Yanmar Industrial Engine 2TNV70, 3TNV70, 3TNV76 Service Manual 50940077 2009 – PDF DOWNLOAD

Yanmar Industrial Engine 2TNV70, 3TNV70, 3TNV76 Service Manual 50940077 2009 – PDF DOWNLOAD

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Yanmar Industrial Engine 2TNV70, 3TNV70, 3TNV76 Service Manual 50940077 2009 – PDF DOWNLOAD

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Pages : 264
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Yanmar Industrial Engine 2TNV70, 3TNV70, 3TNV76 Service Manual 50940077 2009 – PDF DOWNLOAD

INTRODUCTION:

This Service Manual describes the service procedures for the TNV series indirect injection engines. These engines are certified by the US. EPA. California ARB and/or the 97/68/EC Directive for industrial use.

• Please use this manual for accurate, quick and safe servicing of the engine. Since the directions in this manual are for a typical engine, some specifications and components may be different from your engine. Refer to the documentation supplied by the optional equipment manuiacturer for Specific service instructions.
• Yanmar products are continuously undergoing Improvement. This Service Manual might not address possible iieid modiiications to the equipment. Contact an authorized Yanmar industrial engine dealer or distributor for answers to any questions relating to field modifications.

TABLE OF CONTENTS:

Yanmar Industrial Engine 2TNV70, 3TNV70, 3TNV76 Service Manual 50940077 2009 – PDF DOWNLOAD

