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Yanmar 1GM10 Manuals
Manuals and User Guides for Yanmar 1GM10. We have
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Yanmar 1GM10 manuals available for free PDF download: Service Manual, Shop Manual, User Manual, Operation Manual
Yanmar 1GM10 Service Manual (464 pages)
Yanmar Marine Diesel enginesines Service manual
Brand:
Yanmar
| Category:
Engine
| Size: 14.15 MB
Table of Contents
Contents
3
Engine Model Name
5
Engine Model Name Plate and Clutch Model Name Plate
5
Item Descriptions on the Model Name Plates and Information to be Forwarded to Us
5
Location of Engine Model Name Plate and Clutch Model Name Plate
6
Cylinder Number
7
Location of Stamped Engine Serial Number
7
General
8
Specifications
9
Principal Construction
12
Performance Curves
13
Features
17
Engine Cross-Sections
18
Dimensions
25
Piping Diagrams
32
Basic Engine
37
Cylinder Block Construction
38
Cylinder of Model 1GM10(C) Engine
38
Cylinder of Model 2GM20(F)(C) Engine
39
Cylinder of Model 3GM30(F)(C) Engine
39
Cylinder of Model 3HM35(F)(C) Engine
40
Cylinder Block Inspection
40
Inspecting each Part for Cracks
40
Inspecting the Water Jacket of the Cylinder for Corrosion
40
Cylinder Bore Measurement
41
Oil and Water Passages
41
Color Check Flaw Detection Procedure
41
Boring the Cylinder
43
Measurement of Distortion on the Upper Surface of the Cylinder
44
Purpose of Cup Plug
45
How to Drive in the Cup Plug
45
Cylinder Head Construction
46
Cylinder Head of Model 1GM10(C) Engine
46
Cylinder Head of Model 2GM20(F)(C) Engine
47
Cylinder Head of Models 3GM30(F)(C) and 3HM35(F)(C)
48
Cylinder Head Inspection and Measurement
49
Measurement of Carbon Build-Up at Combustion Surface and Intake and Exhaust Ports
49
Deposit Build-Up in Water Passages
49
Inspection of Corrosion in Water Passages and Anti-Corrosion Zinc
49
Measuring Valve Sinkage
50
Dismounting and Remounting the Cylinder Head
51
Rocker Arm Support Positioning Pin
51
Cylinder Head Assembly Sequence
51
Tightening the Cylinder Head Bolts and Nuts
52
Cylinder Head Nut Loosening Sequence
53
Intake and Exhaust Valves, Valve Guide and Valve Spring
54
Inspecting and Measuring the Intake and Exhaust Valves
54
Inspecting and Measuring Valve Guides
55
Valve Spring
56
Precombustion Chamber and Top Clearance
57
Valve Stem Seal
57
Spring Retainer and Spring Cotter Pin
57
Intake and Exhaust Valve Rocker Arm
58
Insulation Packing
58
Components of Valve Rocker Arm
58
Measuring the Valve Rocker Arm Shaft and Bushing Clearance
60
Valve Rocker Arm and Valve Top Retainer Contact and Wear
60
Valve Clearance Adjusting Screw
60
Classification of the Intake and Exhaust Valve Rocker Arms
60
Adjusting Intake and Exhaust Valve Head Clearance
61
Decompression Mechanism
62
Adjusting Without a Feeler Gauge
62
Disassembling and Reassembling Cylinder Head
63
Piston Assembly Construction
65
Piston Inspection
65
Replacing a Piston
66
Piston Pin
67
Piston Pin Bushing
67
Piston Ring Configuration
68
Piston Rings Inspection
68
Connecting Rod Ass'y Construction
71
Connecting Rod Inspection
71
Crank Pin Bushing
71
Crank Pin and Bushing Clearance (Oil Clearance)
72
Tightening the Connecting Rod Bolts
73
Connecting Rod Side Clearance
73
Crank Pin Bushing Replacement Precautions
73
Piston Bushing and Piston Pin
74
Replacing the Piston Pin Bushing
74
Crankshaft Ass'y and Bearing Construction
75
Constructions of Models 2GM20(F)(C), 3GM30(F)(C) and 3HM35(F)(C) Crankshaft Assembly
76
Crank Journal and Crank Pin
77
Crankshaft Side Gap
79
Disassembly of the Crankshaft
