Yanmar YSE12 Service Manual Download

Page: 1 / 52

Summary of Contents for YSE12

Page 2: ...Relolution 12 6 5 Hunting 1 2 6 6 O u t p u t D e c r e a s e 1 3 6 Knocking during Operation 13 6 8 S u d d e n E n g i n e S t o p 1 4 l 6 9 L u b r i c a t i n g O i l L e a k 1 4 I 6 1 0 F u l O i ll e a k 1 4 6 1 1 W a t e rL e a k 1 5 6 1 2 C o o l i n g W a t e rF a i l u r e 1 5 6 1 3C l u t c h S l i p 1 5 W E A R L I M I T O F E A C H M A I N P A R T T E I N S P E C T I O N A N D s E R V...

Page 3: ...ocedure 9 1 2 Readjustment procedure t 9 2 Inbke ExhaustValve 39 39 39 4T 4r 9 2 1 Adjustmentprocedure _9 3 Fuel Injection Timing 9 3 1 Checkinghints _ b _ _ 9 3 2 Adjustmentprocedure DISASSEMBLY 10 1 Preparation 10 2 Serviceman sKit 10 2 1 Generaltools 10 2 2 Specialtools 10 2 3 Measuringinstruments 10 2 4 Others 10 3 Precautions 10 4 Clul chDisussemblj Prucedu re 42 42 43 43 43 4 48 1 1 12 STERN...

Page 4: ...1 ENGINE IN PHOTOGRARHS Eyenur for ho si ngenqine F t t only for electi l startng Propeller shaft uprinq ...

Page 5: ...up chain gearing available to install on eitherbow or sternside 5 All speed gove rnor insterlocked tith easy to operate durable Yanmar Dickel type fuel injection pump assures minimum load fluctuations and excellent low speed oper ation Rotary type cooling water pump feat rring ample circulating water and simple construc_ tion makesthe engineseizure free Flywheel enclosed in the cllrtch housing pro...

Page 6: ...on Specifications 1 CrI bodr llonoblock casting of water jacket crankcase and oil pan 2 Cyl liner Wet tlpe made of special cast iron and coated with special anticorrosive paint 3 Main bearing 4 Cyl Side cover side precision kelmet metal with thin back metal Fl wheel side Thick meta I Gasket tfpe part of monoblock including valve guides 5 Intake exhaustvalve Mushroom ttpe 6 Intake pipe lntak enenia...

Page 7: ...ng hydraulic lamp Manual startingr oil light 19 Lube oil circulation chart nlet side strainer rochoid pump Outlet side strainer Main bearing metal flywheel side Valve rocker arm chamber Main bearing metal gearcase side Crankpin metal 20 Coolingwater pump Rotary type belt driven from power take off shaft 21 Fuel itrjectio pump Yanmar Dickel type pump 22 Fuel injection nozzle Pintle nozzle Fuel stra...

Page 8: ...duction latio 2 3 1 32 Power take off shaft pulley Spur gear driven alternator and for from crank gear with pulleys cooling water pump lor 1 I i 3 2 PowerTakeoff ShaftPull ys The outside pulley is for the alternator and the inside pulley for the cooling water If the alteinator is not attached the outside pulley can be used as desied to drive a bilge pump Remark The flexible mounting being on engin...

Page 9: ...l a a 6 ReneNcrankcaselube oil Renan Clnrch aa nb I a 3 l Dis harge cooiingqarer alte ottrarion in cold a 2 Chec the recirculated condition of c ling wate a 4 l Check fuel injeciion iniection noise a 2 Adjust th govemor 3 Check fuel injection timing t al n the Ie a a 5 cylinder Eead l RetightcDthe cvlinder a 2 Adjust ih intake exhausr a 3 clean the intemal surfaces of combustion chamber a l Clean ...

