Yanmar LV Series Industrial Diesel Engine Repair Service Manual

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This Workshop Service Repair manual PDF download for the LV Series Yanmar Industrial Diesel Engine has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to fully at every opportunity.


APPLICABLE MODELS :

Yanmar L48V
Yanmar L70V
Yanmar L100V


TABLE OF CONTENTS :

Introduction
Yanmar Warranties
Safety
General Service Information
Periodic Maintenance
Engine
Fuel System
Starter
Charging System
Electric Wiring
Troubleshooting


MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
Part Number : 0BLV0-G00100
Total Pages : 262


This manual describes the service procedures for the LV series air-cooled, vertical single-cylinder, 4-stroke, direct injection engines.

This Service / Repair / Workshop Manual PDF Download contains specs, diagrams, actual real photo illustrations, and schemes. In addition to space savings, nice thing about having completly searcheble PDF files instead of a hard-printed manual is that you can use the Search feature in your PDF reader software (Adobe Acrobat) to find just what your looking for and just print out the exact pages you need or all manual easily. This is the same manual your local dealer will use when doing a repair. This is a must for the Do-It-Yourselfer! Saving Yourself $$$$$$ In Service Repair And Maintenance Costs !!!!

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Cover
Table of Contents
Introduction
Yanmar Warranties
Yanmar Limited Warranty
What is Covered by this Warranty?
How Long is the Warranty Period?
What the Engine Owner Must Do:
To Locate an Authorized Yanmar Industrial Engine Dealer or Distributor:
What Yanmar Will Do:
What is Not Covered by this Warranty?
Warranty Limitations:
Warranty Modifications:
Questions:
Retail Purchaser Registration
Emission System Warranty
Yanmar Co., Ltd. Limited Emission Control System Warranty - USA Only
Your Warranty Rights and Obligations:
California
Manufacturer’s Warranty Period:
Warranty Coverage:
Warranted Parts:
Exclusions:
Owner’s Warranty Responsibilities:
Safety
Safety Statements
Before You Begin Servicing
Safety Precautions
General Service Information
Component Identification
Location of Labels
Specifications
Description of Model Number
Engine Speed Specifications
General Engine Specifications
EPA / ARB Emission Control Information
EPA / ARB Emission Control Regulations - USA Only
EPA / ARB Emission Control Labels - USA Only
The 97/68/EC Directive Certified Engines
Description of Emission Control Engine Family Number
Function of Major Engine Components
Diesel Fuel
Diesel Fuel Specifications
Additional Technical Fuel Requirements
Bio-Diesel Fuels
Filling the Fuel Tank
Priming the Fuel System
Gravity-Fed Fuel System
Electric Pump Pressurized Fuel System
Engine Oil
Engine Oil Specifications
Service Categories
Definitions
Additional Technical Engine oil Requirements:
Engine Oil Viscosity
Engine Oil Capacity (Typical)
Checking Engine Oil
Adding Engine Oil
Abbreviations and Symbols
Abbreviations
Symbols
Unit Conversions
Unit Prefixes
Units of Length
Units of Volume
Units of Mass
Units of Force
Units of Torque
Units of Pressure
Units of Power
Units of Temperature
Tightening Torques for Standard Bolts and Nuts
Tightening Torques for Special Bolts and Nuts
Periodic Maintenance
Before You Begin Servicing
Introduction
The Importance of Periodic Maintenance
Performing Periodic Maintenance
The Importance of Daily Checks
Keep a Log of Engine Hours and Daily Checks
Yanmar Replacement Parts
Tools Required
Tightening Fasteners
Required EPA / ARB Maintenance - USA Only
EPA / ARB Installation Requirements - USA Only
Periodic Maintenance Schedule
Periodic Maintenance Procedures
Daily, Before Operation
Check Battery (If Equipped)
Check Battery Indicator (If Equipped)
Check Engine Oil Level
Check for Engine Oil Leakage
Check Engine Speed Control
Check Spark Arrester (If Equipped)
Check Fuel Level
Check for Fuel Leakage
Daily, After Operation
Check for Engine Oil Leakage
Check for Fuel Leakage
After Initial 50 Hours of Operation
Replace Engine Oil
Clean / Inspect Engine Oil Filter
Every 50 Hours of Operation
Clean Inlet Fuel Screen
Every 200 Hours of Operation
Clean Air Cleaner Element
Replace Engine Oil and Clean / Inspect Engine Oil Filter
Check and Adjust Engine Speed Control
Drain the Fuel Tank and Replace Outlet Fuel Filter
Every 400 Hours of Operation
Adjust Intake and Exhaust Valve Clearance
Replace Outlet Fuel Filter
Every 1000 Hours of Operation
Check Compression
Every 1500 Hours of Operation
Inspect, Clean and Test Fuel Injection Nozzle
