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Yanmar Yse Instruction Manual




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YAIIMAFI trlIESiEL EIGIIUE
rr a
t CONTENTS
1 Description 1
z 24 Exhau Pipe 4
25 Intake Pipe 5
26 Remote Control System t
27 Ater Launching o
4 Pecautions
With New Engine 10
5 11
51 FuelSupply 11
52 LubeOilSupply and Lubricatign 12
53 Checkinguel lrijection 15
6l How to Start rhe Engins 16
62 After Starti 17
7 18
L 20
9 Periodical
Checks 21
91 22
92 EverylO0 Hours 23
93 26
Evry500 Hours 27
10 Adjustment and Reassembly
Stripping 29
101 Precautions
102 Pecautions
11 Air Venting
of 31
12 Checking FuelInjection
13 Checking andAdiusting Timing 37
15 Stripping of Pump 38
V a l v 15 1 Deliv er v q
152 Regulator 39
153 Plunger 40
16 41
1 DESCRIPTION
OF PARTS
Clut c h hous ing
Fuel t ank oil ation pump
Fuelcock
Gearlever
Aiternator ll
Fueltank
drai npl ug
only with electrical
Engine feet Enginefeet
starting
L u b eo i l d ra i np i p e
Not fitted
pin Eve nur for rarlng snatt
1 ilirtate pipe
Fl ex ible
c ou
Coolingwater pump
Flex ible mountinq Rotarytype
Rocke bbx
Draincock wate
typeCXlwith attached
2 21 Engine
1 Useharddry timber An excessive
bed causes vibration
which may resultin a shaftandother damage
I cm 3 4 squareCut out the necessary
21 Usetimberof at least sections
to clutch case
3 Angle of inclination the type of boat and the placeof
it lnstalling
at angleabove this
limit leadsto the speed
of the boat andto
abnormal f
t4l Makesurethat the engine bed securel I
irmly to the hull Leave
enoughspace the engine
beneath bed to permittight Tri
eningof the nutsfor the engineset bolts
5 Great care should be taken when installingthe enginethe propelle shaft and
thrust shatcan be 22 Mounting
1 Mount the engine
onto the bed
21 Tighten the set bolts evenly and securely Oo not try to tighten them orcibly
if the is not correctly aligned
1
3 propeller shaft o
intermediate shatif present to the
engine irstly checkthe clearance
al both shaft couplings l4easue the
clearance at the top bottom let
and right of the coupling flange with
a thickness gauge and repeat until the
clearance doesnot exceed 02 mm
at any point lf the centerof the
engine thrust tat is too high
planethe engine bed if it is too low
inserta floor platebetween the
engine and the bed
4 Recheck
23 System
1 Attach the V belt for the to the pulleyin the center
of the
PTOshaft Adjust the belt tensionsothat delection is about 5 mm whenthe
middleof the belt is presseddown with the thumb Adjust by looseningthe
coolang water pump set boltsand the pump
NB Operatingthe coolingwater pump without waterwill resultin
damage to the not operateuntil the water
2 Fit the Kingstoncock to the hull
3 Measure the distances rom the
Kingston cock to the coolingwater
pump intakeand om the engine
cooling water outlet to the outside
o f t he hull Cut a u b b e rh o s e i d
l3 mm od 20 mm into the
correct length
NB The rubber hose is not
suppliedas standard
3 i
14 Connect the Kingstoncock to the intakewith the one hose
and engine to the outsideo the hull with the other hoseas
and straight Then secure tightly with Thermostatfor coolingwater is equipped for
asstandard in
cold weather
24 Exhaust
Pipe
a Drytype
1 Attach the dry type silencerto the exhaust langeon the attachthe exhaust pipe to the outlet o the l it is necessary
to bendthe exhaust
radiuso the curvature
is at least100 mm
3 pipe centerrestat an appropriate
point on the hull
b Wet type Attach the exhaust gaspipe to the exhaust
elbowthen attachthe wet type
silencerto the Connect the outlet o the silencer
to the outsideo the hull with the rubber
hoseid48 mm
exhaust
3 Connect the to the water intakeport o the wet type
silencer
with the t
To lize PT 16r rup9rY
25 IntakePipe
En g ine room
Fit an extension pipeto the intakepipe as
shownin the figure This permitsfresh Exhaust
air to be suckedin rom outsidethe engine pr pe
room and prevents aultsdue to temper Camp
by poor th e engt ne
r oom
Usea resinor iron pipe Avoid irregular
onos
of intakepiper
YSES 386 mm
YS12 427 mm
3 pipe is not supplied
NB Extension asstandard
overthe intakepon to prevent
Attach a shelter the pipe
dirt and waterfrom entering
26 21 SpeedControl Lever
