Yanmar L100AE Diesel Engine Replacement Manuals

Manuals and User Guides for Yanmar L100AE Diesel Engine Replacement. We have 1 Yanmar L100AE Diesel Engine Replacement manual available for free PDF download: Service Manual

Yanmar L100AE Service Manual (131 pages)

Diesel engine Yanmar L-A series

Brand: Yanmar | Category: Engine | Size: 13.82 MB

General Safety
5
Serial Number Location
6
Service Rules
6
Contents
7
Specifications
9
Cross Sectional Views
13
Longitudinal Sectional View
14
Camshaft PTO Plan View
15
Crankshaft PTO Plan View
15
Service Standards
16
Intake/Exhaust Valve Seats Service Standards
16
Intake/Exhaust Valves & Valve Guides Service Standards
16
Valve Springs Service Standards
16
Intake/Exhaust Valve Rocker-Arm, Rocker Shaft and Push Rods Service Standards
17
Valve Clearance Service Standards
17
Valve Opening/Closing Timing Service Standards
18
Piston Service Standards
18
Piston Pin Service Standards
19
Piston and Rings Service Standards
19
Piston Ring Service Standards
19
Connecting Rod Service Standards
20
Crankshaft and Main Bearing Service Standards
21
Camshaft Service Standards
22
Tappet Service Standards
22
Crankcase Cover Service Standards
23
Cylinder Block Service Standards
24
Oil Pump (Trochoid Pump) Service Standards
25
Disassembly and Reassembly
26
Tools
26
Meters, Instruments and Service Accessories
28
Instruments
30
Tightening Torques
31
Maintenance Schedule
32
Disassembly Procedures
33
Removing the Fuel Tank
33
Removing the Exhaust Silencer
33
Removing the Air Cleaner
33
Removing the Cooling Fan Case/Starter Pulley/Air Intake Bend
34
Removing the Valve Rocker Arm Assembly
34
Fuel Injection Valve Disassembly
34
Removing the Cylinder Head
35
Removing the Fuel Pump
35
Removing the Crankcase Cover
35
Removing the Camshaft
35
Removing the Balancer Shaft
36
Removing the Piston and Connecting Rod Assembly
36
Removing the Flywheel
36
Removing the Crankshaft
36
Reassembly Procedures
37
Installing the Crankshaft
37
Installing the Flywheel
37
Installing the Piston and Connecting Rod
37
Installing the Camshaft, Balancer Shaft
38
Fuel Injection Pump Reassembly
38
Installing Crankcase Cover
38
Attaching the Crankcase Cover and Tightening Three Orders
39
Installing the Cylinder Head
39
Inserting the Push Rods
39
Valve Rocker Arm Assembly
39
Installing the Valve Rocker Arm Cover
40
Installing the Fuel Injection Valve
40
Installing the Intake Bend
40
Installing the Cooling Fan Case
40
Installing the Air Cleaner
41
Installing the Starting Motor
41
Installing the Fuel Tank
41
Recoil Starter - Disassembling Procedures
42
Recoil Starter - Assembling Procedures
43
Recoil Starter - Checks after Reassembly
44
Checking and Servicing
45
Cylinder Head Checking and Servicing
45
Combustion Surfaces Servicing
45
Intake and Exhaust Valve Seats, Valve Guides Servicing
45
In/Ex Valve Guide and Valve Stem Table
46
Valve Spring Servicing
47
Measuring the Top Clearance
47
Intake and Exhaust Valve Rocker Arms and Push Rods Servicing
48
Piston Servicing
49
Adjusting the Valve Clearance
49
Identification of Cylinder Head
49
Piston Pin Servicing
50
Checking Piston Pin Hole
50
Piston O.D. Table
50
Clearance between Piston and Sleeve Table/Piston Pin Hole I.D. Table
50
Piston Rings Servicing
51
Clearance between Piston Pin Hole and Pin Table
51
Piston Ring Side Clearance
52
Measuring the Clearance between the Piston Ring and Groove (Side Clearance)
52
Measuring of Ring End Gap
52
Checking the Connecting Rod
53
Small and Large End Hole of Connecting Rod Table
54
Checking the Crank Pin Metals
54
Connecting the Piston and Connecting Rod
55
Clearance between Crank Pin and Metal Table
55
Tightening Torque Table
55
Undersized Crank Pin Metal, Part No. Table
55
Piston Top Mark
56
