Introduces Lift Trucks and Skid Steer Loaders Cummins Engine Disassembly （1）

        This article mainly introduces Lift Trucks and Skid Steer Loaders   Cummins Engine Disassembly

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 NOTE: Put tag on all hoses, lines, linkage, and electrical connections as they are removed to identify location and aid the installation process.
A WARNING Always disconnect the negative(-) cable first.
Disconnect the battery cables.
A WARNING Allow the engine to cool before draining to avoid burns from hot liquid.
AWARNING Coolant is toxic. Keep away from children and animals. Save for reuse or dispose of in accordance with local regulations.
Drain the engine coolant.

AWARNING Some state and federal agencies in the United States of America have determined that used oil is carcinogenic and can cause reproductive toxicity. Avoid inhalation of vapors, ingestion, and prolonged contact with used engine oil. Always use the proper procedures to dispose of the oil.
Drain the lubricating oil.
       Engine Oil:7.5 liters [1.98 U.S. ga]
Disconnect the starter cable, engine ground straps, cab or chassis to engine hoses, tubing, electrical wires and hydraulic lines.

Disconnect the drive units from the flywheel housing and flywheel.
Remove all chassis components necessary to remove the engine from the equipment.
Prepare a stable stand, Part No.3375193 or 3375194, which will prevent the engine from falling over.
Engine Weight(approx.):255kg [562 b]

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Remove the starting motor.

Install the bracket, Part No.3163625, on the engine.
A WARNING This component weighs 23kg [50 Ib] or more. To avoid personal injury, use a hoist or get assistance to lift this component. The engine lifting equipment must be designed to lift the engine without causing personal injury.
Put the engine on the stand.

Cover all the engine openings to prevent dirt and debris from entering the engine.
Fan Pulley AWARNING Be careful not to injure your fingers or damage the alternator when moving the alternator toward the cylinder block.
Loosen the mounting capscrew of the adjustment plate(1). Loosen the alternator mounting capscrew and nut.
Move the alternator toward the cylinder block, and remove the belt (2).
Remove the fan pulley.
Fan Remove the four capscrews, retainer plate, fan, and spacer.
Alternator Remove the adjusting capscrew and washer.
Remove the capscrew, adjustment plate, and spacer.
Remove the remaining capscrew and alternator.
 Lubricating Oil Filter
Remove the lubricating oil filter.

Dipstick Guide
 Remove the dipstick and dipstick guide.

Water Pump
Remove the mounting capscrews, water pump, gasket, and o-ring.
Discard the gasket and o-ring.
Themostat Remove the two mounting capscrews,thermostat housing,thermostat and seal

Exhaust Manifold Remove the eight capscrews, exhaust manifold, and gasket.
Discard the gasket.
Fuel lnjection Tubing Remove the clamp.
Remove the sleeve nuts and the fuel injection tubing from the fuel injection pump and the cylinder head.
Intake Manifold Remove the eight capscrews, intake manifold, and air inlet connection. Remove the grid heated, if equipped.
Remove the four capscrews, air inlet connection, and o-ring. Discard the o-ring.
Spill Tube

 Remove the spring hose clamps and hose.
Remove the spill tube.
Injector A CAUTION Be careful not to damage the tip of the injector when removing.
Remove the mounting capscrew, washer, and injecdor.
NOTE: When removing the injector, clean around the injector, and insert a blind plug to prevent dust or dirt from entering the engine.
NOTE: Mark the injectors with tags showing the cylinder number, and keep it in a safe place.
If there is no abnormality in the injector, install it in the same position during assembly.
Rocker Lever Cover Remove the three capscrews, isolator assemblies, rocker lever cover, and o-ring.