Page 10: ...l oil when burned is combined witi water to produce sulphuric acid v hichcorrodes metallic parts 3 No dust or moisture content Dust and moisture contained in fuel oil can cause faster wear or sticking of the plunger of fuel injection pump and injection nozzle 4 Appropdate viscosity Fuel viscosity has a relation to the condition of injection It should be such that the pluoger and the nozzlevalve wi...

Page 11: ... a umber of additives to improve the properties of their lubricaung oils 5 2 2 Classification by viscositv Lube oil viscosity should be so selected as to suit the ambient temperature SAE ViscosityTable t I F SAE No o F 17 8 C I l0oFta8aoc Sayboliunive sal Kinematic viscosity CSt ybotl uoiYersar viscosiry CSI lo c 5W below4 000 below869 10w 6 000a l 2 000 1 303a 2 606 20w r2 000b48 000 2 606b 10323...

Page 12: ...lo Marine Oil 10w 20 30 40 RPM DeIo Multi Service Oil 10w 20 20W 20 30 40 MOBIL Delvac Special 10w 20 30 40 Delvac 20W 40 20w 40 20w 40 Delvac 1100Series 20 20w 10w 20 20w 30 40 DeIvac 1200Series 20 20w 10w 20 20w 30 40 50 ESSO Estor HD r0w 20 30 40 Esso Lube HD 20 30 40 50 StandardDiesel Oil 10w 20 30 40 B P British Petroleuno B B B B P Energol P Venellus P Diesel 53 P venellus 2 0 w 3 0 2 0 w 3 ...

Page 13: ...ake xhaust Fit valve with quick successlvemovemenls 2 Calbod or wear on valve seat Renewcylinder head 24 3 Worn valve guide 4 lntake exhaustvalve stuck Loose or uns mmetricalll tightened nozzle guard 2 Fuel injection nozzle 2 FaultJ or lost packing Repair or renew Change oil Cylinder liner r piston 1 UnsuitableIubeoil 2 Gasoline overcharged at start up 3 Stuckor worn piston ring 27 30 4 Seized or ...

Page 14: ...ltage drop under no load Renewii below 12V 12 Govelllor lever 1 Not properly adjusted Readjust 38 F l t I Dilficult Start up 4 Checkpoint Possiblecause Remedy l Temperature 1 Lo a Select suitable lube oiL Use start up accelerator 2 Fuel oil l Unsuitable qualit Change fuel oil 7 3 Injection 1 Stuck or worn nozzle valve Cleanor renew 1 9 2 Low injectionpressure Ad iust to 160kg cmz 20 3 Worn plunger...

Page 15: ...il Renew 27 30 6 4 Momentary Hith peed Revolution Check point Possible cause Re6edy 1 Regulator handle l Sudden operatioD Do not move it sudd nly Governorsyatem 1 Misadjusted lever Readjust 38 2 Stuckregulator spindle Cleao and correct 6 5 Hunting Check point Possiblecause Remedy 1 Govemor system 1 Misadj usted lev r Readjust 38 2 Stuck regulator spiodle Cleanand correct 3 Malfuction of No I lever...

Page 16: ...bondeposit Remove 6 Moving parts l Stuck or seized cylinder liner and piston Correct orarenert 27 30 2 Stuck or seized crankpin metal Correct or renew 26 3 Stuckor seizedmain bearing metal Correct or renew 32 4 Stuckor seizedpiston pin and pin metal Correct or renew 27 Check point Possiblecause Remedy 1 Tightening parts 1 Loose endnut Retighten 2 Irose connecting rod bolts and nuts Retighten 3 Oth...

Page 17: ... Changefuel oil 5 Load 1 Overload Reduce load F 14 t 6 9 Lub oil Leak 6 10 FuelOil Leak Checkpoint Possiblecause Remedy 1 Contact surfaces of parts 1 Loose bolts and nuts Retighten 2 Scratched packings Renew 2 Slidingparts 1 Scratched or worn oil seals or shafts Renew 3 Lube oil tube 1 Loose bolts or scratched Retighten or renew Checkpoint Possiblecause Remedy 1 Firel tank cock reutlner 1 Loose bo...

