' Yanmar Gm Series Maintenance Guide'

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Maintenance of Pleasureboat Diesel EngineGM Series1Safety Precaution for Inspection1 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 you2 Fire 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 fires3 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 injury4 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 scalded5 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 clothing6 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 burns2Engine Vertical watercooled 4cycle diesel engineEngine Model 1GM10 2GM20F 3GM30FNumber of cylinders 1 2 3 59kW8PS3400min rating output 1 1 1 66kW9PS3600min output 1 1 1 Engine Lube oil L 13L 20L 27L oil capacity Clutch oil L 025L 025L 03L3Fuel oil lube oil and cooling water31 fuel oil1 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 fluidity2 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 use32 Lube oil1 Selection of Engine oil Use the following lube oil API Classification CD SAE Viscosity 15W402 2 Selection of Marine gear lube oil API Classification CD SAE Viscosity 303 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 containers33 Cooling water Fresh water cooling type1 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 overheat2 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 system3 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 reduced4 Do not mix different brands of antifreeze or antirust Mixing reduces cooling efficiency and leads to parts damage5 When the amount of cooling water is too low refill with fresh water and Inspection41 Fuel Oil System411 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 starting412 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 50hrs413 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 system42 Lube Oil System421 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 startup422 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 starting423 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 year424 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 hours43 Cooling Water System431 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 starting432 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 joint433 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 hours434 Inspection and Replace Anticorrosive 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 anticorrosive zinc Replace the anticorrosive 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 hours44 Inspection of the Electrical Parts441 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 startup442 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 hours443 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 hours5 Principal Specifications 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 2005kgcm2 Lubricant pressure Mpa 039005 4005kgcm252 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 kgfm6 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 atlow speedCheck to see which alarm indicator is lit then stop the engine and inspectWhen you cannot determine the source of the problem return to port at low speed and ask your Yanmardealer for repairAlarm buzzer sounds and alarm come onFaulty battery Check battery fluid Adjust Vbelt tension or replaceVbelt is loose or damaged beltCharge Lamp Alternator is not generating Ask for repairs buzzer does not sound Check and replenish cooling water in fresh water tank waterLeakage in fresh water cooling system Ask for repairs for water leakageFresh water cooling pump is damaged Ask for repairsCW Temp Lamp goes on Inside of CW system is dirty Ask for repairsLO 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 looseExhaust Alarm Lamp goes on Damaged cooling seawater pump Check seawater pump impellerFaulty Alarm DeviceNOTICEDo not operate the engine if alarm devices are not working accidents may result if difficulties are not spotted due to faulty alarm lampsBefore starting when switch is turned from OFF ON alarm devices do not work Circuit broken or buzzerAlarm buzzer does not sound Ask for repairs damagedSome alarm lamps do not light up Circuit broken or lamp burnt out Ask for repairsAfter starting when switch returns from START ON alarm devices do not workAlarm buzzer does not cut off Short circuit Ask for repairsSome alarm lamps do not go out Damaged sensor or switch Ask for FailuresNo fuel Replenish fuel bleedAir in fuel line BleedBad fuel Replace with recommended fuelClogged fuel filter Replace fuel filterPoor fuel injection Ask for repairs Pressure leakage fromStarter does not turn Ask for repairs intakeexhaust battery charge Check battery fluid recharge Remote rust from terminalFaulty cable connection at terminal starter switch Ask for repairsStarter does not turn or turns toosolely Faulty starter Ask for repairscan be turned by handCannot be turned manually Inner parts seized or damaged Ask for repairsPoor exhaust colorOverload Reduce fuel Replace with recommended fuelFaulty spraying of FO injection Ask for repairs Excessive intakeexhaust valveBlack smoke emitted Ask for repairs top fuel Replace with recommended fuelFaulty spraying of FO injection Ask for repairsFuel injection timing off Ask for repairs Lube oil smoke emitted Ask for repairs consumption

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