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warning - A Motor Diesel

1. 11 14 Reassembly of 11 16 Installation of 42222222 11 18 Dynamo Component 11 19 Dynamo Wiring Diagram eie 11 20 Operation of sic e corte ales 11 20 Dynamo Standard 11 21 Testing Of c 11 22 Testing Stator Coil 11 22 Testing Stator Coil 11 22 Testing Dynamo Regulated 11 22 burgi fe 11 22 Removal of ke t a Rire 11 22 Disassembly of Dynamo sss 11 23 YANMAR TNV IDI Service Manual ALTERNATOR Reassembly of 11 23 Installation or 11 24 11 2 TNV IDI Service Manual YANMAH BEFORE YOU BEGIN SERVICING NO SEVER HAZARD Stop the engine before you begin to service it NEVER leave the key in the key switch when you are servicing the engine Someone may accidentally start the engine and not realize you are servicing it This could result in a serious injur
2. 4 19 Engine General Specifications 4 20 YANMAR TNV IDI Service Manual 4 1 GENERAL SERVICE INFORMATION Principal Engine Specifications 4 21 2 4 21 m 4 22 ede 4 23 Engine Service 2 44404 4 25 Tightening Torques for Standard Bolts and Nuts 4 26 Tightening 2 2 2 4 27 Standard Torque Chats uoo 4 27 Abbreviations and 44040000 4 28 PUSS zie eL 4 28 CM mt 4 28 Unit 4 4 29 Bondi cce 4 29 Units of Length 4 29 Units 4 29 Units of IWS 4 29 OT ICS ete m 4 29 Unis ot TOGU m 4 29 Units of Pressure 4 29 Units Ol POWED goi sp qas ede P awe 4 29 Units 4 4 444 1222 4 29 4 2 TNV IDI Service Manual YANMAR GENERAL SERVICE INFORMATION COMPONENT IDENTIFICATION Figure 4 1 shows where major engine components are located 1 19 8 LS a 7 2
3. Correct the Ring Joint Positions See Reassembly of Pistons on page 6 53 13 7 TROUBLESHOOTING This Page Intentionally Left Blank 13 8 TNV IDI Service Manual YANMAR Trouble Symptom Cause Starting Problem Insufficient Engine Output Engine Does Not Start Engine Starts But Stops Soon Exhaust Color Exhaust Smoke Ordinary High Knocking Sound During Combustion Abnormal Engine Sound Uneven Combustion Sound Engine Surging During ldling During Work Operation Excessive Engine Vibration Difficulty in Returning to Low Speed Excessive Fuel Consumption Engine Cil Engine Coolant Air Intake Dilution by Diesel Fuel Oil with Water Low Oil Pressure Low Water Temperature Overheat Pressure Drop Pressure Rise Exhaust Temperature Rise Corrective Action TROUBLESHOOTING Reference Page Reverse Assembly of Piston Rings White O White O Excessive Oil Consumption Excessive Blow by Gas Reassemble Correctly See Heassembly of Pistons on page 6 53 Worn Crankpin and Journal Bearing Measure and Replace See Inspection of Crankshaft and Camshaft Components on page 6 46 Loose Connecting Rod Bolt Tighten to the Specified Torque See Special Torque Chart on page 6 15 Foreign Matter Trapped in Combustion Chamber Disassemble and Repair See Di
4. 10 11 Disassembly of Starter 10 11 Cleaning and 10 14 Reassembly of Starter 10 18 Check Pinion Projection Length 10 21 No Load mm ee 10 22 Installation of Starter 10 22 YANMAR TNV IDI Service Manual STARTER MOTOR This Page Intentionally Left Blank 10 2 TNV IDI Service Manual YANMAR STARTER MOTOR Been _____ AWARNNG SERVICING SHOCK HAZARD Turn off the battery switch if SEVER HAZARD equipped or disconnect the negative battery cable before servicing the electrical system Stop the engine before you begin to service it NEVER leave the key in the key switch when you are servicing the engine Someone may accidentally start the engine and not realize you are servicing it This could result in a Failure to comply could result in death serious injury or serious injury If you must service the engine while it is operating remove all jewelry tie other body parts and clothing away gt gt amp pi 7 from moving rotating parts xm E FUME BURN HAZARD Always read and follow safety related precautions found on containers of hazardous substances like parts
5. REFER TO OWNER S MANUAL FOR MAINTENANCE SPECIFICATIONS AND ADJUSTMENTS YANMAR CO LTD EPA amp ARB GENERAL SERVICE INFORMATION THE 97 68 EC DIRECTIVE CERTIFIED ENGINES The engines described in this manual have been certified by the 97 68 EC Directive To identify the engines that meet this certification the 97 68 EC emission control label is affixed on the engines IMPORTANT ENGINE INFORMATION THIS ENGINE CONFORMS 10 97 68 DIRECTIVE ENGINE FAMILY ____________ ENGINE MODEL o APPROVAL NUMBER _______________ YANMAR CO LTD 97 68 EC ENGINE FAMILY The EPA ARB labels and the 97 68 EC label all have an Engine Family field The following is an explanation of the Engine Family designation 3 YDX L 1 33 M 3 5 2005 6 2006 7 2007 YANMAH TNV IDI Service Manual L Method of air aspiration Number of cylinders Engine speed specifications Displacement liter Non road Off road engine Yanmar Diesel 2005 Model Year GENERAL SERVICE INFORMATION FUNCTION OF MAJOR ENGINE COMPONENTS Components Functions Air Cleaner The air cleaner prevents airborne contaminants from entering the engine Since the air cleaner is application specific it must be carefully selected by an application engineer It is not part of the basic engine package as shipped from the Yanmar
6. 6 8 6 8 Idler Gear Shaft and 4 2 4 22 6 9 Timing Gear 44420442 21 6 9 Crankshaft and Pistons 6 9 rr c 6 9 Crankshaft Reconditioning 6 10 o D 6 10 Be 6 11 PIStOMRINO e a 6 11 Connecting 6 12 Eze ccc E 6 13 Cylinder Block Specifications 8 6 13 Cylinder ARM 6 13 Special Torque Chart teed 6 14 Torque for Bolts and 5 6 14 Special Service 0 04 6 15 Measuring instruments 6 17 S sida 6 19 6 1 ENGINE Cylinder Head Components 6 19 Disassembly of Cylinder Head 6 20 Cleaning of Cylinder Head Components 6 24 Inspection of Cylinder Head Components 6 24 Reassembly of Cylinder 6 29 Measuring and Adjusting Valve Clearance 6 34 Cylinder BIOCK c
7. seusniq pue Ajqwasse 2001 yoedsu s JoyeoIpul Jojeoipur eu AAO NO 330 NO Yyoums Win 4 Joyeolpul seoq Burp lt 670 uey 5591 4 sl oDeyoA jeur 1 5 je pue jeu 71e JOA 670 uey 901 si eDeyo 1 ieneg at 4 Jojeoipur ieyeq 1 epis punog Joyeusaye jeuruue 9 pue 7 joeuuoosiq 4 1 Kieyneq je eBeyoA 005 Buiuuni AAO NO Joyeoipui 0 peeds Yyoums 8 330 440 Jojeorpul seop euiBu3 Hes NO NO Jojeoipur 330 youms Ke TNV IDI Service Manual YANMAR 11 8 ALTERNATOR ALTERNATOR COMPONENTS Yanmar Part No 129423 77200 alternator is used in this section to show the service procedures for t
8. eoe deJ 10 ON eAnoejep joejuoo quiesse yoyms oneuDelN SHA eoe doJ pue joedsu amp 9jeJedo Jeyejs seoq uononpei Asayyegq JO ON jo 1 SHA ON JeoD pue uoluld SHA SHA S seoq ON ON pseoy SHA A punos Buyenjoe 5 ON 5 S ues jou seop SHA pue uonisod Ty LO 3N ON s 01 YIYS 9AO A ON 10 7 YANMAH TNV IDI Service Manual STARTER MOTOR STARTER MOTOR COMPONENTS Needle Bearing Pinion Housing Pinion Retaining Ring Pinion Stop Pinion Shift Lever Solenoid Switch Assembly Snap Ring Washer Bushing Intermediate Housing Reduction Gear Washer Through Bolt End Housing Figure 10 1 0002486 17 Brush Plate and Holder 18 Field Assembly 19 Armature 20 Bushing 21 Plate 22 Planetary Gear 3 used 23 Washer 3 used 24 Pinion Shaft TNV IDI Service Manual YANMAR STARTER MOTOR il SHOCK HAZARD Turn off the battery switch if equipped or disconnect the negative battery cable before servicing the electrical system
9. euru eAneBeu 1 euuoosip S1n990 uie qoJd e euiBue uonipuoo 1oedsu uonnjo es MOIS peoejdai s Jeyiejs 5 eoe deiJ 10 SJA lo eo ejdes seoq sal 41904100 ON y SHA sjeuiuJe sjeuluue pue eoejdei Jo 5 ON in ewou si ji quiesse YOUMS eoe dai Jam JOJ OW 5 J Ajquiesse ejnjeuue eoe dai jou seusnJg JI eoejda1 pue usnJq pepeeu se eoejdai pue uoiuid ueewjeq uoiuid pue Buuds uoneuuojep Je e YIYS JOodsu uBue uonoefoud uoiuid 1snfpy suonoeuuoo eo2uioe 3 K quiesse oneuBe A Ajejes youms iesseoeu pue oneuBeui oj dn Hum yoedsu 1eygeq eoejdai 10 uonnjoA eJ 5 0000102 ulejs s joedsu SHA uonnjo eiJ
10. 12 3 Electrical Wire Resistance ran eor RE 12 4 Battery Cable 12 5 Electrical Wire Sizes Voltage Drop 12 6 Conversion of AWG to European 5 12 7 YANMAR TNV IDI Service Manual ELECTRIC WIRING This Page Intentionally Left Blank 12 2 TNV IDI Service Manual YANMAH ELECTRIC WIRING PRECAUTIONS Failure to follow these precautions may result in the failure of an electrical component and the loss of warranty coverage on that item as well as related items Make sure that all users read and understand these precautions Do not reverse the positive and negative ends of the battery cable The alternator diode and stator coil will be damaged 0000050en When the battery indicator goes out it should not come on again The battery indicator only comes on during operation if the alternator fails or if the V belt breaks However if an LED is used in the battery indicator the LED will shine faintly during normal operation 0000051en Make sure that the combined total resistance of the battery cable in both directions between the starter motor and the battery is within the value indicated in the Battery Cable Resistance chart in the Electric Wiring Section of this manual The starter motor will malfunction
11. 2 3 To Locate an Authorized Yanmar Industrial Engine Dealer or Distributor 2 4 What Yanmar Will DO 12 erret io roten rete 2 4 What is Not Covered by this Warranty 2 4 Warranty Limitations cc entrent rcm nien ies 2 5 Warranty Modifications 2 2 5 e VI 2 5 Retail Purchaser 2 5 Yanmar Co Ltd Limited Emission Control System Warranty USA 2 6 Your Warranty Rights and Obligations 2 6 Manufacturer s Warranty 2 6 Warranty Coverage 2 7 Warranted Pars 2 7 Iii x 2 8 Owner s Warranty 2 8 YANMAR TNV IDI Service Manual YANMAR WARRANTIES This Page Intentionally Left Blank 2 2 TNV IDI Service Manual YANMAR YANMAR WARRANTIES YANMAR LIMITED WARRANTY What is Covered by this Warranty Yanmar warrants to the original retail purchaser that a new Yanmar TNV Series Industrial Engine will be free from defects in material and or workmanship for the duration of the warranty period Note Yanmar engines may be equipped with exter
12. STOP SOLENOID 7123 3215 60 ance 116 RELAY So x 404 YAZAKI NO Bes 19650 77910 FUSIBLE LINK X 0 850 B FOR 2 3TNV 70 FOR 3TNV 76 STARTER MOTOR STARTER MOTOR 1 10KW 10KW D 119515 7 10 119717 77010 XYAZAKI NO EMERGENCY STOP SWITCH dea 30A LOCATION OPTIONAL 1 FUSE BATTERY W VT TIMER EMERGENCY SWITCH a TIME 3sec X YAZAKI NO YAZAKI NO YAZAKI YAZAKI NO 7123 2237 00 7122 2237 00 2 2 7122 2046 7123 2249 C BR MARK WIRE COLOR SOLENOID B DETAIL A YAZAKI NO 119643 66900 HOLD O49 7123 2228 DIODE REVERSING PRESSURE 6007 HELI PRE HEATING O i FORWARD CURRENTI OFF Jol White 19653 72 PRE HEAT LAMPCAF TER 3 sec LIN LESS THAN 3 4W 1 Red START O wW 5 ena R W Red White KEY SWITCH DIAGRAM 7122 3016 m Items marked with are X A not provided by Yanmar GLOW PLUG 11V 9 A PER ONE 0002427 119717 77800 PRE HEAT TIME 3 sec YANMAH TNV IDI Service Manual 14 13 WIRING DIAGRAM This Page Intentionally Left Blank 14 14 TNV IDI Service Manual YANMAR
13. series SERVICE MANUAL 2TNV70 3TNV70 3TNV76 P N OBTNVO U0100 INDUSTRIAL ENGINES Disclaimers We reserve the right to change specifications and to improve our products without notice or obligation Yanmar and YANMAR are registered trademarks of Yanmar Co Ltd in Japan the United States and other countries All Rights Reserved No part of this publication may be reproduced or used in any form by any means graphic electronic or mechanical including photocopying recording taping or information storage and retrieval systems without the written permission of Yanmar Co Ltd 2005 Yanmar Co Ltd 1 ii TNV IDI Service Manual YANMAR TABLE OF CONTENTS Page Introduction 1 1 Yanmar 2 1 LE MIU E NEUE MI 3 1 General Service Information 22 22 4 4 2 4 1 Periodic Maintenance nnn nnn nnen n nnen 5 1 6 1 Er dp T 7 1 Cooling System 2222 2 8 1 Lubrication 2124 4 9 1 Starter MOU ore aa oa ME bx MERI RENE 10 1 ripple aie detec eee ate ee ees 11 1 Electric Wiring ETE ee tena ear
14. S 12 1 Di pij deere ee 13 1 YANMAR TNV IDI Service Manual TABLE OF CONTENTS This Page Intentionally Left Blank i TNV IDI Service Manual YANMAR Section 1 INTRODUCTION This manual describes the service procedures for the TNV series indirect injection engines These engines are certified by the U S 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 manufacturer for specific service instructions Yanmar products are continuously undergoing improvement This Service Manual might not address possible field modifications to the equipment Contact an authorized Yanmar industrial engine dealer or distributor for answers to any questions relating to field modifications YANMAR TNV IDI Service Manual 1 1 INTRODUCTION This Page Intentionally Left Blank 1 2 TNV IDI Service Manual YANMAR Section 2 YANMAR WARRANTIES Page Yanmar Limited 2 3 What is Covered by this Warranty 2 3 How Long is the Warranty Period 2 3 What the Engine Owner Must Do
15. sees 7 11 Fuel Injection Lines iuueni terrre 7 12 Removal of High Pressure Fuel Injection Lines 7 12 Installation of High Pressure Fuel Injection Lines 7 12 Removal of Fuel Return Line 4 44444112 7 18 Installation of Fuel Return Line 7 13 Fuel Injection PUMP o ee c S 7 14 Removal of Fuel Injection Pump 7 14 Installation of Fuel Injection Pump 7 17 Checking and Adjusting Fuel Injection Timing 7 20 Checking Fuel Injection Timing 7 20 Adjusting Fuel Injection 420442022 7 23 z l nee e 7 24 Removal of Fuel Injectors 20022 111 7 24 Testing of Fuel Injectors 2 7 25 Disassembly and Inspection of Fuel Injectors 7 28 Adjusting Fuel Injector Pressure 7 29 Reassembly of Fuel Injectors 1 7 30 YANMAR TNV IDI Service Manual 7 1 FUEL SYSTEM 7 2 Installation of the Fuel Injectors TNV IDI Service Manual YANMAR FUEL SYSTEM BEFORE YOU BEGIN SERVICING NG SEVER HAZARD Stop the engine before you begin to service it NEVER leave the key in the key
16. Check the electrical harnesses for cracks abrasions and damaged or corroded connectors ALWAYS keep the connectors and terminals clean Failure to comply could result in death or serious injury 0000009en Note While starter motor design varies between models the basic repair procedures are the same The following procedures are typical and may differ from the starter being serviced Removal of Starter Motor 1 Disconnect the battery cables at the battery negative cable first 2 Remove the electrical wires from the solenoid switch assembly 3 Remove the starter mounting bolts Figure 10 2 1 Remove the starter motor from the flywheel housing YANMAR TNV IDI Service Manual STARTER MOTOR 0002126 Figure 10 2 Disassembly of Starter Motor 1 Make alignment marks across all mating joints 2 Disconnect the field wire from the solenoid switch Figure 10 3 0000138 Figure 10 3 3 Remove the two bolts or nuts retaining the solenoid switch assembly Figure 10 4 1 to the pinion housing Remove the solenoid switch assembly and dust covers Figure 10 4 2 Remove the plunger Figure 10 4 4 and torsion spring Figure 10 4 3 from the pinion housing 10 9 STARTER MOTOR 0000140A Figure 10 4 4 Remove the two bolts Figure 10 5 1 securing the rear cover Figure 10 5 2 to the brush holder assembly Figure 10 5 3 0000142A
17. Engine Starts Exhaust but Stops Color Soon Exhaust Smoke Corrective Action Reference Pages High Knocking Sound During Combustion Difficulty in Returning to Low Speed Engine Does Not Start Ordinary Abnormal Engine Sound During Idling During Work Operation Excessive Engine Vibration Excessive Fuel Consumption Excessive Oil Consumption Dilution by Diesel Fuel Oil with Water Low Oil Pressure Excessive Blow by Gas Overheat Low Water Temperature Pressure Rise Exhaust Temperature Rise Q D c See Clean Air Cleaner Element on page 5 29 Uneven Combustion Sound Clogged Air Filter Clean Air Filter Drop Engine Used at High Temperatures or at Study Output Drop and Load High Altitude Matching Clogged Exhaust Pipe Clean Exhaust Pipe Starting Motor Defect Repair or Replace Stater Motor See Starter Motor on page 10 9 See Removal of Alternator on Alternator Defect Repair or Replace Alternator page 11 12 or Removal of Dynamo on page 11 20 Open Circuit in Wiring Repair Open Circuit Electrical System Air Exhaust Gas System Battery Voltage Drop Inspect and Change the Battery See Check Battery on page 5 24 YANMAR TNV IDI Service Manual T TROUBLESHOOTING This Page Intentionally Left Blank 13 18 TNV IDI Service Manual YANMAR WIRING DIA
18. 0000025en Be environmentally responsible Follow these procedures for hazardous waste disposal Failure to follow these procedures may seriously harm the environment Follow the guidelines of the EPA or other governmental agency for the proper disposal of hazardous materials such as engine oil diesel fuel and engine coolant Consult the local authorities or reclamation facility NEVER dispose of hazardous materials irresponsibly by dumping them into a sewer on the ground or into ground water or waterways 0000013en Drain the fuel filter water separator whenever there are contaminants such as water collected in the bottom of the cup NEVER wait until the scheduled periodic maintenance if contaminants are discovered YANMAR TNV IDI Service Manual PERIODIC MAINTENANCE The cup of the separator is made from semi transparent material In the cup is a red colored float ring The float ring will rise to the surface of the water to show how much needs to be drained Also some optional fuel filter water separators are equipped with a sensor to detect the amount of contaminants This sensor sends a signal to an indicator to alert the operator Drain the fuel filter water separator as follows 8 ff Ti T L Se 6 47 SE 1 7 Figure 5 7 0000590A 1 Position an approved container
19. See Installation of High Pressure Fuel Injection 18 Operate the engine and check for fuel and lube Lines on page 7 13 oil leaks IMPORTANT When installing a new or repaired fuel injection pump add 5 7 oz 150 200 cc of new clean engine oil to the fuel injection pump at the fill plug located in the upper outside section of the governor housing Reinstall the coolant pump V pulley Figure 7 21 4 spacer Figure 7 21 3 if equipped and engine coolant fan Figure 7 21 2 TNV IDI Service Manual YANMAR CHECKING AND ADJUSTING FUEL INJECTION TIMING Note The following procedure is performed on the No 1 cylinder While checking and adjusting the timing on only No 1 cylinder is usually sufficient the same procedure can be performed on any and all cylinders Checking Fuel Injection Timing Note Some fuel may drain from the fuel injection pump during this process Make provisions to contain any such spillage 1 Ensure the fuel injection pump is primed with fuel See Priming The Fuel System on page 4 12 2 Clean the area around the fuel injection pump Note The stop solenoid must be removed to allow fuel to flow through the fuel injection pump 3 Remove two screws Figure 7 22 1 Remove the fuel shutoff solenoid Figure 7 22 2 and O ring Figure 7 22 3 0002468 Figure 7 22 YANMAR TNV IDI Service Manual FUEL SYSTEM Set the throttle to the HIGH IDLE position
20. 0002416 Figure 7 15 20 Remove the three nuts fastening the fuel injection pump to the gear case Remove the fuel injection pump Leave the fuel injection pump drive gear in the gear case and meshed with the idler gear Do not rotate the crankshaft with the injection pump removed 0000083en 2 If the fuel injection pump requires servicing it must be sent to an authorized Yanmar FIE repair facility for repair and calibration or replaced with a new fuel injection pump 7 17 FUEL SYSTEM NEVER remove or attempt to remove the tamper proof devices from the full load fuel adjusting screw or the high speed throttle limit screw on the fuel injection pump and governor assembly These adjustments have been made at the factory to meet all applicable emissions regulations and then sealed NEVER attempt to make any adjustments to these sealed adjustment screws If adjustments are required they can be made only by a qualified fuel injection shop that will ensure the injection pump continues to meet all applicable emissions regulations and then replace the tamper proof seals Tampering with or removing these devices may void the Yanmar Limited Warranty 0000146en 7 18 Installation of Fuel Injection Pump 1 RON Ensure the fuel injection pump drive gear is aligned with the idler gear using the reference marks made earlier 1 0002096 Figure 7 16 If installin
21. Type A 119910 77200 Nominal Output 20 Amps Weight 3 97 lbs 1 8 kg Revolution Direction As Viewed From Pulley Clockwise Rating Continuous Battery Voltage 12 Volts Rated Revolution 3500 rpm Operating Range 1400 6600 rpm Grounding Characteristics Negative Side of Circuit Integrated Regulator IC Regulator A Belt Outside Diameter of Pulley 2 56 in 65 mm Special M Belt 2 28 in 58 mm Belt Shape YANMAR TNV IDI Service Manual Type A or Type Special M 11 7 ALTERNATOR ALTERNATOR TROUBLESHOOTING Jeuuouqe JON epoip joedsu eoe des apis eAneBeu epoip 12edsu 1 0 uonipuoo x99u2 159 uoueq eui oj ejqeoijdde osje si poujow eu 2 GL pue usemjeq si G G epis neq pue usemjeq doup eAisseax3 apis eAnisod 12edsu J9jeo46 eDeyoA Aieyeg a 601 06 010 Jejeunjo Z Aieyeq e esp S JON WIP SI 40jeoipur A yeg ip SI Joyeolpul jeneg joedsu eoejdei 10 joedsu Seusej Jojeoipur
22. 40 BR BR OJO 90 oO RI 100 8 6 6 4 4 4 2 2 MLM N HR KR oO OD PM ALA OD oO oO mM me BR RL 24 Volts 5 _ A A N o r 10 o A o 15 o o 20 o 25 30 40 50 AJ O 60 A AJ oO MM 70 NM AJAJ OoJ o 80 90 oO oO BR RI 12 6 AR AR HR NINININI AJAI oO OJO A AR OJOJ BR OO TNV IDI Service Manual YANMAR Conductor Size AWG Conductor Diameter mm ELECTRIC WIRING CONVERSION OF AWG TO EUROPEAN STANDARDS Conductor Cross sectional Area 25 0 455 0 163 24 0 511 0 205 23 0 573 0 259 22 0 644 0 325 21 0 723 0 412 20 0 812 0 519 19 0 992 0 653 18 1 024 0 823 17 1 15 1 04 16 1 29 1 31 15 1 45 1 65 14 1 63 2 08 13 1
23. 11 8 12 8 MPa See Procedure on page 7 27 120 130 kgf cm Note Fuel injector pressures given are for used parts New injectors 5 hours operation or less will read approximately 72 5 psi 0 5 MPa 5 kgf cm2 higher YANMAR TNV IDI Service Manual FUEL SYSTEM SPECIAL SERVICE TOOLS Note Tools not having Yanmar part numbers must be acquired locally Tool Name Application Illustration Torque Wrench Locally Available For tightening nuts and bolts to the specified torque a 0000840 MEASURING INSTRUMENTS Instrument Name Application Illustration Fuel Injector Tester Locally Available For observing injection spray pattern of fuel injection nozzle and measuring injection pressure Spill Timing Tool Shop Fabricated Used to set fuel injection timing Make from a short piece of the end of a high pressure fuel line a high pressure fuel line nut and a short piece of clear plastic tubing a thin nozzle from an aerosol spray can works well Drill out the end of the fuel line to accept the nozzle Use a small amount of silicone sealant to seal the nozzle into the fuel line 7 8 TNV IDI Service Manual YANMAR This Page Intentionally Left Blank YANMAR TNV IDI Service Manual FUEL SYSTEM 7 9 FUEL SYSTEM FUEL SYSTEM DIAGRAM 9 8 10 12 7 1 1 3 5 S 2 4 11 6 0001058A 1 Diesel Fuel Supply 4 Elect
24. Cooling System Liquid Cooled With Radiator Lubricating System Forced Lubrication With Trochoid Pump Normal Oil Pressure at Rated Engine Speed Normal Oil Pressure at Low Idle Speed 42 64 psi 0 29 0 44 MPa 2 96 4 49 kgf cm 8 5 psi 0 06 MPa 0 6 kgf cm or greater Starting System Electric Starting Starter Motor DC12V 1 5 hp 1 1 KW Alternator DC12V 40A Recommended Battery Capacity 12V 36 Amp Hour 5h rating Dimensions L x W x H 19 09 x 7 17 x 21 06 in 485 x 436 x 535 mm Engine Oil Pan Capacity 3 6 1 9 qt 3 4 1 8 L Dipstick Upper Limit Lower Limit Engine Coolant Capacity 0 2 gal 0 9 L Engine Only Standard Cooling Fan Engine Specifications Without Radiator Engine oil capacity for a Deep Standard oil pan Refer to the operation manual provided by the 4 22 13 19 in 335 mm O D 6 Blades Pusher Type driven machine manufacturer for the actual engine oil capacity of your machine May vary depending on application TNV IDI Service Manual YANMAR ENGINE SERVICE INFORMATION Inspection Item GENERAL SERVICE INFORMATION Standard Intake Exhaust Valve Gap 0 006 0 010 in 0 15 0 25 mm Fuel Injection Timing See Checking and Adjusting Fuel Injection Timing on page 7 21 Fuel Injection Pressure 1711 1842 psi 11 8 12 8 MPa 120 130 kgf cm 2TNV70 3TNV70
25. FIRE AND EXPLOSION HAZARD Diesel fuel is extremely flammable and explosive under certain conditions Place an approved container under the air bleed port when you prime the fuel system Never use a shop rag to catch the fuel Wipe up any spills immediately ALWAYS close the air bleed port after you complete priming the system Wear eye protection The fuel system is under pressure and fuel could spray out when you open the air bleed port If the unit has an electric fuel pump turn the key switch to the ON position for 10 to 15 seconds or until the fuel coming out of the air bleed port is free of bubbles to allow the electric fuel pump to prime the system If the unit has a mechanical fuel pump operate the fuel priming pump several times until the fuel coming out of the air bleed port is free of bubbles Failure to comply will result in death or serious injury 0000006en SAFETY DANGER EXPLOSION HAZARD NEVER check the remaining battery charge by shorting out the terminals This will result in a spark and may cause an explosion or fire Use a hydrometer to check the remaining battery charge If the electrolyte is frozen slowly warm the battery before you recharge it Failure to comply will result in death or serious injury 0000007en 3 8 NG SEVER HAZARD Keep hands and other body parts away from moving rotating parts such as the cooling fan flywhe
26. S ola 522 2 2 E 2 2 5 5 8 8 5 13 4 5 2 2 5 gt lt 8 52 81 9 p sg 5 2 5 25 5 85 5 91 g Cause 2 5 2 lt 5 25 Excessive Radiator Cooling Replace Thermostat e E 2 See Disassembly of Engine g Insufficient Radiator Cooling O Replace Thermostat or Check for Coolant Pump on page 8 7 Or Loose Fan Belt Check and Adjust Cooling Fan V z belt on page 5 21 S Insufficient Engine Coolant Level O Check Water Leakage from Engine See Engine Coolant System 8 Coolant System Check on page 8 7 Cracked Water Jacket Repair or Replace 2 7 2 D A Stretched Fan Belt O Adjust the Belt Tension 2 EAE fooling Defective Thermostat Check or Replace 2 22 2 Incorrect Engine ojo ojo Use Correct Engine Oil e OI Speciticatane Engine Oil System Leakage O O Repair of Oil Pump on 5 Insufficient Delivery C i Ss 7 5 y Capacity of See Disassembly of Oil Pump on Trochoid Pump Check and Repair page 9 9 5 m See Replace Engine Oil and Clogged Engine Oil Filter 5 gg g Clean Replace Engine Oil Filter on page 5 27 5 Defective Pressure Regulating Valve Clean Adjust or Replace oo of Oil Pump on Insuffi
27. 1 Cylinder No 1 If there is no valve clearance and the piston is at TDC of the compression stroke extreme wear or damage to the cylinder head or valves may be possible If adjusting each cylinder individually the cylinder to be adjusted first does not have to be the No 1 cylinder Select and adjust the cylinder where the piston is nearest to the top dead center after turning Adjust the remaining cylinders in the order of firing by turning the crankshaft each time To decrease the number of rotations required to check all cylinders of a 3 cylinder engine other cylinders can also be checked as indicated in the chart below 2 cylinder engines must have each cylinder adjusted when the piston is at TDC Example On a 3 cylinder engine with the No 1 piston at TDC on the compression stroke both valves closed the valves indicated on the top line of the chart can be adjusted without rotating the crankshaft To adjust the remaining two valves rotate the crankshaft until the No 1 piston is at TDC on the exhaust stroke exhaust valve only open 2 3 Valve Intake Exhaust Intake Exhaust Intake Exhaust No 1 Cylinder at TDC Compression No 1 Cylinder at TDC Exhaust Remove the intake manifold valve cover See Removal of Intake Manifold Valve Cover on page 6 22 Rotate the crankshaft clockwise as seen from the coolant pump end to bring No 1 piston to TDC of the compression stroke whi
28. 6 36 Crankshaft amp Camshaft 6 36 Disassembly of Cylinder Block Components 6 37 Disassembly of Camshaft and Timing Components 6 38 Disassembly of Crankshaft and Piston Components 6 42 Inspection of Crankshaft and Camshaft Components 6 46 Reconditioning the Crankshaft 6 51 Honing ate 6 52 Reassembly of Crankshaft and Piston Components 6 53 Reassembly of Camshaft and Timing Components 6 59 62 ENGINE BEFORE YOU BEGIN SERVICING To prevent possible eye injury always wear SAFETY GLASSES while servicing the engine 0000013en _ NG SEVER HAZARD Stop the engine before you begin to service it NEVER leave the key in the key switch when you are servicing the engine Someone may accidentally start the engine and not realize you are servicing it This could result in a serious injury If you must service the engine while it is operating remove all jewelry tie back long hair and keep your hands other body parts and clothing away from moving rotating parts Failure to comply could result in death or serious injury 0000010en FUME BURN HAZARD Always read and follow safety related precautio
29. ntake Manifold Turbocharger Systems Exhaust Manifold Positive Crankcase Ventilation System Hoses belts connectors and assemblies associated with emission control systems Since emissions related parts may vary slightly between models certain models may not contain all of these parts and other models may contain the functional equivalents YANMAR TNV IDI Service Manual 2 7 YANMAR WARRANTIES Limited Emission Control System Warranty USA Only Continued Exclusions Failures other than those arising from defects in material and or workmanship are not covered by this warranty The warranty does not extend to the following malfunctions caused by abuse misuse improper adjustment modification alteration tampering disconnection improper or inadequate maintenance or use of non recommended fuels and lubricating oils accident caused damage and replacement of expendable items made in connection with scheduled maintenance Yanmar disclaims any responsibility for incidental or consequential damages such as loss of time inconvenience loss of use of equipment engine or commercial loss Owner s Warranty Responsibilities As the engine owner you are responsible for the performance of the required maintenance listed in your owner s manual Yanmar recommends that you retain all documentation including receipts covering maintenance on your non road compression ignition engine but Yanmar cannot deny warranty solely for th
30. 0000059en SAFETY NEVER attempt to modify the engine s design or safety features such as defeating the engine speed limit control or the diesel fuel injection quantity control Modifications may impair the engine s safety and performance characteristics and shorten the engine s life Any alterations to this engine may void its warranty Be sure to use Yanmar genuine replacement parts 0000079en It is important to perform daily checks Periodic maintenance prevents unexpected downtime reduces the number of accidents due to poor machine performance and helps extend the life of the engine 0000060en YANMAR TNV IDI Service Manual Identify all parts and their location using an appropriate method It is important that all parts are returned to the same position during the reassembly process 0000080en Do not rotate the crankshaft with the injection pump removed 0000083en Keep the piston pin parts piston assemblies and connecting rod assemblies together to be returned to the same position during the reassembly process Label the parts using an appropriate method 0000088en SAFETY Do not allow the honing tool to operate in one position for any length of time Damage to the cylinder wall will occur Keep the tool in constant up and down motion 0000090en Any part which is found defective as a result of inspection or any part whose measured val
31. 0000120 Figure 10 19 Measure Brush Length Measure the length of the brush Replace the brush if the length is less than the limit 0000121 Figure 10 20 See Starter Motor Specifications on page 10 6 for the service limit 10 14 Brush Holder Brush Holder Insulation Test Check for continuity between each brush holder and the base using a multimeter The multimeter should not indicate continuity If the multimeter indicates continuity replace the brush holder 0000122 Figure 10 21 Brush Spring Test Test the spring force for each brush spring Replace the brush spring if the force is not within the range Uy 0000123 Figure 10 22 See Starter Motor Specifications on page 10 6 for the service limit TNV IDI Service Manual YANMAR Solenoid Switch If the starter motor becomes wet replace the solenoid switch even if the solenoid switch assembly function is normal Shunt Coil Continuity Test Check for continuity between the S terminal and the switch body using a multimeter The multimeter should indicate continuity If the multimeter does not indicate continuity replace the solenoid switch 0000124 Figure 10 23 Series Coil Continuity Test Check for continuity between the S and M terminals using a multimeter The multimeter should indicate continuity If the multimeter does not indicate continuity replace the solenoid switch YANMAR TNV IDI Service Manual ST
32. 3TNV70 Version VM Type Vertical Inline Diesel Engine Combustion System Ball Type Swirl Chamber Aspiration Natural No of Cylinders 3 Bore x Stroke 2 756 x 2 913 in 70 x 74 mm Displacement 52 105 cu in 0 854 L Continuous Rated Output Max Rated Output Net High Idling 2570 x25 2780 25 2995 25 Engine Weight Dry With Flywheel Housing 183 0 Ib 83 kg Firing Order 1 3 2 1 No 1 Cylinder on Flywheel Side Fuel Injection Timing See Checking and Adjusting Fuel Injection Timing on page 7 21 PTO Position Flywheel Side Direction of Rotation Counterclockwise Viewed From Flywheel Side Cooling System Liquid Cooled With Radiator Lubricating System Forced Lubrication With Trochoid Pump Normal Oil Pressure at Rated Engine Speed 42 64 psi 0 29 0 44 MPa 2 96 4 49 kgf cm Normal Oil Pressure at Low Idle Speed 8 5 psi 0 06 MPa 0 6 kgf cm or greater Starting System Electric Starting Starter Motor DC12V 1 3 hp 1 0 KW Alternator DC12V 18A Recommended Battery Capacity 12V 52 Amp Hour 5h rating Dimensions L x W x H 504 x 19 84 x 16 81 x 19 92 in 19 84 x 16 81 x 21 10in 504 x 427 x 536 mm 19 84 x 16 81 x 19 92 In 427 x 506 mm 504 x 427 x 506 Engine
33. A DANGER 7 fj FIRE AND EXPLOSION HAZARD Diesel fuel is extremely flammable and explosive under certain conditions Only fill the fuel tank with diesel fuel Filling the fuel tank with gasoline may result in a fire and will damage the engine NEVER refuel with the engine running Wipe up all spills immediately Keep sparks open flames or any other form of ignition match cigarette static electric source away when fueling refueling NEVER overfill the fuel tank Fill the fuel tank Store any containers containing fuel in a well ventilated area away from any combustibles or sources of ignition Failure to comply will result in death or serious injury 0000005en TNV IDI Service Manual YANMAR DANGER Diesel fuel is extremely flammable and explosive under certain conditions Be sure to place the diesel fuel container on the ground when transferring the diesel fuel from the pump to the container Hold the hose nozzle firmly against the side of the container while filling it This prevents static electricity buildup which could cause sparks and ignite fuel vapors NEVER place diesel fuel or other flammable material such as oil hay or dried grass close to the engine during engine operation or shortly after shut down Failure to comply will result in death or serious injury 0000014en FIRE AND EXPLOSION HAZARD YANMAR TNV IDI Service Manual
34. Although atomized burner like shape the needle does not pulsate Bar shape with excessive after drops Drops Possible Cause Normal injector is good Normally caused by carbon contamination of the nozzle tip Sometimes caused by flaws in or damage to the needle tip 1 Caused by excessive carbon contamination of the nozzle tip Sometimes caused by internal contamination Figure 7 33 If the fuel injector fails any tests it should be serviced or replaced as necessary If the pressure is outside specified limits adjust the pressure See Adjusting Fuel Injector Pressure on page 7 29 YANMAR TNV IDI Service Manual 1 Damage to the seat 2 Contamination of seat by fine foreign particles 3 Excessively worn seat Sticking of needle Excessively damaged or worn seat Contamination of seat by foreign matter Damaged or broken internal parts or nozzle case nut 7 27 FUEL SYSTEM Disassembly and Inspection of Fuel Injectors Never use a steel wire brush to clean fuel injectors Damage to the nozzle and other components is likely to result 1 Clean carbon from used injectors using clean diesel fuel Hardened deposits or varnish can be cleaned using a brass wire brush gt ta E 1 Return Fuel Fitting Nut 2 Return Fuel Fitting 3 Injector Body 4 Pressure Adjusting Shims 5 Spring 6 Spring Seat 7 V
35. GENERAL SERVICE INFORMATION DANGER 7 fj FIRE AND EXPLOSION HAZARD Diesel fuel is extremely flammable and explosive under certain conditions Before you operate the engine check for fuel leaks Replace rubberized fuel hoses every two years or every 2000 hours of engine operation whichever comes first even if the engine has been out of service Rubberized fuel lines tend to dry out and become brittle after two years or 2000 hours of engine operation whichever comes first Failure to comply will result in death or serious injury 0000015en Only use diesel fuels recommended by Yanmar for the best engine performance to prevent engine damage and to comply with EPA ARB warranty requirements Only use clean diesel fuel NEVER remove the primary strainer if equipped from the fuel tank filler port If removed dirt and debris could get into the fuel system causing it to clog 0000004en GENERAL SERVICE INFORMATION Note that a typical fuel tank is shown The fuel tank on the equipment being serviced may be different 1 Clean the area around the fuel cap Figure 4 3 1 2 Remove the fuel cap Figure 4 3 1 from the fuel tank Figure 4 3 2 3 Observe the fuel level sight gauge Figure 4 3 3 and stop fueling when gauge shows fuel tank is full NEVER overfill the fuel tank 4 Replace the fuel cap Figure 4 3 1 and hand tighten Over tighteni
36. PERIODIC MAINTENANCE CAUTION CE Be environmentally responsible Follow these procedures for hazardous waste disposal Failure to follow these procedures may seriously harm the environment Follow the guidelines of the EPA or other governmental agency for the proper disposal of hazardous materials such as engine oil diesel fuel and engine coolant Consult the local authorities or reclamation facility NEVER dispose of hazardous materials irresponsibly by dumping them into a sewer on the ground or into ground water or waterways 0000013en Replace the fuel filter at specified intervals to prevent contaminants from adversely affecting the diesel fuel flow 1 Stop the engine and allow it to cool 2 Close the fuel cock of the fuel filter water separator 5 31 PERIODIC MAINTENANCE 3 Turn the retaining ring Figure 5 14 1 to the left Figure 5 14 2 Carefully remove the cup Figure 5 14 3 and pour the fuel into an approved container and dispose properly Hold the bottom of the cup with a shop towel to prevent the fuel from dripping Wipe up any spills immediately Remove the element Figure 5 14 4 by pulling it down Replace the element with a new one gt D Applicable Fuel Filter Part No 2TNV70 3TNV70 3TNV76 119810 55650 N Wash the inside of the cup with clean fuel Check the condition of the cup O ring Figure 5 14 6
