Assembly Instructions

L-AE SERIES
L-N SERIES
L-V SERIES
© 2010 Yanmar Co. Ltd.

Date of issue: Apr. 2010

Assembly Instructions
1. ASSEMBLY INSTRUCTIONS

1. ASSEMBLY INSTRUCTIONS (ORIGINAL)

FOR YANMAR L-SERIES DIESEL ENGINES
For partly completed machinery, according to Machinery Directive 2006/42/EC, as described in Annex VI.

1.1 Coverage
This document shows instructions to install the L-series single cylinder air cooled diesel engines correctly
into the machine on the assembly line, so as not to compromise the safety and health of people around the
engine*. Not following these instructions might cause danger, damage or serious injury.
* For any other technical information regarding the installation of the engine, not limited to safety and
health only, please refer to the Application Manual and/or Operation Manual of the engine
concerned.

1.2 Product Overview

■ General description
The following Base engine models of the L-series are sold in Europe. The base model name is always
followed by a code of at lease eight numbers and characters, that can vary per application and engine
specification.
For example: L70N5DF1T1AA.

L-AE series L-N series L-V series

L48AE L48N L48V
L70AE L70N L70V
L100AE L100N L100V

These engines are designed to deliver power to drive machines by means of a “direct coupled drive” or
“belt drive”, for a wide range of applications and not for independent running or applications for which the
engine is not intended.
Since designing the application and installing the engine require special knowledge and skill, always
consult your authorized Yanmar industrial engine dealer or distributor in order to:
• Select optional equipment to match the specific operational conditions and environment.
• Maximize engine performance with a minimum amount of downtime and safety related incidents by
carefully matching the characteristics of the engine with the driven machine.
• Plan for safe fuel piping, exhaust piping, electrical wiring, ventilation, and accurate engine installation.
• Design your applications in such a way that they meet requirements of the local authorities.

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1.3 Component Identification
Figure 1 shows where major engine components are located.

1 2 3 4 5 6

12 11 10 9 8 7
034962-00X

1 – Fuel Tank 7 – Power Take off

2 – Top Cover 8 – Crankcase
3 – Air Cleaner 9 – Electric Starter
4 – Muffler 10 – Recoil Starter
5 – M8 Hole for Lifting Eye 11 – Oil Fill Cap
6 – Decompression Lever 12 – Speed Control Device
Figure 1

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1.4 Safety
■ Safety statements
Yanmar is concerned for your safety and your machine's condition. Safety statements are one of the
primary ways to call your attention to the potential hazards associated with incorporating Yanmar L-series
engines into the final machine.
Follow the precautions listed throughout these assembly instructions before and during installation and
initial operation, for your safety, the safety of others and to protect the performance of your engine.
Keep the labels free from dirt or torn and replace them if they are lost or damaged. Also, if you need to
replace a part that has a label attached to it, make sure you order the new part and label at the same time.

1.5 Explanation Safety Symbols

This safety alert symbol appears NOTICE

A
with most safety statements. It
means attention, become alert, Caution without the safety alert symbol indicates a
your safety is involved! Please read potentially hazardous situation that can cause
and abide by the message that damage to the machine, personal property and/or
follows the safety alert symbol. the environment or cause the machine to operate
improperly.

DANGER
Danger (the word “DANGER” is in white letters
with a red rectangle behind it) - indicates an
imminently hazardous situation which, if not
avoided, will result in death or serious injury.
Danger is limited to the most extreme
situations.

WARNING
Warning (the word “WARNING” is in black
letters with an orange rectangle behind it) –
indicates a potentially hazardous situation
which, if not avoided, could result in death or
serious injury.

CAUTION
Caution (the word "CAUTION" is in black letters
with a yellow rectangle behind it) - indicates a
potentially hazardous situation which, if not
avoided, may result in minor or moderate injury.

