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Yanmar L60AE User Manual

Yanmar L60AE
130 pages
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Table of Contents

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Yanmar L60AE Specifications

General IconGeneral
Engine ModelL60AE
Number of Cylinders3
Fuel SystemDirect injection
Starting SystemElectric starter
Engine Type4-stroke diesel
Lubrication SystemForced lubrication
Cooling SystemWater-cooled

Summary

INTRODUCTION

GENERAL SAFETY

STOP THE ENGINE BEFORE SERVICING

Essential safety precaution to perform before any engine servicing.

PREVENTING FIRES

Guidelines for handling flammable substances and maintaining fire safety.

PRECAUTIONS FOR THE BATTERY

Safety measures when working with the battery.

SERIAL NUMBER LOCATION

SERVICE RULES

SPECIFICATIONS

Specifications

Detailed technical data for engine models L40AE through L100AE.

Cross Sectional Views

Illustrations showing internal engine component layouts.

SERVICE STANDARDS

Intake/Exhaust Valve Seats

Specifications for intake and exhaust valve seats.

Intake/Exhaust Valves & Valve Guides

Measurements for valve guides and valve stems.

Valve Clearance

Standards for intake and exhaust valve clearance.

DISASSEMBLY AND REASSEMBLY

Tools

List of necessary tools, jigs, and meters for disassembly.

Tightening Torques

Torque specifications for fastener tightening during assembly.

Maintenance Schedule

Recommended maintenance intervals for engine components.

Disassembly Procedures

Step-by-step instructions for engine disassembly.

CHECKING AND SERVICING

Cylinder Head

Procedures for checking and servicing the cylinder head.

Intake/Exhaust Valve Seats

Checking valve seats for wear and distortion.

Intake/Exhaust Valves, and Valve Guides

Checking valve guides and valve stems.

Valve Spring

Checking valve spring for wear and measuring tension.

CRANKSHAFT, MAIN BEARING AND FLYWHEEL

Crankshaft

Checking crankshaft for damage and journal wear.

Main Bearing Metal

Checking main bearing metal for wear and proper seating.

Flywheel

Checking flywheel timing marks.

CAMSHAFT AND TAPPET

Camshaft

Checking camshaft and bearing clearances.

Tappet

Checking tappet condition and outer surface for wear.

TIMING GEARS

Checking the Timing Gears

Procedures for checking and reassembling timing gears.

CRANKCASE COVER

Crankcase Cover

Checking crankcase cover and tightening torque.

CYLINDER SLEEVE AND CYLINDER BLOCK

Cylinder Sleeve

Measuring cylinder sleeve I.D. and checking for wear.

Cylinder Block

Checking cylinder block I.D. and bearing fit.

LUBRICATION SYSTEM

Lubricating Oil Pump

Procedures for measuring and installing the lubricating oil pump.

FUEL SYSTEM

Fuel Injection Pump Specifications

Technical specifications for the YDLLA-P fuel injection pump.

Fuel Injection Pump Disassembly and Reassembly

Detailed steps for disassembling and reassembling the fuel injection pump.

Fuel Injection Valve

Checking and adjusting the fuel injection valve.

SPEED CONTROL DEVICE

Fuel Filter

Information on checking and replacing the fuel filter.

Position of Governor Spring Hole

Table showing governor spring hole positions for different models.

ELECTRICAL SYSTEM

Wiring Diagrams

Diagrams for the L40AE-L100AE engines' charging generator systems.

STARTER MOTOR

Specifications and Performance Curve

Technical data and performance graphs for starter motors.

Construction

Description of the main parts of the starter motor.

Conventional type starter motor

Details on the standard electric starter motor construction.

Reduction type starter motor

Details on the reduction type starter motor construction.

GENERATOR, REGULATOR AND RECTIFIER

Specifications

Technical specifications for generators, regulators, and rectifiers.

Generator Check

Procedures for checking the generator's operation.

Stator Coil Continuity Test

Testing stator coil continuity.

Coil Insulation Test

Testing coil insulation.

AIR HEATER (OPTIONAL)

Air Heater System Circuit

Diagrams of the air heater system circuits.

BATTERY

Battery Capacity and Battery Cables

Information on battery capacity and cable selection.

Battery Inspection

Procedures for checking battery electrolyte level and specific gravity.

Battery Charging

Guidelines for safely charging the battery.

ADJUSTMENT

Adjustment of Fuel Injection Timing

Procedure for adjusting fuel injection timing.

Bleeding Air from Fuel System

Steps to bleed air from the fuel system.

Fuel Injection Volume Limitation

Procedure for adjusting fuel injection volume.

Adjusting the Clearance on Intake/Exhaust Valve Head

Adjusting intake and exhaust valve head clearance.

TROUBLESHOOTING

No Fuel Injection Sound

Diagnosing and resolving issues with no fuel injection sound.

Low Compression Pressure

Troubleshooting low compression pressure issues.

Leak in Crankcase

Diagnosing and fixing leaks in the crankcase.

Recoil Too Heavy

Troubleshooting heavy recoil issues.

TEST RUN

Before Starting

Pre-start checks and procedures for the engine.

Starting

Detailed steps for starting the engine.

Operation

Procedures for operating the engine after starting.

Stopping

Procedures for safely stopping the engine.

HELICAL INSERTING PART FOR REPAIR

Helical Inserting Part for Repair

General information and use of helical inserts for thread repair.

Size of Helical Inserting Part

Dimensions and specifications of helical inserts.

Procedure for Helical Inserting Part

Step-by-step guide for installing helical inserts.

APPENDIX 1: DIFFERENCE BETWEEN PARTS UNDER SPEC. S AND D

Crankcase Cover

Comparison of crankcase cover differences between S and D specifications.

Camshaft Assy

Comparison of camshaft assembly differences between S and D specifications.

Flywheel

Comparison of flywheel differences between S and D specifications.

Piston

Comparison of piston differences between S and D specifications.

APPENDIX 2: DETAILS OF SPECIAL TOOLS

Oil Seal Fitting Tool

Details and specifications for the oil seal fitting tool.

Oil Seal Fitting Guide

Instructions for using the oil seal fitting guide.

Valve Stem Seal Fitting Tool

Details and specifications for the valve stem seal fitting tool.

Flywheel Tightening Handle

Diagram and dimensions for the flywheel tightening handle.

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