Monday, April23, 2018

Maintenance Of Pleasureboat Diesel Engine Gm Series

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Maintenance of Pleasureboat Diesel Engine
GM Precaution for Inspection 1 Battery Fluid Battery fluid is diluted sulfuric acid It can blind you if it gets in your eyes or burn your skin Keep
the fluid away from your body Wash it off immediately with a large quantity of fresh water if you get any on you 2 Fire due to Electric Always turn
off the battery switch or detach the earth cable before inspecting the electrical system Failure to do so could cause and fires 3 Precautions for
Moving Parts Stop the engine before you service it If you must inspect while the engine is operating never touch moving parts Keep your body and
clothing well clear of all moving parts as this could result in injury 4 Precautions for Removing Hot Oil and Water to Prevent Burns If extracting oil
from the engine while it is still hot do not let the oil splash on you Wait until the temperature has dropped before removing cooling water from the
engine to avoid getting scalded 5 Burns from Contact with Hot Engine Parts The whole engine is hot during operation and immediately after stopping The
turbocharger exhaust manifold exhaust pipe and engine are very hot Never touch these parts with your body or clothing 6 Burns from Scalding l Never
remove the filler cap of the fresh water cooler while the engine is still hot Stream and hot water will spurt out and seriously burn you Wait until
the water temperature has dropped then wrap a cloth around the cap and loosen it slowly l After inspection refasten the filler cap firmly If the cap
is not secure steam or scalding water may be emitted during operation causing burns 2Engine Type Engine Model Number of cylinders Cont rating output
Max output Lube oil capacity Engine L oil Clutch oil L Vertical watercooled 4cycle diesel engine 1GM10 2GM20F 3GM30F 1 2 3 1 1 1 1 13L 025L 20L
025L 27L 03L
3Fuel oil lube oil and cooling water 31 fuel oil
1 1 Selection of fuel oil Use the following diesel fuels or equivalents Select fuels of a higher quality for best engine performance Diesel fuel
standard for various countries
l l l l
ISO 8217 DMA ASTM D975 Grade No1D or No2D JIS K2204 Grade No2 No3 or specialNo3 BS 2869 Part1 classA1 or A2
At low temperatures fuel oil becomes difficult to ignite and will not flow easily making starting difficult Select fuel oil of a cetane of 45 or
greater to insure ignitability and use the outside temperature as a guide for selecting the proper grade to insure fluidity 2 Handling of Fuel the
fuel oil in a clean container Store the container in a place away from rain and dirt as water and dust mixed in with the fuel cause engine failure
Keep the fuel container stationery for several hours to allow any dirt or water to settle to the bottom Use a pump to extract the clear filtered fuel
from the top of the container for use
32 Lube oil 1 Selection of Engine oil Use the following lube oil API CD SAE Viscosity 15W40 2 2 Selection of Marine gear lube oil API CD SAE
Viscosity 30 3 Handling the Lube handling and storing lube oil be careful not to allow dust and water to enter the lube oil Clean around the filler
port before refilling Do not mix lube oils of different types or brands Mixing may reduce the lubricating performance Different oils are used for the
engine and the marine gear Be careful to use the correct oil for each one and store in separate clearly labeled Cooling water Fresh water cooling
type 1 Always use soft water tap water for the fresh water Never use dirty water or hard water Impurities in the cooling water cause scale and rust to
build up in the cooling system reduction cooling efficiency and causing the engine to overheat 2 During the cold season add antifreeze to the cooling
water to prevent freezing Failure to add antifreeze will result in damage to various parts in the cooling water system 3 Refer to the instruction
accompanying the antifreeze for the proper mixing ratio Select the ratio for the lowest temperature of the cold season If the mixture is too thick the
cooling efficiency will be reduced 4 Do not mix different brands of antifreeze or antirust Mixing reduces cooling efficiency and leads to parts damage
5 When the amount of cooling water is too low refill with fresh water and Inspection 41 Fuel Oil System 411 411 Checking and Supplying Fuel Oil Check
the fuel level inside the fuel tank and supply with the recommended fuel if necessary Inspection daily before starting 412 Draining the fuel tank 1
Put a pan under the drain to catch the fuel 2 Loosen the drain cock at the bottom of the fuel tank and drain off any water and dirt collected inside 3
Once the water and dirt have been drained off and the fuel coming out is clear close the drain plug Inspection every 50hrs 413 Replacing the fuel
1 Close the fuel cook 2 Turn the element casing fixing screw to the left with the filter wrench and remove 3 Clean the filter casing 4 Turn the
element casing fixing screw to the right use the filter wrench to tighten 5 Be sure be bleed air out of the fuel system
42 Lube Oil System 421 Checking and Supplying Engine oil 1 Check the engine oil level with the oil dipstick 2 If the oil level is low supply with the
recommended lube oil using the filler port Supply oil up to the upper mark on the oil dipstick Inspection daily before Check and supply of Marine
