Part of the Yanmar Repair Manuals.
With a TS190 or TS230 stripped down on the stand, the questions come fast: how much liner wear is acceptable, what the ring end gaps should measure, and in what sequence the head nuts get pulled down. This 68 page Yanmar service manual answers them for the TS190, TS190R, TS230 and TS230R single cylinder diesels, in both hopper cooled and radiator cooled form.
It walks the engine end to end: full disassembly and reassembly procedure, then inspection and servicing of the cylinder head, liner, piston and rings, crankshaft, connecting rod, balancer mechanism, camshaft, gearcase, fuel system, governor, lubrication and cooling. Service standards, a maintenance schedule and a bolt and nut torque table back up the procedures, and a troubleshooting chapter covers hard starting, overheating, knock and oil consumption. It is a PDF download, so you can print the pages you need and keep them at the bench.
What's Inside This Yanmar TS190(R), TS230(R) Manual
| System | Pages | Key Topics |
|---|---|---|
| External View | 5 | TS190R (Radiator), TS190 (Hopper), TS230R (Radiator), TS230 (Hopper) |
| Specifications | 6 | Combustion System, No. of Cylinders - Bore X Stroke, Displacement, Rated Continuous Output, Compression Ratio, Lubrication System |
| Cross Sectional View | 7 | TS190R, TS230R |
| Installation Dimensions | 8-9 | Center of Cylinder, Center of Crankshaft, Exhaust Pipe Seat, Flywheel, Engine Foundation Bolt |
| Installation and Engine Performance | 10 | Unpacking Inspection, Common Base and Engine, Remote Control of Regulator |
| V-Pulley and V-Belt | 11-12 | V-Belt Installation, Tension Adjustment, Belt Stretching Method, Pulley Size Selection, Centering of Pulleys |
| Disassembly and Reassembly | 13-30 | Preparation for Disassembly, Disassembling/ Assembling Tools, Meters, Instruments and Service Accessories, Disassembling Procedure, Disassembly of Radiator |
| Cylinder Head | 31-34 | Exhaust Valve, Intake Valve, Valve Spring, Drain Cock, Intake Valve Rocker Arm, Valve Rocker Arm Support, Bonnet |
| Piston and Piston Ring | 35-37 | Cylinder Liner |
| Crankshaft | 38-40 | Oil Seal, Main Bearing Housing, Gasket, Snap Ring, Ball Bearing, Balance Weight, Crankshaft Gear |
| Gearcase and Gears | 41-45 | Balancer Mechanism, Connecting Rod, Camshaft and Tappet |
| Fuel System | 46-49 | Fuel Injection Pump, Fuel Injection Valve, Plunger, Delivery Valve, Nozzle |
| Lubrication System | 50-53 | Governor System |
| Cooling System | 54-55 | Radiator Cap, V-Belt, Sub-Tank, Cooling Fan Bearing, Hopper Core, Baffle Board |
| Breather | 56-57 | Air Cleaner, Other Accessories |
| Maintenance Schedule | 58 | Fuel Level Check, Fuel Filter Element Cleaning, Lubricating Oil Change, Cooling Water Refill, V-Belt Tension Adjustment, Valve Clearance Adjustment |
| Service Standards | 59-60 | Combustion Surface, Intake/exhaust Valve, Piston Ring End Gaps, Connecting Rod, Crankshaft, Cylinder Liner |
| Main Bolt/Nut Tightening Torques | 61 | Cylinder Head Stud Bolt, Connecting Rod Bolt, Flywheel End Nut, Fan Clamping Nut, Main Bearing Housing Clamping Bolt, Pipe Joint Bolt |
| Troubleshooting | 62-67 | Insufficient Output, Incorrect Fuel Injection System, Overheating, Excessive Engine Oil Consumption, Difficult Starting, Engine Knock |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| All Models | ||
| Injection angle | 150° | p. 49 |
| Valve clamp nut tightening torque | 130-180 kg-cm | p. 49 |
| Injection timing | BTDC 19°±1 | p. 6 |
| Injection pressure | 200+5-0 kg/cm² | p. 6 |
| Cylinder head nut tightening torque | 2700-2900 kg-cm | p. 61 |
| TS190(R) | ||
| Displacement, TS190(R) | 1,007 l | p. 6 |
| Lubricating oil capacity (oil pan) Effective/Total, TS190(R) | 2.0/3.6 ℓ (US gal) | p. 6 |
| Connecting rod bolt tightening torque, TS190(R) | 580-620 kg-cm | p. 61 |
| TS230(R) | ||
| Displacement, TS230(R) | 1,132 l | p. 6 |
| Lubricating oil capacity (oil pan) Effective/Total, TS230(R) | 3.0/6.0 ℓ (US gal) | p. 6 |
| Connecting rod bolt tightening torque, TS230(R) | 780-820 kg-cm | p. 61 |
Yanmar TS190(R), TS230(R) Common Problems This Manual Covers
Hard starting or no start
Air in the fuel lines, a fouled filter or weak compression will leave one of these singles cranking without firing. The troubleshooting chapter works through difficult starting alongside insufficient output and incorrect fuel injection, so you can rule causes out in order instead of guessing.
