Yanmar L48N, L70N, L100N Industrial Engine Service Manual 0BLN0-G00100

Description

• Model List:
  • L48N, L70N, L100N Industrial Engine

• 1. Table of Contents
• 2. Introduction
• 3. Yanmar Warranties
• 3.1. Yanmar Limited Warranty
• 3.1.1. What is Covered by this Warranty
• 3.1.2. How Long is the Warranty Period
• 3.1.3. What the Engine Owner Must Do
• 3.1.4. To Locate an Authorized Yanmar Industrial Engine Dealer or Distributor
• 3.1.5. What Yanmar Will Do
• 3.1.6. What is Not Covered by this Warranty
• 3.1.7. Warranty Limitations
• 3.1.8. Warranty Modifications
• 3.1.9. Questions
• 3.1.10. Retail Purchaser Registration
• 3.2. Warranty
• 3.2.1. Warranty Coverage
• 3.2.2. Exclusions
• 3.2.3. Owners Warranty Responsibilities
• 3.3. Safety Statements
• 3.4. Before You Begin Servicing
• 3.5. Safety Precautions
• 4. General Service Information
• 4.1. Component Identification
• 4.2. Location of Labels
• 4.3. Specifications
• 4.3.1. Description of Model Number
• 4.3.2. Engine Speed Specifications
• 4.3.3. General Engine Specifications
• 4.4. Function of Major Engine Components
• 4.5. Diesel Fuel
• 4.5.1. Diesel Fuel Specifications
• 4.5.1.1. Additional Technical Fuel Requirements
• 4.5.1.2. Bio-Diesel Fuels
• 4.5.2. Filling the Fuel Tank
• 4.5.3. Priming the Fuel System
• 4.5.3.1. Gravity-Fed Fuel System
• 4.5.3.2. Electric Pump Pressurized Fuel System
• 4.6. Engine Oil
• 4.6.1. Engine Oil Specifications
• 4.6.1.1. Service Categories
• 4.6.1.2. Definitions
• 4.6.1.3. Additional Technical Engine oil Requirements
• 4.6.2. Engine Oil Viscosity
• 4.6.3. Engine Oil Capacity (Typical)
• 4.6.4. Checking Engine Oil
• 4.6.5. Adding Engine Oil
• 4.7. Abbreviations and Symbols
• 4.7.1. Abbreviations
• 4.7.2. Symbols
• 4.8. Unit Conversions
• 4.8.1. Unit Prefixes
• 4.8.2. Units of Length
• 4.8.3. Units of Volume
• 4.8.4. Units of Mass
• 4.8.5. Units of Force
• 4.8.6. Units of Torque
• 4.8.7. Units of Pressure
• 4.8.8. Units of Power
• 4.8.9. Units of Temperature
• 4.9. Tightening Torques for Standard Bolts and Nuts
• 4.10. Tightening Torques for Special Bolts and Nuts
• 5. Periodic Maintenance
• 5.1. Before You Begin Servicing
• 5.1.1. Introduction
• 5.1.2. The Importance of Periodic Maintenance
• 5.1.3. Performing Periodic Maintenance
• 5.1.4. The Importance of Daily Checks
• 5.1.5. Keep a Log of Engine Hours and Daily Checks
• 5.1.6. Yanmar Replacement Parts
• 5.1.7. Tools Required
• 5.1.8. Tightening Fasteners
• 5.2. Periodic Maintenance Schedule
• 5.3. Periodic Maintenance Procedures
• 5.3.1. Daily, Before Operation
• 5.3.1.1. Check Battery (If Equipped)
• 5.3.1.2. Check Battery Indicator (If Equipped)
• 5.3.1.3. Check Engine Oil Level
• 5.3.1.4. Check for Engine Oil Leakage
• 5.3.1.5. Check Engine Speed Control
• 5.3.1.6. Check Spark Arrester (If Equipped)
• 5.3.1.7. Check Fuel Level
• 5.3.1.8. Check for Fuel Leakage
• 5.3.2. Daily, After Operation
• 5.3.2.1. Check for Engine Oil Leakage
• 5.3.2.2. Check for Fuel Leakage
• 5.3.3. After Initial 50 Hours of Operation
• 5.3.3.1. Replace Engine Oil
• 5.3.3.2. Clean / Inspect Engine Oil Filter
• 5.3.4. Every 50 Hours of Operation
• 5.3.4.1. Clean Inlet Fuel Screen
• 5.3.5. Every 200 Hours of Operation
• 5.3.5.1. Clean Air Cleaner Element
• 5.3.5.2. Replace Engine Oil and Clean / Inspect Engine Oil Filter
