Yanmar YSM8-Y Marine Diesel Engine Service Repair Manual

1
(No Transcript)
2
ModelYSM

• CHAPTER 1 GENERAL
• Exterior Views. .. .
• Specifications.....
• Principal Gonstruction ...........................
  .. 4-3
• Performance Gurves ..............................
  1-4

• CHAPTER 8 STARTING SYSTEM
• Starting System Construction .
• Electric Starting System
• Overdrive Hand-Operated System .
• Ghain-Overdrive Hand-Operated System.

... ..
. 1-1 . 1-2
8-1 8-2 . 8-3 8-5
. 1-6 1-8 .... 1-12 . 1-19
5. Features . . . . . . . ... . . . . . . . . . .
. . . . . . . .

• tSection ...............
• 6 Exten v.â
• System Diagrams ..
• Accessories ..

CHAPTER 9 REDUCTION AND REVERSING GEAR

1. Construction. .. ... .. . ...............
.9-1 .. 9-6
.. ..
2. Installation .. . .... . . . . .

1. Handling the Reduction and Reversing Gears
   .......... 9-7
2. Inspection and Servicing .........................
   .. 9-8
3. Disassembling the Reduction and Reversing
   Gears...... 9-14
4. Reassembling the Reduction and Reversing Gears
   ...... 9-17

• CHAPTER 2 BASIC ENGINE
• Cylinder Block ......... .. ..................
  2-1
• Cylinder Liner....... . .. ..
• Cylinder Head.. . .............
• Piston . .. . ..... . ... ......... .. ...
  2-17
• Connecting Rod ..................................
  2-ZZ
• Grankshaft ......................................
  2-26
• Camshaft ............................ ..........
  2-31
• Timing Gear .. ..... .................... 2-34
• CHAPTER 3 FUEL SYSTEM
• 2 I j ti n p . ...
• Injection Nozzle- - ......... ...3-15
• Fuel Filter. ... . ..... .... .. . .........
  3-20
• Fuel Feed Pump..................................
  3-21
• Fuel Tank .......................................3
  -24
• CHAPTER 4 GOVERNOR
• Governor... ....................................
  4-1

.... . 2-3 ....... . 2-6

• CHAPTER 10 REMOTE CONTROL SYSTEM
• CÔMÇIOSÏtÏOFI .
• Gonstruction.

10-1 40-2

• CHAPTER 11 ELECTRICAL SYSTEM
• Composition . ....... . ......................
  11-1
• Battery . .............. .......................
  11-3

3. Starter Motor ....... .........
...... .. .
.. 11-6 . 11-14 11-22
3 32

1. Alternator ...
2. Alarm Circuit..

... .. . .
. ". .
..

• 6. Other Electric Equipment.............
  ............ 11-25
• CHAPTER 12 INSTALLATION AND FITTING
• Propeller and Stern Arrangement
  ................... 12-1
• Engine Installation ..............................
  . 12-2
• Stern Equipment.................................
  12-10
• Interior Piping and Wiring .......................
  .. 12-14
• Front Power Take-Off .............................
  12-19
• CHAPTER 13 OPERATING INSTRUCTIONS
• Fuel Oil and Lubricating Oil. ..
  ................... 13-1
• Engine Operating Instructions... . . .. .
  ... .. 13-8
• Troubleshooting and Repair........................
  13-12
• CHAPTER 14 DISASSEMBLY AND REASSEMBLY
• Disassembly and Reassembly Precautions. .. . 14-1
• Disassembly and Reassembly Tools
  ................. 14-2
• Other..........................................
  14-11
• Disassembly ....................................
  14-12