80
Side Gap Maintenance Standard and Wear Limit
80
Main Bearing Construction
82
Inspecting the Crank Bearing
82
Inspecting the Thrust Metal
83
Inspecting the Intermediate Main Bearing
83
Replacing the Crank Bearing
84
Crankshaft Oil Seal
85
Oil Seal Insertion Precautions
85
Oil Seal Type and Size
85
Flywheel and Housing
86
Specifications of Flywheel
86
Dimensions of Flywheel and Flywheel Housing
87
Ring Gear
89
Position of Top Dead Center
89
Construction of the Camshaft
90
Camshaft of Engine Model 1Gm10(C)
90
Camshaft of Engine Model 2GM20(F)(C)
91
Camshaft of Engine Models 3GM30(F)(C) and 3HM35(F)(C)
91
Valve Timing Diagram
92
Camshaft Inspection
92
Camshaft Height
92
Journals of Camshaft
92
Camshaft Ball Bearing
93
Tappets
93
Camshaft Deflection
93
Push Rods
94
Fuel Cam Check
94
Fuel Cam Assembly Precautions
94
Timing Gear Train Construction
96
Timing Gear of Model 1GM10(C)
96
Timing Gear of Models 2GM20(F)(C), 3GM30(F)(C) and 3HM35(F)(C)
97
Disassembly and Reassembly of the Timing Gear
98
Backlash Inspection
99
Inspecting the Gear Tooth Surface
100
Inspecting the Gear Boss
100
Fuel System
101
Fuel Injection System
102
Fuel Injection System Construction
103
Fuel Injection System Specifications
103
Injection Pump Construction
104
Specifications and Performance of Fuel Injection Pump
109
Injection Volume Characteristics of Fuel Injection Pump
109
Operation of Fuel Injection Pump
111
Fuel Control
112
Action of the Delivery Valve and the Sucking-Back of Fuel
112
Disassembly of Fuel Injection Pump
113
Dismantling of Fuel Pump of Model 2GM20(F)(C), 3GM30(F)(C) and 3HM35(F)(C)
114
Inspecting Injection Pump Parts
115
Plunger
116
Delivery Valve
116
Assembling the Fuel Injection Pump
117
Plunger Spring and Delivery Valve Spring
117
Plunger Guide
117
Inspection after Reassembly
121
Control Rack Resistance Test
121
Fuel Injection Timing
121
Injection Pump Adjustment
123
Setting Pump on Tester
123
Measuring the Sliding Resistance of the Fuel Control Rack
123
Adjusting the Plunger Top Clearance
123
Checking the Cylinder Injection Interval
124
Delivery Valve Oil-Tight Test
124
Plunger Pressure Test
124
Measuring the Fuel Injection Volume
124
Adjustment of Injection Volume for each Cylinder
125
Injection Nozzle Construction
126
Specifications for Nozzle Valve
126
Yanmar Throttle Nozzle
127
Nozzle Operation
127
Injection Nozzle Disassembly and Reassembly
127
Injection Nozzle Inspection and Adjustment
128
Carbon and Corrosion on the Nozzle Body
128
Checking Nozzle Action
128
Adjusting the Nozzle Injection Pressure
129
Nozzle Seat Oil Tightness Check
129
Checking the Spray Condition
129
Inspecting the Nozzle Spring
129
Fuel Filter Construction
130
Fuel Filter Specifications
130
Fuel Filter Inspection
130
Fuel Feed Pump Construction
131
Fuel Feed Pump Specifications
131
Fuel Feed Pump Disassembly and Reassembly
132
Inspecting and Adjusting the Fuel Feed Pump
132
Checking the Pump for Fuel Oil Leaks
132
Checking the Pump for Engine Oil Leaks
132
Aging, Breakdown and Cracking of the Diaphragm
133
The Contact Area and Mounting Condition of Valve
133
Diaphragm Spring and Rocker Arm Spring
133
Fuel Tank (Option)
134
Fuel Tank Dimension
135
Governor
136
Governor Construction
137
Governor Operation
141
Governor Performance
141
Governor Disassembly
142
Governor Parts Inspection and Replacement
142
Regulator Spring
142
Sleeve
143
Thrust Collar
143
Thrust Needle Bearing
143
Governor Weight
143
Regulator Lever and Handle
144
Injection Limiter Construction
145
Injection Limiter Inspection
145
Injection Limiter Adjustment