37. Replace if necessary 9 Reinstall the cup to the mounting flange and turn the retaining ring Figure 5 14 1 to the right Figure 5 14 5 Hand tighten only 10 Open the fuel cock of the fuel filter water separator 0000589 Figure 5 14 11 Prime the fuel system See Priming The Fuel System on page 4 12 12 Check for fuel leaks 5 32 Clean Fuel Filter Water Separator A DANGER 4 K FIRE AND EXPLOSION HAZARD Diesel fuel is extremely flammable and explosive under certain conditions NEVER use diesel fuel as a cleaning agent Failure to comply will result in death or serious injury 0000012en A DANGER UA n FIRE AND EXPLOSION HAZARD Diesel fuel is extremely flammable and explosive under certain conditions When you remove any fuel system component to perform maintenance such as changing the fuel filter place an approved container under the opening to catch the fuel NEVER use a shop rag to catch the fuel Vapors from the rag are extremely flammable and explosive Wipe up any spills immediately Wear eye protection The fuel system is under pressure and fuel could spray out when you remove any fuel system component Failure to comply will result in death or serious injury 0000009en TNV IDI Service Manual YANMAR e Be environmentally
38. When the crankcase pressure reaches a predetermined value the diaphragm opens a passage that allows crankcase fumes to be routed to the intake manifold 0002135 Figure 5 18 To inspect the diaphragm and spring Figure 5 18 3 1 Remove the bolts retaining the diaphragm cover Figure 5 18 4 2 Remove the diaphragm cover spring diaphragm plate Figure 5 18 5 and diaphragm YANMAR TNV IDI Service Manual PERIODIC MAINTENANCE 3 Inspect the diaphragm for tears Inspect the spring for distortion Replace components if necessary 4 Reinstall the diaphragm diaphragm plate spring and diaphragm cover Tighten the diaphragm bolts to the specified torque Failure of the diaphragm and or spring will cause the loss of pressure control and allow an excessive amount of crankcase fumes to be routed to the intake manifold This could result in excessive deposits in the intake system high engine exhaust smoke levels excessive engine oil consumption and or engine run on due to the burning of the engine oil 5 37 PERIODIC MAINTENANCE Every 2000 Hours of Operation Perform the following maintenance every 2000 hours of operation Check and Replace Fuel Hoses and Engine Coolant Hoses Lap the Intake and Exhaust Valves Check and Replace Fuel Hoses and Engine Coolant Hoses CAUTION ao Be environmentally responsible Follow these procedures for hazardous waste disposal
39. load fuel adjusting screw or the high speed throttle limit screw on the fuel injection pump and governor assembly These adjustments have been made at the factory to meet all applicable emissions regulations and then sealed NEVER attempt to make any adjustments to these sealed adjustment screws If adjustments are required they can be made only by a qualified fuel injection shop that will ensure the injection pump continues to meet all applicable emissions regulations and then replace the tamper proof seals Tampering with or removing these devices may void the Yanmar Limited Warranty 0000146en Never use a steel wire brush to clean fuel injectors Damage to the nozzle and other components is likely to result 0000172en Do not loosen or remove the four bolts retaining the fuel injection pump drive gear to the fuel injection pump hub Do not disassemble the fuel injection pump drive gear from the hub Correct fuel injection timing will be very difficult or impossible to achieve 0000031en Remove or install the high pressure fuel injection lines as an assembly whenever possible Disassembling the high pressure fuel injection lines from the retainers or bending any of the fuel lines will make it difficult to reinstall the fuel lines 0000047en After marking the position of the pump drive gear do not rotate the engine crankshaft Rotating the crankshaft will cause the fuel
40. 1 Plug the open ends of the lines to minimize leakage and prevent contamination YANMAR TNV IDI Service Manual FUEL SYSTEM 0002210 Figure 7 8 Remove the fuel supply line Figure 7 8 2 from the fitting on the fuel injection pump Plug or cap all openings to minimize leakage and prevent contamination Remove the throttle cable from the fuel injection pump Separate the stop solenoid wiring connector Figure 7 8 3 Remove the lube oil line Figure 7 9 1 from the fuel injection pump and cylinder block IMPORTANT Take care to not damage or bend the lube oil line 0002239 Figure 7 9 7 15 FUEL SYSTEM 13 Remove the fuel injection pump cover Figure 7 10 1 from the gear case cover Figure 7 10 2 Note The fuel injection pump cover is secured with an adhesive sealant Use a gasket scraper to separate the fuel injection pump cover from the gear case cover 0002211 Figure 7 10 14 To aid in reassembly make reference marks Figure 7 11 1 on the fuel injection pump drive gear and idler gear After marking the position of the pump drive gear do not rotate the engine crankshaft Rotating the crankshaft will cause the fuel injection pump to become misaligned 0000048en 1 0002096 Figure 7 11 7 16 Do not loosen or remove the four bolts retaining the fuel injection pump drive gear to the fuel injection pump hub Do not disassemble the fuel inj
41. 5 Using a wrench on the crankshaft pulley bolt rotate the crankshaft in a clockwise direction while looking through the flywheel inspection port Figure 7 23 1 Rotate the crankshaft until the injection timing marks on the flywheel are visible for No 1 cylinder gt A A Figure 7 23 6 Typical flywheel markings are as shown in Figure 7 24 1 Note A typical flywheel will have multiple timing grids depending on the number of cylinders Any grid and its corresponding cylinder can be used to check the fuel injection timing 7 21 FUEL SYSTEM de 4 N a 0002071 15 BTDC Before Top Dead Center 20 BTDC 25 BTDC Direction of Rotation TDC Top Dead Center Figure 7 24 Note The TDC Top Dead Center mark can be identified by having a cylinder number stamped near the TDC line Figure 7 25 1 7 Highlight the timing reference mark on the flywheel housing Figure 7 25 2 or engine back plate Figure 7 26 2 Highlight the TDC Top Dead Center mark Figure 7 25 1 Figure 7 26 1 on the flywheel 1 ak Ore II 0002065 Figure 7 25 7 22 2 1 0002142 Figure 7 26 8 Highlight the target timing mark Figure 7 27 1 Figure 7 26 1 on the flywheel timing grid as determined in the Injection Timing Chart Figure 7 28 on page 7 23
42. Bushing Inside Diameter 1 4567 1 4577 in 37 000 37 025 mm 1 4596 in 37 075 mm Oil Clearance Timing Gear Backlash Inspection Item 0 0010 0 0030 in 0 025 0 075 mm Standard 0 0069 in 0 175 mm Limit See Inspection of Idler Gear and Shaft on page 6 52 Reference Page Crank Gear Cam Gear Idler Gear Fuel Injection Pump Gear and PTO Gear CRANKSHAFT AND PISTONS SPECIFICATIONS Crankshaft Inspection Item 0 0024 0 0047 in 0 06 0 12 mm Standard 0 0055 in 0 14 mm Limit See Checking Timing Gear Backlash on page 6 38 Reference Page Bend 1 2 the dial gauge reading 0 0008 in 0 02 mm Roundness 0 0004 in 0 01 mm or less 0 0008 in 0 02 mm Journal Outside Diameter 1 6517 1 6520 in 41 952 41 962 mm 1 6497 in 42 902 mm Bearing Inside Diameter 1 6528 1 6536 in 41 982 42 002 mm Connecting Rod Journals Bearing Insert Thickness 0 0592 0 0594 in 1 503 1 509 mm Oil Clearance 0 0008 0 0020 in 0 020 0 050 mm 0 0043 in 0 110 mm See Inspection of Crankshaft on page 6 50 ENGINE Crankshaft Cont Inspection Item Standard Limit Reference Page Main Bearing Journal Journal Outside Diameter 1 8485 1 8489 in 46 952 46 962 mm 1 8465 in 46 902 mm Bearing Inside Diameter 1 8497
43. Carefully clean the radiator cap and the surrounding area before you remove the cap NEVER mix different types of engine coolants This may adversely affect the properties of the engine coolant 0000006en 8 12 TNV IDI Service Manual YANMAR Section 9 LUBRICATION SYSTEM Page Before You Begin 2 2 010 1 9 3 9 5 Pump Service 4 9 5 Lubrication System 9 7 Checking Engine 444040111 9 8 9 8 Pump Components 9 8 Disassembly of PUMP 9 9 Cleaning and 9 10 Reassembly of Oil Pump eese 9 11 YANMAR TNV IDI Service Manual 9 1 LUBRICATION SYSTEM This Page Intentionally Left Blank 9 2 TNV IDI Service Manual YANMAR LUBRICATION SYSTEM BEFORE YOU BEGIN SERVICING vtt NEVER permit anyone to operate the engine or driven machine without proper training Read and understand this Operation Manual before you operate or service the machine to ensure that you follow safe operating practices and maintenance procedures Machine safety signs and labels are addition
44. Continued Warranty Coverage This warranty is transferable to each subsequent purchaser for the duration of the warranty period Repair or replacement of any warranted part will be performed at an authorized Yanmar industrail engine dealer or distributor Warranted parts not scheduled for replacement as required maintenance in the Operation Manual shall be warranted for the warranty period Warranted parts scheduled for replacement as required maintenance in the operation manual are warranted for the period of time prior to the first scheduled replacement Any part repaired or replaced under warranty shall be warranted for the remaining warranty period During the warranty period Yanmar is liable for damages to other engine components caused by the failure of any warranted part during the warranty period Any replacement part which is functionally identical to the original equipment part in all respects may be used in the maintenance or repair of your engine and shall not reduce Yanmar s warranty obligations Add on or modified parts that are not exempted may not be used The use of any non exempted add on or modified parts shall be grounds for disallowing a warranty Warranted Parts This warranty covers engine components that are a part of the emission control system of the engine as delivered by Yanmar to the original retail purchaser Such components may include the following Fuel Injection System Cold Start Enrichment System
45. EPA ARB Emission Control Regulations USA Only 4 4 Emission Control 4 4 BPA yb IM 4 5 The 97 68 EC Directive Certified 4 5 Engine Family ME 4 5 Function of Major Engine Components 4 6 Function of Cooling System Components 4 8 Diesel Fuel qw c PUT 4 9 Diesel Fuel Specifications 01000011 4 9 Filling the Fuel Tank eterne tmt 4 10 Priming The Fuel System 4 12 e CM LT X m 4 13 Engine Oil Specifications 4 13 Engine Oil Viscosily a se terere OR eR pon RR HER 4 14 Checking Engine 4 14 Adding Engine c 4 14 Engine Oil Capacity 4 15 Engine COON AIT P P a 4 16 Engine Coolant 2 2 2 4 16 Filling Radiator With Engine 4 18 Engine Coolant Capacity 4 18 T 4 19 Description of Model 4 19 Engine Speed
46. Figure 10 28 0000128 Figure 10 27 10 16 TNV IDI Service Manual YANMAR 3 Reinstall the pinion clutch assembly Figure 10 29 2 return spring if equipped and pinion stop Figure 10 29 3 onto the pinion shaft Figure 10 29 1 Reinstall the retaining ring Figure 10 29 4 in the groove in the pinion shaft Slide the pinion stop over the retaining ring 2 0000152B Figure 10 29 Apply a light coat of NFC F6A grease to the contact surfaces of the shift lever Reassemble the shift lever Figure 10 30 2 spacer if equipped Figure 10 30 1 and pin Reinstall the pinion shaft assembly Figure 10 30 4 in the pinion housing Figure 10 30 3 Be sure the shift lever properly engages the pinion 1 2 4 0000148 Figure 10 30 YANMAR TNV IDI Service Manual STARTER MOTOR Apply a light coat of NFC F6A grease to the surface of the plunger and the hole that engages the shift lever Attach the plunger to the shift lever Reinstall the plate onto the intermediate housing and carefully reinstall the armature assembly Figure 10 31 2 into the pinion shaft assembly 0000144A Figure 10 31 9 Reinstall the field assembly Figure 10 31 3 over the armature assembly and align to the pinion housing 10 Position the brush springs in brush holders Reinstall the brushes in the brush holders Reversing the brushes will cause the start
47. Figure 6 101 1 Be sure to circle each bolt hole If equipped reinstall the crankcase extension Figure 6 101 2 Reinstall the oil pan and tighten the bolts securely 0002184 Figure 6 101 ENGINE Final Assembly of Engine 1 2 Reinstall the starter motor Reinstall the cylinder head See Heassembly of Cylinder Head on page 6 31 Reinstall the engine in the machine Reconnect the fuel and coolant lines Reinstall the alternator Reconnect and adjust the throttle cable Reconnect all electrical connections Fill the engine with oil and coolant Reconnect the battery cables negative cable last ENGINE Section 7 FUEL SYSTEM Page Before You Begin Servicing sess 7 2 7 5 Fuel Injection PUMP Sep 7 5 Stop Solenoid EKEk 7 6 Fuel System Specifications 2 7 7 Special Torque Chart eser rente Ren hnius 7 7 Test and Adjustment Specifications 7 7 Special Service TOMS errori repertae rix een 7 8 Measuring Instruments tence sss eeede iex ke enun nauis 7 8 Fuel System Diagram sccicestvccsvaicnieniebenocestdacestuiuetoreestenesnetteteorsanaenss 7 10 Fuel System Components
48. Ns E Uo D A A Applicable Engine Oil Filter Part No 2TNV70 3TNV70 119305 35150 0000587B 3TNV76 Figure 5 1 6 Remove the oil drain plug Figure 5 2 1 Allow oil to drain 7 After all oil has been drained from the engine reinstall the oil drain plug Figure 5 2 1 and tighten to 14 17 ft lbs 19 6 23 5 N m 2 0 2 4 kgf m 8 Dispose of used oil properly 5 20 TNV IDI Service Manual YANMAR 4 Addnew engine oil to the engine as specified in Adding Engine Oil on page 4 14 0000587C Figure 5 3 Check and Adjust Cooling Fan V belt The V belt will slip if it does not have the proper tension This will prevent the alternator from generating sufficient power Also the engine will overheat due to the engine coolant pump pulley slipping Check and adjust the V belt tension deflection as follows 1 Press the V belt down with your thumb with a force of approximately 22 ft lbs 98 N m 10 kgf m to check the deflection There are three positions to check for V belt tension Figure 5 4 A B and C You can check the tension at whichever position is the most accessible The proper deflection of a used V belt at each position is YANMAR TNV IDI Service Manual PERIODIC MAINTENANCE Used V belt Tension A B 3 8 1 2 1 4 3 8 in 5 16 1 2 in 10 14 mm 7 10 mm 9 13 mm 0000652B Figure 5 4 If necessary adjust the V belt te
49. cleaners primers sealants and sealant removers Check the electrical harnesses for cracks abrasions and damaged or corroded connectors ALWAYS keep the connectors and terminals clean 0000009en Failure to comply could result in death or serious injury 0000010en Failure to comply could result in death or serious injury 0000014en YANMAR TNV IDI Service Manual 10 3 STARTER MOTOR FLYING OBJECT HAZARD ALWAYS wear eye protection when servicing the engine and when using compressed air or high pressure water Dust flying debris compressed air pressurized water or steam may injure your eyes Failure to comply may result in minor or moderate injury 0000003en The starter motor can be damaged if operated continuously longer than 10 seconds while performing the no load test 0000034en Make sure that the combined total resistance of the battery cable in both directions between the starter motor and the battery is within the value indicated on the wiring diagram The starter motor will malfunction or break down if the resistance is higher than the specified value 0000054en The starter motor is water proofed according to JIS D 0203 R2 which protects the motor from rain or general cleaning Do not use high pressure wash or submerse the starter motor in water 0000055en Use a specialized battery charger to recharge a
50. contact with the eyes or skin should occur flush eyes and wash immediately with clean water Failure to comply may result in minor or moderate injury 0000005en Only use the engine coolant specified Other engine coolants may affect warranty coverage cause an internal buildup of rust and scale and or shorten engine life Prevent dirt and debris from contaminating the engine coolant Carefully clean the radiator cap and the surrounding area before you remove the cap NEVER mix different types of engine coolants This may adversely affect the properties of the engine coolant 0000006en Engine Coolant Specifications Use a Long Life Coolant LLC or an Extended Life Coolant ELC that meets or exceeds the following guidelines and specifications 4 15 GENERAL SERVICE INFORMATION Alternative Engine Coolant If an Extended or Long Life Coolant is not available alternatively you may use an ethylene glycol or propylene glycol based conventional coolant green Notes 1 ALWAYS use a mix of coolant and water NEVER use water only 2 Mix coolant and water per the mixing instructions on the coolant container 3 Water quality is important to coolant performance Yanmar recommends that soft distilled or demineralized water be used to mix with coolants 4 NEVER mix extended or long life coolants and conventional green coolants 5 NEVER mix different types and or colors of
51. mgKOH g test method JIS K 201 5 2 2 ASTM D4739 Engine Oil Viscosity Select the appropriate engine oil viscosity based on the ambient temperature and use the SAE Service Grade Viscosity Chart in Figure 4 5 lt SAE 10W gt 20W gt 1 i 4 SAE 30 14 F 32 F 50 F 68 F 86F 104 F 20 C 10 C 0 C 10 C 20 C 30 C 40 0000005 Figure 4 5 Checking Engine Oil 1 Make sure engine is level 2 Remove dipstick Figure 4 6 1 and wipe with clean cloth 3 Fully reinsert dipstick 4 Remove dipstick The oil level should be between upper Figure 4 6 2 and lower Figure 4 6 3 lines on the dipstick 5 Fully reinsert dipstick 4 13 GENERAL SERVICE INFORMATION 0000587C Figure 4 6 Adding Engine Oil Make sure engine is level 2 Remove oil cap Figure 4 6 4 3 Add indicated amount of engine oil at the top or side engine oil filler port Figure 4 6 5 4 Wait three minutes and check oil level 5 Add more oil if necessary 6 Replace oil cap Figure 4 6 4 and hand tighten Over tightening may damage the cap 4 14 Engine Oil Capacity Typical Note These are the engine oil capacities associated with a Deep Standard oil pan Oil capacity will vary dependant upon which optional oil pan is used Refer to the operation manual provided by the driven machine manufacturer for the actual engine oil capa
52. nozzle firmly against the side of the container while filling it This prevents static electricity buildup which could cause sparks and ignite fuel vapors NEVER place diesel fuel or other flammable material such as oil hay or dried grass close to the engine during engine operation or shortly after shut down Failure to comply will result in death or serious injury 0000014en 3 6 TNV IDI Service Manual YANMAR A DANGER CRUSH HAZARD When you need to transport engine for repair have a helper assist you to attach it to a hoist and load it on a truck NEVER stand under a hoisted engine If the hoist mechanism fails the engine will fall on you causing serious injury or death Failure to comply will result in death or serious injury 0000008en A DANGER OL Diesel fuel is extremely flammable and explosive under certain conditions Before you operate the engine check for fuel leaks Replace rubberized fuel hoses every two years or every 2000 hours of engine operation whichever comes first even if the engine has been out of service Rubberized fuel lines tend to dry out and become brittle after two years or 2000 hours of engine operation whichever comes first Failure to comply will result in death or serious injury 0000015en FIRE AND EXPLOSION HAZARD YANMAR TNV IDI Service Manual SAFETY DANGER 7 j
53. 0098 in 0 25 mm See Removal of Camshaft on page 6 41 Bend 1 2 the dial gauge reading 0 0 0008 in 0 0 02 mm 0 0020 in 0 05 mm Cam Lobe Height 1 3439 1 3490 in 34 135 34 265 mm 1 3343 in 33 89 mm Bushing Inside Diameter 1 5748 1 5778 in 40 000 40 075 mm 1 5807 in 40 150 mm Gear End Camshaft Outside Diameter 1 5724 1 5732 in 39 940 39 960 mm 1 5711 in 39 905 mm Oil Clearance 0 0016 0 0053 in 0 040 0 135 mm 0 0096 in 0 245 mm Bushing Inside Diameter Shaft Outside 1 5748 1 5758 in 40 000 40 025 mm 1 5787 in 40 100 mm Diameter Bearing Inside Camshaft Outside Diameter Intermediate 1 5713 1 5722 in 39 910 39 935 mm 1 5699 in 39 875 mm Diameter Cil Clearance 0 0026 0 0045 in 0 065 0 115 mm 0 0089 in 0 225 mm Bushing Inside Diameter 1 5748 1 5758 in 40 000 40 025 mm 1 5787 in 40 100 mm Flywheel End Camshaft Outside Diameter 1 5724 1 5732 in 39 940 39 960 mm 1 5711 in 39 905 mm Oil Clearance 6 8 0 0016 0 0033 in 0 040 0 085 mm 0 0077 in 0 195 mm See Inspection of Camshaft on page 6 51 YANMAR Idler Gear Shaft and Bushing Inspection Item Standard Limit ENGINE Reference Page Shaft Outside Diameter 1 4547 1 4557 in 36 950 36 975 mm 1 4528 in 36 900 mm
54. 129423 77200 alternator is used in this section to show the service procedures for the representative alternator Yanmar Part No 171301 77201 dynamo is used in this section to show the service procedures for the representative dynamo For specific part detail see the Parts Catalog for the engine you are working on STANDARD AND OPTIONAL DYNAMO INFORMATION YANMAR Part Number Mfg Mfg Part Number Specification 171301 77201 Kokusan GP8138 DC12V 15A 119910 77200 Kokusan GP9191 DC12V 20A STANDARD AND OPTIONAL ALTERNATOR INFORMATION YANMAR Part Number Mfg Mfg Part Number Specification 119620 77201 Denso 100211 4531 DC12V 40A 129423 77200 Denso 101211 1170 DC12V 40A with Pulse 129961 77200 Denso 101211 2591 DC12V 55A 119626 77210 Denso 101211 2951 DC12V 55A with Pulse TNV IDI Service Manual YANMAR ALTERNATOR SPECIFICATIONS Yanmar Part Number ALTERNATOR 129423 77200 Nominal Output 13 5 Volts Heat 40 Amps Weight 6 17 lbs 2 8 kg Revolution Direction As Viewed From Pulley Clockwise Rating Continuous Battery Voltage 12 Volts Rated Revolution 5000 rpm Operating Range 1350 18000 rpm Grounding Characteristics Negative Side of Circuit Integrated Regulator IC Regulator Outside Diameter of Pulley 2 724 in 69 2 mm Belt Shape DYNAMO SPECIFICATIONS Yanmar Part Number
55. 23kPa 635mm Aq or less Clean or replace the air cleaner element if the air intake restriction exceeds the above mentioned value YANMAR TNV IDI Service Manual PERIODIC MAINTENANCE PERIODIC MAINTENANCE SCHEDULE Daily and periodic maintenance is important to keep the engine in good operating condition The following is a summary of maintenance items by periodic maintenance intervals Periodic maintenance intervals vary depending on engine application loads diesel fuel and engine oil used and are hard to establish definitively The following should be treated only as a general guideline Establish a periodic maintenance plan according to the engine application and make sure you perform the required periodic maintenance at intervals indicated Failure to follow these guidelines will impair the engine s safety and performance characteristics shorten the engine s life and may affect the warranty coverage on your engine See Yanmar Co Ltd Limited Emission Control System Warranty USA Only on page 2 6 Consult your authorized Yanmar dealer or distributor for assistance when checking items marked with a e 0000024enTNVIDISM 5 17 PERIODIC MAINTENANCE O Check Replace 6 Contact your authorized Yanmar industrial engine dealer or distributor Periodic Maintenance Interval System Check Item Daily Every Ever
56. 28 4 and spring retainer Figure 6 28 5 Using a valve spring compressor tool compress the valve spring YANMAR ENGINE 7 Insert the valve keepers Figure 6 28 2 and 2 slowly release the tension in the valve spring Reinstall the valve cap Figure 6 28 1 Repeat steps on all remaining valves Reassembly of Cylinder Head 1 Carefully clean both the combustion surface of the cylinder head and the top surface of the cylinder block Place a new cylinder head gasket Figure 6 29 2 on the cylinder block 2 Position the cylinder head on the cylinder head gasket 0002149 1 Fan End a 2 Camshaft Side Figure 6 30 Reassembly of Rocker Arm Assembly 2 0001914 0002150 6 29 Figure 6 31 3 Lightly oil the threads of the cylinder head bolts IMPORTANT _ Figure 6 29 1 Tighten the bolts to the Ensure the lubrication holes Figure 6 31 specified torque in two steps as shown in the 1 in the rocker arm shaft are oriented chart below Tighten in the sequence shown in correctly with respect to the rocker arms Figure 6 30 See Special Torque Chart on Figure 6 31 2 page 6 15 for specification First Step 1 2 of final torque Second Step Final torque 4 Insert the push rods in their respective positions 6 31 ENGINE 1 Lubricate the rocker arm shaft Slide the rocker arm supports Figure 6 32 5 springs Figure 6 32 4
57. 29 4 N m 3 0 kgf m 43 ft lbs 58 8 N m 6 0 kgf m 112 148 in lbs 12 7 16 7 N m 1 3 1 7 kgf m 173 225 in lbs 19 6 18 734 N m 2 0 3 5 kgf m 18 25 ft lbs Pipe Joint Bolt 24 5 34 3 N m 2 5 3 5 kgf m 29 36 ft lbs 39 2 49 0 N m 4 0 5 0 kgf m 36 43 ft lbs 49 0 58 8 N m 5 0 6 0 kgf m Note Lubricating oil is not applied to threaded portion and seat surface 4 24 TNV IDI Service Manual YANMAH Tightening Fasteners Use the correct amount of torque when you tighten fasteners on the machine Applying excessive torque may damage the fastener or component and not enough torque may cause a leak or component failure STANDARD TORQUE CHART Thread size x Pitch mm M8x1 25 GENERAL SERVICE INFORMATION The tightening torque in the Standard Torque Chart on page 4 25 should be applied only to the bolts with a 7 head JIS strength classification 7T Apply 80 torque when tightened to aluminum alloy 0000023enTNVIDISM Apply 6095 torque to bolts that are not listed M10x1 5 M12x1 75 M14x1 5 M16x1 5 in Ibs 19 2 36 4 65 7 101 7 167 7 Tightening Torque 10 8 1 0 25 5 2 9 49 0 4 9 88 3 9 8 137 x 9 8 22 6 9 8 1 1 0 1 YANMAR TNV IDI Service Manual 2 6 0 3 5 0 0 5 9 0 x 1 0 14 0 1 5 23 0 2 0 4 25 GENERAL SERVICE INFORMATION AB
58. 5 3 sz 8S 9 5 9 5 5 29 8 92 9 5 9 Cause 215 12 z m r ix 5j ajaoaulajululaloj a3julo j li aca n Air in Fuel System Bleed the Air page 4 12 See Check and Replace Fuel Clogged or Cracked Fuel Line Clean or Replace Hoses and Engine Coolant Hoses on page 5 38 uu Check the Fuel Tank Cock Fuel Insufficient Fuel Supply to Fuel Injection olo Filter Fuel Line and Fuel Feed See the appropriate procedure in Pump Pump Periodic Maintenance on page 5 1 5 2 E Uneven Injection Volume from Fuel olololo Check and Adjust See Testing of Fuel Injectors on Injection Pump page 7 25 2 Excessive Fuel Injection Volume O Check and Adjust 222 of Fuel Injectors Poor Spray Pattern from Fuel Injection olololo olololo Check and Adjust See Testing of Fuel Injectors on Nozzle page 7 25 Foreign Matter Trapped in the Priming Failure Valve Inside the Priming Pump ren Components on Disassemble and Clean pag Clogged Strainer at Feed Pump Inlet Clean the Strainer See Drain Fuel Tank on page 5 26 YANMAR TNV IDI Service Manual 13 15 TROUBLESHOOTING This Page Intentionally Left Blank 13 16 TNV IDI Service Manual YANMAR TROUBLESHOOTING Trouble Symptom Insufficient Starting Problem Engine Output Engine Surging Engine Air Engine Oil Coolant Intake
59. Compression Pressure at 470 15 psi 3 24 0 1MPa 33 1 kgf cm 370 15 psi 2 55 0 1 MPa 26 1 kgf cm 250 rpm 250 76 498 x 15 psi 3 43 0 1MPa 35 1 kgf cm 399 15 psi 2 75 0 1 MPa 28 1 kgf cm At rated output 42 64 psi 0 29 0 44 MPa 2 96 4 49 kgf cm Lubricating Oil Pressure When idling 8 5 psi 0 06 MPa 0 6 kgf cm or greater Valve Opening Temperature Full Opening Lift Temperature Thermostat 157 163 F 70 73 C 0 32 in 8 mm or Above 185 F 85 C Temperature Coolant Switch YANMAR TNV IDI Service Manual 225 235 F 107 113 C 4 23 GENERAL SERVICE INFORMATION TIGHTENING TORQUES FOR STANDARD BOLTS AND NUTS Nominal Thread Diameter x Pitch Tightening Torque Remarks 87 104 in lbs Use 80 of the value at left 9 8 11 8 N m when the tightening part is 1 0 1 2 kgf m aluminum 200 251 in lbs Use 60 of the value at left 22 6 28 4 N m for 4T bolts and lock nuts M8 x 1 25 mm 2 3 2 9 kgf m 33 40 ft lbs M10x 1 5mm 44 1 53 9 N m Hexagon Bolt 7T 4 5 5 5 kgf m and Nut 58 72 ft lbs M12 x 1 75 mm 78 4 98 0 N m 8 0 10 kgf m 94 108 ft lbs M14 x 1 5 mm 127 5 147 1 N m 18 15 kgf m 159 174 ft lbs M16 x 1 5 mm 215 7 235 4 N m 22 24 kgf m 87 in lbs 9 8 N m 1 0 kgf m 173 in lbs 19 6 N m 2 0 kgf m 22 ft lbs
60. Figure 4 7 3 and fill it to the LOW COLD mark Figure 4 7 4 with engine coolant Reinstall the cap 6 Check the hose Figure 4 7 5 that connects the reserve tank Figure 4 7 3 to the radiator Be sure it is securely connected and there are no cracks or damage If the hose is damaged engine coolant will leak out instead of going into the reserve tank 7 Run the engine until it is at operating temperature Check the level of engine coolant in the reserve tank When the engine is running and the engine coolant is at normal temperature the coolant level in the tank should be at the FULL HOT mark Figure 4 7 6 If the engine coolant is not at the FULL HOT mark Figure 4 7 6 add additional engine coolant to the reserve tank to bring the level to the FULL HOT mark Engine Coolant Capacity Typical Note Capacities listed are for engine only without a radiator Refer to the operation manual provided by the driven machine manufacturer for actual engine coolant capacity on your machine The following are the engine coolant capacities for various Yanmar TNV engines Engine Coolant Engine Model Capacity 2TNV70 0 6 qt 0 6 L 3TNV70 1 0 qt 0 9 L 3TNV76 1 0 qt 0 9 L 4 17 GENERAL SERVICE INFORMATION SPECIFICATIONS Description of Model Number 3 TNV 76 T 0 0000 L Customer Code Rated rpm Turbocharged No symbol indicates naturally aspirated Engine Se
61. Fitting Nut Fuel Return Fitting Injector Body Pressure Adjusting Shims Spring Spring Seat Valve Stop Spacer Nozzle Valve Nozzle Body 0 Nozzle Case Nut eoeouduooesom Figure 7 37 The injection pressure will change by approximately 100 142 psi 0 69 0 98 MPa 7 10 kgf cm for every 0 004 in 0 1 mm shim thickness See the parts catalog for available shims 1 Disassemble the fuel injector assembly See Disassembly and Inspection of Fuel Injectors on page 7 28 2 Remove or add adjusting shims as needed 3 Reassemble the fuel injector assembly See Reassembly of Fuel Injectors on page 7 30 7 29 FUEL SYSTEM 4 Retest the fuel injector See Testing of Fuel Injectors on page 7 25 lf the injector cannot be adjusted to the appropriate pressure discard the fuel injector Reassembly of Fuel Injectors 1 Secure the injector in a soft jawed vice with the nozzle end up Reinstall the shims nozzle spring nozzle spring seat valve stop spacer nozzle valve and nozzle body Reinstall the nozzle case nut Tighten it to specification Installation of the Fuel Injectors T Insert the nozzle seat and nozzle protector in the cylinder head Reinstall the fuel injector in the cylinder head and tighten to specification Reinstall the high pressure and return fuel lines See Installation of High Pressure Fuel Injection Lines on page 7 13 and Installation of Fuel Return Line on page 7 14 T
62. Injection Pump O Check and Adjust See Checking and Adjusting Fuel Injection Timing on page 7 21 gt a Incorrect Diesel Fuel Use Correct Fuel Oil ET Fuel Specifications on Water in Fuel System Draining the Fuel Filter 3 Clogged Fuel Filter Clean Replace YANMAR TNV IDI Service Manual 13 13 TROUBLESHOOTING This Page Intentionally Left Blank 13 14 TNV IDI Service Manual YANMAR Trouble Symptom Insufficient Poor TROUBLESHOOTING Starting Problem Engine Exhaust 9 Engine Engine Cil Engins D Surging Coolant Intake Output Color 5 E 9 Starts Exhaust During 8 e but Stops Color Work o c c Soon S53 Exhaust 2 5 2 _ o 5 5 3 E o Corrective Action Reference Pages Smoke 1512105 I e 3 0 c ou gt o 6 o 6 3 9 2 5 2 olo O 99o9 9 nmo 6 lt 2 D H o ES c S 2 56 5 2 1 9 1 6 88s 2 258 s S g x g x Els S 2 901
63. Manual YANMAR 0 028 in 0 7 mm Check Inner Rotor and Gear Boss Clearance on page 9 11 LUBRICATION SYSTEM LUBRICATION SYSTEM DIAGRAM Oil Filter Bypass Valve Fuel Injection Pump Oil Pressure Switch Cylinder Body Main Gallery Pressure Regulator Valve RM Idle Gear Camshaft Crank Oil Pump Shaft Bearing Journal Rocker Arm Suction Pipe Bearing Crank Pin Strainer Rocker Arm Tappet Cam Face Oil Pan 0001624 Figure 9 1 YANMAR TNV IDI Service Manual LUBRICATION SYSTEM CHECKING ENGINE OIL PRESSURE Perform an engine oil pressure check if there is any indication of low oil pressure such as the oil pressure indicator is on or the oil pressure gauge indicates low oil pressure See Engine Oil Pressure on page 9 5 for the engine oil pressure 1 Disconnect the wire lead from the oil pressure switch Figure 9 2 1 0000020A Figure 9 2 2 Remove the oil pressure switch 3 Install a mechanical oil pressure gauge in the oil pressure switch port 4 Start the engine Ifthe mechanical oil pressure test gauge indicates good oil pressure replace the faulty oil pressure switch or faulty machine oil pressure gauge Ifthe mechanical oil pressure test gauge indicates low oil pressure troubleshoot the lubrication system to locate the cause of the low oil pressu
64. Separator The fuel filter water separator removes contaminants sediments and water from diesel fuel going to the fuel filter This is a required component of the fuel system This is standard equipment with every engine The separator is installed between the fuel tank and the fuel pump Periodically drain the water from the fuel filter water separator using the drain cock at the bottom of the separator Fuel Priming Lever If the unit has a mechanical fuel pump a fuel priming lever on the mechanical fuel pump primes the fuel system The fuel system needs to be primed before you start the engine for the first time if you run out of fuel or if fuel system service is performed To prime the fuel system operate the fuel priming lever until the cup in the fuel filter is full of fuel 4 6 TNV IDI Service Manual Components GENERAL SERVICE INFORMATION Functions Fuel Tank The fuel tank is a reservoir that holds diesel fuel When fuel leaves the fuel tank it goes to the fuel filter water separator Next fuel is pumped to the fuel filter by the fuel pump Next the fuel goes to the fuel injection pump Since fuel is used to keep the fuel injection pump cool and lubricated more fuel than necessary enters the injection pump When the injection pump pressure reaches a preset value a relief valve allows excess fuel to be returned back to the fuel tank The fuel tank is a required engine compon
65. and rocker arms Figure 6 32 1 onto the shaft Note The rocker arm shaft fits tightly in the rocker arm supports Clamp the support in a padded vise Twist and push on the rocker arm shaft to reinstall Note On 3 cylinder models the set screw is located in the center support On 2 cylinder models the set screw is located in the front cooling fan end support 2 Align the hole in the rocker arm shaft Figure 6 32 7 and the hole in the rocker arm support Figure 6 32 5 Reinstall the alignment set screw Figure 6 32 6 0002160 Figure 6 32 3 Place the rocker arm shaft assembly onto the cylinder head 4 f removed reinstall the valve adjusting screws Figure 6 32 3 and lock nuts Figure 6 32 2 5 Align the push rods with their respective rocker arms 6 Reinstall and tighten the rocker arm shaft retaining bolts to the specified torque 7 Tighten the rocker arm shaft alignment screw 6 32 8 Adjust the valve clearance See Measuring and Adjusting Valve Clearance on page 6 34 Reassembly of Intake Manifold Valve Cover 1 Reinstall the glow plugs Figure 6 33 1 and tighten to specification Reinstall the electrical harness Figure 6 33 2 2 0002146 Figure 6 33 YANMAR Lightly grease a new valve cover gasket Figure 6 34 4 Place the gasket in the groove of the intake manifold valve cover Figure 6 34 3 Place the valve cover on the cylinder
66. available O ring the material is different 0000042en TNV IDI Service Manual YANMAR COOLING SYSTEM INTRODUCTION This section of the Service Manual describes the procedures necessary to service the 2TNV70 3TNV70 and 3TNV76 engine coolant pump COOLING SYSTEM DIAGRAM 5 0002046 1 Oylinder Head 3 Engine Coolant Pump 5 Coolant Recovery Tank 2 Thermostat 4 Radiator 6 Cylinder Block Figure 8 1 YANMAR TNV IDI Service Manual COOLING SYSTEM ENGINE COOLANT PUMP COMPONENTS 8 6 Dow Ie Thermostat Cover Thermostat Special O Ring Engine Coolant Pump 0001959 Temperature Switch 9 Engine Coolant Pump V Gasket Pulley Engine Coolant Pump Gasket 10 Spacer V Belt 11 Engine Coolant Fan Figure 8 2 TNV IDI Service Manual YANMAR ENGINE COOLANT SYSTEM CHECK Check the engine coolant system for leakage 1 With the radiator properly filled install a cooling system tester Figure 8 3 1 1 0000577A Figure 8 3 2 Apply 10 8 14 8 psi 75 105 kPa 0 75 1 05 kgf cm to the cooling system If the pressure reading drops the engine coolant system is leaking Identify the source of the leak and repair ENGINE COOLANT PUMP Disassembly of Engine Coolant Pump Verify the condition of the engine coolant pump before disassembling it from the engine Check the engine coolant pump shaft bearing for abnormal noise sticking excessive play and water
67. battery well ventilated While the engine is running or the battery is charging hydrogen gas is produced which can be easily ignited Keep sparks open flame and any other form of ignition away while the engine is running or battery is charging Failure to comply will result in death or serious injury 0000003en 3 4 TNV IDI Service Manual YANMAR SAFETY DANGER DANGER 7 7 FIRE AND EXPLOSION HAZARD FIRE AND EXPLOSION HAZARD Diesel fuel is extremely flammable and Diesel fuel is extremely flammable and explosive under certain conditions explosive under certain conditions When you remove any fuel system NEVER remove the fuel cap with the component to perform maintenance engine running such as changing the fuel filter place an approved container under the opening to catch the fuel Failure to comply will result in death or serious injury 0000011en NEVER use a shop rag to catch the fuel Vapors from the rag are extremely BEEN DANGER flammable and explosive A DANGER Wipe up any spills immediately i Wear eye protection fuel system is under pressure and fuel could spray out when you remove any fuel system FIRE AND EXPLOSION HAZARD component Diesel fuel is extremely flammable and Failure to comply will result in death or explosive under certain conditions serious injury NEVER use diesel fuel as a cleaning agen
68. camshaft Figure 7 1 2 and a pump housing Figure 7 1 3 A delivery valve Figure 7 1 4 connects to a high pressure fuel line for each cylinder The fuel injection pump housing contains a governor Figure 7 1 5 Fuel from the fuel tank to the fuel injection pump is delivered by a low pressure electric fuel pump On a few special models a mechanical fuel pump is used instead of an electric pump The mechanical fuel pump is mounted to the fuel injection pump housing in place of the cover plate Figure 7 1 6 Fuel to be injected into the cylinders is pressurized by the up and down motion of each camshaft driven plunger and is then supplied by the high pressure fuel lines to the respective fuel injector FUEL SYSTEM NEVER remove or attempt to remove the tamper proof devices from the full load fuel adjusting screw or the high speed throttle limit screw on the fuel injection pump and governor assembly These adjustments have been made at the factory to meet all applicable emissions regulations and then sealed NEVER attempt to make any adjustments to these sealed adjustment screws If adjustments are required they can be made only by a qualified fuel injection shop that will ensure the injection pump continues to meet all applicable emissions regulations and then replace the tamper proof seals Tampering with or removing these devices may void the Yanmar Limited Warranty 0000146en
