1GM10 1GM10C GM 1GM10V - Galion 22galion22.tk/blog/wp-content/uploads/2013/08/Yanmar_1GM10_OM_… · gm series operation manual 1gm10 1gm10c 1gm10v p/n: 0agmm-g00100 marine engines

GMseries

OPERATION MANUAL1GM10

1GM10C1GM10V

P/N: 0AGMM-G00100

MARINEENGINES

Disclaimers:All information, illustrations and specifications in this manual are based on the latestinformation available at the time of publishing. The illustrations used in this manual areintended as representative reference views only. Moreover, because of our continuousproduct improvement policy, we may modify information, illustrations and / or specificationsto explain and / or exemplify a product, service or maintenance improvement. We reservethe right to make any change at any time without notice. Yanmar and areregistered trademarks of Yanmar Co., Ltd. in Japan, the United States and / or othercountries.All Rights Reserved: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 storageand retrieval systems - without the written permission of Yanmar Marine International.© 2007 Yanmar Marine International

1207

ii GM Series Operation Manual© 2007 Yanmar Marine International

TABLE OFCONTENTS

PageIntroduction .............................................................. 1

Record of Ownership . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2Safety ....................................................................... 3

Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4Before You Operate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4During Operation and Maintenance . . . . . . . . . . . . . . . . . . . . . 4

Location of Safety Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Product Overview ...................................................... 9

Yanmar GM Features and Applications . . . . . . . . . . . . . . . . . . . . . . . 9New Engine Break-In . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Component Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11Service Side - 1GM10 with KM2P . . . . . . . . . . . . . . . . . . . . . . 11Non-Service Side - 1GM10 with KM2P . . . . . . . . . . . . . . . . 12

Location of Nameplates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13Emission-Control Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Major Components and Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14Control Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Instrument Panel (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15Optional Single-Lever Throttle and ShiftConsole . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Before You Operate .................................................. 19Diesel Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Diesel Fuel Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19Filling the Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23Engine Oil Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23Engine Oil Viscosity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

GM Series Operation Manual iii© 2007 Yanmar Marine International

Checking the Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24Adding Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Marine Gear or Sail-Drive Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25Marine Gear Oil Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . 25Sail-Drive Oil Specifications - SD20 . . . . . . . . . . . . . . . . . . . . 25Checking Marine Gear Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25Adding Marine Gear Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26Checking and Adding Sail-Drive Oil . . . . . . . . . . . . . . . . . . . . 26

Cranking the Engine Manually . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26Cranking the Engine Electrically . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Recheck the Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28Daily Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Visual Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28Checking Diesel Fuel and Engine Oil . . . . . . . . . . . . . . . . . . 29Checking and Refilling Marine Gear Oil . . . . . . . . . . . . . . . 29Checking the Battery Electrolyte Level . . . . . . . . . . . . . . . . 29Checking the Alternator Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29Checking the Throttle and Shift Console . . . . . . . . . . . . . . 29Checking the Warning Indicators . . . . . . . . . . . . . . . . . . . . . . . 29Preparing Fuel, Oil and Coolant in Reserve . . . . . . . . . . 29

Engine Operation ...................................................... 31Starting the Engine Electrically . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Starting the Engine Manually . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33Restarting After Starting Failure . . . . . . . . . . . . . . . . . . . . . . . . . 34Starting at Low Temperatures . . . . . . . . . . . . . . . . . . . . . . . . . . . 34After the Engine Has Started . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Throttle and Shift Lever Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36Acceleration and Deceleration . . . . . . . . . . . . . . . . . . . . . . . . . . 36Shifting the Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Precautions During Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37Shutting Down the Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38Checking the Engine After Operation . . . . . . . . . . . . . . . . . . . . . . . . . 39

Periodic Maintenance ................................................ 41Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

The Importance of Periodic Maintenance . . . . . . . . . . . . . 43Performing Periodic Maintenance . . . . . . . . . . . . . . . . . . . . . . 43The Importance of Daily Checks . . . . . . . . . . . . . . . . . . . . . . . . 43Keep a Log of Engine Hours and Daily Checks . . . . . 43Yanmar Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43Tools Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

TABLE OF CONTENTS

iv GM Series Operation Manual© 2007 Yanmar Marine International

Ask Your Authorized Yanmar Marine Dealer orDistributor For Help . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43Tightening Fasteners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

EPA Maintenance Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45EPA Requirements for USA and Other ApplicableCountries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45Conditions to Ensure Compliance with EPAEmission Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45Inspection and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

Periodic Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46Inspection and Maintenance of EPA Emission-Related Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

Periodic Maintenance Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49After Initial 50 Hours of Operation . . . . . . . . . . . . . . . . . . . . . . 49Every 50 Hours of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52Every 150 Hours of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . 53Every 250 Hours of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . 54Every 1000 Hours of Operation . . . . . . . . . . . . . . . . . . . . . . . . . 58

Troubleshooting ....................................................... 59Troubleshooting After Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59Troubleshooting Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

Long-Term Storage ................................................... 65Prepare Engine for Long-Term Storage . . . . . . . . . . . . . . . . . . . . . . 65Draining the Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

Specifications .......................................................... 67Principal Engine Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

1GM10 Engine Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . 671GM10C Engine Specifications . . . . . . . . . . . . . . . . . . . . . . . . . 691GM10V Engine Specifications . . . . . . . . . . . . . . . . . . . . . . . . . 71

System Diagrams ..................................................... 73Piping Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

Emission System Warranty ........................................ 81Non-Road Emission System Warranty . . . . . . . . . . . . . . . . . . . . . . . 81

Yanmar Co., Ltd. Limited Emission ControlSystem Warranty - USA Only . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81Maintenance Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84

TABLE OF CONTENTS

GM Series Operation Manual v© 2007 Yanmar Marine International

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TABLE OF CONTENTS

vi GM Series Operation Manual© 2007 Yanmar Marine International

INTRODUCTIONWelcome to the world of Yanmar Marine!Yanmar Marine offers engines, drivesystems and accessories for all types ofboats, from runabouts to sailboats, and fromcruisers to mega yachts. In marine leisureboating, the worldwide reputation of YanmarMarine is second to none. We design ourengines to respect nature. This meansquieter engines, with minimal vibrations,cleaner than ever. All of our engines meetapplicable regulations, including emissions,at the time of manufacture.To help you enjoy your Yanmar GM seriesengine for many years to come, pleasefollow these recommendations:

• Read and understand this OperationManual before you operate the engine toensure that you follow safe operatingpractices and maintenance procedures.

• Keep this Operation Manual in aconvenient place for easy access.

• If this Operation Manual is lost ordamaged, order a new one from yourauthorized Yanmar Marine dealer ordistributor.

• Make sure this manual is transferred tosubsequent owners. This manual shouldbe considered a permanent part of theengine and remain with it.

• Constant efforts are made to improve thequality and performance of Yanmarproducts, so some details included in thisOperation Manual may differ slightly fromyour engine. If you have any questionsabout these differences, please contactyour authorized Yanmar Marine dealer ordistributor.

• The specifications and components(instrument panel, fuel tank, etc.)described in this manual may differ fromones installed on your vessel. Please referto the manual provided by themanufacturer of these components.

• Refer to the Yanmar Limited WarrantyHandbook for a complete warrantydescription.

GM Series Operation Manual 1© 2007 Yanmar Marine International

RECORD OF OWNERSHIPTake a few moments to record the information you need when you contact Yanmar forservice, parts or literature.

Engine Model:

Engine Serial No.:

Date Purchased:

Dealer:

Dealer Phone:

INTRODUCTION

2 GM Series Operation Manual© 2007 Yanmar Marine International

SAFETYYanmar considers safety of greatimportance and recommends that anyonewho comes in close contact with itsproducts, such as those who install,operate, maintain or service Yanmarproducts, exercise care, common senseand comply with the safety information inthis manual and on the engine’s safetydecals. Keep the decals from becomingdirty or torn and replace them if they are lostor damaged. Also, if you need to replace apart that has a decal attached to it, makesure you order the new part and decal at thesame time.

!

This safety alert symbol appearswith most safety statements. Itmeans attention, become alert,your safety is involved! Pleaseread and abide by the messagethat follows the safety alertsymbol.

! DANGERIndicates a hazardous situation which, ifnot avoided, will result in death orserious injury.

! WARNINGIndicates a hazardous situation which, ifnot avoided, could result in death orserious injury.

! CAUTIONIndicates a hazardous situation which, ifnot avoided, could result in minor ormoderate injury.

NOTICEIndicates a situation which can causedamage to the engine, personal propertyand / or the environment or cause theequipment to operate improperly.


SAFETY PRECAUTIONSGeneral InformationThere is no substitute for common senseand careful practices. Improper practices orcarelessness can cause burns, cuts,mutilation, asphyxiation, other bodily injuryor death. This information contains generalsafety precautions and guidelines that mustbe followed to reduce risk to personal safety.Special safety precautions are listed inspecific procedures. Read and understandall of the safety precautions before operationor performing repairs or maintenance.Before You Operate

! DANGERThe safety messages that follow haveDANGER level hazards.

NEVER permit anyone toinstall or operate theengine without propertraining.

• Read and understand this OperationManual before you operate or service theengine to ensure that you follow safeoperating practices and maintenanceprocedures.

• Safety signs and decals are additionalreminders for safe operating andmaintenance techniques.

• See your authorized Yanmar Marinedealer or distributor for additional training.

During Operation andMaintenance

! DANGERThe safety messages that follow haveDANGER level hazards.

Crush HazardNEVER stand under a hoistedengine. If the hoist mechanismfails, the engine will fall on you.

Fire HazardEnsure that appropriate firedetection and extinguishingequipment are installed andchecked periodically forproper operation.

SAFETY


! WARNINGThe safety messages that follow haveWARNING level hazards.

Explosion HazardWhile the engine is running orthe battery is charging,hydrogen gas is beingproduced and can be easilyignited. Keep the area around

the battery well-ventilated and keep sparks,open flames and any other form of ignitionout of the area.

Fire and Explosion HazardDiesel fuel is flammable and explosiveunder 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 awell-ventilated area, away from anycombustibles or sources of ignition.

Fire HazardUndersized wiring systemscan cause an electrical fire.

Sever HazardNEVER wear jewelry,unbuttoned cuffs, ties orloose-fitting clothing andALWAYS tie back long hairwhen working near moving /

rotating parts such as the flywheel or PTOshaft. Keep hands, feet and tools away fromall moving parts.

Alcohol and Drug HazardNEVER operate the enginewhile under the influence ofalcohol or drugs or if you arefeeling ill.

Exposure HazardALWAYS wear personalprotective equipmentincluding appropriateclothing, gloves, work shoes,eye and hearing protection as

required for the task at hand.

Entanglement HazardNEVER leave the key in thekey switch when you areservicing the engine.Someone may accidentallystart the engine and not realize

you are servicing it.

NEVER operate the engine while wearing aheadset to listen to music or radio becauseit will be difficult to hear the warning signals.

Stop the engine before you begin to serviceit.

SAFETY


! WARNINGPiercing Hazard

Avoid skin contact with high-pressure diesel fuel spraycaused by a fuel system leaksuch as a broken fuel injectionline. High-pressure fuel can

penetrate your skin and result in seriousinjury. If you are exposed to high-pressurefuel spray, obtain prompt medical treatment.

NEVER check for a fuel leak with yourhands. ALWAYS use a piece of wood orcardboard. Have your authorized YanmarMarine dealer or distributor repair thedamage.

Burn HazardSome of the engine surfacesbecome very hot duringoperation and shortly aftershutdown. Keep hands andother body parts away fromhot engine surfaces.

Exhaust HazardNEVER block windows, ventsor other means of ventilation ifthe engine is operating in anenclosed area. All internalcombustion engines create

carbon monoxide gas during operation andspecial precautions are required to avoidcarbon monoxide poisoning.

! CAUTIONThe safety messages that follow haveCAUTION level hazards.

Poor Lighting HazardEnsure that the work area is adequatelyilluminated. ALWAYS install wire cages onportable safety lamps.

Tool HazardALWAYS use tools appropriate for the taskat hand and use the correct size tool forloosening or tightening engine parts.

Flying Object HazardALWAYS wear eye protection whenservicing the engine or when usingcompressed air or high-pressure water.Dust, flying debris, compressed air,pressurized water or steam may injure youreyes.

SAFETY


NOTICEThe safety messages that follow haveNOTICE level hazards.It is important to perform daily checks aslisted in the Operation Manual.Periodic maintenance prevents unexpecteddowntime, reduces the number of accidentsdue to poor engine performance and helpsextend the life of the engine.

See your authorized Yanmar Marine dealeror distributor if you need to operate theengine at high altitudes. At high altitudes theengine will lose power, run rough andproduce exhaust gases that exceed thedesign specifications.

ALWAYS be environmentallyresponsible.

Follow the guidelines of the EPA or othergovernmental agencies for the properdisposal of hazardous materials such asengine oil, diesel fuel and engine coolant.Consult the local authorities or reclamationfacility.NEVER dispose of hazardous materials bydumping them into a sewer, on the groundor into ground water or waterways.

If a Yanmar Marine Engine is installed at anangle that exceeds the specifications statedin the Yanmar Marine Installation manuals,engine oil may enter the combustionchamber causing excessive engine speed,white exhaust smoke and serious enginedamage. This applies to engines that run

continuously or those that run for shortperiods of time.If you have an installation with two or threeengines and only one engine is operating,the water pickup (thru-hull) of the non-running engine(s) should be closed. This willprevent water from being forced past theseawater pump and entering the engine.The result of water entering the engine couldcause engine seizure or other seriousproblems.