Introduces YANMAR MARINE DIESEL ENGINE 3YM30/3YM20/2YM15 Precautions for Service WorK

 This article mainly introduces YANMAR MARINE DIESEL ENGINE 3YM30/3YM20/2YM15 Precautions for Service WorK

                       Yanmar Engine Diagnostic Service Tool Software

 (1) Precautions for Safety Read the safety precautions given at the beginning of this manual carefully and always mind safety in work.
(2) Preparation for Service Work Preparation is necessary for accurate, efficient service work. Check the customer ledger file for the history of the engine.
· Preceding service date
· Period/operation hours after preceding service
· Problems and actions in preceding service
· Replacement parts expected to be required for service
· Recording form/check sheet required for service
(3) Preparation before Disassembly
· Prepare general tools, special service tools, measuring instruments, oil, grease, non-reusable parts, and parts expected to be required for replacement.
· When disassembling complicated portions, put match-marks and other marks at places not adversely affecting the function for easy reassembly.
(4) Precautions in Disassembly

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· Each time a parts is removed, check the part installed state, deformation, damage, roughening, surface defect, etc.
Arrange the removed parts orderly with clear distinction between those to be replaced and those to be used again.
· Parts to be used again shall be washed and cleaned sufficiently.
Select especially clean locations and use clean tools for disassembly of hydraulic units such as the uel injection pump.
(5) Precautions for Inspection and Measurement Inspect and measure parts to be used again as required to determine whether they are reusable or not.
(6) Precautions for Reassembly
· Reassemble correct parts in correct order according to the specified standards(tightening torques, and adjustment standards). Apply oil important bolts and nuts before tightening when specified.
· Always use genuine parts for replacement.
· Always use new oil seals,O-rings, packing and cotter pins.
· Apply sealant to packing depending on the place where they are used. Apply of grease to sliding contact portions, and apply grease to oil seal lips.
(7) Precautions for Adjustment and Check Use measuring instruments for adjustment to the specified service standards.

 For Yanmar Diesel Engine Agriculture Excavator Tractor Marine Generator Diagnostic tool

Introduces MARINE DIESEL ENGINE 3YM30/3YM20/2YM15 Safety Rules and Precautions

     This article mainly introduces YANMAR MARINE DIESEL ENGINE 3YM30/3YM20/2YM15 Safety Rules and Precautions

For Yanmar Diesel Engine Agriculture Excavator Tractor Marine Generator Diagnostic tool

1. SAFETY LABELS
· Most accidents are caused by negligence of basic safety rules and precautions. For accident prevention, it is important to avoid such causes before development to accidents.
Please read this manual carefully before starting repair or maintenance to fully understand safety precautions and appropriate inspection and maintenance procedures.
Attempting at a repair or maintenance job without sufficient knowledge may cause an unexpected accident.
· It is impossible to cover every possible danger in repair or maintenance in the manual. Sufficient consideration for safety is required in addition to the matters marked A cAuTloN]. Especially for safety precautions in a repair or maintenance job not described in this manual, receive instructions from a knowledgeable leader.
· Safety marks used in this manual and their meanings are as follows:

A DANGERDANGERindicates animminent hazardous situaton which，if not avoided，WILL result in death or serious injury.
A WARNINGWARNING indicates a potentialy hazardous situation which，if not avoided，COULD result in death or serious injury.
CAUTION-indicates a potentially hazardous situation which，if A CAUTION hotavoe.mayPGR.RSNG--品5e GW.
·NOTICE-indicates that if not observed，the product performance or quality may not be guaranteed.

