Yanmar Engine Starting Motor Disassembly Introduce

This article introduces Yanmar engine starting motor (4TNV94L 98 and 4TNV106 (T)) disassembly introduce

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(1) Disassembling order
1) Nut M8 (Disconnect the connecting wire.) See the disassembly drawing.
2) Screw M4 (2)
3) Through bolt M5 (2)
4) Rear cover
5) Brush holder
6) Yoke assy.
7) Armature
8) Bolt M6 (2)
9) Magnetic switch
10) Dust cover
11) Shift lever
12) Screw M4 (3)
13) Bearing retainer
14) Gear case
15) Pinion stopper clip
16) Pinion stopper
17) Return spring
18) Pinion shaft
19) Clutch assy


(2) Disassembly procedure
1) Nut M8
Remove the magnetic switch nut M8 (12 mm),
and disconnect the connecting wire.



2) Screw M4 (2)


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3) Through bolt M5 (2)



4) Rear cover
Remove the M4 screw fastening the brush holder
and remove through bolt M5 for rear cover
removal.


5) Brush holder Pull the brush spring up with the brush spring puller. On the negative (-) side, bring the brush spring into contact with the side of the brush for
lifting from the commutator surface. On the positive (+) side, extract the brush from the brush holder.



6) Yoke Assy.



7) Armature Remove the brush holder. The armature and yoke assy can now be removed.




8) Bolt M6 (2)



9) Magnetic switch Remove bolt M6 (10 mm), and the magnetic switch can be removed.


10) Dust cover



11) Shift lever Take the dust cover out from the gear case. The shift lever can be removed

12) Screw M4 (3)

13) Bearing retainer


14) Gear case Remove screw M4, and the bearing retainer and clutch assy can be removed.


15) Pinion stopper clip Remove the bearing retainer at the edge and the bearing, and shift the pinion stopper toward the inion. use a plain screwdriver and pry to
remove the pinion stopper clip


16) Pinion stopper


17) Return spring


18) Pinion shaft

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19) Clutch Assy Remove the pinion stopper clip. The pinion stopper, return spring, pinion shaft and bearing retainer can be removed. Disassembly is completed now

Introduce how to disassemble and inspect Yanmar marine engine fuel injection pump

 Introduce how to disassemble and inspect Yanmar marine engine fuel injection pump

1，The fuel feed pump pumps fuel from the fuel tank, passes it through the fuel filter element, and supplies it to the fuel injection pump.
The fuel feed pump is mounted on the side of this engine and is driven by the (eccentric) cam of the fuel pump cam-
shaft. It is provided with a manual priming lever so that fuel can be supplied when the engine is stopped.
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2，5-1 Construction of fuel feed pump

1. Bottom body                            8. Lever assembly
2. Piston spring                            9.O-ring
3. Piston                                      10. Stop pin
4. Diaphragm spring                   11. Top body assembly
5. Diaphragm assembly              12. Packing
6. Pin                                           13. Cover
7. Lever return spring                 14. Small screw                                  
                                                   15. Cap
                                               

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3 Disassembly and reassembly of fuel feed pump
3. 1 Disassembly
(1) Remove the fuel feed pump mounting nut, and take the fuel feed pump off the fuel injection pump.
(2) Clean the fuel feed pump assembly with fuel oil.
(3) After checking the orientation of the arrow on the cover, make match marks on the upper body and cover, remove the small screw, and disassemble the cover, upper body and lower body.
4. Reassembly
(1) Clean all parts with fuel oil, inspect, and replace any defective parts.
(2) Replace any packings on parts that have been disassembled.
(3) Make sure that the intake valve and discharge vaive on upper body are mounted in the proper direction, and that you don't forget the valve packing.
(4) Assemble the diaphragm into the body, making sure the diaphragm mounting holes are lined up (do not force).
(5) Align the match marks on the upper body of the pump and cover, and tighten the small screws evenly.

5， Fuel feed pump inspection
(1) Place the fuel feed pump in kerosene, cover the dis charge port with your finger, move the priming lever and check for air bubbles (Repair or replace any part which emits air bubbles).

(2) Attach a vinyl hose to the fuel feed pump intake, keep the pump at the specified depth from the fuel oil surface, move the priming lever by hand and check for sudden spurts of fuel oil from the discharge port. If oif is not spurted out, inspect the diaphragm and diaphragm spring and repair/replace as necessary.
(3) Diaphragm inspection Parts of the diaphragm that are repeatedly burned wifl become thinner or deteriorate over a long period of time.
Check the diaphragm and replace if necessary.

(4) Valve contact/mounting Clean the valve seat and vaive with air to remove any foreign matter.