.6-3 ... 6-6 .. 6-7
. 7-7 .7-8 .. . 7-g
Prinlsd in Japan A 0 A1001 8311
3
Chapter 1 General 1. Exterior Views
SMS YSM
1. Exterior Views
1-1 Starboard
MI x ing elbow
Cool ing water temperature sender
t
Fuel inject ion nozzle
Regulator handle
Intake silencer
Lu bricat ing oiI filter
\ Fuel injection pump Rocker arm chamber
Cool ing water drain cock
1-2 Port
Fuel fi lter
Tachometer sender
Alternator
Clutch Control lever
Cooling water pump
Output shaft coupling
Printed in papan A 0A 1001 8311
-1
4
2. Specifications
Chapter 1 General 2. Speci ications
Model Model Model YSM8- R t YSM8-Y t YSM12- R t YSM12-Y
Type Type Type Horizontal 4-cycle water-cooled diesel engine Horizontal 4-cycle water-cooled diesel engine Horizontal 4-cycle water-cooled diesel engine
Combustion chamber Combustion chamber Combustion chamber Precombustion type Precombustion type Precombustion type
Number of cylinders Number of cylinders Number of cylinders 1 1 1
Bore stroke Bore stroke Bore stroke mm 75 75 85 1
Displacement Displacement Displacement 4 0.331 0.510
Continuous rated Continuous rated OUtput/crankshaft speed HP/rpm 7/320 I t 10/3000
Continuous rated Continuous rated Mean piston speed mls 8.0 9.0
output output Mean piston speed mls 8.0 9.0
(DIN 6270A) (DIN 6270A) Mean piston speed mls 8.0 9.0
(DIN 6270A) (DIN 6270A) Propeller speed rpm 1639 1093 1639 1093 t 1518 t 980 1518 980
One hour rating One hour rating Output/crankshaft speed HP/rpm 8/3200 12/3000
One hour rating One hour rating Mean piston speed mls 8.0 9.0
(DIN 6270B) (DIN 6270B) Mean piston speed mls 8.0 9.0
(DIN 6270B) (DIN 6270B) Propeller speed rpm 1639 1093 t 1639 1093 1518 t 080 1518 980
Compression ratio Compression ratio Compression ratio 231 211
Fuel injection timing Fuel injection timing Fuel injection timing deg bTDC 25 bTDC 25 bTDC 25
Fuel injection préssure Fuel injection préssure Fuel injection préssure kg/cm 160 10 160 10 160 10
Engine weight (dry) Engine weight (dry) Engine weight (dry) kg 102 92 130 120
Power takeoff position Power takeoff position Power takeoff position Flywheel side Flywheel side Flywheel side
Direction of rotation Direction of rotation Crankshaft Gounterclockwise (viewed from clutch side) Gounterclockwise (viewed from clutch side) Gounterclockwise (viewed from clutch side)
Direction of rotation Direction of rotation Propeller shaft Counterclockwise (viewed from clutch side) Counterclockwise (viewed from clutch side) Counterclockwise (viewed from clutch side)
Cooling system Cooling system Cooling system Sea water forced cooling (rubber impeller water pump) Sea water forced cooling (rubber impeller water pump) Sea water forced cooling (rubber impeller water pump)
Lubrication system Lubrication system Lubrication system Closed forced lubrication Closed forced lubrication Closed forced lubrication
Starting system Starting system Starting system Electric Manual with manual Electric Manual with manual Electric Manual with manual
Reduction gear system Reduction gear system Reduction gear system Spur gear constant- mesh system Spur gear constant- mesh system
Glutch Glutch Glutch Wet single-disc mechanical type Wet single-disc mechanical type
Reduction ratio Reduction ratio Ahead 1.95 2.93 1.95 2.93 1.95 2.93 1.95 2.93 1.98 t 3.06 1.98 3.06
Reduction ratio Reduction ratio Astern 1.95 2.93 1.95 2.93 1.95 2.93 1.95 2.93 1.98 3.06 1.98 3.06
Engine size Engine size Overall length mm 608 t 598 608 t 598 638 628
Engine size Engine size Overall width mm 602 576 602 576 673 647
Engine size Engine size Overall height mm 436 544 436 544 485 591
Lubricating oil capacity (rale angle 8) Lubricating oil capacity (rale angle 8) Crankcase Total/Effective î 1.9/0.8 1.9/0.8 3.0/1.0
Lubricating oil capacity (rale angle 8) Lubricating oil capacity (rale angle 8) Clutch Total/Effective y 0.7i0.2 0.7i0.2 0.7/0.2
No- load No- load Maximum rpm 3400 3400 3400 3400 3150 3150
engine speed Mium Mium rom 650 t 600 650 t 600 650
Printed in Japan AOA 1001 8311
1-2
5
Chapter 1 General 3. Principal Construction
SM/ YSM
3. Principal Construction
Group Part Construction
Engine block Cylinder block Integrally-cast water jacket and crankcase
Engine block Cylinder liner Wet type coated with anticorrosion paint
Engine block Main bearing Metal housing type
Intake and exhaust systems and valve mechanism Cylinder head Gasket separate valve guide
Intake and exhaust systems and valve mechanism Intake and exhaust valves Poppet type, seat angle 90
Intake and exhaust systems and valve mechanism Intake pipe Intake inertia type steel pipe
Intake and exhaust systems and valve mechanism Exhaust silencer Water-cooled mixing elbow type (optional)
Intake and exhaust systems and valve mechanism Valve mechanism Overhead valve push rod, rocker arm system
Intake and exhaust systems and valve mechanism Intake silencer Round polyurethane sound absorbing type
Main moving elements Crankshaft Stamped forging
Main moving elements Flywheel Attached to crankshaft by tapered
Main moving elements Piston Oval type
Main moving elements Piston pin Floating type
Main moving elements Piston rings 3 compression rings, 1 oil ring
Lubrication syslem Oil pump Trochoid pump
Lubrication syslem Oil filter Full-flow type, steel plate element
Lubrication syslem Oil level gauge Dipstick
Cooling system Water pump Rubber impeller type
Cooling system Thermostat Wax pellet type
Bilge system Bilge pump Rubber impeller tandem type) combined with C.W. pump (optional)
Fuel system Fuel injection pump Bosch PFR type
Fuel system Fuel injection valve Semi-throttle valve
Fuel system Fuel strainer Paper element
Governor Governor Gentrifugal all-speed mechanical type
Start ing system Electric Pinion ring gear type starter motor
Start ing system Manual Over-driven chain starting
Electrical system Charger Alternator (with built-in IC regulator)
Reduction reversing Reduction gear Spur gear constant-mesh system
Clutch system Clutch Wet single disc mechanical type
Printed in Japa p AOA 1001 8311
1-3
6
Chapter 1 General Per ormance Curves
SMS YSM