If you have an installation with two or threeengines, and only one engine is operating,please note that if the propeller shaftthru-hull (stuffing box) is lubricated byengine water pressure and the engines areinterconnected, care must be taken thatwater from the running engine does notenter the exhaust of the non-runningengine(s). This water could cause seizure ofthe non-running engine(s). See yourauthorized Yanmar Marine dealer ordistributor for a complete explanation of thiscondition.

If you have an installation with two or threeengines, and only one engine is operating,it is important to limit the amount of throttleapplied to the running engine. If you observeblack smoke or movement of the throttledoes not increase engine rpm, you areoverloading the engine that is running.Immediately throttle back to approximatelytwo-thirds throttle or to a setting where theengine performs normally. Failure to do somay cause the running engine to overheator cause excess carbon buildup which mayshorten the engine's life.

SAFETY


LOCATION OF SAFETY DECALSFigure 1 shows the location of safety decals on Yanmar GM series marine engines.

GM Engines

128296-07350

WARNING

(1)

0005961

Figure 11 – Part Number: 128296–07350

SAFETY


PRODUCT OVERVIEWYANMAR GM FEATURESAND APPLICATIONSThe GM series engines are four-strokedirect injection diesels equipped with directseawater coolant systems.The 1GM10 is a naturally aspirated1-cylinder engine equipped with a KM2Pmarine gear.The 1GM10C is a naturally aspirated1-cylinder engine equipped with an SD20sail-drive.The 1GM10V is a naturally aspirated1-cylinder engine equipped with a KM3Vmarine gear.The engines are equipped with a marinegear or sail-drive unit.These engines are designed for pleasurecraft use.It is recommended that new vessels bepropped so the engines can operate at100 to 200 rpm above the Maximum RatedPower Output rpm (3700 to 3800) to allowfor some added weight and hull resistance.The engine must be able to reach theMaximum Rated Power Output (3600 rpm)under full load at all times.Failure to do so can lead to reduced vesselperformance and increased smoke levels,and can cause permanent damage to yourengine, which is not covered by warranty.

The engine must be installed correctly withcoolant lines, exhaust gas lines andelectrical wiring. Any auxiliary equipmentattached to the engine should be easy to useand accessible for service. To handle thedrive equipment, propulsion systems(including the propeller) and other onboardequipment, always observe the instructionsand cautions given in the operation manualssupplied by the shipyard and originalequipment manufacturers.The GM series engines are designed to beoperated at maximum throttle (3600 rpm) forless than 5% of total engine time (30 minutesout of every 10 hours) and cruising speed(3400 rpm or less) for less than 90% of totalengine time (9 hours out of every 10 hours).The laws of some countries may require hulland engine inspections, depending on theuse, size and cruising area of the boat. Thestructural design, vessel application andinstallation of this engine all requirespecialized knowledge and engineeringskills. See Yanmar’s local subsidiary in yourregion or your authorized Yanmar Marinedealer or distributor.


New Engine Break-InAs with all reciprocating engines, the wayyour engine is operated during its first 50hours of operation plays a very significantrole in determining how long it will last andhow well the engine will perform over itslifetime.A new Yanmar diesel engine must beoperated at suitable speeds and powersettings during the break-in period to allowbearing surfaces and other friction-relatedcomponents, such as piston rings and valveguides, to wear in properly in order tostabilize engine lubrication and combustion.During the break-in period, the enginecoolant temperature gauge should bemonitored closely. The temperature shouldremain between 71˚ and 87˚C (160˚ and190˚F).During the first 10 hours of operation, theengine should be operated at maximum rpmminus 400 to 500 rpm (approximately 60 to70% of load) most of the time. This willensure the sliding parts break in properly.NOTICE: During this period, avoidoperating at maximum engine speedand load to avoid damaging or scoringsliding parts.NOTICE: NEVER operate at WOT (wideopen throttle) for more than a minute ata time during the first 10 hours ofoperation.Do not operate the engine at low idle or atlow speed and light load for more than30 minutes at a time. Since unburned fueland engine oil will adhere to the piston ringswhen operating at low speeds for longperiods, this will interfere with propermovement of the rings and the diesel fuelconsumption may increase. Low idle speeddoes not allow break-in of sliding parts.

If operating the engine at low speed and lightload, you must race the engine to clean thecarbon from the cylinders and the fuelinjection valve.Perform this procedure in open waters:• With the clutch in NEUTRAL, accelerate

from the low speed position to the highspeed position briefly.

• Repeat this process five times.Once past the initial 10 hours until 50 hours,the engine should be used over its fulloperating range, with special emphasis onrunning at relatively high power settings.This is not the time for an extended cruise atidle or low speed. The boat should beoperated at maximum speed minus 400 rpmmost of the time (approximately 70% load),with a 10-minute run at maximum minus 200rpm (approximately 80% load) every30 minutes and a 4 to 5 minute period ofoperation at WOT (wide open throttle) onceevery 30 minutes. During this period, be surenot to operate the engine at low speed andlight load for more than 30 minutes. Ifoperating engine at low speed and light loadis necessary, race the engine after low idleoperation.To complete engine break-in, perform AfterInitial 50 Hours maintenance procedures.See After Initial 50 Hours of Operation onpage 49.

PRODUCT OVERVIEW


COMPONENT IDENTIFICATIONService Side - 1GM10 with KM2PFigure 1 and Figure 2 illustrate a typicalversion of a 1GM10 engine. Your enginemay have different equipment from thatillustrated.

(1)(2)

(3)

(4)(5)

(6)

(7)

(8)

(9)

(10)(11)

(12)

(13)

(14)

(15)

(16)

0005850

Figure 11 – Nameplate2 – Thermostat Cover3 – Fuel Injection Pump4 – Idle Adjuster5 – Oil Filler Cap6 – Fuel Injection Limiter7 – Engine Stop Lever8 – Crankshaft V-Pulley

9 – Seawater Pump10 – Engine Oil Filter11 – Regulator Handle12 – Fuel Feed Pump13 – Engine Oil Dipstick14 – Mounting Flange15 – Mixing Elbow16 – Fuel Filter

PRODUCT OVERVIEW


Non-Service Side - 1GM10 withKM2P

(1)(2)

(3)

(4)

(5)

(6)(7)

(8)

(9)

(10)

0005849

Figure 21 – Decompression Lever2 – Fuel Injection Valve3 – Intake Silencer (Air Cleaner)4 – Tachometer Sensor5 – Marine Gear Dipstick

6 – Marine Gearbox7 – Output Shaft Coupling8 – Shift Lever9 – Starter Motor10 – Alternator

PRODUCT OVERVIEW


LOCATION OFNAMEPLATESThe nameplate of the Yanmar GM seriesengine is shown in Figure 3. Check theengine’s model, output, rpm and serialnumber on the nameplate. Replace it if it isdamaged 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 3The engine nameplate is attached to theengine rocker arm cover.The marine gear nameplate (Figure 4) isattached to the marine gear. Check themarine gear’s model, gear ratio, oil used, oilquantity and serial number.

MODE L KMGEAR RATIOOIL SAE 20/30HDOIL QT Y. LTR.NO.

0004529

Figure 4

Emission-Control LabelsTo ensure safe operation, emission-controllabels have been attached to the engine.Their location is shown in Figure 6. Theyshould always be visible. Replace labels ifdamaged or lost.

0005987

Figure 5

EPA & ARB label

0005988

Figure 6

PRODUCT OVERVIEW


MAJOR COMPONENTS AND FUNCTIONSName of Component Function

Decompression Lever Opens the exhaust valve and releases cylinder pressure to aid in manual enginestarting

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 leverup and down supplies fuel to the engine when the fuel system needs to be primed.

Engine Oil Filler Port Filler port for engine oilMarine Gear Oil Filler Port Filler port for marine gear oil

Engine Oil FilterFilters fine metal fragments and carbon from the engine oil. Filtered engine oil isdistributed to the engine’s moving parts. The filter is a spin-on type and the elementshould be replaced periodically. See Replacing the Engine Oil Filter Element onpage 50.

Cooling System Direct seawater cooling

Seawater Pump Pumps seawater from outside the vessel and through the engine. The seawaterpump has a replaceable rubber impeller.

Zinc AnodeThe metal surfaces of the seawater cooling system are prone to corrosion. Thezinc anode is installed in the cylinder block to prevent this. The surface of the zincanode erodes so it needs to be replaced at fixed intervals in order to fully protectthe seawater cooling system of the engine.

Intake Silencer (AirCleaner)

The intake silencer guards against dirt entering the engine induction system andreduces the noise of air intake.

Nameplates Nameplates are provided on the engine and the marine gear and contain themodel, 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


CONTROL EQUIPMENTThe control equipment at the helm makes remote control operation possible. It consists ofthe instrument panel, which is connected to the engine by a wire harness, and the throttleand shift console, which is connected by control cables to the engine control lever and marinegear.Instrument Panel (Optional)Equipment and FunctionsThe instrument panel is located at the helm and is available in two options. The followingcontrols and indicators enable you to start, stop and monitor the condition of the engine duringoperation.

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 Panel2 – Seawater in Marine Gear Warning Lamp3 – Water Temperature Warning Lamp4 – Oil Pressure Warning Lamp5 – Battery Low Charge Warning Lamp6 – Key Switch7 – Warning Buzzer8 – Start Button9 – Option “B” Instrument Panel10 – Engine Tachometer11 – Instrument Panel Light Switch12 – Hour Meter

PRODUCT OVERVIEW


GaugesInstrument FunctionTachometer Shows the engine rotation speed

Hour MeterShows the number of operating hours; can be used as a guidefor periodic maintenance checks. The hour meter is located atthe bottom of the tachometer.

Instrument Panel Lights When turning the key switch to ON, the gauges will illuminate foreasier viewing.

Key SwitchWhen the key is in the OFF position(Figure 8, (1)) the electric current is off. Thekey can be inserted or removed in thisposition.

OFF ON

(2)(1)

0005847

Figure 81 – OFF Position2 – ON PositionThe ON position (Figure 8, (2)) allowselectrical current to the controls andequipment and allows the engine to keeprunning. To stop the engine, keep the keyswitch in the ON position and pull the enginestop knob. After stopping the engine, turnthe key to the OFF position.

Engine Decompression LeverThe engine decompression lever(Figure 9, (3)) releases cylinder pressureto aid in manual starting.

(3)(2)

(1)

0005838

Figure 91 – RUN Position2 – Decompression Position3 – Decompression LeverRaising the decompression lever to thedecompression position (Figure 9, (2))opens the exhaust valve and makes handcranking of the engine possible. Returningthe lever to its RUN position (DOWN)(Figure 9, (1)) closes the exhaust valve andnormal engine operation can resume.

PRODUCT OVERVIEW


Indicators and Alarms (Optional)When a sensor detects a problem duringoperation, the indicator on the instrumentpanel will light and an alarm will sound.Indicators are located on the instrumentpanel. The alarm is located on the back ofthe panel. Under normal operatingconditions, the indicators are off.

Figure 10Battery Low Charge Indicator(Figure 10) - When the alternator output istoo low, the indicator will light. Whencharging begins, the indicator will turn off.No alarm will sound for low battery charge.

Figure 11Water Temperature Indicator and Alarm(Figure 11) - When water temperaturereaches the maximum allowabletemperature (95˚C [203˚F] or higher), theindicator will light and the alarm will sound.Continuing operation at temperaturesexceeding the maximum limit will result indamage and seizure. Check the load andtroubleshoot the cooling system.

Figure 12Engine Oil Low Pressure Indicator andAlarm (Figure 12) - When the engine oilpressure falls below normal, the oil pressuresensor will send a signal to the indicatorcausing it to light and the alarm to sound.Stop operation immediately to avoiddamage to the engine. Check the oil leveland troubleshoot the lubrication system.

Figure 13Water in Sail-Drive Seal Indicator and Alarm(Figure 13) - When seawater is detectedbetween the seals of the sail-drive, theindicator will light and the alarm will sound.Engine Stop ControlThe engine is stopped by pulling out theengine stop knob (Figure 14, (1)). Thiscable is connected to the engine stop leverand cuts off the fuel supply to the engine.

(3)

(1) (2)

0005842

Figure 141 – Engine Stop Knob2 – Bulkhead3 – Engine Stop Cable

PRODUCT OVERVIEW


AlarmsCheck that indicators and alarms are working normally when the key is turned to ON.

Key Switch OFF ⇒ ON START ⇒ ONEngine Before start RunningAlarm Sound No sound

Indicators

Battery Low Charge Indicator ON OFFWater Temperature Indicator OFF OFFEngine Oil Low Pressure Indicator ON OFFWater In Sail-Drive Indicator OFF OFF

Note: All warning indications will continue until the engine starts or the key switch is in theOFF position.

Optional Single-Lever Throttleand Shift ConsoleThis console (Morse Type) uses a singlelever to operate the throttle and the shiftingmechanism.FORWARD (FWD) (Figure 15, (1)) - Thedrive shaft is engaged and the enginepropels the vessel forward.

FWD

REV

NEUTRALIPULLI

CLUTCH

(1)(2)

(3)

(4)

0005846

Figure 151 – FORWARD (FWD)2 – NEUTRAL (N)3 – REVERSE (REV)4 – Pull out the lever to disengage the

clutch.