Cover…………………………………………………………………… 1
Table of Contents………………………………………………………… 3
Introduction…………………………………………………………….. 5
Yanmar Warranties………………………………………………………… 7
Yanmar Limited Warranty……………………………………………….. 9
What is Covered by this Warranty?…………………………………… 9
How Long is the Warranty Period?……………………………………. 9
What the Engine Owner Must Do:……………………………………… 9
To Locate an Authorized Yanmar Industrial Engine Dealer or Distributor:…. 10
What Yanmar Will Do:………………………………………………. 10
What is Not Covered by this Warranty?……………………………….. 10
Warranty Limitations:……………………………………………… 11
Warranty Modifications:……………………………………………. 11
Questions:……………………………………………………….. 11
Retail Purchaser Registration………………………………………. 11
Emission System Warranty………………………………………………. 12
Yanmar Co., Ltd. Limited Emission Control System Warranty – USA Only……….. 12
Your Warranty Rights and Obligations:……………………………….. 12
California……………………………………………………. 12
Manufacturer’s Warranty Period:…………………………………….. 12
Warranty Coverage:………………………………………………… 13
Warranted Parts:………………………………………………….. 13
Exclusions:………………………………………………………. 14
Owner’s Warranty Responsibilities:………………………………….. 14
Safety………………………………………………………………….. 15
Safety Statements…………………………………………………….. 17
Safety Precautions……………………………………………………. 18
General Service Information……………………………………………….. 31
Component Identification………………………………………………. 33
Location of Labels……………………………………………………. 34
Engine Nameplate (Typical)…………………………………………. 34
EPA / ARB Emission Control Regulations – USA Only………………………… 34
Emission Control Labels……………………………………………….. 34
EPA / CARB Labels (Typical)………………………………………… 35
The 97/68/EC Directive Certified Engines………………………………… 35
Engine Family………………………………………………………… 35
Function of Major Engine Components…………………………………….. 36
Function of Cooling System Components…………………………………… 38
Diesel Fuel………………………………………………………….. 39
Diesel Fuel Specifications…………………………………………. 39
Additional Technical Fuel Requirements…………………………… 39
Bio-Diesel Fuels………………………………………………. 40
KIT PARTS LIST FOR B20 (TNV IDI Engines)…………………………. 42
Filling the Fuel Tank……………………………………………… 43
Priming the Fuel System……………………………………………. 44
Engine Oil…………………………………………………………… 45
Engine Oil Specifications………………………………………….. 45
Service Categories………………………………………………… 45
Definitions…………………………………………………… 45
Additional Technical Engine oil Requirements:…………………….. 45
Engine Oil Viscosity………………………………………………. 45
Checking Engine Oil……………………………………………….. 45
Adding Engine Oil…………………………………………………. 46
Engine Oil Capacity (Typical)………………………………………. 46
Engine Coolant……………………………………………………….. 47
Engine Coolant Specifications………………………………………. 48
Additional Technical Coolant Specifications:……………………… 48
Alternative Engine Coolant……………………………………… 48
Filling Radiator with Engine Coolant………………………………… 48
Engine Coolant Capacity (Typical)…………………………………… 49
Specifications……………………………………………………….. 50
Description of Model Number………………………………………… 50
Engine Speed Specifications………………………………………… 50
Engine General Specifications………………………………………. 51
Principal Engine Specifications………………………………………… 52
2TNV70…………………………………………………………… 52
3TNV70…………………………………………………………… 53
3TNV76…………………………………………………………… 54
Engine Service Information…………………………………………….. 55
Tightening Torques for Standard Bolts and Nuts…………………………… 56
Abbreviations and Symbols……………………………………………… 58
Abbreviations…………………………………………………….. 58
Symbols………………………………………………………….. 58
Unit Conversions……………………………………………………… 59
Unit Prefixes…………………………………………………….. 59
Units of Length…………………………………………………… 59
Units of Volume…………………………………………………… 59
Units of Mass…………………………………………………….. 59
Units of Force……………………………………………………. 59
Units of Torque…………………………………………………… 59
Units of Pressure…………………………………………………. 59
Units of Power……………………………………………………. 59
Units of Temperature………………………………………………. 59
Periodic Maintenance……………………………………………………… 61
Introduction…………………………………………………………. 63
Precautions………………………………………………………….. 64
The Importance of Periodic Maintenance………………………………. 64
Performing Periodic Maintenance…………………………………….. 64
Yanmar Replacement Parts…………………………………………… 64
Required EPA / ARB Maintenance – USA Only……………………………. 64
EPA / ARB Installation Requirements – USA Only……………………….. 64
Periodic Maintenance Schedule………………………………………….. 65
Periodic Maintenance Procedures………………………………………… 67
After Initial 50 Hours of Operation…………………………………. 67
Replace Engine Oil and Engine Oil Filter…………………………. 67
Check and Adjust Cooling Fan V-Belt……………………………… 69
Every 50 Hours of Operation………………………………………… 70
Drain Fuel Filter / Water Separator……………………………… 70
Check Battery…………………………………………………. 72
Every 250 Hours of Operation……………………………………….. 73
Drain Fuel Tank……………………………………………….. 73
Replace Engine Oil and Engine Oil Filter…………………………. 74
Check and Clean Radiator Fins…………………………………… 75
Check and Adjust Cooling Fan V-Belt……………………………… 75
Check and Adjust the Governor Lever and Engine Speed Control……….. 75
Clean Air Cleaner Element………………………………………. 76
Every 500 Hours of Operation……………………………………….. 78
Replace Air Cleaner Element…………………………………….. 78
Replace Fuel Filter……………………………………………. 78
Clean Fuel Filter / Water Separator……………………………… 80
Every 1000 Hours of Operation………………………………………. 81
Drain, Flush and Refill Cooling System with New Coolant……………. 81
Adjust Intake / Exhaust Valve Clearance………………………….. 83
Every 1500 Hours of Operation………………………………………. 83
Inspect, Clean and Test Fuel Injectors…………………………… 83
