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Yanmar Manuals
Engine
L40AE
Service manual
Yanmar L40AE Service Manual
Diesel engine yanmar l-a series
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Table Of Contents
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Contents
Table of Contents
Troubleshooting
Bookmarks
Table of Contents
General Safety
Serial Number Location
Service Rules
Contents
Specifications
Cross Sectional Views
Longitudinal Sectional View
Camshaft PTO Plan View
Crankshaft PTO Plan View
Service Standards
Intake/Exhaust Valve Seats Service Standards
Intake/Exhaust Valves & Valve Guides Service Standards
Valve Springs Service Standards
Intake/Exhaust Valve Rocker-Arm, Rocker Shaft and Push Rods Service Standards
Valve Clearance Service Standards
Valve Opening/Closing Timing Service Standards
Piston Service Standards
Piston Pin Service Standards
Piston and Rings Service Standards
Piston Ring Service Standards
Connecting Rod Service Standards
Crankshaft and Main Bearing Service Standards
Camshaft Service Standards
Tappet Service Standards
Crankcase Cover Service Standards
Cylinder Block Service Standards
Oil Pump (Trochoid Pump) Service Standards
Disassembly and Reassembly
Tools
Meters, Instruments and Service Accessories
Instruments
Tightening Torques
Maintenance Schedule
Disassembly Procedures
Removing the Fuel Tank
Removing the Exhaust Silencer
Removing the Air Cleaner
Removing the Cooling Fan Case/Starter Pulley/Air Intake Bend
Removing the Valve Rocker Arm Assembly
Fuel Injection Valve Disassembly
Removing the Cylinder Head
Removing the Fuel Pump
Removing the Crankcase Cover
Removing the Camshaft
Removing the Balancer Shaft
Removing the Piston and Connecting Rod Assembly
Removing the Flywheel
Removing the Crankshaft
Reassembly Procedures
Installing the Crankshaft
Installing the Flywheel
Installing the Piston and Connecting Rod
Installing the Camshaft, Balancer Shaft
Fuel Injection Pump Reassembly
Installing Crankcase Cover
Attaching the Crankcase Cover and Tightening Three Orders
Installing the Cylinder Head
Inserting the Push Rods
Valve Rocker Arm Assembly
Installing the Valve Rocker Arm Cover
Installing the Fuel Injection Valve
Installing the Intake Bend
Installing the Cooling Fan Case
Installing the Air Cleaner
Installing the Starting Motor
Installing the Fuel Tank
Recoil Starter - Disassembling Procedures
Recoil Starter - Assembling Procedures
Recoil Starter - Checks after Reassembly
Checking and Servicing
Cylinder Head Checking and Servicing
Combustion Surfaces Servicing
Intake and Exhaust Valve Seats, Valve Guides Servicing
In/Ex Valve Guide and Valve Stem Table
Valve Spring Servicing
Measuring the Top Clearance
Intake and Exhaust Valve Rocker Arms and Push Rods Servicing
Piston Servicing
Adjusting the Valve Clearance
Identification of Cylinder Head
Piston Pin Servicing
Checking Piston Pin Hole
Piston O.D. Table
Clearance between Piston and Sleeve Table/Piston Pin Hole I.D. Table
Piston Rings Servicing
Clearance between Piston Pin Hole and Pin Table
Piston Ring Side Clearance
Measuring the Clearance between the Piston Ring and Groove (Side Clearance)
Measuring of Ring End Gap
Checking the Connecting Rod
Small and Large End Hole of Connecting Rod Table
Checking the Crank Pin Metals
Connecting the Piston and Connecting Rod
Clearance between Crank Pin and Metal Table
Tightening Torque Table
Undersized Crank Pin Metal, Part No. Table
Piston Top Mark
Crankshaft Servicing
Main Bearing Metal Servicing
Flywheel Servicing
Camshaft Servicing
Checking the Timing Gears
Tappet Servicing
Crankcase Cover Servicing
Replacing the Crankshaft Oil Seal and Camshaft Oil Seal
Cylinder Sleeve and Cylinder Block Servicing
Lubrication System Servicing
Cylinder Sleeve I.D. Table
Lubricating Oil Pump
Fuel System Servicing
Fuel Injection Pump
Fuel Pump Mounting Flange
Configuration of Fuel Oil Pump
Fuel Pump Disassembly and Reassembly
Fuel Injection Valve
Fuel Injection Nozzle Diagram
Fuel Injection Valve Assembly
Speed Control Device Servicing
Position of Governor Spring Hole
Fuel Filter Servicing
Electrical System Servicing
L40AE - L100AE Engines Wiring Diagram (for 12V-15A/125V-3A Charging Generator)
L40AE - L100AE Engines Wiring Diagram (for 12V - 3A Charging Generator)
L40AE - L100AE Engines Wiring Diagram (for 12V - 1.7A Charging Generator)
L40AE - L100AE Engines Wiring Diagram (for 12V - 1A Charging Generator)
L40AE - L100AE Engines Wiring Diagram (with Air Heater and Timer, for 12V - 15A/12V - 3A Charging Generator)
L40AE - L70AE Engines Wiring Diagram, (Generator for Lighting) for 12V-25W/40W (Use Lamp Only)
For 6V-15W (Use Lamp Only)
Starter Motor Servicing
Starter Motor Specifications and Performance
Characteristics Curve
Starter Motor Construction
Conventional Type Sterter Motor (Standard Electric Starter) Diagram
Over-Running Clutch Diagram
Reduction Type Starter Motor (Option for L75AE-SE - L100AE-SE)
Reduction Type Starter Motor Operation
Reduction Type Starter Motor Disassembly
Reduction Type Disassembly
Magnetic Switch Removal
Dust Cover and Shift Lever Removal
Clutch Assembly/Disassembly
Reduction Type Starter Motor Inspection
Armature Inspection
Field Coil Inspection
Magnetic Switch Inspection
Pinion/Brush Inspection
Brush Dimensions
Reduction Type Starter Motor Adjustment and Performance Test
Reduction Type Starter Motor Reassembly Precautions
Reduction Type Starter Motor Characteristics Test
Reduction Type Starter Motor Maintenance Standards
Generator (Dynamo), Regulator and Rectifier Servicing/Specifications
Dynamo Construction
Generator Check
Inspection of Dynamo/Regulator (Combination)
Inspection of Discrete Regulator (Simplified Inspection)
Inspection of Rectifier
Air Heater Servicing
Battery Servicing
Battery Capacity and Battery Cables
Battery Inspection
Battery Charging
Adjustment
Adjustment of Fuel Injection Timing
Bleeding Air from Tuel System
Fuel Injection Volume Limitation
Adjusting the Clearance on Intake/Exhaust Valve Head
Adjusting the Valve Head Clearance
Troubleshooting
No Fuel Injection Sound
Low Compression Pressure
Recoil too Heavy
Failure of Starter Motor (Starter)
Insufficiently Charged Battery
Normal Fuel Injection and Compression and Light Recoil, but Engine Is Still Hard to Start
Unexpected Reverse Rotation at Startup
Reverse Rotation of Engine
Racing
Uneven Rotation
Output Drops
Sudden Stops During Operation
Abnormal Exhaust Color
Black/Bluish-White Exhaust
Test Run
Before Starting
Operation
Stopping
Helical Inserting Part for Repair
Procedure for Using Helical Insert Part
Difference between Parts under Spec. S and D
Details of Special Tools
Flywheel Tightening Handle
Flywheel Extractor
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This manual is also suitable for:
L48ae
L60ae
L90ae
L100ae
L70ae
L75ae
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