1 The speed control lever can be
operatedbi meanso the remote
control cable Installthis in a
convenient place
t2l Lay the remotecontol cableas R emote control
should caote
havea radiusof at least30 cm
I 3 Grease
the coreof the remotecontrol stengthby meansof the adjusting
bolts
For emote control operation of the the wire to the
snall YSESand ySE12 hole in the lever Models only areequipped
with remotecontrol decompression handle 3 metercableis optional
269 Gear Lever
A hole is providedin the attachment of a o remotecontrol accoding to the conditions
on your boat lt can be itted to morse
type a bracketor pump is fitred bracket and pump are available
4
SystemFor YSE9XYand Parts
The electical
system comprises the following 1 Starter 2 Alternator 3 Dush
panel 4 Wireharness 5 6 Battery 7 Oil pressure
the followingmust be O these asoptionals to any alteration without notice
Charging alternator 12V 25Al4P
WireharnesF 3 m for wire harness
extension
tor
12V 40Ah for requentuse
Battery
l 2 V7 0 A h fo r b oat not useddai l Y
Oil pressure
warninglight
Oil pressue
waning
Pressure
switch
for assembly
Oil pressure
Wiring
1 the wire haness
Connect aso llows
and terminals
Connect to instrument panel side
Connect
to Connect to starterside
Greenterminal Join to oil pressute Pessure switch is optional extras
Blueteminal Join with to starter
magner
Black
terminar terminar
to starter
Please
connect
accoding
to the colo indication
Red Connectto instrument pJncl side
a or work load under 10A
21 Installthe instrUment
panelin a convenient position Threemeters extension
canbe obtainedif wie harnessA is too short Select
a dry placeee from
31 Connectthe Connect battery terminaland Connect togetherwith the blue cord round teminal o the
wire harnessB
Starter cable Connect battery terminal and ater set bott
earthto body Connect together with rhe blackcord
round terminalof the wire harness B
41 Makesureall terminals
are securely
connected
then coatwith grease
5 morethat all the connections
273 Check
Prepae
the enginefor startingand turn the ignitionkey
Checkthat opeationis normalsee 7
Never engine
operate cables
with thestarter disconnected srnce oangerouov rOfffi
disconnected
with the battery i theV is
L
C hargi ngl i ght
4V3W
Oi l pressure
w arni ng l i ght
h Work1gi t
unde 1CiJ switch
P t7rz
motor
Startang
Sta r te r in sta lla tio n
b o lt
A s t h e r i s n o e a th o b ta in e a th co n n e ctio n fr o m the engi ne or bai try
3 AFTER LAUNCHING
1 Checkthat there is no water or air leak from the gland of the stern tub or the
Kingstoncock joints
l2l Check that the engineset bolts and shaft coupling are 3 Release the compression with the decompression lever and gently turn the
starting handle Comparethe resistance when the gearlever is
in when it is in the engaged reverse
no appreciable
is correct howeverif the resis
is much strongerwhen the clutch is engaged recheckthe
rLtce
s alignment of the the engine to avoidbrakage of the
propeller shaft and other I
4 PRECAUTIONS
WITH NEW ENGINE
Overloading the engine beforeit is properlyrun in shortens
its life The irst 150 hoursof operation shouldbe treatedasa runningin period
1 No irst 50 hoursof runningin periodAvoid
operating
at DIN A ratingspeed with exhaust
l2l Ater 50 hourso the lubeoil in the crankcase
and clutch
caseAlso cleanthe 3 Thereafter the crankcase
change lubeoil every 100 hoursand the clutch
caselubeoil every250 hourso prolongs
enginelife l
4 To eplacethe lubeoil first discharge
the old oil while the engineis still warm
and cleanthe insidewith light oil Then add the new oil i
At 10 hoursper day operation
50 hours 150hours
Every 10
5 days rdays 100
50 hours
C h a n g elu b e o il a n d Change lube oil and
ctean l ube oi l i l tr
c le a n lu b e o ililte r
50 hours 30Ohous
Evey 25
doyr 25O
C h a n g lu b e o il
7t
5 B E FOREOP E RAT I O N
51 FuelSupply
0 t FUel
lightoil J l S K2 2 0 4o r e q u i v a l e n t
Used ies el
Recommended
brandnames
of fuel
S upplier BandName I
S he l ld i e s o l i n o
er l o c a l t
S HE LL
equrv a re n l
C A LT E X Caltex diesel oil
MOBIL M ob i ld i e s eo
l il
ESSO Essodiesel
B P B r it is h
BPdiesel
Petroleum
512 Fuel Tank Capacity
F ill the fu el ta nk with dies elf uel Tank