145
No-Load Maximum Speed Limiter Construction
147
No-Load Maximum Speed Limiter Handling Precautions
147
Idling Adjuster
148
Engine Stop Lever Construction
149
Engine Stop Lever Inspection
149
Intake and Exhaust System
150
Intake and Exhaust System of Model 1GM10(C)
151
Intake and Exhaust System of Model 2GM20(F)(C)
151
Intake and Exhaust System of Models 3GM30(F)(C) and 3HM35(F)(C)
152
Intake Silencer Construction
153
Inspection of the Intake Silencer
153
Washing the Intake Silencer Element
153
Exhaust System
154
Exhaust Manifold and Mixing Elbow
154
U Type Mixing Elbow
154
Exhaust Manifold Inspection
155
Mixing Elbow Inspection
155
Construction of Breather
156
Breather for Model 1GM10(C)
156
Breather for Models 2GM20(F)(C) and 3GM30(F)(C)
156
Breather for Model 3HM35(F)(C)
157
Lubrication System
158
Lubricating Oil Passage of Model 1GM10(C)
159
Lubrication Oil Passage of Model 2GM20(F)(C)
160
Lubrication Oil Passage of Model 3GM30(F)(C) and 3HM35(F)(C)
161
Table of Capacity for Lubricating Oil System
162
Oil Pump Construction
163
Lubricating Oil Pump on Model 1Gm10(C)
163
Lubricating Oil Pump on Models 2GM20(F)(C), 3GM30(F)(C) and 3HM35(F)(C)
164
Specifications of Lubrication Oil Pump
164
Oil Pump Disassembly
165
Oil Pump Inspection
166
Outer Rotor and Pump Body Clearance
166
Outer Rotor and Inner Rotor Clearance
166
Pump Body and Inner Rotor, Outer Rotor Side Clearance
166
Oil Filter Construction
167
Oil Filter Replacement
168
Replacing the Oil Filter
169
In Case of Oil Leakage
169
Oil Pressure Regulator Valve Construction
170
Oil Pressure Regulator Valve Specifications
171
Oil Pressure Measurement
172
Direct Sea-Water Cooling System
173
Cooling System Composition
174
Cooling Water Route
174
Piping
174
Cooling Water Passage of Engine Model 1GM10(C)
175
Cooling Water Passage of Engine Model 2GM20(C)
176
Cooling Water Passage of Engine Models 3GM30(C) and 3HM35(C)
177
Water Pump Construction and Operation
178
Cooling Water Pump of Engine Model 1GM10(C)
178
Cooling Water Pump of Engine Models 2GM20(C) and 3GM30(C)
179
Cooling Water Pump of Engine Model 3HM35(C)
180
Water Pump Disassembly
181
Water Pump Specifications
181
Water Pump Reassembly Precautions
182
Water Pump Handling Precautions
182
Water Pump Inspection
182
Thermostat Construction and Operation
184
Thermostat Inspection
185
Care Must be Taken When Assembling the Thermostat
186
Anticorrosion Zinc Principles
187
Anticorrosion Zinc Inspection
188
Kingston Cock Construction
189
Kingston Cock Handling Precautions
189
Kingston Cock Inspection
189
Bilge Strainer
190
Bilge Pump Specifications
190
Bilge Pump Performance
190
Fresh Water Cooling System
191
Cooling System Diagrams
192
Cooling System Configuration
193
Sea Water Pump
194
Fresh Water Pump Construction
195
Pump Capacity and Characteristic
196
Pump Disassembly
196
Pump Inspection and Measurement
196
Heat Exchanger Construction
198
Water Flow in Water Cooling Tube
200
Heat Exchanger Specifications
200
Heat Exchanger Disassembly
201
Heat Exchanger Inspection and Cleaning
201
Cooling Pipe
201
Heat Exchanger Body
201
Filler Cap Construction
202
Filler Cap Pressure Control
202
Filler Cap Inspection
202
Subtank Function
202
Installation of Subtank
203
Maintenance During Use
203
Thermostat Operation
204
Thermostat Construction
205
Cooling Water Temperature Switch
207
Precautions
208
Ventilator
208
Cooling Water
208
Antifreeze
208
Rust Inhibitor
209
Idling the Engine When Stopping
209
Cleaning the Heat Exchanger Tube
209
Modifying the Cooling System
210
Direct Sea Water-Cooled Engine and Fresh Water-Cooled Engine