2. Safety Precautions
(1) SERVICE AREA
· Sufficient Ventilation AWARNING Inhalalion ofexhaust tumes and dustpaticles may be hazardous toones health. Running engines welding, sanding, painting, and polishing tasks should be only done in well ventilated areas.
· Safe/Adequate Work Area ACAUTION The service area should be clean, spacious, level and free from holes in the floor, to prevent "slip"or "trip and fall"type accidents.
· Clean, orderly arranged place ACAUTION Nodust mud, ol orparts should belet onthe floor surface.
[ Failure to Observe]
An unexpected accident may be caused.
A CAUTION]: Bright, Safelyluminated Area.
The work area should be well lit or iluminated in a safe manner. For work in enclosed or dark areas,a "drop cord"should be utilized. The drop cordmust have a wire cage to prevent bulb breakage and possible ignition of flammable substances.
A CAUTION]: SatGt, Eauipment Fire extinguisher(s), first aid kit and eye wash /shower station should be close at hand(or easily accessible) in case of an emergency.
(2) WORK-WEAR(GARMENTS)
· Safe Work Clothing A CAUTION Appropriate safety wear (gloves, special shoes/boots, eye/ear protection, head gear, harness', clothing, etc.) should be used/worn to match the task at hand. Avoid wearing jewelry, unbuttoned cuffs, ties or loose fitting clothes around moving machinery.A serious accident may occur if caught wgpme"Hdin moving/rotating machinery.
(3) TOOLS AWARNING :A0propriate Lifing /Holding When lifting an engine, use only a lifting device(crane, jack, etc.) with sufficient lifting capacity. Do not overload the device. Use only a chain, cable, or lifting strap as an attaching device. Do not use rope, serious injury may result.
To hold or support an engine, secure the engine to a support stand, test bed or test cart designed to carry the weight of the engine. Do not overload this device, serious injury may result.

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Never run an engine without being properly secured to an engine support stand, test bed or test cart, serious injury may result.
A WARNINGADprOriate TOOls Always use tools that are designed for the task at hand. Incorrect usage of tools may result in damage to the engine and or serious personal injury.
(4) GENUINE PARTS and MATERIALS
· Genuine Parts ACAUTIONAMays use genuine YANMAR parts or YANMAR recommended parts and goods. Damage to the engine, shortened engine life and or personal injury may result
（5）FASTENER TORQUE
·Torquing Fasteners A WARNING Always follow the torque values and procedures as designated in the service manual.Incorrect values，procedures and or tools may cause污一元，damage to the engine and or personal injury.
（6）Electrical
·Short Circuits AWARNING Always disconnect the（-）Negative battery cable before working on the
9p④
electrical system.An accidental"short circuit"may cause damage，fire and or personal injury.Remember to connect the（-）Negative battery cable（back onto the battery）LAST
AWARNING Charging wet celled batteries produces hydrogen gas. Hydrogen gas is extremely explosive. Keep sparks, open flame and any other form of ignition away. Explosion may occur causing severe personal injury.
· Battery Electrolyte AWARNING Bateries cotain sufuric acid. Do NoT alow t o come in contact wih clothing, skin and or eyes, severe bums will result.
(7) WASTE MANAGEMENT Observe the following instructions with regard to hazardous waste A CAUTION disposal. Negligence of these will have a serious impact on environmental pollution concems.
1) Waste fluids such as lube oil, fuel and coolant shall be carefully put into separate sealed containers and disposed of properly.
2) Do NOT dispose of waste materials irresponsibly by dumping them into the sewer, overland or into natural waterways.

（8）FURIHER PRECAUTIONS
·Fueling/Refueling A WARNING Keep sparks，open flames or any other form of ignition（match，cigarette，etc.）away when fueling/refueling the unit.Fire and or an explosion may么
result.
A WARNING]
·Hot Surfaces.
Do NOT touch the engine（or any of its components）during running or shortly after shutting it down.Scalding/serious burns may result.Alow the engine to cool down before attempting to approach the unit.
ublMiardilin.
·Rotating Parts A WARNING Be caretul around moving/rotating parts.Loose clolhing，jewelry，ies or tools may become entangled causing damage to the engine and or severe personal injury.
A WARNING]· Preventing bums from scalcing
1) Never open the filler cap shortly after shutting the engine down.
Steam and hot water will spurt out and seriously bum you. Allow the engine to cool down before attempt to open the filler cap.

                                      Yanmar Heavy Equipment EPC 11.2009

2) Securely tighten the filler cap after checking the cooling water.
Steam can spurt out during engine running, if tightening loose.
· Safety Label Check ACAUTION Pay attention to the product safety label.
A safety label(caution plate) is affixed on the product for calling special attention to safety.
If it is missing or illegible, always affix a new one.