NEUTRAL (N) (Figure 15, (2)) - The driveshaft is disengaged from the propeller andthe engine idles.REVERSE (REV) (Figure 15, (3)) - Thedrive shaft is engaged and the enginepropels the vessel aft.With the lever in the NEUTRAL position, pullthe 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 anaccelerator, increasing the engine speed(rpm) as it is pushed further in the FWD orREV direction. When the lever is pulled out,engine speed can be controlled withoutmoving the vessel. The clutch is disengagedand the vessel is in NEUTRAL (no-loadposition).Note: Yanmar recommends the use of asingle-lever type console for the remotecontrol system. If only a two-lever type isavailable in the market, reduce enginespeed to 1000 rpm or less before engagingand disengaging the marine gear clutch.

PRODUCT OVERVIEW


BEFORE YOU OPERATEThis section of the Operation Manualdescribes diesel fuel and engine oil, andhow to replenish them. It also describes thedaily engine checks.Before performing any operations within thissection, review the Safety section onpage 3.

DIESEL FUELDiesel Fuel SpecificationsNOTICE: Only use diesel fuelsrecommended by Yanmar for the bestengine performance, to prevent enginedamage and to comply with EPAwarranty requirements. Only use cleandiesel fuel.Diesel fuel should comply with the followingspecifications. The table lists severalworldwide specifications for diesel fuels.

DIESEL FUELSPECIFICATION LOCATION

ASTM D975 No. 2-D, No.1-D, USA

EN590:96 European UnionISO 8217 DMX InternationalBS 2869-A1 or A2 United KingdomJIS K2204 Grade No. 2 Japan


Additional Technical FuelRequirements• 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% ispreferred.

• Total aromatics content should notexceed 35% by volume. Less than 30% ispreferred.

• 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. Fillingthe fuel tank with gasoline may result in a fireand will damage the engine. NEVER refuelwith the engine running. Wipe up all spillsimmediately. Keep sparks, open flames orany other form of ignition (match, cigarette,static electric source) well away whenrefueling.

ALWAYS store any containers containingfuel in a well-ventilated area, away from anycombustibles or sources of ignition.

ALWAYS put the diesel fuel container on theground when transferring the diesel fuelfrom the pump to the container. Hold thehose nozzle firmly against the side of thecontainer while filling it. This prevents staticelectricity buildup which could cause sparksand ignite fuel vapors.

BEFORE YOU OPERATE


Fuel Tank (Optional)NOTICE: Water and / or dust in the fuelmay cause engine failure. When fuel isstored, check that the inside of thestorage container is clean and dry, andthat the fuel is stored away from dirt orrain.Install a drain cock (Figure 1, (2)) at thebottom of the fuel tank to remove water andcontaminants from the sediment bowl(Figure 1, (1)).

0004542

(3)

(1) (2)

Figure 11 – Sediment Bowl2 – Drain Cock3 – Fuel Line to EngineThe fuel outlet should be positioned20 to 30 mm (0.75 to 1.125 in.) above thebottom of the tank (Figure 2, (4)) so thatonly clean fuel is distributed to the engine.

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

(1)

(2)(3)

(8)

(10)

(4)

(6)

(7)

(9)

(5)

0004788

Figure 21 – Fuel Filter2 – 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 Cock7 – Fuel Cock8 – Fuel Return Line9 – To Fuel Injection Pump10 – Fuel Tank

BEFORE YOU OPERATE


Filling the Fuel TankBefore filling the fuel tank for the firsttime:Rinse the fuel tank with kerosene or dieselfuel. Dispose of waste properly.To fill the fuel tank:NOTICE: Operate bilge ventilation(blowers) for a minimum of 5 minutes topurge fumes from engine compartmentafter refueling. Never operate bilgeblower while refueling. Doing so canpump explosive fumes into the enginecompartment 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 hosenozzle firmly against the filler portwhile filling. This prevents staticelectricity buildup which couldcause sparks and ignite fuel vapors.

4. Stop fueling when the gauge shows thefuel tank is full. CAUTION! NEVERoverfill the fuel tank.

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

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

0004512

Figure 3

BEFORE YOU OPERATE


ENGINE OILEngine Oil SpecificationsNOTICE: Only use the engine oilspecified. Other engine oils may affectwarranty coverage, cause internalengine components to seize and / orshorten engine life. NEVER mix differenttypes of engine oil. This may adverselyaffect the lubricating properties of theengine oil.Use an engine oil that meets or exceeds thefollowing guidelines and classifications:• API Service Categories: CD or higher

TBN value: 9 or moreThe oil must be changed when the TotalBase Number (TBN) has been reduced to2.0.TBN (mgKOH/g) test method: JISK-2501–5.2–2(HCI), ASTM D4739(HCI)

• Recommended SAE Viscosity: 10W30,15W40. Engine oil 10W30 and 15W40can be used throughout the year.

• NEVER use API Service Category CG-4or CH-4 oils.

NOTICE: 1. Be sure the engine oil, engine oil

storage containers and engine oilfilling equipment are free ofsediment or water.

2. Change the engine oil after the first50 hours of operation and then atevery 150 hours thereafter. SeeChanging the Engine Oil on page50.

3. Select the oil viscosity based on theambient temperature where theengine is being operated. See theSAE Service Grade Viscosity Chart(Figure 4).

4. Yanmar does not recommend theuse of engine oil “additives.”

Handling Engine Oil1. When handling and storing engine oil,

be careful not to allow dust and water tocontaminate the oil. Clean around thefiller port before filling.

2. Do not mix oils of different types orbrands. Mixing may cause the chemicalcharacteristics of the oil to change andlubricating performance to decrease,reducing the engine’s life.

3. Engine oil should be replaced at thespecified intervals, regardless of theengine’s operation history. SeePeriodic Maintenance Schedule onpage 46.

Engine Oil Viscosity

-4°F 14°F 32°F 50°F 68°F 86°F 104°F (-20°C) (-10°C) (0°C) (10°C) (20°C) (30°C) (40°C)

SAE 10W-30

SAE 15W-40

0000005

Figure 4Select the appropriate engine oil viscositybased on the ambient temperature shown inthe SAE Service Grade Viscosity Chart inFigure 4.NOTICE: If you intend to operate yourequipment at temperatures outside thelimits shown, you must consult yourauthorized Yanmar Marine dealer ordistributor for special lubricants orstarting aids.

BEFORE YOU OPERATE


Checking the Engine Oil1. Make sure the engine is off. It is

recommended that the engine be aslevel as possible before checking theoil.

2. Remove the dipstick (Figure 5, (2))and wipe with a clean cloth. NOTICE:Prevent dirt and debris fromcontaminating the engine oil.Carefully clean the dipstick and thesurrounding area before youremove the cap.

(1) (2)

(4)

(3)

0005852

Figure 51 – Filler Port2 – Dipstick3 – Upper Limit4 – Lower Limit

3. Fully reinsert the dipstick.4. Remove the dipstick. The oil level

should be between the upper(Figure 5, (3)) and lower(Figure 5, (4)) lines on the dipstick.

5. Add oil if necessary. See AddingEngine Oil on page 24.

6. Fully reinsert the dipstick.

Adding Engine Oil1. NOTICE: Prevent dirt and debris from

contaminating the engine oil.Carefully clean the dipstick and thesurrounding area before you removethe cap. Remove the yellow oil filler portcap from filler port (Figure 5, (1)) on therocker arm cover and fill with engine oil.

2. Fill with engine oil to the upper limit(Figure 5, (3)) on the dipstick(Figure 5, (2)). NOTICE: NEVER overfillthe engine with engine oil.

Engine Oil Capacity1GM10 (V) (C) Full: 1.5 L (1.5 qt)

3. Insert the dipstick fully to check the level.NOTICE: ALWAYS keep the oil levelbetween upper and lower lines on theoil cap / dipstick.

4. Hand-tighten the filler port cap securely.

BEFORE YOU OPERATE


MARINE GEAR OR SAIL-DRIVE OILMarine Gear Oil SpecificationsUse marine gear oil that meets or exceedsthe following guidelines and classifications:KM2P-1 (S), (G) or (GG):• API Service Categories: CD or higher• SAE Viscosity: #20 or #30Sail-Drive Oil Specifications -SD20Refer to the Sail-Drive Operation Manual forthe procedure to fill or replace the drive oil.SD20:• API Service Category: GL4.5• SAE Viscosity: 90 or 80W90• QuickSilver® 1 High Performance Gear

Lube

Checking Marine Gear Oil1. Turn the engine off. Make sure the engine

is as level as possible and wipe area cleanaround the marine gear filler port(Figure 6, (4)).

(1)

(3)(4)

(2)

0005851

Figure 61 – Dipstick2 – Upper Limit3 – Lower Limit4 – Marine Gear Filler Port

Marine Gear Oil CapacityKM2P 0.3 L (0.63 pt)

2. Remove the filler cap at the top of thehousing.

3. Remove the dipstick (Figure 6, (1)) andwipe with a clean cloth.

4. Fully reinsert the dipstick.5. Remove the dipstick. The oil level should

be between the upper (Figure 6, (2)) andlower (Figure 6, (3)) lines on the dipstick.

6. Fully reinsert the dipstick.

1 QuickSilver is a registered trademark of Brunswick Corporation.

BEFORE YOU OPERATE


Adding Marine Gear Oil1. Make sure the engine is as level as

possible.2. Remove the filler cap / dipstick

(Figure 6, (1)) at the top of the housing.3. Fill with oil to the upper limit on the

dipstick (Figure 6, (2)). NOTICE:NEVER overfill the marine gear withoil.

4. Fully reinsert the dipstick.5. Hand-tighten the filler port cap.Checking and Adding Sail-DriveOilRefer to the Sail-Drive Operation Manual forthe procedure for checking and filling thesail-drive oil.

CRANKING THE ENGINEMANUALLYNOTICE: When performing enginebreak-in or if the engine has not beenused for a long period of time, engine oilwill not be distributed to all theoperating parts. Using the engine in thiscondition will lead to seizure.After a long period of non-use, distributeengine oil to each part by cranking theengine. Perform the following procedurebefore beginning operation:1. Open the seacock.2. Open the fuel cock.3. Put the remote control shift lever in the

NEUTRAL position.4. Raise the decompression lever

(Figure 7, (3)) up.

(3)(2)

(1)

0005838

Figure 71 – RUN Position2 – Decompression Position3 – Decompression Lever

BEFORE YOU OPERATE


5. Slide the starter handle(Figure 8, (2)) on the starter shaft(Figure 8, (1)), align the groove andpin, and turn the engine over about 10times.

(1)

(2)

0005888

Figure 81 – Starter Shaft2 – Starter Handle

6. Listen for any abnormal noises whilecranking the engine.

7. Remove the starter handle.8. Place the decompression lever in the

RUN position.

CRANKING THE ENGINEELECTRICALLYNOTICE: When performing enginebreak-in or if the engine has not beenused for a long period of time, engine oilwill not be distributed to all of theoperating parts. Using the engine in thiscondition will lead to seizure.After a long period of non-use, distributeengine oil to each part by cranking theengine. Perform the following procedurebefore beginning operation:1. Open the seacock.2. Open the fuel cock.

Note: If the engine has not beenoperated for a long period of time,check that the key can be movedfrom the OFF to the ON positionsmoothly.

3. Put the remote control shift lever in theNEUTRAL position.

4. Pull the engine stop knob(Figure 9, (1)) out and holdcontinuously while cranking.

(3)

(1) (2)

0005842

Figure 91 – Engine Stop Knob2 – Bulkhead3 – Engine Stop Cable

5. With the key in the ON position, pushthe start button and the engine willbegin cranking.

6. Continue cranking for about 5 secondsand listen for any unusual noises.

BEFORE YOU OPERATE


NOTICE: If the engine stop knob isreleased (pushed in) during thecranking procedure, the engine willstart. NEVER start the engine in thismode.Recheck the Engine OilWhen the oil is distributed throughout theinternal components, start the engine andrun at no load for about 5 minutes. This willensure that all oil galleys, oil filters and oiltubes are full of oil. Shut the engine downand recheck the engine oil level. SeeChecking the Engine Oil on page 24. Add oilto the proper level, if necessary.

DAILY CHECKSBefore starting for the day, make sure theYanmar engine is in good operatingcondition. CAUTION! It is important toperform daily checks as listed in thisOperation Manual. Periodicmaintenance prevents unexpecteddowntime, reduces the number ofaccidents due to poor engineperformance and helps extend the life ofthe engine. Make sure you check thefollowing items:Visual Checks1. Check for engine oil leaks.2. Check for fuel leaks.WARNING! Avoid

skin contact with the high-pressurediesel fuel spray caused by a fuelsystem leak, such as a broken fuelinjection line. High-pressure fuelcan penetrate your skin and resultin serious injury. If you are exposedto high-pressure fuel spray, obtainprompt medical treatment. NEVERcheck for a fuel leak with yourhands. ALWAYS use a piece ofwood or cardboard. Have yourauthorized Yanmar Marine dealer ordistributor repair the damage.

3. Check for engine seawater leaks.4. Check for damaged or missing parts.5. Check for loose, missing or damaged

fasteners.6. Check the electrical harnesses for

cracks, abrasions, and damaged orcorroded connectors.

