Yanmar YSE8 Service Manual Download

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Summary of Contents for YSE8

Page 2: ...elolution 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...

Page 3: ...cedure 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...

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

Page 5: ...p 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...

Page 6: ...n 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 Sid...

Page 7: ...g 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 me...

Page 8: ...uction 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...

Page 9: ...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...

Page 10: ...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...

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...

Page 12: ...o 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 20...

Page 13: ...ke 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...

Page 14: ...tage 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...

Page 15: ...l 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 Stuckr...

Page 16: ...ondeposit 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 r...

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...

Page 18: ...e 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 R...

Page 19: ...take 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 1...

Page 20: ...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 no...

Page 21: ...ws 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 wo...

Page 22: ...ivery 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...

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 sprin...

Page 24: ...ng 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...

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 Cooli...

Page 26: ...er 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 Ren...

Page 27: ...gine 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 3...

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 Seatwidt...

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...

Page 30: ...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...

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 maJdmumallowa...

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...

Page 33: ...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...

Page 34: ...er 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 Th...

Page 35: ...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 lha...

Page 36: ...le 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 Y...

Page 37: ...l 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 t...

Page 38: ...tion 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...

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 co...

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 0...

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...

Page 42: ...ke 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 cle...

Page 43: ...ctly 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...

Page 44: ...ight 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 Spa...

Page 45: ...l 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...

Page 46: ...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...

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 No...

Page 48: ...ation 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...

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

Page 50: ...eadgear 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 ass...

Page 51: ...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 Ien...

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

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Yanmar YSE8, Service Manual

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