• Performance Curves
• YSM8-R, YSM8-Y
• Fuel consumption at flywheel output

J/h 2.0 1.8 1.6 1.4 1.2 1.0 0.8

Specific fuel consumption at flywheel output
g/HPh 240 230 220 210 200
Torque measured at the flywheel kgm
Output measured at the propeller shaft HP 10






/ r
v


8
6
4 3
1
1200 1600 2000 20 30
2400 2800 40 50
3200 rpm rps
The Engine Flywheel Output is Approx. 5
Higher. Note These curves show the average
performance of respective engines in test
operation at our plant
Pri'nted iit Japan A0A1001 8311
1-4
7
Chapter / Cieneral 4. Per ormance Curves 2.
YSM12- R, YSM12-Y Fuel consumption at flywheel
output t/h 3.0 2.6 2.2 1.8 1. 4 1.0 0.6 Specifi
c fuel consumption at flywheel output g/H Ph
230 220 210 200 190











Torque measured at the flywheel
kgm 34 3.2 3.0

2.8
Output measured at the propeller shaft H P 12
11 10
8 7 6
'r
4
3
3200 rpm FjgS
1200 1600 20 30
2000
2400 40
2800
The Engine Flywheel Output is Approx. 5
Higher. Note These curves show the average
performance of respective engines in test
operation at our plant
Printed in Japan A 0A 1001 8311
1-5
8
Thank you very much for your reading.
Please Click Here. Then Get COMPLETE MANUAL. NO
WAITING

• NOTE
• If there is no response to click on the link
  above, please download the PDF document first
  and then click on it.