7. Check hoses for cracks, abrasions, anddamaged, loose or corroded clamps.

BEFORE YOU OPERATE


8. Check the fuel filter / water separator forwater and contaminants. If you find anywater or contaminants, drain the fuelfilter / water separator. See Draining theFuel Filter / Water Separator on page52. If you have to drain the fuel filter /water separator frequently, drain thefuel tank and check for water in your fuelsupply. See Draining the Fuel Tank onpage 49.

CAUTION! If any problem is notedduring the visual check, the necessarycorrective action should be taken beforeyou operate the engine.Checking Diesel Fuel and EngineOilFollow the procedures in Filling the FuelTank on page 22 and Checking the EngineOil on page 24 to check these levels.Checking and Refilling MarineGear OilSee Checking Marine Gear Oil on page 25.Checking the Battery ElectrolyteLevelCheck the battery electrolyte level beforeuse. See Inspecting the Battery ElectrolyteLevel (Serviceable Batteries Only) on page53.

Checking the Alternator BeltCheck the belt tension before use.See Checking and Adjusting the AlternatorV-Belt Tension on page 51.Checking the Throttle and ShiftConsoleCheck the operation of the throttle and shiftcontrol lever. Make sure it moves smoothly.If it is hard to operate, grease the joints of thecontrol cable and lever bearings. If the leverhas excessive play, adjust the control cableconnectors and clamps. See Inspecting andAdjusting the Throttle and Shift ControlCables on page 51.Checking the Warning IndicatorsCheck to ensure the engine instruments andwarning indicators are functioning properly.See Alarms on page 18. Check them oftenduring operation.Preparing Fuel, Oil and Coolant inReservePrepare sufficient diesel fuel for the day’soperation. Always store engine oil andcoolant in reserve (for at least one refill)onboard, to be ready for emergencies.

BEFORE YOU OPERATE



BEFORE YOU OPERATE


ENGINE OPERATIONThis section of the Operation Manualdescribes the procedures for starting theengine, checking engine performanceduring operation and shutting down theengine.Before performing any operations within thissection, read the following safetyinformation and review the Safety section onpage 3.

! WARNINGFire and Explosion Hazard

NEVER jump-start the engine.Sparks caused by shorting thebattery to the starter terminalsmay cause a fire or explosion.ONLY use the key switch to

start the engine.

Sudden Movement HazardBe sure the boat is in open water away fromother boats, docks or other obstructionsbefore increasing rpm. Avoid unexpectedequipment movement. Shift the marine gearinto the NEUTRAL position any time theengine is at idle.

To prevent accidental equipmentmovement, NEVER start the engine in gear.

Sever HazardKeep children and pets awaywhile the engine is operating.

Exhaust HazardNEVER block windows, ventsor other means of ventilation ifthe engine is operating in anenclosed area. All internalcombustion engines create

carbon monoxide gas during operation andspecial precautions are required to avoidcarbon monoxide poisoning.


NOTICEIf any indicator illuminates during engineoperation, stop the engine immediately.Determine the cause and repair the problembefore you continue to operate the engine.If the alarm indicator lamps and audiblealarm fail to display or sound when theignition switch is in the ON position, see yourauthorized Yanmar Marine dealer ordistributor for service before operating theengine.

Observe the following environmentaloperating conditions to maintain engineperformance and avoid premature enginewear:• Avoid operating in extremely dusty

conditions.• Avoid operating in the presence of

chemical gases or fumes.• NEVER run the engine if the ambient

temperature is above +40˚C (+104˚F) orbelow -16˚C (+5˚F).

• If the ambient temperature exceeds+40˚C (+104˚F), the engine may overheatand cause the engine oil to break down.

• If the ambient temperature is below -16˚C(+5˚F), rubber components such asgaskets and seals will harden causingpremature engine wear and damage.

• Contact your authorized Yanmar Marineengine dealer or distributor if the enginewill be operated outside of this standardtemperature range.

NEVER engage the starter motor while theengine is running. Damage to the startermotor pinion and / or ring gear will result.

STARTING THE ENGINEELECTRICALLYNOTICE: If the vessel is equipped with awater lift (water lock) muffler, excessivecranking could cause seawater to enterthe cylinders and damage the engine. Ifthe engine does not start after crankingfor 10 seconds, close the thru-hull waterintake valve to avoid filling the mufflerwith water. Crank for 10 seconds or untilthe engine starts. When the engine doesstart, stop the engine immediately andturn the switch to the OFF position.1. Open the seacock (if equipped).2. Open the fuel cock.3. Put the remote control shift lever in the

NEUTRAL position (Figure 1, (1)).Note: Safety equipment shouldmake it impossible to start theengine in any position other thanNEUTRAL.

(1)

0005890

Figure 11 – NEUTRAL (N)

4. Turn the master battery switch (ifequipped) to ON.

ENGINE OPERATION


5. Turn the key switch to the ON position(Figure 2, (2)). Ensure that theinstrument panel indicators light andthe alarm sounds. This indicates thatthe indicators and the alarm areworking correctly.

Note: The water temperaturealarm indicator and water in Sail-Drive indicator should not come onduring start-up.

OFF ON

(2)(1)

0005847

Figure 21 – OFF position2 – ON position

6. Push the start button. Release the startbutton when the engine has started.NOTICE: NEVER hold the startbutton for longer than 15 secondsor the starter motor will overheat.

7. The alarm should stop and the indicatorlamps should go out. NOTICE: If anyindicator fails to illuminate when thekey switch is in the ON position, seeyour authorized Yanmar Marinedealer or distributor for servicebefore operating the engine.

Starting the Engine Manually1. Open the seacock (if equipped).2. Open the fuel cock.3. Put the remote control shift lever in the

NEUTRAL position (Figure 3, (1)).Note: Safety equipment shouldmake it impossible to start theengine in any position other thanNEUTRAL.

(1)

(2)

0005888

Figure 31 – Starting Shaft2 – Starting Handle

4. Turn the master battery switch (ifequipped) to ON.

ENGINE OPERATION


5. Raise the decompression lever up. SeeCranking the Engine Manually on page26.

6. Slide the starter handle(Figure 3, (2)) on the starter shaft(Figure 3, (1)), align the groove andpin, and turn by hand.

7. Turn the handle vigorously. Whenengine rotation is rapid, return thedecompression handle to the RUNposition.

8. Remove the starter handle from thestarter shaft after the engine starts.

Restarting After Starting FailureBefore pushing the start button again, besure the engine has stopped completely.NEVER attempt to restart the engine whilethe engine is running. The pinion gear on thestarter motor will be damaged.NOTICE: NEVER hold the start button forlonger than 15 seconds or the startermotor will overheat.NOTICE: NEVER attempt to restart theengine if the engine has not stoppedcompletely. Pinion gear and startermotor damage will occur.Air Bleeding from the Fuel SystemAfter Starting FailureIf the engine does not start after severalattempts, there may be air in the fuel system.If air is in the fuel system, fuel cannot reachthe fuel injection pump. Bleed the air fromthe fuel system according to the followingsteps:1. Check the fuel tank level.2. Loosen the air vent bolt at the top of the

fuel / water separator. When fuel is freeof bubbles, retighten the air vent bolt.

3. Loosen the air vent bolts of the fuel filterand fuel injection pump.

4. Pump fuel with the fuel feed pump bymoving the lever on the left side of thefuel feed pump up and down.

5. Allow the fuel containing air bubbles toflow out of the air vent bolt holes.

6. When the fuel no longer contains airbubbles, tighten the air vent bolts.

7. Try starting the engine again.Starting at Low TemperaturesComply with local environmentalrequirements. Do not use starting aids.NOTICE: NEVER use an engine startingaid such as ether. Engine damage willresult. Using a starting aid may void thewarranty.To limit white smoke, run the engine at lowspeed and under moderate load until theengine reaches normal operatingtemperature. A light load on a cold engineprovides better combustion and fasterengine warm-up than no-load.Avoid running the engine at idling speed anylonger than necessary.After the Engine Has StartedAfter the engine has started, check thefollowing items at a low engine rpm.1. Check that the gauges, indicators and

alarm are normal.2. Check for any water, fuel, engine

coolant or engine oil leaks. If any leaksare found, shut down the engine andperform the necessary repairs.WARNING! NEVER check for a fuelleak with your hands. ALWAYS usea piece of wood or cardboard. Haveyour authorized Yanmar Marinedealer or distributor repair thedamage. Avoid skin contact with thehigh-pressure diesel fuel spraycaused by a fuel system leak suchas a broken fuel injection line. High-pressure fuel can penetrate yourskin and result in serious injury. Ifyou are exposed to high-pressurefuel spray, obtain prompt medicaltreatment.

ENGINE OPERATION


3. Check that the exhaust color, enginevibration and sound are normal.

4. When there are no problems, keep theengine at low speed with the boat stillstopped to distribute engine oil to allparts of the engine.

5. Check that water is being dischargedfrom the seawater outlet pipe.Operation with inadequate seawaterdischarge will damage the impeller ofthe seawater pump. If seawaterdischarge is too low, stop the engineimmediately. Identify the cause andrepair. NOTICE: The engine will seizeif it is operated when coolingseawater discharge is inadequateor if load is applied without anywarm-up operation.• Is the seacock open?• Is the inlet of the seacock on the hull

bottom clogged?• Is the seawater suction hose broken

or does the hose suck air because ofa loose clamp?

When operating the engine at low speed forlong periods of time, race the engine onceevery two hours. Race the engine with theclutch in NEUTRAL, accelerate from the lowspeed position to the high speed positionand repeat this process about five times.This cleans out carbon from the cylindersand the fuel injection valves.NOTICE: Neglecting to race the enginewill result in poor exhaust color andreduce engine performance.Periodically operate the engine nearmaximum speed while underway. This willgenerate higher exhaust temperatures,which will help clean out hard carbondeposits, maintain engine performance andprolong the life of the engine.For troubleshooting assistance, seeTroubleshooting After Starting on page59 or Troubleshooting Chart on page61.If necessary, see your authorized YanmarMarine dealer or distributor.

ENGINE OPERATION


THROTTLE AND SHIFTLEVER OPERATIONAcceleration and DecelerationNote: Direction of travel will vary dependingon installation location.Use the throttle handle to controlacceleration and deceleration. Move thehandle slowly.Shifting the EngineNOTICE: Shifting the marine gear whileoperating at high speed or not pushingthe handle fully into position (partialengagement) will result in damage tomarine gear parts and abnormal wear.1. Before using the marine gear, be sure

to move the throttle handle to a low idleposition (less than 1000 rpm). Move thethrottle handle slowly to a higher speedposition after completing clutchengagement.

2. NOTICE: NEVER shift the marinegear at high engine speed. Duringnormal operation, the marine gearshould only be shifted with theengine at idle. When moving thehandle between FORWARD(Figure 4, (1)) and REVERSE(Figure 4, (3)), bring the clutch toNEUTRAL (Figure 4, (2)) and pausebefore slowly shifting to the desiredposition. Do not shift abruptly fromFORWARD to REVERSE or vise versa.

FWD

REV

NEUTRALIPULLI

CLUTCH

(1)(2)

(3)

(4)

0005846

Figure 41 – FORWARD (FWD)2 – NEUTRAL (N)3 – REVERSE (REV)4 – Pull the lever to disengage the

clutch.

ENGINE OPERATION


PRECAUTIONS DURINGOPERATIONAlways check for problems during engineoperation.1. Is sufficient seawater being discharged

from the seawater outlet?If the discharge is too little, stop theengine immediately and correct theproblem.

2. Is the exhaust color normal?The continuous emission of blacksmoke indicates engine overloading.This shortens engine life and should beavoided.

3. Be aware of any abnormal vibration andunusual engine noises. NEVERoperate at speeds that produce violentvibrations. Depending on the hullstructure, engine and hull resonancemay become great at a certain speedrange. Avoid operating in this range.Stop the engine and inspect anyunusual engine noise.

4. Ensure that there are no warningindicators active. If an indicatoractivates during operation, lower theengine speed immediately, check theindicator and stop the engine forrepairs.

5. Check for any water, oil or fuel leaks.Check the engine room periodically.WARNING! NEVER check for a fuelleak with your hands. ALWAYS usea piece of wood or cardboard. Haveyour authorized Yanmar Marinedealer or distributor repair thedamage. Avoid skin contact with thehigh-pressure diesel fuel spraycaused by a fuel system leak suchas a broken fuel injection line. High-pressure fuel can penetrate yourskin and result in serious injury. Ifyou are exposed to high-pressurefuel spray, obtain prompt medicaltreatment.

6. Is there sufficient fuel in the tank?Replenish fuel in advance to avoidrunning out of fuel during operation.

7. When operating the engine at lowspeed for long periods of time, race theengine once every two hours. Race theengine with the clutch in NEUTRAL,accelerate from the low speed positionto the high speed position and repeatthis process about five times. Thiscleans out carbon from the cylindersand the fuel injection valves.

NOTICE: Never turn OFF the batteryswitch or spark the battery duringoperation. Damage to electrical partswill result.

ENGINE OPERATION


SHUTTING DOWN THEENGINENOTICE: NEVER stop the engineabruptly during operation. Yanmarrecommends that when shutting theengine down, allow the engine to run,without load, for 5 minutes. This willallow the engine components thatoperate at high temperatures, such asthe exhaust system, to cool slightlybefore the engine itself is shut down.1. Reduce the engine speed to low idle

and put the shift control lever inNEUTRAL.