• 5.3.5.3. Check and Adjust Engine Speed Control
• 5.3.5.4. Drain the Fuel Tank and Replace Outlet Fuel Filter
• 5.3.6. Every 500 Hours of Operation
• 5.3.6.1. Adjust Intake and Exhaust Valve Clearance
• 5.3.6.2. Replace Outlet Fuel Filter
• 5.3.6.3. Inspect, Clean and Test Fuel Injection Nozzle, if required
• 5.3.7. Every 1000 Hours of Operation
• 5.3.7.1. Check Compression
• 5.3.8. Every 2000 Hours of Operation
• 5.3.8.1. Check and Replace Fuel Hoses
• 5.4. Before You Begin Servicing
• 5.5. Introduction
• 5.6. Specifications
• 5.6.1. Cylinder Head Assembly
• 5.6.1.1. Valve Clearance
• 5.6.1.2. Cylinder Head
• 5.6.1.3. Intake / Exhaust Valve Seat
• 5.6.1.4. Intake / Exhaust Valves, Guides and Seals
• 5.6.1.5. Push Rod
• 5.6.1.6. Valve Spring
• 5.6.1.7. Rocker Arm and Shaft
• 5.6.2. Crankshaft, Balancer Shaft, Piston and Connecting Rod
• 5.6.2.1. Crankshaft
• 5.6.2.2. Balancer Shaft
• 5.6.2.3. Piston Ring
• 5.6.2.4. Connecting Rod
• 5.6.3. Camshaft and Tappet
• 5.6.3.1. Camshaft
• 5.6.4. Cylinder Block and Crankcase Cover
• 5.6.4.1. Cylinder Block
• 5.6.4.2. Crankcase Cover
• 5.6.5. Oil Pump (Trochoid Pump)
• 5.6.6. Special Torque Specifications
• 5.7. Special Service Tools
• 5.8. Measuring Instruments
• 5.9. Cylinder Head
• 5.9.1. Removal of Cylinder Head
• 5.9.1.1. L48N Models
• 5.9.1.2. L70N and L100N Models
• 5.9.1.3. All Models
• 5.9.2. Disassembly of Cylinder Head
• 5.9.3. Inspection of Cylinder Head Components
• 5.9.3.1. Valve Face and Valve Seat
• 5.9.3.2. Valves and Valve Guides
• 5.9.3.3. Valve Springs
• 5.9.3.4. Rocker Arms and Push Rods
• 5.9.3.5. Cylinder Head Distortion
• 5.9.4. Reassembly of Cylinder Head
• 5.9.4.1. Reassembly of Intake / Exhaust Valves
• 5.9.5. Installation of Cylinder Head
• 5.9.6. Calculating Cylinder Head Gasket Thickness
• 5.9.7. Checking Actual Piston TDC (Top Dead Center)
• 5.9.8. Measuring and Adjusting Valve Clearance
• 5.9.9. Removal of Engine
• 5.9.10. Disassembly of Engine
• 5.9.11. Inspection of Engine Components
• 5.9.11.1. Piston, Piston Rings and Wrist Pin
• 5.9.11.2. Connecting Rod
• 5.9.11.3. Crankshaft, Main Bearing and Flywheel
• 5.9.11.4. Crankshaft
• 5.9.11.5. Bearings
• 5.9.11.6. Camshaft and Tappet
• 5.9.11.7. Balancer Shaft
• 5.9.11.8. Timing Gears
• 5.9.11.9. Cylinder Bore
• 5.9.11.10. Honing and Boring
• 5.9.11.11. Inspection and Service of Engine Oil Pump
• 5.9.12. Reassembly of Engine
• 5.9.12.1. Replacement of Throttle Shaft Seal – L48N Models
• 5.9.12.2. Replacement of Throttle Shaft Seal – L70N and L100N Models
• 5.9.12.3. Replacement of Crankshaft Seals
• 5.9.12.4. Reassembly of Piston, Piston Rings and Connection Rod
• 5.9.12.5. Installation of Crankshaft
• 5.9.12.6. Installation of Piston and Connecting Rod
• 5.9.12.7. Installation of Camshaft and Balancer Shaft
• 5.9.12.8. Installation of Crankcase Cover
• 5.9.12.9. Final Engine Assembly
• 5.9.13. Installation of Engine
• 6. Fuel System
• 6.1. Before You Begin Servicing
• 6.2. Introduction
• 6.3. Specifications
• 6.3.1. Test and Adjustment Specifications
• 6.3.2. Special Torque Specifications
• 6.4. Special Service Tools
• 6.5. Measuring Instruments
• 6.6. Fuel System Operation
• 6.6.1. Fuel Injection Pump
• 6.6.2. Fuel Injector
• 6.7. Fuel System Diagram