Introduces Removal of Perkins 2806F Enginethe Exhaust Gas Valve (NRS)

 This article mainly introduces Removal of Perkins 2806F Enginethe Exhaust Gas Valve (NRS)

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1. Disconnect hose assembly (1) and remove O-ring
seal (2) (not shown). Position the hose assembly
away from the NOx Reduction System (NRS)
exhaust gas valve.
2. Disconnect hose assembly (3) and remove O-ring
seal (4) (not shown). Position the hose assembly
away from the NRS exhaust gas valve.
3. Cut cable straps (5) from harness assembly (6)
and harness assembly (7). Ensure that all cable
4 straps are removed from the harness assemblies.

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5. Remove bolt (14) from clip (13).
6. Sufficiently loosen V-band clamp (24) to allow
removal of tube assembly (20).
7. Remove bolt (19) and clamp (18).
8. Remove bolts (22) from clamp (23). Remove
spacer blocks (21). Note the position and the
orientation of the spacer blocks for installation
purposes.
9. Remove tube assembly (20) from venturi tube
assembly (16). Remove V-band clamp (24) from
the NOx Reduction System (NRS) exhaust cooler.
10. Remove O-ring seals (17) (not shown) from tube
assembly (20).
11. Sufficiently loosen V-band clamp (15) to allow
venturi tube assembly (16) to be removed from
NRS exhaust gas valve (12). Use suitable tooling
to support to the venturi tube assembly away from
the engine.
12. Loosen hose clamp (8) and hose clamp (10) for
hose assembly (9).
13. Remove bolts (11) from NRS exhaust gas valve
(12). Support the NRS exhaust gas valve as the
bolts are removed.
14. Remove NRS exhaust gas valve (12) from hose
assembly (9).

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Illustration 75 g06072658
15. If necessary, follow Step 15.a through Step 15.g
to remove bracket (34) for the NRS exhaust gas
valve from the cylinder head.
a. Cut cable straps (29). Ensure that all cable
straps are removed.
b. Disconnect harness assembly (30) from engine
harness assembly (25).
c. Remove bolt (26) for engine harness assembly
(25). Remove bolt (28) for bracket (27). Position
engine harness assembly away from bracket
(34).
d. Remove bolt (31) and spacer (32) (not shown)
for the breather hose assembly.
e. Remove bolt (33) and bolt (36) for exhaust
balance solenoid valve (37). Ensure that the
tube assemblies are not strained as the bolt is
removed.
f. Remove bolts (38) and position fuel pressure
regulator (39) away from bracket (34).
g. Remove bolts (35) from bracket (34). Remove
the bracket from the cylinder head.

Introduces Removaland of the Air Control Valve

          This article mainly introduces Removaland  of the  Air Control Valve

                                           Perkins Engine ECM Flash File

1. Disconnect the Original Equipment Manufacturer
(OEM) hose assembly from inlet connection (5) ofair control valve assembly (4). Refer to the OEM for the correct procedure.
2. Disconnect harness assembly(1) from air control valve assembly(4).
3. loosen clamp(3) from hose assembly(2).
4. Loosen hose clamp(7) for tube assembly(6).
5. Disconnect tube assembly(6) from air control valve assembly(4).
6. Remove bolt (8) from bracket(9). Remove remaining bolt and remove air control valve assembly(4) from hose assembly (2).

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7. If necessary, follow Step 7.a through Step 7.e to disassemble air control valve assembly(4).
a. Place the air control valve assembly(4) in a suitable support.
b. Make temporary marks on elbow connection
(10), connection(17), and air control valve assembly(4) for installation purposes.
c. Remove bolts(16) and remove elbow connection(10) and connection(17) from air control valve assembly(4).
d. Remove O-ring seal(11)(not shown) and O-ring seal(15)(not shown).
e. If necessary, mark temporary marks on elbow connection(14) and connection(17).
Loosen locking nut(13)(not shown). Removeelbow connection(14) from connection(17).
Remove O-ring seal(12)(not shown).
Installation Procedure
1. Ensure that all components of the air control valve assembly are free from wear, damage,
or restriction.

