Tes SERVICE MANUAL LAND USE GENERATOR ENGINE AY4OL-ET YANMARForeword: This Service Manual has been developed for the exclusive use of service and repair professionals such as Yanmar authorized distributors and Yanmar authorized dealers. It is written with these professionals in mind and may not contain the necessary detail or safety statements that may be required for a non-professional to perform the service or repair properly and/or safely. Disclaimers: All information, illustrations and specifications in this manual are based on the latest, information available at the time of publishing. The illustrations used in this manual are intended as representative reference views only. Moreover, because of our continuous product improvement policy, we may modify information, illustrations and/or specifications to explain and/or exemplify a product, service or maintenance improvement. We reserve the right to make any change at any time without notice. Yanmar and YANIMAR are registered trademarks of YANMAR CO., LTD. in Japan, the United States and/or other countries. All Rights Reserved No part of this publication may be reproduced or used in any form by any means - graph- ic, electronic, or mechanical, including photocopying, recording, taping, or information storage and retrieval systems - without the written permission of YANMAR CO., LTD. Please review and comply with the applicable laws and regulations of the international export control regimes at the territory or country where the product and manual are intended to be imported and used. MODEL AYAOL-ET (50/60 Hz switchable) SERVICE MANUAL CODE OBAYL-EN0030 AMI Rights Reserved, Copyright. YANMAR CO., LTD.CONTENTS FOR YOUR SAFETY 1 Safety Notice .... 1 Safety Precautions 2 Location of Safety Labels. 6 Safety Precautions when Lifting the Engine 8 9 9 0 1 ENGINE SPECIFICATIONS . Engine Specifications Location of Components 1 Fuel Oil, Lubricating Oil, and Cooling Water. 1 DISASSEMBLY AND ASSEMBLY Disassembly and Assembly Tools Disassembly Assembly ENGINE MAINTENANCE AND INSPECTION. . Cylinder Head 66 Cylinder Liner. 75 Piston 7 Connecting Rod. 80 Camshaft 83 Crankshaft and Main Bearing 84 Flywheel Area : : 1 Timing Gear 92 Lubricating Oil System 93 Cooling Water System 98 Fuel System 101 Coupling Alignment of Exhaust Manifold 106 MAINTENANCE SERVICE OF TURBOCHARGER 112 Specifications. 112 Structure 112 Maintenance Service Standard 114 Periodic Inspection Procedure : : 115 Disassembly 116 Cleaning and Inspection Procedures. 120 Assembly 124 After reassembling 130 Troubleshooting 131MAINTENANCE SERVICE FOR ELECTRICAL PARTS .......... 133 Starter oe coscsteee oe 133, Alternator 134 Electric Wiring Diagram 135 PERIODIC INSPECTION... - 136 Periodic Inspection Chart. 136 Long-term Storage 139 STANDARD MAINTENANCE TABLE .... . 140 Standard Maintenance Table 140 Standard Adjustment Value 143 TIGHTENING TORQUE CHART OF MAJOR BOLTS AND NUTS ... . Tightening Torque of Major Bolts and Nuts Ea 144 Standard Bolt Tightening Torque 147 Pipe Joint Bolt Tightening Torque 147 TROUBLESHOOTING AND COUNTERMEASURES . 148 Failure when Starting 148 Failure while Operating 149 TOOL DRAWINGS ... - 153FOR YOUR SAFETY — 1 FOR YOUR SAFETY The main causes for accidents is that basic safety rules and precautions were not obeyed. Itis important to prevent accidents before they happen by avoiding the causes. Before you start any repair or maintenance work, read this, manual carefully and make sure that you understand the applicable inspection or maintenance procedures and the safety precautions, If you do any repair or maintenance work without necessary knowledge, it can cause unforeseen accidents, Safety Notice Itis not possible to predict all dangers that can occur during repair or maintenance and indicate them in a manual Therefore, be extra careful on safety beyond what is expressed in this manual and on the safety decals. Especially during repair or maintenance work that is not described in the manual, obey the instructions by qualified- mechanics. Safety labels Safety labels are attached to the engine. Please consider them for your safety. Make sure