Yanmar 1GM10, 1GM10C, 1GM10V Operation Manual

series

OPERATION MANUAL

1GM10 1GM10C 1GM10V

P/N: 0AGMM-G00100

MARINE

ENGINES

Disclaimers:

All information, illustrations and specifications in this manual are based on the latest information available at the time of publishing. The illustrations used in this manual are intended as representative reference views only. Moreover, because of our continuous product improvement policy, we may modify information, illustrations and / or specifications to explain and / or exemplify a product, service or maintenance improvement. We reserve the right to make any change at any time without notice. Yanmar and are registered trademarks of Yanmar Co., Ltd. in Japan, the United States and / or other countries.

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.

1207

ii GM Series Operation Manual

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

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

TABLE OF CONTENTS

iv GM Series Operation Manual

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 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 ........................................... 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

GM Series Operation Manual v

This Page Intentionally Left Blank

TABLE OF CONTENTS

vi GM Series Operation Manual

INTRODUCTION

Welcome to the world of Yanmar Marine! Yanmar Marine offers engines, drive systems and accessories for all types of boats, from runabouts to sailboats, and from cruisers to mega yachts. In marine leisure boating, the worldwide reputation of Yanmar Marine is second to none. We design our engines to respect nature. This means quieter engines, with minimal vibrations, cleaner than ever. All of our engines meet applicable regulations, including emissions, at the time of manufacture.

To help you enjoy your Yanmar GM series engine for many years to come, please follow these recommendations:

• Read and understand this Operation Manual before you operate the engine to ensure that you follow safe operating practices and maintenance procedures.

• Keep this Operation Manual in a convenient place for easy access.

• If this Operation Manual is lost or damaged, order a new one from your authorized Yanmar Marine dealer or distributor.

• Make sure this manual is transferred to subsequent owners. This manual should be considered a permanent part of the engine and remain with it.

• Constant efforts are made to improve the quality and performance of Yanmar products, so some details included in this Operation Manual may differ slightly from your engine. If you have any questions about these differences, please contact your authorized Yanmar Marine dealer or distributor.

• The specifications and components (instrument panel, fuel tank, etc.) described in this manual may differ from ones installed on your vessel. Please refer to the manual provided by the manufacturer of these components.

• Refer to the Yanmar Limited Warranty Handbook for a complete warranty description.

GM Series Operation Manual 1

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:

INTRODUCTION

2 GM Series Operation Manual

SAFETY

Yanmar considers safety of great importance and recommends that anyone who comes in close contact with its products, such as those who install, operate, maintain or service Yanmar products, exercise care, common sense and comply with the safety information in this manual and on the engine’s safety decals. Keep the decals from becoming dirty or torn and replace them if they are lost or damaged. 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.

This safety alert symbol appears with most safety statements. It means attention, become alert, your safety is involved! Please read and abide by the message that follows the safety alert symbol.

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.

GM Series Operation Manual 3

SAFETY PRECAUTIONS

General Information

There is no substitute for common sense and careful practices. Improper practices or carelessness can cause burns, cuts, mutilation, asphyxiation, other bodily injury or death. This information contains general safety precautions and guidelines that must be followed to reduce risk to personal safety. Special safety precautions are listed in specific procedures. Read and understand all of the safety precautions before operation or performing repairs or maintenance.

Before You Operate

DANGER

The safety messages that follow have DANGER level hazards.

NEVER permit anyone to install or operate the engine without proper training.

• Read and understand this Operation Manual before you operate or service the engine to ensure that you follow safe operating practices and maintenance procedures.

• Safety signs and decals are additional reminders for safe operating and maintenance techniques.

• See your authorized Yanmar Marine dealer or distributor for additional training.

During Operation and Maintenance

DANGER

The safety messages that follow have DANGER level hazards.

Crush Hazard

NEVER stand under a hoisted engine. If the hoist mechanism fails, the engine will fall on you.