Manual Section: 12. Troubleshooting p. 62Overheating under load
Scale in the cooling passages or a neglected radiator or hopper lets temperature climb until the engine loses power or seizes a ring. The inspection and servicing chapter covers the cooling system along with the components heat damages first, the cylinder head and liner.
Manual Section: 8. Inspection and Servicing p. 31Blue smoke and rising oil use
Worn rings and a glazed or worn liner push oil past the piston and show up as smoke and a dropping dipstick. The service standards tables give piston ring end gaps and cylinder liner limits, so you can measure and decide whether parts are reusable or done.
Manual Section: 10. Service Standards p. 59Dirty injector, rough running
A carboned injection valve upsets the spray pattern and brings smoke, knock and uneven running. The maintenance schedule calls for fuel injection valve cleaning every 600 hours, alongside fuel filter cleaning and oil change intervals.
Manual Section: 9. Maintenance Schedule p. 58V-belt slipping or wearing fast
Wrong tension or misaligned pulleys on the drive belt cause squeal, glazing and short belt life. The manual has a dedicated chapter on V-belt installation, tension adjustment, pulley size selection and centering of pulleys.
Manual Section: 6. V-Pulley and V-Belt p. 11Leaks or knock after reassembly
A head gasket that weeps or a rod bearing that hammers after a rebuild usually traces back to fasteners pulled down by feel. The torque table lists values for the cylinder head studs, connecting rod bolts, flywheel end nut and main bearing housing bolts, so nothing goes back together on guesswork.
Manual Section: 11. Main Bolt/Nut Tightening Torques p. 61Frequently Asked Questions
Which engines does this manual cover?
It covers the Yanmar TS190 and TS230 single cylinder diesels in both variants: the TS190R and TS230R with a radiator, and the TS190 and TS230 with a hopper. Disassembly procedures for both the radiator and the hopper are included.
Does it include torque specs for the head and rod bolts?
Yes. The Main Bolt/Nut Tightening Torques section lists the cylinder head clamping nuts at 2700 to 2900 kg-cm, connecting rod bolts at 580 to 620 kg-cm for the TS190 and 780 to 820 kg-cm for the TS230, plus flywheel, fan and main bearing housing fasteners. p. 61
Are injection pump timing and injector settings covered?
Yes. The Specifications section gives injection timing of BTDC 19 degrees plus or minus 1 and an injection pressure of 200 kg/cm2, and the Inspection and Servicing chapter covers the fuel system and governor in detail. p. 6
Does it give wear limits for rebuilding the engine?
Yes. The Service Standards section tabulates limits for the combustion surface, intake and exhaust valves, piston ring end gaps, connecting rod, crankshaft and cylinder liner, so you can measure each part and decide what to reuse and what to replace. p. 59
How will I receive this Service Manual?
This is a 68-page searchable PDF ready for immediate download. Works on any device, so pull it up on your phone while you're under the hood. No shipping, no waiting.
Can I print this manual?
Yes. The PDF has no DRM restrictions, so print any page or section you need for your shop. Works with any standard printer.
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