Table Of Contents - Yanmar 1GM10 Shop Manual

Table of Contents

Table Of Contents3
Quick Reference Data6
Tune-Up Specifications6
Approximate Engine Oil Capacities6
Freshwater (Closed) Cooling System Capacity6
General Torque Specifications7
General Information8
Manual Organization8
Chapter One8
Service Hints10
Parts Replacement11
Torque Specifications Info11
Fasteners11
Iso Metric Screw Threads12
Machine Screws12
Bolts12
Nuts13
Self-Locking Fasteners13
Openings For Tools View13
Machine Screws View13
Washers14
Cotter Pins14
Circlips15
Lubricants15
Engine Oil15
Grease16
Rtv Gasket Sealant16
Threadlock16
Basic Hand Tools16
Screwdrivers17
Pliers18
Locking Pliers18
Circlip Pliers18
Box-End, Open-End And Combination Wrenches19
Adjustable Wrenches19
Socket Wrenches19
Torque Wrench, Impact Driver19
Precision Measuring Tools20
Feeler Gauge20
Hammers20
Outside Micrometers21
Dial Indicator21
Cylinder Bore Gauge21
Telescoping Gauges21
Compression Gauge22
Multimeter Or Vom22
Battery Hydrometer22
Screw Pitch Gauge22
Mechanic's Tips23
Removing Frozen Nuts And Screws23
Removing Broken Screws Or Bolts23
Expendable Supplies23
Remedying Stripped Threads24
Removing Broken Or Damaged Studs24
Bearing Replacement25
Bearing Removal25
Bearing Installation26
Shrink Fit27
Seals30
Decimal And Metric Equivalents Table31
Troubleshooting32
Chapter Two32
Starting System Operation33
Starting System On-Boat Testing34
Slow Running Starter34
Starter Solenoid Clicks, Starter Does Not Run34
Starter Solenoid Chatters (No Click), Starter Does Not Run34
Starter Spins But Does Not Rotate Flywheel35
Starter Will Not Disengage When Start Switch Is Released35
Loud Grinding Noises When Starter Runs35
Starter Solenoid Resistance Tests35
Charging System Diagram36
Charging System Troubleshooting37
Charging System Tests37
Alternator Regulated Voltage Test37
Fuel System Troubleshooting38
Alternator Current Output Test38
Voltage Output Test38
Engine Will Not Start39
Engine Stops Suddenly39
Engine Speed Decreases Unexpectedly39
Engine Will Not Run Under Full Load39
Cooling System Troubleshooting40
Fuel Injection System Diagram40
Engine Overheating40
Blue Smoke41
White Smoke41
Black Smoke41
Engine Noises41
Engine Troubleshooting42
Lubrication System Troubleshooting42
Engine Misses42
Low Oil Pressure42
Cooling System42
Lubrication System (1 Gm And 1 Gm1O Models) Diagram43
Lubrication System (2Gm And 2Gm2O Models) Diagram44
Lubrication System (3Gm, 3Gm3O, 3Hm And 3Hm35Models) Diagram45
Oil Pressure Test46
Engine Troubleshooting Table46
Starter Motor No-Load Specifications47
Oil Pressure Table47
Operation, Lubrication, Maintenance And Tune-Up48
Ruel Requirements48
Preoperational Checks48
Chapter Three48
Starting Checklist49
Engines Without Remote Control49
Engines Equipped With Remote Control49
Stopping The Engine50
Emeregency Engine Stopping50
Post-Operatinal Checks50
Engine Maintenance And Lubrication50
Engine Oil Level Check51
Engine Oil And Filter Change51
Fuel System Service52
Fuel Lines53
Fuel Filter53
Bleeding Air From Fuel System54
Air Filter54
Drive Belts54
Alternator Drive Belt Adjustment (Models Equipped With Seawater Cooling)55
Alternator Drive Belt Adjustment (Models Equipped With Freshwater Cooling)55
Seawater Pump Drive Belt Adjustment (2Gm, 2Gm20, 3Gm, 3Gm30, 3Hm And 3Hm35 Models)55
Alternator Drive Belt Replacement (All Models)56
Seawater Pump Drive Belt Replacement56
Crankcase Breather56
Anticorrosion Maintenance57
Seawater (Standard) Cooling Systems59
Flushing The System59
Anode Mountings Diagram59
Freshwater (Closed) Cooling Systems60
Remote Reservoir Checking/Filling60
Coolant60
Fresh Water Heat Exchanger Diagram61
Flushing And Refilling Freshwater Coolant System62
Battery Maintenance62
Battery Cutaway View63
Engine Tune-Up63
Compression Test63
Valve Clearance Adjustment64
Idle Speed Adjustment65
Transmisson Oil66
Transmission Oil Level Check67
Maintenance Schedule Table67
Engine Oil Viscosity67
Engine Oil Crankcase Capacity67
Freshwater (Closed) Cooling System Capacity Table68
Tune-Up Specificationis Table68
Compression Specifications68
Lay-Up And Fitting Out69
Chapter Four69