69. connecting rod to contact the crankshaft journal during piston installation Damage to the crankshaft bearing journal may result Lubricate piston piston rings and cylinder with clean engine oil or assembly lubricant Rotate the crankshaft so the crankpin for the piston being installed is near bottom dead center 0000226 1 Top Compression Ring Gap 2 Second Compression Ring End Gap 3 Oil Ring End Gap Figure 6 92 IMPORTANT Ensure piston ring gaps are located correctly Figure 6 92 Using a piston ring compressor compress the piston rings IMPORTANT The piston and connecting rod must be reinstalled with the correct orientation When installed correctly the identification mark Figure 6 93 2 stamped into the top of the piston will be on the same side of the engine as the fuel injection pump Figure 6 93 1 and the embossed mark Figure 6 93 3 cast into the connecting rod beam will face the flywheel end of the engine Figure 6 93 5 6 57 ENGINE 4 Carefully reinstall the piston and rod assembly 7 Apply a light coat of clean engine oil to the rod Be sure the match marks Figure 6 93 4 cap bolts Reinstall the connecting rod cap stamped into the connecting rod and cap are Figure 6 94 2 Tighten the connecting rod facing the fuel injection pump side of the bolts to the specified torque in two stages 1 2 cylinder block and the piston identification then full torq
70. coolant from circulating into the radiator until the engine coolant temperature reaches a preset temperature When the engine is cold no engine coolant flows through the radiator Once the engine reaches its operating temperature the thermostat opens By letting the engine warm up as quickly as possible the thermostat reduces engine wear deposits and emissions Cooling System 4 8 TNV IDI Service Manual DIESEL FUEL Diesel Fuel Specifications Diesel fuel should comply with the following specifications The table lists several worldwide specifications for diesel fuels Diesel Fuel Specification Location No 2 D No 1 D ASTM D975 94 USA EN590 96 ISO 8217 DMX BS 2869 A1 or A2 European Union International United Kingdom JIS K2204 Grade No 2 Japan KSM 2610 Korea GB252 China Additional Technical Fuel Requirements The fuel cetane number should be equal to 45 or higher The sulfur content must not exceed 0 5 by volume Less than 0 05 is preferred Bio Diesel fuels See Bio Diesel Fuels on page 4 9 NEVER mix kerosene used engine oil or residual fuels with the diesel fuel Water and sediment in the fuel should not exceed 0 05 by volume Keep the fuel tank and fuel handling equipment clean at all times Poor quality fuel can reduce engine performance and or cause engine damage Fuel additives are not recommended Some fuel additives ma
71. cooling system with new coolant every 1000 hours or once a year whichever comes first 0002923 1 Allow engine and coolant to cool Figure 5 17 2 Remove the radiator cap Figure 5 16 1 9 3 Remove the drain plug or open the drain cock After draining the engine coolant flush the Figure 5 16 2 at the lower position of the radiator and engine block to remove any rust radiator and drain the engine coolant scale and contaminants Then reinstall and tighten the drain plug or close the drain cock at the radiator Reinstall and tighten the engine block drain plug 6 Fill radiator and engine with engine coolant See Filling Radiator With Engine Coolant on page 4 17 YANMAR TNV IDI Service Manual 5 35 PERIODIC MAINTENANCE Adjust Intake Exhaust Valve Clearance Proper adjustment is necessary to maintain the correct timing for opening and closing the valves Improper adjustment will cause the engine to run noisily resulting in poor engine performance and engine damage See Measuring and Adjusting Valve Clearance on page 6 34 5 36 Every 1500 Hours of Operation Perform the following maintenance every 1500 hours of operation Inspect Clean and Test Fuel Injectors Inspect Crankcase Breather System Inspect Clean and Test Fuel Injectors 2 HIGH PRESSURE HAZARD Avoid skin contact with the high pressure diesel fuel spray caused by a fuel system leak
72. extended life coolants 6 Replace the coolant every 1000 engine hours or once a year Additional Technical Coolant Specifications ASTM D6210 D4985 US JIS K 2234 Japan SAE J814C J1941 J1034 or J2036 International 4 16 TNV IDI Service Manual YANMAR Filling Radiator With Engine Coolant Fill the radiator and reserve tank as follows This procedure is for filling the radiator for the first time or refilling it after it is flushed Note that a typical GENERAL SERVICE INFORMATION Pour the engine coolant s owly into the radiator until it is even with the lip of the engine coolant filler port Make sure that air bubbles do not develop as you fill the radiator radiator is illustrated 1 0000029 Figure 4 7 Check to be sure the radiator drain plug is installed and tightened or the drain cock Figure 4 7 1 is closed Also make sure the coolant drain plug Figure 4 8 1 in the cylinder block is closed 0002923 Figure 4 8 Remove the radiator cap Figure 4 7 2 by turning it counter clockwise about 1 3 of a turn YANMAR TNV IDI Service Manual Reinstall the radiator cap Figure 4 7 2 Align the tabs on the back side of the radiator cap with the notches on the engine coolant filler port Press down and turn the cap clockwise about 1 3 of a turn 5 Remove the cap of the reserve tank
73. factory Periodic replacement of the air cleaner filter element is necessary See the Periodic Maintenance Schedule on page 5 19 for the replacement frequency Alternator The alternator is driven by a V belt which is powered by the crankshaft V pulley The alternator supplies electricity to the engine systems and charges the battery while the engine is running Dipstick Engine Oil The engine oil dipstick is used to determine the amount of engine oil in the crankcase Electric Fuel Pump The electric fuel pump makes sure there is a constant supply of diesel fuel to the fuel injection pump The electric fuel pump is electro magnetic and runs on 12 VDC An electric fuel pump may be installed as standard equipment based on engine model and specification If an electric fuel pump is installed turn the key switch to the ON position for 10 to 15 seconds to prime the fuel system Engine Oil Filter The engine oil filter removes contaminants and sediments from the engine oil Periodic replacement of the engine oil filter is necessary See thePeriodic Maintenance Schedule on page 5 19 for the replacement frequency Fuel Filter The fuel filter removes contaminants and sediments from the diesel fuel Periodic replacement of the fuel filter is necessary See the Periodic Maintenance Schedule on page 5 19 for the replacement frequency Please note that the word diesel is implied throughout this manual when the word fuel is used Fuel Filter Water
74. hear the warning signals Failure to comply could result in death or serious injury 0000005en YANMAR TNV IDI Service Manual PERIODIC MAINTENANCE 22 Awarning i BURN HAZARD Batteries contain sulfuric acid NEVER allow battery fluid to come in contact with clothing skin or eyes Severe burns could result ALWAYS wear safety goggles and protective clothing when servicing the battery If contact with the skin and or eyes should occur flush with a large amount of water and obtain prompt medical treatment Failure to comply could result in death or serious injury 0000007en HIGH PRESSURE HAZARD Avoid skin contact with the high pressure diesel fuel spray caused by a fuel system leak such as a broken fuel injection line High pressure fuel can penetrate your skin and result in serious 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 0000008en PERIODIC MAINTENANCE il SHOCK HAZARD Turn off the battery switch if equipped or disconnect the negative battery cable before servicing the electrical system Check the electrical harnesses for cracks abrasions and dam
75. impair the safety and performance of the machine and shorten its life If the idle speed limit screws require adjustment see your authorized Yanmar industrial engine dealer or distributor 0000017en Figure 5 11 Clean Air Cleaner Element Note that a typical air cleaner is shown in Figure 5 12 and Figure 5 13 for illustrative purposes only The engine performance is adversely affected when the air cleaner element is clogged with dust Be sure to clean the air filter element periodically 1 Unlatch and remove the air cleaner cover Figure 5 12 1 2 Remove the element Figure 5 12 2 outer element if equipped with two elements YANMAR TNV IDI Service Manual PERIODIC MAINTENANCE FLYING OBJECT HAZARD ALWAYS wear eye protection when servicing the engine and when using compressed air or high pressure water Dust flying debris compressed air pressurized water or steam may injure your eyes Failure to comply may result in minor or moderate injury 0000003en Blow air Figure 5 12 3 through the element from the inside out using 42 71 psi 0 29 0 49 MPa 3 0 5 0 kgf cm2 compressed air to remove the particulates Use the lowest possible air pressure to remove the dust without damaging the element If the air cleaner is equipped with a double element only remove and replace the inner element Figure 5 13 1 if the engine lacks power or the dust indicator actuat
76. impair the engine s safety and performance characteristics shorten the engine s life and may affect the warranty coverage on your engine See Yanmar Co Ltd Limited Emission Control System Warranty USA Only on page 2 6 Consult your authorized Yanmar dealer or distributor for assistance when checking items marked with a e 0000024enTNVIDISM The starter motor can be damaged if operated continuously longer than 10 seconds while performing the no load test 0000034en If the fuel filter water separator is positioned higher than the fuel level in the fuel tank water may not drip out when the fuel filter water separator drain cock is opened If this happens turn the air vent screw on the top of the fuel filter water separator 2 3 turns counterclockwise Be sure to tighten the air vent screw after the water has drained out 0000025en TNV IDI Service Manual YANMAR SAFETY When the engine is operated in dusty Do not operate the engine if the conditions clean the air cleaner alternator is producing unusual sounds element more frequently Damage to the alternator will result NEVER operate the engine with the air 900909890 cleaner or element s removed This may cause foreign material to enter the engine and damage it If the engine coolant pump must be 22 2 replaced replace the engine coolant pump as an assembly only Do not attempt to repair the engine coolant The
77. internal engine components to seize and or shorten engine life Prevent dirt and debris from contaminating the engine oil Carefully clean the oil cap dipstick and the surrounding area before you remove the cap NEVER mix different types of engine oil This may adversely affect the lubricating properties of the engine oil NEVER overfill Overfilling may result in white exhaust smoke engine overspeed or internal damage 0000005en Only use the engine coolant specified Other engine coolants may affect warranty coverage cause an internal buildup of rust and scale and or shorten engine life Prevent dirt and debris from contaminating the engine coolant Carefully clean the radiator cap and the surrounding area before you remove the cap NEVER mix different types of engine coolants This may adversely affect the properties of the engine coolant 0000006en NEVER overfill the engine with engine oil ALWAYS keep the oil level between the upper and lower lines on the oil cap dipstick 0000015en TNV IDI Service Manual YANMAR SAFETY For maximum engine life Yanmar New Engine Break In recommends that when shutting the engine down you allow the engine to idle without load for five minutes This will allow the engine components that operate at high temperatures such as the turbocharger if equipped and exhaust system to cool slightly before the engine itself is s
78. maximum air intake restriction shall pump or replace individual components be 0 90 psi 6 23 kPa 635 mm Aq or 0000041 less Clean or replace the air cleaner element if the air intake restriction exceeds the above mentioned value Use a new special O ring between the ees engine coolant pump and the joint Be sure to use the special O ring for each engine model Although the O ring dimensions are the same as a commercially available O ring the material is different Do not short circuit the charging system between alternator terminals IG and L Damage to the alternator will result 0000042en 0000035en Remove or install the high pressure fuel injection lines as an assembly whenever possible Disassembling the high pressure fuel injection lines from the retainers or bending any of the fuel lines will make it difficult to reinstall the fuel lines Do not remove the positive battery 0000047 cable from alternator terminal B while the engine is operating Damage to the alternator will result Do not connect a load between alternator terminals L and E Damage to the alternator will result 0000036en After marking the position of the pump drive gear do not rotate the engine crankshaft Rotating the crankshaft will cause the fuel injection pump to become Do not turn the battery switch OFF while misaligned the engine is operating Damage to the 0000048en altern
79. near the opposite end Figure 6 16 1 Record the measurements See Intake Exhaust Valve and Guide on page 6 7 for the service limit 1 ET 20 Figure 6 16 0000197 Valve Stem Bend Place the valve stem on a flat inspection block or layout bed Roll the valve until a gap can be observed between a portion of the valve stem and the surface of the block or bed Use a feeler gauge to measure the gap Figure 6 17 Record the measurements See Intake Exhaust Valve and Guide on page 6 7 for the service limit Figure 6 17 ENGINE Valve Recession Note The valve guides must be installed to perform this check Insert the valves into their original locations and press them down until they are fully seated Use a depth micrometer Figure 6 18 to measure the difference between the cylinder head gasket surface and the combustion surface of each exhaust and intake valve Figure 6 19 Record the measurements See Cylinder Head on page 6 6 for the service limit 0000193 Figure 6 18 0001755 Figure 6 19 6 27 ENGINE Valve Face and Valve Seat Always check the clearance between the valve and valve guide before grinding or lapping the valve seats See Intake Exhaust Valve and Guide on page 6 7 for the service limit If the clearance exceeds the limit replace the valve and or valve guide to bring the clearance within the limit Roughness or burrs will cause p
80. or into ground water or waterways 0000013en YANMAR TNV IDI Service Manual 3 15 SA FETY NEVER attempt to modify the engine s design or safety features such as defeating the engine speed limit control or the fuel injection quantity control Failure to comply may impair the engine s safety and performance characteristics and shorten the engine s life Any alterations to this engine may affect the warranty coverage of your engine See Yanmar Limited Warranty on page 2 3 0000044TNVIDISM NEVER use high pressure water or compressed air at greater than 28 psi or a wire brush to clean the radiator fins Radiator fins damage easily 0000016en The tightening torque in the Standard Torque Chart on page 4 25 should be applied only to the bolts with a 7 head JIS strength classification 7T Apply 80 torque when tightened to aluminum alloy 0000023enTNVIDISM Apply 60 torque to bolts that are not listed NEVER attempt to adjust the low or high idle speed limit screw This may impair the safety and performance of the machine and shorten its life If the idle speed limit screws require adjustment see your authorized Yanmar industrial engine dealer or distributor 0000017en Establish a periodic maintenance plan according to the engine application and make sure you perform the required periodic maintenance at intervals indicated Failure to follow these guidelines will
81. prior to reinstalling the camshaft See Installation of Gear Case on page 6 58 1 If removed reinstall the camshaft end plate Figure 6 96 1 key and timing gear Figure 6 96 4 onto the camshaft using a press Heat the gear to 356 392 F 180 200 C and press onto the end of the camshaft 2 Lubricate the camshaft Figure 6 96 2 with clean engine oil or assembly lube Slowly insert the camshaft through the front of the engine 3 Reinstall and tighten the cap screws 0002186 Figure 6 96 4 ENGINE Lubricate the camshaft lobes and tappets with clean oil or assembly lube Reinstall the tappets in their respective locations in the cylinder block Push the tappets fully into the tappet bores until they make solid contact with the camshaft If removed reinstall the fuel injection pump Adjust the fuel injection timing after installation See Checking and Adjusting Fuel Injection Timing on page 7 21 Installation of Timing Gears 1 2 Set No 1 piston to top dead center Rotate the camshaft until mark Figure 6 98 C is approximately at the 9 o clock position Lubricate the idler gear Figure 6 97 2 bushing Figure 6 96 3 and idler gear shaft Figure 6 96 1 with clean engine oil or assembly lube 0002182 Figure 6 97 Align the timing gears as shown in Figure 6 98 Reinstall the idler gear and idler gear shaft Be sure the oil hole in the bush
82. responsible Follow these procedures for hazardous waste disposal Failure to follow these procedures may seriously harm the environment Follow the guidelines of the EPA or other governmental agency for the proper disposal of hazardous materials such as engine oil diesel fuel and engine coolant Consult the local authorities or reclamation facility NEVER dispose of hazardous materials irresponsibly by dumping them into a sewer on the ground or into ground water or waterways 0000013en Periodically clean the fuel filter water separator element and inside cup 1 Position an approved container under the cup Figure 5 15 1 of the fuel filter water separator to collect the contaminants 2 Close Figure 5 15 2 the fuel cock 3 Turn the retaining ring Figure 5 15 4 to the left Figure 5 15 5 4 Carefully remove the cup Figure 5 15 1 and pour the fuel into an approved container and dispose properly Hold the bottom of the cup with a shop towel to prevent the fuel from dripping Wipe up any spills immediately 5 Keepthe retaining spring Figure 5 15 6 and float Figure 5 15 7 handy for reassembly 6 Remove the element Figure 5 15 8 by pulling it down 7 Replace the element with a new one YANMAR TNV IDI Service Manual PERIODIC MAINTENANCE Applicable Mesh Filter Part No 2TNV70 3TNV70 3TNV76 171081 55910 8 Wash the inside of the cup with cl
83. the service standard or limit before the next service as determined from the state of current rate of wear should be replaced even though the part currently meets the service standard limit 0000120en IMPORTANT Mark all valve train components so they can be installed in their original locations Note Record all measurements taken during inspection Inspection of Push Rods Push Rod Bend Determine if the bend of the push rods is within the specified limit Place the push rods on a flat inspection block or layout bed 2 Roll the push rods until a gap can be observed between a portion of the push rod and the surface of the block or layout bed Use a feeler gauge to measure the gap Figure 6 11 See Push Rod on page 6 7 for the service limit 0000204 Figure 6 11 6 25 ENGINE Inspection of Rocker Arm Assembly Rocker Arm Shaft Hole Diameter Use a telescoping gauge and micrometer to measure the inside diameter of all the rocker arm support brackets and the rocker arms Figure 6 12 Record the measurements See Rocker Arm and Shaft on page 6 8 for the service limit Inspect contact areas Figure 6 12 1 for excessive wear or damage 0001916 Figure 6 12 Rocker Arm Shaft Outside Diameter Use a micrometer to measure rocker arm shaft diameter Measure at each rocker arm location in two directions 90 apart Figure 6 13 Record the measurements See Rocker Arm and Shaft on page 6 8
84. the fuel line nuts always use a line or flare nut wrench Start all line nuts by hand Use a wrench to just snug all line nuts Tighten the line nuts on the fuel injection pump to the specified torque See Special Torque Chart on page 7 7 Use one wrench to hold the fuel return line nut and fuel return line from rotating Use a second wrench to tighten the high pressure fuel line nuts to the specified torque Figure 7 5 See Special Torque Chart on page 7 7 gt Figure 7 5 7 13 FUEL SYSTEM Removal of Fuel Return Line 1 Clean the area to keep contaminants from entering the fuel system 6 Plug or cap all openings to minimize leakage and prevent contamination Installation of Fuel Return Line Remove the high pressure fuel injection lines Figure 7 5 as an assembly See Removal of High Pressure Fuel Injection Lines on page 7 13 The fuel return line is a one piece assembly Use care not to bend or twist the fuel return line 0000171en IMPORTANT Always use one wrench to hold the fuel injector body when loosening or tightening the fuel return line with a second wrench Figure 7 6 While holding each fuel injector Figure 7 6 4 with a wrench remove all fuel return line nuts Figure 7 6 2 Carefully remove the fuel return line assembly Figure 7 6 3 Remove and discard the copper gasket Figure 7 6 1 from each fuel injector IMPORTANT Alway
85. the fuel tank with diesel fuel Filling the fuel tank with gasoline may result in a fire and will damage the engine NEVER refuel with the engine running Wipe up all spills immediately Keep sparks open flames or any other form of ignition match cigarette static electric source away when fueling refueling NEVER overfill the fuel tank Fill the fuel tank Store any containers containing fuel in a well ventilated area away from any combustibles or sources of ignition Failure to comply will result in death or serious injury 0000005en TNV IDI Service Manual YANMAR DANGER GOL FIRE AND EXPLOSION HAZARD Diesel fuel is extremely flammable and explosive under certain conditions Before you operate the engine check for fuel leaks Replace rubberized fuel hoses every two years or every 2000 hours of engine operation whichever comes first even if the engine has been out of service Rubberized fuel lines tend to dry out and become brittle after two years or 2000 hours of engine operation whichever comes first Failure to comply will result in death or serious injury 0000015en YANMAR TNV IDI Service Manual PERIODIC MAINTENANCE A DANGER GL Diesel fuel is extremely flammable and explosive under certain conditions Be sure to place the diesel fuel container on the ground when transferring the diesel fuel from the pump to the container Hol
86. thermometer Figure 8 9 2 in warm water 8 10 Q 0000577A Figure 8 9 Slowly increase temperature of the water using an external heat source The thermostat is normal if it starts to open at the temperature value stamped on the flange of the thermostat and fully opens as the temperature of the water is increased Radiator Cap 1 m Check for proper operation of the radiator cap Install the radiator cap Figure 8 10 1 on a cooling system tester 0000577A Figure 8 10 Apply 10 8 14 8 psi 75 105 kPa 0 75 1 05 kgf cm to the radiator cap The radiator cap relief valve must open within the specified range TNV IDI Service Manual YANMAR Reassembly of Engine Coolant Pump 1 Reinstall the thermostat Figure 8 11 1 0001959C Figure 8 11 2 Reinstall the thermostat cover Figure 8 11 2 Tighten the thermostat cover bolts Reinstall the temperature switch Figure 8 11 3 using a new gasket Figure 8 11 4 Position the engine coolant pump on the engine using a new gasket Figure 8 11 6 Use a new special O ring Figure 8 11 5 on assembly between the engine coolant pump and the joint Use a new special O ring between the engine coolant pump and the joint Be sure to use the special O ring for each engine model Although the O ring dimensions are the same as a commercially available O ring the material is different 00000
87. to comply may result in minor or moderate injury 0000020B Figure 8 5 0000014en 4 Remove the engine coolant fan guard if equipped engine coolant fan Figure 8 6 1 spacer Figure 8 6 2 and engine coolant pump V pulley Figure 8 6 3 8 8 TNV IDI Service Manual YANMAR 7 Remove the thermostat cover Figure 8 7 1 lt gt 2 0001959 8 7 8 Remove the thermostat Figure 8 7 2 Remove the temperature switch Figure 8 7 3 and gasket Figure 8 7 4 Discard the gasket YANMAR TNV IDI Service Manual COOLING SYSTEM COOLING SYSTEM Cleaning and Inspection Temperature Switch 1 Check for proper operation of the temperature switch Connect a continuity light or ohmmeter to the temperature switch Connect one lead to the terminal of the switch Figure 8 8 1 and the other lead to the metal portion of the switch Figure 8 8 2 1 0000577A Figure 8 8 Place the temperature switch and an accurate thermometer Figure 8 8 3 in engine coolant Slowly increase temperature of the fluid using an external heat source The temperature switch is normal if the continuity light or ohmmeter indicates continuity when the fluid temperature reaches 225 F 235 F 107 C 113 C Thermostat 1 Check for proper operation of the thermostat Place the thermostat Figure 8 9 1 and an accurate
88. tool Follow manufacturer s instructions for correct operation 2 Wash the pistons in an appropriate solvent using a soft brush 3 Visually inspect each piston for cracks Pay particular attention to the ring lands between the piston ring grooves 4 Measure the diameter of the piston skirt at 90 to the wrist pin bore as shown Figure 6 64 Measurements must be taken at a specified distance Figure 6 64 1 from the bottom of the piston based on engine model Record the measurements See Piston on page 6 11 for specifications 5 Subtract the piston measurement from the greatest measurement acquired during cylinder inspection see Inspection of Cylinder Block to obtain piston to cylinder clearance Record the measurements See Piston on page 6 11 for specifications 0000235 Figure 6 64 6 47 ENGINE 6 Measure the diameter of the wrist pin bore on both sides of the piston Figure 6 65 See Piston on page 6 11 for specifications Record the measurements A A 0000237 Figure 6 65 Measure the outside diameter of the wrist pin in three places and at 90 See Piston on page 6 11 for specifications Record the measurements ax NS Figure 6 66 Using a micrometer measure the thickness of each piston ring See Piston Ring on page 6 12 for specifications Record the measurements Place a new piston ring in the groove as shown Figure 6 67 Use a feeler gauge to measure the gap be
89. top surface of the outer rotor 4 Reinstall the oil pressure regulator valve Figure 9 11 4 into the oil pump cover Figure 9 11 5 Apply Loctite 242 red to the valve plug Follow Loctite package instructions 5 Reinstall the oil pump cover Figure 9 11 5 Apply Loctite 290 green or Loctite 262 red to the oil pump cover screws Follow Loctite package instructions Tighten the pump cover screws to 52 70 in Ibs 5 9 7 9 N m 0 6 7 9 kgf m LUBRICATION SYSTEM 6 Reinstall the crankshaft pulley and gear case cover See Hemoval of Timing Gear Case Cover on page 6 38 7 Reinstall the engine coolant pump V pulley Figure 9 12 3 spacer Figure 9 12 2 engine coolant fan Figure 9 12 1 and engine coolant fan guard if equipped 0001959B Figure 9 12 8 Reinstall the V belt Tighten the V belt to the proper tension as described in Check and Adjust Cooling Fan V belt on page 5 28 9 12 TNV IDI Service Manual YANMAH Section 10 STARTER MOTOR Page Before You Begin 04 44042 1 10 3 10 5 Starter Motor Information 10 5 Starter Motor 10 6 Starter Motor Troubleshooting 10 7 Starter Motor 10 9 cds deer 10 11 Removal of Starter Motor
90. under the fuel filter water separator Figure 5 7 1 to collect the contaminants 2 Close Figure 5 7 2 the fuel cock Figure 5 7 3 3 Turn the retaining ring Figure 5 7 4 to the left Figure 5 7 9 4 Carefully remove the cup Figure 5 7 1 Remove the retaining spring Figure 5 7 6 and float Figure 5 7 7 from the cup Pour the fuel into an approved container and dispose properly Hold the bottom of the cup with a shop towel to prevent the fuel from dripping Wipe up any spills immediately 5 Clean the inside of the cup 6 Inspect the condition of the mesh filter Figure 5 7 10 Clean the mesh filter if necessary 7 Inspect the condition of the O ring Figure 5 7 11 Replace the O ring if necessary 5 23 PERIODIC MAINTENANCE 8 Put the float Figure 5 7 7 and retaining Check Battery spring Figure 5 7 6 inside the cup 9 Reinstall the cup to the mounting flange A DANGER Figure 5 7 8 and turn the retaining ring Figure 5 7 4 to the right Figure 5 7 5 Hand tighten only 10 Open the fuel cock Figure 5 7 3 11 Be sure to prime the diesel fuel system when you are done See Priming The Fuel System on EXPLOSION HAZARD page 4 12 NEVER check the remaining battery 12 Check for fuel leaks charge by shorting out the terminals This will result in a spark and may cause an explosion or fire Use a hydrometer to check the remaining If the
91. will be approximately 72 5 psi 0 5 MPa 5 kgf cm higher than one that has been operated for five hours or longer 5 Pump the operating lever slowly to hold the pressure steady at a point just below the opening pressure and hold that pressure for 5 seconds Observe the injector to see that it is sealing properly and is not dripping If fuel leaks from the return line fitting check that the nozzle case nut is tight Service or replace the injector if fuel continues to leak from either the return line fitting or nozzle Pump the operating lever more rapidly to repeatedly pop the injector and observe the spray pattern The pattern should be a very fine uniform spray Figure 7 33 If dripping or an uneven pattern is seen Figure 7 33 service or replace the injector TNV IDI Service Manual YANMAR Fuel Injector Test Results FUEL SYSTEM Injection Pattern 0001742 0001744 Pressure Gauge Reading 0001747 Gauge needle fluctuates around the valve opening pressure 0001748 Gauge needle fluctuates around the valve opening pressure 0001749 Gauge needle stays ata position near the valve opening pressure 0001750 Although the gauge needle reaches the valve opening pressure the pressure drop is large 0001751 Pressure does not increase even when the tester lever is operated Atomization Pattern 5 10 cone and roughly uniform Atomization is excessively one sided
92. 0002066 Figure 7 27 TNV IDI Service Manual YANMAR FUEL SYSTEM Fuel Injection Timing Chart Model Class VM CH VH Engine Speed rpm 2000 2100 2200 2300 2600 2700 3000 3000 3600 3100 3400 3500 3600 2TNV70 Injection 15 18 3TNV70 Timing 15 18 21 20 21 3TNV76 BIDC 1 15 16 18 212 20 212 7 28 9 Remove all high pressure injection lines See Removal of High Pressure Fuel Injection Lines on page 7 13 10 Turn on all fuel supply valves Note As the injection pump injects fuel to a cylinder only once in every two engine revolutions it may be necessary to rotate the crankshaft twice to see fuel being pumped from the timing tool or delivery valve of the cylinder you are using to check injection timing 11 Install the spill timing tool made in shop Figure 7 29 1 onto the delivery valve for the cylinder being checked Note If a timing tool is not available timing can be checked by watching the fuel in the delivery valve itself N 1 D x K 2 m y lt 7 26 0000592 7 29 YANMAR TNV IDI Service Manual Note The following references to the direction of rotation are made facing the cooling fan end of the engine and are adjusted by turning the crankshaft 12 Slowly rotate the crankshaft clockwise using a wrench on the crank
93. 0830 0000820 YANMAR ENGINE Special Service Tools Cont Tool Name Applicable model and tool size Illustration Camshaft Bushing Tool L1 L2 di d2 For Removing 0 709 in 2 756 in 1 772 in 1 890 in Camshaft 18 mm 70 mm 45 mm 48 mm 44 03 0 6 Allowance 4106 203 Bushing Locally Manufactured 0000822 Flex Hone For Preparing Part No Cylinder Bore Cylinder Wall ylinder Walls 129400 92410 ps 5 0000823 Piston Ring Compressor Yanmar Part No 955500 02476 For Installing The Piston Insertion Tool is Applicable for Pistons 2 362 4 921 in 60 125 mm Diameter Pistons 0000824 Piston Ring Tool For Removing Installing of Piston Rings Available Locally 0000825 6 17 ENGINE MEASURING INSTRUMENTS Instrument Name Application Illustration Dial Indicator Available Locally Measure shaft bend and end play Test Indicator Available Locally Measurements of narrow or deep portions that cannot be measured by dial gauge 0000832 Magnetic Stand Available Locally For holding the dial gauge when measuring Micrometer Available Locally For measuring the outside diameters of crankshaft pistons piston pins etc 0000834 Cylinder Bore Gauge Available Locally For measuring the inside diameters of cylinder liners bearing bores etc 0000
94. 1 8505 in 46 982 47 002 mm Bearing Insert Thickness 0 0791 0 0793 in 2 009 2 014 mm See Inspection of Crankshaft on page 6 50 0 0008 0 0020 in 0 0047 in Oil Clearance 0 020 0 050 mm 0 120 mm Crankshaft Reconditioning Reference Item Finishing Precision Page 1 6418 1 6422 in 41 702 41 712 mm 1 8387 1 8391 in 46 702 46 712 mm 0 138 0 150 in 3 5 3 8 mm 0 8S Super Polish Thrust Face Finish 1 6 Connecting Rod Journal Undersize Finished Size See Reconditioning the Crankshaft on page 6 51 Main Bearing Journal Undersize Finished Size Journal Radius Journal Face Finish Thrust Bearing Reference Inspection Item Standard Limit Page 0 0044 0 0098 in 0 0110 in 0 111 0 250 mm 0 28 mm 0 0760 0 0780 in 0 0728 in 1 930 1 980 mm 1 850 mm Crankshaft End Play All Models See Removal ofCrankshaft on page 6 44 Bearing Thickness 6 10 YANMAR Piston Inspection Item Standard Limit ENGINE Reference Page Piston Outside Diameter Measure at 90 to the Piston Pin 2 3TNV70 2 7543 2 7555 69 960 69 990 mm 2 7526 in 69 915 mm 3TNV76 2 9904 2 9915 in 75 955 75 985 mm 2 9886 in 75 910 mm Piston Diameter Measurement Location Upward From the Bottom of the Piston 0 8661 0 9843 in 22 0 25 0 mm Piston to Cyl
95. 11 5 TNV IDI Service Manual YANMAR 2 Remove the three bolts Figure 11 6 1 retaining the rear cover Figure 11 6 2 to the rear frame assembly 0000257A Figure 11 6 Remove the brush holder Figure 11 6 3 Remove the brush springs Figure 11 6 4 and brushes Figure 11 6 5 Remove the bolt retaining the regulator assembly Figure 11 7 1 to the holder Figure 11 7 2 0000258A Figure 11 7 YANMAH TNV IDI Service Manual ALTERNATOR Remove the bolts retaining the holder Figure 11 7 2 to the rear frame housing Remove the holder Remove the nut Figure 11 7 3 retaining the insulation bushing Figure 11 7 4 Remove the insulation bushing Remove the two bolts Figure 11 8 1 and two nuts Figure 11 8 2 securing the rear frame housing to the front frame housing 0000265A Figure 11 8 Using a press remove the rotor assembly Figure 11 9 1 from the front frame housing Figure 11 9 2 and rear frame housing Figure 11 10 1 100266A Figure 11 9 11 13 ALTERNATOR 9 Remove the stator assembly Figure 11 10 1 from the front frame housing 0000260A Figure 11 11 Reassembly of Alternator 1 If removed reinstall the two thrust washers Figure 11 12 3 and bearing cover Figure 11 10 Figure 11 12 2 in the rear frame housing Lubricate the outside diameter of a new bearing 10 If itis necessary to re
96. 2 0000583A 1 Lifting Eye Flywheel End 10 Mechanical Fuel Pump If 18 Fuel Filter 2 Engine Coolant Pump Equipped 19 Fuel Return To Fuel Tank 3 Lifting Eye Engine Cooling 11 Fuel Priming Lever 20 Top Filler Port Engine Oil Fan End 12 Dipstick Engine Oil 21 Rocker Arm Cover 4 Engine Cooling Fan 13 Engine Oil Filter 22 Flywheel 5 V Belt 14 Governor Lever 23 Starter Motor 6 Crankshaft V Pulley 15 Fuel Injection Pump 24 Exhaust Manifold 7 Side Filler Port Engine Oil 16 Intake Manifold 25 Alternator 8 Drain Plug Engine Oil 17 Air Intake Port From Air 9 Fuel Inlet Cleaner Engine oil drain plug location may vary based on oil pan options Figure 4 1 YANMAR TNV IDI Service Manual 4 3 GENERAL SERVICE INFORMATION LOCATION OF LABELS Figure 4 2 shows the location of regulatory and safety labels on Yanmar TNV series engines 0000585A Figure 4 2 The typical location of the emission control information label is shown Figure 4 2 1 Typical location of the engine nameplate is shown Figure 4 2 2 Engine Nameplate Typical MAX OUTPUT DISPLACEMENT ENGINE NO YANMAR DIESEL ENGINE YANMAR DIESEL ENGINE CO LTD MADE IN JAPAN 0000287 4 4 EPA ARB EMISSION CONTROL REGULATIONS USA ONLY Yanmar TNV engines meet Environmental Protection Agency EPA U S Federal emission control standards as well as the California Air Resources Board ARB California re
97. 2145 Figure 11 27 11 21 ALTERNATOR 3 Reinstall the front bearings Figure 11 28 5 and spacer Figure 11 28 6 4 Reinstall the flat washer Figure 11 28 4 flywheel Figure 11 28 3 pulley half Figure 11 28 2 and through bolt Figure 11 28 1 0002144 Figure 11 28 5 Reinstall the flat washer Figure 11 23 4 lock washer Figure 11 23 3 and nut Figure 11 23 2 Tighten the nut to the specified torque 6 Reinstall the rear cap Figure 11 23 1 1 0002143 Figure 11 29 11 22 Installation of Dynamo 1 Position the dynamo on the gear case Loosely reinstall the nut Figure 11 19 2 on the gear case stud and the V belt adjuster bolt Figure 11 19 1 6 2 1 1 1 Figure 11 30 2 Reconnect the dynamo output wire connector 3 Reinstall the V belt Tighten the V belt to the proper tension as described in Check and Adjust Cooling Fan V belt on page 5 28 4 Startthe engine Listen for any unusual sounds from the alternator Do not operate the engine if the alternator is producing unusual sounds Damage to the alternator will result 0000039en 5 Verify that the charge indicator is ON while the engine is operating If the charge indicator is not ON repair the problem before operating the engine TNV IDI Service Manual YANMAR Section 12 ELECTRIC WIRING Page Electric Wiring Precautions 2
98. 3 4 0000151A Figure 10 9 13 Remove the pinion stop Figure 10 10 3 return spring if equipped and pinion clutch assembly Figure 10 10 2 from the pinion shaft Figure 10 10 1 0002487 Figure 10 11 15 Inspect the intermediate bushing Figure 10 11 2 and replace if worn or damaged 16 Inspect armature bushing Figure 10 11 7 and replace if worn or damaged YANMAR TNV IDI Service Manual 10 11 STARTER MOTOR Cleaning and Inspection Armature Commutator Surface Inspection If the commutator surface is rough polish the surface with a 500 to 600 emery cloth 0000117 Figure 10 12 Measure Commutator Outside Diameter Measure the commutator outside diameter Replace the armature if the measurement is less than the limit 0000113 Figure 10 13 See Starter Motor Specifications on page 10 6 for the service limit 10 12 Measure Commutator Insulation Depth Measure the depth of the insulating material Figure 10 14 1 between commutator segments Figure 10 14 2 If the depth measures less than the limit use a hacksaw blade Figure 10 14 3 to remove the insulating material until the depth is within the limit A normal commutator condition is indicated in Figure 10 14 4 An abnormal commutator condition is indicated in Figure 10 14 5 3 0000118 Figure 10 14 See Starter Motor Specifications on page 10 6 for the service