Yanmar Heavy Equipment EPC 11.2009

(5) Inspect the diaphragm spring and piston spring for sett!-
ing and the piston for wear, and replace as necessary.
NOTE: Replace parts as an assembly.

Yanmar 3JH2 Series Maring Diesel Engine Inspection of fuel injection pump Guide

 This article mainly introduces Yanmar 

 

3JH2 Series Maring Diesel Engine  Inspection of fuel injection pump

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(1) Inspection of plunger
1) Thoroughly wash the plungers, and replace plungersthat have scratches on the plunger lead or are dis.
colored.
2) The plunger is in good condition if it slides down smoothly when it is tiited about 60. Repeat this several times while turning the plunger. Repair or replace if it slides down too quickly or if it stops part way.

(2)Inspection of delivery valve

Yanmar Heavy Equipment EPC 11.2009

1) Replace as a set if the delivery valve suck-back collar or seat are scratched, scored, scuffed, worn, etc.
2) The valve is in good condition if it returns when released after being pushed it down with your finger(while the holes in the bottom of the delivery guide seat are covered). Replace if necessary.
3) Likewise, the valve should completely close by its own weight when you take your finger off the holes in the bottom of the delivery guide sheet.
NOTE: When fitting new parts, wash with diesel oil and perform the above inspection.

(3) Inspection of pump
1) Inspect for extreme wear of roller guide sliding surface. Scratches on the roller pin sliding surface are not a problem.
2) Inspect the plunger barrel seat.
If there are burrs or discoloration, repair or replace as this will lead to dilution of the iubricant.

(4) Inspection of fuel camshaft and bearings
1) Fuel camshaft Inspect for scratches or wear of camshaft, deformation
of key grooves and deformation of screws on both ends, and replace if necessary.
2) Bearings Replace if the taper rollers or outer race surface is flak-
ed or worn.
NOTE: Replace fuel camshafts and bearings together.

(5) Inspection of roller guide assembly
1) Roller

NOTE: Replace fuel camshafts and bearings together.
(5) Inspection of roller guide assembly
1) Roller

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Replace if the surface is worn or flaked.
2) Rolter Guide Replace if the outer roller pin hole is extensively worn or there are many scratches.
3) Replace if the play of the roller guide assembly pin/roller is 0.2mm(0.0078in.) or more.

4) Injection timing adjustment boft Replace if the surface in contact with the plunger side is unevenly or excessively worn.

(6) Inspection of rack and pinion

1) Rack
Inspect for bending of rack and wear or deformation of fit with pinion.
2) Pinion Inspect for wear or deformation of fit with rack.
NOTE: If the tooth surface or sliding surlace is not in good working order, rack resistance increases, affecting the condition of the engine (rough rom, over running, etc.).
(7) inspection of plunger spring and delivery spring Inspect springs for scratches, cracks, breakage, uneven wear and rust.

(8) Inspection of oil seais Inspect oit seals to see if they are burred or scratched.

(9) inspection of roller guide stop Inspect the side of the tip, replace if excessively worn.

(10) Inspection of O-rings Inspect and replace if they are burred or cracked.

Yanmar Maring Diesel Engine Disassembly of Fuel Injection Pump Guide

  Yanmar 3JH2 Series  Maring Diesel Engine Disassembly of fuel injection pump guide  

 

Yanmar Engine Diagnostic Service Tool Software

 When disassembling the fuel pump, separate the parts for each cylinder and be careful not to get them mixed up.
Be especially careful to keep the plunger/plunger barrel, delivery valve/delivery valve seat and other assemblies separate for each cylinder (the parts of each assembly must be kept with that assembly and put back in the same cylinder).
Preparation
1. Wash off the dirt and grease on the outside of thepump with cleaning oil(kerosene or diesel oil) before disassembly.
2. Perform work in a clean area.
3. Take off the fuel pump bottom cover and remove lubri.
   cant oil.
4. Turn the fuel pump upside down to drain fuel oil.

(1)Loosen the nut with a box spanner and take it off, holding it with the hole in the fuel coupling ring or holding the coupling with a vise and take out the governor weight assembly.

(2) Remove the fuel feed pump.
NOTE: Do not disassemble the fuel feed pump. See in-
structions for fuel feed pump for details.

(3) Remove the fuel pump side cover.

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(4) Turn the camshaft until the roller guide is at themaximurm head, and insert the plunger spring support plate in between the plunger spring washer B lower side) and fuel pump unit.

NOTE: If the camshaft does not turn, put double nuts on the end of the cam shaft or remove the coupling.
(5) Remove the camshaft wood ruff key.
(6) Put a screwdriver in the two grooves on the camshaft bearing holder mounting surface, and pull out the cam-
shaft bearing hotder.