2. If necessary, follow Step 2.a through Step2.e to assemble air control valve assembly(4).
a. Place the air control valve assembly(4) ina suitable support.
b. Install a new O-ring seal(11)(not shown) and new O-ring seal(15)(not shown) to the recesses of elbow connection(10) and connection(17). Ensure that the O-ring seals are correctly seated into the recesses.
C. Align elbow connection(10) and connection
(17) with the temporary marks on air control valve assembly(4).
d. Install bolts(16) to connection(17) and elbow connection(10). Tighten the bolts to a torque of
28N·m(248 lbin).
e. If necessary, install a new O-ring seal(12)(not shown) to elbow connection(14). Install the elbow connection to connection(17). Align the elbow connection with the temporary marks.
Tighten locking nut (13)(not shown) to a torque of 30N'm (266 lbin).

                                        

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3. Install air control valve assembly(4) into hose assembly(2).
4. Position bracket(9) onto air control valve assembly(4) and install bolts (8). Tighten the bolts to a torque of 28 N-m (248 lb in). Ensure that thebracket is not strained as the bolt is tightened.
5. Tighten clamp (3) for hose assembly (2) to a torque of 11 N-m (97 lb in).
6. Connect tube assembly(6) to air control valve assembly(4). Tighten hose clamp(7) to a torque of 4.5N-m (40 lb in).
Tighten tube nut for tube assembly(6) to a toque of 30 N·m (266 lb in).
7. Connect harness assembly(1) to air control valve assembly(4).
8. Connect the OEM hose assembly to inlet connection(5) of air control valve assembly(4). Refer to the OEM for the correct procedure and torque value.

Introduces Perkins 2806F Engine Solenoid Valve(Exhaust Balance)-Remove

 This article mainly introduces Perkins 2806F Engine Solenoid Valve(Exhaust
Balance)-Remove

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1. Disconnect harness assembly(1) from harness assembly(2).
2. Disconnect tube assembly(4) from balance valve
(5).
3. Remove bolt (4) and bolt (8) for tube assembly (7).
4. Disconnect tube assembly(7) from balance valve
(5).
5. Remove bolt (6) from balance valve(5). Remove the balance valve from the bracket.

6. If necessary, follow Step 6.a through Step 6.d to disassemble balance valve(5).
a. Place the assembly of balance valve(5) in a suitable support.
b. Make temporary marks on elbow connection
(14) and balance valve(5) for installation purposes.
C. Loosen lock nut(13) and remove elbow connection(14) balance valve(5). RemoveO-
ring seal(12).
d. Remove adapter(10) from balance valve(5).
Remove O-ring seal(11).

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7. If necessary, follow Step 7.a through Step 7.b to remove tube assembly(4).
a. Remove bolt (16) from the tube clip for tube assembly(4).
b. Disconnect tube assembly(4) from adapter
(15). Remove the tube assembly.

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8. Ifnecessary, follow Step 8.a through Step 8. cto remove tube assembly(7).
a. Remove bolt(17) and bolt (18) from the tube clip for tube assembly(7). Ensure that the tube clips are not damaged as the bolts are removed.
b. Disconnect tube nut(20) for tube assembly(7)
from waste gate actuator(19).
c. Remove tube assembly(7).

Perkins 2806F EngineTurbocharger-Install

 
          This article mainly introduces Perkins 2806F EngineTurbocharger-Install 

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NOTICE Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened component life.
1. Ensure all the components of the turbocharger are free from wear, damage, and restriction. Replace any component that is worn, damaged, or not free from restriction.

llustra6on 5390d0rr8502. Ifnecessary, follow Step 2.a through Step 2. fto install tube assembly(8) and tube assembly(15).a. Install a new O-ing seal(23)(not shown) to the elbow connection for tube assembly(8). Ensure that the O-ring seal is correctly seated into the recess of the elbow connection.
b. Install tube assembly (8) and hand tighten tube nut(24). Install bolts(20)(not shown) hand tight. Ensure that O-ring seal (23)(not shown) is not dislodged as the tube assembly is installed.c. Install a new O-fing seal(22)(not shown) to the elbow connection for tube assembly (15).
Ensure that the O-ring seal is correctly seated into the recess if the elbow connection.
d. Install tube assembly(15). Install bolts(21) and hand tighten.
e. Tightening of bolts(21), bolt (20)(not shown), and tube nut(24) will be required after the turbocharger has been installed.
f. For a turbocharger that is already installed, tighten bols (21), bolt(20)(not shown), and tube nut(24) as follows: Tighten bols (21) to a torque of47 N-m
(35 lbft).
Tighten bolt (20)(not shown) to a torque of
47N·m (35 ib ft).
Tighten tube nut (24) to a torque of65N-m
(48 lbft).

