Maintenance Of Pleasureboat Diesel Engine Gm Series

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Maintenance of Pleasureboat Diesel Engine GM Series 1Safety Precaution for Inspection 1Battery 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 you2Fire due to Electric ShortCircuits Always turn off the battery switch or detach the earth cable before inspecting the electrical system Failure to do so could cause and 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 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 scalded5Burns 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 clothing6Burns from ScaldinglNever 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 lAfter inspection refasten the filler cap firmly If the cap is not secure steam or scalding water may be emitted during operation causing burns 2Engine Specifications Type Vertical watercooled 4cycle diesel engine Engine Model 1GM10 of cylinders 1 2 3 Cont rating output Max output Lube oil capacity Engine oil L 13L 20L 27L Clutch oil L 025L 025L 03L 3Fuel oil lube oil and cooling water 31 fuel oil Diesel fuel standard for various countries 4Maintenance and Inspection 41 Fuel Oil System 411411 Checking and Supplying Fuel Oil Check the fuel level inside the fuel tank and supply with the recommended fuel if necessary Inspection daily before the fuel tank 1Put a pan under the drain to catch the fuel 2Loosen the drain cock at the bottom of the fuel tank and drain off any water and dirt collected inside 3Once the water and dirt have been drained off and the fuel coming out is clear close the drain plug Inspection every 50hrs 413Replacing the fuel filter 1Close the fuel cook 2Turn the element casing fixing screw to the left with the filter wrench and remove 3Clean the filter casing 4Turn the element casing fixing screw to the right use the filter wrench to tighten 5Be sure be bleed air out of the fuel system 42 Lube Oil System 421Checking and Supplying Engine oil 1Check the engine oil level with the oil dipstick 2If 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 startup 422Check and supply of Marine gear oil 1Check the marine gear oil level with the oil dipstick 2Supply with the recommended oil if necessary Check the oil level with the dipstick while to the upper mark Inspection daily before starting 423 Replacing the Engine Lube Oil and Lube Oil Filters 1Drain 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 2Replace 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 3Fill with new lube oil 1 Fill with the specified amount of engine oil 241Remove the oil inlet cap on the top of the bonnet and fill with oil 241Remove 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 241Replace 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 1Sj9ZYllU 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 431Check and supply of cooling water 1Check 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 2When 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 241Check 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 241Check and supply cooling water daily at the subtank Do not remove the fresh water cooler f1iller cap regularly 241The 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 starting 432Checking 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 241Is the Kingston cock open 241Is the inlet of the Kingston cock clogged 241Is the sea water suction hose broken or does the hose suck in air due to a loose joint 433Inspecting 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 1Loosen the side cover set bolt and remove the side cover 2Illuminate the inside of the seawater pump with a flashlight and inspect If any of the following problems is found disassembly and maintenance are necessary 241Impeller blades are cracked or nicked Edges or surfaces of the blades are marred or worm The impeller must be replaced periodically every 2000 hrs 241Wear plate is damaged 3If 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 hours 434Inspection and Replace Anticorrosive zinc seawater cooling line1Close the Kingston cock 2Drain the cooling seawater 3Remove the plug labeled ZINC and indicated in the diagram 4Check the zinc on the inside of the plug to determine the amount of wear to the anticorrosive zinc oRVpbbWCWp 241Replace the anticorrosive zinc when it has been reduced to less than 12 of its original size 241If there is only a little bit of wear clean the surface by sanding off any corroded areas 5Replace plug 6Open the Kingston cock and check water leakage Inspection every 500 hours 44 Inspection of the Electrical Parts 441 Inspection of Battery lCheck the level of fluid in the battery When the amount of fluid nears the lower limit fill with battery fluid available in the marketto the upper limit If operation continues with insufficient battery fluid the battery life is shortened and the battery may overheat and explode lBattery fluid tends to evaporate more quickly in the summer and the fluid level should be checked earlier than the specified times lIf the engine turns over at a slower than usual rate and refuses to start recharge the battery lIf the engine still will not start after charging replace the battery Inspection daily before startup 442 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 1Press 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 2To adjust the Vbelt tension loosen the set bolt and move the alternator 3Replace the belt if it is damaged Inspection every 500 hours Replace every 2000 hours 443Adjusting the Remote Control Handle 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 1Adjusting the Governor Remote Control Handle 241Check 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 241Check 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 241If 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 2Adjusting the Clutch Remote Control Handle for the Marine Gear 241Check to see that the clutch lever on the engine side is in the neutral position when the remote control handle is in NEUTRAL 241 If the position of the clutch lever is incorrect loosen the setting screw of the cable 241Check the clutch lever in FWD Forward REV Reverse making sure it is correctly aligned 241Make any necessary adjustments using NEWTRAL as the central point Inspection every 250 hours 5 Principal specifications 51 Specifications Engine Model 1GM10 speed min1 85026125 High idling speed min1 382526125 zZN5GMi0jUA Firing order 121 13421 Valve clearance Suction 02261003 Exhaust 02261003 Injection timing FID bTDC 152602611 bTDC 152602611 bTDC 182602611 Injection pressure Mpa 196261049 pressure Mpa 039261005 4026105kgcm252 List of tightening torques Engine Model 1GM10 head Nm 735 75 kgfm Main nut and bolts 1177120 kgfmAuxiliary bolts 29430 kgfmInjection nozzle Nm 19620 kgfmConnecting rod Nm 24525 kgfm6 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 Vbelt is loose or damaged Adjust Vbelt tension or replace belt Charge Lamp Alarm buzzer does not is not generating electricity Ask for repairs Insufficient cooling water in fresh water tank Check and replenish cooling 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 Insufficient discharge of cooling seawater Kingston cock is closed Kingston cock is clogged Suction hose is damaged or joints loose Exhaust Alarm Lamp goes on Damaged cooling seawater pump Check seawater pump impeller Faulty Alarm Device NOTICE 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 Alarm buzzer does not sound Circuit broken or buzzer damaged Ask for repairs 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 Starter does not turn Pressure leakage from intakeexhaust valves Ask for repairs Insufficient battery charge Check battery fluid recharge Faulty cable connection at terminal Remote rust from terminal retighten Faulty starter switch Ask for repairs Starter does not turn or turns too solely can be turned by handFaulty starter Ask for repairs Cannot be turned manually Inner parts seized or damaged Ask for repairs Poor exhaust color Overload Reduce load Insufficient fuel Replace with recommended fuel Faulty spraying of FO injection Ask for repairs Black smoke emitted Excessive intakeexhaust valve top clearance Ask for repairs Insufficient fuel Replace with recommended fuel Faulty spraying of FO injection Ask for repairs Fuel injection timing off Ask for repairs White smoke emitted Lube oil burnsexcessive consumption Ask for repairs

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