that you replace safety decals that are lost or difficult to read. Follow the same handling instructions for used engines as well as you do with new engines. ‘The symbols on the safety decals have the following meanings. DANGER indicates a hazardous situation which, if not avoided, will result ADANGER in death or serious injury. WARNING indicates a hazardous situation which, if not avoided, could result in death or serious injury. CAUTION indicates a hazardous situation which, if not avoided, could ACAUTION result in minor or moderate injury. NOTICE indicates a situation which can cause damage tothe machine, ees personal property and/or the environment or cause the equipment to operate improperty.2— FOR YOUR SAFETY Safety Precautions Follow these precautions for safe service. 1 Precautions on maintenance facility (Place) Ventilate Ventilate the workplace well. DO NOT BLOCK ventilation equipment such as windows, vent, and other ventilators, Breathing poisonous gas, dust, exhaust gas, etc. is dangerous, ACAUTION Brighten up Make sure the workplace has sufficient and safe lighting. Secure enough space and flat floor The facility (place) for checkup and maintenance service must have enough space, and have. flat floor with no pit. Otherwise it may cause accidents such as falling or tripping. Keep the place clean and tidy Make sure no dust, oil, or small parts are on the floor. Otherwise it may cause accidents. Know your fire-extinguishing equipment Know where and how to use the fire extinguisher. Always have the fire extinguisher nearby whenever using fire. Make sure proper inspection is done to the fire extinguisher. Beware of emergency Know what to do in case of fire or other accidents. Decide where and how to contact the emergency contact, and keep phone number: obvious place.FOR YOUR SAFETY — 3 Precautions on work a a AWARNING | Hold or lift in an appropriate manner Do not hold or lift when supported only by a block, wooden piece or a jack. Do all holding and lifting from the specified lifting points and fixtures, and use equipment that easily handles the weight. Make sure you use the right ropes without deformation or disconnection. ACAUTION Wear safe equipment and clothes Worker must put on a helmet, protective goggles, safety shoes, and other safety equipment that matches the task The work clothes must fit well. Do not wear oil-stained clothes because it easily catches fire. Use applicable tools Use the correct tools for the task. Using incorrect tools causes injury, or damage to the machine. Tighten all bolts and nuts with the specified torques Otherwise parts may become loose and fall, causing parts damage or personal injury. Do not work in uncomfortable po: It may cause injury. Do not work on the engine. Use a work table that is stable and suits the engine size and height.4 — FOR YOUR SAFETY 1 Precautions on handling the product ADANGER Beware of fire and oi Keep away from fire when supplying fuel. It may cause fire and explosion. I you spill fuel, wipe it clean. Oil and other burnable objects may ignite fire. DO NOT place them nearby the engine. Beware of hot water spouting Do not open the radiator cap when the temperature is high. Hot water may spout out and cause burn injury. Beware of fire from electronics During maintenance service, make sure you take off the (-) terminal of the battery. It can cause electric shock and short-circuit of the harness, leading to fire Beware of rotating parts Keep your hands, body, tools away from rotating parts while the engine is running. Otherwise it can get caught and cause injury. Ventilate around the battery Flammable gas is generated when charging the battery. Do not let fire nearby. Ventilate well. Otherwise it may explode. Be careful when opening the side cover Do not open the side cover on the crank case side for at least 10 minutes after engine stop. Otherwise, freshwater may enter and explode. Be careful when starting the engine Make sure there is nobody near the engine. If there is, give them a signal and make sure they are safe, and then start the engi Remove the turning bar, and store it in the specified