• 6.8. Fuel System Components
• 6.9. Checking and Adjusting Fuel Injection Timing
• 6.9.1. Checking Fuel Injection Timing
• 6.9.2. Adjusting Fuel Injection Timing
• 6.10. Fuel Injection Pump
• 6.10.1. Removal of Fuel Injection Pump
• 6.10.2. Installation of Fuel Injection Pump
• 6.10.3. Replacement and/or Adjustment of the Fuel Limiter
• 6.11. Fuel Injector
• 6.11.1. Removal of Fuel Injector
• 6.11.2. Testing of Fuel Injector
• 6.11.3. Disassembly and Inspection of Fuel Injector
• 6.11.4. Adjusting Fuel Injector Pressure
• 6.11.5. Reassembly of Fuel Injector
• 6.11.6. Installation of the Fuel Injector
• 6.12. Speed Control Device
• 6.12.1. Variable Speed Type
• 6.12.2. Remote Control Type
• 6.12.3. Variable Speed Friction Plate Type
• 6.12.4. Constant Speed Type
• 7. Starter
• 7.1. Before You Begin Servicing
• 7.2. Introduction
• 7.3. Specifications
• 7.4. Special Service Tools
• 7.5. Measuring Instruments
• 7.6. Electric Starter Motor Components (Standard)
• 7.7. Electric Starter Motor Troubleshooting
• 7.8. Testing Electric Starter Motor Operation (Standard)
• 7.8.1. Checking Pinion Projection Length
• 7.8.2. No-Load Test
• 7.9. Electric Starter Motor (Standard)
• 7.9.1. Disassembly of Electric Starter Motor
• 7.9.2. Inspection and Testing of Electric Starter Motor Components
• 7.9.2.1. Armature
• 7.9.2.2. Field Coil
• 7.9.2.3. Brush Holder
• 7.9.2.4. Solenoid Switch
• 7.9.3. Reassembly of Electric Starter Motor
• 7.10. Recoil Starter
• 7.10.1. Disassembly of Recoil Starter
• 7.10.1.1. L48N and L70N
• 7.10.2. Reassembly of Recoil Starter
• 8. Charging System
• 8.1. Before You Begin Servicing
• 8.2. Introduction
• 8.3. Specifications
• 8.3.1. General Specifications
• 8.3.2. Unregulated Output Test Specifications
• 8.3.3. Regulated Output Test Specifications
• 8.3.4. Special Torque Specifications
• 8.4. Special Service Tools
• 8.5. Measuring Instruments
• 8.6. Charging System Operation
• 8.7. Charging System Wiring Diagrams
• 8.7.1. V – 3 A and 12 V – 15 A System
• 8.7.2. V – 1.7 A System
• 8.7.3. V – 1 A System
• 8.7.4. V – 3 A and 12 V – 15 A with Intake Air Heater and Timer
• 8.8. Charging System Components
• 8.9. Testing of Charging System and Components
• 8.9.1. Testing Regulated Output
• 8.9.2. Testing Unregulated Output
• 8.9.3. Testing Stator Coil Continuity
• 8.9.4. Testing Stator Coil Short-to-Ground
• 8.9.5. Testing of Regulator / Rectifier
• 8.9.5.1. Regulator Number RS5112
• 8.9.5.2. Regulator Number RS2190
• 8.9.6. Testing of Rectifier
• 8.9.6.1. ZR2117 (Half-Wave Rectifier)
• 8.9.6.2. ZR2120 (Full-Wave Rectifier)
• 8.9.7. Removal of Stator
• 8.9.8. Installation of Stator
• 9. Electric Wiring
• 9.1. Electric Wiring Precautions
• 9.2. Electrical Wire Resistance
• 9.3. Battery Cable Resistance (If Equipped)
• 9.4. Electrical Wire Sizes – Voltage Drop
• 9.5. Conversion of AWG to European Standards
• 10. Troubleshooting
• 10.1. Before You Begin Servicing
• 10.2. Introduction
• 10.3. Specifications
• 10.3.1. Cylinder Compression Pressure
• 10.4. Measuring Instruments
• 10.5. Troubleshooting By Measuring Compression Pressure
• 10.5.1. Measuring Compression Pressure
• 10.5.2. Low Compression Troubleshooting Chart
• 10.6. Troubleshooting Quick Reference Charts
• 10.7. Troubleshooting Charts
• 11. BACK COVER