99. 42en YANMAR TNV IDI Service Manual N COOLING SYSTEM Reinstall the engine coolant pump bolts Tighten the bolts Inspect and reinstall the coolant hoses and the temperature switch lead wire Reinstall the engine coolant pump V pulley Figure 8 12 3 spacer Figure 8 12 2 engine coolant fan Figure 8 12 1 and engine coolant fan guard if equipped 4 0001959B Figure 8 12 COOLING SYSTEM 8 Inspect the condition of the V belt There must be clearance Figure 8 13 1 between the V belt and the bottom of the pulley groove If there is no clearance Figure 8 13 2 between the V belt and the bottom of the pulley groove replace the V belt TN 1 2 0000584 Figure 8 13 Reinstall the V belt Tighten the V belt to the proper tension See Check and Adjust Cooling Fan V belt on page 5 28 10 Reinstall and tighten the drain plug or close the 11 drain cock in the radiator Reinstall and tighten the engine block drain plug or reconnect the coolant hose at the oil cooler Fill radiator and engine with engine coolant See Drain Flush and Refill Cooling System with New Coolant on page 5 34 Only use the engine coolant specified Other engine coolants may affect warranty coverage cause an internal buildup of rust and scale and or shorten engine life Prevent dirt and debris from contaminating the engine coolant
100. 500 hours even if it is not damaged or dirty When replacing the element clean the inside of the air cleaner case Figure 5 12 4 If the air cleaner is equipped with a double element only remove and replace the inner element Figure 5 13 1 if the engine lacks power or the dust indicator actuates if equipped This is in addition to replacing the outer element TNV IDI Service Manual Replace Fuel Filter DANGER FIRE AND EXPLOSION HAZARD Diesel fuel is extremely flammable and explosive under certain conditions When you remove any fuel system component to perform maintenance such as changing the fuel filter place an approved container under the opening to catch the fuel NEVER use a shop rag to catch the fuel Vapors from the rag are extremely flammable and explosive Wipe up any spills immediately Wear eye protection The fuel system is under pressure and fuel could spray out when you remove any fuel system component Failure to comply will result in death or serious injury 0000009en For maximum engine life Yanmar recommends that when shutting the engine down you allow the engine to idle without load for five minutes This will allow the engine components that operate at high temperatures such as the turbocharger if equipped and exhaust system to cool slightly before the engine itself is shut down 0000008en YANMAR TNV IDI Service Manual
101. 6 75 1 See Crankshaft on page 6 9 for specifications Take measurements at several places around each bearing surface If not within specification grind the journals and install undersize bearings or replace the crankshaft Record the measurements 1 2 0001733A Figure 6 75 YANMAR Reconditioning the Crankshaft If any of the crankshaft journals do not meet the specifications it may be possible to grind any or all of them to an undersize The connecting rod bearings main bearings and thrust bearing inserts are available as 0 010 in 0 25 mm undersize If the journals are ground undersize the following finishing standards must be adhered to N JAL 0000234A Item Finishing Precision Connecting Rod Journal 1 6418 1 6422 in Undersize Finished Size 41 702 41 712 mm Main Bearing Journal 1 8387 1 8391 in Undersize Finished Size 46 702 46 712 mm Journal Radius R ce Pes m Journal Face Finish Ry 0 8S Super Polish Thrust Face Finish 1 1 6 Figure 6 76 Inspection of Camshaft 1 Use V blocks and a dial indicator to check camshaft bend Figure 6 77 Place the indicator on the center bearing journal ENGINE 0002196 Figure 6 77 Rotate the camshaft and observe the runout Record the measurements See Camshaft on page 6 8 for specifications Measure the height of each lobe Figure 6 78 1 Recor
102. 83 2 63 12 2 05 3 31 11 2 30 4 15 10 2 59 5 27 2 91 6 62 3 26 8 35 3 67 10 6 4 11 13 3 4 62 16 8 5 19 21 2 5 83 26 7 6 54 33 6 7 35 42 4 0 1 0 8 25 53 4 00 2 0 9 27 67 5 000 3 0 10 40 85 0 0000 4 0 11 68 107 2 00000 5 0 13 12 135 1 000000 6 0 14 73 170 3 1 1 circular mil 0 0005067 YANMAR TNV IDI Service Manual 12 7 ELECTRIC WIRING This Page Intentionally Left Blank 12 8 TNV IDI Service Manual YANMAR Section 13 TROUBLESHOOTING Page Special Service pura np uan etn eR 13 3 Troubleshooting By Measuring Compression Pressure 13 4 Quick Reference Table For Troubleshooting 13 6 YANMAR TNV IDI Service Manual TROUBLESHOOTING This Page Intentionally Left Blank 13 2 TNV IDI Service Manual YANMAR SPECIAL SERVICE TOOLS Compression Gauge Kit For measuring compression pressure Gauge Yanmar Part No TOL 97190080 TROUBLESHOOTING YANMAR TNV IDI Service Manual 13 3 TROUBLESHOOTING TROUBLESHOOTING BY MEASURING COMPRESSION PRESSURE Compression pressure drop is one of major causes of increasing blow by gas engine oil contamination or increased engine oil consumpti
103. 835 Calipers Available Locally For measuring outside diameters depth thickness and width C 0000836 Depth Micrometer Available Locally For measuring of valve recession 0000837 6 18 Square Available Locally For measuring valve spring inclination and straightness of parts L 0000838 YANMAR Measuring instruments Cont Instrument Name Application ENGINE Illustration V Block Available Locally For measuring shaft bend 0000839 Torque Wrench Available Locally For tightening nuts and bolts to the specified torque pcc 0000840 Feeler Gauge Available Locally For measuring piston ring gaps piston ring clearance and valve adjustment clearance 6 19 ENGINE CYLINDER HEAD Cylinder Head Components 21 0002130 Figure 6 1 6 20 YANMAR ENGINE 1 Baffle Plate Disassembly of Cylinder Head 2 Oil Fill Cap Prepare a clean flat working surface on a 3 Valve Cover Intake Manifold workbench large enough to accommodate the 4 Gasket cylinder head assembly Discard all gaskets 5 Rocker Arm Shaft O rings and seals Use new gaskets O rings and 6 Hocker Arm Shaft Support seals on reassembly of cylinder head 7 Adjuster Lock Nut 8 Valve Adjuster Screw IMPORTANT 9 Rocker Arm Mark all valve train components so they can 10 Retaining Ring be installed in their original locat
104. 970 2 990 mm 0 1161 in 2 950 mm Side Clearance 0 0008 0 0024 in 0 020 0 060 mm 0 0071 in 0 180 mm End Clearance 0 0059 0 0138 in 0 150 0 350 mm 0 0173 in 0 440 mm Piston Ring Cont Inspection Item Standard ENGINE Reference Page Ring Groove Width 0 0610 0 0618 in 1 550 1 570 mm Ring Width 0 0579 0 0587 in 1 470 1 490 mm 0 0571 in 1 450 mm Top Ring Side Clearance 0 0024 0 0039 in 0 060 0 100 mm End Clearance 0 0059 0 0118 in 0 150 0 300 mm 0 0154 in 0 390 mm Ring Groove Width 0 0622 0 0628 in 1 580 1 595 mm 0 0667 in 1 695 mm Ring Width 3TNV76 Second Ring 0 0563 0 0571 in 1 430 1 450 mm 0 0555 in 1 410 mm Side Clearance 0 0005 0 0065 in 0 013 0 165 mm 0 0112 in 0 285 mm End Clearance 0 0071 0 0130 in 0 180 0 33 mm 0 0165 in 0 42 mm Ring Groove Width 0 1185 0 1193 in 3 010 3 030 mm 0 1232 in 3 130 mm Ring Width Oil Ring 0 1169 0 1177 in 2 970 2 990 mm 0 1161 in 2 950 mm Side Clearance 0 0008 0 0024 in 0 020 0 060 mm 0 0071 in 0 180 mm End Clearance Connecting Rod Connecting Rod Small End Inspection Item 0 0079 0 0177 in 0 200 0 450 mm Standard 0 0213 in 0 540 mm Limit See Inspection of Pist
105. ARTER MOTOR 0000125 Figure 10 24 Coil Resistance Test See Starter Motor Specifications on page 10 6 for the service limit Contact Continuity Test Depress the plunger at the bottom of the solenoid switch Check for continuity between the B and M terminals using a multimeter The multimeter should indicate continuity If the multimeter does not indicate continuity replace the solenoid switch E 0000126 Figure 10 25 10 15 STARTER MOTOR Pinion Clutch Assembly Reassembly of Starter Motor Pinion Clutch Assembly Inspection 1 Apply a light coat of NPC FC6A grease to the Manually rotate the pinion clutch assembly in the pinion shaft drive direction It should rotate freely in the drive 2 Reassemble the reduction gear direction and is locked by turning it in the opposite Figure 10 28 4 pinion shaft direction Replace the pinion clutch assembly if the Figure 10 28 5 planetary gears results are different Figure 10 28 6 and washers into the intermediate housing Figure 10 28 3 Reinstall snap ring Figure 10 28 1 4 0000127 10 26 Slide the pinion clutch assembly on the shaft It should slide smoothly on the shaft Rust too much grease or damage could prevent the pinion clutch from sliding smoothly If the pinion clutch assembly does not slide smoothly clean the shaft and pinion clutch assembly or replace the damaged component 0002487
106. BREVIATIONS AND SYMBOLS Abbreviations A ampere AC alternating current ACEA Association des Constructeurs Europ ens d Automobilies Ah ampere hour approx approximately API American Petroleum Institute ARB Air Resources Board ATDC after top dead center BTDC before top dead center degree Celsius CARB California Air Resources Board CCA cold cranking amp cm centimeter cm cubic centimeter cm min cubic centimeter per minute cu in cubic inch DC direct current DI direct injection DVA direct volt adapter EPA Environmental Protection Agency ESG electronic speed governor F degree Fahrenheit fl oz fluid ounce U S floz min fluid ounce U S per minute ft foot ft lb foot pound ft Ibf min foot pound force per minute g gram gal hr gallon U S per hour gal gallon U S GL gear lubricant hp horsepower U S hrs hours inside diameter IDI indirect injection in inch in Ib inch pound JASO Japanese Automobile Standards Organization kg kilogram 4 26 kgf cm kgf m km kPa kW L L hr Ib Ibf mL mm MPa mV N N m No O D 02 PS psi qt RPM SAE sec t TBN TDC V VAC VDC W Symbols o T kilogram force per square centimeter kilogram force meter kilometers kilopascal kilowatt liter liter per hour pound pond force milliliter millimeter megapascal millivolt newton newton meter number outside diameter ounce horsepowe
107. CHARACTERISTICS 12V ey eee coe 1 DN 1 1 1 J L 4 v LNAYYND LNdLNO 7x 103 6 ALTERNATOR SPEED min 0002138 Figure 11 22 11 19 YANMAH TNV IDI Service Manual ALTERNATOR TESTING OF DYNAMO Use a circuit tester or multimeter to perform the following tests Testing Stator Coil Continuity 1 Disconnect the dynamo output wire connector 2 Connect one meter lead to each of the stator wire terminals and read the meter Results The meter reading should indicate continuity If continuity is not indicated the windings are open and the stator must be replaced Testing Stator Coil Short to Ground 1 Disconnect the dynamo output wire connector 2 Test continuity between each stator wire terminal and engine ground Results The meter reading should indicate infinity If the meter reading indicates continuity the windings are shorted to ground and the stator must be replaced Testing Dynamo Regulated Output 1 Test and record the battery voltage with the engine not running 2 Start the engine and operate it at normal operating rpm 3 Again check the battery voltage with the engine running Results The meter reading with the engine running must be higher than with the engine not running f results are not correct test the stator for continuity and shorts to the ground Chec
108. CT HAZARD ALWAYS wear eye protection when servicing the engine and when using compressed air or high pressure water Dust flying debris compressed air pressurized water or steam may injure your eyes Failure to comply may result in minor or moderate injury 0000003en HAZARD Carefully rotate the alternator toward the cylinder block while loosening the V belt Failure to comply may result in minor or moderate injury 0000014en 2 x NEVER permit anyone to operate the engine or driven machine without proper training Read and understand this Operation Manual before you operate or service the machine to ensure that you follow safe operating practices and maintenance procedures Machine safety signs and labels are additional reminders for safe operating and maintenance techniques See your authorized Yanmar industrial engine dealer or distributor for additional training 0000002en Do not short circuit the charging system between alternator terminals IG and L Damage to the alternator will result 0000035en TNV IDI Service Manual ALTERNATOR Do not connect a load between Using a non specified V belt will cause alternator terminals L and E Damage to inadequate charging and shorten the the alternator will result belt life Use the specified belt 0000036en 0000052en Do not operate the engine if the Agricultu
109. ER install the engine in a floodplain unless proper precautions are taken to avoid being subject to a flood NEVER expose the engine to the rain 0000003en TNV IDI Service Manual YANMAR Observe the following environmental operating conditions to maintain engine performance and avoid premature engine wear NEVER run the engine if the ambient temperature is above 113 F 45 C or below 5 F 15 C If the ambient temperature exceeds 113 F 45 C the engine may overheat and cause the engine oil to break down If the ambient temperature falls below 5 F 15 C rubber components such as gaskets and seals will harden causing premature engine wear and damage Contact your authorized Yanmar industrial engine dealer or distributor if the engine will be operated in either temperature extreme Contact your authorized Yanmar industrial engine dealer or distributor if you need to operate the engine at high altitudes At high altitudes the engine will lose power run rough and produce exhaust gases that exceed the design specifications 0000065en NEVER hold the key in the START position for longer than 15 seconds or the starter motor will overheat 0000007en YANMAR TNV IDI Service Manual PERIODIC MAINTENANCE For maximum engine life Yanmar recommends that when shutting the engine down you allow the engine to idle without load for five minutes This will al
110. ESISTANCE ELECTRIC WIRING Maximum Total Battery Cable Length Positive Cable Negative Cable a 12V Starter Motor Output Less Than 2 68 hp 2 kW Greater Than 2 68 hp 2 kW m ft m 1 5 4 75 N A 2 3 7 4 N A 3 8 12 6 2 3 4 6 15 3 2 8 0 1 0 5 9 19 5 3 5 00 2 0 7 0 22 8 4 2 000 3 0 9 3 30 5 5 6 0000 4 0 11 9 39 0 7 1 00000 5 0 N A N A 8 3 000000 6 0 N A N A Note Total allowable resistance of the complete battery cable circuit positive cable negative cable a a Resistance Q of a battery switch or other electrical equipment having high resistance For starter motors of less than 2 68 HP 2 kW the total resistance must be less than 0 002 Q For starter motors of greater than 2 68 HP 2 kW the total resistance must be less than 0 0012 YANMAR TNV IDI Service Manual 12 5 ELECTRIC WIRING ELECTRICAL WIRE SIZES VOLTAGE DROP Total current on circuit in amps 12 Volts Length of conductor from source of current to device and back to source feet 20 25 30 40 50 60 70 80 90 100 110 120 130 140 150 5 A a4 o A o 10 o A o 15 o o 20 25 30
111. Failure to comply will result in death or serious injury 0000006en YANMAR TNV IDI Service Manual PERIODIC MAINTENANCE EXHAUST HAZARD NEVER operate the engine in an enclosed area such as a garage tunnel underground room manhole or ship s hold without proper ventilation NEVER block windows vents or other means of ventilation if the engine is operating in an enclosed area All internal combustion engines create carbon monoxide gas during operation Accumulation of this gas within an enclosure could cause illness or even death Make sure that all connections are tightened to specifications after repair is made to the exhaust system Failure to comply could result in death or serious injury 0000003en PERIODIC MAINTENANCE NG SEVER HAZARD Keep hands and other body parts away from moving rotating parts such as the cooling fan flywheel or PTO shaft Wear tight fitting clothing and keep your hair short or tie it back while the engine is running Remove all jewelry before you operate or service the machine NEVER start the engine in gear Sudden movement of the engine and or machine could cause death or serious personal injury NEVER operate the engine without the guards in place Before you start the engine make sure that all bystanders are clear of the area Keep children and pets away while the engine is operating Check before starting the engine th
112. Failure to follow these procedures may seriously harm the environment Follow the guidelines of the EPA or other governmental agency for the proper disposal of hazardous materials such as engine oil diesel fuel and engine coolant Consult the local authorities or reclamation facility NEVER dispose of hazardous materials irresponsibly by dumping them into a sewer on the ground or into ground water or waterways 0000013en Regularly check the fuel system and engine coolant system hoses If they are cracked or degraded replace them Replace the hoses at least every two years See Check and Replace Fuel Hoses and Engine Coolant Hoses on page 5 38 Lap the Intake and Exhaust Valves Adjustment is necessary to maintain proper contact of the valves and seats See Inspection of Intake and Exhaust Valves on page 6 27 5 38 TNV IDI Service Manual YANMAR Section 6 ENGINE TNV IDI Service Manual Before You Begin Servicing 6 3 Ig ipse 6 6 Cylinder Head Specifications 1 6 6 Adjustment Specifications 41 6 6 CV liner IBA EN 6 6 Intake Exhaust Valve and Guide 6 7 c 6 7 Valve Spring eee 6 7 Hocker Arm and 6 8 Camshaft and Timing Gear Train Specifications
113. Figure 10 5 5 Remove the two through bolts Remove the rear cover Figure 10 5 2 6 Pull the brush springs up using a brush spring puller On the negative side bring the brush spring into contact with the side of the brushes to hold the brushes clear of the commutator surface On the positive side remove the brushes from the brush holder assembly Figure 10 6 10 10 0000143 Figure 10 6 7 Remove the brush holder assembly Figure 10 7 1 0000144A Figure 10 7 8 Pull the field assembly Figure 10 7 3 off from the armature assembly Figure 10 7 2 9 Remove the armature from the intermediate housing 10 Remove the intermediate housing gear and pinion shaft assembly Figure 10 8 4 from the pinion housing Figure 10 8 3 Disengage from the shift lever as it is removed 11 Remove the shift lever Figure 10 8 2 pin and spacer Figure 10 8 1 TNV IDI Service Manual YANMAR STARTER MOTOR 1 2 4 0000148 Figure 10 8 TS m Figure 10 10 12 Pull the pinion stop Figure 10 9 1 down to expose the retaining ring Using a flat blade 14 Remove the snap ring Figure 10 11 1 screwdriver remove the retaining ring Remove the pinion shaft Figure 10 11 5 Figure 10 9 2 from the pinion shaft planetary gears Figure 10 11 6 washers and reduction gear Figure 10 11 4 from the intermediate housing Figure 10 11
114. GRAM ELECTRIC WIRING Note The following wiring diagram is representative of a common installation using a Yanmar engine The actual installation may be equipped with a variety of electrical components and wiring harnesses Contact the machine manufacturer for specific information X YAZAKI NO YAZAKI NO SA FUSE 7193 2128 7122 2128 Bd ELECTRICAL FUEL FEED PUMP DC18V 154 SUMITOMO NO BI rg 119225 52102 6189 0442 0443 00 70 0 5Kg cm OFF o 114250 39450_ 4 0 PRESS SWITCH Plat CB104 DCieV 14 PILOT LAMP BATO DCI2V LESS THAN 3 4W Li LA206 W TEMP SWITCH XCB104 12 0 44 GENERATOR 3 4W PILOT LAMP gt 553 072 40 o DC12V LESS THAN 3 4W x SUMITOMO NO STOP SOLENOID 6195 0060 TIMER T S SUMITOMO NO wes x _ 5 ET 00 5 5S5 5 5 D oo YAZAKI NO YAZAKI YAZAKI NO E p AA verd oo _ m eme FM YAZAKI MOs YAZAKI NO 1 1 D AVIOD Ens Qc On x 000 SOLENOID DC12V Em mm az gt HOLD 0 49A by lr O SUMITOMO NO 12 1 lt 5 PULL 36 5A mm7 6195 0024 14 4 11633 77932 4 SUMITOMO NO 7222 6234 40 SAFETY RELAY E ee
115. Oil Pan Capacity 3 0 1 Dipstick Upper Limit Lower Limit 3 7 2 1 qt 8 5 2 0 L Dipstick Upper Limit Lower Limit 6 qt 2 8 1 5 L Dipstic Lower Limit per Limit Engine Coolant Capacity 0 2 gal 0 9 L Engine Only Standard Cooling Fan Engine Specifications Without Radiator Engine oil capacity for a Deep Standard oil pan Refer to the operation manual provided by the driven machine manufacturer for the actual engine oil capacity of your machine YANMAR TNV IDI Service Manual 5 Blades Pusher Type May vary depending on application 4 21 GENERAL SERVICE INFORMATION 3TNV76 Engine Model 3TNV76 Version VM Type Vertical Inline Diesel Engine Combustion System Aspiration Ball Type Swirl Chamber Natural No of Cylinders 3 Bore x Stroke 2 992 x 3 228 in 76 x 82 mm Displacement 68 029 cu in 1 115 L Continuous Rated Output Max Rated Output Net 14 9 20 3 High Idling 267 5 25 Engine Weight Dry With Flywheel Housing 242 6 Ib 110 kg Firing Order 1 8 2 1 No 1 Cylinder on Flywheel Side Fuel Injection Timing See Checking and Adjusting Fuel Injection Timing on page 7 21 PTO Position Flywheel Side Direction of Rotation Counterclockwise Viewed From Flywheel Side
116. The fuel injector is essentially a spring loaded valve When fuel pressure from the fuel injection pump reaches a pre determined level the pintle valve is forced off its seat and fuel is atomized as it passes between the pintle and seat The timing and quantity of the fuel injected into the cylinder is controlled by the fuel injection pump and governor assembly 7 6 Stop Solenoid The ML fuel injection pumps are equipped with a stop solenoid that controls the fuel flow inside the fuel injection pump With the starter switch in the OFF position no current flows to the stop solenoid and the solenoid plunger is extended holding the fuel injection pump fuel rack in the closed position and not allowing fuel to flow through the injection pump and to the engine When the starter switch is turned to the start position the pull coil 36 5 Amp draw white wire inside the solenoid is activated and pulls the solenoid plunger into the solenoid This releases the fuel injection pump fuel rack allowing fuel to flow through the injection pump and allowing the engine to start and run When the starter switch is returned to the ON or RUN position the pull coil no longer receives current and the hold coil 0 5 Amp draw red wire inside the solenoid is activated The hold coil holds the solenoid plunger in the RUN position allowing fuel to continue flowing and the engine to continue running To stop the engine the key switch is tu
117. Yanmar industrial engine dealer or distributor 0000017en Establish a periodic maintenance plan according to the engine application and make sure you perform the required periodic maintenance at intervals indicated Failure to follow these guidelines will impair the engine s safety and performance characteristics shorten the engine s life and may affect the warranty coverage on your engine See Yanmar Co Ltd Limited Emission Control System Warranty USA Only on page 2 6 Consult your authorized Yanmar dealer or distributor for assistance when checking items marked with a e 0000024enTNVIDISM YANMAR TNV IDI Service Manual PERIODIC MAINTENANCE If the fuel filter water separator is positioned higher than the fuel level in the fuel tank water may not drip out when the fuel filter water separator drain cock is opened If this happens turn the air vent screw on the top of the fuel filter water separator 2 3 turns counterclockwise Be sure to tighten the air vent screw after the water has drained out 0000025en When the engine is operated in dusty conditions clean the air cleaner element more frequently NEVER operate the engine with the air cleaner or element s removed This may cause foreign material to enter the engine and damage it 0000026en The maximum air intake restriction shall be 0 90 psi 6 23 kPa 635 mm Aq or less Clean or replace the air cleaner e
118. adiator cap and the surrounding area before you remove the cap NEVER mix different types of engine coolants This may adversely affect the properties of the engine coolant 0000006en Do not loosen or remove the four bolts retaining the fuel injection pump drive gear to the fuel injection pump hub Do not disassemble the fuel injection pump drive gear from the hub Correct fuel injection timing will be very difficult or impossible to achieve 0000031en Identify all parts and their location using an appropriate method It is important that all parts are returned to the same position during the reassembly process 0000080en Keep the piston pin parts piston assemblies and connecting rod assemblies together to be returned to the same position during the reassembly process Label the parts using an appropriate method 0000088en Do not allow the honing tool to operate in one position for any length of time Damage to the cylinder wall will occur Keep the tool in constant up and down motion 0000090en Any part which is found defective as a result of inspection or any part whose measured value does not satisfy the standard or limit must be replaced 0000119en ENGINE Any part determined to not meet the service standard or limit before the next service as determined from the state of current rate of wear should be replaced even though the part cu
119. aged or corroded connectors ALWAYS keep the connectors and terminals clean Failure to comply could result in death or serious injury 0000009en NO SEVER HAZARD Stop the engine before you begin to service it NEVER leave the key in the key switch when you are servicing the engine Someone may accidentally start the engine and not realize you are servicing it This could result in a serious injury If you must service the engine while it is operating remove all jewelry tie back long hair and keep your hands other body parts and clothing away from moving rotating parts Failure to comply could result in death or serious injury 0000010en 5 10 4 SE PE BURN HAZARD If you must drain the engine oil while it is still hot stay clear of the hot engine oil to avoid being burned ALWAYS wear eye protection Failure to comply could result in death or serious injury 000001 1en FLYING OBJECT HAZARD ALWAYS wear eye protection when servicing the engine and when using compressed air or high pressure water Dust flying debris compressed air pressurized water or steam may injure your eyes Failure to comply may result in minor or moderate injury 0000003en TNV IDI Service Manual YANMAR COOLANT HAZARD Wear eye protection and rubber gloves when you handle Long Life or Extended Life engine coolant I
120. ailure to comply could result in death or serious injury BURN HAZARD Batteries contain sulfuric acid NEVER allow battery fluid to come in contact ______ with clothing skin or eyes Severe BURN HAZARD f you must drain the engine oil while it is still hot stay clear of the hot engine oil to avoid being burned Failure to comply could result in death or serious injury 000001 1en burns could result ALWAYS wear safety goggles and protective clothing ull when servicing the battery If contact with the skin and or eyes should Sy occur flush with a large amount of water and obtain prompt medical SHOCK HAZARD treatment Turn off the battery switch if equipped or disconnect the negative battery cable before servicing the electrical system Failure to comply could result in death or serious injury 0000007en Check the electrical harnesses for cracks abrasions and damaged or corroded connectors ALWAYS keep the connectors and terminals clean Failure to comply could result in death or serious injury 0000009en 3 10 TNV IDI Service Manual YANMAR SAFETY NO SEVER HAZARD To prevent possible eye injury always Stop the engine before you begin to 72 it y wear SAFETY GLASSES while servicing the engine NEVER leave the key in the key switch when you are servicing the engine Someone may accid
121. al reminders for safe operating and maintenance techniques See your authorized Yanmar industrial engine dealer or distributor for additional training 0000002en YANMAH TNV IDI Service Manual NO SEVER HAZARD Stop the engine before you begin to service it NEVER leave the key in the key switch when you are servicing the engine Someone may accidentally start the engine and not realize you are servicing it This could result in a serious injury If you must service the engine while it is operating remove all jewelry tie back long hair and keep your hands other body parts and clothing away from moving rotating parts Failure to comply could result in death or serious injury 0000010en 1 qu BURN HAZARD Keep your hands and other body parts away from hot engine surfaces such as the muffler exhaust pipe turbocharger if equipped and engine block during operation and shortly after you shut the engine down These surfaces are extremely hot while the engine is operating and could seriously burn you Failure to comply could result in death or serious injury 0000015en LUBRICATION SYSTEM iD ue FUME BURN HAZARD Always read and follow safety related precautions found on containers of hazardous substances like parts cleaners primers sealants and sealant removers Failure to comply could result in death or serious inju
122. aler or distributor by visiting the Yanmar Co LTD website at http www yanmar co jp The Japanese language page will be displayed For English language click on English Click on Network in the web site heading to view the Yanmar Worldwide Network Choose and Click on the desired product group Click on the Icon closest to your region Click on the desired country or Associate company to locate your nearest authorized Yanmar industrial engine dealer or distributor You may also contact Yanmar by clicking on Inquiry in the web site heading and typing in your question or comment What Yanmar Will Do Yanmar warrants to the original retail purchaser of a new Yanmar engine that Yanmar will make such repairs and or replacements at Yanmar s option of any parts s of the Yanmar product covered by this Warranty found to be defective in material and or workmanship Such repairs and or replacements will be made at a location designated by Yanmar at no cost to the purchaser for parts or labor What is Not Covered by this Warranty This Warranty does not cover parts affected by or damaged by any reason other than defective materials or workmanship including but not limited to accident misuse abuse Acts of God neglect improper installation improper maintenance improper storage the use of unsuitable attachments or parts the use of contaminated fuels the use of fuels oils lubrica
123. alve Stop Spacer 8 Nozzle Valve 9 Nozzle Body 10 Nozzle Case Nut Figure 7 34 7 28 Place the fuel injector in a soft jawed vice with the nozzle pointing up Remove the nozzle case nut Carefully remove the injector from the vice Turn the injector over and remove the nozzle body nozzle valve valve stop spacer nozzle spring seat nozzle spring and shims Inspect the sealing surfaces Figure 7 35 2 between the valve stop spacer and nozzle body for nicks or scratches Check the contact area between the valve stop spacer and the nozzle valve Figure 7 35 1 for scoring or pitting Use a magnifying glass to inspect 1 gt Q c o 0001333A Figure 7 35 TNV IDI Service Manual YANMAR 7 Perform a nozzle valve slide test a Wash nozzle body and valve in clean diesel fuel b While holding the nozzle body vertical pull the nozzle valve about 2 3 of the way out Figure 7 35 c Release the valve It should fall smoothly to its seat by its own weight 0001332A Figure 7 36 Replace the fuel injector assembly if it fails any inspection Adjusting Fuel Injector Pressure The fuel injectors open when pressure reaches a predetermined pressure threshold They close when the pressure is reduced below that threshold The pressure threshold can be adjusted by adding or removing shims Figure 7 37 4 YANMAR TNV IDI Service Manual FUEL SYSTEM Return Fuel
124. and fail if the resistance is higher than the specified value 0000057en YANMAR TNV IDI Service Manual ELECTRIC WIRING Removing the battery cables or the battery while the engine is operating may cause damage to the current limiter depending on the electrical equipment being used This situation could cause loss of control of output voltage The continuous high voltage of 23 24 volts for 5000 rpm dynamo will damage the current limiter and other electrical equipment 0000058en Reversing the battery cable connections at the battery or on the engine will destroy the SCR diode in the current limiter This will cause the charging system to malfunction and may cause damage to the electrical harnesses 0000059en 12 3 ELECTRIC WIRING ELECTRICAL WIRE RESISTANCE Metric Nominal mm Ohms Foot Resistance 0 5 0 009967 0 8 0 006340 0 004359 0 002685 0 001704 0 001073 0 000707 0 000421 0 000270 0 000158 0 1 0 0 000130 0 000103 00 2 0 0 000087 000 3 0 0000 4 0 0 000066 0 000051 Wiring voltage drop should not exceed 5 0 05 x 12 Volts 0 6 Volts Voltage Drop Current Amps x Length of Wire Feet x Resistance per Foot Ohms Example Current draw of 100 Amps x 3 feet of 4 AWG wire 100 Amps x 3 Feet x 0 000270 0 08 Volts Voltage Drop TNV IDI Service Manual YANMAR BATTERY CABLE R
125. and forth to measure the end play Record the measurement See Camshaft on page 6 8 for the service limit 2 0002191 Figure 6 46 Method B Use a feeler gauge to measure the clearance between the thrust plate Figure 6 47 1 and front camshaft bearing Figure 6 47 2 Record the measurement See Thrust Bearing on page 6 10 for the service limit 1 2 0001710B Figure 6 47 ENGINE Remove two bolts Figure 6 48 3 retaining the camshaft thrust plate Figure 6 48 1 0002186 Figure 6 48 Extract the tappets Figure 6 48 5 through the top of the cylinder block Mark the tappets so they can be reinstalled in the same location Slowly pull the camshaft Figure 6 48 2 assembly out of the engine being careful not to damage the front camshaft bushing Remove the camshaft drive gear Figure 6 48 4 only if the gear or camshaft require replacement Use a knife edge puller and a press to remove the gear The gear is a shrink fit and will need to be heated to 356 392 F 180 200 C to remove Removal of Gear Case Note The camshaft must be removed before the gear case can be removed See Removal of Camshaft on page 6 41 Remove bolts Figure 6 49 4 Note It is not necessary to remove the fuel injection pump from the gear case to remove the gear case If the fuel injection pump does not need to be repaired leave it mounted to the timing
126. and seals Use new gaskets O rings and seals on reassembly of engine Identify all parts and their location using an appropriate method It is important that all parts are returned to the same position during the reassembly process 0000080en IMPORTANT Mark all valve train components so they can be installed in their original locations Note Record all measurements taken during disassembly If the engine will be completely disassembled the following preliminary steps should be performed 1 Disconnect the battery cables at the battery Always disconnect the negative cable first 2 Remove the throttle cable electrical connections intake and exhaust system connections and fuel supply lines from the engine 3 Remove the alternator See Hemoval of Alternator on page 11 12 4 Drain the engine coolant from the radiator and cylinder block See Drain Flush and Refill Cooling System with New Coolant on page 5 34 Remove the cooling system components from the engine 5 Remove the engine from the machine Mount the engine to a suitable engine repair stand having adequate weight capacity 6 37 ENGINE Be sure to secure the engine solidly to prevent injury or damage to parts due to falling during work on the engine 0000009en 6 Clean the engine by washing with solvent air or steam cleaning Carefully operate so as to prevent any foreign matter or fluids from entering the engine or any fuel sys
127. aning and Inspection Wash the oil pump cover the oil pressure regulator valve the oil pump cavity and the inner and outer rotors Inspect the parts for wear or damage Replace as necessary Note If the oil pump cavity is damaged the gear case cover must be replaced If any oil pump component clearance exceeds its limit the oil pump must be replaced as an assembly 0000015en Check Outer Rotor Outside Clearance 1 Reinstall the outer and inner rotors The dots on the rotor faces must face up Make sure that the pilot on the back of the inner rotor fits into the bore of the oil pump cavity and the top surface of the inner rotor is flush with the top surface of the outer rotor 2 Determine the outside clearance of the outer rotor Insert a feeler gauge between the outer rotor Figure 9 7 1 and the gear case oil pump cavity Figure 9 7 2 N 0001151A Figure 9 7 Record the measurement s and see Outer Rotor Outside Clearance specifications on page 9 5 for the service limits 9 10 Outer Rotor to Inner Rotor Tip Clearance Determine the outer rotor to inner rotor tip clearance Insert a feeler gauge between the top of an inner rotor tooth Figure 9 8 1 and the top of an outer rotor tooth Figure 9 8 2 and measure the clearance MO d 0001150B 1 2 Figure 9 8 Record the measurement s and see Outer Rotor to Inner Rotor Tip Clearance specifications on page 9 10 fo
128. anmar co jp If it is not possible to access the web site please contact the nearest Yanmar dealer or distributor YANMAR TNV IDI Service Manual 2 5 YANMAR WARRANTIES YANMAR CO LTD LIMITED EMISSION CONTROL SYSTEM WARRANTY USA ONLY Your Warranty Rights and Obligations California The California Air Resources Board CARB the Environmental Protection Agency EPA and Yanmar Co Ltd hereafter referred to as Yanmar are pleased to explain the emission control system warranty on your industrial compression ignition engine In California model year 2000 or later off road compression ignition engines must be designed built and equipped to meet the State s stringent anti smog standards In all states 1998 and later non road compression ignition engines must be designed built and equipped to meet the United States EPA emissions standards Yanmar warrants the emission control system on your engine for the periods of time listed below provided there has been no abuse neglect or improper maintenance of your engine Your emission control system may include parts such as the fuel injection system and the air induction system Also included may be hoses belts connectors and other emission related assemblies Where a warrantable condition exists Yanmar will repair your non road compression ignition engine at no charge to you including diagnosis parts and labor Manufacturer s Warranty Period The model year 1998 or later certified an
129. asure the next cylinder Continue until all valves are adjusted 6 35 ENGINE CYLINDER BLOCK Crankshaft amp Camshaft Components SS 4 1 gt 9 d 4 12 e d 4 fi 2 16 ia Sp 15 0 14 A 31 82 30 Lyd ri 17 29 2 18 28 WA 8 9 0002180 Figure 6 38 d YANMAR Cylinder Block Camshaft Bushing Gear Case Dowel 2 used O Ring Gear Case Cover Front Crankshaft Seal Fuel Injection Pump Gear Cover Tappets Camshaft Camshaft Gear Key Camshaft End Plate Camshaft Gear Idler Gear Shaft ldler Gear Bushing Idler Gear Oil Pickup O ring Oil Pickup Crankshaft Crankshaft Gear Key Crankshaft Gear Crankshaft Pulley Main Bearing Inserts Main Bearing Cap Crankcase Extension Oil Pan Thrust Bearings Flywheel Connecting Rod Cap Connecting Rod Bearing Inserts Connecting Rod Wrist Pin Bushing Circlip Wrist Pin Piston Oil Ring Second Compression Ring Top Compression Ring Dowel 2 used Crankshaft Rear Seal Flywheel Housing ENGINE Disassembly of Cylinder Block Components Prepare a clean flat working surface on a workbench large enough to accommodate the engine components Discard all used gaskets O rings