Page 18: ...de of crank case 1 Scractched liner packing Renew Check point Posaible cause Remedy 1 Kidgston cock 1 Dirty mouth Clean 2 Cockin closedposition Opencock 2 Coolingwater pipe flange 1 Scratchedpackings Renew 22 2 Loosetighteningparts Retighten 3 Pump drive belt 1 Slackbelt Tighten Adjust finger depressed deflexion to 5 mm 4 Coolingwater pump 1 Scratched or worn imDeller Renew 22 Check point Poasible...

Page 19: ...ntake exhaustvalveand valveguide 0 0 5 2 5 0 3 0 0 5 2 5 0 3 Piston ring end clearance 0 3 0 1 1 5 F Cylinder liner top I D 0 3 0 85 0 34 Piston skirt O D 75 0 23 85 0 26 Pistonpin O D 23 0 1 0 2 8 0 11 Pistonpin metal I D 0 1 0 2a 0 1 1 Crankshaftpin O D 0 1 3 0 CrankshaJt journal O D 44 0 13 0 1 6 Crankpin metal I D 42 0 1 1 0 12 Main bearing metal I D 11 0 1 3 Top piston ring chrome lated Bread...

Page 20: ...p and the fuel injection valve nozzle are super high precision finished to atomize fuel oil at an elevated pressute so it can be intimately mixed witl air Care should therefoie be taken that they do not get dirty or scratched during disassembly and reassembly And it is important that the are washedin clear cleaning oil before rea6sembly 8 1 r Fuel iniection pump DisassembledPump I t Resuraio body ...

Page 21: ...ews using an offset wrench dolrblehead wrenchi Cloeking Servicing a i h i F F Check point Remedy Part code iust scratches wear on delivery lalve seat and ball 1 2 Cleanif dusty Renew if scratched or wotn YSES YSEI2 Delivery valve assembly 101300 51300 Remark Common to all models Dust scratchea wear on regdator oeedle 1 Cleanif dusty 2 Renew if scratched YSE8 YSE12 Regulator needle 171590 51420 Rem...

Page 22: ...livery valve Note This completes the reassembly however air venting of fuel injection pump and adjustment of governor lever are still necessary for engne start up 8 1 2 Fueliniectionvalve nozzle A o 6 e ff n E UJ r l I r DiBaBsembly 1 Detach the fuel iujection valve 2 Remove the fuel injection valve lock nut 3 Remove the nozzle valve assembly If it is difficult to take out the nozzle body drive it...

Page 23: ... power take off shalt right ventingis necessar y l Attach tbe inter spildae sti ing seat nozzle spring adjustingplate packing and nozzlespdng holder to the fuel injectionvalve body Be sure of the spring side of the spdng seat anddo not drop the spring adjustingplates Attach the nozzle valve and the nozzle bod to the fuel injection valve bodJ Vise the fuel injection valve and tightenvarious parts f...

Page 24: ...ang The tuel injection system includes the fuel talk the fuel injection pump the fuel injection pipe and the fuel injection nozzle Air contained in this fuel iniection system prevents fuel injection In case of Juel failure and phenthe fuel injection pump is disassembled air ente the fuel injection system Purge the system of air Air Venting Procedure ril 1 Place the fuel cock in the open position r...

Page 25: ... then after attaching the iniection pipe securely tighten the tuel trrmp side nipple ConJirm if tuel leak out of the nut of the fuel injectio valve side ard then tightsn securely the nut 2l 3 4 2 CoolingWaterPump The YSE type cooling water pump of the rotary tlpe contains a rubber impeller it car feed a sufficient quantity of cooling water to all the parts at high speod as well as at low speed Dis...

Page 26: ...ler Renew if scratched Renew il the gap between impeller and pump body side exceeds0 5 mm 6E8 YSE12 Impeller r04211 42070 Scratches or weai on plpp body and cover surfaces ove which impeller slides Renew if scratched oi Pump body YSEs I YSEI2 104211 42010 Pump body 104211 42080 Scratches or weat on pump seal Wea or rust on bearing Renew if scratched or YSES YSEl2 Pump seal 104211 42100 Renew if wo...