211
Modification Method
211
Testing a Modified Engine
211
Kit for Modification into a Fresh Water-Cooled Engine
211
Disassembly of Sea Water-Cooled Engine
212
Drain the Cooling Sea Water
212
Remove the Cooling Water Pipe
212
Remove the Fuel Oil Pipe
212
Remove the Fuel Filter
213
Remove the Remote Control Bracket
213
Remove the Mixing Elbow
213
Remove the Exhaust Manifold
213
Remove the Thermostat Cover
214
Remove the Thermostat Bracket
214
Remove the Cooling Water By-Pass Connection
214
Remove the CSW Pump
214
Advertisement
Yanmar 1GM10 Shop Manual (241 pages)
Brand:
Yanmar
| Category:
Engine
| Size: 63.39 MB
Table of Contents
Table of Contents
3
Freshwater (Closed) Cooling System Capacity
6
Quick Reference Data
6
Tune-Up Specifications
6
Approximate Engine Oil Capacities
6
General Torque Specifications
7
Chapter One
8
General Information
8
Manual Organization
8
Service Hints
10
Fasteners
11
Parts Replacement
11
Torque Specifications Info
11
Bolts
12
ISO Metric Screw Threads
12
Machine Screws
12
Machine Screws View
13
Nuts
13
Openings for Tools View
13
Self-Locking Fasteners
13
Cotter Pins
14
General Information
14
Washers
14
Circlips
15
Engine Oil
15
Lubricants
15
Basic Hand Tools
16
Grease
16
RTV Gasket Sealant
16
Threadlock
16
Screwdrivers
17
Circlip Pliers
18
Locking Pliers
18
Pliers
18
Adjustable Wrenches
19
Box-End, Open-End and Combination Wrenches
19
Socket Wrenches
19
Torque Wrench, Impact Driver
19
Feeler Gauge
20
Hammers
20
Precision Measuring Tools
20
Cylinder Bore Gauge
21
Dial Indicator
21
Outside Micrometers
21
Telescoping Gauges
21
Battery Hydrometer
22
Compression Gauge
22
Multimeter or vom
22
Screw Pitch Gauge
22
Expendable Supplies
23
Mechanic's Tips
23
Removing Broken Screws or Bolts
23
Removing Frozen Nuts and Screws
23
Remedying Stripped Threads
24
Removing Broken or Damaged Studs
24
Bearing Removal
25
Bearing Replacement
25
Bearing Installation
26
Shrink Fit
27
Seals
30
Decimal and Metric Equivalents Table
31
Chapter Two
32
Parts Replacement
32
Troubleshooting
32
Starting System Operation
33
Troubleshooting
33
Slow Running Starter
34
Starter Solenoid Chatters (no Click), Starter Does Not Run
34
Starter Solenoid Clicks, Starter Does Not Run
34
Starting System On-Boat Testing
34
Loud Grinding Noises When Starter Runs
35
Starter Solenoid Resistance Tests
35
Starter Spins but Does Not Rotate Flywheel
35
Starter will Not Disengage When Start Switch Is Released
35
Charging System Diagram
36
Alternator Regulated Voltage Test
37
Charging System Tests
37
Charging System Troubleshooting
37
Alternator Current Output Test
38
Fuel System Troubleshooting
38
Voltage Output Test
38
Engine Speed Decreases Unexpectedly
39
Engine Stops Suddenly
39
Engine will Not Run under Full Load
39
Engine will Not Start
39
Cooling System Troubleshooting
40
Engine Overheating
40
Fuel Injection System Diagram
40
Black Smoke
41
Blue Smoke
41
Engine Noises
41
White Smoke
41
Cooling System
42
Engine Misses
42
Engine Troubleshooting
42
Low Oil Pressure
42
Lubrication System Troubleshooting
42
Lubrication System (1 GM and 1 GM1O Models) Diagram
43
Lubrication System (2GM and 2GM2O Models) Diagram
44
Lubrication System (3GM, 3GM3O, 3HM and 3Hm35Models) Diagram
45
Engine Troubleshooting Table
46
Oil Pressure Test
46
Oil Pressure Table
47
Starter Motor No-Load Specifications
47
Chapter Three
48
Starting Checklist
49
Operation, Lubrication, Maintenance and Tune-Up
48
Preoperational Checks
48
Ruel Requirements
48
Engines Equipped with Remote Control
49
Engines Without Remote Control
49