130. at any tools or shop rags used during maintenance have been removed from the area Failure to comply could result in death or serious injury 0000002en A Ee ER Se BURN HAZARD Keep your hands and other body parts away from hot engine surfaces such as the muffler exhaust pipe turbocharger if equipped and engine block during operation and shortly after you shut the engine down These surfaces are extremely hot while the engine is operating and could seriously burn you Failure to comply could result in death or serious injury 0000015en 5 8 ALCOHOL AND DRUG HAZARD NEVER operate the engine while you are under the influence of alcohol or drugs NEVER operate the engine when you are feeling ill Failure to comply could result in death or serious injury 0000004en TNV IDI Service Manual YANMAR 92830 PLD A am EXPOSURE HAZARD Wear personal protective equipment such as gloves work shoes eye and hearing protection as required by the task at hand NEVER wear jewelry unbuttoned cuffs ties or loose fitting clothing when you are working near moving rotating parts such as the cooling fan flywheel or PTO shaft ALWAYS tie back long hair when you are working near moving rotating parts such as a cooling fan flywheel or PTO shaft NEVER operate the engine while wearing a headset to listen to music or radio because it will be difficult to
131. ating conditions are as follows SAE J1349 ISO 3046 1 Atmospheric Condition Room temperature 77 F 25 C Atmospheric pressure 29 53 in Hg 100 kPa 750 mm Hg Relative humidity 3096 Fuel Temperature at Fuel Injector Pump Inlet 104 F 40 C With Cooling Fan Air Cleaner Muffler Yanmar Standard After Engine Break In Period Output Allowable Deviation x 396 e 1 PS 0 7355 kW 1 hp SAE Society of Automotive Engineers 0 7457 kW YANMAR TNV IDI Service Manual 4 19 GENERAL SERVICE INFORMATION PRINCIPAL ENGINE SPECIFICATIONS 2TNV70 Engine Model 2TNV70 Version Type Vertical Inline Diesel Engine Combustion System Ball Type Swirl Chamber Aspiration Natural No of Cylinders 2 Bore x Stroke 2 756 x 2 913 in 70 x 74 mm Displacement 34 777 cu in 0 570 L Continuous Rated Output rpm min 3000 hp SAE 10 9 kW 8 16 PS 11 1 Max Rated Output Net rpm min 2800 3000 3000 hp SAE 11 44 12 23 12 03 kW 8 53 9 12 8 97 PS 11 6 12 4 12 2 High Idling 2995 3210 3165 rpm 25 25 25 Engine Weight Dry With Flywheel Housing 145 5 10 66 kg Firing Order 1 3 2 1 No 1 Cylinder on Flywheel Side Fuel Injection Timing See Checking and Adjusting Fuel Injection Timing on page 7 21 PTO Position Flywheel Si
132. ator will result 0000037en 0000038en YANMAR TNV IDI Service Manual 3 17 SAFETY Do not use a high pressure wash Make sure that the combined total directly on the alternator Water will resistance of the battery cable in both damage the alternator and result in directions between the starter motor inadequate charging and the battery is within the value indicated on the wiring diagram The starter motor will malfunction or break down if the resistance is higher than the specified value Do not reverse the positive and negative ends of the battery cable The alternator diode and stator coil will be damaged 0000050en 0000054en The starter motor is water proofed according to JIS D 0203 R2 which protects the motor from rain or general When the battery indicator goes out it cleaning Do not use high pressure should not come on again The battery wash or submerse the starter motor in indicator only comes on during water operation if the alternator fails or if the V belt breaks However if an LED is used in the battery indicator the LED will shine faintly during normal operation Use a specialized battery charger to 00000517 recharge a battery with a voltage of 8 volts or less Booster starting a battery with a voltage of 8 volts or less will generate an abnormally high voltage Using a non specified V belt will cause and destroy electrical equipment inadequate charg
133. battery with a voltage of 8 volts or less Booster starting a battery with a voltage of 8 volts or less will generate an abnormally high voltage and destroy electrical equipment 0000056en TNV IDI Service Manual YANMAR INTRODUCTION This section of the Service Manual covers the servicing of starter motor Yanmar Part No 119717 77010 is standard equipment on 3TNV76 model engines and is used in this section to show the service procedures for a representative starter motor For specific part detail see the Yanmar Parts Catalog for the engine being serviced STARTER MOTOR INFORMATION STARTER MOTOR YANMAR Mfg No Load Loaded Part Mfg Model Specification Terminal Amperage Terminal Amperage Number Number Voltage Draw RPM Voltage Draw Torque REM 42 in Ib 119515 428000 DC12V 1 3 hp 3000 1240 77010 Denso 2190 1 0 kW 11 5 90A Max Min 8 0 200 Max 048 kg m Min 61 in Ib 119717 428000 DC12V 1 5 hp 3000 1130 77010 Denso 1590 1 1 kW 11 5 90A Max Min 8 7 230 Max 119740 Denso 428000 DC12V 1 9 hp 11 5 Max 3000 350 Max S NI 1000 77010 3310 1 4 kW Min 138 kgrm Mim YANMAR TNV IDI Service Manual 10 5 STARTER MOTOR STARTER MOTOR SPECIFICATIONS Yanmar Part Number 428000 1590 428000 2190 Nominal Output 1 5 hp 1 1 kW Weight 6 6 Ibs 3 0 kg Revolution Direction As Viewed Fro
134. cient Engine Oil Level Add Correct Engine Oil 2 Engine page Overfilled Engine Crankcase Check Engine Oil See Checking Engine Oil on page 4 13 YANMAR TNV IDI Service Manual 13 11 TROUBLESHOOTING This Page Intentionally Left Blank 13 12 TNV IDI Service Manual YANMAR TROUBLESHOOTING Trouble Symptom Insufficient Poor B Enaine Air Starting Problem Engine Exhaust 9 9 D Surging Coolant Intake Output Color 5 Engine E Starts Exhaust During 6 but Stops Color Work o lt c c c Soon S S4 5 e E algio 5 5 515512 9 m E Corrective Action Reference Page E Smoke 25 o 5 37 8 5s o o S o 5 z olo a o g o 2 amp 51 2 2 2 e c amp o 522 2 2 E 3 2 2 2 5 2 18 5 5 2 2 515 55 2 9 9 amp Cause 2 0 lt 5 25 Too Early Timing of Fuel Injection Pump Check and Adjust 22 2 g Too Late Timing of Fuel
135. city of your machine The following are the engine oil capacities for various Yanmar TNV engines Dipstick Upper Limit Lower Limit 1 7 0 9 qt 1 6 0 8 L 2 4 1 4 qt 2 3 1 3 L 1 7 0 8 qt 1 6 0 8 L 3TNV70 CL 3 0 1 6 qt 3TNV70 VM 2 8 1 5 L 3 7 2 1 qt 3 5 2 0 L 3 0 1 6 qt 2 8 1 5 L 3 6 1 9 qt 8 4 1 8 L Engine Model 2TNV70 VM 2TNV70 CH 2TNV70 VH 3TNV70 CH 3TNV70 VH 3TNV76 VM TNV IDI Service Manual YANMAR GENERAL SERVICE INFORMATION ENGINE COOLANT DANGER SCALD HAZARD NEVER remove the radiator cap if the engine is hot Steam and hot engine coolant will spurt out and seriously burn you Allow the engine to cool down before you attempt to remove the radiator cap Securely tighten the radiator cap after you check the radiator Steam can spurt out during engine operation if the cap is loose ALWAYS check the level of the engine coolant by observing the reserve tank Failure to comply will result in death or serious injury 0000002en 7 BURN HAZARD Wait until the engine cools before you drain the engine coolant Hot engine coolant may splash and burn you Failure to comply could result in death or serious injury 0000016en YANMAR TNV IDI Service Manual COOLANT HAZARD Wear eye protection and rubber gloves when you handle Long Life or Extended Life engine coolant If
136. clearance Figure 5 6 2 between you remove any tue system the V belt and the bottom of the pulley groove component to perform maintenance replace the V belt such changing the fuel filter place an approved container under the opening to catch the fuel 6 Install the new V belt Refer to the table for proper tension NEVER use a shop rag to catch the New V belt Tension fuel Vapors from the rag are extremely A B C flammable and explosive 5 16 7 16in 3 16 5 16in 1 4 7 16 in Wipe up any spills immediately 8 12 mm 5 8mm 7 11 mm Wear eye protection The fuel system mE is under pressure and fuel could spray 7 After adjusting run the engine for 5 minutes or out when you remove any fuel system more Check the tension again using the component specifications for a used V belt Failure to comply will result in death or Used V belt Tension serious injury A B 0000009en 3 8 1 2 in 1 4 3 8 in 5 16 1 2 in 10 14 mm 7 10 mm 9 13 mm 5 22 TNV IDI Service Manual YANMAR If the fuel filter water separator is positioned higher than the fuel level in the fuel tank water may not drip out when the fuel filter water separator drain cock is opened If this happens turn the air vent screw on the top of the fuel filter water separator 2 3 turns counterclockwise Be sure to tighten the air vent screw after the water has drained out
137. ct with the eyes or skin should occur flush eyes and wash immediately with clean water Failure to comply may result in minor or moderate injury 0000005en FLYING OBJECT HAZARD ALWAYS wear eye protection when servicing the engine and when using compressed air or high pressure water Dust flying debris compressed air pressurized water or steam may injure your eyes Failure to comply may result in minor or moderate injury 0000003en Be sure to secure the engine solidly to prevent injury or damage to parts due to falling during work on the engine 0000009en PINCH HAZARD Carefully rotate the alternator toward the cylinder block while loosening the V belt Failure to comply may result in minor or moderate injury 0000014en If any oil pump component clearance exceeds its limit the oil pump must be replaced as an assembly 0000015en TNV IDI Service Manual Only use diesel fuels recommended by Yanmar for the best engine performance to prevent engine damage and to comply with EPA ARB warranty requirements Only use clean diesel fuel NEVER remove the primary strainer if equipped from the fuel tank filler port If removed dirt and debris could get into the fuel system causing it to clog 0000004en If any problem is noted during the visual check the necessary corrective action should be taken before you ope
138. d cause illness or even death Make sure that all connections are tightened to specifications after repair is made to the exhaust system Failure to comply could result in death or serious injury 0000003en Perform periodic maintenance procedures in an open level area free from traffic If possible perform the procedures indoors to prevent environmental conditions such as rain wind or snow from damaging the machine TNV IDI Service Manual YANMAR Yanmar Replacement Parts Yanmar recommends that you use genuine Yanmar parts when replacement parts are needed Genuine replacement parts help ensure long engine life Required EPA ARB Maintenance USA Only To maintain optimum engine performance and compliance with the Environmental Protection Agency EPA Regulations Non road Engines and the California Air Resources Board ARB California it is essential that you follow the Periodic Maintenance Schedule on page 5 17 and Periodic Maintenance Procedures on page 5 19 EPA ARB Installation Requirements USA Only The following are the installation requirements for the EPA ARB Unless these requirements are met the exhaust gas emissions will not be within the limits specified by the EPA and ARB Maximum Exhaust Gas Restriction shall be 2TNV70 0 85 psi 5 88 kPa 600 mm Aq or less e 3TNV70 and 3TNV76 1 70 psi 11 76 kPa 1200 mm Aq or less Maximum air intake restriction shall be 0 90 psi 6
139. d labeled non road compression ignition engines are warranted for the periods listed below If any emission related part on your engine is found to be defective during the applicable warranty period the part will be replaced by Yanmar Engine Type Warranty Period by Number of Years or Hours of Operation Constant speed engines rated at or above The warranty period is five 5 years or 3 000 hours of use whichever occurs first 50 hp SAE 37 kW In the absence of a device to measure the hours of use the engine has a warranty period of five 5 years Constant speed engines rated under 50 hp The warranty period is two 2 years or 3 000 hours of use whichever occurs first SAE 37 kW with rated speeds greaterthan In the absence of a device to measure the hours of use the engine has a or equal to 3 000 rpm warranty period of two 2 years Engines rated at or above 26 hp SAE The warranty period is five 5 years or 3 000 hours of use whichever occurs first 19 kW In the absence of a device to measure the hours of use the engine has a warranty period of five 5 years Engines rated under 26 hp SAE 19 kW The warranty period is two 2 years or 3 000 hours of use whichever occurs first In the absence of a device to measure the hours of use the engine has a warranty period of two 2 years 2 6 TNV IDI Service Manual YANMAR WARRANTIES Limited Emission Control System Warranty USA Only
140. d the hose nozzle firmly against the side of the container while filling it This prevents static electricity buildup which could cause sparks and ignite fuel vapors NEVER place diesel fuel or other flammable material such as oil hay or dried grass close to the engine during engine operation or shortly after shut down Failure to comply will result in death or serious injury 0000014en FIRE AND EXPLOSION HAZARD DANGER 7 j FIRE AND EXPLOSION HAZARD Diesel fuel is extremely flammable and explosive under certain conditions NEVER use diesel fuel as a cleaning agent Failure to comply will result in death or serious injury 0000012en PERIODIC MAINTENANCE DANGER DANGER iL 7 FIRE AND EXPLOSION HAZARD FIRE AND EXPLOSION HAZARD Diesel fuel is extremely flammable and Diesel fuel is extremely flammable and explosive under certain conditions explosive under certain conditions NEVER remove the fuel cap with the When you remove any fuel system engine running component to perform maintenance such as changing the fuel filter place an approved container under the opening to catch the fuel Failure to comply will result in death or serious injury 000001 1en NEVER use a shop rag to catch the fuel Vapors from the rag are extremely DANGER flammable and explosive Wu is under pressure and fuel could spray out w
141. d the measurements See Camshaft on page 6 8 for specifications 0001712A Figure 6 78 Measure the diameter of the gear end Figure 6 79 1 intermediate Figure 6 79 2 and flywheel end Figure 6 79 3 bearing journals Record the measurements See Camshaft on page 6 8 for specifications 0001713A Figure 6 79 ENGINE Inspection of Camshaft Bushing and Bores 1 Measure the I D of the front bushing and the remaining bores in the cylinder block Record the measurements See Camshaft on page 6 8 for specifications If the camshaft bushing is not within specification replace using the appropriate service tool If the remaining bores are not within specification the cylinder block will require replacement as there are no bearing inserts used Inspection of Idler Gear and Shaft 1 Measure the outside diameter Figure 6 80 1 of the idler gear shaft Figure 6 79 2 Record the measurements See Idler Gear Shaft and Bushing on page 6 9 for specifications 2 Measure the inside diameter Figure 6 79 3 of the idler gear bushing Figure 6 79 4 Record the measurements See dler Gear Shaft and Bushing on page 6 9 for specifications 4 1 3 2 Figure 6 80 Honing and Boring Pistons must move freely in the cylinders while maintaining adequate compression and oil sealing If the cylinder walls are scuffed scored out of round or tapered beyond specifications re bore and hone t
142. de Direction of Rotation Counterclockwise Viewed From Flywheel Side Cooling System Liquid Cooled With Radiator Lubricating System Forced Lubrication With Trochoid Pump Normal Oil Pressure at Rated Engine Speed 42 64 psi 0 29 0 44 MPa 2 96 4 49 kgf cm Normal Oil Pressure at Low Idle Speed 8 5 psi 0 06 MPa 0 6 kgf cm or greater Starting System Electric Starting Starter Motor DC12V 1 3 hp 1 0 kW Alternator DC12V 18A Recommended Battery Capacity 12V 36 Amp Hour 5h rating Dimensions L x W x H 16 38 x 16 81 x 20 24 in 416 x 427 x 514 mm 16 38 x 16 81 x 19 06 in 419 x 427 x 484 mm 16 38 x 16 81 x 19 06 in 416 x 427 x 484 mm Engine Oil Pan Capacity 2 4 1 4 qt 2 3 1 31 Dipstick Upper Limit Lower Limit 1 7 0 8 qt 1 6 0 8 L Dipstick Upper Limit Lower Limit 1 7 0 9 qt 1 65 0 8 L Dipstick Upper Limit Lower Limit Engine Coolant Capacity 0 2 gal 0 9 L Engine Only Standard Cooling Fan 11 42 in 290 mm O D 5 Blades Pusher Type Engine Specifications Without Radiator Engine oil capacity for a Deep Standard oil pan Refer to the operation manual provided by the driven machine manufacturer for the actual engine oil capacity of your machine May vary depending on application 4 20 TNV IDI Service Manual YANMAR 3TNV70 Engine Model GENERAL SERVICE INFORMATION
143. drive gear from the hub Correct fuel injection timing will be very difficult or impossible to achieve 0000031en If the oil pump must be replaced replace it as an assembly only Do not replace individual components 0000030en SAFETY Observe the following environmental operating conditions to maintain engine performance and avoid premature engine wear NEVER run the engine if the ambient temperature is above 113 F 45 C or below 5 F 15 C If the ambient temperature exceeds 113 F 45 C the engine may overheat and cause the engine oil to break down If the ambient temperature falls below 5 F 15 C rubber components such as gaskets and seals will harden causing premature engine wear and damage Contact your authorized Yanmar industrial engine dealer or distributor if the engine will be operated in either temperature extreme Contact your authorized Yanmar industrial engine dealer or distributor if you need to operate the engine at high altitudes At high altitudes the engine will lose power run rough and produce exhaust gases that exceed the design specifications 0000065en If any indicator illuminates during engine operation stop the engine immediately Determine the cause and repair the problem before you continue to operate the engine 0000029en Only use the engine oil specified Other engine oils may affect warranty coverage cause
144. driven by a V belt which is powered by the crankshaft V pulley The purpose of the engine cooling fan is to circulate air through the radiator Engine Coolant Pump The engine coolant pump circulates the engine coolant through the cylinder block and cylinder head and returns the engine coolant to the radiator Radiator The radiator acts as a heat exchanger As the engine coolant circulates through the cylinder block it absorbs heat The heat in the engine coolant is dissipated in the radiator As the engine cooling fan circulates air through the radiator the heat is transferred to the air Radiator Cap The radiator cap controls the cooling system pressure The cooling system is pressurized to raise the boiling point of the engine coolant As the engine coolant temperature rises the system pressure and the coolant volume increases When the pressure reaches a preset value the release valve in the radiator cap opens and the excess engine coolant flows into the reserve tank As the engine coolant temperature is reduced the system pressure and volume is reduced and the vacuum valve in the radiator cap opens allowing engine coolant to flow from the reserve tank back into the radiator Reserve Tank The reserve tank contains the overflow of engine coolant from the radiator If you need to add engine coolant to the system add it to the reserve tank not to the radiator Thermostat A thermostat is placed in the cooling system to prevent engine
145. e after grinding Lap the valve face to the valve seat using a mixture of valve lapping compound and engine oil Be sure to thoroughly wash all parts to remove all grinding powder or compound Inspection of Valve Springs Inspect the valve springs If damage or corrosion is seen or if measurements exceed the specified limits replace the springs Record the measurements Fractures Check for fractures on the inside and outside portions of the springs If the valve spring is fractured replace the valve spring Corrosion Check for corrosion of spring material caused by oxidation ENGINE Squareness Reassembly of Cylinder Head Use a flat surface and a square to check each spring for squareness Figure 6 22 See Valve Spring on page 6 7 for the service limit Use new gaskets O rings and seals on reassembly of cylinder head IMPORTANT Liberally oil all components during assembly to prevent premature wear or damage Reassembly of Valve Guides 1 The valve guides are installed into the cylinder head with an extremely tight press fit Before installing the valve guides place the valve guides in a freezer for at least twenty minutes This will cause the valve guides to contract 9000201 making it easier to install the valve guides in Figure 6 22 place Free Length 2 Immediately after removing the valve guides from the freezer insert the valve guides Use a caliper to measure the length of the spr
146. e coolant may splash and burn you Failure to comply could result in death or serious injury 0000016en COOLANT HAZARD Wear eye protection and rubber gloves when you handle Long Life or Extended Life engine coolant If contact with the eyes or skin should occur flush eyes and wash immediately with clean water Failure to comply may result in minor or moderate injury 0000005en TNV IDI Service Manual YANMAR PERIODIC MAINTENANCE e Be environmentally responsible Follow these procedures for hazardous waste disposal Failure to follow these procedures may seriously harm the environment Follow the guidelines of the EPA or 2 m other governmental agency for the proper disposal of hazardous Figure 5 16 materials such as engine oil diesel 4 Drain the coolant from the engine block fuel and engine coolant Consult the Remove the coolant drain plug local authorities or reclamation facility Figure 5 17 1 from the engine block NEVER dispose of hazardous materials irresponsibly by dumping them into a sewer on the ground or into ground water or waterways 0000013en Engine coolant contaminated with rust or scale reduces the cooling effect Even when extended life engine coolant is properly mixed the engine coolant gets contaminated as its ingredients deteriorate Drain flush and refill the
147. e lack of receipts or for your failure to ensure the performance of all scheduled maintenance Yanmar may deny your warranty coverage of your non road compression ignition engine if a part has failed due to abuse neglect improper maintenance or unapproved modifications Your engine is designed to operate on diesel fuel only Use of any other fuel may result in your engine no longer operating in compliance with applicable emissions requirements You are responsible for initiating the warranty process You must present your engine to a Yanmar dealer as soon as a problem exists The warranty repairs should be completed by the dealer as expeditiously as possible If you have any questions regarding your warranty rights and responsibilities or would like information on the nearest Yanmar dealer or authorized service center you should contact Yanmar America Corporation at 1 800 872 2867 2 8 TNV IDI Service Manual YANMAR Section 3 SAFETY Page Safety Statements dian peri tuaus teen decal 3 3 stretto 3 4 Before You 0 4 0 3 4 During Operation and 3 4 YANMAR TNV IDI Service Manual 3 1 SAFETY This Page Intentionally Left Blank 3 2 TNV IDI Service Manual YANMAR SAFETY STATEMENTS Yanmar is concerned for your safety and your machine s condition Safety statements are one o
148. e Procedures 5 19 After Initial 50 Hours of Operation 5 19 Every 50 Hours of 5 22 Check Battery 5 24 Every 250 Hours of Operation 5 26 Every 500 Hours of Operation 5 30 Every 1000 Hours of 5 34 Every 1500 Hours of 5 36 Every 2000 Hours of 5 38 YANMAR TNV IDI Service Manual PERIODIC MAINTENANCE This Page Intentionally Left Blank 5 2 TNV IDI Service Manual YANMAR PERIODIC MAINTENANCE This section of the Service Manual describes the procedures for proper care and maintenance of the PN DANGER engine e EXPLOSION HAZARD NEVER check the remaining battery charge by shorting out the terminals This will result in a spark and may cause an explosion or fire Use a hydrometer to check the remaining battery charge NEVER permit anyone to operate the engine or driven machine without proper training Read and understand this Operation Manual before you operate or service the machine to ensure that you follow safe operating practices and Failure to comply wi
149. ean fuel 9 Check the condition of the cup O ring Replace if necessary 10 Put the float Figure 5 15 7 and retaining spring Figure 5 15 6 inside the cup 11 Reinstall the cup to the mounting flange Figure 5 15 9 and turn the retaining ring Figure 5 15 4 to the right Figure 5 15 10 Hand tighten only 0000590B Figure 5 15 12 Open the fuel cock Figure 5 15 3 13 Prime the fuel system See Priming The Fuel System on page 4 12 14 Check for fuel leaks 5 33 PERIODIC MAINTENANCE Every 1000 Hours of Operation Perform the following maintenance every 1000 hours of operation Drain Flush and Refill Cooling System with New Coolant Adjust Intake Exhaust Valve Clearance Drain Flush and Refill Cooling System with New Coolant A DANGER SCALD HAZARD NEVER remove the radiator cap if the engine is hot Steam and hot engine coolant will spurt out and seriously burn you Allow the engine to cool down before you attempt to remove the radiator cap Securely tighten the radiator cap after you check the radiator Steam can spurt out during engine operation if the cap is loose ALWAYS check the level of the engine coolant by observing the reserve tank Failure to comply will result in death or serious injury 0000002en 5 34 BURN HAZARD Wait until the engine cools before you drain the engine coolant Hot engin
150. earance 0 2341 0 2346 in 5 945 5 960 mm 0 0016 0 0026 in 0 040 0 067 mm 0 2323 in 5 90 mm 0 0067 in 0 17 mm Valve Stem Bend 0 0004 in 0 010 mm See Inspection of Valve Springs on page 6 26 Valve Guide Projection From Cylinder Head 0 3858 0 3937 in 9 8 10 0 mm Valve Guide Installation Method Push Rod Inspection Item Cold fitted Standard Limit See Reassembly of Valve Guides on page 6 29 Reference Page Push Rod Bend Valve Spring Inspection Item Less than 0 0012 in 0 03 mm Standard 0 0012 in 0 03 mm See Push Rod Bend on page 6 25 Reference Page Free Length 1 4882 in 37 8 mm Squareness 0 0512 1 3 Inspection of Valve Springs on page 6 28 ENGINE Rocker Arm and Shaft Inspection Item Standard Limit Reference Page Arm Shaft Hole Diameter 0 4724 0 4732 in 12 000 12 020 mm 0 4752 in 12 07 mm Shaft Outside Diameter 0 4711 0 4718 in 11 966 11 984 mm 0 4701 in 11 94 mm Oil Clearance 0 0006 0 0021 in 0 016 0 054 mm 0 0051 in 0 13 mm CAMSHAFT AND TIMING GEAR TRAIN SPECIFICATIONS Camshaft Inspection Item Standard Limit See Inspection of Hocker Arm Assembly on page 6 26 Reference Page End Play 0 0020 0 0059 in 0 05 0 15 mm 0
151. ecked to move axially as excess end play could cause a false reading See Timing Gear Backlash on page 6 9 for service limits 0002190 Fuel Injection Pump Drive Gear Camshaft Drive Gear Auxiliary Drive Gear Optional Crankshaft Drive Gear Idler Gear ex ie Figure 6 40 YANMAR Measuring Idler Gear to Crankshaft Gear Backlash 1 Install a dial indicator as shown in Figure 6 41 0002192 Figure 6 41 Rotate the idler gear back and forth to check idler gear to crankshaft gear backlash Total indicator reading is backlash Record the measurement Measuring Idler Gear to Camshaft Gear Backlash 1 Drive a small wooden wedge between the crankshaft gear and idler gear to prevent the idler gear from rotating Install a dial indicator to read camshaft gear backlash Rotate camshaft drive gear against idler gear to measure backlash Record the measurement Check the idler gear to fuel injection pump drive gear backlash in the same manner as the camshaft drive gear Record the measurement ENGINE Removal of Timing Gears 1 Remove the bolts from the idler gear shaft Figure 6 42 1 Remove the idler gear shaft idler gear Figure 6 42 2 and bushing Figure 6 42 3 00021 Figure 6 42 Do not remove the crankshaft gear unless it is damaged and requires replacement If the gear must be removed remove it using a gear puller Removal of the camshaft gear requi
152. ection pump drive gear from the hub Correct fuel injection timing will be very difficult or impossible to achieve 0000031en 15 Do not loosen or remove the four bolts Figure 7 12 3 retaining the pump drive gear to the hub Only remove the single drive gear nut Figure 7 12 1 and washer Figure 7 12 2 leaving the hub attached to the gear 2 Figure 7 12 16 Hold the gear train stationary using a large socket wrench on the crankshaft pulley bolt Loosen the fuel injection pump drive gear retaining nut Figure 7 12 1 and turn it out to the end of the fuel injection pump shaft TNV IDI Service Manual YANMAR 17 Remove the pump drive gear and hub from the injection pump drive shaft as an assembly using an appropriate two bolt gear puller Figure 7 13 0002209 Figure 7 13 Note The fuel injection pump drive gear can be removed from the gear case however it is best to let it remain in the gear case 18 Once the fuel injection pump drive gear and hub assembly has popped loose from the tapered fuel injection pump drive shaft carefully remove the drive gear nut Figure 7 14 1 and lock washer Figure 7 14 2 0002183A Figure 7 14 YANMAR TNV IDI Service Manual FUEL SYSTEM 19 Locate the mark Figure 7 15 1 stamped into the upper outside mounting boss of the fuel injection pump Highlight this mark and make a corresponding mark on the gear case or front plate
153. ed Other engine oils may affect warranty After Initial 50 Hours of Operation coverage cause internal engine components to seize and or shorten Perform the following maintenance after the initial engine life 50 hours of operation Prevent dirt and debris from contaminating the engine oil Carefully clean the oil cap dipstick and the Check and Adjust Cooling Fan V Belt surrounding area before you remove the cap Replace Engine Oil and Engine Oil Filter Replace Engine Oil and Engine Oil NEVER mix different types of engine Filter oil This may adversely affect the AwARNNG lubricating properties of the engine oil NEVER overfill Overfilling may result in white exhaust smoke engine overspeed or internal damage Mr 0000005en a BURN HAZARD ______ CAUTION _____ f you must drain the engine oil while it is still hot stay clear of the hot engine oil to avoid being burned e ALWAYS wear eye protection Failure to comply could result in death Be environmentally responsible Follow Or sernousanjury these procedures for hazardous waste 0000011en disposal Failure to follow these procedures may seriously harm the environment Follow the guidelines of the EPA or other governmental agency for the proper disposal of hazardous materials such as engine oil diesel fuel and engine coolant Consult the local authorities or reclamation facility NEVER dispose of hazardous mat
154. el or PTO shaft Wear tight fitting clothing and keep your hair short or tie it back while the engine is running Remove all jewelry before you operate or service the machine NEVER start the engine in gear Sudden movement of the engine and or machine could cause death or serious personal injury NEVER operate the engine without the guards in place Before you start the engine make sure that all bystanders are clear of the area Keep children and pets away while the engine is operating Check before starting the engine that any tools or shop rags used during maintenance have been removed from the area Failure to comply could result in death or serious injury 0000002en TNV IDI Service Manual YANMAR EXHAUST HAZARD NEVER operate the engine in an enclosed area such as a garage tunnel underground room manhole or ship s hold without proper ventilation NEVER block windows vents or other means of ventilation if the engine is operating in an enclosed area All internal combustion engines create carbon monoxide gas during operation Accumulation of this gas within an enclosure could cause illness or even death Make sure that all connections are tightened to specifications after repair is made to the exhaust system Failure to comply could result in death or serious injury 0000003en ALCOHOL AND DRUG HAZARD NEVER operate the engine while you are und
155. embled with the correct orientation When correctly assembled the piston identification mark Figure 6 84 1 stamped into the top of the piston will be on the opposite side of the connecting rod as the match marks Figure 6 84 3 stamped into the connecting rod and connecting rod cap When reinstalled in the cylinder the embossed mark Figure 6 84 2 cast into the beam of connecting rod Will face the flywheel end of the engine 6 53 ENGINE Note The actual appearance of the match marks will vary but they will always be in 6 0 the same locations 2 2 2 3 4 Caki a wed 0000227A 2 Fuel Injection Pump Side of Engine Piston Identification Mark Embossed Mark on Connecting Rod Connecting Rod and Cap Match Marks Flywheel End of Engine Camshaft Side of Engine E106 R Ouran gt Figure 6 85 0002089 Figure 6 84 4 Place the connecting rod into the piston The match marks Figure 6 85 4 on the connecting rod and cap must be on the opposite side as the piston identification mark Figure 6 85 2 on the top of the piston 6 54 3 through the piston and connecting rod 6 Reinstall the second circlip Figure 6 86 4 and ensure it is securely seated in the groove 3 0001705A Figure 6 86 Note Reinstall the top and second piston rings with the sta
156. ent Mechanical Fuel Pump Side and Top Filler Port Engine Cil Starter Motor YANMAR TNV IDI Service Manual The mechanical fuel pump is a diaphragm type of pump and is installed on the fuel injection pump body The mechanical fuel pump is standard equipment on some engine models and is driven by acam on the camshaft of the fuel injection pump The mechanical fuel pump is not installed on the fuel injection pump if the electric fuel pump is installed You can fill the crankcase with engine oil from either the side or top filler port depending upon which one is most convenient The starter motor is powered by the battery When you turn the key switch in the operator s console to the START position the starter motor engages with the ring gear installed on the flywheel and starts the flywheel in motion GENERAL SERVICE INFORMATION FUNCTION OF COOLING SYSTEM COMPONENTS Components Functions The TNV engine is liquid cooled by means of a cooling system The cooling system consists of a radiator radiator cap engine cooling fan engine coolant pump thermostat and reserve tank Note that all cooling system components are required for proper engine operation Since some of the components are application specific they must be carefully selected by an application engineer The application specific items are not part of the basic engine package as shipped from the Yanmar factory Engine Cooling Fan The engine cooling fan is
157. entally start the servicing it This could result in a serious injury 0000013en If you must service the engine while it Avi is operating remove all jewelry tie back long hair and keep your hands other body parts and clothing away BURN HAZARD from moving rotating parts Keep your hands and other body parts away from hot engine surfaces such as the muffler exhaust pipe turbocharger if equipped and engine block during operation and shortly after you shut the engine down These engine is operating and could m eS seriously burn you 1 Failure to comply could result in death or serious injury 0000010en Failure to comply could result in death or serious injury 0000015en BURN HAZARD Wait until the engine cools before you drain the engine coolant Hot engine coolant may splash and burn you Failure to comply could result in death or serious injury 0000016en YANMAR TNV IDI Service Manual 3 11 SAFETY O ab ue FUME BURN HAZARD Always read and follow safety related precautions found on containers of hazardous substances like parts cleaners primers sealants and sealant removers Failure to comply could result in death or serious injury 0000014en COOLANT HAZARD Wear eye protection and rubber gloves when you handle Long Life or Extended Life engine coolant If conta
158. er motor to turn backwards 10 17 STARTER MOTOR 11 Carefully reinstall the brush holder Figure 10 32 3 assembly 12 Reinstall the rear cover Figure 10 32 2 and secure with two bolts Figure 10 32 1 0000142A Figure 10 32 13 Reinstall the two through bolts and tighten securely 14 Reinstall the return spring if equipped Figure 10 33 3 on the solenoid plunger Figure 10 33 4 Reinstall the solenoid switch coil Figure 10 33 1 and shields Figure 10 33 2 Secure with nuts or bolts 0000140A Figure 10 33 15 Reconnect the wire to the solenoid switch assembly Tighten the nut Reinstall the cover over the connection 10 18 000013 Figure 10 34 TNV IDI Service Manual YANMAR Check Pinion Projection Length 1 Connect the positive lead from a battery to the S terminal Connect the negative lead to the terminal Lightly pull the pinion away from the gear housing Turn the switch ON and measure the pinion moving distance L in the thrust direction Perform this test within 10 seconds 0000132 Figure 10 35 See Starter Motor Specifications on page 10 6 for the service limit YANMAR TNV IDI Service Manual STARTER MOTOR If the measured L dimension is outside the standard range adjust the dust covers to obtain the standard range Dust covers Figure 10 36 1 are available in 0 020 in 0 5 mm and 0 031 in 0 8 mm thickn
159. er Rotor Outside Clearance 42 64 psi 0 29 0 44 MPa 2 96 4 49 kgf cm Standard Limit 8 8 psi 0 06 MPa 0 6 kfg cm or greater Reference Page 2TNV70 3TNV70 3TNV76 Outer Rotor Side Clearance 0 0047 0 0083 in 0 12 0 21 mm Standard 0 0118 in 0 30 mm Limit Check Outer Rotor Outside Clearance on page 9 10 Reference Page 2TNV70 3TNV70 3TNV76 Outer Rotor to Inner Rotor Model 2TNV70 3TNV70 3TNV76 YANMAR TNV IDI Service Manual 0 0008 0 0028 in 0 02 0 07 mm Tip Clearance 0 0047 in 0 12 mm Check Outer Rotor Side Clearance on page 9 11 Standard Limit heterence Page Outer Rotor to 0 0063 in Inner Rotor Tip 0 16 mm Clearance on page 9 10 9 5 LUBRICATION SYSTEM Inner Rotor and Gear Boss Clearance Parts Standard Dimension Standard Clearance Standard Clearance Limit Reference Page Inside Clearance of Inner Rotor Gear Boss Diameter 2 0886 2 0925 in 53 05 53 15 mm Rotor Diameter 2 1043 2 1083 in 53 45 53 55 mm 0 012 0 020 in 0 3 0 5 mm 0 024 in 0 6 mm Inner Rotor Width Across Flat Clearance 9 6 Width Across Flat of Gear Boss 1 9468 1 9587 in 49 45 49 75 mm Width Across Flat of Rotor 1 9665 1 9705 in 49 95 50 05 mm 0 008 0 024 in 0 2 0 6 mm TNV IDI Service