2. Accelerate from low speed to highspeed and repeat five times. This willclean out the carbon from the cylindersand the fuel injection nozzles.

3. Allow the engine to run at low speed(approximately 1000 rpm) without loadfor five minutes.

4. With the key in the ON position, pull andhold the engine stop knob(Figure 5, (1)) until the engine hascome to a complete stop. After theengine has stopped, turn the key switchto OFF.

Note: Continue to hold the enginestop knob until the engine iscompletely stopped. If the knob isreleased before the engine hascompletely stopped, it may restart.

(3)

(1) (2)

0005842

Figure 51 – Engine Stop Knob2 – Bulkhead3 – Control Cable

5. Turn off the master battery switch (ifequipped).

6. Remove the key.7. Close the fuel cock.8. Close the seacock (if equipped).

NOTICE: Be sure to close theseacock. Neglecting to close theseacock could allow water to leakinto the boat and may cause it tosink.

Note: The engine may be stopped by raisingthe decompression lever, but avoid doing soexcept in times of emergency. Thedecompression lever releases compressionpressure in the cylinder which causes theengine to stop. However, fuel injection doesnot stop and fuel continues to be pumpedinto the cylinder. This can lead to abnormalcombustion when the engine is restartedand is not desirable.

ENGINE OPERATION


CHECKING THE ENGINEAFTER OPERATION• Check that the key switch is in the OFF

position and master battery switch (ifequipped) is turned to OFF.

• Fill the fuel tank. See Filling the FuelTank on page 22.

• Close the seacock (if equipped).NOTICE: Be sure to close the seacock.Neglecting to close the seacock couldallow water to leak into the boat andmay cause it to sink.

• If there is a risk of freezing, drain theseawater system. See Draining theCooling System on page 66.

• At temperatures below 0˚C (32˚F), drainseawater system and connect the engineheater (if equipped).

ENGINE OPERATION



ENGINE OPERATION


PERIODIC MAINTENANCEThis section of the Operation Manualdescribes the procedures for proper careand maintenance of the engine.Before performing any maintenanceprocedures within this section, read thefollowing safety information and review theSafety section on page 3.

SAFETY PRECAUTIONS ! WARNING

Crush HazardIf you need to transport anengine for repair, have ahelper assist you attach itto a hoist and load it on atruck.

The engine lifting eyes are engineered to liftthe weight of the marine engine only.ALWAYS use the engine lifting eyes whenlifting the engine.

Additional equipment is necessary to lift themarine engine and marine gear together.ALWAYS use lifting equipment withsufficient capacity to lift the marine engine.


! WARNINGWelding Hazard

• ALWAYS turn off the battery switch (ifequipped) or disconnect the negativebattery cable and the leads to thealternator when welding on theequipment.

• Connect the weld clamp to thecomponent to be welded and as close aspossible to the welding point.

• NEVER connect the weld clamp to theengine or in a manner which would allowcurrent to pass through a mountingbracket.

• When welding is completed, reconnectthe leads to the alternator prior toreconnecting the batteries.

Exhaust HazardALWAYS ensure that allconnections are tightened tospecifications after repair ismade to the exhaust system.All internal combustion

engines create carbon monoxide gas duringoperation and special precautions arerequired to avoid carbon monoxidepoisoning.

Shock HazardALWAYS turn off thebattery switch (ifequipped) or disconnectthe negative battery cablebefore servicing the

equipment.

ALWAYS keep the electrical connectorsand terminals clean. Check the electricalharnesses for cracks, abrasions, anddamaged or corroded connectors.

NOTICEAny part which is found defective as a resultof inspection, or any part whose measuredvalue does not satisfy the standard or limit,must be replaced.

Modifications may impair the engine’ssafety and performance characteristics andshorten the engine’s life. Any alterations tothis engine may void its warranty. Be sure touse Yanmar genuine replacement parts.

PERIODIC MAINTENANCE


PRECAUTIONSThe Importance of PeriodicMaintenanceEngine deterioration and wear occur inproportion to the length of time the enginehas been in service and the conditions theengine is subjected to during operation.Periodic maintenance prevents unexpecteddowntime, reduces the number of accidentsdue to poor engine performance and helpsextend the life of the engine.Performing PeriodicMaintenanceWARNING! NEVER block windows,vents or other means of ventilation if theengine is operating in an enclosed area.All internal combustion engines createcarbon monoxide gas during operation.Accumulation of this gas within anenclosure could cause illness or evendeath. Make sure that all connectionsare tightened to specifications after anyrepair is made to the exhaust system.Failure to comply could result in deathor serious injury.The Importance of Daily ChecksThe Periodic Maintenance Scheduleassumes that the daily checks areperformed on a regular basis. Make a habitof performing daily checks before the startof each operating day. See Daily Checks onpage 28.

Keep a Log of Engine Hours andDaily ChecksKeep a log of the number of hours the engineis operated each day and a log of the dailychecks performed. Also note the date, typeof repair (e.g., replaced alternator), andparts used for any service needed betweenthe periodic maintenance intervals. Periodicmaintenance intervals are every 50, 150,300 and 600 engine hours. Failure toperform periodic maintenance will shortenthe life of the engine.Yanmar Replacement PartsYanmar recommends that you use genuineYanmar parts when replacement parts areneeded. Genuine replacement parts helpensure long engine life.Tools RequiredBefore you start any periodic maintenanceprocedure, make sure you have the toolsyou need to perform all of the required tasks.Ask Your Authorized YanmarMarine Dealer or Distributor ForHelpOur professional service technicians havethe expertise and skills to help you with anymaintenance or service-related procedures.



Tightening FastenersUse the correct amount of torque when youtighten fasteners on the engine. Applyingexcessive torque may damage the fasteneror component and not enough torque maycause a leak or component failure. Whenworking on critical components that requirecalibrated tools, special procedures andspecific tightening sequences, consult withyour Yanmar distributor or dealer.

NOTICE: The tightening torque in theStandard Torque Chartshould be applied only tothe bolts with a “7” head(JIS strength classification:7T). Apply 60% torque to

bolts that are not listed. Apply 80%torque when tightened to aluminumalloy.

Bolt diameter x pitch(mm) M6x1.0 M8x1.25 M10x1.5 M12x1.75 M14x1.5 M16x1.5

TighteningTorque

N·m 11.0 ± 1.0 26.0 ± 3.0 50.0 ± 5.0 90.0 ± 10.0 140.0 ± 10.0 230.0 ± 10.0kgf·m 1.1 ± 0.1 2.7 ± 0.3 5.1 ± 0.5 9.2 ± 1.0 14.3 ± 1.0 23.5 ± 1.0lb-ft 8.0 ± 0.7 19.0 ± 2.1 37 ± 3.6 66.0 ± 7.2 103 ± 7.2 170 ± 7.2lb-in — — — — — —



EPA MAINTENANCEREQUIREMENTSTo maintain optimum engine performanceand compliance with the EnvironmentalProtection Agency (EPA) Regulations forEngines, it is essential that you follow thePeriodic Maintenance Schedule on page46 and the Periodic MaintenanceProcedures on page 49.EPA Requirements for USA andOther Applicable CountriesThe following are the requirements for theEPA. Unless these requirements are met,the exhaust gas emissions will not be withinthe limits specified by the EPA.The EPA emission regulation is applicableonly in the USA and other countries thathave adapted the EPA requirements in partor in whole. Determine and follow theemission regulations in the country whereyour engine will be operating.Conditions to EnsureCompliance with EPA EmissionStandardsThe 1GM10, 1GM10C and 1GM10V areEPA-certified engines.The following are the conditions that must bemet in order to ensure that the emissionsduring operation meet the EPA standards:• Ambient temperature: -20˚ to +40˚C

(-4˚ to +104˚F)• Relative humidity: 80% or lowerThe diesel fuel should be:• ASTM D975 No. 1-D or No. 2-D, or

equivalent (minimum of cetane No. 45)The lubricating oil should be:• Type API, Class CD or higher

Perform the inspections as outlined inPeriodic Maintenance Procedures on page49 and keep a record of the results.Pay particular attention to these importantpoints:• Replacing the engine oil• Replacing the engine oil filter• Replacing the fuel filter• Cleaning the intake silencer (air cleaner)Note: Inspections are divided into twosections in accordance with who isresponsible for performing the inspection:the user or the manufacturer.Inspection and MaintenanceSee Inspection and Maintenance of EPAEmission-Related Parts on page 48 for theEPA emission-related parts. Inspection andmaintenance procedures not shown in theInspection and Maintenance of EPAEmission-Related Parts on page 48section are covered in PeriodicMaintenance Schedule on page 46.This maintenance must be performed tokeep the emission values of your engine inthe standard values during the warrantyperiod. The warranty period is determinedby the age of the engine or the number ofhours of operation.



PERIODIC MAINTENANCESCHEDULEDaily and periodic maintenance is importantto keep the engine in good operatingcondition. The following is a summary ofmaintenance items by periodicmaintenance intervals. Periodicmaintenance intervals vary depending onengine application, loads, diesel fuel andengine oil, and are hard to establishdefinitively. The following should be treatedonly as a general guideline. CAUTION!Establish a periodic maintenance planaccording to the engine application andmake sure you perform the requiredperiodic maintenance at the intervalsindicated. Failure to follow theseguidelines will impair the engine’ssafety and performance characteristics,shorten the engine’s life and may affectthe warranty coverage on your engine.See your authorized Yanmar Marinedealer or distributor for assistancewhen checking items marked with a ●.



◯: Check or Clean ◊: Replace ●: Contact your authorized Yanmar Marine dealer or distributor

System Item

Periodic Maintenance IntervalBefore

StartingSee Daily

Checks onpage 28.

Initial 50Hours

Every50

HoursEvery150

Hours

Every250

Hoursor 1Year

Every1000

Hours or4 Years

Whole Visually inspecting the engineexterior ◯

Fuel System*

Inspecting the fuel level ◯ Draining the fuel tank ◯ ◯ Draining the fuel filter / waterseparator ◯ Replacing the fuel filter element ◊ Inspecting the fuel injection timing ●Inspecting the fuel injectionnozzle spray pattern* ●*

LubricatingSystem

Inspecting the oil levelEngine ◯ MarineGear ◯

Changing the oilEngine ◊ ◊ MarineGear ◊ ◊

Inspecting the function of the oilpressure warning lamp

◯ DuringOperation

Replacing the engine oil filterelement ◊ ◊

CoolingSystem

Inspecting the seawater outlet ◯ DuringOperation

Inspecting the seawater pumpimpeller ◯ ◊

Inspecting the zinc anode ◊

Air Intake andExhaustSystem

Cleaning the intake silencer (airfilter) ◯ Cleaning the exhaust / watermixing elbow ◯ Cleaning the breather pipe ◯ Inspecting the exhaust gascondition

◯ DuringOperation

ElectricalSystem

Inspecting the function of thebattery charge warning lamp ◯ Inspecting the battery electrolytelevel ◯ ◯ Checking and adjusting thealternator V-belt tension ◯ ◯ ◊

Checking the wiring connectors ◯

EngineCylinder Headand Block

Inspecting for fuel, oil or engineleaks

◯ AfterStarting

Tightening all major nuts andbolts ●Adjusting the intake / exhaustvalve clearances ◯ ●

MiscellaneousItems

Inspecting and adjusting thethrottle and shift control cables ◯ ● Adjusting the propeller shaftalignment ◯ ●

* For EPA requirements, see Inspection and Maintenance of EPA Emission-Related Parts on page 48.Note: These procedures are considered normal maintenance and are performed at theowner’s expense.



Inspection and Maintenance of EPA Emission-Related Parts• Marine diesel engines less than 37 kW (50 hp metric) are certified as EPA non-road

engines• Marine diesel engines greater than 37 kW (50 hp metric) are certified as EPA CI marine

enginesInspection and Maintenance of EPA Emission-Related Parts for Non-RoadMarine Engines

Parts IntervalClean fuel injection nozzle 1500 hoursCheck fuel injection nozzle pressure and spray pattern 3000 hoursCheck fuel injection pump adjustment 3000 hours

Note: The inspection and maintenance items shown above should be performed at yourYanmar Marine dealer or distributor.



PERIODIC MAINTENANCEPROCEDURESAfter Initial 50 Hours ofOperation

Perform the following maintenance after theinitial 50 hours of operation.• Draining the Fuel Tank• Draining the Fuel Filter / Water

Separator• Changing the Engine Oil• Replacing the Engine Oil Filter

Element• Changing the Marine Gear Oil• Checking and Adjusting the

Alternator V-Belt Tension• Inspecting and Adjusting the

Intake / Exhaust Valve Clearances• Inspecting and Adjusting the Throttle

and Shift Control Cables• Adjusting the Propeller Shaft

AlignmentDraining the Fuel TankWARNING! When you are draining thefuel tank to perform maintenance, put anapproved container under the openingto catch the fuel. NEVER use a shop ragto catch the fuel. Vapors from the rag areflammable and explosive. Wipe up anyspills immediately. Wear eye protection.The fuel system is under pressure andfuel could spray out when you removeany fuel system component.

1. Put a pan under the drain cock(Figure 1, (2)) to catch the fuel.

0004542

(3)

(1) (2)

Figure 11 – Sediment Bowl2 – Drain Cock3 – Fuel Line to Engine

Note: Optional fuel tank shown.Actual equipment may differ.