Emeregency Engine Stopping
50
Engine Maintenance and Lubrication
50
Post-Operatinal Checks
50
Stopping the Engine
50
Engine Oil and Filter Change
51
Engine Oil Level Check
51
Fuel System Service
52
Fuel Filter
53
Fuel Lines
53
Air Filter
54
Bleeding Air from Fuel System
54
Drive Belts
54
Alternator Drive Belt Adjustment (Models Equipped with Freshwater Cooling)
55
Alternator Drive Belt Adjustment (Models Equipped with Seawater Cooling)
55
Seawater Pump Drive Belt Adjustment (2GM, 2GM20, 3GM, 3GM30, 3HM and 3HM35 Models)
55
Alternator Drive Belt Replacement (All Models)
56
Crankcase Breather
56
Seawater Pump Drive Belt Replacement
56
Anticorrosion Maintenance
57
Cooling System
58
Anode Mountings Diagram
59
Flushing the System
59
Seawater (Standard) Cooling Systems
59
Coolant
60
Freshwater (Closed) Cooling Systems
60
Remote Reservoir Checking/Filling
60
Fresh Water Heat Exchanger Diagram
61
Battery Maintenance
62
Flushing and Refilling Freshwater Coolant System
62
Battery Cutaway View
63
Compression Test
63
Engine Tune-Up
63
Valve Clearance Adjustment
64
Idle Speed Adjustment
65
Transmisson Oil
66
Engine Oil Crankcase Capacity
67
Engine Oil Viscosity
67
Maintenance Schedule Table
67
Transmission Oil Level Check
67
Compression Specifications
68
Freshwater (Closed) Cooling System Capacity Table
68
Tune-Up Specificationis Table
68
Lay-Up and Fitting out
69
Chapter Four
69
Lay.upandfitt1Ngout
69
Cooling System Draining
70
Seawater Cooling System
70
Adding Antifreeze
71
Freshwater (Closed) Cooling Section
71
Freshwater (Closed) Cooling System
71
Fitting out
72
Seawater Cooling Section
72
Chapter Five
74
Diesel Engine Fundamentals
74
Single-Cylinder Engines
74
4-Stroke Diesel Engine Principles
75
Engine Removal Precautions
76
Engine Serial Number and Code
76
Replacement Parts (Engine)
76
Breather Assembly
77
Engine Removal/Installation
77
Valve Cover
77
Valve Cover Assembly Diagram
78
Cylinder Head Diagram
79
Cylinder Head Removal
79
Decompressoin Mechanism
79
Cylinder Head Inspection
80
Cylinder Head Installation
81
Rocker Shaft Assembly
82
Valve Components Diagram
83
Valve Removal
83
Valves and Valve Seats
83
Valve Inspection
84
Piston/Connecting
85
Valve Guide Replacement
85
Piston Pin Removal/Installation
86
Piston/Cylinder
87
Piston Ring Fit/Installation
88
Connecting Rod Inspection
89
Connecting Rod Bearing Clearance Measurement
90
Piston/Connecting Rod Installation
90
Timing Gearcase
91
Lubrication System Maintenance
92
Oil Pump
92
Oil Pump Removal and Installation
93
Oil Pump Disassembly, Inspection and Reassembly
94
Flywheel Removal/Installation
95
Oil Pickup
95
Pressure Relief Valve
95
Crankshaft Assembly Diagram
96
Crankshaft Removal and Installation
97
Camshaft Removal and Installation
99
Crankshaft Inspection
99
Main Bearings
99
Core Plug Replacement
101
Cylinder Block Cleaning and Inspection
101
Core Plug Removal and Installation
102
Engine Specifications Table (1GM, 1Gml0 )
103
Cylinder Head
104
Engine Serial Number and Code (Multicylinder)
105
Yanmar 1GM10 Shop Manual (241 pages)
Brand:
Yanmar
| Category:
Engine
| Size: 67.6 MB
Table of Contents
Contents
3
Quick Reference Data
6
Tune-Up Specifications
6
Freshwater (Closed) Cooling System Capacity
6
Engine Models
6
General Torque Specifications
7
General Information
8
Manual Organization
8
Notes, Cautions and Warnings
9
Safety First
9
Service Hints
10
Parts Replacement
11
Torque Specifications
11
Fasteners
11
ISO Metric Screw Threads
12
Machine Screws
12
Bolts
12
Openings for Tools
13
Nuts
13
Self-Locking Fasteners
13
Washers
14
Cotter Pins