capac ity is as ollo ws
Removing Wate and Dirt Presentin Fuel
Water and dirt which lead to o the engine are sometimes
p resen tin the uel oil
12 Leave the drum standingfor about
10 daysto allowany waterand dirt
to sinkto the bottom Filter the
oil througha cleaninely woven
cotton or silk cloth Leave standing
Avoid rockingor shaking the drum about 10 days
Throw away sediment
514 DrainingFuel Tank
To remove the waterand dirt accumulated
in the bottom o the uel tank drain rom
the drainplug everyday beforefilling fuel
D rai n pl Li g
52 LubeOil Supplyand Lubrication
L u beO il
Recommended
brandnames
o lubeoil for crankcase
and gearbox
S A E N o I
lt Supplier
1 B r a n d Na m e
b e lo w lOo C 10 2ooc 20 350C
over 35oC
S h e l l R or e lla Oil
20t20w
2020w
40 50
SH L L S h e e lT a lo n a Oil 10w 30
20 50
S h e l l R i m u la Oil 20120w 20tzut
R P M D e l o M a r in e Oil t0w 30
20 50
CALTEX
RPIVI
D e l o lM u lti Se r vice
20120w 30
Oil 20 50
10w 40
D e l v a cS p cia l low 20
Delvac20W40 20w40 20w40
MO B I L
10w 30
D e l v a c I 1 0 0 Se r ie s 2020vt 50
2020v 40
l0w 30
Delvac
1200Series 2020w 50
2020w 40
EstorHD 10w 20
f 30
ESSO EssoLube HD 20 50
S t a n d a r d D i se lOil 10w 20 50
a 40
BP E n e r g o l ICM
BP V a n e llu s 30
20w30 20w30 50
BP n e rg o l DS3 40
BP V a n e llu s5 3
Re m a r ks T h e vis cosi ty grade of the l ube oi l shoul d
b e ch oosed to srri th
l ambi enl ai r
te m p arature
521 Crank Case
Remove the oil ilter capand fill with lube oil up to the the
dipstick To checkthe level screwing in the
cap Avoid overfilling and 13
Th e vo lum eof lubeoil i s a sfo l l o w s
522 Clutch Case
t he lubeoilf ille r c a pa n di l l w i th
R e mo ve
lubeoil up to the the
dipstick Usethe same oil asfor the volumeo lubeoil is I
The correctoil levelcanonly be ship is level
523 the and starting with iube
53 Checking
1 Openthe fuel cock The uel is fed
t h ought he f uel i l te r to th e fu e l
injec t ionpum p
2 Setthe speed
contol leverto LOW
andt he gearleve r
to N E U T R AL
3 Raise
the leverand
turn the 5 or 6 times
Checkthat you canhearfuel being
injected
l4 lf you beinginject
ed like squeasing noise air is present
in t he f uel injecti o n
s y s te ma n dm u s t
be vented Beerto 15
6 STARTING
61 How to Start the Engine
61l 1 Set the speed
control lever
to LOW
12 Raise the decompession leverand turn the or 6
ti m esunt ilt he f ly w h e e E
l ains
mo me n tu m
3 Release the decompression leveand urther 2 or 3 turns The enginemust start
612 1 control leverto LOW
Set the speed
l2l Wheninsertthe ignitionkey and turn
i1 to the ON position the chargelamp
lred and the oil light
redlight up l the lightsdo not
behave correctly checkthe electracal Ch a r g el i ghr
system
3 Raisethe decompression lever Whenturn the ignitionkey to the STARTING
position
the charge warninglight redgoes
lamp redis up and the oil pressure
out This turnsthe starter
1 4 H old t he k ey in t h i s p o s i ti o no r a b o u t5 s e c o n d u gai ns
s nti l the engi ne mo
mentumthen release the decompression lever The enginenow stats
R eleaste he k ey im me d i a te l y to the ON posi ti on
so th a t i t re l u rn s
As engine speed increases the charge light red and the oil pressure waning
light red go out
5 l the enginefailsto startevenwhen the key is held in the STARlNG position
for 10 seconds returnit to the allow 30 seconds
for the
recovers Holdingthe key in the continuously leadsto aultsin the circuit
6 lf the enginestill failsto injectionand 16
613 Startingin Cold Weaer
In weather pour about 05ccof gasoline throughthe intakepipe
carenot to add too muchgasoline knockingand
asthis causes
co mpr es s ion
leak ageIn
s te a d
o fg a s o l i n eYa
n ma rA e rosol canal sobeused
extra
Neitherneedbe used when the enqine is warm
62 AFTER Starting
1 As the engine start
ing Remove
the fix the pin
to the t2 Checkthe visualoil pressure
indica
tor to seethat lubeoil is circulating
properly With engines usingelect
ric startingand equipped with an oil
pressure the oil
pressure warninglight redis of
3 Checkthat coolingwater is comingout of the lf it is
not stop the engine and checkthe water system or blockages continuing
in t his c o n d i ti o n