160. er the influence of alcohol or drugs NEVER operate the engine when you are feeling ill Failure to comply could result in death or serious injury 0000004en YANMAR TNV IDI Service Manual SAFETY 2 98 3D PLB A m EXPOSURE HAZARD Wear personal protective equipment such as gloves work shoes eye and hearing protection as required by the task at hand NEVER wear jewelry unbuttoned cuffs ties or loose fitting clothing when you are working near moving rotating parts such as the cooling fan flywheel or PTO shaft ALWAYS tie back long hair when you are working near moving rotating parts such as a cooling fan flywheel or PTO shaft NEVER operate the engine while wearing a headset to listen to music or radio because it will be difficult to hear the warning signals Failure to comply could result in death or serious injury 0000005en SAFETY 7 2 HIGH PRESSURE HAZARD Avoid skin contact with the high pressure diesel fuel spray caused by a fuel system leak such as a broken fuel injection line High pressure fuel can ALWAYS wear eye protection penetrate your skin and result in serious injury If you are exposed to high pressure fuel spray obtain prompt medical treatment NEVER check for a fuel leak with your _ AWARNNG your Mi or ad or cardboard Have your authorized Yanmar industrial engine dealer or distributor repair the damage c F
161. erials irresponsibly by dumping them into a sewer on the ground or into ground water or waterways 0000013en YANMAR TNV IDI Service Manual 5 19 PERIODIC MAINTENANCE The engine oil on a new engine becomes Remove the engine oil filter as follows contaminated from the initial break in of internal parts It is very important that the initial oil and filter change is performed as scheduled 1 Turn the engine oil filter Figure 5 2 2 counterclockwise Figure 5 2 4 using a filter wrench Note The oil drain plug may be in another location is an optional oil pan is used Drain the engine oil as follows pois C 60 S NG PA ji a 9 a 10 Q Make sure the engine is level A 2 Start the engine and bring it up to operating T 3 temperature ei Ore 4 3 Stop the engine A a 4 Remove the oil filler cap Figure 5 1 1 to aos vent the engine crankcase and allow the engine g He oil to drain more easily 2 5 Position a container under the engine to collect waste oil C i 1 0000651B Figure 5 2 2 Clean the engine oil filter mounting face 3 Lightly coat the gasket on the new oil filter with 1 engine oil Install the new engine oil filter manually by turning it clockwise Figure 5 2 3 until it contacts the mounting surface Tighten an additional 3 4 of a turn using the filter wrench SU OE TUNE N Suit 41605
162. es if equipped The inner element should not be removed when cleaning or replacing the outer element The inner element is used to prevent dust from entering the engine while servicing the outer element 5 29 PERIODIC MAINTENANCE 0000070A Figure 5 12 0000071A Figure 5 13 4 Replace the element with a new one if the element is damaged excessively dirty or oily 5 Clean inside of the air cleaner cover 6 Install the element into the air cleaner case Figure 5 12 4 7 Install the air cleaner cover making sure you match the arrow Figure 5 12 5 on the cover with the arrow on the case Figure 5 12 6 8 Latch the air cleaner cover to the case When the engine is operated in dusty conditions clean the air cleaner element more frequently NEVER operate the engine with the air cleaner or element s removed This may cause foreign material to enter the engine and damage it 0000026en 5 30 Every 500 Hours of Operation Perform the following maintenance every 500 hours of operation Replace Air Cleaner Element Replace Fuel Filter Clean Fuel Filter Water Separator Replace Air Cleaner Element The maximum air intake restriction shall be 0 90 psi 6 23 kPa 635 mm Aq or less Clean or replace the air cleaner element if the air intake restriction exceeds the above mentioned value 0000046en Replace the air cleaner element Figure 5 12 2 every
163. esses 0000133 Figure 10 36 10 19 STARTER MOTOR No Load Test Test the characteristics of the starter motor by performing a no load test The starter motor can be damaged if operated continuously longer than 10 seconds while performing the no load test 0000034en 1 Secure the starting motor in a vise or other suitable fixture 2 Connect an ammeter Figure 10 37 1 in series between the battery positive 4 terminal Figure 10 37 2 and the main positive terminal Figure 10 37 3 on the starter motor Note The ammeter and all wire leads used in this test must have a capacity equal to or greater than the amperage draw specification for the starter motor being tested 3 Connect a wire lead between the mounting base of the starter motor Figure 10 37 4 and the battery negative terminal Figure 10 37 5 4 Connect a voltmeter Figure 10 37 7 to the battery negative terminal Figure 10 37 5 and the main positive battery terminal Figure 10 37 3 on the starter motor 5 Install a switch Figure 10 37 6 in a circuit between the battery positive terminal Figure 10 37 2 and the starter solenoid switch terminal Figure 10 37 8 on the starter motor 6 Use a suitable tachometer to monitor the rpm of the starter 7 Turn the switch to the ON position to energize the solenoid and operate the starter Monitor the rpm amperage draw and voltage For t
164. est specifications see Starter Motor Information on page 10 5 for the appropriate starter motor 10 20 0002127A Figure 10 37 Installation of Starter Motor 1 Reinstall the starter motor to the flywheel housing Reinstall the starter mounting bolts Figure 10 38 1 Tighten the bolts to specification See Standard Torque Chart on page 4 25 0002126 Figure 10 38 Reconnect the electrical wires to the solenoid switch assembly Be sure to place the cover over the battery positive cable connection Reconnect the battery negative cable last TNV IDI Service Manual YANMAR Section 11 ALTERNATOR Page Before You Begin 04 4444 01 11 3 1 gare ONO n 11 6 Standard and Optional Dynamo Information 11 6 Standard and Optional Alternator Information 11 7 Alternator punkten ar 11 8 Dynamo Specifications T 11 8 Alternator Troubleshooting eee 11 9 Alternator Components 2 22240404 nennen 11 11 Alternator Wiring 11 12 Alternator Standard 2 11 13 Ha 11 14 Removal of 11 14 Disassembly of
165. eye protection Failure to comply could result in death or serious injury 000001 1en FLYING OBJECT HAZARD ALWAYS wear eye protection when servicing the engine and when using compressed air or high pressure water Dust flying debris compressed air pressurized water or steam may injure your eyes Failure to comply may result in minor or moderate injury 0000003en If the engine coolant pump must be replaced replace the engine coolant pump as an assembly only Do not attempt to repair the engine coolant pump or replace individual components 0000041en HAZARD Carefully rotate the alternator toward the cylinder block while loosening the V belt Failure to comply may result in minor or moderate injury 0000014en Only use the engine coolant specified Other engine coolants may affect warranty coverage cause an internal buildup of rust and scale and or shorten engine life Prevent dirt and debris from contaminating the engine coolant Carefully clean the radiator cap and the surrounding area before you remove the cap NEVER mix different types of engine coolants This may adversely affect the properties of the engine coolant 0000006en Use a new special O ring between the engine coolant pump and the joint Be sure to use the special O ring for each engine model Although the O ring dimensions are the same as a commercially
166. f contact with the eyes or skin should occur flush eyes and wash immediately with clean water Failure to comply may result in minor or moderate injury 0000005en PERIODIC MAINTENANCE Only use diesel fuels recommended by Yanmar for the best engine performance to prevent engine damage and to comply with EPA ARB warranty requirements Only use clean diesel fuel NEVER remove the primary strainer if equipped from the fuel tank filler port If removed dirt and debris could get into the fuel system causing it to clog 0000004en Only use the engine oil specified Other engine oils may affect warranty coverage cause internal engine components to seize and or shorten engine life Prevent dirt and debris from contaminating the engine oil Carefully clean the oil cap dipstick and the surrounding area before you remove the cap NEVER mix different types of engine oil This may adversely affect the lubricating properties of the engine oil NEVER overfill Overfilling may result in white exhaust smoke engine overspeed or internal damage 0000005en Only use the engine oil specified Other engine oils may affect warranty coverage cause internal engine components to seize and or shorten engine life Prevent dirt and debris from contaminating the engine oil Carefully clean the oil cap dipstick and the surrounding area before you remove the cap NEVER mix differen
167. f the primary ways to call your attention to the potential hazards associated with Yanmar TNV engine operation Follow the precautions listed throughout the manual before operation during operation and during periodic maintenance procedures for your safety the safety of others and to protect the performance of your engine Keep the labels from becoming dirty 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 This safety alert symbol appears with most safety statements It means attention become alert your safety is involved Please read and abide by the message that follows the safety alert symbol A 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 0000001 en Warning the word WARNING is black letters with an orange rectangle behind it indicates a potentially hazardous situation which if not avoided could result in death or serious injury 0000001 en YANMAR TNV IDI Service Manual SAFETY Caution the word CAUTION is in black letters with a yellow rectangle behind it indicates a potentially hazardous situation which if not avoided may re
168. ferring to the table below No Item Cause Corrective Action Clogged element Clean the element 1 Air Cleaner Element Broken element Replace the element Defect at element seal portion Valve Clearance Excessive or no clearance Adjust the valve clearance Valve Timing Incorrect valve clearance Adjust the valve clearance Replace the gasket 4 Cylinder Head Gasket Gas leak from gasket Retighten the cylinder head bolts to the specified torque Intake Exhaust Valve Sticking valve Replace the intake exhaust valve Gas leak due to worn valve seat Valve Seat or foreign matter trapped in Lap the valve seat valve Piston Gas leak due to scratching or Piston Ring wear Perform honing and use an oversized part Cylinder QUICK REFERENCE TABLE FOR TROUBLESHOOTING The following table summarizes the general trouble symptoms and their causes If any trouble symptom occurs take corrective action before it becomes a serious problem so as not to shorten the engine service life 13 6 TNV IDI Service Manual YANMAR TROUBLESHOOTING CHARTS Trouble Symptom Cause Starting Problem Insufficient Engine Output Engine Starts But Stops Soon Exhaust Color Exhaust Smoke High Knocking Sound During Combustion Uneven Combustion Sound Engine Surging During ldling During Work Operation Excessive Engine Vibration Difficulty in Returning t
169. fold gasket Figure 6 2 8 Removal of Glow Plugs 1 2 Remove the glow plugs from the cylinder head Disconnect the glow plug harness Figure 6 4 2 from the glow plugs Figure 6 4 1 6 22 2 Removal of Rocker Arm Assembly 1 Remove the bolts Figure 6 4 1 and nuts Figure 6 4 2 that retain the rocker arm shaft supports Remove the rocker arm shaft assembly from the cylinder head Note Identify the push rods so they can be reinstalled in their original locations 3 Remove the push rods and identify for reinstallation 0002147 YANMAR Disassembly of Rocker Arm Assembly 1 Remove the rocker arm shaft alignment set screw Figure 6 5 6 from support Figure 6 5 5 Note On 3 cylinder models the set screw is located in the center support On 2 cylinder models the set screw is located in the front cooling fan end support 2 Remove two retaining rings Figure 6 5 8 Note The rocker arm shaft fits tightly in the rocker arm supports Clamp the support in a padded vise Twist and pull out on the rocker arm shaft to remove Reverse this process when reinstalling the rocker arm shaft into the supports 3 Slide the rocker arm shaft Figure 6 5 7 out of the rocker arm supports Figure 6 5 5 springs Figure 6 5 4 and rocker arms Figure 6 5 1 Note Mark the rocker arms so they can be reinstalled with the original matching valve and push
170. for the service limit 0001952 6 13 6 26 Inspection of Valve Guides Visually inspect the valve guides for distortions scoring or other damage Note Measure valve guides while they are installed in cylinder head Use a telescoping gauge and micrometer to measure the inside diameter of the valve guide Measure in three places and 90 apart Figure 6 14 Record the measurements See Intake Exhaust Valve and Guide on page 6 7 for the service limit Replace valve guides if not within specification EHO 0001869 Figure 6 14 Inspection of Cylinder Head Cylinder Head Distortion Place the cylinder head flat and inverted combustion side up on the bench Use a straight edge and feeler gauge to measure cylinder head distortion Figure 6 15 Measure diagonally and along each side Record the measurements See Cylinder Head on page 6 6 for the service limit 0000192 Figure 6 15 YANMAR If distortion exceeds the service limit resurface or replace the cylinder head Remove only enough material to make the cylinder head flat but do not remove more than 0 008 in 0 20 mm Inspection of Intake and Exhaust Valves Visually inspect the intake and exhaust valves Replace any valves that are obviously discolored heavily pitted or otherwise damaged Valve Stem Diameter Use a micrometer to measure the valve stem diameter Measure the valve stem near the combustion end and
171. fuel filter water separator is battery charge positioned higher than the fuel level in the fuel tank water may not drip out If the electrolyte is frozen slowly warm when the fuel filter water separator the battery before you recharge it drain cock is opened If this happens Failure to comply will result in death or turn the air vent screw on the top of the serious injury fuel filter water separator 2 3 turns counterclockwise after the water has drained out 0000025en pos BURN HAZARD Batteries contain sulfuric acid NEVER allow battery fluid to come in contact with clothing skin or eyes Severe burns could result ALWAYS wear safety goggles and protective clothing when servicing the battery If contact with the skin and or eyes should occur flush with a large amount of water and obtain prompt medical treatment 0000007en Failure to comply could result in death or serious injury 0000007en 5 24 TNV IDI Service Manual YANMAR PERIODIC MAINTENANCE If the engine cranking speed is so slow that the CAUTION o engine does not start recharge the battery If the engine still will not start after charging have your authorized Yanmar industrial engine A dealer distributor check the battery and the engine s starting system If operating the machine where the ambient Be environmentally responsible Follow temperature could drop to 5 F 15 C or le
172. fuel system Operate the engine and check for leaks Adjusting Fuel Injection Timing If the timing marks did not align when performing the Checking Fuel Injection Timing procedure on page 7 21 the following steps must be performed to properly time the engine 1 Leave the spill timing tool installed in the fuel injection pump 2 Determine if the timing is advanced or retarded by comparing the position of the target timing mark on the flywheel grid with the timing mark on the flywheel housing or back plate 0002469 Figure 7 30 3 Loosen the nuts fastening the fuel injection pump to the gear case 4 If the injection timing was less than the target timing the injection timing is retarded and will need to be advanced To advance the injection timing rotate the top of the fuel injection pump away from the engine 7 24 If the injection timing was greater than the target timing the injection timing is advanced and will need to be retarded To retard the injection timing rotate the top of the fuel injection pump toward the engine 5 Adjust the position of the fuel injection pump and tighten the fuel injection pump mounting nuts 6 Recheck the fuel injection timing Repeat the fuel injection timing see Checking Fuel Injection Timing on page 7 21 and adjustment see Adjusting Fuel Injection Timing on page 7 24 procedures until the timing is correct 7 Remove the spill t
173. g cm in Hg 60 in Hg 60 in Hg 60 Units of Power hp metric or PS hp metric or PS hp SAE hp SAE kw kW x KK KKK KK X X X X X X 0 0689 6 8950 0 0703 14 5030 100 0000 29 5300 0 1450 0 0100 0 0102 98 0700 0 9807 14 2200 0 0333 3 3770 0 0344 0 9863201 0 7354988 1 0138697 0 7456999 1 3596216 1 3410221 Units of Temperature F 1 8 C 32 0 556 F 32 N m kgf m N m kgf m ft lb in Ib N m ft lb in Ib kgf m bar kPa kg cm psi kPa in Hg 60 F psi bar kg cm psi bar kPa bar kPa kg cm hp SAE kW hp metric or PS kW hp metric or PS hp SAE 4 27 GENERAL SERVICE INFORMATION This Page Intentionally Left Blank 4 28 TNV IDI Service Manual YANMAR Section 5 PERIODIC MAINTENANCE Page ie npo m 5 16 The Importance of Periodic 5 16 Performing Periodic Maintenance 5 16 Yanmar Replacement Parts 5 17 Required EPA ARB Maintenance USA Only 5 17 EPA ARB Installation Requirements USA Only 5 17 Periodic Maintenance 5 17 Periodic Maintenanc
174. g hereunder must be brought within one 1 year after the cause of action accrues or it shall be barred Some states and countries do not allow certain limitations on warranties or for breach of warranties This Warranty gives you specific legal rights and you may also have other rights which vary from state to state and country to country Limitations set forth in this paragraph shall not apply to the extent that they are prohibited by law Warranty Modifications Except as modified in writing and signed by the parties this Warranty is and shall remain the complete and exclusive agreement between the parties with respect to warranties superseding all prior agreements written and oral and all other communications between the parties relating to warranties No person or entity is authorized to give any other warranty or to assume any other obligation on behalf of Yanmar either orally or in writing Questions If you have any questions or concerns regarding this Warranty please call or write to the nearest authorized Yanmar industrial engine dealer distributor or other authorized facility Retail Purchaser Registration It is very important for the original retail purchaser to register the Yanmar product Registration enables Yanmar to provide the best support for your Yanmar product As soon as possible after the purchase of your engine Yanmar highly recommends that you use the following website to register your purchase http www y
175. g rod bearing inserts into the connecting rod and connecting rod cap Install the rod cap and tighten the bolts to the specified torque Measure the inside diameter Record the measurements See Crankshaft on page 6 9 for specifications Inspection of Tappets 1 Inspect the tappet contact surfaces for abnormal wear Figure 6 72 1 Normal wear will be even as shown in Figure 6 72 2 Slight surface defects can be corrected using an oilstone 1 2 Figure 6 72 0002194 Measure the outside diameter of the tappet stem Figure 6 73 1 Record the measurements See Tappet on page 6 14 for the service limit 6 49 ENGINE 0002195 Figure 6 73 3 Measure the tappet bores in the cylinder block Record the measurements See Tappet on page 6 14 for the service limit Inspection of Crankshaft 1 Place the crankshaft end journals Figure 6 74 4 on V blocks 2 Place a dial indicator Figure 6 74 3 on a center main bearing surface Nitty n 4 4 0000232A Figure 6 74 3 Rotate the crankshaft and observe runout Record the measurements See Crankshaft on page 6 9 for specifications 4 Usethe color check method or Magnaflux to inspect the crankshaft for cracks Replace the crankshaft if evidence of fractures is found 6 50 Measure the outside diameter of each crankpin Figure 6 75 2 and main bearing journal Figure
176. g the fuel injection pump on an engine with the front gear case removed the fuel injection pump drive gear can be aligned with the idler gear by aligning the stamped marks Figure 7 17 A B C on the fuel injection pump drive gear idler gear and crankshaft drive gear Ensure all three timing marks A B C are aligned 0002190 Fuel Injection Pump Drive Gear Camshaft Drive Gear Optional Accessory Drive Gear Crankshaft Drive Gear Idler Gear Figure 7 17 TNV IDI Service Manual YANMAR FUEL SYSTEM 3 Install a new O ring on the fuel injection pump 6 Align the reference marks Figure 7 19 1 mounting flange and retain using grease made during disassembly on both the fuel Note Ensure the tapered surface of the fuel injection pump mounting flange and gear case injection pump shaft is clean and dry If installing a replacement fuel injection pump align the manufacturer applied mark on the 4 Align the key on the fuel injection pump shaft pump mounting flange with the mark made on with the keyway in the fuel injection pump drive the timing gear cover gear hub Reinstall the fuel injection pump into the fuel injection pump drive gear and gear housing Install the pump retaining nuts finger tight 5 Reinstall the fuel injection pump drive gear lock washer Figure 7 18 2 and nut Figure 7 18 1 Do not lubricate threads of the nut or shaft Hold the crankshaft pulley bolt with a socket wrench and tighten the d
177. gauge and the compression gauge adapter at the cylinder to be measured Crank the engine until the compression gauge reading is stabilized Figure 13 1 After performing the compression check remove the compression gauge and compression gauge adapter from the cylinder Reinstall the fuel injector and high pressure fuel injection lines See Installation of the Fuel Injectors on page 7 30 and Installation of High Pressure Fuel Injection Lines on page 7 13 TNV IDI Service Manual TROUBLESHOOTING Standard Compression Pressure Engine compression pressure list reference value Compression Pressure Engine Model at 250 rpm 250 min Deviation Between Cylinders Standard Limit 2TNV70 470 x 15 psi 370 15 psi 3TNV70 3 24 0 1 MPa 33 1 kgf cm 2 55 0 1 MPa 26 1 kgf cm 29 to 43 psi 3TNV76 498 15 psi 399 15 psi 0 2 to 0 3 MPa 2 to 3 kgf cm 3 43 0 1 MPa 35 1 kgf cm 2 75 0 1 MPa 28 1 kgf cm Engine Speed and Compression Pressure Use for Reference 3TNV76 4 a0 77 8 o UA E 3 92 MPa 86 3 43 MPa a oe 2 94 MPa Pues o 15 1 96 200 250 300 350 400 Engine Speed min 0001915 Figure 13 2 YANMAR TNV IDI Service Manual 13 5 TROUBLESHOOTING Measured Value and Troubleshooting When the measured compression pressure is below the limit value inspect each part by re
178. gear case See Hemoval of Fuel Injection Pump on page 7 15 6 41 ENGINE 2 Remove the gear case Figure 6 49 1 from Disassembly of Crankshaft and the cylinder block Piston Components 3 Inspect and measure the camshaft bushing See Camshaft for service limits 1 damaged or Removal of Pistons worn beyond service limits remove the 4 Remove O rings Figure 6 49 2 Keep the piston pin parts piston assemblies and connecting rod assemblies together to be returned to the same position during the reassembly process Label the parts using an appropriate method 0000088en IMPORTANT High hour engines may have a ridge near the top of the cylinders that will catch the piston rings and make it impossible to remove the pistons Use a suitable ridge reamer to remove ridges and carbon prior to removing pistons 0002187 Figure 6 49 Note Pistons can fall from cylinder block if engine is inverted Rotate the engine so the connecting rods are horizontal before removing the connecting rod caps 6 42 YANMAR Using a feeler gauge measure the connecting rod side clearance as shown Figure 6 50 See Connecting Rod on page 6 13 for the standard limit lf the measurement is out of specification replace the crankshaft connecting rod or both 0000219 Figure 6 50 IMPORTANT Mark the connecting rod caps and connecting rods so the caps and connecting rods stay together Remove the bearing cap Do not rem
179. gulations Only engines that conform to ARB regulations can be sold in the State of California Refer to the specific EPA ARB installation page 5 17 and maintenance page 5 17 the Periodic Maintenance section of this manual Also refer to the System Warranty USA Only on page 2 6 EMISSION CONTROL LABELS Since emission control regulations are being issued on a global basis it is necessary to identify which regulations a particular engine complies with We have listed several different types of labels you might find on your engine TNV IDI Service Manual YANMAR EPA ARB Labels IMPORTANT ENGINE INFORMATION THIS ENGINE CONFORMS TO __ MODEL YEAR U S EPA REGULATIONS NONROAD COMPRESSION IGNITION ENGINES THIS ENGINE IS CERTIFIED TO OPERATE ON US 2D FUEL ENGINE FAMILY LL LITERS ENGINE MODEL FUEL RATE L ISTROKE L__ kW L_ RPM REFER TO OWNERS MANUAL FOR MAINTENANCE SPECIFICATIONS AND ADJUSTMENTS YANMAR CO LTD EPA Less Than 50 HP SAE 37kW IMPORTANT ENGINE INFORMATION THIS ENGINE CONFORMS TOC Y CALIFORNIA AND U S EPA REGULATIONS FOR OFF ROAD C ENGINES THIS ENGINE 5 CERTIFIED TO OPERATE ON Type 2 D FUEL ENGINE FAMILY 7 DISPLACEMENT __ LITERS ENGINE MODEL 55 CONTROL SYSTEM EM FUEL RATE __ STROKE Q
180. he representative alternator For specific part detail see the Parts Catalog for the engine you are working on 1 Nut 11 Rear Frame Housing Bearing 21 2 Pulley 12 Bearing Cover 22 3 Collar 13 Thrust Washer 23 4 Front Frame Housing 14 Thrust Washer 24 5 Stator Assembly 15 Nut 2 25 6 Stud 2 16 Nut 26 7 Front Frame Housing Bearing 17 Insulation Bushing 27 8 Bearing Cover 18 Spring 2 28 9 Bearing Cover Bolt 4 19 Brush Holder 29 10 Rotor Assembly 20 Rear Frame Housing Figure 11 1 YANMAH TNV IDI Service Manual 0000255 Bolt 2 Holder IC Regulator Assembly Bolt 2 Bolt Brush 2 bolt Rear Cover Bolt 3 11 9 ALTERNATOR ALTERNATOR WIRING DIAGRAM 1 oe E 7A SS zu 2 3 A BT A o m 77 77 5 1 Key Switch 3 Load 6 IC Regulator Assembly 2 Charge Lamp 3 4 Watts 4 Battery Max 5 Alternator Assembly Figure 11 2 Do not short circuit the charging system Do not remove the positive battery between alternator terminals IG and L cable from alternator terminal B while Damage to the alternator will result the engine is operating Damage to the 0000035 alternator will result 0000037en Do not connect a load between alternator terminals L and E Damage to the alternator w
181. head Reinstall and tighten bolts Figure 6 34 1 2 securely 0002131 Figure 6 34 Reinstall the exhaust manifold using a new gasket Tighten the bolts and nuts Figure 6 34 5 6 securely Reinstall the fuel injectors See nstallation of the Fuel Injectors on page 7 30 Reinstall the high pressure and return fuel injection lines See Installation of the Fuel Injectors on page 7 30 Reinstall the coolant pump See Heassembly of Engine Coolant Pump on page 8 1 1 Reinstall the alternator See Installation of Alternator on page 11 16 ENGINE 6 33 ENGINE Measuring and Adjusting Valve Clearance Measure and adjust while the engine is cold Notes The No 1 piston position is onthe flywheel end of the engine opposite end of the radiator The firing order is 1 3 2 for 3 cylinder engines and 1 2 for 2 cylinder engines 3 cylinder engines fire every 240 of crankshaft rotation 2 cylinder engines are an uneven fire engine No 2 cylinder fires 180 after No 1 The crankshaft then rotates 540 before No 1 cylinder fires again Valve clearance of both the intake and exhaust valves can be checked with the piston for that cylinder at top dead center TDC of the compression stroke When a piston is at TDC of the compression stroke both rocker arms will be loose and the cylinder TDC mark on the flywheel will be visible in the timing port of the flywheel housing 3 Cylinder Engines
182. hen you remove any fuel system CRUSH HAZARD component Failure to comply will result in death or serious injury Wipe up any spills immediately Wear eye protection The fuel system When you need to transport engine for repair have a helper assist you to attach it to a hoist and load it on a ae truck NEVER stand under a hoisted engine If the hoist mechanism fails the engine will fall on you causing serious injury or death Failure to comply will result in death or serious injury 0000008en 5 6 TNV IDI Service Manual YANMAR DANGER Chi FIRE AND EXPLOSION HAZARD Diesel fuel is extremely flammable and explosive under certain conditions Place an approved container under the air bleed port when you prime the fuel system Never use a shop rag to catch the fuel Wipe up any spills immediately ALWAYS close the air bleed port after you complete priming the system Wear eye protection The fuel system is under pressure and fuel could spray out when you open the air bleed port If the unit has an electric fuel pump turn the key switch to the ON position for 10 to 15 seconds or until the fuel coming out of the air bleed port is free of bubbles to allow the electric fuel pump to prime the system If the unit has a mechanical fuel pump operate the fuel priming pump several times until the fuel coming out of the air bleed port is free of bubbles
183. hut down e On the initial engine start up allow the engine to idle for approximately 15 minutes while you check for proper engine oil pressure diesel fuel leaks engine oil leaks coolant leaks and for proper operation of the indicators and or gauges During the first hour of operation vary the engine speed and the load on the engine Short periods of maximum engine speed and load are desirable 0000008en NEVER use an engine starting aid such Avoid prolonged operation at as ether Engine damage will result minimum or maximum engine speeds and loads for the next four to five hours During the break in period carefully observe the engine oil pressure and engine temperature During the break in period check the e engine oil and coolant levels frequently Be environmentally responsible Follow these procedures for hazardous waste disposal Failure to follow these procedures may seriously harm the environment NEVER engage the starter motor while the engine is running This may damage Follow the guidelines of the EPA or the starter motor pinion and or ring other governmental agency for the gear proper disposal of hazardous 0000012en materials such as engine oil diesel fuel and engine coolant Consult the local authorities or reclamation facility NEVER dispose of hazardous materials irresponsibly by dumping them into a sewer on the ground
184. ighten to specifications Prime the fuel system See Priming The Fuel System on page 4 12 Operate the engine and check for fuel leaks 7 30 TNV IDI Service Manual YANMAR FUEL SYSTEM This Page Intentionally Left Blank YANMAR TNV IDI Service Manual 7 31 FUEL SYSTEM 7 32 TNV IDI Service Manual YANMAR Section 8 COOLING SYSTEM Page Before You Begin Servicing 2 8 3 22255 M 8 5 Cooling System Diagram 0 44 1 8 5 Engine Coolant Pump Components 8 6 Engine Coolant System 2220 8 7 Engine Coolant PUMP oiii uie 8 7 Disassembly of Engine Coolant Pump 8 7 Cleaning and 2 0 8 8 10 Reassembly of Engine Coolant Pump 8 11 YANMAR TNV IDI Service Manual COOLING SYSTEM 8 2 This Page Intentionally Left Blank TNV IDI Service Manual YANMAR COOLING SYSTEM BEFORE YOU BEGIN SERVICING SCALD HAZARD NEVER remove the radiator cap if the engine is hot Steam and hot engine coolant will spurt out and seriously burn you Allow the engine to cool down before you attempt to remove the radiator cap Securely tighten the radiator cap after you check the radiator Steam can spurt out during engine operation if the cap i
185. ile the engine is operating If the charge indicator is not ON repair the problem before operating the engine TNV IDI Service Manual YANMAR DYNAMO COMPONENT LOCATION ALTERNATOR Yanmar Part No 171301 77201 dynamo is used in this section to show the service procedures for the representative dynamo For specific part detail see the Parts Catalog for the engine you are working on 1 Rear Cover 6 Output Wire and Connector 2 Nut 7 Plate 3 Lock Washer 8 Spacer 4 Flat Washer 9 Stator Assembly 5 Rear Bearing 10 Front Bearing 2 Figure 11 20 YANMAR TNV IDI Service Manual 11 12 0002140 11 Flat Washer 12 Flywheel Assembly 13 Pulley Half 14 Through Bolt 11 17 ALTERNATOR DYNAMO WIRING DIAGRAM 1 1 Dynamo 2 IC Regulator Assembly 3 Key Switch OPERATION OF DYNAMO The dynamo consists of a series of permanent magnets that rotate around a stationary stator coil The magnets are attached to the flywheel which is rotated via the engine cooling fan drive belt The resultant output is an AC alternating current 4 0002137 4 Charge Lamp 3 4 Watts 6 Load Figure 11 21 signal The AC is converted to DC direct current in the IC Regulator Rectifier The IC Regulator Rectifier outputs charging DC current to the battery 11 18 TNV IDI Service Manual YANMAR ALTERNATOR DYNAMO STANDARD OUTPUT STANDARD
186. ill result 0000036en 11 10 TNV IDI Service Manual YANMAH ALTERNATOR ALTERNATOR STANDARD OUTPUT Output Current 13 5 Volts Constant Ambient Temperature at 77 F 25 C EI ES E 0 45 6 7 8 Alternator RPM x10 Figure 11 3 YANMAR TNV IDI Service Manual 11 11 ALTERNATOR ALTERNATOR SHOCK HAZARD Turn off the battery switch if equipped or disconnect the negative battery cable before servicing the electrical system Check the electrical harnesses for cracks abrasions and damaged or corroded connectors ALWAYS keep the connectors and terminals clean Failure to comply could result in death or serious injury 0000009en Removal of Alternator T Disconnect the electrical wires from the alternator 2 Loosen the V belt HAZARD Carefully rotate the alternator toward the cylinder block while loosening the V belt Failure to comply may result in minor or moderate injury 0000014en Remove the V belt adjuster from the alternator bolt Figure 11 4 1 Remove the nut Figure 11 4 2 from the gear case stud Remove the alternator 11 12 0000264 Figure 11 4 Disassembly of Alternator T Remove the nut Figure 11 5 1 from the shaft of the rotor assembly Remove the pulley Figure 11 5 2 2 0000256 Figure
187. iming tool 8 Reinstall the shut off solenoid 9 Reinstall the high pressure fuel injection lines See Installation of High Pressure Fuel Injection Lines on page 7 13 10 Replace the flywheel inspection port cover 11 Prime the fuel system Operate the engine and check for leaks FUEL INJECTORS Removal of Fuel Injectors 1 Close any fuel valves in the fuel supply line 2 Clean the area around the fuel injection pump and fuel injectors to keep contaminants from entering the engine or fuel system 3 Remove the high pressure fuel injection lines as an assembly See Removal of High Pressure Fuel Injection Lines on page 7 13 4 Remove the fuel return line Figure 7 31 2 and copper washer Figure 7 31 3 from the fuel injectors See Removal of Fuel Return Line on page 7 14 Note The fuel injectors used on IDI engines screw into the cylinder head 5 Remove the fuel injectors Figure 7 31 4 TNV IDI Service Manual YANMAR FUEL SYSTEM Testing of Fuel Injectors Never use a steel wire brush to clean fuel injectors Damage to the nozzle and other components is likely to result 0000172en 1 Thoroughly clean the fuel injector nozzle using clean diesel fuel and a brass wire brush 2 Visually inspect the fuel injectors and nozzle protectors for deposits or damage Clean repair or replace as necessary Note Test the fuel injector using an injection nozzle tester Operate the tester ER f
188. inder Clearance 2 3TNV70 0 0012 0 0020 in 0 030 0 050 mm 3TNV76 0 0014 0 0022 in 0 035 0 055 mm Wrist Pin Hole Inside Diameter Pin Outside Diameter 0 8661 0 8665 in 22 000 22 009 mm 0 8659 0 8661 in 21 995 22 000 mm 0 8677 in 220 039 mm 0 8648 in 21 965 mm Oil Clearance 0 0000 0 0006 in 0 000 0 014 mm 0 0029 in 0 074 mm See Inspection of Pistons and Piston Rings on page 6 47 6 11 ENGINE Piston Ring Inspection Item Standard Reference Page 2 3TNV70 6 12 Top Ring Ring Groove Width 0 0610 0 0618 in 1 550 1 570 mm Ring Width 0 0579 0 0587 in 1 470 1 490 mm 0 0571 in 1 450 mm Side Clearance 0 0024 0 0039 in 0 060 0 100 mm End Clearance 0 0059 0 0118 in 0 150 0 300 mm 0 0154 in 0 390 mm Second Ring Ring Groove Width 0 0606 0 0614 in 1 540 1 560 mm 0 0654 in 1 660 mm Ring Width Side Clearance 0 0579 0 0587 in 1 470 1 490 mm 0 0020 0 0035 in 0 050 0 090 mm 0 0571 in 1 950 mm 0 0083 in 0 210 mm See Inspection of Pistons and Piston Rings on page 6 47 End Clearance 0 0071 0 0130 in 0 180 0 33 mm 0 0165 in 0 42 mm Oil Ring Ring Groove Width 0 1185 0 1193 in 3 010 3 030 mm 0 1232 in 3 130 mm Ring Width 0 1170 0 1177 in 2
189. ines from the retainers or bending any of the fuel lines will make it difficult to reinstall the fuel lines 0000047en Note To prevent rounding the fuel line nuts always use a line or flare nut wrench Close any fuel valves in the fuel supply line 2 Clean the area to keep contaminants from entering the fuel system 3 Place a drain pan under the fuel injection pump to catch any spillage 4 Loosen the high pressure lines at the fuel injection pump 5 Use one wrench to hold the fuel return line nut and fuel return line from rotating Use a second wrench to loosen the high pressure fuel line nut Repeat with the remaining fuel injectors Figure 7 4 FUEL SYSTEM 6 Finish loosening all the fuel line nuts and remove the high pressure fuel lines as an assembly being careful not to bend any of the fuel lines Be sure to protect the fuel system from contamination by plugging or covering all open connections Plug or cap all openings to minimize leakage and prevent contamination Installation of High Pressure Fuel Injection Lines Remove or install the high pressure fuel injection lines as an assembly whenever possible Disassembling the high pressure fuel injection lines from the retainers or bending any of the fuel lines will make it difficult to reinstall the fuel lines 0000047en y l 0002237 Figure 7 4 YANMAR TNV IDI Service Manual Note To prevent rounding
190. ing Figure 6 24 1 in their proper positions Figure 6 23 See Valve Spring on page 6 7 for the service limit 0002152 Figure 6 24 0000200 Figure 6 23 6 29 ENGINE 3 Finish installing the valve guides Figure 6 25 1 to the proper height Figure 6 25 3 using the valve guide installation tool Figure 6 25 2 See Intake Exhaust Valve and Guide on page 6 7 0001756A Figure 6 25 Reassembly of Intake and Exhaust Valves IMPORTANT Always install new valve stem seals The exhaust valve stem seals can be identified by having yellow paint Ensure they are installed in the correct locations Oil the lip of the valve stem seal Figure 6 26 2 Using the valve stem seal installation tool Figure 6 26 1 install a new valve stem seal on each of the valve guides Figure 6 26 3 0001873 Figure 6 26 6 30 Measure the distance Figure 6 27 1 from the cylinder head to valve stem seal to ensure proper clearance Figure 6 27 2 between the valve guide and seal See Intake Exhaust Valve and Guide on page 6 7 0001874 Figure 6 27 Place the cylinder head assembly on its exhaust port side Place all the valves Figure 6 28 6 in their proper location in the cylinder head 0002151 Figure 6 28 Place the cylinder head on the workbench with the combustion side down to install the valve springs Reinstall the valve spring Figure 6