14
Lubricants
15
Circlips
15
Engine Oil
15
RTV Gasket Sealant
16
Threadlock
16
Basic Hand Tools
16
Grease
16
Screwdrivers
17
Pliers
18
Locking Pliers
18
Circlip Pliers
18
Box-End, Open-End and Combination Wrenches
19
Adjustable Wrenches
19
Socket Wrenches
19
Torque Wrenches
19
Precision Measuring Tools
20
Feeler Gauge
20
Hammers
20
Vernier Caliper
21
Outside Micrometers
21
Dial Indicator
21
Cylinder Bore Gauge
21
Compression Gauge
22
Multimeter or vom
22
Battery Hydrometer
22
Screw Pitch Gauge
22
Mechanic's Tips
23
Surface Plate
23
Expendable Supplies
23
Removing Frozen Nuts and Screws
23
Remedying Stripped Threads
24
Removing Broken or Damaged Studs
24
Bearing Replacement
25
Removing Broken Screws and Bolts
25
Bearing Removal
25
Bearing Installation
26
Shrink Fit
27
Parts View
28
Seals
30
Yanmar Models
31
Decimal and Metric Equivalents
31
Troubleshooting
32
Starting System
33
Starting System Operation
33
Starting Circuit (Typical)
33
On-Boat Testing
34
Slow Running Starter
34
Starter Solenoid Clicks, Starter Does Not Run
34
Starter Solenoid Chatters (no Click), Starter Does Not Run
34
Starter Solenoid Resistance Tests
35
Starter Motor No-Load Current Draw Test
35
Starter Spins but Does Not Rotate Flywheel
35
Starter will Not Disengage When Start Switch Is Released
35
Charging System (Typical)
36
Charging System
37
Charging System Tests
37
Alternator Regulated Voltage Test
37
Fuel System
38
Alternator Current Output Test
38
Voltage Output Test
38
Current Output Test
39
Cooling System
40
Engine Overheating
40
Fuel Injection System
40
Engine Exhaust Smoke
41
Engine Noises
41
Clicking or Tapping Noises
41
Knocking Noises
41
Engine Troubleshooting
42
Lubrication System
42
Engine will Not Start
42
Engine Misses
42
Lubrication System (1 GM and 1 GM 10 Models)
43
Lubrication System (2 GM and 2 GM 20 Models)
44
Lubrication System (3GM, 3GM30, 3HM and 3HM35 Models)
45
Oil Pressure Test
46
Starter Motor No-Load Specifications
47
Oil Pressure
47
Operation, Lubrication, Maintenance and Tune-Up
48
Fuel Requirements
48
Preoperational Checks
48
Starting Checklist
49
Engines Without Remote Control
49
Engines Equipped with Remote Control
49
Warm Engine
49
Stopping the Engine
50
Emergency Engine Stopping
50
Post-Operational Checks
50
Engine Maintenance and Lubrication
50
Engine Oil Level Check
51
Engine Oil and Filter Change
51
Fuel System Service
52
Fuel Lines
53
Fuel Filter
53
Air Filter
54
Drive Belts
54
Bleeding Air from the Fuel System
54
Alternator Drive Belt Adjustment (Models Equipped with Seawater Cooling)
55
Seawater Pump Drive Belt Adjustment (2GM, 2GM20, 3GM, 3GM30, 3HM and 3HM35 Models)
55
Crankcase Breather
56
Alternator Drive Belt Replacement (All Models)
56
Seawater Pump Drive Belt Replacement (2GM, 2GM20, 3GM, 3GM30, 3HM and 3HM35 Models)
56
Alternator Maintenance
57
1GM and 1GM10 Models
57
2GM, 2GM20, 3GM, 3GM30, 3HM and 3HM35 Models
58
Sacrificial Anode Original Sizes
58
Seawater (Standard) Cooling System
59
Flushing the System
59
Anode Mountings
59
Freshwater (Closed) Cooling System
60
Inspection
60
Check/Fill Coolant (Not Equipped with Remote Reservoir)
60
Check/Fill Coolant (Equipped with a Remote Reservoir)
60
Freshwater Heat Exchanger (Typical)
61
Battery
62
Flushing and Refilling Freshwater Coolant System
62
Engine Tune-Up
63
Compression Test
63
Battery Cutaway View
63
Valve Clearance Adjustment
64
Idle Speed Adjustment
65
Valve Clearance Adjustment (All Models)
65
Idle Speed Adjustment (1GM and 1GM10 Models)
65
Transmission
66
Transmission Oil
66
Transmission Models KM2A, KM2C, KM2P, KM3A and KM3P