Lay.upandfitt1Ngout69
Cooling System Draining70
Seawater Cooling System70
Adding Antifreeze71
Freshwater (Closed) Cooling System71
Freshwater (Closed) Cooling Section71
Seawater Cooling Section72
Fitting Out72
Single-Cylinder Engines74
Diesel Engine Fundamentals74
Chapter Five74
4-Stroke Diesel Engine Principles75
Engine Serial Number And Code76
Replacement Parts (Engine)76
Engine Removal Precautions76
Breather Assembly77
Valve Cover77
Engine Removal/Installation77
Valve Cover Assembly Diagram78
Cylinder Head Diagram79
Decompressoin Mechanism79
Cylinder Head Removal79
Cylinder Head Inspection80
Cylinder Head Installation81
Rocker Shaft Assembly82
Valves And Valve Seats83
Valve Components Diagram83
Valve Removal83
Valve Inspection84
Piston/Connecting85
Valve Guide Replacement85
Piston Pin Removal/Installation86
Piston/Cylinder87
Piston Ring Fit/Installation88
Connecting Rod Inspection89
Connecting Rod Bearing Clearance Measurement90
Piston/Connecting Rod Installation90
Timing Gearcase91
Lubrication System Maintenance92
Oil Pump92
Oil Pump Removal And Installation93
Oil Pump Disassembly, Inspection And Reassembly94
Flywheel Removal/Installation95
Pressure Relief Valve95
Oil Pickup95
Crankshaft Assembly Diagram96
Crankshaft Removal And Installation97
Main Bearings99
Camshaft Removal And Installation99
Crankshaft Inspection99
Cylinder Block Cleaning And Inspection101
Core Plug Replacement101
Core Plug Removal And Installation102
Engine Specifications Table (1Gm, 1Gml0 )103
Cylinder Head104
Multicylinder Engines105
Engine Serial Number And Code (Multicylinder)105
Engine Removal/Installation (Multicylinder)106
Replacement Parts106
Valve Cover (2Gm, 2Gm20, 3Gm And 3Gm30)107
Breather Assembly (Multicylinder)107
Valve Cover (3Hm And 3Hm35)108
Decompression Mechanism108
Exhaust Manifold Removal And Installation109
Exhaust Manifold With Closed Cooling System View110
Cylinder Head Removal (Multicylinder)111
Cylinder Head Inspection (Multicylinder)111
Cylinder Head Installation (Multicylinder)114
Rocker Shaft Assembly (Multicylinder)115
Valves And Valve Seats (Multicylinder)116
Valve Removal (Multicylinder)117
Valve Inspection (Multicylinder)117
Valve Guide Replacement (Multicylinder)118
Push Rods (Multicylinder)119
Piston/Connecting (Multicylinder)119
Piston Pin Remova/Installation (Multicylinder)120
Piston/Cylinder (Multicylinder)120
Piston Ring Fit/Installation (Multicylinder)121
Connecting Rod Inspection (Multicylinder)122
Connecting Rod Bearing Clearance Measurement (Multicylinder)123
Piston/Connecting Rod Installation (Multicylinder)123
Timing Gearcase (Multicylinder)124
Governor Assembly Diagram126
Lubrication System (Multicylinder Engines)126
Oil Pump Removal And Installation (Multicylinder)126
Oil Pump Disassembly, Inspection And Reassembly (Multicylinder)127
Oil Pressure Regulator Diagram (Multicylinder)128
Pressure Relief Valve (Multicylinder)128
Oil Pickup (Multicylinder)128
Flywheel Removal/Installation (Multicylinder)128
Crankshaft Removal And Installation (Multicylinder)129
Crankshaft Diagram (Multicylinder)130
Crankshaft Inspectioni (Multicylinder)132
Main Bearings (Multicylinder)132
Camshaft Removal And Installation (Multicylinder)133
Intermediate Main Bearing133
Cylinder Block Cleaning And Inspection (Multicylinder)134
Camshaft Assembly View135
Cylinder Liners 2Gm, 3Gm And 3Hm (Including F And D Series) Models135
Core Plug Replacement (Multicylinder)137
Engine Specifications (2Gm And 2Gm20)138
Engine Specifications (3Gm And 3Gm30)139
Engine Specifications (3Hm And 3Hm35)141
Fuel Injection And Governor Systems144
Fuel Injection Fundamentals144
Fuel Injection System View145
Fuel Injector146
Fuel And Fuel Filters146
Injection Pump View147
Fuel Injection System Bleeding148
Fuel Transfer Pump148
Fuel Injection Timing150
Adjust Fuel Injection Timing151
Fuel Injector Info152
Fuel Injector Removal And Installation153
Fuel Injection Pump Removal And Installation155
Fuel Pump Testing156
Fuel Pump Removal And Installation156
Fuel Lines Inspection157
Governor System Operation158
Governor System Diagrams159
Governor System Adjustments160