Fire Hazard

Ensure that appropriate fire detection and extinguishing equipment are installed and checked periodically for proper operation.

SAFETY

4 GM Series Operation Manual

WARNING

The safety messages that follow have WARNING level hazards.

Explosion Hazard

While the engine is running or the battery is charging, hydrogen gas is being produced and can be easily

ignited. Keep the area around the battery well-ventilated and keep sparks, open flames and any other form of ignition out of the area.

Fire and Explosion Hazard

Diesel fuel is flammable and explosive under certain conditions.

NEVER use a shop rag to catch the fuel.

Wipe up all spills immediately.

NEVER refuel with the engine running.

Store any containers containing fuel in a well-ventilated area, away from any combustibles or sources of ignition.

Fire Hazard

Undersized wiring systems

can cause an electrical fire.

Sever Hazard

NEVER wear jewelry, unbuttoned cuffs, ties or loose-fitting clothing and ALWAYS tie back long hair

when working near moving / rotating parts such as the flywheel or PTO shaft. Keep hands, feet and tools away from all moving parts.

Alcohol and Drug Hazard

NEVER operate the engine

while under the influence of

alcohol or drugs or if you are

feeling ill.

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

GM Series Operation Manual 5

WARNING

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.

CAUTION

The safety messages that follow have CAUTION level hazards.

Poor Lighting Hazard

Ensure that the work area is adequately illuminated. ALWAYS install wire cages on portable safety lamps.

Tool Hazard

ALWAYS use tools appropriate for the task at hand and use the correct size tool for loosening or tightening engine parts.

Flying Object Hazard

ALWAYS wear eye protection when servicing the engine or when using compressed air or high-pressure water. Dust, flying debris, compressed air, pressurized water or steam may injure your eyes.

SAFETY

6 GM Series Operation Manual

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

continuously or those that run for short periods of time. If you have an installation with two or three engines and only one engine is operating, the water pickup (thru-hull) of the nonrunning engine(s) should be closed. This will prevent water from being forced past the seawater pump and entering the engine. The result of water entering the engine could cause engine seizure or other serious problems.

If you have an installation with two or three engines, and only one engine is operating, please note that if the propeller shaft thru-hull (stuffing box) is lubricated by engine water pressure and the engines are interconnected, care must be taken that water from the running engine does not enter the exhaust of the non-running engine(s). This water could cause seizure of the non-running engine(s). See your authorized Yanmar Marine dealer or distributor for a complete explanation of this condition.

If you have an installation with two or three engines, and only one engine is operating, it is important to limit the amount of throttle applied to the running engine. If you observe black smoke or movement of the throttle does not increase engine rpm, you are overloading the engine that is running. Immediately throttle back to approximately two-thirds throttle or to a setting where the engine performs normally. Failure to do so may cause the running engine to overheat or cause excess carbon buildup which may shorten the engine's life.

SAFETY

GM Series Operation Manual 7

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

8 GM Series Operation Manual

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.

Failure to do so can lead to reduced vessel performance and increased smoke levels, and can cause permanent damage to your engine, which is not covered by warranty.

The engine must be installed correctly with coolant lines, exhaust gas lines and electrical wiring. Any auxiliary equipment attached to the engine should be easy to use and accessible for service. To handle the drive equipment, propulsion systems (including the propeller) and other onboard equipment, always observe the instructions and cautions given in the operation manuals supplied by the shipyard and original equipment manufacturers.

The GM series engines are designed to be operated at maximum throttle (3600 rpm) for less 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 total engine time (9 hours out of every 10 hours).

The laws of some countries may require hull and engine inspections, depending on the use, size and cruising area of the boat. The structural design, vessel application and installation of this engine all require specialized knowledge and engineering skills. See Yanmar’s local subsidiary in your region or your authorized Yanmar Marine dealer or distributor.

GM Series Operation Manual 9

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 87˚C (160˚ and 190˚F).

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.