66
Transmission Models KBW10D and KBW10E
66
Transmission Oil Level Check
67
Maintenance Schedule
67
Engine Oil Viscosity
67
Engine Oil Crankcase Capacity
67
Freshwater (Closed) Cooing System Capacity
68
Compression Specifications
68
Lay-Up and Fitting out
69
Cooling System Draining
70
Seawater Cooling System
70
Adding Antifreeze
71
Freshwater (Closed) Cooling Section
71
Fitting out
72
Seawater Cooling Section
72
Single-Cylinder Engines
74
Diesel Engine Fundamentals
74
4-Stroke Diesel Engine Principles
75
Engine Serial Number and Code
76
Replacement Parts
76
Engine Removal Precautions
76
Valve Cover
77
Breather Assembly
77
Removal/Installation
77
Valve Cover Assembly
78
Decompression Mechanism
79
Cylinder Head
79
Removal
79
Installation
81
Rocker Shaft Assembly
82
Cylinder Head Tightening Sequence
82
Valves and Valve Seats
83
Valve Removal
83
Valve Components
83
Push Rods
85
Piston/Connecting Rod Assembly
85
Valve Guide Replacement
85
Piston/Connecting Rod Removal
85
Piston Pin Removal/Installation
86
Piston/Cylinder Bore Check
87
Piston Ring Fit/Installation
88
Connecting Rod Inspection
89
Connecting Rod Bearing Clearance Measurement
90
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Yanmar 1GM10 User Manual (240 pages)
ONE, TWO & THREE CYLINDER ENGINES
Brand:
Yanmar
| Category:
Engine
| Size: 21.89 MB
Table of Contents
Table of Contents
3
Quick Reference Data
6
Chapter One
8
GENERAL Information
8
Manual Organization
8
Notes, Cautions and Warnings
9
Safety First
9
Service Hints
10
Parts Replacement
11
Torque Specifications
11
Fasteners
11
Chapter Two
32
Starting System
33
Charging System
37
Charging System Tests
37
Fuel System
38
Cooling System
40
Engine Troubleshooting
42
Cooling System
42
Lubrication System
42
Chapter Three
48
Operation, Lubrication, Maintenance and Tune-Up
48
Fuel Requirements
48
Preoperational Checks
48
Starting Checklist
49
CHAPTER Four
69
Lay-Up
69
Single-Cylinder Engines
74
Diesel Engine Fundamentals
74
Engine Serial Number and Code
76
Replacement Parts
76
Engine Removal Precautions
76
Valve Cover
77
Breather Assembly
77
Decompression Mechanism
79
Cylinder Head
79
Rocker Shaft Assembly
82
Chapter Six
105
Engine Serial Number and Code
105
Replacement Parts
106
Engine
106
Valve Cover
107
Breather Assembly
107
Decompression Mechanism
108
Exhaust Manifold
109
Cooling System
111
Lubrication System
126
Drive Disc
129
Crankshaft
130
Crankshaft
133
Yanmar 1GM10 Operation Manual (92 pages)
GM Series Marine Engines
Brand:
Yanmar
| Category:
Engine
| Size: 9 MB
Table of Contents
Table of Contents
3
Introduction
7
Record of Ownership
8
Safety
9
Safety Precautions
10
General Information
10
Before You Operate
10
During Operation and Maintenance
10
Location of Safety Decals
14
Product Overview
15
Yanmar GM Features and Applications
15
New Engine Break-In
16
Component Identification
17
Service Side - 1GM10 with KM2P
17
Non-Service Side - 1GM10 with KM2P
18
Location of Nameplates
19
Emission-Control Labels
19
Major Components and Functions
20
Control Equipment
21
Instrument Panel (Optional)
21
Optional Single-Lever Throttle and Shift Console
24
Before You Operate
25
Diesel Fuel
25
Diesel Fuel Specifications
25
Fuel System
27
Filling the Fuel Tank
28
Engine Oil
29
Engine Oil Specifications
29
Engine Oil Viscosity
29
Checking the Engine Oil
30
Adding Engine Oil
30
Marine Gear or Sail-Drive Oil
31
Marine Gear Oil Specifications
31
Sail-Drive Oil Specifications - SD20
31
Checking Marine Gear Oil
31
Adding Marine Gear Oil
32
Checking and Adding Sail-Drive Oil
32
Cranking the Engine Manually