o per at ion re s u l ts i n the cool i ng
i n w e a rto th e i mpel l er w ater
pum p lf c oolin g w a te rc i rc u l a ti o ni s b a d re move the pump i ntakepi peand
p m e
t4 With engines
checkthat the chargelight is off This
light goesout at about650 rpm and begins
charging
5 Allow the engine to idle for about 5 minutes with the gearleverin the
o NE U RA L pos i ti o n T h i sa l l o w sl u b eo i l to c i rcul ateto al l metalparts and
is in cold weather Puttingthe engine into ly ater seizure anddamage to movingparts
Whenoperating or the first time ater launching let the engine idle or 20
o minutes then gradually increase engine speed
6 After checking the that operationis 17l Finally
c hec kt h a t n o a b n o rman arepresent
a te ro r o i l l eaks
l o i s ew
7 DURING OP E RA TI O N
1 Neveroperate the fi r s t r educ ingeng i n e
speed to SL OW
Changing gearat high englne speeds
damages the friction discsand accel
erates wear Sudden changesfrom
full speed ahead to astern must
always be avoided exceptin emer
gencies
The engaged gent
ly and disengaged qlickly Adjust
the speed of the boat with the ac
celerator lever neverslip the clutch
t2 lf the oil pressure
stoplube oil is not
circulating properly But this is not appliedin the caseo low indicatesthat the lube oil is old and With engines equipped with
an oil pressure normalif the
oil pressure warninglight is of
3 that coolingwater is comingout of the coolingwater pipe
i outlet l the low of water is low o the pipingsystem and the stopthe
engine
and check
4 With engines checkthat the charge
lightsup there is a fault in the charging
light is OFF lf it
repair
5 Chec kt he f uel o i l l e v e l
i n th e ta n k
and add fuel when it approaches the
lowermarking on the fuel gauge
Operating with insufficient uel can
esultin air entering the uel iniec
tion system stopping the engine
Depending on t h e l o a d a fu l l fu e l
or 35 h o u rso
t ank las t s
oper at ion
61 O nc ea day t ur n th e l u b eo i l fi l te r
handle severaltimes This emoves
to the ilter plates
dirt adhering
17 Checkthe coloro the exhaust
Blackexhaust indicates that the
engine is beingo v e rl o a d e d
an d
operation must neverbe continued
f or longper iodi n th i s c o n d i ti o n
8 Depending on the installation and
structure of the hull vibrationmay
occurwhen engine soeed eaches a
is due to resonsn
c e of t he engine a n d th e h u l l N o te
the c ondit ions u n d e rw h i c h th i so c
c ur sand av oidr u n n i n gth e e n g i n eat
that particular speed ol frl ter handl e
warepump Rolaytype
s Check or waier gasanloit 19
8 STOPPING
1 Al way sr educ e g ra d u a l l y
speed
t2l To s t opt he engin ep u t th e g e a rl e v e r
i n N E U T R ALl et the engi ne
i dl ethen
setthe speed control leverto STOP Avoid stopping the engine by means o
the decompression lever this causes fuel to accumulate in the combustion
chamber and canresultin accidents at the next time o W it h engines
us in g
e l e c tri c the key and
rn th e k e y O FF R emove
s ta rti n gtu
attachthe supplied
Close the fuel cock
51 ln cold we ath er dr ain of f t he c ool
ing water to prevent reezing Close
the lever on the Kingston cock and
dra in o the wa ter r om ins ide t he
en gin e thro ug h the dr ar n c oc k under
neath the cylinder head loosen and
remove the cooling water pump
intake and outlet pipes drain of the water
f rom in sid e th e pi pes t hen t ur n he engine
severa ltimeswith t he s t ar t ing handle t o
dischargethe water from inside the cooling
water pump
6 Wip e of an y dirt w hile t he engine
is stillwa rm
t7l Stop the engine at the compiession
stroke by turning it with the start
ing ha nd le u ntil re s is t anc eis elt
Do not use the At this posiiion the intake and
em ov e the c ool i ng c
exhaust valvesae closed protecting w ater pump i ntake
the cylind er a nd v alv e s eat s r om and oul rt p pes and
expel the w ater rom
m oisture i nsi de the pump
8 l necessary
coverthe mouth of the an empty canto
preventrain waterfrom enteringthe engine
2 0
9 P E RIODICA L
CHE CK S
R e g u l arc hec k ingis vi ta l i f th e e n g i n ei s to b e k e p t i n goodcondi ti onS chedul es