Page 27: ...ngine and operate it to verify that its discharge ls as specified betow a YSE8 YSE12 Eoolit hr 460lit hr Pump shaft speed 2000 rpm Crankshaft speed 3200 rpm Pump shalt speed 1900 rpm Crankshaft speed 3000 rpm If operated ithogt water the rubber impeller with burn Never operate without water 8 3 CYlinderHead The cylinddr head is a gasket type the valve guides and the cylindet head are in one piece ...

Page 28: ... valve L042ll 11100 104511 11110 Scmtchesor wear on intake exhaust valveseating sudace Renew if steppedwear or deep scratches Fit if poor fitting ot shallow scratches Refer to next column Note Seatwidth should be less than 2 mm Lap if scratched or worn to a broader ridth than Specified Lapping method If heavily wor nor scratched correct with a seat cutter i 1 Lap till scratches are gone with coars...

Page 29: ... evenly in the diagonal direction rC I 2l Cylinder headlock nut tightening torque YSES YSET2 Tightening torque 8 8 2 4 PistonandConnecting RodAssembly ital at its smaller end and crankpin metal at its lalger end The piston rings are com posed of three pressure rings and one oil ring Piston and Coinecting Rod Assembly As Disassembled Connecting rod lock nut tightening torque r 8ton of hidr silicon ...

Page 30: ...t the piston when it is lo be talien out or inserteci 2 l Remove t1 ropiston pin stop rings 2 Z Heat ttlrepiston pin for 15 min in oil at oil temperalure of 8tr C 2 3 Take out the piston pin using the exclu sive tool Checking Sewicing a Note 1t is recommended that parts be renewed at ma x allowable values Checkpoint Remedy ring using a Thickness YSE8 YSEI No I ring plated B 2 0 0 t5 2 5 0 15 T 3 3...

Page 31: ... andmax in lhe abovetablerepresent nominalvalues in nm andnaximum allowablevaluesin Inn Standddgap YSE8 0 2to 0 4nm YSEI2 0 3to 0 5mm R new ifthe gapexc eds 1 5n1m Renew if weal xceedsthe maJdmumallowable YSE8 YSEI2 std std diam 7 s 6 o 23 8 s d 0 26 YSE8 YSEI2 l M200 22300 103438 223ffi Renewif wearexc eds theinaximumatlowable YSE8 YSE12 std 234 o 10 286 11 pistonpin Measure O D trsinga a 2 8 ...

Page 32: ... YSE8 YSE12 Crankpin 104200 23340 103338 23300 t Croas sectional views of piston rings i j No 1 ring Barrel faced t e that fits exactly in liner allow chrode plated ing minidru tr g s escape No 2 ring Tapered tj pe that also serves to scrape oil down No 3 ring lE ou Reaasembly 1 Reaasembly of piston dngs 1 1 Clean piston Iing grooves before ring placement preferably with ar old ring Oroken Beveled...

Page 33: ...l at oil temperature of about 8f C Use either light oil or heavy oil 2 4 Insert the connecting rod into the piston then insert the piston pin from the ll ide without piston pin snap ring DO NOT INSERT IT BY FORCE 2 5 Place the other piston pin stop ring 2 A Check Iat both the pistoq and the connectiDgrod move lightly If they do not I lr ovelightly seizure will result I _ 8 5 CylinderLiner The cyli...

Page 34: ...der liner t04211 0t100 10451I 01100 Liner packing 101204 01300 103388 1300 2 Anothersirnplerrnethod Ins rtanewringintoNo l rinS position of liner tlEnmeasur th ring endgapusinga clea ance guage Note Thering inserted should beperpendicular to liner 3 Visualdet rmination Renewal 1 Attach lock nuts to two cylinder head set bolts positioned slmmetrically to each other and pull out the liner with the l...