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1. ASSEMBLY INSTRUCTIONS
1.6 General Instructions
Assembly Step Instruction Safety Remark
1. Storage If possible, store the engine in its
original packaging. WARNING
Take precautions that the engine/box is CRUSH HAZARD!
always stable and cannot fall on the
ground. • When you need to transport an
Keep the number of stacked up engine for repair, have a helper
packages within the maximum allowed assist you to attach it to a hoist
according to the type of package. and load it on a truck.

•Never stand under a hoisted

engine. If the hoist mechanism
fails, the engine will fall on you,
causing death or serious injury.
Protect the engine packaging from
water and moisture. • Failure to comply will result in death or
serious injury.

2. Opening The engine can be delivered in different

packaging types of packaging: CAUTION
• Carton box
Beware of sharp nails or edges when opening
• Steel returnable pallet
the packaging.
Remove the bolts or nuts that connect
the engine foots to the pallet by using
proper tools.
3. Hoist Take precautions that the engine is
always stable and cannot fall to the WARNING
ground.
CRUSH HAZARD!
Check the engine weight (see Table 1)
and decide the suitable lifting method. Crane operating
overhead.
Check the damage of lifting gears and
chains before lifting up the engine.
Stay alert!
Use the threaded M8 hole in one of the
cylinder head bolts to mount a lifting
eye (see Figure 1). Attach the lifting
gear to the lifting eye only.
Lift the engine from the pallet in the
upright position only and do not
approach under and surroundings of
the lifted engine.

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Table 1 Yanmar engine reference weights (dry)
Base engine model Engine weight (kg)
L48AE/L48N/L48V 32
L70AE/L70N/L70V 41
L100AE/L100N/L100V 53.5

Note: Weights are for reference only.

The actual engine weight can vary,
depending on which auxiliary parts are
mounted. Be sure your lifting equipment
is plentiful capable of lifting this engine
weight safely.

NOTICE
When working on the engine, always use personal
protective equipment and protective clothing
according to the local safety regulations.
• Use appropriate tools only.
• Bolt tightening torques should be applied as
specified by the manufacturer.

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1. ASSEMBLY INSTRUCTIONS

Assembly Step Instruction Safety Remark

4. Clean working Keep all openings in the engine
(temporarily) protected, to prevent dirt CAUTION
or dust entering the engine.
WEAR EYE PROTECTION!
Only install the engine in a clean
environment. Dust or dirt particles will • Always wear eye protection
cause damage to the engine. when servicing the engine and
Only install clean parts and hoses on
when using compressed air or
the engine. Hoses should be clean on high-pressure water. Dust, flying
the inside as well. debris, compressed air,
pressurized water or steam may
injure your eyes.
• Failure to comply may result in minor or
moderate injury.

5. Prepare engine Before incorporating the engine to the

room machine, check if the anti-vibration
mounts are mounted correctly and on
the right position.
In some cases it might be necessary to
install certain parts already on the
engine or in the engine room before
incorporating the engine in the
machine.
Be sure all preparations are made in
the engine room to install the engine
smoothly in the machine.
6. Engine If applicable, install the engine on a sub
incorporation frame first. NOTICE
Before installing the engine in the • Never attempt to modify the engine’s design or
machinery, check and replace any safety features such as defeating the engine
parts, which may have been damaged speed limit control or the diesel fuel injection
during transport or hoist.
quantity control.
Do not temporarily remove parts from
the engine to be used as spare parts, • Modifications may impair the engine’s safety and
for other machines, or any other performance characteristics and shorten the
purpose. engine’s life. Any alterations to this engine may
void its warranty. Be sure to use Yanmar genuine
replacement parts.

7. Mounting the Be sure the space where the engine

engine should be installed in the machine is CAUTION
clean and gives good access for the
Keep hands clear.
engine.
Let down the engine and place the
engine or the sub frame on the
anti-vibration mounts and tighten the
bolts correctly, so the engine is fixed
securely to the machine.
Disconnect the lifting equipment only
when the engine is fixed securely to the
machine.
High pressure diesel fuel injection
pipes should not be in contact with
other parts.