location.FOR YOUR SAFETY — 5. ACAUTION Be careful with hot parts Do not touch the engine's hot parts during or right after oper: Itmay cause burn injury. Be careful with battery fluid Battery fluid is diluted sulfuric acid. Make sure not to get it on your clothes or skin. It can make holes to clothes and burn your skin. Precautions on use of genuine parts NOTICE Use genuine parts Always use genuine parts and lubricating ol Otherwise it may shorten the engine's lifetime or cause accidents 1 Precautions on disposing waste NOTICE Be careful when disposing waste + Do not dispose waste oil or waste fluid such as fuel and lubricating oll, to sewage, rivers, lake, ocean, etc. + Appropriately dispose hazardous waste in accordance with laws and regulations, e.g. commission a professional waster collector, etc.6 — FOR YOUR SAFETY Location of Safety Labels + This shows the locations of safety labels + Ifthe labels are damaged or lost, replace them with new ones. A bank (L bank) side 741616-07270, 441616-07220. 441616-07200 441616-07240 |a consi © Cylinder numbers ‘A bank (Left bank)] OOOOOO OOOOO® B bank (Right bank)] FlywheelFOR YOUR SAFETY — 7 MB bank (R bank) side La ey [zee] A y S, oS IS SS ti cote e8 — _ FOR YOUR SAFETY Safety Precautions when Lifting the Engine Dropping the engine while lifting is very dangerous. Follow the instructions below to prevent accidents during lifting * The lifting requires specific license and qualification depending on the derrick and the weight of the load. Make sure that it is done by qualified persons. + Before working, make sure the lifting tools and mounting bolts have no damage and are in good shape. If you find any fault, stop immediately and contact your YANMAR dealer or distributor. + Before working, check the mass indicated in the Specifications. Mass of the engine differs depending on its type. + If equipment that is not written in the Specifications is attached, remove the equipment first before lifting. + Select lifting tools (e.g. wire rope and shackle) that are appropriate for heavy loads. + Select the wire rope length so that the engine does not tilt during lifting. * Before lifting, examine the lifting tools and make sure that they have no damage and are in good shape. * Protect the parts of the engine or driven equipment that touch the wire rope with protective material. * The tension of the wire rope changes depending on the lifting angle. Make sure that the angle is within 60". + While lifting or moving the engine, do not go under the engine or near the engine. Refer to Specifications for mass.ENGINE SPECIFICATIONS — 9 ENGINE SPECIFICATIONS Engine Specifications Engine name: AY40L-ET (50/60 Hz switchable) Fuel injection pump. - a Unit ‘Specifications Type. - Vertical, water-cooled, cycle dlesel engine [Combustion chamber = Direct injection ype FTurbocharging : Exhaust gas turbacharger with air cooker ‘Number of eyinders- Inner diameter x Siroke mm FTlal cyinder ciaplacement t Output ew 1106 Wa At continuous rating Crankshaft speed rnin? 1500 7800 laximum capac vA 1250 et apecty | ouput applying generator wv 1000 Top clearance / Valve clearance ‘am 1156 # 0.108 /0.30 + 0.05 (SUC), 050 0.05 (EXH) Bosch set type (YANMAR) (1PE-1617) Spuaton ade Ati) Noroperatonsde @ bank) _|&F9.) 51180605 a = ao 00 Bor 90 a OO SO" 307 OF BtA6-84A2-82-AS-B5-A1 -BS-A4-85-A2-81 : = FRadator cooing (slated separately) Engine cooing Cooking water capacity c 129 Method = Freed eatin by gear pump Engine beating | Lubriang a cpaciy [Oven] 120 Tubicatng of coier [Type | ald Ye Type = ‘TO13M1 (MHI) Footages Goong system 5 Tr eeaing Labreatng ier : Forced baton by engine brewing a Tipe 7 Comgate nye oot oem 5 Freshwater cooing Siang sem : Elecic ater Dryergine mass is 60 Cylinder numbers ‘Abank (Left bank)| Flywheel OOOOOO OOOOOO B bank (Right bank)10 — _ ENGINE SPECIFICATIONS Location of Components HA bank (L bank) side Electronic governor Fuel injection pump Ful fier SS Me STE SS . Turbocharger Cooling water pump T (roshwater) Lubscating ol | | ‘supply port IB bank (R bank) side Aircoolor Lubvicatng oi iter : - Lubicating ol cooler Sy SS IES. Fuel feed