gear oil 1 Check the marine gear oil level with the oil dipstick 2 Supply with the recommended oil if necessary Check the oil level with the dipstick
while to the upper mark Inspection daily before Replacing the Engine Lube Oil and Lube Oil Filters 1 Drain off the lube oil It is easier and more
effective to drain the engine lube oil while the engine is still warm after operation 1 After removing the oil dipstick attach the hose of the oil
drain pump to the dipstick guide hole 2 Drain off the oil with the drain pump 2 Replace the lube oil filter 1 Turn the lube oil filter to the left
with the filter wrench and remove 2 Clean the filter installation face 3 Apply engine oil to the installation face and put on the new filter turning
it to the right by hand Next tighten an additional 34 of a turn with the filter wrench 3 Fill with new lube oil 1 Fill with the specified amount of
engine oil Remove the oil inlet cap on the top of the bonnet and fill with oil Remove the oil dipstick and check the level of the oil with the gauge
on the stick Oil should be filled to the upper mark on the dipstick gauge Replace the dipstick and tighten the oil inlet cap firmly by hand 2Run the
engine for approximately 5 minutes and check to see if there is any oil leakage 3 Approximately 10 minutes after stopping check the oil level again
with the oil dipstick and more oil if necessary Replace first after initial 50 hours Second time and thereafter every 250 hours 1 year
424 Replacing the Marine Gear Lube Oil Replace the lube oil in the marine gear by using the procedure described above Replace first after initial 50
hours second time every 250 hours thereafter every 1000 hours
43 Cooling Water System 431
Check and supply of cooling water 1 Check the cooling water level in the subtank If the water level is close to the lower limit remove the sub tank
cap and fill with fresh water to the upper limit 2 When the water level in the subtank is low remove the filler cap for the fresh water tank and check
the amount of cooling water in the fresh water tank Fill with fresh water to overflowing if the level is low Check the fresh water level before
operation while the engine is cold Checking the water level while the engine is hot is dangerous and the cooling water reading will be misleading due
to thermal expansion Check and supply cooling water daily at the subtank Do not remove the fresh water cooler f1iller cap regularly The amount of
water in the sub tank will increase during operation This is normal When the engine is stopped the temperature of the cooling water will drop causing
the extra water in the sub tank to return to the fresh water tank Inspection daily before Checking discharged from the seawater outlet pipe Check
that sufficient cooling water is discharged from the seawater outlet pipe Operation with too little seawater discharge will burn the impeller of the
seawater pump If seawater discharge is too small stop the engine immediately identify the cause and repair Is the Kingston cock open Is the inlet of
the Kingston cock clogged Is the sea water suction hose broken or does the hose suck in air due to a loose joint 433 Inspecting Inner Parts of the
Seawater Pump
The inside parts of the seawater pump will deteriorate with use and discharge performance falls At the specified interval or when the volume of
seawater discharged is reduced inspect the seawater pump in accordance with the following procedures 1 Loosen the side cover set bolt and remove the
side cover 2 Illuminate the inside of the seawater pump with a flashlight and inspect If any of the following problems is found disassembly and
maintenance are necessary Impeller blades are cracked or nicked Edges or surfaces of the blades are marred or worm The impeller must be replaced
periodically every 2000 hrs Wear plate is damaged 3 If no damage is found when inspecting the inside of the pump replace the side cover Fit the Oring
to the groove of the joint face before replacing the side cover If a large amount of water leaks continuously from the seawater pump during operation
disassembly and maintenance replacement of the mechanical seal are necessary When disassembly and maintenance of the seawater pump are necessary
consult your Yanmar dealer or distributor Inspection every 1000 hours Replace every 2000 and Replace zinc seawater cooling line 1 2 3 4 Close the
Kingston cock Drain the cooling seawater Remove the plug labeled ZINC and indicated in the diagram Check the zinc on the inside of the plug to
determine the amount of wear to the the zinc when it has been reduced to less than 12 of its original size If there is only a little bit of wear
clean the surface by sanding off any corroded areas 5 Replace plug 6 Open the Kingston cock and check water every 500 hours
44 Inspection of the Electrical Parts 441 Inspection of l
Check the level of fluid in the battery When the amount of fluid nears the lower limit fill with battery fluid available in the market to the upper
limit If operation continues with insufficient battery fluid the battery life is shortened and the battery may overheat and explode Battery fluid
tends to evaporate more quickly in the summer and the fluid level should be checked earlier than the specified times If the engine turns over at a