Inspect Crankcase Breather System……………………………….. 84
Every 2000 Hours of Operation………………………………………. 85
Check and Replace Fuel Hoses and Engine Coolant Hoses……………… 85
Lap the Intake and Exhaust Valves……………………………….. 85
Engine………………………………………………………………….. 87
Before You Begin Servicing…………………………………………….. 89
Introduction…………………………………………………………. 90
Cylinder Head Specifications…………………………………………… 90
Adjustment Specifications………………………………………….. 90
Cylinder Head…………………………………………………….. 90
Intake / Exhaust Valve and Guide……………………………………. 91
Push Rod…………………………………………………………. 91
Valve Spring……………………………………………………… 91
Rocker Arm and Shaft………………………………………………. 92
Camshaft and Timing Gear Train Specifications……………………………. 92
Camshaft…………………………………………………………. 92
Idler Gear Shaft and Bushing……………………………………….. 93
Timing Gear Backlash………………………………………………. 93
Crankshaft and Pistons Specifications…………………………………… 93
Crankshaft……………………………………………………….. 93
Crankshaft Reconditioning………………………………………….. 94
Thrust Bearing……………………………………………………. 94
Piston…………………………………………………………… 95
Piston Ring………………………………………………………. 96
Connecting Rod……………………………………………………. 97
Connecting Rod Small End……………………………………….. 97
Connecting Rod Big End…………………………………………. 98
Connecting Rod Distortion………………………………………. 98
Tappet…………………………………………………………… 98
Cylinder Block Specifications………………………………………….. 98
Cylinder Block……………………………………………………. 98
Special Torque Chart………………………………………………….. 99
Torque for Bolts and Nuts………………………………………….. 99
Special Service Tools………………………………………………….100
Measuring Instruments………………………………………………….102
Cylinder Head…………………………………………………………104
Cylinder Head Components……………………………………………104
Disassembly of Cylinder Head………………………………………..105
Removal of Intake Manifold / Valve Cover………………………….106
Removal of Glow Plugs…………………………………………..106
Removal of Rocker Arm Assembly…………………………………..106
Disassembly of Rocker Arm Assembly……………………………….107
Removal of Cylinder Head………………………………………..107
Removal of Intake / Exhaust Valves……………………………….108
Removal of Valve Guides…………………………………………108
Cleaning of Cylinder Head Components…………………………………109
Inspection of Cylinder Head Components……………………………….109
Inspection of Push Rods…………………………………………109
Inspection of Rocker Arm Assembly………………………………..110
Inspection of Valve Guides………………………………………110
Inspection of Cylinder Head……………………………………..110
Inspection of Intake and Exhaust Valves…………………………..111
Inspection of Valve Springs……………………………………..112
Reassembly of Cylinder Head…………………………………………113
Reassembly of Valve Guides………………………………………113
Reassembly of Intake and Exhaust Valves…………………………..114
Reassembly of Cylinder Head……………………………………..115
Reassembly of Rocker Arm Assembly………………………………..116
Reassembly of Intake Manifold / Valve Cover……………………….117
Measuring and Adjusting Valve Clearance………………………………118
3-Cylinder Engines……………………………………………..118
Cylinder Block………………………………………………………..120
Crankshaft and Camshaft Components…………………………………..120
Disassembly of Cylinder Block Components……………………………..121
Disassembly of Camshaft and Timing Components…………………………122
Removal of Timing Gear Case Cover………………………………..122
Checking Timing Gear Backlash……………………………………122
Measuring Idler Gear-to-Crankshaft Gear Backlash…………………..123
Measuring Idler Gear-to-Camshaft Gear Backlash…………………….123
Removal of Timing Gears…………………………………………123
Removal of Oil Pan……………………………………………..124
Removal of Camshaft…………………………………………….125
Removal of Gear Case……………………………………………126
Disassembly of Crankshaft and Piston Components……………………….126
Removal of Pistons……………………………………………..126
Removal of Crankshaft…………………………………………..128
Inspection of Crankshaft and Camshaft Components………………………130
Replacement of Crankshaft Oil Seals………………………………130
Crankshaft Bearing Oil Clearance…………………………………131
Inspection of Cylinder Block…………………………………….131
Inspection of Pistons, Piston Rings and Wrist Pin………………….132
Inspection of Connecting Rod…………………………………….133
Inspection of Tappets…………………………………………..134
Inspection of Crankshaft………………………………………..135
Reconditioning the Crankshaft……………………………………….135
Inspection of Camshaft………………………………………….136
Inspection of Camshaft Bushing and Bores………………………….137
Inspection of Idler Gear and Shaft……………………………….137
Honing and Boring………………………………………………….137
Reassembly of Crankshaft and Piston Components………………………..138
Reassembly of Pistons…………………………………………..139
Installation of Crankshaft………………………………………141
Installation of Pistons…………………………………………142
Reassembly of Camshaft and Timing Components………………………….144
Installation of Gear Case……………………………………….144
Installation of Camshaft………………………………………..144
Installation of Timing Gears…………………………………….145
Installation of Gear Case Cover………………………………….145
Installation of Oil Pan…………………………………………146
Final Assembly of Engine………………………………………..146
Fuel System………………………………………………………………147
Before You Begin Servicing……………………………………………..149
Introduction………………………………………………………….150
Fuel Injection Pump………………………………………………..150
Stop Solenoid……………………………………………………..151
Fuel System Specifications……………………………………………..152
Special Torque Chart……………………………………………….152
Test and Adjustment Specifications…………………………………..152
Special Service Tools………………………………………………….153
Measuring Instruments………………………………………………….153
Fuel System Diagram……………………………………………………154
Fuel System Components…………………………………………………155
Fuel Injection Lines…………………………………………………..156
Removal of High-Pressure Fuel Injection Lines…………………………156
Installation of High-Pressure Fuel Injection Lines…………………….157