Every 2000 Hours of Operation
Check and Replace Fuel Hoses
Engine
Before You Begin Servicing
Introduction
Specifications
Cylinder Head Assembly
Valve Clearance
Cylinder Head
Intake / Exhaust Valve Seat
Intake / Exhaust Valves, Guides and Seals
Push Rod
Valve Spring
Rocker Arm and Shaft
Crankshaft, Balancer Shaft, Piston and Connecting Rod
Crankshaft
Balancer Shaft
Piston
Piston Ring
Connecting Rod
Camshaft and Tappet
Camshaft
Tappet
Cylinder Block and Crankcase Cover
Cylinder Block
Crankcase Cover
Oil Pump (Trochoid Pump)
Special Torque Specifications
Special Service Tools
Measuring Instruments
Cylinder Head
Removal of Cylinder Head
L48V Models
L70V and L100V Models
All Models
Disassembly of Cylinder Head
Inspection of Cylinder Head Components
EGR Passage
Valve Face and Valve Seat
Valves and Valve Guides
Valve Springs
Rocker Arms and Push Rods
Cylinder Head Distortion
Reassembly of Cylinder Head
Reassembly of Intake / Exhaust Valves
Installation of Cylinder Head
Calculating Cylinder Head Gasket Thickness
Checking Actual Piston TDC (Top Dead Center)
Measuring and Adjusting Valve Clearance
Engine
Removal of Engine
Disassembly of Engine
Inspection of Engine Components
Piston, Piston Rings and Wrist Pin
Connecting Rod
Crankshaft, Main Bearing and Flywheel
Crankshaft
Bearings
Camshaft and Tappet
Balancer Shaft
Timing Gears
Cylinder Bore
Honing and Boring
Inspection and Service of Engine Oil Pump
Reassembly of Engine
Replacement of Throttle Shaft Seal - L48V Models
Replacement of Throttle Shaft Seal - L70V and L100V Models
Replacement of Crankshaft Seals
Reassembly of Piston, Piston Rings and Connection Rod
Installation of Crankshaft
Installation of Piston and Connecting Rod
Installation of Camshaft and Balancer Shaft
Installation of Crankcase Cover
Final Engine Assembly
Installation of Engine
Fuel System
Before You Begin Servicing
Introduction
Specifications
Test and Adjustment Specifications
Special Torque Specifications
Special Service Tools
Measuring Instruments
Fuel System Operation
Fuel Injection Pump
Fuel Injector
Fuel System Diagram
Fuel System Components
Checking and Adjusting Fuel Injection Timing
Checking Fuel Injection Timing
Adjusting Fuel Injection Timing
Fuel Injection Pump
Removal of Fuel Injection Pump
Installation of Fuel Injection Pump
Replacement and/or Adjustment of the Fuel Limiter
Fuel Injector
Removal of Fuel Injector
Testing of Fuel Injector
Disassembly and Inspection of Fuel Injector
Adjusting Fuel Injector Pressure
Reassembly of Fuel Injector
Installation of the Fuel Injector
Speed Control Device
Variable Speed Type
Remote Control Type
Variable Speed Friction Plate Type
Constant Speed Type
Starter
Before You Begin Servicing
Introduction
Specifications
Special Service Tools
Measuring Instruments
Electric Starter Motor Components (Standard)
Electric Starter Motor Troubleshooting
Testing Electric Starter Motor Operation (Standard)
Checking Pinion Projection Length
No-Load Test
Electric Starter Motor (Standard)
Disassembly of Electric Starter Motor
Inspection and Testing of Electric Starter Motor Components
Armature
Field Coil
Brush Holder
Solenoid Switch
Pinion
Reassembly of Electric Starter Motor
Recoil Starter
Disassembly of Recoil Starter
L48V and L70V
L100V
Reassembly of Recoil Starter
Charging System
Before You Begin Servicing
Introduction
Specifications
General Specifications
Unregulated Output Test Specifications
Regulated Output Test Specifications
Special Torque Specifications
Special Service Tools
Measuring Instruments
Charging System Operation
Charging System Wiring Diagrams
12 V - 3 A and 12 V - 15 A System
12 V - 1.7 A System
12 V - 1 A System
12 V - 3 A and 12 V - 15 A with Intake Air Heater and Timer
Charging System Components
Testing of Charging System and Components
Testing Regulated Output
Testing Unregulated Output
Testing Stator Coil Continuity
Testing Stator Coil Short-to-Ground
Testing of Regulator / Rectifier
Regulator Number RS5112
Regulator Number RS2190
Testing of Rectifier
ZR2117 (Half-Wave Rectifier)
ZR2120 (Full-Wave Rectifier)
Stator
Removal of Stator
Installation of Stator
Electric Wiring
Electric Wiring Precautions
Battery Cable Resistance (If Equipped)
Electrical Wire Sizes - Voltage Drop
Conversion of AWG to European Standards
Troubleshooting
Before You Begin Servicing
Introduction
Specifications
Cylinder Compression Pressure
Measuring Instruments
Troubleshooting By Measuring Compression Pressure
Measuring Compression Pressure
Low Compression Troubleshooting Chart
Troubleshooting Quick Reference Charts
Back Cover

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