va rya c c or dingt o oper a ti n g c o n d i ti o n s p o f fu e l o i l and l ubeoi l used
ty etcbut
the serve asa roughguide For the relevant
paragraphs
Da lly
Every100 Evety 250 Everys00
Check and retill n
6 Drain fuel tank
Q re o e re i l l i nq
C l e a n a n d e p l a c e fu e i ilte r e le m e n t cl R epl cetQ
C h e c k o i l l e v e l i n ca n k ca sea n d clu tch
L u b r i c a t i o n s t a r tin gsh a ft ch a in e tc
f u r n l u b e o i l f i l t e r h a n d le
a n d cle a n lu b e o il filte r
Disassemble
C h a n g el u b e o i l i n cr a n k ca se
C h a n g el u b e o i l i n e lu tch ca se at
5 Drain a A
3 C h e c k c o o l i n g w a te r cir cu la tr o n
F 9 C h e c k f u e l i n j e c t i o n so u n d J
A d j u s t f u e l i n j e c t io n r e g u la to r
C h e c k f u e l i n j e c t io n tim in g
C l e a n n e e d l e v a l v J
Retighten
A d i u s t i n t a k e a n d e xh a u stva lve
C l e a n c o m b u s t i o n su r a ce
E C l e a n p r e c o m b u s tio n ch a m b e r
L a p i n t a k e a n d e xh a u st va lve s
C h e c k v a l v e s t e m sa n d va lve g u id e s
Clean br e a t h e r v a l v e
Chec k b e l t t e n s i o n c o o l i n g wa te r p u m p a n d
Replac ea n t r c o r r o s i v ez i n c
p i s t o n c h e c k r in g s
Dis as s e m b l e J
91 Daily
911 Fueland LubeOil
1 O pent he dr ainpl u go n th e u e l ta n k
and remove the dirt and waterac
cumulated at the bottom o the tank
IIB W it h engin e u
s singe l e c tri c
cver the starter
and alternator with a sheet of
vinyl to protectthem rom oil
D rai n pl ug
t2 C hec kt he f ueloil l e v e li n th e ra n k
a n d r ef ill if nec es s a ry
RotarY
Waterpump
3 C hec kt he lubeoil te v e il n th e c ra n k
case and up to
th e upperm ar k in g
o n th e d i p s ti c k
4 urn the handleo the lube oil ilter
on the outlet sideseveral
timesto the
let or right
912 from the cooling
waterpump Also checkfor water
the th a sm all
am ountof o i l
914 Fuel Cr ankt he engi n e
b e fo res ta rti n g
a n dc h e c kth at fuel i ni ecti oni s normal
915 DrainingOff the In cold weather
drainof the the
waterfrom inside the drain cooling
water pump intakeand outlet pipesand expelthe waterrom insidethe
PumP seeSection 8
w ater pump i ntake
a and ourl et pi pes and
drai n off the w ater
92 Y ery 100 Hours
921 Remove The ilte is located
the uel oil ilter and washit in kerosene
belowthe fuel cock Strip as follows
2 3
1 t he uel o i l p i p ea n d u n s c re w
R em ov e th e 2 n u tssecuri ng
the fuel cocksetbol t
21 Pull out the fuel cock and removeit Leave
the oil gauge
attached
r t th e b a c ko f th e fu e l c ockand a 19 mm spanner
l ns er ta 17 m m sp a n n ea at
the hexagonal section on the filter sideLoosen and remove
To assemble ollow the reverse procedure Takespecial carewith the 0 rings
on the uel cockjoint Retighten the nut s Us inga si n g l e
s p a n n e r
tightenthem securely and evenly
asshownin the diagram
T ight ening
t o q u e
637 tl b
1 2 4k g m
2 4
923 Checkthe tensionof the cooling
water pump andgenerator v
belts Pressdown with the thumb
In the centeof the beltsnormal
deflectionis about 5 mm To e
adjustthe tension loosen the set
boltso the or alternator
and reposition it
924 Drainoff the lubeoilfrom inside
the crankcase and washthe inte
r ior wit h lig h to i l T h e nf i l l w i rh
a lubeoil Thisshouldbe perform
ed after the irst 50 hoursof
operationin the case o a new
a engr ne l
1 Dr ainof f t he o l d l u b eo i l a fte r fi rs t
runningthe engine until it is warm
The drain plug is located belowthe
l2l Remove the washthe inside o the crankcase
with light oil beforeilling with
new oil
925 Clean the insideof the lubeoil
ilte Remove the 3 ilter cover
setboltsand pull out the filter
Wash light oil
Brusho dirt adhering to the
filter 25
926 Clean the breather valve
The breather valve is attached to
th e in sid eo f t he r ear c y linder
cover Remove the breather valve
assemblyfrom the cover and
witho ut str ipping was h it t hor
o ug hly in l ight oil
r1 I
it 93 Every250 Hours
931 exhaust
valvetip
and rockerarm clearances
t1 Checking
shouldbe donewhen the engineis cold t
t2 Rem ov e t he r o c k e rb o x c o v e r
a n dro ta teth e e ngi ne manual l y
unti l otpr ari on