pump “Turbocharger \ — i Z e 7 66 Starter Conta lubricant terENGINE SPECIFICATIONS — 11 Fuel Oil, Lubricating Oil, and Cooling Water @ Fuel oil Use diesel fuel that is most applicable for the engine performance (JIS-K2204 2), with cetane index of 45 or higher. Lubricating oil For commercial lubricating oll, use API Grade CD, CF or CH Cooling water Always use clean water (tap water) as cooling water. The chart below shows the recommended quality of cooling water. Recommended quality of cooling water . with viscosity of SAE standard 15W-40, PH 651080 250) Total hardness (CaCO3) = 100 ppm Chioride ion (C2) concentration 5 100 ppm M Alkalinity 306 100 ppm [Ararsonium ion (NH) 0.05 ppm Sulfate fon (S04) = 100 ppm Evaporation residue =400 ppm ‘As a cooling water, only use freshwater mixed with 30% to 55% of Long Life Coolant (LLC): YANMAR ROYAL FREEZE. Without this mixture, scale and rust develops inside the system, thus deteriorating the cooling performance, ROYAL FREEZE is anti-corrosion and can be used throughout the year. Ifyou choose to use a commercial LLC, it must be YANMAR genuine, or have the same or higher quality. Do not use anything that includes component that causes corrosion to aluminum.12— DISASSEMBLY AND ASSEMBLY DISASSEMBLY AND ASSEMBLY Disassembly and Assembly Tools The following tools are required for disassembling and assembling the engine. ™ General hand tools Name of tool (Parts No) Mustration| Name of tool (Parts No) Mlustration Piston ring removallinsertion tool 196410-92140 Feeler gauge 0.4 mm 28312-100750. 0.25 mm 28312-20750 (0.3. mm 28312-300750 0.95 mm 28312-960750_ (0.5 mm 28312-50070 Circlip pliers (for shaft) 28190-00020 Angle gauge for cyinder head bolt (633) +148620-92400 Circlip pliers (for holes) 28190-00130 Turing bar 126410-02720@ Special hand tools DISASSEMBLY AND ASSEMBLY — 13, [Tools for removing/inserting small-end bushing of connecting rod Paris number. 148920-92010 Ag 4. 108" Dimension Material A 8 ec [To ,e 2 Das 367 22 062 04 100 | 20 | sac Tools for removing the cylinder liner Parts number. 748620-62030, Hexagon nut (M24) 26732-20002 Washer Bacon Liner remover (Upper) 438670-92010 tine block (oper) Line at a Cylinder liner 14062-82030 Liner remover (owen ‘40820.02100 ‘Stopper nut (M24) 2orr2-240002 a [Tools for inserting the piston Piston liting bolt Parts number; 144626-92160 aA, sB |e D 100 [40 [ 10 [wexto ‘Tools for inserting the piston Parts number: 14860-92140 } y A 8 c z 3 Pe 1900 | 017895 | 0155969 [-—e—_|14 —_ DISASSEMBLY AND ASSEMBLY [Tools for removing fuel injection valve Parts number, 748620-02020 Satbolt 42903-92060 Hexagon flange nut 10 :26986-100002 Fil valve remover "52628-92171 [Tools for removing and attaching the flywheel Refer to P153 [TOOL DRAWINGS] 1- Fitting too! (Drawing No, 0522230-7590-7) - 2 Flywheel insertion guide pin (Drawing No, 0527236-6010-24a) aot 5 220DISASSEMBLY AND ASSEMBLY — 15 [Tool for inserting the camehatt [Refer to P153 [TOOL DRAWINGS] 1- Camshatt insertion guide (Drawing No.: 0522236-6010-4) 260 [Tool for inserting the valve guide Refer to P153 [TOOL DRAWINGS} 11-Valve guide press fitting too! (Drawing No.: 0521236-4970-5) Valve guide insertion too g Valve guide, 7 C 120 [Tool for tightening the nozzle tool Refer to P153 [TOOL DRAWINGS] Nozzle sleeve tightening tool (Drawing No. 0521236-0430-1) 085.5. 10016 — DISASSEMBLY AND ASSEMBLY [Tools for inserting the crankshaft oll seal [Refer to P153 [TOOL DRAWINGS] (EEE) _ Hexagon socket head CELE AP ott 20570 (P15) J Hexagon head bolt 126100 1- Insertion tool 2- Mounting plate 3 Spacer fr mounting plate (Drawing No. 0522230-1180-1) (Drawing No. 0522230-1150-2) (Drawing No. 0522230-110-9) ra oa 1315 ee 4- SFW guide '5- High torque bolt (Drawing No. 0622230-1160-4) (Drawing No. 0522236-2710-8) 280 035DISASSEMBLY AND ASSEMBLY — 17 [Tools for inserting the valve stem seal ‘Too! for inserting the valve stem seal (exhaust valve) (Drawing No.: 148628-22020) Refer to P153 [TOOL DRAWINGS] ‘Too! for inserting the valve stem seal (intake valve) (Drawing No.: 148628-92030) olor with 20 Tool for installing cam gear ‘Assembled drawing of the tools, (Drawing No. 0522236-2710-02) Refer to P153 [TOOL DRAWINGS] 41 - Guide pin (Drawing No.: 0522236-2710-1) Ma0xt 2.