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Yanmar Gm Series Maintainance Manual




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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 Vertical watercooled 4cycle diesel engine
Engine Model 1GM10 2GM20F of cylinders 1 2
3
rating output
1 1 1
output
1 1 1
Engine
Lube oil L 13L 20L 27L
capacity
Clutch oil L 025L 025L 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 ISO 8217 DMA
l ASTM D975 Grade No1D or No2D
l JIS K2204 Grade No2 No3 or specialNo3
l 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 Oil
l Keep 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
l 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 Oil
l When 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
l 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 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 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 filter
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 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 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 Inspection every 1000 hours
Replace every 2000 Inspection and Replace zinc seawater cooling line
1 Close the Kingston cock
2 Drain the cooling seawater
3 Remove the plug labeled ZINC and indicated in the diagram
4 Check the zinc on the inside of the plug to determine the amount of wear to the zinc
Replace 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 leakage
Inspection every 500 hours
44 Inspection of the Electrical Parts
441 Inspection of Battery
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
l Battery fluid tends to evaporate more quickly in the summer and the fluid level should be
checked earlier than the specified times
l If the engine turns over at a slower than usual rate and refuses to start recharge the battery
l If the engine still will not start after charging replace the battery
Inspection 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 Adjusting 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 Engine Model 1GM10 2GM20F 3GM30F
Idling speed min1 85025
High idling speed min1 382525
Firing order 121 13421
Suction 02003
Valve clearance
Exhaust 02003
Injection timing FID bTDC 151 bTDC 151 bTDC 181
Injection pressure Mpa 196049 Lubricant pressure Mpa 039005 List of tightening torques
Engine Model 1GM10 2GM20F 3GM30F
Main nut and bolts
735 1177120 kgfm
Cylinder head Nm
75 kgfm Auxiliary bolts
29430 kgfm
Injection nozzle Nm 19620 kgfm
Connecting rod Nm 24525 kgfm
6 Trouble and you should encounter some difficulty during operation refer to the following table for Trouble Probable
Cause Measure
Problem occurs during 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 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 is loose or damaged
belt
Charge Lamp
Alternator is not generating
Ask for repairs
buzzer does not sound
Check and replenish cooling water in fresh water tank
in fresh water cooling system Ask for repairs for water 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
Kingston cock is discharge of cooling seawater
Suction hose is damaged or
joints Alarm Lamp goes on Damaged cooling seawater pump Check seawater pump Alarm not operate the engine if alarm devices are not working
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 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 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
battery charge Check battery fluid recharge
Remote rust from cable connection at terminal
starter switch Ask for does not turn or turns too
solely
Faulty starter Ask for repairs
can be turned by hand
Cannot be turned manually Inner parts seized or damaged Ask for repairs
Poor exhaust Reduce fuel
Replace with recommended fuel
Faulty spraying of FO injection Ask for repairs
Excessive valve
Black smoke emitted Ask for repairs
top fuel Replace with recommended fuel
Faulty spraying of FO injection Ask for repairs
Fuel injection timing off Ask for repairs
Lube oil smoke emitted Ask for repairs
consumption

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