oc c ur s T his cl o s e ste i n ta k ea n de x h a u sv
t a l ves
3 Checkthe clearance
between
rockerarm with a eelergauge
is 02 mm
4 lf necessary
adjustthe clearance
by means
of the rockerarm Tightenthe locknut securely
after Fee er gauge
7 O2mn a
I Ei
L
l l 04
932 Change the lubeoil in the crank
c as eP um po u t th e o l d o i l fro m
the crankcase while the engine is
still warm Reillwith new lube
r oil
a 94 Every500 Hours
941 Strip and cleanthe lap the your dealer
if possible
1 Remove the strip the chamber
valvesprings
ano valves
21 Remove
rust and insidethe chamber
on the
on the surface
valvesats and on the top o the piston
TakeCare not to damage the 31 Checkthe clearance the clearance
between is
excessively
widethe be replaced
Also checkthat there is insidethe rockearm chambe
i4 Lap the valveseats
First remove partswiln
the roughest
coarse lapping powder Then lap
with a ine lapping powderand inish
witli lubeoit
942 Replacthe f uel f ilter elemen
943 Disassemble the fuel and cleanthe needle
reassembly 944 leveruel details
Adjustthe governor see
Section14
945 Checkuel 946 Replace the anticorrosive zinc
Rem ov e t h e a n ti c o rro s i vzeinc
coverlocated at the sideof the
pipe
c y linder side a n d re p l a c eth e
F z inc
Anticorrosive zinc prevents elect
rolytic corrosion inside the engine
F ailur e to replace i t re g u l a rl y
leads to serious damage
947 Takeout the pistonand remove the piston
replace
consultyour dealerif l
li 2l1iEsfi
lr 28
STRIPPING
10 ADJUSTMENT AND 1 Precautions
and maintenance helpensure that the engine is kept
in good conditionat all times In this way faultscanbe repaired in their serious breakdowns o the engineis oncea yearthe engine must be
strippedand overhauled be
sureto observe the ollowing Thisapplies to engines
of commercial structureand functiono eachpart so
asnot to wastetime or cause
damage by parts lMakea
noteof the methodo assembly of eachpart and be sureyou know how to
Prepare the a boadon which to arrange Washall partsthor
oughlyand placethem on the boardin the Usethe propertools Take carenot to damage the parts
or scratch
4 To etconto the boltsto which they
belongwhen placingthem on the board
5 o te th e p o s i ti o n
Dur ings t r ippi n gn marksThe ol l ow i ng
o f a l i g n ment parts
havealignment marks Connecting rod BIG end camshaft gearand crankshaft
gearjoint for thrust shatand propeller shaft or intermediate
shaft Where
necessary makeyourown alignment marks
6 Repair
worn sections
hammermarks
scratches
andother minor damagelt 1
is not necessary
to removelarge entirelybut be sureto smooth
scratches
down allr oughe d g e s
t7l Cleanthe inside o the crankcaseand other partswhich are normallydif
icult to reach
2 9
102 Precautions
In general reassembly Note the following
in reverse
1 Washall alignall ensure
2 Ti ght enall nut san d b o l tse v e n l y
3 all split pinsclaw washers
Replce and packings
l4l lMakesurethat split pinsfit tightly into the holes
and split the endsafter
be sureto bendclaw washers properly
5 Smear the all bearings partswith lubeoil
and other slidingand interlocking
Ap ply m anuallyd o n o t u s ea c l o th
6 Gjvespecial attentionto the governor to the adjust
ment of the governor and the uel take careto adjust
uel correctly
t7l t rk so n c o n n e c ti ng
Be s ur et o alignall a l i g n m e nma rod B IG endgears
8 Ater reassembly
turn the engine
with the starting
handleand checkthat no
is produced
noiseor abrasion
abnormal
e Checkthat thereare no leaksin the and lubeoil pipe
systems
is complete checkonce morethat everything is normal Then
supplyfuel and lubeoil and carryout a the allow at least
3 itting Repair
any at this time f
11 AIR VE NTING OF FUE L INJ E CT I O NSYSTEM
The uel comprises the fuel tank the fuel fuel
injectionpipe and the uel Fuel is not injected if air is present
wherein th is system
Air entersthe system whenfuel runsout andwhen the fuel injectionpump asstripp
ed lt shouldbe vented asollows
1 Replacethe fuel cock in the open
l2l Loosen the nipples at eachend
of the fuel Set the governorlever to LOW
l 3 Loosen the by about two turnsand when
bubbleree uel comesout 1i
I securely tightenthe deliveryvalve b
holderand thenater attaching
the the fuel pump Jt