2. Open the drain cock and drain waterand sediment. Close the drain cockwhen the fuel is clean and free of water.

Draining the Fuel Filter / WaterSeparatorWARNING! When removing any fuelsystem component to performmaintenance (such as changing the fuelfilter), put an approved container underthe opening to catch the fuel. NEVERuse a shop rag to catch the fuel. Vaporsfrom the rag are flammable andexplosive. Wipe up any spillsimmediately. Wear eye protection. Thefuel system is under pressure and fuelcould spray out when removing any fuelsystem component.1. Close the fuel cock.2. Put a pan under the fuel / water

separator.3. Remove the fuel filter cover and drain

any water and dirt collected inside.4. Reassemble the fuel filter.



5. Purge air from the fuel system. See AirBleeding from the Fuel System AfterStarting Failure on page 34.

Changing the Engine OilThe engine oil in a new engine becomescontaminated from the initial break-in ofinternal parts. It is very important that theinitial oil replacement is performed asscheduled. This includes the replacement ofthe oil filter at this time.It is easiest and most effective to drain theengine oil after operation while the engine isstill warm. WARNING! If you must drainthe engine oil while it is still hot, stayclear of the hot engine oil to avoid beingburned. ALWAYS wear eye protection.1. Turn the engine OFF.2. NOTICE: Prevent dirt and debris

from contaminating engine oil.Carefully clean the dipstick and thesurrounding area before youremove the dipstick. Remove theengine oil dipstick. Attach the oil drainpump (if equipped) and pump out theoil. For easier draining, remove theengine oil fill cap.

3. Fill with new engine oil. See AddingEngine Oil on page 24. NOTICE:NEVER mix different types of engineoil. This may adversely affect thelubricating properties of the engineoil. NEVER overfill. Overfilling mayresult in white exhaust smoke,engine overspeed or internaldamage.

4. Perform a trial run and check for oilleaks.

5. Approximately 10 minutes afterstopping the engine, remove the oildipstick and check the oil level. Add oilas necessary.

Replacing the Engine Oil FilterElement1. Turn the engine off.2. Turn the engine oil filter (Figure 2)

counterclockwise with a wrench.

0004797

Figure 23. Remove the engine oil filter.4. Clean the face of the filter mounting

flange and apply a light coat of oil to thegasket of the new oil filter.

5. Install a new filter element and tightenby hand until the seal touches thehousing.

6. Turn filter an additional 3/4 turn with abox wrench. Tighten to 20 to 24 N·m(14 to 17 lb-ft.).


Changing the Marine Gear OilNote: Refer to the Operation Manualsupplied with your marine gear or sail-driveunit for service and maintenance details.During initial operation, the oil is quicklycontaminated due to the initial wear ofinternal parts. The lubricating oil musttherefore be replaced early.1. Remove the cap from the filler port and

attach an oil drain pump. Drain themarine gear oil.

2. Fill the marine gear with clean marinegear oil. See Marine Gear OilSpecifications on page 25.




4. After approximately 10 minutes, stopthe engine and check the oil level. Addoil if the level is too low.

Checking and Adjusting theAlternator V-Belt TensionInadequate V-belt tension will causereduced electrical power generation andincrease the wear on the belt. Too much V-belt tension can cause damage to thealternator bearing.NOTICE: NEVER get any oil on thebelt. Oil on the belt causes slipping andstretching. Replace the belt if it isdamaged.WARNING! Perform this check with theengine off and the key removed to avoidcontact with moving parts.1. Inspect the V-belt for any damage or

wear and replace it if necessary.2. Find a location on the belt that is in the

middle of the two pulleys.3. Check the tension by pushing on the

middle of the belt.With proper tension, the belt shoulddeflect 8 to 10 mm (approximately3/8 in.).

4. Loosen the alternator bolt and move thealternator to adjust the V-belt tension,as required.

5. Hold the alternator in position andtighten the bolt.

6. Recheck tension by repeating step 3.Inspecting and Adjusting theIntake / Exhaust Valve ClearancesProper adjustment is necessary to maintainthe correct timing for opening and closingthe valves. Improper adjustment will causethe engine to run noisily, resulting in poorengine performance and engine damage.See your authorized Yanmar Marine dealeror distributor to adjust the intake / exhaustvalve clearances.

Inspecting and Adjusting theThrottle and Shift Control CablesVarious control levers and cables on theengine and marine gear are connected tothe throttle and shift control console. Theentire assembly loosens and stretches withprolonged use and initial break-inmovements. It is dangerous to operateunder these conditions. The throttle andshift control console should always bemaintained in proper adjustment and shouldbe inspected periodically.NOTICE: The high speed stop bolt on theengine governor is set at the factory. Donot adjust. Adjustments to this bolt willvoid the engine warranty.Adjusting the Governor Control Cable1. With the engine off, move the throttle

lever to the high speed position.2. Check the governor control lever on the

engine and verify that the lever ismaking contact with the high speedstop bolt.

3. Move the throttle lever to the low speedposition.

4. Verify that the governor control lever onthe engine is in contact with the lowspeed stop bolt.

If adjustment is needed, loosen the bracketthat holds the control cable and adjust itsposition as necessary. Adjust the highspeed position first and then the low speedposition. NOTICE: The high speed stopbolt on the engine governor is set at thefactory. Do not adjust. Adjustments tothis bolt will void the engine warranty.



Adjusting the Marine Gear ControlCable1. Check that the control lever moves to

the correct position when the remotecontrol cable handle is moved to theNEUTRAL, FORWARD and REVERSEpositions.

2. Use the NEUTRAL position as thestandard for adjustment. When there isdeviation, loosen the bracket for theshift control cable on the marine gearand adjust its position as necessary.

Adjusting the Propeller ShaftAlignmentThe flexible engine mounts are compressedslightly during initial engine operation andmay cause misalignment between theengine and the propeller shaft.After the first 50 hours of operation, thealignment should be checked andreadjusted if necessary. This is considerednormal maintenance and the adjustmentrequires specialized knowledge andtechniques. Consult your authorizedYanmar Marine dealer or distributor.

Every 50 Hours of OperationAfter you complete the initial 50-hourmaintenance procedures, perform thefollowing procedures every 50 hours ofoperation.• Draining the Fuel Filter / Water

SeparatorDraining the Fuel Filter / WaterSeparatorWARNING! When you remove any fuelsystem component to performmaintenance (such as changing the fuelfilter), put an approved container underthe opening to catch the fuel. NEVERuse a shop rag to catch the fuel. Vaporsfrom the rag are flammable andexplosive. Wipe up any spillsimmediately. Wear eye protection. Thefuel system is under pressure and fuelcould spray out when you remove anyfuel system component.See Draining the Fuel Filter / WaterSeparator on page 49.



Every 150 Hours of OperationPerform the following maintenance every150 hours of operation.• Changing the Engine Oil• Changing the Marine Gear Oil• Inspecting the Battery Electrolyte

LevelChanging the Engine OilSee Changing the Engine Oil on page 50.Changing the Marine Gear OilRefer to the Operation Manual supplied withyour marine gear or sail-drive unit for serviceand maintenance details.Inspecting the Battery ElectrolyteLevel (Serviceable Batteries Only)WARNING! Batteries contain sulfuricacid. NEVER allow battery fluid to comein contact with clothing, skin or eyes.Severe burns could result. ALWAYSwear safety goggles and protectiveclothing when servicing the battery. Ifbattery fluid contacts the eyes and / orskin, immediately flush the affected areawith a large amount of clean water andobtain prompt medical treatment.NOTICE: Battery fluid tends toevaporate in high temperatures,especially in summer. In suchconditions, inspect the battery earlierthan specified.1. Make sure the engine is off and the key

is removed.2. Turn the master battery switch to OFF

(if equipped) or disconnect the negative(-) battery cable.

3. Remove the plugs and check theelectrolyte level in all cells. NOTICE:NEVER attempt to remove thecovers or fill a maintenance-freebattery.

4. If the electrolyte level is lower than theminimum fill level (Figure 3, (1)), fillwith distilled water (Figure 3, (2))(available locally) to the upper level(Figure 3, (3)) of the battery.

UPPER LEVEL LOWER LEVEL

(2)

(3)

(1)

0004566

Figure 31 – Lower Level2 – Battery Fluid3 – Upper Level

If the engine cannot be started or the rpmdoes not rise to rated output, measure thespecific gravity of the battery with ahydrometer. The specific gravity of a fullycharged battery is 1.27 or more at 20°C(68°F). Specific gravity of 1.24 or lowerrequires battery charging.If charging the battery does not raise thespecific gravity, replace the battery.Note: The maximum fill level isapproximately 10 to 15 mm(3/8 to 9/16 in.) above the plates.



NOTICE: The standard alternator withthe recommended battery is designedto produce electrical power for regularengine operations only. If power isbeing used for onboard lights and othersystems, the charging system may beinadequate. Consult your authorizedYanmar Marine dealer or distributor.

Every 250 Hours of OperationPerform the following maintenance every250 hours or 1 year of operation.• Draining the Fuel Tank• Replacing the Fuel Filter Element• Inspecting the Fuel Injection Nozzle

Spray Pattern• Replacing the Engine Oil Filter

Element• Inspecting the Seawater Pump

Impeller• Inspecting the Zinc Anode• Cleaning the Intake Silencer (Air

Filter)• Cleaning the Exhaust / Water Mixing

Elbow• Cleaning the Breather Pipe• Checking and Adjusting the

Alternator V-Belt Tension• Checking the Wiring Connectors• Inspecting and Adjusting the Intake /

Exhaust Valve Clearances• Inspecting and Adjusting the Throttle

and Shift Control CablesDraining the Fuel TankSee Draining the Fuel Tank on page 49.



Replacing the Fuel Filter ElementWARNING! When you remove any fuelsystem component to performmaintenance (such as changing the fuelfilter), put an approved container underthe opening to catch the fuel. NEVERuse a shop rag to catch the fuel. Vaporsfrom the rag are flammable andexplosive. Wipe up any spillsimmediately. Wear eye protection. Thefuel system is under pressure and fuelcould spray out when you remove anyfuel system component.When there is dirt in the fuel, the filterbecomes clogged and the fuel will not floweasily. Check and replace the element.1. Close the fuel cock of the fuel tank.2. Place an approved container under the

fuel filter.3. Loosen the retaining ring

(Figure 4, (2)) counterclockwise with afilter wrench.

Note: When removing the fuelfilter, hold the bottom of the fuelfilter with a cloth to prevent the fuelfrom spilling. Wipe up any spilledfuel immediately.

(1)

0004804

(2)

Figure 41 – Fuel Filter Housing2 – Retaining Ring

4. Remove the fuel filter housing(Figure 4, (1)) and remove theelement. Replace the element with anew one.

5. Apply a thin film of clean diesel fuel tothe sealing surface of the new filtergasket.

6. Clean the inside of the fuel filter housingthoroughly, install the O-ring and hand-tighten the retainer ring. Use a filterwrench and tighten to 12 N·m(8.8 lb-ft).

7. Air will enter the fuel system when thefilter is disassembled and should bevented. Bleed the fuel system. See AirBleeding from the Fuel System AfterStarting Failure on page 34. Dispose ofwaste properly.

Inspecting the Fuel Injection NozzleSpray PatternSee your authorized Yanmar Marine dealeror distributor.Replacing the Engine Oil FilterElementSee Replacing the Engine Oil FilterElement on page 50.Inspecting the Seawater PumpImpellerNote: The seawater pump impeller must bereplaced every 1000 hours or every fouryears, even if it is not damaged.The seawater pump impeller will wear anddeteriorate with prolonged use. This willreduce its capacity to move cooling waterthrough the engine. Inspect the seawaterpump impeller at its scheduled maintenanceinterval or sooner if the discharge volume ofseawater is diminished. Refer to Figure 5when performing this inspection.



1. Loosen the cover bolts and remove thepump side cover (Figure 5, (7)).

(1)

(2)

(3)

(4)

(5)(6)

(7) 0005887

Figure 51 – Cam2 – Inlet3 – Outlet4 – Seawater Pump Body5 – Impeller6 – Gasket7 – Side Cover

2. Inspect the internal components of thepump.

• Inspect the impeller blades(Figure 5, (5)). Look for nicks, cracks andany evidence of damage. This includesexcessive scratches and marring of thesurface of the impeller blades.

• Inspect the condition of the pump body(Figure 5, (4)). Look for corrosion andevidence of structural damage to anysurface that is in contact with the impellerblades. Make sure the walls of the pumpchamber are smooth and free of gougesand corrosive pitting.

If no damage is found, reassemble the sidecover.

Inspect the drain pipe under the pumpduring operation. If excessive amounts ofwater leak continuously, the oil seal needsto be replaced. See your authorized YanmarMarine dealer or distributor.NOTICE: During normal operation, thepump impeller rotates in acounterclockwise direction(Figure 6, (1)). Use caution wheninstalling the impeller to ensure that allthe blades of the impeller are set in theproper direction. When turning theengine over manually, do not reversethe normal direction of engine rotationor the blades of the seawater pumpimpeller (Figure 6, (3)) may be damaged.

