.842g/cm3 at 15C. Fuel temperature at the inlet of the fuel injection
pump.
1 hp metric = 0.7355 kW
68
SPECIFICATIONS
1GM10C Engine Specifications
Type
Combustion
System
Number of
Cylinders
Bore and
Stroke
Displacement
Continuous
Rating Output
Maximum
Rating Output
Brake Mean
Effective
Pressure
Piston Speed
Output at
Crankshaft /
Engine Speed
Brake Mean
Effective
Pressure
Piston Speed
Compression Ratio
23.0 : 1
15 1
At flywheel end
Crankshaft
Propeller Shaft
(Ahead)
Cooling System
Lubrication System
Starting
System
Type
Starting Motor
AC Generator
12V, 35A
Model
SD20
Type
Marine Gear
System
*
**
Reduction
Ratio
Forward
2.64 : 1
Reverse
2.64 : 1
Propeller
Speed
Forward
1290 rpm
Reverse
1290 rpm
Rating Condition: Temperature of fuel: 25C at fuel pump inlet; ISO 3046-1
Rating Condition: Temperature of fuel: 40C at fuel pump inlet; ISO 8665
69
SPECIFICATIONS
Dimensions
Engine
Lubricating Oil
Capacity (8
Rake Angle)
Overall Length
Overall Width
Overall Height
Total
Effective
Note: Density of fuel: 0.842g/cm3 at 15C. Fuel temperature at the inlet of the fuel injection
pump.
1 hp metric = 0.7355 kW
70
SPECIFICATIONS
1GM10V Engine Specifications
Type
Combustion
System
Number of
Cylinders
Bore and
Stroke
Displacement
Continuous
Rating Output
Maximum
Rating Output
Break Mean
Effective
Pressure
Piston Speed
Output at
Crankshaft /
Engine Speed
Break Mean
Effective
Pressure
Piston Speed
Compression Ratio
23.0 : 1
15 1
At flywheel end
Crankshaft
Propeller Shaft
(Ahead)
Cooling System
Lubrication System
Starting
System
*
**
Type
Starting Motor
AC Generator
12V, 35A
Rating Condition: Temperature of fuel: 25C at fuel pump inlet; ISO 3046-1
Rating Condition: Temperature of fuel: 40C at fuel pump inlet; ISO 8665
71
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
Weight
Overall Length
Overall Width
Overall Height
Total
Effective
90 kg (198 lb)
Note: Density of fuel: 0.842g/cm3 at 15C. Fuel temperature at the inlet of the fuel injection
pump.
1 hp metric = 0.7355 kW
72
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
73
SYSTEM DIAGRAMS
20
19
0005993
Figure 1
74
SYSTEM DIAGRAMS
Key
Notation
Description
Fuel Pump
Drilled Hole
To Main Bearing
Screw Joint
To Main Bearing
Bayonet Joint
To Oil Pan
Cock
STP
Steel Pipe
RH
Rubber Hose
10
Exhaust Gas
VH
Vinyl Pipe
11
Cooling Water
12
Mixing Elbow
13
Fuel Inlet
14
15
Fuel Filter
16
Exhaust Gas
17
Cooling Water
18
Thermostat
19
Seawater Inlet
20
Seawater Pump
21
Fuel Filter
22
23
24
75
SYSTEM DIAGRAMS
WIRING DIAGRAMS
0005995
Figure 2
76
SYSTEM DIAGRAMS
Color Coding
Key
Description
Red
Battery
White
Battery Switch
Black
Starter Motor
Orange
Alternator
L/B
Blue/Black
Not Used
W/L
White/Blue
Y/W
Yellow/White
W/R
White/Red
Tachometer Sender
L/R
Blue/Red
W/B
White/Black
R/B
Red/Black
10
Tachometer
11
Buzzer
12
13
14
15
Charge Lamp
16
17
Key Switch
18
Light Switch
19
20
Fuse
21
77
SYSTEM DIAGRAMS
0005994
Figure 3
78
SYSTEM DIAGRAMS
Color Coding
Key
Description
Red
Battery
White
Battery Switch
Black
Starter Motor
Orange
Alternator
L/B
Blue/Black
Not Used
W/L
White/Blue
Y/W
Yellow/White
W/R
White/Red
Spare Connector
L/R
Blue/Red
Spare Connector
W/B
White/Black
10
R/B
Red/Black
11
Buzzer
12
13
14
Charge Lamp
15
16
Key Switch
17
18
Fuse
79
SYSTEM DIAGRAMS
80
EMISSION SYSTEM
WARRANTY
NON-ROAD EMISSION
SYSTEM WARRANTY
California
The California Air Resources Board
(CARB), the Environmental Protection
Agency (EPA) and Yanmar Co., Ltd.
hereafter referred to as Yanmar, are pleased
to explain the emission control system
warranty on your compression-ignition
engine. In California, model year 2000 or
later off-road compression-ignition engines
must be designed, built and equipped to
meet the states stringent anti-smog
standards. In all states, 1998 and later nonroad compression-ignition engines must be
designed, built and equipped to meet the
United States EPA emissions standards.
Yanmar warrants the emission control
system on your engine for the periods of time
listed below provided there has been no
abuse, neglect or improper maintenance of
your engine.
81
Warranted Parts:
82
Exclusions:
Failures other than those arising from
defects in material and / or workmanship are
not covered by this warranty. The warranty
does not extend to the following:
malfunctions caused by abuse, misuse,
improper adjustment, modification,
alteration, tampering, disconnection,
improper or inadequate maintenance or use
of non-recommended fuels and lubricating
oils; accident-caused damage, and
replacement of expendable items made in
connection with scheduled maintenance.
Yanmar disclaims any responsibility for
incidental or consequential damages such
as loss of time, inconvenience, loss of use
of equipment / engine or commercial loss.
Customer Assistance
83
Maintenance Log
Date
84
Operating
Hours
Maintenance Performed
Dealer Name
Stamp or
Signature
Date
Operating
Hours
Maintenance Performed
Dealer Name
Stamp or
Signature
85
86