Page 35: ...o two 4ead set bolts oositioned vmmetricall v to each other thentighten Check that the li er top is about 0 2 mm projecting from the cylinder body Mea surethe inside diaroeter of the liner to check lhat it is oI the sa medimension i n b t h a a n L l 6 d i r e c t i n s 8 6 Crankshaft andMainBearing Metal The crankshaft is induction hardened and super high precision finished The main bear ing meta...

Page 36: ...ble dim abl Main bearing 0 1I 52 0 13 YSts8 YSEI2 104200 02100 r04500 02r00 Flywheel 104200 02120 103338 02100 Remark Alsofor Ts60 Alsofor TSl05 Renew if wear exceedsthe maximum allowa ble value YSE8 YSEI2 dim able Thrust 3 2 5 0 J YSE8 YSEI2 Thrusi 1M200 021l0 10450G02110 Remark Alsofor T560 TSl05 i r f Renewal of Main Bearing Metal 1 Drawing out of gear case side main bearing metal 1 1 Draw out ...

Page 37: ...al insertion tool with the chamfer edside of the bearing metal contour facing the cylinder body 2 4 Insert both the bearihg metal in sertion tool and tbe beadng metal into the bearing metal hole from the crankca seside Bearing metal insertion tool t t l s f At With tbe oil holes Hy andof the b o r ttr yriou b agfeerng exac the bearing m rnetal the nut till 2 6 Remove Drawing out of flWheel side ma...

Page 38: ...rtion tool ioto the bearing metal fully with the use of a hammer 4 4 Remove the insertion tool and check that tbe knock pin and the lock groove as weU a 3oil holes agree completely 4 5 Attach tlle oiL seal f 3 8 7 Electfical EquiDment The electric starter for the YSE sedesdreselengrnes djrectly coupled to bh flvwheel housing starts the engine in engagement with the ring gear of the fl wheel The ge...

Page 39: ... oKW 1 OKW Gear ratio tr4 9 72 65 r26 s 1 4 0 I I Disassemb 1 Removethe 2 Take off the starter from the engine bandcover and clean the four carbonbrushes F Checking Servicing Check point Remedy Part code Brush wear Measure with vernier Renew if the total leneth is below 9 5 mm Nominal length mm min allowabl length mm Total length 9 5 Weakened or broken brush Renew if weakenedor broken Reassembly 1...

Page 40: ... output 72v 25A 5 000 rym Earth polarity side grounded I r iit i Checking Servicing a t Check point Remedy Part code Voltage aDd current 1 Limit voltage 14 0 5V 2 Chargingcurrent 25A or more at 14Vl5 000 rpm Alternator Measure the charging current vhen the terminal voltage of the battery is 14V witi the resistance load connectedirl parallel witi the battery 3 Renew the assembly if the above specif...

Page 41: ... the cross recessed head screw for ttre pump adiusting lever a d tighten the lock nut on the other side I rrn the corulecting screw punchmart counter clockwise by 90 then tighten the lock nut 6 a Check tbat when the p rmpadjustiDg lever is pushedto the regulator spindle moves boo Temporary high speed rotation will result if the entsineis sDindle does not move Note If the pump adiusting lever moves...

Page 42: ...oke TD mark 2 Inosen the valve clearance adjusting screw lock nut 3 Adjust the clearance to 0 2 mm by means of the valve clearance adjustitrg screvr Note Adjust both suction valve and exhaust valve clearances to 0 2 mm whe the engine is cool 4 Fix the adjustingscrew using a driver then tighten the lock nut 9 3 Fuel IniectionTiming 6 u h r n i n d f h a h r n d l o t h r f h o f r o l b 1 to 6 will...

Page 43: ...ectly by repeating the step 4 three or four times 9 3 2 Adjustmentprocedure 1 2 Detach the fuel injection pump and the pump mount Increase or decrease the number of the fuel injection timing adjushnent plates If the timing is advanced increase the number of the adiustment plates delayed decraease the number 0 1 mm of plate thicknessis equivalent to approximately 2 of time difference Mount the luel...