slower than usual rate and refuses to start recharge the battery If the engine still will not start after charging replace the daily before
Checking the Tension of the VBelt of the Alternator When there is not enough tension in the Vbelt the belt will slip making it impossible for the
alternator to generate power Additionally the fresh water pump will not work causing the engine to overheat Check the tension of the Vbelt in the
following manner 1 Press the Vbelt down with your thumb at the middle of the belt to check the tension The give in the Vbelt should measure about 8
10mm at the depression 2 To adjust the Vbelt tension loosen the set bolt and move the alternator 3 Replace the belt if it is damaged Inspection every
500 hours Replace every 2000 the Remote Control Handle
The remote control handles and the engine control levers are connected by an accelerator cable Over time the cable becomes stretched and the
connections loose causing deviation in the position which makes operation unsafe Inspect the cable periodically and adjust if necessary 1 Adjusting
the Governor Remote Control Handle Check to see that the speed lever on the engine side is touching the high speed limiting bolt when the governor
handle is put in H High Speed Check to see that the speed lever on the engine side is touching the low speed limiting bolt when the governor handle
is put in L Low Speed If the speed lever does not touch the limiting bolt for either the high or low speed when you check them loosen the setting
screws on the fittings for the accelerator cable and adjust the position of the cable
2 Adjusting the Clutch Remote Control Handle for the Marine Gear Check to see that the clutch lever on the engine side is in the neutral position
when the remote control handle is in NEUTRAL If the position of the clutch lever is incorrect loosen the setting screw of the cable Check the clutch
lever in FWD Forward REV Reverse making sure it is correctly aligned Make any necessary adjustments using NEWTRAL as the central point
Inspection every 250 hours
5 Principal 51 Engine Model Idling speed High idling speed 1GM10 min1 min1 2GM20F 85025 382525 order Suction Exhaust Injection timing FID Injection
pressure Lubricant pressure Valve clearance Mpa Mpa
121 13421 02003 02003 bTDC 151 bTDC 151 bTDC 181 196049 2005kgcm2 039005 List of tightening torques Engine Model Cylinder head Injection nozzle
Connecting rod
2GM20F 3GM30F Main nut and bolts 1177120 kgfm 735 Nm 75 kgfm Auxiliary bolts 29430 kgfm Nm 19620 kgfm Nm 24525 Trouble and If you should encounter
some difficulty during operation refer to the following table for Trouble Probable Cause Measure Problem occurs during operation NOTICE When the
alarm equipment indicates a problem immediately put the clutch in neutral and run the engine at low speed Check to see which alarm indicator is lit
then stop the engine and inspect When you cannot determine the source of the problem return to port at low speed and ask your Yanmar dealer for repair
Alarm buzzer sounds and alarm come on Faulty battery Check battery fluid Adjust Vbelt tension or replace Vbelt is loose or damaged belt Charge Lamp
Alternator is not generating Ask for repairs electricity Alarm buzzer does not sound Check and replenish cooling Insufficient cooling water in fresh
water tank water Leakage in fresh water cooling system Ask for repairs for water leakage Fresh water cooling pump is damaged Ask for repairs CW Temp
Lamp goes on Inside of CW system is dirty Ask for repairs LO Press Alarm Lamp goes on Insufficient engine oil Replenish engine oil Kingston cock is
closed Insufficient discharge of cooling seawater Kingston cock is clogged Suction hose is damaged or joints Alarm Lamp goes on Faulty Alarm Device
cooling seawater pump Check seawater pump impeller
Do not operate the engine if alarm devices are not working properly Serious accidents may result if difficulties are not spotted due to faulty alarm
lamps Before starting when switch is turned from OFF ON alarm devices do not work Circuit broken or buzzer Alarm buzzer does not sound Ask for
repairs damaged Some alarm lamps do not light up Circuit broken or lamp burnt out Ask for repairs After starting when switch returns from START ON
alarm devices do not work Alarm buzzer does not cut off Short circuit Ask for repairs Some alarm lamps do not go out Damaged sensor or switch Ask for
repairs Starting Failures No fuel Replenish fuel bleed Air in fuel line Bleed Bad fuel Replace with recommended fuel Clogged fuel filter Replace fuel
filter Poor fuel injection Ask for repairs Pressure leakage from Starter does not turn Ask for repairs valves Insufficient battery charge Check
battery fluid recharge Remote rust from terminal Faulty cable connection at terminal retighten Faulty starter switch Ask for repairs Starter does not
turn or turns too solely Faulty starter Ask for repairs can be turned by hand Cannot be turned manually Poor exhaust color Overload Insufficient fuel
Faulty spraying of FO injection Black smoke emitted Insufficient fuel Faulty spraying of FO injection Fuel injection timing off White smoke emitted
Lube oil consumption Inner parts seized or damaged Ask for repairs Reduce load Replace with recommended fuel Ask for repairs Excessive valve top
clearance Ask for repairs Replace with recommended fuel Ask for repairs Ask for repairs Ask for repairs

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