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Assembly Step Instruction Safety Remark
8. Connect engine Note:
and machine • The sequence of making the
connections may vary depending on
each application.
• For most L-series engines the
muffler, air cleaner, fuel tank and fuel
line are already installed on the
engine unit.
• The machinery manufacturer should
supply external connections that are
not part of the engine specification,
like fuel hoses, inlet- and exhaust
piping and electrical wiring.
8a. Connect the Connect all power take-off devices
PTO according to the instructions of these CAUTION
devices.
Entrapment hazard!
Use the correct bolt type and tightening
torque to connect them.
Install the engine with output axis
aligned with the centre of the driven
device on the machine.
Do not apply more overhang load than
specified.
8b. Install fuel line If an external fuel tank is used, mount
parts the electrical fuel feed pump (if
(For external applicable) and Fuel filter according to
fuel tank only) the instruction manual from Yanmar.
8c. Connect the Only use fuel hoses that are made from
fuel hoses diesel fuel resistant material and have
(For external the correct diameter and pressure
fuel tank only) class.
Be sure not to mix up the fuel supply
and the fuel return line connections.
Connect the hoses with suitable hose
clamps.
When fuel hoses are bundled with a
clamp, the fuel hoses should be
protected by corrugated tube.
8d. Install the Install the suitable air cleaner and
intake system connect it to the air intake manifold.
(For external The air intake hose should be
air cleaner reinforced to avoid being deformed by
only) vacuum pressure.
8e. Install the The exhaust pipe and/or muffler have
exhaust to be connected properly to the exhaust
system flange using the correct Yanmar
(For external exhaust gasket.
muffler only) If a part of the exhaust system is
mounted to the machine frame, a
flexible pipe must be installed between
that part and the engine to allow engine
movements.

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1. ASSEMBLY INSTRUCTIONS
Assembly Step Instruction Safety Remark
8f. Install the Do not use the high-pressure diesel
electrical fuel injection pipe or fuel hoses as WARNING
system fixation for any other parts, like
(For electric electrical wiring.
SHOCK HAZARD!
starter only) All wire connectors need to be secured • Turn off the battery switch (if
using connector clamps to prevent the equipped) or disconnect the
wire leads from breaking. negative battery cable before
Do not clamp the wires to any fuel-, or servicing the electrical system.
exhaust system componen.
Never secure the wires on a hot • Check the electrical harnesses for cracks,
surface, sharp edge, rotating, or abrasions, and damaged or corroded
vibrating part. connectors. Always keep the connectors and
Avoid placing wiring in contact with oil. terminals clean.
Insulate the wires completely.
• Failure to comply could result in death or
Install a fuse to protect the harness serious injury.
against problems, such as a short
circuit.
8g. Connect the The battery needs to be firmly secured
battery and immovable using a mounting CAUTION
(For electric bracket.
Batteries can leak sulphuric acid
starter only) Do not reverse the connection of the fluid.
positive and negative leads of the
battery cables. This will destroy the
regulator and could cause the wire
harness to burn.
The battery cable length needs to be
adjusted properly and clamped.
8h. Connect The engine speed control cable should
speed control be connected properly.
cable The cable should be adjusted in such a
(For remote way, that both the minimum and
speed control maximum engine speed position can
lever only) be reached.
9. Fill engine oil Only use the recommended engine oil
type. WARNING
Fill engine oil before starting the FIRE HAZARD!
engine.
Engine oil is flammable.
Use the indicated oil fill cap to fill the oil
to the correct oil level.
Wipe off any spilled oil.