- Press fiting tool (Drawing No,: 0522236-2710-2) 55 ero t 3 High torque bolt (Drawing No.: 0522236-2710-3)18 — DISASSEMBLY AND ASSEMBLY Exhaust manifold centering tool 1 - Exhaust manifold guide pin 8 (Drawing No. 0522230-7590-20) M12 serow | z 3 - Exhaust manifold dummy flange (double) (Drawing No. 0522230-7590-24) [Refer to P153 [TOOL DRAWINGS] 2- Exhaust manifold dummy joint (Drawing No.: 0522230-7590-23) 124 4- Taper pin (Drawing No. 0522230-7590-27) Taper 49DISASSEMBLY AND ASSEMBLY — 19 1 Measuring instruments Instrument name Description Tiustration Scale (vm): 0.01 Pron Range (mm) For measuring the bending and gap of 0-5 the shaf, surtace distortion, et. 0-10 / Pee eeraat For measuring small or narrow, deep ‘mal dial indicators, 4 Main arm (diameter « length) (mm): 12176 For attaching the dial gauge to various 10» 165, positions for accurate viewing. 42% 165 14% 183, Magnetic stand 50-75 150-175 Range (mm): 10-16. 50-100 |For measuring he inner dameteretihe | 18236 100-160 | eyinder ner beens, te 35-60 150-200 Cylinder gauge Range (mm) nie 0-25 75-100 For measuring the outer diameter of a 25-50 125-150 crankshaft, piston, piston pin, etc ve ; ‘Scale (mm): 0.05 For measuring various outer diameters, femier caliper Range (mm): 0- 150 depths, thicknesses, widths, ete For measuring the vaive sinkage and Depth micrometer | Range (mm): 0-25 liner projection For measuring the tit of valve spring, or square Sze mm) 100 squareness of various parts. ‘Size (mm): Nee 400 « 50 x 55 For measuring the bending of a shaft20 — DISASSEMBLY AND ASSEMBLY instrument name Description Thastration Aperture za(mm | _Pangedter For tightening bolts and EE in nuts fo specified torques. | 6-14 a Torque wrench 17,10,21 304-157 Range (Nem: 39-118 392-2746 (aes 98-441 392-4116 = 392-1765 For measuring ci clearance betwaen Pee Length: 759 pisces | Pston rings and piston grooves or between shaft couplings during installation For inspecting the concentration of anti- Model; UFB-N, ‘freeze solution and charging condition of the battery fluid Battery electrolyte Hester Pressure gauge Nozzle tester pease For inspecting spray condition and the injection pressure of the fuel injection valve Fuel injection valve side High pressure pipe [ihe x '5 Pusher fitting Deffection gauge For measuring the deflection of the crankshaft Deflection gauge For observing the gauge with a mirror mirror when measuring Penetrant (0.45 L) Developer: (0.45 L) For finding cracks in each part, Cleaning agent: (0.45 L) Penetration test (for flaw detection)Sealant and compound DISASSEMBLY AND ASSEMBLY — 21 Instrument name Featured and application Liquid gasket ThreeBiond (181101) Non-dying liquid gasket, solventless type, easy to remove, and superior in seawater resistance, Applicable to various mating surfaces, ThreeBond (781102) Non- ae M v TE crinderhoas BI _crankchatt and camahat Vv Vv Earn > Cylinder numbers ‘A bank (Left bank)| OOOOOO OOOOO® B bank (Right bank] Flywhee!DISASSEMBLY AND ASSEMBLY — 23 Hem and points (Disassembly) Tlustration| Remove the electrical parts. [1] Sensors and switches + LO. fiter bypass vaive switch (1) + Chattering relay for starter (2) [2] Starter 4.Remove the starter. [3] Alternator 4.Remove the V-belt cover (1) 2. Remove the adjuster bar (2) 3.Remove the V-belt (3). 4, Remove the alternator (4) 5.Remove the alternator driving unit (6).24 —_ DISASSEMBLY AND ASSEMBLY ‘Step Tems and points (Disassembly) Mlustration 1 [4] Fuel fitter 4. Remove the fuel fiter (pipings). + Remove the fuel hose. 2. Remove the fuel filter. [5] Lubricating oil filter and lubricating oil cooler 1. Remove the lubricating oil filter (1). 2.Remove the lubricating oil cooler (2) [6] Lubricating oil filter bracket and lubricating oil pressure control valve 1. Remove the lubricating oil pipe (1). 2. Remove the lubricating oil fter bracket (2) 3. Remove the lubricating oll pressure control valve (3). — IMPORTANT Mask the passage (1), (2) and (4) of the lubricating oil after removing the pipe to prevent contamination.