Do not operate the engine at low idle or at low speed and light load for more than 30 minutes at a time. Since unburned fuel and engine oil will adhere to the piston rings when operating at low speeds for long periods, this will interfere with proper movement of the rings and the diesel fuel consumption may increase. Low idle speed does not allow break-in of sliding parts.

If operating the engine at low speed and light load, you must race the engine to clean the carbon from the cylinders and the fuel injection valve.

Perform this procedure in open waters:

• With the clutch in NEUTRAL, accelerate from the low speed position to the high speed position briefly.

• Repeat this process five times.

Once past the initial 10 hours until 50 hours, the engine should be used over its full operating range, with special emphasis on running at relatively high power settings. This is not the time for an extended cruise at idle or low speed. The boat should be operated at maximum speed minus 400 rpm most of the time (approximately 70% load), with a 10-minute run at maximum minus 200 rpm (approximately 80% load) every 30 minutes and a 4 to 5 minute period of operation at WOT (wide open throttle) once every 30 minutes. During this period, be sure not to operate the engine at low speed and light load for more than 30 minutes. If operating engine at low speed and light load is necessary, race the engine after low idle operation.

To complete engine break-in, perform After

Initial 50 Hours maintenance procedures. See After Initial 50 Hours of Operation on page 49.

PRODUCT OVERVIEW

10 GM Series Operation Manual

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)

(4) (5)

(6) (7)

(8)

(9)

(10)

(11)

(12)

(13)

(14)

(15)

(16)

0005850

Figure 1

1 – 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

GM Series Operation Manual 11

Non-Service Side - 1GM10 with KM2P

(1)

(2)

(3)

(4)

(5)

(6)

(7)

(8)

(9)

(10)

0005849

Figure 2

1 – Decompression Lever 2 – Fuel Injection Valve 3 – Intake Silencer (Air Cleaner) 4 – Tachometer Sensor 5 – Marine Gear Dipstick

6 – Marine Gearbox 7 – Output Shaft Coupling 8 – Shift Lever 9 – Starter Motor 10 – Alternator

PRODUCT OVERVIEW

12 GM Series Operation Manual

LOCATION OF NAMEPLATES

The nameplate of the Yanmar GM series engine is shown in Figure 3. Check the engine’s model, output, rpm and serial number on the nameplate. Replace it if it is damaged or lost.

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) is attached to the marine gear. Check the marine gear’s model, gear ratio, oil used, oil quantity and serial number.

MODE L KM GEAR RATIO OIL SAE

/30 HD OIL QT Y. LTR. NO.

0004529

Figure 4

Emission-Control Labels

To ensure safe operation, emission-control labels have been attached to the engine. Their location is shown in Figure 6. They should always be visible. Replace labels if damaged or lost.

0005987

Figure 5

EPA & ARB label

0005988

Figure 6

PRODUCT OVERVIEW

GM Series Operation Manual 13

MAJOR COMPONENTS AND FUNCTIONS

Name of Component Function

Decompression Lever

Opens the exhaust valve and releases cylinder pressure to aid in manual engine starting

Fuel Filter

Removes dirt and water from the fuel. Drain the filter periodically. The filter element (filter) should be replaced periodically.

Fuel Feed Pump (Priming Lever)

Pumps fuel from the tank to the fuel injection system. Pumping the priming lever up 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 is distributed to the engine’s 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 Direct seawater cooling

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.

Intake Silencer (Air Cleaner)

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.

Engine Oil Dipstick Gauge stick for checking the engine oil level

PRODUCT OVERVIEW

14 GM Series Operation Manual

CONTROL EQUIPMENT

The control equipment at the helm makes remote control operation possible. It consists of the instrument panel, which is connected to the engine by a wire harness, and the throttle and shift console, which is connected by control cables to the engine control lever and marine gear.