Governor Assembly View161
Governor Components Removal/Inspection/Installation161
Governor System Tightening Torques164
Governor Spring Free Length Table164
Governor Sleeve And Crankshaft Specifications164
Chapter 8: Cooling System165
Seawater (Standard) Cooling System165
Seawater Cooling System Diagram (1Gm And 1Gm10)166
Chapter Eight166
Seawater Cooling System Diagram (2Gm And 2Gm20)167
Seawater Cooling System Diagram (3Gm And 3Gm30)168
Freshwater (Closed) Cooling System Diagram/Description169
Closed Cooling System (Typical) Diagram170
Heat Exchanger Diagram171
Thermostat171
Thermostat Removal/Installation172
Thermostat Testing (Out Of Engine)173
Thermostat Testing (In Engine)173
Cooling Systems173
Hose Replacement174
Overheated Engine174
Slow Engine Warm-Up174
Drive Belts Description175
Drive Belt Routing Diagram175
Alternator Belt Drive Replacement175
Seawater Pump176
Seawater Pump Drive Belt Replacement (Except 1Gm And 1Gm10 Engines)176
Seawater Pump Precautions177
Water Pump Operating Mistakes177
Seawater Pump Removal/Installation177
Seawater Pump Disassembly/Assembly178
Seawater Pump Diagram (1Gm And 1Gm10 Models)179
Seawater Pump Diagram (2Gm, 2Gm20,3Gm And 3Gm30 Models)181
Seawater Pump Diagram (3Hm And 3Hm35 Models)182
Freshwater Pump Removal/Installation183
Freshwater Cooling System Maintenance183
Pressure Testing183
Closed Cooling System Diagram185
Cleaning The Seawater Section Of The Heat Exchanger185
Freshwater Exhaust Manufold/Heat Exchanger Diagram186
Seawater Cooling System Maintenance187
Seawater/Freshwater Pumps Tightening Torques188
Recommended Thermostat188
Electrical System189
Chapter Nine189
Switches189
Electrical System - Safety Precautions190
Electrical System - Care And Inspection191
Battery Testing192
Charging193
Jump Starting193
Electrical Protection194
Battery Cables194
Charging System195
Preliminary Testing195
Starting System196
Starter Removal/Installation196
Alternator Removal/Installation196
Solenoid Removal/Installation197
Brush Replacement197
Starter Motor Diagram (Except 3Hm And 3Hm35 Models)198
Starter Motor Diagram (3Hm And 3Hm35 Models)199
Senders201
Oil Pressure Sender201
Battery Cutoff Switch201
Coolant Temperature Sender202
Coolant And Oil Pressure Warning Lamps203
Charging System Warning Lamp203
Alarm Buzzer203
Tachometer203
Tachometer Sender204
Tachometer Gauge204
Battery Capacity Table204
Alternator And Starter Motor Tightening Torques204
Transmission - Km Series205
Cone Clutch View206
Shifter View (Km2A, Km2C And Km3A Models)206
Chapter Ten206
Shifter View (Km2P, And Km3P Models)207
Transmission (Km) Removal And Installation207
Transmission-Km Series207
Transmission (Km) Disassembly208
Transmission (Km) Inspection209
Input Shaft Inspection209
Intermediate Shaft Inspection210
Output Shaft Inspection210
Output Shaft Diagram211
Shifter Diagram (Km2A, Km2C And Km3A Models)212
Transmission (Km) Reassembly214
Shifter Diagram (Km2P And Km3P Models)215
Shifter Detent (Km2P And Km3P Models)215
Bearing Adjustment217
Output Shaft218
Drive Disc Removal/Installation219
Drive Disc Inspection219
Engine Transmission Models Table220
Tightening Torques Table (Transmission Km Series)220
Clutch Groove Width220
Output Shart Table220
Shifter Data Tables221
Transmission - Kbw Series222
Chapter Eleven222
Operation222
Transmission (Kbw Series) Removal/Installation223
Transmission (Kbw Series) Overhaul223
Transmission (Kbw Series) Disassembly223
Transmission (Kbw Series) Diagram224
Input Shaft (Kbw)226
Intermediate Shaft (Kbw)226
Output Shaft (Kbw)226
Transmission (Kbw) Inspection227
Transmission (Kbw) Reassembly228
Shifter (Kbw)229
Bearing Adjustment (Kbw)230
Drive Disc (Kbw) Removal/Installation231
Drive Disc (Kbw) Inspection231
Engine/Transmission (Kbw) Data232
Tightening Torques (Kbw)232
Clutch Specifications (Kbw)232
Drivedisc232
Index233
Battery236
Wiring Diagrams237
Early Models With Large Instrument Panel Wiring Diagram237
Early Models With Small Instrument Panel (No Tachometer) Wiring Diagram238
Late Models With Large Instrument Panel Wiring Diagram239
Late Models With Small Instrument Panel (No Tachometer) Wiring Diagram240