32
Cranking the Engine Electrically
33
Recheck the Engine Oil
34
Daily Checks
34
Visual Checks
34
Checking Diesel Fuel and Engine Oil
35
Checking and Refilling Marine Gear Oil
35
Checking the Battery Electrolyte Level
35
Checking the Alternator Belt
35
Checking the Throttle and Shift Console
35
Checking the Warning Indicators
35
Preparing Fuel, Oil and Coolant in Reserve
35
Yanmar 1GM10 Operation Manual (94 pages)
Marine Engines
Brand:
Yanmar
| Category:
Engine
| Size: 11.33 MB
Table of Contents
Marine Engines
1
Table of Contents
3
Introduction
7
Record of Ownership
8
Safety
9
Safety Precautions
10
General Information
10
Before You Operate
10
During Operation and Maintenance
10
Location of Safety Decals
14
Product Overview
15
Yanmar Gm Features and Applications
15
New Engine Break-In
16
Component Identification
17
Service Side - 1GM10 with KM2P
17
Non-Service Side - 1GM10 with KM2P
18
Location of Nameplates
19
Major Components and Functions
20
Control Equipment
21
Instrument Panel (Optional)
21
Single-Lever Throttle and Shift Console (Optional)
28
Before You Operate
31
Introduction
31
Safety Precautions
31
Diesel Fuel
32
Diesel Fuel Specifications
32
Engine Oil
35
Engine Oil Specifications
35
Engine Oil Viscosity
36
Checking the Engine Oil
36
Adding Engine Oil
37
Marine Gear or Sail-Drive Oil
37
Marine Gear Oil Specifications
37
Sail-Drive Oil Specifications - SD20
37
Checking Marine Gear Oil
38
Adding Marine Gear Oil
38
Checking and Adding Sail-Drive Oil
38
Cranking the Engine Manually
39
Cranking the Engine Electrically
40
Recheck the Engine Oil
40
Daily Checks
41
Visual Checks
41
Checking Diesel Fuel and Engine Oil
41
Checking and Refilling Marine Gear Oil
41
Checking the Battery Electrolyte Level
41
Checking the Alternator Belt
42
Checking the Throttle and Shift Console
42
Checking the Warning Indicators
42
Preparing Fuel, Oil and Coolant in Reserve
42
Yanmar 1GM10 Operation Manual (44 pages)
MARINE DIESEL ENGINE
Brand:
Yanmar
| Category:
Engine
| Size: 8.05 MB
Table of Contents
Table of Contents
2
Introduction
3
For Your Safety
4
Warning Symbols
4
Safety Precautions
4
Warning Labels
7
Product Explanation
8
Use, Driving System, Etc
8
Engine Specifications
9
Direct Seawater Cooling Type, GM Series
9
Direct Seawater Cooling Type, GMC Series
10
Direct Seawater Cooling Type, GMV Series
11
Names of Parts
12
Major Servicing Parts
13
Control Equipment
14
Control Panel
14
Single Lever Remote Control Handle (Morse Type) - Optional
16
Stopping Equipment
16
Decompression Equipment
16
Operation
17
Fuel Oil, and Lube Oil
17
Fuel Oil
17
Lube Oil
18
Before Initial Operation
19
Supply Fuel Oil
19
Supply Engine Lube Oil
19
Supply Clutch Lube Oil
19
Cranking
20
Check and Resupply Lube Oil
20
Operating Your Engine
21
Inspection before Starting
21
How to Start the Engine
22
Operation
24
Cautions During Operation
24
Stopping the Engine
25
Long Term Storage
26
Maintenance & Inspection
27
General Inspection Rules
27
List of Periodic Inspection Items
28
Periodic Inspection Items
30
Inspection on Initial 50 Hrs. of Operation (or after 1 Month)
30
Inspection Every 50 Hours (or Monthly)
30
Inspection Every 150 Hours
32
Inspection Every 300 Hrs
32
Inspection Every 600 Hrs
33
EPA Requirements
34
EPA and ARB Certification Plate
34
Conditions to Insure Compliance with Emission Standards
35
Inspection and Maintenance
36
Emission System Warranty Statement
36
Yanmar 1GM10 Operation Manual (94 pages)
GM Series
Brand:
Yanmar
| Category:
Engine
| Size: 4.95 MB
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