4 Now turn the engine with the
starting handle about 30 times
Oil is circulated and comes out
from the nippleon the injection
valveside Whenno moreair
bubbles are presentin the oil
tightenthe nipple
5 Continue turningthe engine
until you hearthe soundof fuel
indicates
that the air vented
VALVE
12 CHE CK INGFUE L INJE CT I O N
Badexhau color and reduced output powerare often the resulto fuel 1 Remove the fuel takeout the fuel semblyfrom
the t2l Installthe engine
asshownin the 3 Vent the air from the uel injection
a 4 After air venting turn the starting
t handle and observe the atomization
of the uel asit is injected rom the
nozzle Keepyour facewell clear
5 Normallyfuel is injected in a ine
lf uel atomization is the Fuel iniection and check
that the nozzle valvehasnot seized due to
Fuel val ve spri ng cl amp
dirt etcin the nozzlebody The the Fuel val vesP ri ngcl after stripping washthese packrng
taking 9 N ozzl e spri nq adj usl i ng
partsin light oil and keepthem cleanThen onc above
lf injectionis still auly haveyour local replace the adjustthe fuel uel 60 kgcm2
13 ADJUSTINGFUEL The functiono the governor is to to variations in the loadon the
e n g i n eT hef uel injecti o n re g u l a to rtra n s m i ts th e a cti injectionpump by regulating the amountof uel supplied
stable operation at all times The egulator must be adiusted whenever the uel pump
is stripped and when uel indistinct after long periods o
operalron
Whenuel indistinct asfotlows
adtust
1 Loosen the connecting
screw
l oc k nut
12 Turn the connecting
screw90o coun
t that the punch mark
comes to the nearside
3 Tightenthe lf necessary or if the uel iniection pump har bn
siipped adiust asfollows
1 L oos en s c r ew 2a n d l o c k n u t 4
t2 Set the speed
control leverto H lGH
screw3 its bottom end doesnot
3 Screwin connecting
bottom surface lever5 Sel the punch
o the governor
mark 6 to the that the groovein the screwheadis parallel
t to t he pum padju s ti n g
l e v e rl
0 Inserta screwdrive
into the grooveon the tfrftthe regulator
until it It
5 holdingthe pump with your teft handto
preventit moving Securewith locknut 8
t a D
6 Tun the engineby handand listenfor the soundo fuel no
soundis hear d
the causei s p ro b a b l y
o n e o f th e fol l ow i ng i nsuffi ci ent
ai r
venting
regulator spindlenot screwed in ar enough wear in valveseato
valve
screw3 90o Now turn the connecting so that the grooveis
t o t h e p u mp a d j u s ti n g
a t r ightangles l e v e r1
8 Ti ght enloc k nut4
Run the engine
and lf it is still repeat
the Positiono punchmarkin 7
t t
14 CHECKINGAND ADJUSTING TIMING
The fuel this engineis 8o o
crankshaft rotation Checkthe timing asollows
1 Remove
the coverof the crankcase
2 Setthe speed
control leverto HIGH
Raisethe decompression leverand gentlyturn the com
pression strokelock throughthe openhatchand stopwhen the scale readings
on the into view
4 Turn the PTO shator startingshaft in the directiono rotationand stop im
J mediately you hearthe soundof fuel Readoff the scale read
I ingsby the notch in the edgeof the reading
Repeat calculate the average
Fuel injection 120 lf timing is too lateor
too the adjustment shimsbetween the fuel
injectionpump body One 1 mm timing by lo one 2 mm adjustment shim by
add shims
20 l timing is advahced if timing is delayed
15 STRIPPING
AND REASSEMBLY
OF FUEL INJECTION
PUMP
The fuel injectionpump shouldonly be stripped for the purpose of eplacing worn
p a rtsplungeras s y del
i v e ry
valve
a s s y
re g u l a ton etc l f uel i nj ecti on
e e dl e fai l s
to occurater air venting or adjustment o the uel the be stripped or cleaningor aultsin the irel resultfom the useo impureuel and
ailure
to cleanthe uel ilter maintenance is vital
The instruciions givenhereare intended only to acquaint the userwith the sructure
of the fuel As stated above stripping shouldnevebe Partsin fuel injection
pump
i l l
I Resurator I l F uel Ini ec ti on pum p
2 l D el i v er y v l v hol ds r
si1 3 l Oer i v s y v al v s ar
4 l D el i v s r y v al v
A 5 l D el i very vrvspri ns
gioi e 6 l A esual to body
i i 7 IF egul ai o s pi dl
l9 l a l R esul to sp ng
9l R egul tor nes c l 16
ll ll a I
idry
r Ld
Ydei l
rJ
l G as k t pac k i ng