9
Chapter 1 General 5. Features
SMS YSM

• Features
• Superior combustion performance
• The unique Yanmar swirl precombustion chamber
  combus- tion system and new cooling system
  display superior com- bustion performance in all
  types of operation. Low-speed, low- load
  combustion performance, especially demanded for
  marine applications, is also superb, and stable
  perfor- mance is maintained over a wide range of
  speeds. Since starting characteristics are also
  excellent and warm-up is fast, full engine
  performance can be obtained within a short time.

• Easy handling and simplified operation
• The slope of the breather has been increased to
• withstand violent rollings, even up to 30o,
  thereby
• eliminating lubricating oil worries.
• A bracket has been mounted on the clutch so that
  speed-clutch control can be performed with Morse
  remote control device.
• By taking account of cabin electric power
  con- sumption, the capacity of the alternator has
  been increased.
• Because of the adoption of alarm lamps which
  light up when there is a rise in the temperature
  of the cooling water or a drop in the pressure of
  the lubricating oil, engine troubles are
  prevented.

2. Low operating costs Excellent combustion and
low friction reduce fuel costs, while the
optimized piston shape and ring configuration and
improved cooling system reduce oil consumption.
Continuous operating time has been extended
and operating costs reduced through improved
durability.

• Easy installation
• The four-point support type engine installing
  leg has
• greatly facilitated engine installation.
• Since the instrument panel can be installed
  separately it can be placed anywhere on board for
  easy mon- itoring.
• Rubber hoses are employed for the easy
  installation of
• on-board piping.
• Electrical wiring can be connected quickly and
  easily with connectors.

3. Reduced weight and size Reduction of the
overall length and weight of the engine has been
achieved by forging the clutch case
and mounting of an aluminum alloy, and by
adopting a new- type, small-size reduction and
reversing gear, which is coupled direction to the
flywheel. Moreover, since this is a horizontal
type engine, its height has been significantly
reduced, leaving much more space for cargo, etc.

• Hundreds of hours of operation without an
  overhaul
• The main moving parts, valve mechanism and
  combustion
• chamber have adopted designs and engineering
  materials which are ideally suited for high-speed
  engines. And since the cooling water is always
  kept at a constant high temperature by the
  thermostat, liner/ring wear is limited and the
  heat load around the combustion chamber is low,
  thereby ensuring lasting quality and increased
  durability.
• Quiet operation
• All the machine parts which produce reciprocating
  motions and are the source of vibrations in the
  engine, have been reduced in weight and perfectly
  balanced, cutting vibrations to a minimum. Also,
  because of the adoption of an intake silencer and
  mixing exhaust, noise has been greatly reduced
  without sacrificing engine speed.

Printed in Japan A 0A 1001 8311
1-6
10
6. Engine Cross-section
Chapter 1 General 6. Sectional Views
10

1. Cylinder liner
2. Cylinder head
3. 1ntake valve
4. Exhaust valve
5. Valve spring
6. Valve rocker arm chambi r
7. Camshaft gear
8. Camshaft
9. Tappet
10. Push rod
11. Valve rocker arm
12. Valve rocker arm support
13. Decompression shaft
14. Precombustion chamber
15. Mixing elbow
16. Crankshaft
17. Main bearing
18. Balance weight
19. Piston

40
37
Pri nted in Japan A 0A 1001 8311
1-7
11
Chapt ' 1 General 7. Exterior Views
(0)
ts 0 c I (6 ) s0 (6S0) 0 L
(8 0) 5Z d
12
Chapter1 General 7. Exterior Views
(ZS0) 5t'Io -
(8z'0) æ (y 0)
(tg0 S Lø
(6sz I) (t j 0) SL (L89t)
(6t 0) 5
(Z0SL) S9E
P s
(2O)Z
(69 I)
(SZ0) 59G (8Z0) SIZE
lL9t')
13
(No Transcript)