The procedure for welding Crank Gear A

Attachment for Yanmar Service News No.20-2-G-06-005-L

“Starting Failure due to Crank Gear Slip & Restoration Method”

© YANMAR POWER TECHNOLOGY CO., LTD 作成⽇︓ 2020/06/01

 Crank Gear A Welding Instructions

Crank Gear A Welding Instructions

＜Preparation＞
① Extract lube oil from sump tank on the common bed.
② Remove LO pump, FO feed pump and bypass filter.

＜Fire Protection＞
① Clean Crank Gear A by parts cleaner
② Install the protection sheet around the journal area and fix it by magnet.
(Double or triply the protection sheet above to prevent piercing by welding spatters.

＜Crank Gear A Welding＞

※When gear slip occurs, engine immediately stop, so that the surface between gear A
and crank shaft will not be worn down and keep center position of both crank shaft and
gear A. Crank gear A is drive gear , so that welding gear at any position is available.
Crank gear A is fixed between crank shaft and crank gear B, and welding can be done at it
is. Yanmar has confirmed back lash of LO pump is not affected by welding.

① Insert electrode through the bypass filter installation hole for welding.
(Implement welding according to the instructions given in the attached sheet.)
② Remove slags after completing welding

＜After Welding＞
① Remove slags and spatters deposited on the protection sheet with vacuum cleaner.
② Clean the welded area and remove the protection sheets
③ Reassemble the LO pump, etc. for restoring the engine.
④ Measure back lash of LO Pump gear (Standard : 0.20±0.05mm)
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Crank Gear (A) Welding Instructions

Work Schedule

Item Work Time

Preparation • LO extraction 1 hour
• Removal of engine parts ※LO extraction time
excluded.

Fire Protection • Installing welding spatter 1 hour

protection sheet
Welding crank gear • Degreasing 1 hour
• Welding
• Removal of slags
Works after • Removal of slags & spatters; 3 hour
welding cleaning
• Removal of protection sheets
• Engine restoration
• Measure back lash

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 Crank Gear (A) Welding Instructions

Necessary Equipment for welding

No. Name Q’ty Purpose

1 Parts Cleaner 3 Degrease welding area
2 Protection Sheet 1 Avoid slag and spatter
3 Magnet 5 Fix Protection Sheet
4 Welding Machine 1 Welding
5 Electrode - Welding Please refer P.8
6 Marker Pen 1 Marking
7 LED Light 1 Lighting
8 Magnet 1 Fix LED light
9 Cleaner 1 Clean slug , Spatter in sump tank
10 Consumable Parts ー To install engine parts Please refer P.5
11 Pick Gauge 1 To check back lash of LOP Gear after welding

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Crank Gear (A) Welding Instructions

Consumable Parts

Parts Name Parts Number Q’ty

O Ring １A P 60.0 24311-000600 2
Packing 146623-35270 2
Packing 138673-01990 2
Liquid Bond 977771-1207C 1
Packing 152673-39160 2
Packing 43400-003170 2

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Crank Gear (A) Welding Instructions

Preparation (Taking engine parts out)

Bypass filter Installation

Hole

LO Pump FO Feed Pump

Installation Hole Installation Hole
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Crank Gear (A) Welding Instructions

Installing Welding Sparks Protection Sheet

Crank gear A
Gear case
Welding sparks
protection sheet
Crankshaft

LO pump installation hole

FO feed pump installation hole

Welding sparks
protection sheet
No.7 Journal
Magnet

① Insert protection sheet through No.6 cyl side cover.

② Pull out protection sheet through gear case LO pump installation hole and FO feed pump
installation hole.
③ Cover whole area under crank gear A with protection sheet and fix with magnet.
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Crank Gear (A) Welding Instructions

Preparation for Protection Sheet

Fix sheet with magnet
4 points

Exhaust side Gear case side

Bypass filter
installation hole
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 Crank Gear (A) Welding Instructions

Specification of Protection Sheet and Electrode

Electrode
Type CM-A76 is recommended.
Please refer specification in right.

Protection Sheet
Size︓400×1000(mm)
Material︓For welding except Glass wool

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Crank Gear (A) Welding Instructions

Procedure of Welding
Electrode
⇒Bending for easy welding
Please weld from these hole

Access hole for welding

（Bypass filter installing hole）

Inside of Gear Case Exhaust Side

（View from engine bottom) Bypass filter installing hole
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 Crank Gear (A) Welding Instructions

Welding procedure

Welding point Welding point

③ Crank
Crankshaft
Shaft ④

② 約80~100mm
80~100㎜

Crank gear(
Gear A
Crank Gear B

 Weld 4 any positions by 90 degree interval. (Welding length: approx. 80〜100mm）

（When crank gear A slips , engine immediately stop and no wearing down surface
between crank shaft and crank gear A and no change of center position. Yanmar
confirmed back lash value didn’t change before and after welding. ）
 To minimize thermal effect of welding, weld at opposite side by turns. Weld in the
order of (①⇒②⇒③⇒④）as shown above.
 After completing welding, check and record backlash with LO pump gear(Standard︓
0.20±0.05mm)
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Crank Gear (A) Welding Instructions

Welding procedure

・ Electrode should be gotten wide angle against the gear, bend it if

necessary.
・ Welding bead is bridged from crankshaft to gear stiffly, and weld full
penetration especially gear side.
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Crank Gear (A) Welding Instructions

Welding condition

Welding from top hole Welding from bottom hole

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Crank Gear (A) Welding Instructions

Check sump tank clean

Check engine parts

Check sump tank Clean slag and spatter

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