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3. If necessary, follow Step 3.a through Step 3.b to install studs (19) to exhaust manifold (16).
a. Apply Tooling (A) to the threads of new studs
(19).
b. install studs(19) to exhaust manifold(16).
Ensure that the studs are correctly orientated.
Tighten the studs to a torque of 18N-m
(159lb in).
4. Attach a suitable lifting device to turbocharger(7).
The weight of the turbocharger is approximately
30kg (66Ib).
5. Install a new gasket(17)(not shown) onto the exhaust manifold. Ensure that the gasketis correctly orientated.
6. Use the lifting device to position turbocharger(7)
onto exhaust manifold(16).
7. Install nuts(18) to turbocharger(7) hand tight.
8. Install a new gasket(13)(not shown) between tube assembly(15) and turbocharger(7).
9. Install Allen head bolts(14) to tube assembly(15)
hand tight.
10. Install a new gasket(10)(not shown) to tube assembly (8). Install Alen head bolts (9) to the tube assembly hand tight.
11. Tighten nuts(18) to a torque of 55 N-m(41 b ft).
12. Tighten Allen head bolts(14) to a torque of
25N-m(221lbin).
13. Tighten Alen head bolts (9) to a torque of25N-m
(221lbin).

14. Iftube assembly (8) and tube assembly(15) had been removed, follow Step through Step to tightenbolts (21), bolt(20)(not shown), and tube nut(24).
a. Tighten bolts (21) to a torque of 47 N-m
(35 lb ft).
b. Tighten bolt (20)(not shown) to a torque of
47Nm(35lb f).
c. Tighten tube nut(24) to a torque of65Nm
(48 b ft)

15. Connect inlet hose(6) to the inlet of turbocharger
(7). Refer to Disassembly and Assembly, Air Cleaner Housing-Remove and Install for the correct procedure.
16. Install a new O-ring seal(2)(not shown). Position elbow connection (3) onto turbocharger (7). Install V-band damp(1). Ensure that the O-ring seal is not dislodged as the elbow and V-band clamp are installed.
17. Follow Step 17.a through Step 17.b to tightenV-
band clamp(1).
a. Tighten V-band clamp(1) on the turbocharger to a torque of 8.5N-m (75 ib in).
b. Lightly tap V-band clamp(1) with a soft faced hammer to seat the V-band clamp. Again, tighten the V-band clamp to a torque of 8.5N-m
(75 b in). Repeat this Step 17.b until the V-band clamp are correctly seated onto the turbocharger.
18. Install a new V-band clamp(4) and connect exhaust connection(5) to turbocharger (7).F ollow Step 18.a through Step 18.b to tighten the V-band clamp.
a. Tighten V-band clamp(4) on the turbocharger to a torque of 8.5N-m (75 lb in).
Note: Ensure that the flexible exhaust section is not strained and the flexible exhaust remains in original alignment.
b. Lightly tap V-band clamp(4) with a soft faced hammer to seat the V-band clamp. Again, tighten the V-band clamp to a torque of9N-m
(80lb in). Repeat this Step 18.b until the V-band clamp are correctly seated onto the
14. If tube assembly(8) and tube assembly(15) had been removed, follow Step through Step to tightenbolts(21), bolt (20)(not shown), and tube nut(24).
a. Tighten bolts(21) to a torque of 47N-m
(35 Ib ft).
b. Tighten bolt(20)(not shown) to a torque of
47N·m(35 Ib ft).
c. Tighten tube nut(24) to a torque of65N-m
(48Ib ft).

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