Yanmar Heavy Equipment EPC 11.2009

NOTE:
1.Be sure not to damage the oil seal with the threaded part of the camshaft.
2.Be careful not to loosen the shims in between the pump and bearing holder.
  Printed in Japan A0A1015-9110SP


(7) Turn the fuel pump upside down, move all the roller guides to the plunger side, and then put the pump on its side. Turn the camshaft to a position so that none of the cylinder cams hit the tappets.
(8) Put a plate against the governor end side of the cam-
shaft and lightly tap it, and pull out the camshaft and drive side bearing.

(9) Remove the roller guide stop.

(10) Use a hammer handle or the like to push up the roller guide from the bottom of the pump, and remove the plunger spring support plate.

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NOTE: The plunger spring may make the roller guide and plunger, etc. fly out when the plunger support plate is removed.


(11) Remove the roller guide.

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NOTE: When you stand the fuel pump up, all of the roller guides drop out at one time. Therefore, first remove the stop bolt for one cylinder at a time, and then the roller guide for each cylinder-continue this process.

(12) Remove the plunger, plunger spring and lower washer from the lower part of the pump.

NOTE:Keep the parts separate for each cylinder.

(13) Loosen the small screw on control pinion.

NOTE:1. Check to make sure the match marks on the pinionlsleeve are correct before loosening the small screw on the control pinion, as the pinion and sleeve come apart when the screw is loosened. If the mark is hard to read or off center, lightly inscribe a new mark. This will serve as a guide when adjusting injection volume later.

(14) Remove the control pinion, sleeve and upper rest.


NOTE:
Keep parts separate for each cylinder.


(15) Remove the con: rol rack stop boit and remove the rack.

NOTE:Be careful not to lose the spring or rest on the control rack.

(16) Loosen the delivery valve retainer stop bolt, and remove the dellvery valve hoider stop.

(17) Remove the delivery valve holder.

(18) Remove the delivery valve assembly.

NOTE:1. Be careful not to lose the delivery valve pack-
ing. delivery valve spring, delivery valve stopper or other small parts.
2. Keep the delivery vave assemblies for each cylinder clearly separated.
(19) Take the plunger barel out from the top of pump.

NOTE:Keep it as a set with the plunger that was remo.
ed earlier

How to Disassembly yanmar Diesel Engine Governor

 

 This article mainly introduces  yanmar marine diesel engine Governor disassembly

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(1)  Remove the governor case.

NOTE: Loosen the hex bolt on models with an angleich spring.

(2) Remove the control lever hex nut, and pulil out the con-
    trol lever from the control lever shaft.

(3) Remove the governor case bolt. Remove the governor case(parallel pin) from the fuel pump until while lightly tapping the governor case with a wooden hammer.
    Create a gap between the governor case and fuel pump by moving parts of the governor lever.

(4) Pull out the governor link snap pin by inserting needle nosed pliers between the fuel pump and governor case.
case.

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(5) The governor and fuel pump come apart by sliding the governor case and fuel pump apart and pulling out the link pin of the fuel control rack.

(6) Remove the stop lever return spring from the governor lever shaft.

(7) Use needle nose pliers to unhook the governor spring from the tension lever and control lever shaft.

(8) Remove the snap-rings on both ends of the governor lever shaft.

Yanmar Heavy Equipment EPC 11.2009

(9) Put a rod 8mm (0.3150in.) in dia. or less in one end of the governor lever shaft, and tap the governor shaft until the O-ring comes out the other side of the governor case.

(10) Atter removing the O-ring. lightly tap the end of the shaft that you removed the O-ring from, and removethe governor lever shaft. Then remove the governor shaft assembly and washer.

(11) Remove the governor link from the governor lever.

NOTE: The governor assembly consists of the governor lever, tension bar, bushing, throttle spring and shifter, and is normally not disassembled.
The spring pin is removed when you replace the shifter or throtle spring.
(12) When you need to pull out the stop lever, remove thestop lever shaft stop pin, and lightly tap the inside of the governor case.

(13) When you need to pull out the control lever shaft, tap the end of the shaft with a wood hammer.

NOTE:1.Do not remove the fuel limit nut from the governor case unless necessary.

(14) Pulil out the governor sleeve on the end of the fuel camshaft by hand.

(15) Turn the governor weight with a box spanner two or three times to loosen it, stopping it with the hole inthe fuel coupling ring or holding the coupling with a vise.

NOTE:When the taper lit comes apart after you have removed the nut，the governor weight may lly out一Be Careful.

(16) Remove the governor weight assembly from the fuel pump cam using the governor weight puling tools.

NOTE: The governor weight assembly is made up ol the governor weight, support and pin. Do not dis.
assemble.
Printed in Japan A0A 1015-9110SP