12 l P tunser barrer ti ght
I r I ls3 I 1l
l i 5 l S pi ns
I prp uocv
lrr iition G
The fuel iniectionpump consists of four sectionsthe pump body 1 the 2 5 the 6 9 and the plunger
assembly
r 0 15
11 Delivery
Valve
How to take apart
1 t he uel i n j e c ti o n
Rem ov e pipe
t2l Remove the This reveals the which accommodates the and the Assembly
1 Wash all Be sure
to mount the partsin the 12 Reattach the the fuel pump body Follow iry air vent
i ng s ee
S ec t ion1 2
152 Regulator
How to take apart
lt1 Loosen the pump adiusting
leversetbolt and removefrom the regulator
spin
d le 7
21 Loosenthe regulatorbody 6 and removeit from the fuel pump body 1
spring8 and regulator
Regulator needle9 can now be removed
Assembly
1 Wash all firstly assemble
the regulator pat First smear a
o the regulator
smallamountof engine oil onto the screwsection Assemble the and regulator
needle 9 at the tip o the
spindle
l2l Insertthe regulator spring8 and 9 in the 6 and in the regulator body rom
I opposite side lf the regulator
spindleis screwed up deeplythe regulator
needleseatmay be damaged
3 Screwthe checkthat it Thengently i
screwdown clockwise I
I J
4 Insetthe fuel pump adjusring
leverinto the top o the regulator
spindle
then
adjustthe fuel regulator
asexplainedin 153 Plunger
How to take apart
l the uel injectionpipe and the pump adjusting
Remove lever
t2 Remove
the and removethe 3 Remove
the two uel pump body removethe uel pump
body Parts13 15 can now be stripped
l the plunger is not worn iedoesnot it is not necessary
go further l the plungerir to be replaced
however 4 Attach the uel pump body ro the cylinderbody in reverse
with the setbolts
F it an ofsetwrench 19 mm careullyonto the plunger
Using a s panneris lik ely t o dam aget he n u t
Assembly
1 fi frc e plunger ba rre l1 0 p l u n g e r
1 3 a n d th e g asketpacki ng11
and ashall partsin cleanoil
l2l Attach the fuel pump body to the cylinderbody in reverse
the plunger the setscrew12 makesurethat the uel holesin
the plunger barrelare positioned with the plunger
mount
ed insidethe plunger barrel Usethe o 3 Checkthat the plunger
moveseasily lf it is stiff loosenthe setscrewand
4 Attach the and washer
14and hold the uel iniection
pump against the cylinderbody Securewith the setbolts Be sureto tighten
16 CHE CK INGP IS T O N
Checking the pistonand replacement
the carried out as
o l l o w s
l Remove the rockerarm chamber and
the cylinderhead Remove carbon
rom the top of the t2l the rearcovero the cylinder
Remove
l3 Remove rod bolt l No lock washer
connecting is used
I 4 Remove the cap 2 o the crank pin metaland rotatethe flywheeluntil the
l pistonis in the Place a rod and knock out
the end o the connecting
the towardsthe l
xamine
Exa the
min outer
uter s rrface
e of
surface f the p
o pistonand
I smooth
nooth down rough parts
parts th oil
with oilstone
Remove
emove the piston
p ston r
rings
ngsv
with r a looloop of wire
iras illustrated
illustr
carbonfrom
li i ated Clean out the
tl carbol
re ring
t the ranggroov
grooves rsanc
and wash l i g h t
in lioht
1 In oil
t Take
ake care
cale not to
to scratch
scr tl
th e
9rooves
Piston Rings
The first ring is wear Whenthe plat
1 ing peels the ring must be other ringsif vertical
scatches
present on the or i of cause compression leadingto reduced output o lube oil
Attach the ringsusingthe wire loop the mark in eachpision
ring is on the take carenot to damage or distort the ringsby
opening them too far Checkthat the ringsturn smoothlyin the ring i
erooves they
do not cleanthe grooves once more
Inserting
Piston
U si n gth e s pec ialt ool rh e p i s to na s
in s e rt
follows
l Se tt he ly wheelt o th e T D C
Po sr t r on
l2l Coatthe pistonwith new lubeoil
and positionthe pistonring ends
at 90o intervals
Insertthe pistonas the JIG end mark to the top Hammqring
in the pistondamages the l4l Whenthe BIG end of the connecting rod fits into the crankpushin the piston
wh ile t ur ningt he l y w h e e l
5 Attach the BIG end metalcapwith the mark upwardsCoat the metalwith
n e w lubeoil
NB Checkthat the metal is present the pistof
when inserting
6 rod boltsand lnsertthe connecting
Tightening
1oque
YSES 217tlb
YSE12 253

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