Introduces YANMAR maring diesel engine 3JH2 Series Governor disassembly

This article mainly introduces YANMAR maring diesel engine 3JH2 Series Governor disassembly

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NOTE: Loosen the hex bolt on models with an angleich spring.
(2) Remove the control lever hex nut, and pul 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.

(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.

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(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.

(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 govermor 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.

 

 
(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.

(14) Pull 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.

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

NOTE: The governor weight assembly is made up of the governor weight, support and pin. Do not dis.
assemble.

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Introduces Installation Perkins 2806F Engine Procedure

   This article mainly introduces Installation Perkins 2806F Engine Procedure

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1. Ensure that all components are clean and free from wear and damage. If necessary, replace any components that are worn or damaged.

2. Ifnecessary, follow Step 2.a through Step 2.g to install bracket(34) for the NRS exhaust gas valve from the cylinder head.

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3. Install NRS exhaust gas valve(12) to hose assembly(9). Loosely install bolts (11) to the NRS exhaust gas valve.
4. Install a new V-band clamp (15) onto NRS exhaust gas valve(12). Ensure that the V-band clamp is correctly orientated.

5. Install venturi tube assembly(16) onto NRS exhaust gas valve(12). Ensure that the V-band clamp is correctly seated onto the venturi tube assembly and the NRS exhaust gas valve.
 Tighten V-band clamp finger tight.
6. Install new O-ring seals (17)(not shown) to tube assembly(20). Apply Tooling(A) to the O-ring seals and the bore of venturi tube assembly(16).
7. Install a new V-band clamp(24) onto the NRS exhaust cooler. Ensure that the V-band clamp is correctly orientated.
8. Install tube assembly(20) into venturitube assembly(16). Ensure that the tube assembly is correctly installed into venturi tube assembly.
 Ensure that V-band clamp (24) is correctly seated onto the NRS exhaust cooler and the tube assembly.
9. Install spacer blocks(21) between the cylinderblock and tube assembly (20). Install clamp (23)
 and bolts(23). Tighten the bolts hand tight.
 Note: Ensure that the spacer blocks as correctly positioned and orientated.
10. Install clamp(18) and bolt(19) for tube assembly
(20).
11. Ensure that venturi tube assembly(16), tube assembly(20), and NRS exhaust gas valve(12)
 are correctly aligned before tightening the bolt and the V-band clamps.
12. Instal bolt(14) to clip(13).
13. Tighten bolts(11) to a torque of28N-m
 (248lb in).
14. Tighten hose clamp(8) and hose clamp(10) forhose assembly(9). Tighten the hose clamps to a torque of 7.5Nm (66 lb in).
15. Tighten V-band clamp(15) and V-band clamp
 (24) to a torque of 12N-m(106 lb in).
16. Tighten bolts(22) to a torque of25N-m
 (221lb in).
17. Tighten bolt(19) to a torque of25 N-m(221 lb in)18. Tighten bolt(14) to a torque of 25N-m(221 lb in)

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19. Connect harness assembly(6) and harness assembly (7) to the engine harness assembly.
20. Install new cable straps (5) to harness assembly
(6) and harness assembly(7). Ensure that all cable straps are installed to the harness assemblies.
Note: Ensure that the cable straps meet Original Equipment Manufacturer (OEM) specifications.
21. Install a new O-ring seal (2)(not shown) to the adapter. Ensure that the O-ring seal is correctly into the recess of the adapter.
22. Connect hose assembly(1). Tighten the hose assembly to a torque of 45 N·m (33 lb   ft). Use a suitable tool hold the adapter as the hose assembly is tightened. Ensure that the adapter is not strained as the hose assembly is tightened.
23. Install a new O-ring seal(4)(not shown) to theadapter. Ensure that the O-ring seal is correctly into the recess of the adapter.  

Introduces Lift Trucks and Skid Steer Loaders Cummins Engine Disassembly (2)

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

   

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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.

a Lubricating Oil Filter Remove the lubricating olil filer.

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.

Thermostat Remove the two mounting capscrews, thermostat housing, thermostat and seal.

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xhaust Manifold Remove the eight capscrews, exhaust manifold, and gasket.
Discard the gasket.

Fuel Injection Tubing Remove the clamp.
Remove the sleeve nuts and the fuel injection tubing from the fuel injection pump and the cylinder head.
 

 Spill Tube Remove the spring hose clamps and hose.
Remove the spill tube.

InjectorACAUTION 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.

Thermostat Remove the two mounting capscrews, thermostat housing, thermostat and seal.

Exhaust Manifold Remove the eight capscrews, exhaust manifold, and gasket.
Discard the gasket.

Fuel Injection Tubing Remove the clamp.
Remove the sleeve nuts and the fuel injection tubing from the fuel injection pump and the cylinder head.

Fuel Injection Tubing Remove the clamp.
Remove the sleeve nuts and the fuel injection tubing from the fuel injection pump and the cylinder head.

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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.

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

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 (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.

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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

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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.

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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.