Instrument Panel (Optional)

Equipment and Functions

The instrument panel is located at the helm and is available in two options. 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)

(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 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

PRODUCT OVERVIEW

GM Series Operation Manual 15

Gauges

Instrument Function

Tachometer Shows the engine rotation speed

Hour Meter

Shows the number of operating hours; can be used as a guide for periodic maintenance checks. The hour meter is located at the bottom of the tachometer.

Instrument Panel Lights

When turning the key switch to ON, the gauges will illuminate for easier viewing.

Key Switch

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

OFF

(2)

(1)

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.

Engine Decompression Lever

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

(3)

(2)

(1)

0005838

Figure 9

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

16 GM Series Operation Manual

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 11

Water Temperature Indicator and Alarm (Figure 11) - When water temperature reaches the maximum allowable temperature (95˚C [203˚F] 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.

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.

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.

Engine Stop Control

The engine is stopped by pulling out the engine stop knob (Figure 14, (1)). This cable is connected to the engine stop lever and 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

GM Series Operation Manual 17

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 the OFF position.

Optional Single-Lever Throttle and Shift Console

This console (Morse Type) uses a single lever to operate the throttle and the shifting mechanism.

FORWARD (FWD) (Figure 15, (1)) - The drive shaft is engaged and the engine propels the vessel forward.

FWD

REV

NEUTRAL

IPULLI

CLUTCH

(1)

(2)

(3)

(4)

0005846

Figure 15

1 – FORWARD (FWD) 2 – NEUTRAL (N) 3 – REVERSE (REV) 4 – Pull out the lever to disengage the

clutch.

NEUTRAL (N) (Figure 15, (2)) - The drive shaft is disengaged from the propeller and the engine idles.

REVERSE (REV) (Figure 15, (3)) - The drive shaft is engaged and the engine propels the vessel aft.

With the lever in the NEUTRAL position, pull the 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 an accelerator, increasing the engine speed (rpm) as it is pushed further in the FWD or REV direction. When the lever is pulled out, engine speed can be controlled without moving the vessel. The clutch is disengaged and the vessel is in NEUTRAL (no-load position).

Note: Yanmar recommends the use of a single-lever type console for the remote control system. If only a two-lever type is available in the market, reduce engine speed to 1000 rpm or less before engaging and disengaging the marine gear clutch.

PRODUCT OVERVIEW

18 GM Series Operation Manual

BEFORE YOU OPERATE

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

Before performing any operations within this section, review the Safety section on page 3.

DIESEL FUEL

Diesel Fuel Specifications

NOTICE: Only use diesel fuels

recommended by Yanmar for the best engine performance, to prevent engine damage and to comply with EPA warranty requirements. Only use clean diesel fuel.

Diesel fuel should comply with the following specifications. The table lists several worldwide specifications for diesel fuels.

DIESEL FUEL SPECIFICATION

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

GM Series Operation Manual 19

Additional Technical Fuel Requirements

• The fuel cetane number should be 45 or higher.

• The sulfur content must not exceed 0.5% by volume. Less than 0.05% is preferred.

• NEVER mix kerosene, used engine oil or residual fuels with the diesel fuel.

• Water and sediment in the fuel should not exceed 0.05% by volume.

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

• Ash content not to exceed 0.01% by volume.

• Carbon residue content not to exceed

0.35% by volume. Less than 0.1% is preferred.

• Total aromatics content should not exceed 35% by volume. Less than 30% is preferred.

• 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. 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.

BEFORE YOU OPERATE

20 GM Series Operation Manual

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 the bottom of the fuel tank to remove water and contaminants from the sediment bowl (Figure 1, (1)).

0004542

(3)

(1)

(2)

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.

Fuel System

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

(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

GM Series Operation Manual 21

Filling the Fuel Tank

Before filling the fuel tank for the first time:

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

To fill the fuel tank:

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 and dirt. WARNING! Hold the hose

nozzle 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 the fuel tank is full. CAUTION! NEVER

overfill the fuel tank.

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

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

0004512

Figure 3

BEFORE YOU OPERATE

22 GM Series Operation Manual

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