191. ing and shorten the belt life Use the specified belt 0000055en 0000056en 0000052en Make sure that the combined total resistance of the battery cable in both Agricultural or other chemicals directions between the starter motor especially those with a high sulfur and the battery is within the value content can adhere to the IC regulator indicated in the Battery Cable This will corrode the conductor and Resistance chart in the Electric Wiring result in battery over charging boiling Section of this manual The starter and charging malfunctions Consult motor will malfunction and fail if the Yanmar before using the equipment in resistance is higher than the specified such an environment or the warranty is value voided 0000057en 0000053en 3 18 TNV IDI Service Manual YANMAR Removing the battery cables or the battery while the engine is operating may cause damage to the current limiter depending on the electrical equipment being used This situation could cause loss of control of output voltage The continuous high voltage of 23 24 volts for 5000 rpm dynamo will damage the current limiter and other electrical equipment 0000058en Reversing the battery cable connections at the battery or on the engine will destroy the SCR diode in the current limiter This will cause the charging system to malfunction and may cause damage to the electrical harnesses
192. ing assembly to ensure long engine life The same procedure is done for both connecting rods and main bearings See Removal of Pistons on page 6 42 or Removal of Crankshaft on page 6 44 for specific information Inspection of Cylinder Block 1 Ensure that oil passages are clear and unobstructed 2 Check for discoloration or evidence of cracks If a fracture is suspected use the color check method or the Magnaflux method to determine if the cylinder block is fractured 3 Measure cylinders for roundness taper and inspect for evidence of scoring Consider honing re boring or replacing the cylinder block if the measurements are not within specification Take measurements at three places c in two directions d and e in each cylinder Collect and record the measurements See Cylinder Block on page 6 14 for specifications 0000230B Figure 6 63 Roundness Roundness can be calculated by subtracting the smaller measured value from the larger measured value of d or e at each measuring location a b c ENGINE Taper Taper can be calculated by subtracting the minimum measured value from the maximum measured value of locations a b c Calculate along both the d axis and e axis and use the larger of the two calculations as the value to compare to the specifications Inspection of Pistons and Piston Rings 1 Clean piston ring grooves using a piston ring groove cleaning
193. ing is facing toward the top of the engine Ensure all three timing marks Figure 6 98 A B C are aligned 6 59 ENGINE 0002190 1 Fuel Injection Pump Gear 2 Camshaft Gear 3 Optional Accessory Drive Gear 4 Crankshaft Gear Figure 6 99 3 PIER 5 Reinstall the crankshaft pulley Figure 6 98 6 Reinstall the washer and bolt Tighten to the 7 When all gears are properly aligned tighten the specified Edid sd Special Torque Chart on idler gear retaining bolts to specified torque page 6 15 for specifications See Special Torque Chart on page 6 15 for specifications Installation of Gear Case Cover 1 Apply a continuous bead of ThreeBond Liquid Gasket No 1212 Yanmar Part No 977770 01212 to the mounting area of the gear case cover Figure 6 99 1 Be sure to circle the bolt holes 2 Reinstall the dowels Figure 6 99 3 and a new O ring Figure 6 99 2 IMPORTANT Be sure to align the flats on the oil pump with the flats on the crankshaft gear 3 Reinstall the timing gear case cover 4 Reinstall and tighten the gear case cover bolts 6 60 YANMAR Installation of Oil Pan 1 Reinstall the oil pickup tube Figure 6 100 1 using a new O ring Figure 6 100 2 0002185 Figure 6 100 Apply a continuous bead of ThreeBond Liquid Gasket No 1212 Yanmar Part No 977770 01212 to the mounting surface of the oil pan Figure 6 101 2 and crankcase extension if equipped
194. injection pump to become misaligned 0000048en Do not rotate the crankshaft with the injection pump removed 0000083en The fuel return line is a one piece assembly Use care not to bend or twist the fuel return line 0000171en TNV IDI Service Manual YANMAR FUEL SYSTEM INTRODUCTION 5 2 0002238 Figure 7 1 This section of the Service Manual describes the procedures necessary to remove install and time the ML fuel injection pump and its associated system components This fuel injection pump is representative of the fuel injection pumps used on other TNV IDI model engines Fuel Injection Pump Note If the ML fuel injection pump itself requires servicing it must be taken to an authorized Yanmar FIE Fuel Injection Equipment repair facility The following describes the features of the ML fuel injection pump manufactured by Yanmar The fuel injection pump is a very important component of the engine It is capable of making very precise fuel delivery adjustments according to the varied loads applied to the engine All of the fuel injection pump components are very precisely machined It is extremely important to follow good service practices and maintain cleanliness when servicing the fuel injection pump YANMAR TNV IDI Service Manual The Yanmar ML Fuel Injection Pump is an in line type pump which consists of a fuel supply plunger Figure 7 1 1 for each cylinder a
195. install the key and timing gear on crankshaft Install new bearing inserts Figure 6 90 1 and thrust bearing Figure 6 90 2 in the cylinder block and main bearing caps Be sure the oil holes in the upper bearing shells align with the oil ports in the cylinder block Apply a liberal coat of clean engine oil to the bearings and crankshaft journals Place the crankshaft into the engine 6 56 IMPORTANT The main bearing caps are numbered and have arrows for proper positioning The No 1 cap is atthe flywheel end The arrows point toward the flywheel end of the engine Reinstall the main bearing caps Figure 6 90 3 Apply a light coat of clean engine oil to the bearing cap bolts and tighten the bolts to the specified torque in two stages 1 2 then full torque See Special Torque Chart on page 6 15 for specifications 0002189 Figure 6 90 6 Rotate the crankshaft to assure it turns freely YANMAR ENGINE 7 Apply ThreeBond Liquid Gasket No 1212 Yanmar Part No 977770 01212 to the mounting flange of the flywheel housing Figure 6 91 2 8 Align the flywheel housing with the two dowel pins Figure 6 91 3 9 Reinstall flywheel housing and seal assembly 10 Reinstall the flywheel Figure 6 91 1 and tighten the bolts to the specified torque See Special Torque Chart on page 6 15 for specifications 0002188 Figure 6 91 Installation of Pistons IMPORTANT Do not allow the
196. ions v balia Note Record all measurements taken during Keeper 13 Valve Spring Retainer 14 Valve Spring 1 Drain coolant from engine into a suitable 15 Valve Stem Seal container See Drain Flush and Refill Cooling 16 Valve Guide System with New Coolant on page 5 34 17 Cylinder Head 18 Exhaust Valve 19 Intake Valve 20 Cylinder Head Gasket Identify all parts and their location using Rod 2 li an appropriate method It is important al ind that all parts are returned to the same 23 Glow Plug Wiring Harness position during the reassembly process 24 Cylinder Head Bolt 0000080en 25 Hocker Arm Shaft Spring 2 Remove the coolant pump See Disassembly of 26 Rocker Arm Shaft Alignment Set Screw Engine Coolant Pump on page 8 7 27 Crankcase Breather Diaphragm 28 3 Remove the high pressure fuel lines and fuel injectors from the cylinder head See Hemoval of Fuel Injectors on page 7 24 29 Spring 30 Crankcase Breather Cover 6 21 ENGINE Removal of Intake Manifold Valve Cover 1 Remove the intake manifold bolts Figure 6 2 1 and valve cover bolts Figure 6 2 2 Remove the valve cover intake manifold Figure 6 2 3 Discard gasket Figure 6 2 4 0002131 Figure 6 2 Remove the exhaust manifold bolts Figure 6 2 5 and nuts Figure 6 2 6 Remove the exhaust manifold Figure 6 2 7 and the exhaust mani
197. k the charging system wiring f no problems are found in previous checks replace the IC regulator 11 20 DYNAMO Removal of Dynamo 1 Disconnect the output wire connector from the dynamo 2 Loosen the V belt PINCH HAZARD Carefully rotate the alternator toward the cylinder block while loosening the V belt Failure to comply may result in minor or moderate injury 0000014en 3 Remove the V belt adjuster from the dynamo bolt Figure 11 23 1 4 Remove the nut Figure 11 23 2 from the gear case stud Remove the dynamo 1 44 2 Figure 11 23 TNV IDI Service Manual YANMAR Disassembly of Dynamo 1 Remove the rear cover Figure 11 24 1 2 Remove the nut Figure 11 23 2 lock washer Figure 11 24 3 and flat washer Figure 11 24 4 M 70 Os 0002143 Figure 11 24 3 Remove the through bolt Figure 11 25 1 pulley half Figure 11 25 2 flywheel Figure 11 25 3 flat washer Figure 11 25 4 bearings Figure 11 25 5 and spacer Figure 11 25 6 0002144 Figure 11 25 4 Remove the screws Figure 11 26 1 and the stator assembly Figure 11 26 2 5 Remove the rear bearing Figure 11 26 3 YANMAR TNV IDI Service Manual ALTERNATOR 0002145 Figure 11 26 Reassembly of Dynamo Reinstall the rear bearing Figure 11 27 3 2 Reinstall the stator Figure 11 27 1 000
198. l Carefully clean the oil cap dipstick and the surrounding area before you remove the cap NEVER mix different types of engine oil This may adversely affect the lubricating properties of the engine oil NEVER overfill Overfilling may result in white exhaust smoke engine overspeed or internal damage 0000005en Engine Oil Specifications Use an engine oil that meets or exceeds the following guidelines and classifications Service Categories API Service Categories CD or higher ACEA Service Categories E 3 E 4 and E 5 JASO Service Category DH 1 Definitions API Classification American Petroleum Institute ACEA Classification Association des Constructeurs Europ ens d Automobilies JASO Japanese Automobile Standards Organization Note 1 Be sure the engine oil engine oil storage containers and engine oil filling equipment are free of sediments and water YANMAR TNV IDI Service Manual GENERAL SERVICE INFORMATION 2 Change the engine oil after the first 50 hours of operation and then at every 250 hours thereafter 3 Select the oil viscosity based on the ambient temperature where the engine is being operated See the SAE Service Grade Viscosity Chart Figure 4 5 4 Yanmar does not recommend the use of engine oil additives Additional Technical Engine oil Requirements The engine oil must be changed when the Total Base Number TBN has been reduced to 2 0 TBN
199. l of hazardous minimum or maximum engine speeds materials such as engine oil diesel and loads for the next four to five fuel and engine coolant Consult the hours local authorities or reclamation facility During the break in period carefully NEVER dispose of hazardous observe the engine oil pressure and materials irresponsibly by dumping engine temperature them into a sewer on the ground or into ground water or waterways 0000013en During the break in period check the engine oil and coolant levels frequently 000001 1en Protect the air cleaner turbocharger if equipped and electric components from damage when you use steam or use high pressure water to clean the engine NEVER engage the starter motor while the engine is running This may damage the starter motor pinion and or ring gear 0000014en 0000012en NEVER overfill the engine with engine oil ALWAYS keep the oil level between the upper and lower lines on the oil cap dipstick 0000015en 5 14 TNV IDI Service Manual YANMAR NEVER use high pressure water or compressed air at greater than 28 psi or a wire brush to clean the radiator fins Radiator fins damage easily 0000016en NEVER attempt to adjust the low or high idle speed limit screw This may impair the safety and performance of the machine and shorten its life If the idle speed limit screws require adjustment see your authorized
200. l the insulation bushing Figure 11 16 4 and nut Figure 11 16 3 0000258A Figure 11 16 7 Reassemble the regulator assembly Figure 11 16 1 to the holder Figure 11 16 2 11 15 ALTERNATOR 8 Reinstall the brush holder Figure 11 17 3 springs Figure 11 17 4 and brushes Figure 11 17 5 9 Reattach the regulator assembly and holder to the rear frame housing 0000257A Figure 11 17 10 Reinstall the rear cover Figure 11 17 2 to the rear frame housing with three bolts Figure 11 17 1 2 Figure 11 18 0000256 11 16 11 Reassemble the pulley Figure 11 18 2 nut Figure 11 18 1 to the shaft of the rotor assembly Tighten the nut Installation of Alternator 1 Position the alternator on the gear case Loosely reinstall the nut Figure 11 19 2 on the gear case stud and the V belt adjuster bolt Figure 11 19 1 0000264 Figure 11 19 2 Reconnect the electrical wires to the alternator Tighten the nuts to 15 20 in Ibs 1 7 2 3 N m 17 23 kgf m 3 Reinstall the V belt Tighten the V belt to the proper tension as described in Check and Adjust Cooling Fan V belt on page 5 28 4 Startthe engine Listen for any unusual sounds from the alternator Do not operate the engine if the alternator is producing unusual sounds Damage to the alternator will result 0000039en 5 Verify that the charge indicator is ON wh
201. le watching the rocker arm motion and timing grid on the flywheel Position where both the intake and exhaust valves are closed 6 34 YANMAR ENGINE 3 Insert a feeler gauge Figure 6 35 1 between rocker arm and valve cap and record the measured valve clearance Use the data for estimating the wear 0001782A Figure 6 35 4 If adjustment is required proceed to the next step 5 Loosen the valve adjusting screw lock nut Figure 6 36 1 and valve adjusting screw Figure 6 36 2 on the rocker arm Check the valve for inclination of the valve cap entrance of dirt or wear 0001783A Figure 6 36 Insert a feeler gauge of the correct thickness Figure 6 37 1 see Adjustment Specifications on page 6 6 between rocker arm and valve cap Turn the valve adjustment screw to adjust the valve clearance so there is a slight drag on the feeler gauge when sliding it between the rocker arm and valve cap Hold the adjusting screw while tightening the valve adjusting screw lock nut Figure 6 36 1 Recheck the clearance Note There is a tendency for the clearance to decrease slightly when the lock nut is tightened It is suggested that the initial clearance adjustment be made slightly on the loose side before tightening the lock nut 0001782A Figure 6 37 Apply oil to the contact surface between adjusting screw and push rod Rotate the crankshaft and me
202. leakage Replace the coolant pump if any of these conditions are present If the engine coolant pump must be replaced replace the engine coolant pump as an assembly only Do not attempt to repair the engine coolant pump or replace individual components 0000041en YANMAR TNV IDI Service Manual COOLING SYSTEM 1 Make sure the engine and engine coolant are not hot 2 Before removing the engine coolant pump or thermostat it will be necessary to drain the engine coolant Drain the coolant into a clean container if the coolant is to be reused Otherwise properly dispose of the coolant Drain the coolant from the radiator Remove the radiator cap Figure 8 4 1 Remove the drain plug or open the drain cock Figure 8 4 2 at the lower portion of the radiator and drain the coolant 2 0000074A Figure 8 4 Drain the coolant from the engine block Remove the coolant drain plug Figure 8 5 1 from the engine block COOLING SYSTEM 0001959B Figure 8 6 5 Disconnect the coolant hoses and the temperature switch lead wire from the engine coolant pump 6 Remove the engine coolant pump 3 Loosen the alternator mounting bolts Loosen Figure 8 6 4 Discard the gasket and remove the V belt and rotate the alternator away from the engine and out of the way PINCH HAZARD Carefully rotate the alternator toward the cylinder block while loosening the V belt Failure
203. lement if the air intake restriction exceeds the above mentioned value 0000046en The tightening torque in the Standard Torque Chart on page 4 25 should be applied only to the bolts with a 7 head JIS strength classification 7T Apply 80 torque when tightened to aluminum alloy 0000023enTNVIDISM Apply 60 torque to bolts that are not listed 5 15 PERIODIC MAINTENANCE It is important to perform daily checks Periodic maintenance prevents unexpected downtime reduces the number of accidents due to poor machine performance and helps extend the life of the engine 0000060en PRECAUTIONS The Importance of Periodic Maintenance Engine deterioration and wear occurs in proportion to length of time the engine has been in service and the conditions the engine is subject to during operation Periodic maintenance prevents unexpected downtime reduces the number of accidents due to poor machine performance and helps extend the life of the engine Performing Periodic Maintenance EXHAUST HAZARD NEVER operate the engine in an enclosed area such as a garage tunnel underground room manhole or ship s hold without proper ventilation NEVER block windows vents or other means of ventilation if the engine is operating in an enclosed area All internal combustion engines create carbon monoxide gas during operation Accumulation of this gas within an enclosure coul
204. limit Armature Coil Continuity Test Check for continuity between the commutator segments using a multimeter The multimeter should indicate continuity If the multimeter does not indicate continuity replace the armature TNV IDI Service Manual YANMAR 0000114 Figure 10 15 Armature Coil Insulation Test Check for continuity between a commutator segment and the shaft or armature using a multimeter The multimeter should not indicate continuity If the multimeter indicates continuity replace the armature 0000115 Figure 10 16 YANMAR TNV IDI Service Manual STARTER MOTOR Measure Armature and Commutator Run Out Measure the armature core run out and the commutator run out using a dial indicator Replace the armature if either of the measurements is not within specifications 0000116 Figure 10 17 See Starter Motor Specifications on page 10 6 for the service limit Field Coil Field Coil Continuity Test Check for continuity between the field coil terminals using a multimeter The multimeter should indicate continuity If the multimeter does not indicate continuity replace the field coil assembly 0000119 Figure 10 18 10 13 STARTER MOTOR Field Coil Insulation Test Check for continuity between either field coil terminal and the yoke using a multimeter The multimeter should not indicate continuity If the multimeter indicates continuity replace the field coil assembly
205. ll result in death or maintenance procedures serious injury If the electrolyte is frozen slowly warm the battery before you recharge it 0000007en Machine safety signs and labels are additional reminders for safe operating and maintenance techniques DANGER See your authorized Yanmar industrial Dd engine dealer distributor for additional training 0000002en FIRE AND EXPLOSION HAZARD Only use the key switch to start the engine NEVER jump start the engine Sparks caused by jumping the battery to the starter terminals may cause a fire or explosion Failure to comply will result in death or serious injury 0000004en YANMAR TNV IDI Service Manual 5 3 PERIODIC MAINTENANCE DANGER SCALD HAZARD NEVER remove the radiator cap if the engine is hot Steam and hot engine coolant will spurt out and seriously burn you Allow the engine to cool down before you attempt to remove the radiator cap Securely tighten the radiator cap after you check the radiator Steam can spurt out during engine operation if the cap is loose ALWAYS check the level of the engine coolant by observing the reserve tank Failure to comply will result in death or serious injury 0000002en 5 4 A DANGER 7 tj FIRE AND EXPLOSION HAZARD Diesel fuel is extremely flammable and explosive under certain conditions Only fill
206. low the engine components that operate at high temperatures such as the turbocharger if equipped and exhaust system to cool slightly before the engine itself is shut down 0000008en NEVER use an engine starting aid such as ether Engine damage will result 0000009en Make sure the engine is installed on a level surface If a continuously running engine is installed at an angle greater than 30 in any direction or if an engine runs for short periods of time less than 3 minutes at an angle greater than 35 in any direction engine oil may enter the combustion chamber causing exessive engine speed and generating white smoke This may cause serious engine damage 0000010en 5 13 PERIODIC MAINTENANCE New Engine Break In On the initial engine start up allow the engine to idle for approximately 15 04 9 minutes while you check for proper engine oil pressure diesel fuel leaks engine oil leaks coolant leaks and for Be environmentally responsible Follow proper operation of the indicators these procedures for hazardous waste and or gauges disposal Failure to follow these procedures may seriously harm the environment During the first hour of operation vary the engine speed and the load on the engine Short periods of maximum Follow the guidelines of the EPA or engine speed and load are desirable other governmental agency for the Avoid prolonged operation at proper disposa
207. lug M10 x 1 25 11 15 ft lbs 14 7 19 6 N m 1 5 2 0 kgf m Not Applied See Reassembly of Intake Manifold Valve Cover on page 6 32 6 15 ENGINE SPECIAL SERVICE TOOLS Note Tools not having Yanmar part numbers must be acquired locally Tool Name Applicable model and tool size Illustration Valve Guide Tool For Removing Valve Guides Valve Guide Tool For Installing Valve Guides Wrist Pin Bushing Tool For Removing Installing of Wrist Pin Bushings L1 L2 1 d2 0 787 in 20 mm 2 953 in 75 mm 0 217 in 5 5 mm 0 374 in 9 5 mm Locally Manufactured L1 L2 di d2 0 394 in 10 mm 2 362 in 60 mm 0 433 in 11 mm 0 669 in 17 mm Allowance Locally Manufactured 0 0 3 L1 L2 0 984 in 25 mm 3 346 in 85 mm 41 03 qo 0 6 Allowance 4106 4270 Locally Manufactured 0000827 0000828 0000829 6 16 Valve Spring Compressor For Removing Installing Valve Springs Stem Seal Tool for Installing Stem Seals Yanmar Part No 129100 92630 1 2 L1 L2 L3 0 591 in 15 mm 0 827 in 21 mm 0 472 in 12 mm 0 433 in 11 mm 2 559 in 65 mm 0 157 in 4 mm or more Allowance d1 0 2 L 120 1 Locally Manufactured 000
208. m Pinion Clockwise Engagement System Magnetic Shift Terminal Voltage Current No load 11 5 V 90 A max Revolution 3000 rpm Terminal Voltage Current 8 7V 230A Torque 61 in Ib 6 9 N m 0 70 kgf m Revolution 1130 rpm min Terminal Voltage Current 2 5 325 max Stalled Torque 73 in lbs 8 24 N m 0 84 kgf m minimum Clutch System Pinion Projection Voltage at 212 F 100 C Overrunning 8 0 V max Pinion DP or Module Number of Teeth M2 54 9 Application Standard Spring Force 3 1 4 0 Ibf 13 7 17 6 1 4 1 8 kgf Brush Standard 0 55 in 14 mm Length Service Limit 0 44 in 11 1 mm Solenoid Pull In Coil Resistance 0 484 W at 68 F 20 C Switch Hold In Coil Resistance 1 055 W at 68 F 20 C Standard Outside Diameter code 1 102 in 28 0 mm Service Limit 1 063 in 27 0 mm Standard Commutator Run Out Service Limit 0 001 in 0 02 mm 0 002 in 0 05 mm Standard Insulation Depth 0 024 in 0 6 mm Service Limit 10 6 0 008 in 0 2 mm TNV IDI Service Manual YANMAR STARTER MOTOR STARTER MOTOR TROUBLESHOOTING uoyws Jo ejeJ Buruejs uoys eoejdeu Jo AAO peuunj SI yous dois seop
209. mped makers mark Figure 6 87 1 facing the top of the piston The makers mark may vary in appearance but will always be located on the top surface of the piston ring adjacent to the piston ring gap The oil ring and oil ring expander can be installed either side up SV 0000225A Figure 6 87 IMPORTANT Always use a piston ring installation tool expander when installing piston rings Never attempt to install piston rings by hand Lubricate and install the wrist pin Figure 6 86 ENGINE Reinstall the oil ring expander Figure 6 88 4 Install the oil ring Figure 6 88 3 with the end gap at 180 from the expander end gap Reinstall the second compression ring Figure 6 88 2 This ring is identified by its dark color and tapered face profile Reinstall the top compression ring Figure 6 88 1 This ring is identified by its silver color and barrel shaped face profile IMPORTANT The oil ring expander Figure 6 88 4 end gap must be located 180 from the oil ring Figure 6 88 3 end gap 1 2 3 0001722B Figure 6 88 6 55 ENGINE 10 Stagger the piston ring end gaps at 120 intervals Figure 6 89 1 2 3 Do not position the top piston ring end gap in line with the wrist pin 1 Top Compression Ring End Gap 2 Second Compression Ring End Gap 3 Oil Ring End Gap Figure 6 89 Installation of Crankshaft 1 If removed re
210. n of Tappets on page 6 49 Reference Page 2 3TNV70 2 7563 2 7567 in 70 010 70 020 mm 2 7638 in 70 200 mm Cylinder Inside Diameter 3TNV76 2 9925 2 9929 in 76 010 76 020 mm 3 0000 in 76 200 mm Roundness Cylinder Bore Taper 6 14 0 0004 in 0 01 mm or less 0 0012 in 0 03 mm See Inspection of Cylinder Block on page 6 47 YANMAR SPECIAL TORQUE CHART Torque for Bolts and Nuts Component Thread Diameter and Pitch Tightening Torque Lubricating Oil Application Thread Portion and Seat Surface ENGINE Reference Page Cylinder Head Bolts M9 x 1 25 mm 40 43 ft lbs 53 9 57 9 N m 5 5 5 9 kgf m Applied See Reassembly of Cylinder Head on page 6 31 Connecting Rod Bolts M7 x 1 0 mm 17 20 ft lbs 22 6 27 5 N m 2 3 2 8 kgf m Applied See Installation of Pistons on page 6 57 Flywheel Bolts M10 x 1 25 mm 59 64 ft lbs 80 4 86 4 N m 8 2 8 8 kgf m Applied See Installation of Crankshaft on page 6 56 Main Bearing Cap Bolts M10 x 1 25 mm 56 60 ft lbs 75 5 81 5 N m 7 7 8 8 kgf m Applied See Installation of Crankshaft on page 6 56 Crankshaft Pulley Bolts M12 x 1 25 mm 61 69 ft lbs 83 3 93 3 8 5 9 5 kgf m 61 69 ft lbs 113 123 N m 11 5 12 5 kgf m See Installation of Crankshaft on page 6 56 Glow P
211. nal components including but not limited to wiring harnesses electrical devices control panels radiators air filters fuel filters and or exhaust systems that are supplied and or installed by manufacturers other than Yanmar For warranty information on such external components please contact the machine or component manufacturer directly or see your authorized Yanmar dealer or distributor THIS WARRANTY IS PROVIDED IN LIEU OF ALL OTHER WARRANTIES EXPRESSED OR IMPLIED YANMAR SPECIFICALLY DISCLAIMS ANY IMPLIED WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE except where such disclaimer is prohibited by law IF SUCH DISCLAIMER IS PROHIBITED BY LAW THEN IMPLIED WARRANTIES SHALL BE LIMITED IN DURATION TO THE LIFE OF THE EXPRESSED WARRANT Y How Long is the Warranty Period The Yanmar standard limited warranty period runs for a period of twenty four 24 months or two thousand 2000 engine operation hours whichever occurs first An extended limited warranty of thirty six 36 months or three thousand 3000 engine operating hours whichever occurs first is provided for these specific parts only the cylinder block cylinder head crankshaft forging connecting rods flywheel flywheel housing camshaft timing gear and gear case The Warranty Period for both the standard limited warranty and the extended limited warranty by duration or operation hours begins on the date of delivery to the original retail purchaser and i
212. ng the fuel cap will damage it 0000002A Figure 4 3 Priming The Fuel System The fuel system needs to be primed under certain conditions Before starting the engine for the first time After running out of fuel and fuel has been added to the fuel tank After fuel system maintenance such as changing the fuel filter and draining the fuel filter water separator or replacing a fuel system component To prime the fuel system if an electric fuel pump is installed 1 Turn the key to the ON position for 10 to 15 seconds This will allow the electric fuel pump to prime the fuel system 4 12 2 NEVER use the starter motor to prime the fuel system This may cause the starter motor to overheat and damage the coils pinion and or ring gear To prime the fuel system if a mechanical fuel pump is installed 1 Operate the fuel priming lever Figure 4 4 1 several times until the fuel filter cup Figure 4 4 2 is filled with fuel 2 NEVER use the starter motor to prime the fuel system This may cause the starter motor to overheat and damage the coils pinion and or ring gear X VE SEO AUN VE aw 54602 4 4 0000649 TNV IDI Service Manual YANMAR ENGINE OIL Only use the engine oil specified Other engine oils may affect warranty coverage cause internal engine components to seize and or shorten engine life Prevent dirt and debris from contaminating the engine oi
213. nited States bio diesel fuels must comply with the American Standard ASTM D 6751 2 Bio fuels should be purchased only from recognized and authorized diesel fuel suppliers Precautions and concerns regarding the use of bio fuels 1 Free methanol in FAME may result in corrosion of aluminum and zinc FIE components 2 Free water in FAME may result in plugging of fuel filters and increased bacterial growth GENERAL SERVICE INFORMATION 3 High viscosity at low temperatures may result in fuel delivery problems injection pump seizures and poor injection nozzle spray atomization 4 FAME may have adverse effects on some elastomers seal materials and may result in fuel leakage and dilution of the engine lubricating oil 5 Even bio diesel fuels that comply with a suitable standard as delivered will require additional care and attention to maintain the quality of the fuel in the equipment or other fuel tanks It is important to maintain a supply of clean fresh fuel Regular flushing of the fuel system and or fuel storage containers may be necessary 6 The use of bio diesel fuels that do not comply with the standards as agreed to by the diesel engine manufacturers and the diesel fuel injection equipment manufacturers or bio diesel fuels that have degraded as per the precautions and concerns above may affect the warranty coverage of your engine See Yanmar Limited Warranty on page 3 v 4 10 Filling the Fuel Tank
214. nk DANGER 7 FIRE AND EXPLOSION HAZARD Diesel fuel is extremely flammable and explosive under certain conditions When you remove any fuel system component to perform maintenance such as changing the fuel filter place an approved container under the opening to catch the fuel NEVER use a shop rag to catch the fuel Vapors from the rag are extremely flammable and explosive Wipe up any spills immediately Wear eye protection The fuel system is under pressure and fuel could spray out when you remove any fuel system component Failure to comply will result in death or serious injury 0000009en 5 26 CAUTION E Be environmentally responsible Follow these procedures for hazardous waste disposal Failure to follow these procedures may seriously harm the environment Follow the guidelines of the EPA or other governmental agency for the proper disposal of hazardous materials such as engine oil diesel fuel and engine coolant Consult the local authorities or reclamation facility NEVER dispose of hazardous materials irresponsibly by dumping them into a sewer on the ground or into ground water or waterways 0000013en Note that a typical fuel tank is illustrated 1 Position an approved container under the diesel fuel tank Figure 5 9 1 to collect the contaminates 2 Remove the fuel cap Figure 5 9 3 3 Remove the drain plug Figure 5 9 2 of
215. ns found on containers of hazardous substances like parts cleaners primers sealants and sealant removers Failure to comply could result in death or serious injury 0000014en FLYING OBJECT HAZARD ALWAYS wear eye protection when servicing the engine and when using compressed air or high pressure water Dust flying debris compressed air pressurized water or steam may injure your eyes Failure to comply may result in minor or moderate injury 0000003en Be sure to secure the engine solidly to prevent injury or damage to parts due to falling during work on the engine 0000009en ENGINE Only use the engine oil specified Other engine oils may affect warranty coverage cause internal engine components to seize and or shorten engine life Prevent dirt and debris from contaminating the engine oil Carefully clean the oil cap dipstick and the surrounding area before you remove the cap NEVER mix different types of engine oil This may adversely affect the lubricating properties of the engine oil NEVER overfill Overfilling may result in white exhaust smoke engine overspeed or internal damage 0000005en Only use the engine coolant specified Other engine coolants may affect warranty coverage cause an internal buildup of rust and scale and or shorten engine life Prevent dirt and debris from contaminating the engine coolant Carefully clean the r
216. nsion Loosen the adjusting bolt Figure 5 5 1 and move the alternator Figure 5 5 2 with a pry bar Figure 5 5 3 to tighten the V belt to the desired tension Then tighten the adjusting bolt 0000653B Figure 5 5 Tighten the V belt to the proper tension There must be clearance Figure 5 6 1 between the V belt and the bottom of the pulley groove If there is no clearance Figure 5 6 2 between the V belt and the bottom of the pulley groove replace the V belt 5 21 PERIODIC MAINTENANCE Every 50 Hours of Operation TR After you complete the initial 50 hour maintenance 2 procedures perform the following procedures every 1 50 hours thereafter Drain Fuel Filter Water Separator 0000364 e Check Battery Figure 5 6 Drain Fuel Filter Water Separator 4 Check the V belt for cracks oil or wear If any of these conditions exist replace the V belt DANGER e New V belt refers to a V belt which has been used less than 5 minutes on a running engine H f Used V belt refers to a V belt which has been used on a running engine for 5 minutes or more FIRE AND EXPLOSION HAZARD 5 Inspect the condition of the used V belt There Diesel fuel is extremely flammable and must be clearance Figure 5 6 1 between explosive under certain conditions the V belt and the bottom of the pulley groove If e Wh i there is no
217. nts or fluids other than those recommended in your Yanmar Operation Manual unauthorized alterations or modifications ordinary wear and tear and rust or corrosion This Warranty does not cover the cost of parts and or labor required to perform normal scheduled maintenance on your Yanmar engine This Warranty does not cover consumable parts such as but not limited to filters belts hoses fuel injector nozzles lubricants and cleaning fluids This warranty does not cover the cost of shipping the product to or from the warranty repair facility 2 4 TNV IDI Service Manual YANMAR YANMAR WARRANTIES Yanmar Limited Warranty Continued Warranty Limitations The foregoing is Yanmar s only obligation to you and your exclusive remedy for breach of warranty Failure to follow the requirements for submitting a claim under this Warranty may result in a waiver of all claims for damages and other relief In no event shall Yanmar or any authorized industrial engine dealer or distributor be liable for incidental special or consequential damages Such consequential damages may include but not be limited to loss of revenue loan payments cost of rental of substitute equipment insurance coverage storage lodging transportation fuel mileage and telephone costs The limitations in this Warranty apply regardless of whether your claims are based on breach of contract tort including negligence and strict liability or any other theory Any action arisin
218. o Low Speed Excessive Fuel Consumption Engine Oil Engine Coolant Air Intake Excessive Oil Consumption Dilution by Diesel Fuel Oil with Water Low Oil Pressure Excessive Blow by Gas Low Water Temperature Overheat Pressure Rise Corrective Action TROUBLESHOOTING Reference Page Improper Intake Exhaust Valve Clearance Engine Does Not Start Adjust the Valve Clearance See Measuring and Adjusting Valve Clearance on page 6 34 Compression Leakage from Valve Seat Exhaust Temperature Rise Lap the Valve Seat See Valve Face and Valve Seat on page 6 28 Intake Exhaust Valve Seizure O Abnormal Engine Sound Pressure Drop Correct or Replace Intake Exhaust Valve See Inspection of Intake and Exhaust Valves on page 6 27 Cylinder Head Gasket Blowout O Ordinary Replace the Gasket See Disassembly of Cylinder Head on page 6 21 Seized or Broken Piston Ring Replace the Piston Ring See Heassembly of Pistons on page 6 53 Worn Piston Ring Piston or Cylinder Engine System Perform Honing and Use Oversize Parts See Honing and Boring on page 6 52 Seized Crankpin Metal or Bearing Repair or Replace See Inspection of Crankshaft and Camshaft Components on page 6 46 Improper Arrangement of Piston Ring Gaps YANMAR TNV IDI Service Manual
219. o restore cylinders to usable condition Slight imperfections can be corrected by honing alone 1 Boring Significant cylinder damage may be corrected by re boring to a given oversize Refer to the appropriate parts catalog for available oversize pistons and rings 6 52 Re boring a cylinder block can only be done in a properly equipped machine shop After re boring oversize pistons and piston rings must be installed After re boring hone the cylinder walls to finish the boring process and prepare the cylinder walls for the new piston rings 2 Honing Done to finish a newly bored cylinder or to de glaze a usable cylinder Minor cylinder imperfections might also be corrected by using a rigid hone Note Move the rotating hone up and down the bore to accomplish a 30 to 40 degree crosshatch Figure 6 81 This will provide an optimum surface to allow proper break in of the new parts Q A jt Xs M 0000248 6 81 Use 50 50 mixture of diesel fuel and engine oil as a honing fluid Do not allow the honing tool to operate in one position for any length of time Damage to the cylinder wall will occur Keep the tool in constant up and down motion 0000090en Use a 300 grit hone at 300 1200 rpm Figure 6 82 YANMAR 0000249 Figure 6 82 IMPORTANT Solvents will not adequately remove honing residue resulting in p
220. of operation after the initial 50 hour V belt maintenance See Check and Adjust Cooling Fan V belt on page 5 21 Check and Adjust the Governor Lever and Engine Speed Control The governor lever and engine speed control throttle lever pedal etc of the machine are connected together by an throttle cable or rod If the cable becomes stretched or the connections loosen the governor lever may not respond to change of engine speed control position This may make operation of the machine unsafe Check the cable periodically and adjust if necessary NEVER force the throttle cable or pedal to move This may deform the governor lever or stretch the cable and cause irregular operation of the engine speed control Checking and adjusting the governor lever 1 Check that the governor lever Figure 5 11 1 makes uniform contact with the high idle Figure 5 11 2 and low idle Figure 5 11 3 speed limit screws when the engine speed control is in the high idle speed or low idle speed position 2 If the governor lever does not make contact with the high idle or low idle speed limit screw adjust the throttle cable TNV IDI Service Manual 3 In some engine speed control applications loosen the throttle cable lock nut Figure 5 11 4 and adjust the cable so the governor lever makes proper contact with the high low idle speed limit screw NEVER attempt to adjust the low or high idle speed limit screw This may