Removal of Fuel Return Line…………………………………………157
Installation of Fuel Return Line…………………………………….158
Fuel Injection Pump……………………………………………………158
Removal of Fuel Injection Pump………………………………………158
Installation of Fuel Injection Pump………………………………….161
Checking and Adjusting Fuel Injection Timing……………………………..164
Checking Fuel Injection Timing………………………………………164
Adjusting Fuel Injection Timing……………………………………..168
Fuel Injectors………………………………………………………..168
Removal of Fuel Injectors…………………………………………..168
Testing of Fuel Injectors…………………………………………..169
Fuel Injector Test Results………………………………………171
Disassembly and Inspection of Fuel Injectors………………………….172
Adjusting Fuel Injector Pressure…………………………………….173
Reassembly of Fuel Injectors………………………………………..174
Installation of the Fuel Injectors…………………………………..174
Cooling System……………………………………………………………175
Before You Begin Servicing……………………………………………..177
Introduction………………………………………………………….178
Cooling System Diagram…………………………………………………178
Engine Coolant Pump Components………………………………………….179
Engine Coolant System Check…………………………………………….180
Engine Coolant Pump……………………………………………………180
Disassembly of Engine Coolant Pump…………………………………..180
Cleaning and Inspection…………………………………………….181
Temperature Switch……………………………………………..181
Thermostat…………………………………………………….181
Radiator Cap…………………………………………………..181
Reassembly of Engine Coolant Pump……………………………………182
Lubrication System………………………………………………………..185
Before You Begin Servicing……………………………………………..187
Introduction………………………………………………………….188
Oil Pump Service Information……………………………………………188
Engine Oil Pressure………………………………………………..188
Outer Rotor Outside Clearance……………………………………….188
Outer Rotor Side Clearance………………………………………….188
Outer Rotor to Inner Rotor Tip Clearance……………………………..188
Inner Rotor and Gear Boss Clearance………………………………….189
Lubrication System Diagram……………………………………………..190
Checking Engine Oil Pressure……………………………………………191
Trochoid Oil Pump……………………………………………………..191
Oil Pump Components………………………………………………..191
Disassembly of Oil Pump…………………………………………….192
Cleaning and Inspection…………………………………………….193
Check Outer Rotor Outside Clearance………………………………193
Outer Rotor to Inner Rotor Tip Clearance………………………….193
Check Outer Rotor Side Clearance…………………………………193
Check Inner Rotor and Gear Boss Clearance…………………………194
Reassembly of Oil Pump……………………………………………..194
Starter Motor…………………………………………………………….195
Before You Begin Servicing……………………………………………..197
Introduction………………………………………………………….198
Starter Motor Information………………………………………………198
Starter Motor Specifications……………………………………………199
Starter Motor Troubleshooting…………………………………………..200
Starter Motor Components……………………………………………….201
Starter Motor…………………………………………………………202
Removal of Starter Motor……………………………………………203
Disassembly of Starter Motor………………………………………..203
Cleaning and Inspection…………………………………………….205
Armature………………………………………………………205
Field Coil…………………………………………………….207
Brush Holder…………………………………………………..208
Solenoid Switch………………………………………………..208
Pinion Clutch Assembly………………………………………….209
Reassembly of Starter Motor…………………………………………210
Check Pinion Projection Length………………………………………212
No-Load Test………………………………………………………212
Installation of Starter Motor……………………………………….213
Alternator……………………………………………………………….215
Before You Begin Servicing……………………………………………..217
Introduction………………………………………………………….218
Standard and Optional Dynamo Information…………………………………218
Standard and Optional Alternator Information……………………………..218
Alternator Specifications………………………………………………218
Dynamo Specifications………………………………………………….219
Alternator Troubleshooting……………………………………………..220
Alternator Components………………………………………………….221
Alternator Wiring Diagram………………………………………………222
Alternator Standard Output……………………………………………..223
Alternator……………………………………………………………224
Removal of Alternator………………………………………………224
Disassembly of Alternator…………………………………………..224
Reassembly of Alternator……………………………………………226
Installation of Alternator………………………………………….228
Dynamo Component Location………………………………………………229
Dynamo Wiring Diagram………………………………………………….230
Operation of Dynamo……………………………………………………230
Dynamo Standard Output…………………………………………………231
Testing of Dynamo……………………………………………………..232
Testing Stator Coil Continuity………………………………………232
Testing Stator Coil Short-to-Ground………………………………….232
Testing Dynamo Regulated Output……………………………………..232
Dynamo……………………………………………………………….232
Removal of Dynamo………………………………………………….232
Disassembly of Dynamo………………………………………………233
Reassembly of Dynamo……………………………………………….233
Installation of Dynamo……………………………………………..234
Electric Wiring…………………………………………………………..235
Electric Wiring Precautions…………………………………………….237
Electric Wire Resistance……………………………………………….238
Battery Cable Resistance……………………………………………….239
Electrical Wire Sizes – Voltage Drop…………………………………….240
Conversion of AWG to European Standards………………………………….241
Troubleshooting…………………………………………………………..243
Special Service Tools………………………………………………….245
Troubleshooting By Measuring Compression Pressure…………………………246
Compression Pressure Measurement Method………………………………246
Standard Compression Pressure……………………………………….247
Engine Speed and Compression Pressure (Use for Reference)………………247
Measured Value and Troubleshooting…………………………………..248
Quick Reference Table For Troubleshooting………………………………..248
Troubleshooting Charts……………………………………………..249
Electric Wiring……………………………………………………….261
Back Cover……………………………………………………………….264