Yanmar Diesel Inboard Shop Manual for One, Two, and Three Cylinder Engines

General Information Troubleshooting Operation, Lubrication, Maintenance and Tune-up Lay-up and fitting Out Single-Cylinder Engines r Multlcyllnder Engines Fuel Injection and Governor Systems Cooling System Electrical System Transmlsslon-KM Series Transmlsslon-KBW Series Index WIring Diagrams

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Contents QUICK REfERENCE DATA . . IX CHAPTER ONE GENERAL INfORMATION .....••....•.......••...•.........•....•...•... t Manual organization. . . . . . . . . . . . . . . . . . . . . . . . . I Notes, cautions and warnings 2 Safety first. 2 Service hints 3 Parts replacement 4 Torque specifications 4 Fasteners 4 Lubricants 8 RTV gasket sealant 9 Threadlock 9 Basic hand tools 9 Precision measuring tools 13 Mechanic's tips 16 Bearing replacement. 18 Seals 23 CHAPTER TWO TROUBLESHOOTING 26 Starting system 27 Charging system 31 Charging system tests 31 Fuel system 32 Cooling system 34 Engine exhaust smoke 35 Engine noises 35 Engine troubleshooting 36 Cooling system 36 Lubrication system 36

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· CHAPTER THREE OPERATION, LUBRICATION, MAINTENANCE AND TUNE-UP 42 Fuel requirements ~ 42 Preoperational checks 42 Starting checklist 43 Stopping the engine 44 Emergency engine stopping 44 Post-operational checks 44 Engine maintenance and lubrication 44 Cooling system 52 Battery 56 Engine tune-up 57 Transmission 60 CHAPTER fOUR LAY -UP AND FITTING OUT AI 63 Lay-up '" 63 Cooling system draining 64 Fitting out 66 CHAPTER nvs SINGLE-CYLINDER ENGINES 68 Diesel engine fundamentals 68 Engine serial number and code 70 Replacement parts 70 Engine removal precautions 70 Valve cover 71 Breather assembly 71 Decompression mechanism 73 Cylinder head 73 Rocker shaft assembly 76 Valves and valve seats 77 Push rods 79 Piston/connecting rod assembly 79 Timing gearcase 85 Lubrication system 86 Flywheel 89 Drive disc 91 Crankshaft.

91 Main bearings 93 Camshaft 93 Cylinder block 95 CHAPTER SIX MULTICYLINDER ENGINES 99 Engine serial number and code 99 Replacement parts 100 Engine 100 Valve cover 101 Breather assembly 101 Decompression mechanism . . . . . . . . . . . . . . . . . . . 102 Exhaust manifold 103 Cylinder head 105 Rocker shaft assembly 109 Valves and valve seats 110 Push rods. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113 Piston/connecting rod assembly 113 Timing gearcase . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118 Lubrication system 120 Flywheel 122 Drive disc 123 Crankshaft.

123 Main bearings 126 Camshaft 127 Cylinder block 128 CHAPTER SEVEN fUEL INJECTION AND GOVERNOR SYSTEMS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 Fuel injection fundamentals 138 Fuel injection pump 149 Fuel injection system bleeding 142 Fuel transfer pump 150 Fuel injection timing 144 Fuel lines 151 Fuel injector 146 Governor system 152

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CHAPTER EIGHT COOLING 5nEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159 Cooling systems -, 159 Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165 Hose replacement 168 Drive belts 169 Seawater pump 170 Freshwater pump 177 Freshwater cooling system maintenance 177 Seawater cooling system maintenance 181 CHAPTER NINE ELECTRICAL SYSTEM . Battery 183 Electrical protection 188 Charging system 189 Starting system 190 Switches 195 · 183 Senders 195 Warning lamps 197 Alarm buzzer.

/ 197 Tachometer 197 CHAPTER TEN TRANSMISSION-KM SERIES Operation 199 Removal/installation 201 Overhaul 202 · 199 Reassembly 208 Bearing adjustment 211 Drive disc 213 CHAPTER ELEVEN TRANSMISSION-KBW SERIES . Operation 216 Removallinstallation 217 Overhaul 217 2 t 6 Bearing adjustment 224 Drive disc 225 INDEX 227 WIRING DIAGRAMS ..........................•...................... 231

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