(4)

(1)

(2)

(3)0005889

Figure 61 – Direction of Rotation2 – Outlet3 – Impeller4 – Inlet



Inspecting the Zinc AnodeThe inspection intervals and replacementschedule for the zinc anode are determinedby seawater characteristics and youroperating environment. Inspect the zincanode a minimum of every 300 hours ofoperation, but shorten this interval if youroperating conditions show a highercorrosion rate.Replace the zinc anode when its surfacearea has been reduced to less than half ofits original size.If neglected, seawater will begin to react withthe internal surface areas of the enginecooling system. This will lead to seawaterleaks, internal corrosion and eventual failureof engine components.The zinc anode is located on the inside ofthe anode plug and is labeled “AnticorrosionZinc.”Cleaning the Intake Silencer (AirCleaner)1. Open the clamps that secure the air

cleaner cover.2. Remove the air filter element.3. Wash the air filter element with a mild

neutral detergent and water.4. Allow the element to dry completely.5. Remove any debris from the filter

housing and cover.6. Reinstall the filter element and secure

the cover with the clamps.

Cleaning the Exhaust / Water MixingElbowThe mixing elbow is attached to the exhaustmanifold. The exhaust gas is mixed withseawater in the mixing elbow.1. Remove the mixing elbow.2. Clean dirt and scale out of the exhaust

and seawater passages.3. If the mixing elbow is damaged, repair

or replace it. See your authorizedYanmar Marine dealer or distributor.

4. Inspect the gasket and replace ifnecessary.

5. Replace the mixing elbow with a newone every 500 hours or two years,whichever comes first, even if nodamage is found.

Cleaning the Breather PipeSee your authorized Yanmar Marine dealeror distributor.Checking and Adjusting theAlternator V-Belt TensionSee Checking and Adjusting the AlternatorV-Belt Tension on page 51.Checking the Wiring ConnectorsSee your authorized Yanmar Marine dealeror distributor.Inspecting and Adjusting theIntake / Exhaust Valve ClearancesSee Inspecting and Adjusting theIntake / Exhaust Valve Clearances on page51. See your authorized Yanmar Marinedealer or distributor.Inspecting and Adjusting theThrottle and Shift Control CablesSee Inspecting and Adjusting the Throttleand Shift Control Cables on page 51.



Every 1000 Hours of OperationPerform the following maintenance every1000 hours or every 4 years of operation,whichever comes first.• Inspecting the Fuel Injection Timing• Inspecting the Seawater Pump

Impeller• Checking and Adjusting the

Alternator V-Belt Tension• Tightening All Major Nuts and Bolts• Adjusting the Propeller Shaft

AlignmentInspecting the Fuel Injection TimingSee your authorized Yanmar Marine dealeror distributor.Inspecting the Seawater PumpImpellerSee Inspecting the Seawater PumpImpeller on page 55.Checking and Adjusting theAlternator V-Belt TensionSee Checking and Adjusting the AlternatorV-Belt Tension on page 51.Tightening All Major Nuts and BoltsSee Tightening Fasteners on page 44 or seeyour authorized Yanmar Marine dealer ordistributor.Adjusting the Propeller ShaftAlignmentSee Adjusting the Propeller ShaftAlignment on page 52. See your authorizedYanmar Marine dealer or distributor.



TROUBLESHOOTINGBefore performing any troubleshootingprocedures within this section, review theSafety section on page 3.If a problem occurs, stop the engineimmediately. Refer to the SYMPTOMcolumn in the Troubleshooting Chart toidentify the problem.

TROUBLESHOOTINGAFTER STARTINGJust after the engine has started, check thefollowing items at a low engine speed:Is sufficient water being dischargedfrom the seawater outlet pipe?If the discharge is low, stop the engineimmediately. Identify the cause and repair.Is the exhaust color normal?The continuous emission of black exhaustsmoke indicates engine overloading. Thisshortens the engine’s life and should beavoided.When operating the engine at low speed forlong periods of time, race the engine onceevery two hours. Race the engine with theclutch in NEUTRAL, accelerate from the lowspeed position to the high speed positionand repeat this process about five times.This is done to clean out carbon from thecylinders and the fuel injection valves.NOTICE: Neglecting to race the enginewill result in poor exhaust color andreduce engine performance.Periodically operate the engine nearmaximum speed while under way. This willgenerate higher exhaust temperatures,which will help clean out hard carbondeposits, maintain engine performance andprolong the life of the engine.


Are there abnormal vibrations or noise?Depending on the hull structure, engine andhull resonance may suddenly increase atcertain engine speed ranges, causing heavyvibrations. Avoid operation in this speedrange. If any abnormal sounds are heard,stop the engine and inspect for the cause.Alarm sounds during operation.If the alarm sounds during operation, lowerthe engine speed immediately, check thewarning lamps and stop the engine forrepairs.Is there water, oil or fuel leakage? Arethere any loose bolts or connections?Check the engine room daily for any leaksor loose connections.Is there sufficient fuel in the fuel tank?Refill the fuel tank in advance to avoidrunning out of fuel. If the tank runs out of fuel,bleed the fuel system.See Air Bleeding fromthe Fuel System After Starting Failure onpage 34.

TROUBLESHOOTINGINFORMATIONIf the engine does not operate properly, referto the Troubleshooting Chart on page 61or see your authorized Yanmar Marinedealer or distributor.Supply the authorized Yanmar Marinedealer or distributor with the followinginformation:• Model name and serial number of your

engine• Boat model, hull material, size (tons)• Use, type of boating, number of hours run• Total number of operation hours (refer to

hour meter), age of boat• The operating conditions when the

problem occurs:• Engine rpm• Color of exhaust smoke• Type of diesel fuel• Type of engine oil• Any abnormal noises or vibration• Operating environment such as high

altitude or extreme ambienttemperatures

• Engine maintenance history andprevious problems

• Other factors that contribute to theproblem

TROUBLESHOOTING


TROUBLESHOOTING CHARTSymptom Probable Cause Measure Reference

Indicators light on theinstrument panel andalarm sounds duringoperation.

Shift to low speed operation immediately, and check which indicator has come on.Stop the engine and inspect. If no abnormality is identified and there is no problemwith operation, return to port at lowest speed and see your authorized YanmarMarine dealer or distributor.

• Engine oil lowpressure alarmindicator lights

Engine oil level is low. Check engine oil level.Add or replace.

See Checkingthe Engine Oil onpage 24.

Engine oil filter is clogged. Replace engine oil filter.Replace engine oil.

See Replacingthe Engine OilFilter Element onpage 50.

• Water in sail-drive sealindicator lights

Rubber sail-drive seal is broken. See your authorizedYanmar Marine dealer ordistributor.

—

Coolant HighTemperature Alarmlights

Insufficient seawater dischargecausing temperature to rise

Check seawater system. —

Contamination inside coolingsystem

See your authorizedYanmar Marine dealer ordistributor.

—

Faulty warning devices Do not operate the engine if alarm devices are not repaired. Serious accidents mayresult if abnormalities are not identified because of faulty indicators or alarm.

Indicators do not light:• When key is turned on• When any trouble

occurs (oil pressure,e.g.)

No electrical current available.Circuit broken or lamp burnedout.

See your authorizedYanmar Marine dealer ordistributor. —

One of the indicatorsdoes not go out.

Sensor switch is faulty. See your authorizedYanmar Marine dealer ordistributor.

—

Battery low chargeindicator does not go outduring operation.

V-belt is loose or broken. Replace V-belt or adjusttension.

See Checkingand Adjusting theAlternator V-BeltTension on page51.

Battery is defective. Check battery fluid leveland specific gravity, orreplace battery.

See Inspectingthe BatteryElectrolyte Level(ServiceableBatteries Only)on page 53.

Alternator power generationfailure.


—

TROUBLESHOOTING


Symptom Probable Cause Measure ReferenceStarting Failures:Starter turns but enginedoes not start.

No fuel Add fuel. Bleed fuelsystem. Ensure that fuelshut-off valve is open.

See Filling theFuel Tank onpage 22.

Fuel filter is clogged. Replace filter element. See Replacingthe Fuel FilterElement on page55.

Improper fuel Replace withrecommended fuel.

See Diesel FuelSpecifications onpage 19.

Problem with fuel injection See your authorizedYanmar Marine dealer ordistributor.

—

Compression leakage fromintake / exhaust valve


—

Starter does not turn orturns slowly (engine canbe turned manually).

Faulty clutch position Shift to NEUTRAL andstart.

See RestartingAfter StartingFailure on page34.

Insufficient battery charge Check fluid level.Recharge. Replace.


Cable terminal contact failure Remove corrosion fromterminals. Tightenbattery cables.


Faulty safety switch device See your authorizedYanmar Marine dealer ordistributor.

—

Faulty starter switch See your authorizedYanmar Marine dealer ordistributor.

—

Power lacking becauseaccessory drive is engaged


—

Engine cannot be turnedmanually.

Internal parts seized See your authorizedYanmar Marine dealer ordistributor.

—

TROUBLESHOOTING


Symptom Probable Cause Measure ReferenceAbnormal Exhaust Color:• Black smoke Engine is overloaded. See your authorized

Yanmar Marine dealer ordistributor.

—

Improper propeller matching See your authorizedYanmar Marine dealer ordistributor.

—

Dirty intake silencer (air cleaner) Clean element. See Cleaning theIntake Silencer(Air Cleaner) onpage 57.

Improper fuel Replace withrecommended fuel.


Faulty spraying of fuel injector See your authorizedYanmar Marine dealer ordistributor.

—

Incorrect intake / exhaust valveclearance


—

• White smoke Improper fuel Replace withrecommended fuel.


Faulty spraying of fuel injector See your authorizedYanmar Marine dealer ordistributor.

—

Fuel injection timing off See your authorizedYanmar Marine dealer ordistributor.

—

Engine burning oil (excessiveconsumption)


—

TROUBLESHOOTING



TROUBLESHOOTING


LONG-TERM STORAGEBefore performing any storage procedureswithin this section, review the Safety sectionon page 3.If the engine will not be used for an extendedperiod of time, special measures should betaken to protect the cooling system, fuelsystem and combustion chamber fromcorrosion and the exterior from rusting.The engine can normally stand idle for up tosix months. If it remains unused for longerthan this, please contact your authorizedYanmar Marine dealer or distributor.

PREPARE ENGINE FORLONG-TERM STORAGENOTICE: NEVER drain closed coolingsystem for long-term storage.Antifreeze must be used to avoidfreezing and damaging of components.Antifreeze will prevent rusting duringlong-term storage.Note: If the engine is close to a periodicmaintenance interval, perform thosemaintenance procedures before putting theengine into long-term storage.1. Wipe off any dust or oil from the outside

of the engine.2. Drain any water from fuel filters.3. Drain the fuel tank completely or fill the

tank to prevent condensation.4. Drain the cooling system. (See Draining

the Cooling System on page 66.)5. Grease the exposed areas and joints of

the remote control cables and thebearings of the throttle and shift controlhandle.

6. Seal the intake silencer, exhaust pipe,etc., to prevent moisture orcontamination from entering engine.

7. Completely drain the bilge in the hullbottom.

8. Waterproof the engine room to preventrain or seawater from entering.

9. Charge the battery once a month tocompensate for the battery’s self-discharge.


10. Remove the key from the key switchand cover the key switch with themoisture cap (if equipped).

DRAINING THE COOLINGSYSTEMIn cold temperatures or before long-termstorage, be sure to drain the seawater fromthe cooling system.1. Put a pan under the seawater drain

cocks.2. Loosen the drain cock at the side of the

thermostat cover and drain the waterfrom the inside.

3. Loosen the three bolts holding the sidecover (Figure 1, (7)) of the seawaterpump. Remove the cover and drain theseawater from the pump body(Figure 1, (4)). Reinstall the cover andretighten the bolts when finished.

(1)

(2)

(3)

(4)

(5)(6)

(7) 0005887

Figure 11 – Cam2 – Inlet3 – Outlet4 – Seawater Pump Body5 – Impeller6 – Gasket7 – Side Cover

4. Close the drain cock.

LONG-TERM STORAGE


SPECIFICATIONSPRINCIPAL ENGINE SPECIFICATIONS1GM10 Engine Specifications

Type Vertical 4-cycle water-cooled diesel engineCombustion System Swirl pre-combustion chamberNumber of Cylinders 1Bore and Stroke 75 mm x 72 mm (2.95 in. x 2.83 in.)Displacement 0.318 L (19.4 cu. in.)

ContinuousRating Output

Output atCrankshaft /Engine Speed

5.9 kW (8 hp metric) / 3400 rpm*

Brake MeanEffectivePressure

6.66 kg/cm² (94.73 psi)

Piston Speed 8.16 m / sec. (26.77 ft / sec.)

MaximumRating Output


6.7 kW (9 hp metric) / 3600 rpm*6.6 kW (9 hp metric) / 3600 rpm**


7.07 kg/cm² (100.56 psi)

Piston Speed 8.64 m / sec. (28.35 ft / sec.)Compression Ratio 23.0 : 1Fuel Injection Timing (BTDC) 15° ± 1°Fuel Injection Pressure 170 ± 5 kg/cm² (2347- 2489 psi)Main Power Take Off At flywheel endFront Power Take Off At crankshaft V-pulley end

Direction ofRotation

Crankshaft Counterclockwise viewed from sternPropeller Shaft(Ahead) Clockwise viewed from stern

Cooling System Direct seawater cooling (Rubber impeller water pump)Lubrication System Complete enclosed forced lubrication system

* Rating Condition: Temperature of fuel: 25˚C at fuel pump inlet; ISO 3046-1** Rating Condition: Temperature of fuel: 40˚C at fuel pump inlet; ISO 8665


Starting SystemType Electric and manualStarting Motor 12 VDC, 1.0 kW (12 VDC, 1.4 hp metric)AC Generator 12V, 35A

Marine GearSystem

Model KM2PType Mechanical cone clutch with single stage for both ahead and astern

ReductionRatio

Forward 2.21 : 1 2.62 : 1 3.22 : 1Reverse 3.06 : 1 3.06 : 1 3.06 : 1Forward 1540 rpm 1298 rpm 1055 rpmReverse 1113 rpm 1113 rpm 1113 rpm

Lubricating OilCapacity 0.3 L (0.317 qt)

Weight 10.3 kg (22.71 lb)

DimensionsOverall Length 554 mm (21.81 in.)Overall Width 410 mm (16.14 in.)Overall Height 485 mm (19.09 in.)