Page 44: ...right tools 10 2 Serviceman s Kit 10 2 1 Glneraltools I I l 4l k l 2 G 4 13 r 1 4 A e fl Pl 1 5 i L6 n 1 8 0 r a Tool Remad s Tool Remarks 1 Spanner 1 0 x 3 9 Pinchers 2 Spanner 1 7 x 9 10 Pliers 3 Spanner 22 x24 11 offs et wrench l set 4 driver 12 Box spanner I set 5 driver 13 Scraper 6 Iron hammer 74 Lead bar 7 Copper hammer l set 8 wooden bammer 16 Wrech for hexagonalsocket headscrew ...

Page 45: ...al 2 Bearing puller Commercial 3 Liner puller Also for T560 Also for TS105 Fll r heel puller Alsotur T560 AIso for TS105 tr ain bearing puller Also for T560 Also for TS105 0 Piston pin puller Also for T560 Also for TS105 7 Piston pin metal puller Also for TS60 Also for TS105 8 Piston insertion tool Also for T560 Also for TS105 9 Main besring insertioo tool Also lbr T560 Also for TS105 1 0 Valve se...

Page 46: ...s hich gi e incidental rotation when other parts are moled 7 Take care not to scratch oil seals andother parts 8 For total disassembly discharge beforehand lube oil cooling ater and fuel from the crar case and from the gear case 10 4 Clutch Disassemblv Procedure 13 Step rocedure TooIs Illustration 1 Remove one cotter pin one slotted Dut and one oodruff key for shifter Pinchers Spanner1 2 Remove th...

Page 47: ... of wire and five bolts from the aheadside Pinchers Spanner 13 8 Remove one aheadfriction disc and one friction disc keep plate 9 Remove one holding frictlotr disc 1 0 Remove one aheadshaft lock nut Note Completely flatten the lock washer Remove one lock washer Ddve Hammer Spanner36 11 Pull out one bearing from the clutch case rear box side Bearidg puller Pull out one small ahead gear one key Gear...

Page 48: ...ration Remove one aheadshaft llith bearing Remove one piece of r ire and five bolts to detach one fric_ tion disc assembly and one bearing from the astem gear Pull out one aheadshaft bearing housing A side Bearing puller a rh 45 ...

Page 49: ...Disassembled Clutch I I F Q enl t isx 46 ...

Page 50: ...headgear 29 Link 1 4 Ahead shaft lock nut 30 Link pin 1 5 washer 31 V lever holder 1 6 Ball bearing 6205 I 11 REASSEMBLY 11 1 Precautions 1 Cleanparts thoroughlY in oil t 2l Use the right tools and assemble the engine faultlessly 3 Apply Iube oil to rotary and sliding parts 4 Use new packings cotter pins and lock washers 5 Makesub assembliesbeforehand 6 correct or renew scratched or worn parts bef...

Page 51: ...e engine be sure to center it in correct alignment ivith the latter Standard Stern Arrangement t I Model Propeller rpm Propeller Propeller shaft Stern tube B diam rn pitch in diam mm length mm diam Iength YSEs t l27 l 4 I 22 1800 16 100 1332 1 3 s 1 2 1639 1 2 7 7 2 YSE8G 751 1 Z 2 o 2000 50 500 8q8 16 7 2 1 1 109 3 1 0 YSE12 1113 1 5 1 0 25 2000 50 500 1316 I 1518 1 3 I r 2 YSET 2G 18 19 2t3 2400...

Page 52: ..._ i r t 1 l k i 4 d s l i ...

Search results

Summary of Contents for YSE12

Reviews:

Related manuals for YSE12

Brands by name

Popular brands

Yanmar YSE12, Service Manual

Search results

Summary of Contents for YSE12

Reviews:

Related manuals for YSE12

Brands by name

Popular brands