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Assembly Step Instruction Safety Remark
10. Fill fuel tank Fill the fuel tank with the correct type of
and fuel line diesel fuel. Do not overfill the fuel tank. DANGER
Open the fuel cock and prime the fuel FIRE AND EXPLOSION HAZARD!
supply line by using gravity or the
electrical fuel feed pump (If applicable). • Diesel fuel is
extremely flammable
If the unit has an electric fuel pump, to
prime the fuel system, turn the key
and explosive under
switch to the ON position for 10 certain conditions.
seconds to allow the electric fuel pump
to prime the system. • Only fill the fuel tank with diesel fuel. Filling
If an external fuel filter is used, the fuel the fuel tank with gasoline may result in a fire
filter has an internal air bleed port. and will damage the engine.
Do not use the starter motor for priming
the fuel system, as this may overheat • Never refuel with the engine running.
the starter motor. • Wipe up any spills immediately.
• Keep sparks, open flames or any other form
of ignition (match, cigarette, static electric
source) well away when refuelling.

11. Check for After filling the fuel and oil systems,
leakages check if no oil or fuel is leaking. NOTICE
Repair any leakage and wipe off spilled If any problem is noted during the visual check,
liquids first before proceeding to engine the necessary corrective action should be taken
operation. Check any repair for leakage before you operate the engine.
again.

12. Install safety Protect all moving or rotating parts

guards driven by the engine with guards or
protective devices.
13. High After and during operation, the engine
temperatures and the exhaust system will be very
hot. Take steps to eliminate the risk of
touching hot parts.
Additional adhesive warning labels for
Hot Surfaces must be attached clearly
visible on a cold surface close to the hot
part(s).

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1. ASSEMBLY INSTRUCTIONS
1.7 Engine Starting
After all parts are installed according the Assembly
instructions, and you have taken into account the WARNING
below instructions and warnings, the engine may BURN HAZARD!
be started. • Keep your hands and other body
Never hold the key in the START position for longer parts away from hot engine
than 15 seconds or the starter motor will overheat. surfaces such as the muffler,
exhaust pipe, turbocharger (if
equipped) and engine block
CAUTION
during operation and shortly after
DO NOT OPERATE WITHOUT you shut the engine down. These
GUARDS IN PLACE surfaces are extremely hot while
• Never start the engine in gear. the engine is operating and could
Sudden movement of the engine seriously burn you.
and/or machine could cause • Allow the engine to cool down before you
serious injury or death. start working on it.
• Failure to comply will result in serious injury.
• Check before starting the engine that any
tools or shop rags used during installation WARNING
have been removed from the engine area.
EXHAUST HAZARD!
• Do not run the engine independently from the
• Never operate the engine in an
machine but only after correct installation in
enclosed area such as a garage,
the machine.
tunnel, ships hold, manhole or
• Be sure all protective guards are installed underground room without proper
properly, so moving or rotating parts cannot ventilation.
be touched.
• Engine's exhaust gas contain Carbon
• Do not use the engine for any other Monoxyd. Accumulation of this gas within an
application as it is intended for. enclosure could cause illness or death.
• At all times the engine must be according to • Never block windows, vents or other
the original specification before running the ventilation if the engine is operating in an
engine. enclosed area.
• Make sure the components connected to the • Make sure that all connections in the exhaust
engine, but not supplied by Yanmar, comply system are tight after repair.
with the engine requirements.
• Do not start the engine inside buildings
without a suction system connected to the
exhaust pipe.

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The manufacturer:
WARNING Yanmar Italy S.P.A.
HIGH-PRESSURE HAZARD! Via Carabelli, 7/9,
• Avoid skin contact with the 21012 Cassano Magnago (VA),
high-pressure diesel fuel spray Italy
caused by a fuel system leak such Represented in Europe by:
as a broken fuel injection line. Yanmar Europe B.V.
High-pressure fuel can penetrate Brugplein 11, 1332 BS Almere,
your skin and result in serious The Netherlands
injury. If you are exposed to
high-pressure fuel spray, obtain
prompt medical treatment.
• Never check for a fuel leak with your hands.
Always use a piece of wood or cardboard.
Have your authorized Yanmar industrial
engine dealer or distributor repair the
damage.
• Failure to comply could result in death or
serious injury.

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