EngineLubricating OilCapacity (8°Rake Angle)

Total 1.3 L (1.373 qt)

Effective 0.6 L (0.634 qt)

Engine Weight with Marine Gear 76 kg (167 lb)

Note: Density of fuel: 0.842g/cm3 at 15˚C. Fuel temperature at the inlet of the fuel injectionpump.1 hp metric = 0.7355 kW

SPECIFICATIONS


1GM10C Engine SpecificationsType Vertical 4-cycle water-cooled diesel engineCombustionSystem Swirl pre-combustion chamber

Number ofCylinders 1

Bore andStroke 75 mm x 72 mm (2.95 in. x 2.83 in.)

Displacement 0.318 L (19.4 cu. in.)





6.66 kg/cm² (94.73 psi)






7.07 kg/cm² (100.56 psi)

Piston Speed 8.64 m / sec. (28.35 ft / sec.)Compression Ratio 23.0 : 1Fuel Injection Timing (BTDC) 15° ± 1°Fuel Injection Pressure 170 ± 5 kg/cm² (2347-2489 psi)Main Power Take Off At flywheel endFront Power Take Off At crankshaft V-pulley end




StartingSystem

Type Electric and manualStarting Motor 12 VDC, 1.0 kW (12 VDC, 1.4 hp metric)AC Generator 12V, 35A

Marine GearSystem

Model SD20Type Sail-Drive unit, dog-type clutch with spiral gearReductionRatio

Forward 2.64 : 1Reverse 2.64 : 1

PropellerSpeed

Forward 1290 rpmReverse 1290 rpm


SPECIFICATIONS


DimensionsOverall Length 412 mm (16.22 in. )Overall Width 410 mm (16.14 in.)Overall Height 485 mm (19.09 in.)

EngineLubricating OilCapacity (8°Rake Angle)

Total 1.3 L (1.373 qt)

Effective 0.6 L (0.634 qt)

Engine Weight with Sail-Drive 104 kg (229 lb)


SPECIFICATIONS


1GM10V Engine SpecificationsType Vertical 4-cycle water-cooled diesel engineCombustionSystem Swirl pre-combustion chamber

Number ofCylinders 1

Bore andStroke 75 mm x 72 mm (2.95 in. x 2.83 in.)

Displacement 0.318 L (19.4 cu. in.)




Break MeanEffectivePressure

6.66 kg/cm² (94.73 psi)





Break MeanEffectivePressure

7.07 kg/cm² (100.56 psi)

Piston Speed 8.64 m / sec. (28.35 ft / sec.)Compression Ratio 23.0 : 1Fuel Injection Timing (BTDC) 15° ± 1°Fuel Injection Pressure 170 ± 5 kg / cm² (2347-2489 psi)Main Power Take Off At flywheel endFront Power Take Off At crankshaft V-pulley end




StartingSystem

Type Electric and manualStarting Motor 12 VDC, 1.0 kW (12 VDC, 1.4 hp metric)AC Generator 12V, 35A


SPECIFICATIONS


Marine GearSystem

Model KM3V

Type V-Drive, Mechanical cone clutch with single stage for both ahead andastern (15°)

ReductionRatio

Forward 2.36 : 1Reverse 3.16 : 1

PropellerSpeed DIN6270A Rating

Forward 1441 rpmReverse 1076 rpm

Lubricating Oil Capacity 0.8 L (0.845 qt)Weight 19.5 kg (43.0 lb)

DimensionsOverall Length 680 mm (26.77 in.)Overall Width 450 mm (17.71 in.)Overall Height 554 mm (21.81 in.)

Lubricating OilCapacity (8°Rake Angle)

Total 1.3 L (1.373 qt)Effective 0.6 L (0.634 qt)

Engine Weight with Marine Gear 90 kg (198 lb)


SPECIFICATIONS


SYSTEM DIAGRAMSPIPING DIAGRAMS

NotationScrew Joint (Union)Spherical Pipe JointDrilled HoleCooling Seawater PipingLubricating Oil PipingFuel Oil Piping

STP Steel PipeRH Rubber HoseVH Vinyl Pipe


1GM10 Piping Diagram

0005

993

19

20

Figure 1

SYSTEM DIAGRAMS


NotationFuel PumpEngine Oil PipeCooling Water PipeDrilled Hole

Spherical Pipe JointScrew JointBayonet Joint

CockSTP Steel PipeRH Rubber HoseVH Vinyl Pipe

Key Description1 Engine Oil Pressure Adjusting Valve2 Oil Pressure Switch3 Fuel Injection Nozzle4 Fuel Return Pipe5 To Main Bearing6 To Main Bearing7 To Oil Pan8 To Valve Rocker Arm9 Cooling Water Drain

10 Exhaust Gas11 Cooling Water12 Mixing Elbow13 Fuel Inlet14 Fuel Feed Pump15 Fuel Filter16 Exhaust Gas17 Cooling Water18 Thermostat19 Seawater Inlet20 Seawater Pump21 Fuel Filter22 Engine Oil Filter (Inlet Side)23 Engine Oil Pump24 Engine Oil Filter (Outlet Side)

SYSTEM DIAGRAMS


WIRING DIAGRAMS1GM10 Series A-Type Instrument Panel

0005

995

Figure 2

SYSTEM DIAGRAMS


Color CodingR RedW WhiteB BlackO Orange

L/B Blue/BlackW/L White/BlueY/W Yellow/WhiteW/R White/RedL/R Blue/RedW/B White/BlackR/B Red/Black

Note: A + B + C < 2.5 m → 20 mm2(Cross sectional area)A + B + C < 5 m → 40 mm2(Cross sectional area)

Key Description1 Battery2 Battery Switch3 Starter Motor4 Alternator5 Not Used6 Cooling Water Temperature Switch7 Engine Oil Pressure Switch8 Tachometer Sender9 Sail-Drive Connector (Rubber Seal

Switch)10 Tachometer11 Buzzer12 Rubber Seal Lamp (Sail-Drive)13 Engine Oil Pressure Lamp14 Cooling Water Temperature Lamp15 Charge Lamp16 Push Button Switch17 Key Switch18 Light Switch19 Not Used (Except 1GM10)20 Fuse21 Extension Cable 3 m (Standard). The

total length extension cable must beless than 6 m.

SYSTEM DIAGRAMS


1GM10 Series B-Type Instrument Panel

0005

994

Figure 3

SYSTEM DIAGRAMS


Color CodingR RedW WhiteB BlackO Orange

L/B Blue/BlackW/L White/BlueY/W Yellow/WhiteW/R White/RedL/R Blue/RedW/B White/BlackR/B Red/Black

Note: A + B + C < 2.5 m → 20 mm2(Cross sectional area)A + B + C < 5 m → 40 mm2(Cross sectional area)

Key Description1 Battery2 Battery Switch3 Starter Motor4 Alternator5 Not Used6 Cooling Water Temperature Switch7 Engine Oil Pressure Switch8 Spare Connector9 Spare Connector

10 Extension Cable 3 m (Standard). Thetotal length extension cable must beless than 6 m.

11 Buzzer12 Engine Oil Pressure Lamp13 Cooling Water Temperature Lamp14 Charge Lamp15 Push Button Switch16 Key Switch17 Not Used (Except 1GM10)18 Fuse

SYSTEM DIAGRAMS



SYSTEM DIAGRAMS


EMISSION SYSTEMWARRANTY

NON-ROAD EMISSIONSYSTEM WARRANTYYanmar Co., Ltd. LimitedEmission Control SystemWarranty - USA OnlyYour Warranty Rights andObligations:Note: Please refer to Yanmar’s LimitedWarranty Handbook for a description of thenormal (non-EPA) warranty.

CaliforniaThe California Air Resources Board(CARB), the Environmental ProtectionAgency (EPA) and Yanmar Co., Ltd.hereafter referred to as Yanmar, are pleasedto explain the emission control systemwarranty on your compression-ignitionengine. In California, model year 2000 orlater off-road compression-ignition enginesmust be designed, built and equipped tomeet the state’s stringent anti-smogstandards. In all states, 1998 and later non-road compression-ignition engines must bedesigned, built and equipped to meet theUnited States EPA emissions standards.Yanmar warrants the emission controlsystem on your engine for the periods of timelisted below provided there has been noabuse, neglect or improper maintenance ofyour engine.

Your emission control system may includeparts such as the fuel injection system andthe air induction system.Where a warrantable condition exists,Yanmar will repair your non-roadcompression-ignition engine at no charge toyou including diagnosis, parts and labor.Manufacturer’s Warranty Period:The model year 1998 or later certified andlabeled non-road compression-ignitionengines are warranted for the periods listedbelow. If any emission-related part on yourengine is found to be defective during theapplicable warranty period, the part will bereplaced by Yanmar.

Engines rated at orabove 19 kW ≤ andless than < 37 kW(25.5 hp ≤ and lessthan < 49.6 hp)

The warranty period isfive (5) years or 3,000hours of use,whichever occurs first.In the absence of adevice to measure thehours of use, theengine has a warrantyperiod of five (5) years.

Engines rated under19 kW >(25.5 hp >)

The warranty period istwo (2) years or 1,500hours of use,whichever occurs first.In the absence of adevice to measure thehours of use, theengine has a warrantyperiod of two (2) years.


Warranty Coverage:This warranty is transferable to eachsubsequent purchaser for the duration of thewarranty period. Repair or replacement ofany warranted part will be performed at anauthorized Yanmar Marine engine dealer ordistributor.Warranted parts not scheduled forreplacement as required maintenance in theOperation Manual shall be warranted for thewarranty period. Warranted partsscheduled for replacement as requiredmaintenance in the operation manual arewarranted for the period of time prior to thefirst scheduled replacement. Any partrepaired or replaced under warranty shall bewarranted for the remaining warrantyperiod.During the warranty period, Yanmar is liablefor damages to other engine componentscaused by the failure of any warranted partduring the warranty period.Any replacement part which is functionallyidentical to the original equipment part in allrespects may be used in the maintenance orrepair of your engine, and shall not reduceYanmar’s warranty obligations. Add-on ormodified parts that are not exempted maynot be used. The use of any non-exemptedadd-on or modified parts shall be groundsfor disallowing a warranty.

Warranted Parts:This warranty covers engine componentsthat are a part of the emission control systemof the engine as delivered by Yanmar to theoriginal retail purchaser. Such componentsmay include the following:• Fuel Injection System• Cold Start Enrichment System• Positive Crankcase Ventilation SystemSince emissions-related parts may varyslightly between models, certain modelsmay not contain all of these parts and othermodels may contain the functionalequivalents.Exclusions:Failures other than those arising fromdefects in material and / or workmanship arenot covered by this warranty. The warrantydoes not extend to the following:malfunctions caused by abuse, misuse,improper adjustment, modification,alteration, tampering, disconnection,improper or inadequate maintenance or useof non-recommended fuels and lubricatingoils; accident-caused damage, andreplacement of expendable items made inconnection with scheduled maintenance.Yanmar disclaims any responsibility forincidental or consequential damages suchas loss of time, inconvenience, loss of useof equipment / engine or commercial loss.

EMISSION SYSTEM WARRANTY


Owner’s Warranty Responsibilities:As the engine owner, you areresponsible for the performance of therequired maintenance listed in yourowner’s manual. Yanmar recommendsthat you retain all documentation, includingreceipts, covering maintenance on yournon-road compression-ignition engine, butYanmar cannot deny warranty solely for thelack of receipts, or for your failure to ensurethe performance of all scheduledmaintenance.Yanmar may deny your warranty coverageof your non-road compression-ignitionengine if a part has failed due to abuse,neglect, improper maintenance orunapproved modifications.Your engine is designed to operate on dieselfuel only. Use of any other fuel may result inyour engine no longer operating incompliance with applicable emissionsrequirements.You are responsible for initiating thewarranty process. You must present yourengine to a Yanmar dealer as soon as aproblem exists. The warranty repairs shouldbe completed by the dealer as expeditiouslyas possible.

Customer AssistanceIf you have any questions regarding yourwarranty rights and responsibilities or wouldlike information on the nearest authorizedYanmar dealer or distributor, you shouldcontact Yanmar Marine USA Corporation forassistance.Yanmar Marine USA Corporation101 International ParkwayAdairsville, GA 30103 USATelephone: 770-877-9894Fax: 770-877-7567

EMISSION SYSTEM WARRANTY


Maintenance LogDate Operating

HoursMaintenance Performed Dealer Name Stamp or

Signature


Date OperatingHours

Maintenance Performed Dealer Name Stamp orSignature



Documents

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