Crankshaft Servicing
57
Main Bearing Metal Servicing
58
Flywheel Servicing
58
Camshaft Servicing
59
Checking the Timing Gears
60
Tappet Servicing
60
Crankcase Cover Servicing
61
Replacing the Crankshaft Oil Seal and Camshaft Oil Seal
63
Cylinder Sleeve and Cylinder Block Servicing
63
Lubrication System Servicing
64
Cylinder Sleeve I.D. Table
64
Lubricating Oil Pump
64
Fuel System Servicing
66
Fuel Injection Pump
66
Fuel Pump Mounting Flange
66
Configuration of Fuel Oil Pump
66
Fuel Pump Disassembly and Reassembly
67
Fuel Injection Valve
68
Fuel Injection Nozzle Diagram
69
Fuel Injection Valve Assembly
69
Speed Control Device Servicing
70
Position of Governor Spring Hole
70
Fuel Filter Servicing
70
Electrical System Servicing
72
L40AE - L100AE Engines Wiring Diagram (for 12V-15A/125V-3A Charging Generator)
72
L40AE - L100AE Engines Wiring Diagram (for 12V - 3A Charging Generator)
73
L40AE - L100AE Engines Wiring Diagram (for 12V - 1.7A Charging Generator)
74
L40AE - L100AE Engines Wiring Diagram (for 12V - 1A Charging Generator)
74
L40AE - L100AE Engines Wiring Diagram (with Air Heater and Timer, for 12V - 15A/12V - 3A Charging Generator)
75
L40AE - L70AE Engines Wiring Diagram, (Generator for Lighting) for 12V-25W/40W (Use Lamp Only)
76
For 6V-15W (Use Lamp Only)
76
Starter Motor Servicing
77
Starter Motor Specifications and Performance
77
Characteristics Curve
77
Starter Motor Construction
78
Conventional Type Sterter Motor (Standard Electric Starter) Diagram
78
Over-Running Clutch Diagram
78
Reduction Type Starter Motor (Option for L75AE-SE - L100AE-SE)
79
Reduction Type Starter Motor Operation
81
Reduction Type Starter Motor Disassembly
82
Reduction Type Disassembly
83
Magnetic Switch Removal
84
Dust Cover and Shift Lever Removal
84
Clutch Assembly/Disassembly
84
Reduction Type Starter Motor Inspection
85
Armature Inspection
85
Field Coil Inspection
86
Magnetic Switch Inspection
86
Pinion/Brush Inspection
87
Brush Dimensions
88
Reduction Type Starter Motor Adjustment and Performance Test
89
Reduction Type Starter Motor Reassembly Precautions
90
Reduction Type Starter Motor Characteristics Test
90
Reduction Type Starter Motor Maintenance Standards
91
Generator (Dynamo), Regulator and Rectifier Servicing/Specifications
92
Dynamo Construction
93
Generator Check
93
Inspection of Dynamo/Regulator (Combination)
94
Inspection of Discrete Regulator (Simplified Inspection)
95
Inspection of Rectifier
96
Air Heater Servicing
97
Battery Servicing
98
Battery Capacity and Battery Cables
98
Battery Inspection
99
Battery Charging
100
Adjustment
101
Adjustment of Fuel Injection Timing
101
Bleeding Air from Tuel System
101
Fuel Injection Volume Limitation
102
Adjusting the Clearance on Intake/Exhaust Valve Head
102
Adjusting the Valve Head Clearance
102
Troubleshooting
103
No Fuel Injection Sound
103
Low Compression Pressure
105
Recoil too Heavy
107
Failure of Starter Motor (Starter)
108
Insufficiently Charged Battery
110
Normal Fuel Injection and Compression and Light Recoil, but Engine Is Still Hard to Start
111
Unexpected Reverse Rotation at Startup
112
Reverse Rotation of Engine
112
Racing
113
Uneven Rotation
114
Output Drops
115
Sudden Stops During Operation
116
Abnormal Exhaust Color
117
Black/Bluish-White Exhaust
118
Test Run
119
Before Starting
119
Operation
121
Stopping
121
Helical Inserting Part for Repair
122
Procedure for Using Helical Insert Part
123
Difference between Parts under Spec. S and D
125
Details of Special Tools
128
Flywheel Tightening Handle
129
Flywheel Extractor
129

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Yanmar L100AE Diesel Engine Replacement Manuals

Yanmar L100AE Service Manual (131 pages)

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