221. ollowing the information provided by the Figure 7 31 tester manufacturer Use clean filtered fuel or FIE calibration fluid for the test 6 Remove the injector nozzle gaskets Figure 7 31 5 and protector 3 Using the correct adaptor connect a fuel Figure 7 31 6 from the cylinder head injector to a nozzle tester Aim the fuel injector into a suitable container to catch the fuel spray YANMAR TNV IDI Service Manual 7 25 FUEL SYSTEM 25 HIGH PRESSURE HAZARD Avoid skin contact with the high pressure diesel fuel spray caused by a fuel system leak such as a broken fuel injection line High pressure fuel can penetrate your skin and result in serious 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 0000008en To prevent possible eye injury always wear SAFETY GLASSES while servicing the engine 0000013en 7 26 Figure 7 32 4 Pump the operating lever of the tester slowly observing the pressure reading at the point where the fuel injector begins spraying fuel Figure 7 33 See Test and Adjustment Specifications on page 7 7 for correct pressure readings Note Opening pressure of a new fuel injector
222. on as a resultant phenomenon or starting failure The compression pressure is affected by the following factors 1 Degree of clearance between piston and cylinder 2 Degree of clearance at intake exhaust valve seat 3 Gasleak from nozzle gasket or cylinder head gasket The pressure will drop due to increased parts wear Pressure drop reduces the durability of the engine A pressure drop may also be caused by scratched cylinder or piston by dust entrance from the dirty air cleaner element or worn or broken piston ring Measure the compression pressure to determine the condition of the engine Compression Pressure Measurement Method 1 Warm up the engine 2 Stop the engine Remove the high pressure fuel injection lines as an assembly from the engine See Removal of High Pressure Fuel Injection Lines on page 7 13 Remove the fuel injector from the cylinder to be measured See Removal of Fuel Injectors on page 7 24 Remove or install the high pressure fuel injection lines as an assembly whenever possible Disassembling the high pressure fuel injection lines from the retainers or bending any of the fuel lines will make it difficult to reinstall the fuel lines 0000047en Crank the engine with the stop handle at the stop position no injection state before installing the compression gauge Figure 13 1 1 adapter Install a gasket at the tip end of the compression gauge adapter Install the compression
223. ons and Piston Rings on page 6 47 Reference Page Wrist Pin Bushing Inside Diameter 0 8671 0 8676 in 22 025 22 038 mm 0 8688 in 22 068 mm See Wrist Pin Outside Diameter 0 8658 0 8661 in 21 991 22 000 mm 0 8647 in 21 963 mm Inspection of Connecting Rod on Oil Clearance 0 0010 0 0019 in 0 025 0 047 mm 0 0041 in 0 105 mm page 6 49 6 13 ENGINE Connecting Rod Big End Inspection Item Standard Reference Page Side Clearance 0 0079 0 0157 in 0 20 0 40 mm Bearing Inside Diameter and Oil Clearance Connecting Rod Distortion Inspection Item See Crankshaft on page 6 9 Standard See Inspection of Connecting Rod on page 6 49 Reference Page Twist and Bend per All Models 3 937 in 100 mm Tappet Inspection Item Less Than 0 001 in 0 03 mm Standard 0 003 in 0 08 mm Limit See Inspection of Connecting Rod on page 6 49 Reference Page Tappet Bore Block Inside Diameter 0 8268 0 8276 in 21 000 21 021 mm 0 8284 in 21 041 mm Tappet Stem Outside Diameter 0 8239 0 8252 in 20 927 20 960 mm 0 8231 in 20 907 mm Oil Clearance 0 0016 0 0037 in 0 040 0 094 mm CYLINDER BLOCK SPECIFICATIONS Cylinder Block Inspection Item Model Standard 0 0053 in 0 134 mm Limit See Inspectio
224. oor seating of a valve Visually inspect the seating surfaces of each valve and valve seat to determine if lapping or grinding is needed Visually inspect all valve faces and valve seats for pitting distortion cracking or evidence of overheating Usually the valves and valve seats can be lapped or ground to return them to serviceable condition Severely worn or damaged components will require replacement Coat the valve seat with a thin coat of bluing compound Install valve and rotate to distribute bluing onto the valve face The contact pattern should be approximately centered on the valve face Figure 6 20 1 and even in width 0001691B Figure 6 20 Also visually inspect the valve seat for even contact Light cutting can be performed by the use of a hand operated cutter Figure 6 21 0001862 Figure 6 21 Valve seat diameter can be adjusted by top grinding with a 150 stone to make the seat diameter smaller and bottom grinding using a 40 stone to make the seat diameter larger Once the seat location has been corrected grind and lap the seat angle Figure 6 21 1 to specification See Cylinder Head on page 6 7 for specifications Grind the valve face and or valve seat only enough to return them to serviceable condition Grinding is needed if the valve and the valve seat do not contact correctly Check the valve recession after grinding If the valve or seat require grinding lap the valv
225. ove the bearing inserts at this time Wipe oil from the bearing insert and crankshaft journal surfaces Place a piece of PLASTIGAGE Figure 6 51 1 along the full width of the bearing insert 0001898 Figure 6 51 ENGINE IMPORTANT Do not rotate crankshaft when using PLASTIGAGE A false reading may result 5 Reinstall the bearing cap and tighten to specification See Special Torque Chart on page 6 15 6 Remove the bearing cap 0001899 Figure 6 52 7 Compare the width of the flattened PLASTIGAGE to the graduation marks on the package Figure 6 52 1 The mark that most closely matches the width of the flattened PLASTIGAGE will indicate the bearing oil clearance Record the measurements See Crankshaft on page 6 9 for clearance specifications 8 Repeat with the remaining connecting rods IMPORTANT Do not allow the connecting rod to contact the crankshaft journal during piston removal Damage to the bearing journal may result 9 Use a wooden dowel against the connecting rod and tap the piston connecting rod assembly out of the cylinder 10 Mark the cylinder number on the piston and connecting rod 6 43 ENGINE 11 Remove the bearing inserts Figure 6 53 2 12 Remove the compression rings Figure 6 53 3 from the piston using a piston ring expander 13 Remove the oil ring Figure 6 53 4 from the piston using a piston ring e
226. place the bearing Figure 11 12 1 Press the bearing into the Figure 11 10 2 in the front frame housing rear frame housing remove the four bolts Figure 11 10 3 securing the plate Figure 11 10 4 to the front frame housing Remove the plate Use a puller to remove the bearing Discard the bearing 11 If itis necessary to replace the bearing Figure 11 11 1 in the rear frame housing 3 use a puller to remove Discard the bearing 2 Remove the bearing cover Figure 11 11 2 1 5 and two thrust washers Figure 11 11 3 59 0000260 11 12 11 14 IDI Service Manual YANMAH 2 If removed lubricate the outside diameter of a new front frame housing bearing Press the bearing Figure 11 13 2 into the front frame housing Reinstall the plate Figure 11 13 4 to the front housing Tighten the four bolts Figure 11 13 3 0000259A Figure 11 13 Position the stator assembly Figure 11 13 1 on the front frame housing studs Lubricate the shaft of the rotor assembly Figure 11 14 1 Press the rotor assembly into the front frame housing Figure 11 14 2 and rear frame housing Figure 11 14 3 100266A Figure 11 14 YANMAR TNV IDI Service Manual ALTERNATOR Align the front frame housing with the rear frame housing Reinstall the two bolts Figure 11 15 1 and two nuts Figure 11 15 2 0000265A Figure 11 15 6 Reinstal
227. precautions found on containers of hazardous substances like parts cleaners primers sealants and sealant removers Failure to comply could result in death or serious injury 0000014en Thoroughly clean all components using a brush and appropriate solvent Each part must be free of carbon gasket material metal filings and other debris Note Record all measurements taken during inspection 6 46 Replacement of Crankshaft Oil Seals Remove the seal Figure 6 61 2 from the gear case cover Figure 6 61 1 Apply a continuous bead of ThreeBond Liquid Gasket No 1212 Yanmar Part No 977770 01212 to the outside diameter of a new oil seal Figure 6 61 2 Install a new seal in the gear case cover with the lip facing in away from the crankshaft pulley Apply lithium grease to the lip of the seal 9 1 UN D 0002181A Figure 6 61 Remove the rear oil seal Figure 6 62 1 from the flywheel housing Figure 6 62 2 Apply a continuous bead of ThreeBond Liquid Gasket No 1212 Yanmar Part No 977770 01212 to the outside diameter of a new oil seal Figure 6 62 1 Install a new seal in the flywheel housing Figure 6 62 2 with the lip facing in away from the flywheel Apply lithium grease to the lip of the seal Figure 6 62 YANMAR Crankshaft Bearing Oil Clearance Oil clearance should be checked during disassembly to determine the extent of wear and dur
228. r metric pound per square inch quart U S revolutions per minute Society of Automotive Engineers second short ton 20006 Total Base Number top dead center volt volt alternating current volt direct current watt angular degree plus minus plus or minus ohm micro percent approximate TNV IDI Service Manual YANMAR UNIT CONVERSIONS Unit Prefixes Prefix mega kilo centi milli micro Units of Length mile ft in in km m cm mm Units of Volume gal U S qt U S cu in cu in fl oz U S fl oz U S cm cm Units of Mass Ib oz kg 9 Units of Force Ibf Ibf N N kgf kgf Symbol Power M k u x KK KK xxx x KK KK KK x x KK KK x 1 000 000 x 1 000 x 0 01 x 0 001 x 0 000001 1 6090 km 0 3050 m 2 5400 cm 25 4000 mm 0 6210 mile 3 2810 ft 0 3940 in 0 0394 in 3 78540 L 0 94635 L 0 01639 16 38700 mL 0 02957 29 57000 mL 1 00000 mL 0 03382 fl oz U S 0 45360 kg 28 35000 g 2 20500 Ib 0 03527 oz 4 4480 N 0 4536 kgf 0 2248 Ibf 0 1020 kgf 2 2050 Ibf 9 8070 N YANMAR TNV IDI Service Manual GENERAL SERVICE INFORMATION Units of Torque ft lb ft lb in Ib in Ib kgf m kgf m kgf m N m N m N m x XM KKK KK 1 3558 0 1383 0 1130 0 0115 7 2330 86 8000 9 8070 0 7376 8 8510 0 1020 Units of Pressure psi psi psi bar bar bar kPa kPa kPa kg cm kg cm k
229. r the service limits TNV IDI Service Manual YANMAR Check Outer Rotor Side Clearance Determine the side clearance of the outer rotor across the pump cavity While pressing down on the outer rotor measure the depression using a depth micrometer 00011521 Figure 9 9 Record the measurement s and see Outer Rotor Side Clearance specifications on page 9 5 for the service limits Check Inner Rotor and Gear Boss Clearance 3 4 2 0000076A Crank Gear Inner Rotor Inside Width Across Flats of Inner Rotor Overall Inside Diameter of Inner Rotor Overall Inside Diameter of Gear Boss Outside Width Across Flats of Gear Boss oF urs Figure 9 10 YANMAH TNV IDI Service Manual LUBRICATION SYSTEM Record the measurement s and see Inner Rotor and Gear Boss Clearance specifications on page 9 6 for the service limits Reassembly of Oil Pump 0001976A Figure 9 11 1 Lubricate the outer rotor Figure 9 11 1 inner rotor Figure 9 11 2 and pump bore in the gear case cover Figure 9 11 3 with clean engine oil 2 Reinstall the outer rotor in the gear case The dot mark on the face of the outer rotor must face up toward the oil pump cover 3 Reinstall the inner rotor into the gear case cover with the dot mark also facing up Make sure that the pilot on the back side of the inner rotor fits into the bore in the gear case cover and the top surface of the inner rotor is flush with the
230. ral or other chemicals alternator is producing unusual sounds especially those with a high sulfur Damage to the alternator will result content can adhere to the IC regulator 0000039en This will corrode the conductor and result in battery over charging boiling and charging malfunctions Consult Yanmar before using the equipment in Do not remove the positive battery such an environment or the warranty is cable from alternator terminal B while voided the engine is operating Damage to the alternator will result 0000053en 0000037en Do not use a high pressure wash directly on the alternator Water will Do not turn the battery switch OFF while damage the alternator and result in the engine is operating Damage to the inadequate charging alternator will result 0000049en 0000038en Do not reverse the positive and negative ends of the battery cable The alternator diode and stator coil will be damaged 0000050en When the battery indicator goes out it should not come on again The battery indicator only comes on during operation if the alternator fails or if the V belt breaks However if an LED is used in the battery indicator the LED will shine faintly during normal operation 0000051en YANMAR TNV IDI Service Manual 11 5 ALTERNATOR INTRODUCTION This section of the Service Manual describes the servicing of the dynamos and alternators Yanmar Part No
231. rate the engine 0000021en NEVER hold the key in the START position for longer than 15 seconds or the starter motor will overheat 0000007en Make sure the engine is installed on a level surface If a continuously running engine is installed at an angle greater than 30 in any direction or if an engine runs for short periods of time less than 3 minutes at an angle greater than 35 in any direction engine oil may enter the combustion chamber causing exessive engine speed and generating white smoke This may cause serious engine damage 0000010en YANMAR TNV IDI Service Manual SAFETY Protect the air cleaner turbocharger if equipped and electric components from damage when you use steam or use high pressure water to clean the engine 0000014en Observe the following environmental operating conditions to maintain engine performance and avoid premature engine wear Avoid operating in extremely dusty conditions Avoid operating in the presence of chemical gases or fumes Avoid operating in a corrosive atmosphere such as salt water spray NEVER install the engine in a floodplain unless proper precautions are taken to avoid being subject to a flood NEVER expose the engine to the rain 0000003en Do not loosen or remove the four bolts retaining the fuel injection pump drive gear to the fuel injection pump hub Do not disassemble the fuel injection pump
232. re See Troubleshooting Charts on page 13 7 Repair as necessary 9 8 TROCHOID OIL PUMP Oil Pump Components 0001955 Crankshaft Oil Pump Cover Oil Pressure Regulator Gear Case Cover Outer Rotor Inner Rotor Figure 9 3 TNV IDI Service Manual YANMAR LUBRICATION SYSTEM Disassembly of Oil Pump If the oil pump must be replaced replace it as an assembly only Do not replace individual components 0000030en 1 Remove the engine coolant fan guard if equipped engine coolant fan Figure 9 4 1 spacer Figure 9 4 2 engine coolant pump V pulley Figure 9 4 3 and V belt 0001955B Figure 9 5 4 Remove the oil pump cover Figure 9 5 1 from the gear case 5 Remove the outer rotor Figure 9 5 3 and inner rotor Figure 9 5 4 from the gear case cover 6 Remove the oil pressure regulator valve Figure 9 6 1 from the oil pump cover 00019598 Figure 9 6 2 Figure 9 4 2 Remove the front crankshaft pulley and gear case cover See Removal of Timing Gear Case Cover on page 6 38 3 Remove the seven 7 oil pump cover screws Figure 9 5 2 O am e Note The oil pump cover screws are installed 1 using a liquid thread lock It may be homens necessary to used localized heat small propane torch and an impact type screwdriver to remove these screws Figure 9 6 YANMAR TNV IDI Service Manual 9 9 LUBRICATION SYSTEM Cle
233. remature piston and ring wear Always wash cylinders using hot soapy water When honing is completed wash the cylinder block with hot water and soap The cylinder wall is adequately cleaned when a white rag wiped in cylinder comes out clean Use brushes to clean all passages and crevices Rinse with hot water and blow dry with compressed air Apply clean engine oil to all steel surfaces to prevent rusting Reassembly of Crankshaft and Piston Components Notes Proceed slowly Make no forced assemblies unless a pressing operation is called for All parts must be perfectly clean and lightly lubricated when assembled Use new gaskets seals and O rings during assembly Liberally apply clean engine oil to all internal parts during assembly All fasteners should be tightened to a given torque If a special torque is not provided in the Special Torque Chart on page 6 15 tighten to standard torque specifications See Standard Torque Chart on page 4 25 ENGINE Reassembly of Pistons 1 Select the parts needed to assemble the piston and connecting rod for one cylinder If removed install a new wrist pin bushing Figure 6 83 7 using a press and the appropriate service tool Be sure to align the oil holes 0001705A Figure 6 83 Reinstall one circlip Figure 6 83 5 into the piston Ensure the circlip is securely seated in the groove IMPORTANT The piston and connecting rod must be ass
234. res the camshaft be removed and placed in a press Do not remove the camshaft gear unless it or the camshaft is damaged and requires replacement See Removal of Camshaft on page 6 41 Do not loosen or remove the four bolts retaining the fuel injection pump drive gear to the fuel injection pump hub Do not disassemble the fuel injection pump drive gear from the hub Correct fuel injection timing will be very difficult or impossible to achieve 0000031en 6 39 ENGINE 4 Do not remove the fuel injection pump drive Removal of Oil Pan gear unless absolutely necessary due to 1 Invert the engine oil pan up on the engine damage to the gear or pump Do not loosen or stand remove the four bolts Figure 6 43 3 retaining pump drive gear to the hub Only 2 Remove the oil pan Figure 6 44 2 remove the nut Figure 6 43 1 and washer 3 Remove the crankcase extension Figure 6 44 Figure 6 43 2 leaving the hub attached to 1 if equipped the gear Remove the pump drive gear and hub as an assembly using a gear puller 0002183 Figure 6 43 0002184 Figure 6 44 4 Remove the oil pickup tube Figure 6 45 1 and O ring Figure 6 45 2 0002185 Figure 6 45 6 40 YANMAR Removal of Camshaft 1 Before removing the camshaft check the camshaft end play Method A Install a dial indicator Figure 6 46 1 on the cylinder block Move the camshaft Figure 6 46 2 back
235. ric Fuel Pump Usedon 8 High Pressure Fuel Injection 2 Fuel Filter Water Separator models without Lines 3 Mechanical Fuel Pump Used mechanical fuel pump 9 Fuel Injectors in place of the electric fuel 5 Low Pressure Fuel Supply 10 Fuel Return from Fuel pump on some models Lines Injectors 6 FuelFilter 11 Air Bleed Orifice 7 Fuel Injection Pump 12 Fuel Return to Tank Figure 7 2 7 10 TNV IDI Service Manual YANMAH FUEL SYSTEM FUEL SYSTEM COMPONENTS 0002208 Figure 7 3 YANMAR TNV IDI Service Manual 7 11 FUEL SYSTEM 7 12 High Pressure Fuel Injection Lines Fuel Return Line Nut Fuel Return Line Fuel Injector Gasket Protector Fuel Return Hose Fuel Injection Pump Drive Gear Nut 9 Lock Washer 10 Fuel Injection Pump Drive Gear Assembly DO NOT remove or loosen the four bolts that fasten the injection pump drive gear to the injection pump drive gear hub 11 Fuel Injection Pump 12 Lube Oil Line TNV IDI Service Manual YANMAR 13 14 15 16 17 18 19 Mechanical Fuel Supply Pump Optional on some models Fuel Return Fitting Low Pressure Fuel Inlet Fitting Fuel Water Separator Electric Fuel Supply Pump Fuel Filter Fuel Filter Mount FUEL INJECTION LINES Removal of High Pressure Fuel Injection Lines Remove or install the high pressure fuel injection lines as an assembly whenever possible Disassembling the high pressure fuel injection l
236. ries No of Cylinders Cylinder Bore mm When ordering parts or making an inquiry about the engine you are working on be sure to include the complete model and serial numbers as shown on the engine nameplate See Location of Labels on page 4 4 Engine Speed Specifications Notation Available Engine Speed 3200 3600 rpm Intended Uses Lawn Mower Construction Industrial Machine 2000 3000 rpm Agricultural Constructive Industrial Machines 3000 3600 rpm 2 pole Generator Sets Irrigation Pumps VH Variable High Speed VM Variable Medium Speed CH Constant High Speed CL Constant Low Speed 4 18 1500 or 1800 rpm 4 pole Generator Sets Irrigation Pumps TNV IDI Service Manual YANMAR GENERAL SERVICE INFORMATION Engine General Specifications Type Vertical Inline Water Cooled 4 Cycle Diesel Engine Combustion System Swirl Chamber Ball Type Starting System Electric Starting Cooling System Radiator Lubricating System Forced Lubrication With Trochoid Pump PTO Position Flywheel End Direction of Rotation Counterclockwise Viewed from Flywheel Side Note The information described in Principal Engine Specifications is for a standard engine To obtain the information for the engine installed in your driven machine please refer to the manual provided by the driven machine manufacturer Engine r
237. rive gear nut to the specified torque See Special Torque Chart on page 7 7 0002416 Figure 7 19 7 Tighten the fuel injection pump retaining nuts to specification See Special Torque Chart on page 7 7 8 Reconnect the fuel supply and return lines to 1 the fuel injection pump E 9 Reconnect the throttle linkage and stop Q0 solenoid connector 10 If installing a new or recalibrated fuel injection pump check the fuel injection timing before 0002183A completing the installation of the fuel injection pump See Checking and Adjusting Fuel Injection Timing on page 7 21 Note While it is not required to check the injection timing when reinstalling the original fuel injection pump it is recommended that it be done 11 Reinstall the lube oil line Figure 7 20 1 Figure 7 18 YANMAR TNV IDI Service Manual 7 19 FUEL SYSTEM 12 13 14 7 20 0000163A Figure 7 21 0002239 Figure 7 20 15 Reinstall the cooling fan V belt Figure 7 21 1 Adjust as described in Apply ThreeBond Liquid Gasket No 1212 Check and Adjust Cooling Fan V belt on Yanmar Part No 977770 01212 or equivalent page 5 28 sealant to the sealing surface of the fuel injection pump cover Reinstall the cover on the 15 ha cooling dan guard ur equipped front of the gear case and tighten the bolts 17 Prime the fuel system See Priming The Fuel Reinstall the fuel injection high pressure lines AVSER
238. rned to the OFF position Current no longer flows to the stop solenoid hold coil the solenoid plunger extends and moves the injection pump fuel rack to the closed position shutting off the fuel flow and stopping the engine Failure of the stop solenoid could result in the engine not starting the engine not continuing to run with the key switch returned to the ON or RUN position or the engine failing to stop when the key switch is turned to the OFF position Use a VOA meter or continuity light to check for a good ground and 12V at the stop solenoid in the correct sequence TNV IDI Service Manual YANMAR FUEL SYSTEM SPECIFICATIONS Special Torque Chart Component Tightening Torque FUEL SYSTEM Lubricating Oil Application Thread Portion and Seat Surface Fuel Injector 29 ft lbs 39 2 N m 4 kgf m Not Applied Fuel Pump Drive Gear Nut 44 51 ft lbs 59 69 N m 6 7 kgf m Not Applied High Pressure Injection Line Nuts 22 25 ft lbs 29 34 N m 3 0 3 5 kgf m Not Applied Fuel Return Line Nuts 18 24 ft lbs 24 33 2 5 3 3 kgf m Not Applied Fuel Injection Pump Mounting Nuts 17 21 ft lbs 23 28 N m 2 3 2 9 kgf m Not Applied Fuel Injector Nozzle Case Nut Test and Adjustment Specifications Fuel Injector Pressure 36 39 ft lbs 49 53 N m 5 0 5 4 kgf m Not Applied Fuel Injection Timing 1711 1856 psi
239. rod 8 0002160 Figure 6 5 4 Remove the valve adjusting screw Figure 6 5 3 and lock nut Figure 6 5 2 from the rocker arms Mark parts so they can be reinstalled on the same rocker arm ENGINE Removal of Cylinder Head 1 Loosen the cylinder head bolts following the sequence shown in Figure 6 6 0002148 1 Cooling Fan End 2 Camshaft Side Figure 6 6 2 Remove the cylinder head bolts Figure 6 7 1 3 Lift the cylinder head away from the cylinder block Discard the cylinder head gasket Figure 6 7 2 Position the cylinder head on the work bench to prevent damage to the combustion surface 0002150 Figure 6 7 6 23 ENGINE Removal of Intake Exhaust Valves 8 1 Place the cylinder head on the work bench with the combustion side down 2 Remove the valve stem cap Figure 6 9 1 and keep with the valve it was installed on 3 Using the valve spring compressor tool compress one of the valve springs Figure 6 8 0000191 Figure 6 8 Remove the valve keepers Figure 6 9 2 5 Slowly release the tension on the valve spring 6 Remove the spring retainer Figure 6 9 3 and valve spring Figure 6 9 4 Figure 6 9 7 Repeat procedure with all remaining valves Note If the valves are to be reused identify them so they can be reinstalled in their original location 6 24 9 1 Turn the cylinder head so the exhaust por
240. rrently meets the service standard limit 0000120en 6 5 ENGINE INTRODUCTION This section of the Service Manual describes servicing of the engine CYLINDER HEAD SPECIFICATIONS Adjustment Specifications Valve Clearance 0 006 0 010 in 0 15 0 25 mm Cylinder Head Inspection Item Standard Limit Reference Page Combustion Surface Distortion Flatness 0 0020 in 0 05 mm or Less 0 0059 in 0 15 mm Intake 0 0157 0 0236 in 0 4 0 6 mm 0 0354 in 0 9 mm See Valve Recession on page 6 27 Valve Recession Exhaust 0 0157 0 0236 in 0 4 0 6 mm 0 0315 in 0 8 mm Intake 120 See Valve Seat Angle Exhaust Valve Seat 90 Valve Seat Seat Correction Angle 6 6 40 150 on page 6 28 Intake Exhaust Valve and Guide Inspection item Standard Limit ENGINE Reference Page Guide Inside Diameter 0 2362 0 2367 in 6 000 6 012 mm 0 2394 in 6 08 mm Valve Stem Outside Diameter Intake 0 2346 0 2352 in b 960 5 975 mm 0 2323 in 5 90 mm Oil Clearance 0 0010 0 0020 in 0 025 0 052 mm 0 0063 in 0 15 mm Valve Stem Bend 0 0004 in 0 010 mm Guide Inside Diameter 0 2362 0 2367 in 6 000 6 012 mm 0 2394 in 6 08 mm Valve Stem Outside Diameter Exhaust Oil Cl
241. ry 0000014en FLYING OBJECT HAZARD ALWAYS wear eye protection when servicing the engine and when using compressed air or high pressure water Dust flying debris compressed air pressurized water or steam may injure your eyes Failure to comply may result in minor or moderate injury 0000003en Only use the engine oil specified Other engine oils may affect warranty coverage cause internal engine components to seize and or shorten engine life Prevent dirt and debris from contaminating the engine oil Carefully clean the oil cap dipstick and the surrounding area before you remove the cap NEVER mix different types of engine oil This may adversely affect the lubricating properties of the engine oil NEVER overfill Overfilling may result in white exhaust smoke engine overspeed or internal damage 0000005en If the oil pump must be replaced replace it as an assembly only Do not replace individual components 0000030en TNV IDI Service Manual YANMAR INTRODUCTION This section of the Service Manual describes the procedures necessary to service the 2TNV70 3TNV70 and 3TNV76 Trochoid oil pumps LUBRICATION SYSTEM See Replace Engine Oil and Engine Oil Filter on page 5 19 for engine oil and engine oil filter replacement procedures OIL PUMP SERVICE INFORMATION Engine Oil Pressure at Rated Engine rpm at Low Idle Speed 2TNV70 3TNV70 3TNV76 Out
242. s loose ALWAYS check the level of the engine coolant by observing the reserve tank Failure to comply will result in death or serious injury 0000002en ARA BURN HAZARD Wait until the engine cools before you drain the engine coolant Hot engine coolant may splash and burn you Failure to comply could result in death or serious injury 0000016en YANMAR TNV IDI Service Manual DANGER SEVER HAZARD Stop the engine before you begin to service it NEVER leave the key in the key switch when you are servicing the engine Someone may accidentally start the engine and not realize you are servicing it This could result in a serious injury If you must service the engine while it is operating remove all jewelry tie back long hair and keep your hands other body parts and clothing away from moving rotating parts Failure to comply could result in death or serious injury 0000010en _____ E De FUME BURN HAZARD Always read and follow safety related precautions found on containers of hazardous substances like parts cleaners primers sealants and sealant removers Failure to comply could result in death or serious injury 0000014en COOLING SYSTEM fi BURN HAZARD f you must drain the engine oil while it is still hot stay clear of the hot engine oil to avoid being burned ALWAYS wear
243. s may adversely affect the lubricating properties of the engine oil NEVER overfill Overfilling may result in white exhaust smoke engine overspeed or internal damage 0000005en YANMAR TNV IDI Service Manual 5 27 PERIODIC MAINTENANCE Check and Clean Radiator Fins FLYING OBJECT HAZARD ALWAYS wear eye protection when servicing the engine and when using compressed air or high pressure water Dust flying debris compressed air pressurized water or steam may injure your eyes Failure to comply may result in minor or moderate injury 0000003en Dirt and dust adhering to the radiator fins reduce the cooling performance causing overheating Make it a rule to check the radiator fins daily and clean as needed Note that a typical radiator is shown in Figure 5 10 for illustrative purposes only Blow off dirt and dust from fins and radiator with 28 psi 0 19 MPa 2 kgf cm or less of compressed air Figure 5 10 1 Be careful not to damage the fins with the compressed air If there is a large amount of contamination on the fins apply detergent thoroughly clean and rinse with tap water NEVER use high pressure water or compressed air at greater than 28 psi or a wire brush to clean the radiator fins Radiator fins damage easily 0000016en 5 28 0000085A Figure 5 10 Check and Adjust Cooling Fan V belt Check and adjust the cooling fan V belt every 250 hours
244. s use a wrench to hold the fuel injector body when loosening or tightening the fuel return line Install a new copper gasket on each fuel injector The fuel return line is a one piece assembly Use care not to bend or twist the fuel return line 0000171en Carefully reinstall the fuel return line assembly Reinstall and hand tighten the fuel return line nuts Hold each fuel injector with one wrench and tighten the fuel return line nuts to the specified torque with a second wrench See Special Torque Chart on page 7 7 Reinstall the high pressure fuel injection line assembly See Installation of High Pressure Fuel Injection Lines on page 7 13 TNV IDI Service Manual YANMAR FUEL INJECTION PUMP Removal of Fuel Injection Pump 1 Loosen the cooling fan V belt 2 Remove the engine coolant fan guard if equipped engine coolant fan Figure 7 7 2 spacer Figure 7 7 3 if equipped V pulley Figure 7 7 4 and cooling fan V belt Figure 7 7 1 8 9 0000163A 10 Figure 7 7 11 3 Close any fuel valves in the fuel supply line 4 Place a drain pan under the fuel injection pump 12 to catch any spillage 5 Clean the area to keep contaminants from entering the fuel system 6 Remove the high pressure fuel injection lines as an assembly See Hemoval of High Pressure Fuel Injection Lines on page 7 13 7 Disconnect the fuel return lines from the fitting on the fuel injection pump Figure 7 8
245. s valid only until the applicable warranted duration has passed or the operation hours are exceeded whichever comes first What the Engine Owner Must Do If you believe your Yanmar engine has experienced a failure due to a defect in material and or workmanship you must contact an authorized Yanmar industrial engine dealer or distributor within thirty 30 days of discovering the failure You must provide proof of ownership of the engine proof of the date of the engine purchase and delivery and documentation of the engine operation hours Acceptable forms of proof of delivery date include but are not limited to the original warranty registration or sales receipts or other documents maintained in the ordinary course of business by Yanmar dealers and or distributors indicating the date of delivery of the Yanmar product to the original retail purchaser This information is necessary to establish whether the Yanmar product is still within the warranty period Thus Yanmar strongly recommends you register your engine as soon as possible after purchase in order to facilitate any future warranty matters You are responsible for the transportation of the engine to and from the repair location as designated by Yanmar YANMAR TNV IDI Service Manual 2 3 YANMAR WARRANTIES Yanmar Limited Warranty Continued To Locate an Authorized Yanmar Industrial Engine Dealer or Distributor You can locate your nearest authorized Yanmar industrial engine de
246. sassembly of Cylinder Block Components on page 6 37 Excessive Gear Backlash Adjust Gear Meshing See Checking Timing Gear Backlash on page 6 38 Worn Intake Exhaust Valve Guide Engine System Continued Measure and Replace See Inspection of Valve Guides on page 6 26 Governor Adjusted Incorrectly Make Adjustment See Check and Adjust the Governor Lever and Engine Speed Control on page 5 28 Improper Open Close Timing of Intake Exhaust Valves YANMAR TNV IDI Service Manual Adjust the Valve Clearance See Measuring and Adjusting Valve Clearance on page 6 34 13 9 TROUBLESHOOTING This Page Intentionally Left Blank 13 10 TNV IDI Service Manual YANMAR Trouble Symptom Insufficient Poor TROUBLESHOOTING c i Starting Problem Engine Exhaust 1 Engine E Output Color 3 ging ake Starts Exhaust During 8 but Stops Color Work z Soon S 5 5 amp 9 5 o o 5 A 5 Slll lls 8 Corrective Action Reference Page 5 5 gt E S 5 1 5 o 5 2 z is alz lza 9519 5 m o 2 E 3 2 512 9 892 ERE 5
247. shaft pulley bolt until fuel is pumped from the nozzle of the spill timing tool 13 Slowly rotate the crankshaft clockwise approximately 2 more revolutions until the timing grid on the flywheel for the cylinder being checked is at approximately 30 BTDC Note The fuel injection pump injects fuel to a cylinder only once every two engine revolutions 14 Flick the nozzle of the timing tool with a finger to remove bubbles and establish a fuel level of approximately 1 2 the height of the nozzle 15 Very slowly rotate the crankshaft clockwise until the fuel level in the nozzle of the spill timing tool or in the delivery valve just begins to move Immediately stop rotating the crankshaft 16 Check the position of the flywheel target timing mark Figure 7 27 1 on the flywheel grid in relation to the timing reference mark Figure 7 27 2 on the flywheel housing or back plate If the two marks are aligned the fuel injection timing is correct If the marks do not align the fuel injection timing must be adjusted See Adjusting Fuel Injection Timing on page 7 24 17 Repeat Steps 11 13 two or three times to verify timing 18 Remove the spill timing tool 7 23 FUEL SYSTEM 19 Reinstall the shut off solenoid 20 Reinstall the high pressure fuel injection lines See Installation of High Pressure Fuel Injection Lines on page 7 13 21 Replace the flywheel inspection port cover 22 Prime the
248. ss these procedures for hazardous waste remove the battery from the machine atthe end disposal Failure to follow these of the day Store the battery in a warm place procedures may seriously harm the until the next use This will help start the engine environment easily at low ambient temperatures Follow the guidelines of the EPA or other governmental agency for the proper disposal of hazardous materials such as engine oil diesel fuel and engine coolant Consult the local authorities or reclamation facility NEVER dispose of hazardous materials irresponsibly by dumping them into a sewer on the ground or into ground water or waterways 0000013en 0000067A Figure 5 8 When the amount of fluid nears the lower limit Figure 5 8 1 fill with distilled water Figure 5 8 2 so it is at the upper limit Figure 5 8 3 If operation continues with insufficient battery fluid the battery life is shortened and the battery may overheat and explode During the summer check the fluid level more often than specified YANMAR TNV IDI Service Manual 5 25 PERIODIC MAINTENANCE Every 250 Hours Operation Perform the following maintenance every 250 hours of operation Drain Fuel Tank Replace Engine Oil and Engine Oil Filter Check and Clean Radiator Fins Check and Adjust Cooling Fan V belt Check and Adjust the Governor Lever and Engine Speed Control Clean Air Cleaner Element Drain Fuel Ta
249. such as a broken fuel injection line High pressure fuel can penetrate your skin and result in serious 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 0000008en Proper operation of the fuel injectors is required to obtain the optimum injection pattern for full engine performance The EPA ARB requires that the fuel injectors are inspected cleaned and tested every 1500 hours See Testing of Fuel Injectors on page 7 25 This procedure is considered normal maintenance and is performed at the owner s expense This procedure is not covered by the Yanmar Limited Warranty TNV IDI Service Manual YANMAR Inspect Crankcase Breather System Proper operation of the crankcase breather system is required to maintain the emission requirements of the engine The EPA ARB requires that the crankcase breather system is inspected every 1500 hours There are three different crankcase breather systems used on the TNV engines Only the non turbo TNV engines crankcase breather system requires periodic maintenance The non turbo TNV engines use a crankcase breather system that has a spring backed diaphragm Figure 5 18 1 in the valve cover Figure 5 18 2
250. sult in minor or moderate injury 0000001en Caution without the safety alert symbol indicates a potentially hazardous situation that can cause damage to the machine personal property and or the environment or cause the machine to operate improperly 0000001en SAFETY SAFETY PRECAUTIONS During Operation and Maintenance Before You Operate DANGER A 0 X SCALD HAZARD NEVER permit anyone to operate the NEVER remove the radiator cap if the dri hi ithout engine is hot Steam and hot engine dem OBS coolant will spurt out and seriously training burn you Allow the engine to cool Read and understand this Operation down before you attempt to remove Manual before you operate or service the radiator cap the machine to ensure that you follow safe operating practices and maintenance procedures Securely tighten the radiator cap after you check the radiator Steam can spurt out during engine operation if Machine safety signs and labels are the cap is loose additional reminders for safe operating ALWAYS check the level of the engine and maintenance techniques coolant by observing the reserve tank See your authorized Yanmar industrial engine dealer or distributor for additional training Failure to comply will result in death or serious injury 0000002en 0000002en DANGER EXPLOSION HAZARD Keep the area around the
251. switch when you are servicing the engine Someone may accidentally start the engine and not realize you are servicing it This could result in a serious injury If you must service the engine while it is operating remove all jewelry tie back long hair and keep your hands other body parts and clothing away from moving rotating parts Failure to comply could result in death or serious injury 0000010en NN De FUME BURN HAZARD Always read and follow safety related precautions found on containers of hazardous substances like parts cleaners primers sealants and sealant removers Failure to comply could result in death or serious injury 0000014en YANMAR TNV IDI Service Manual To prevent possible eye injury always wear SAFETY GLASSES while servicing the engine 0000013en FLYING OBJECT HAZARD ALWAYS wear eye protection when servicing the engine and when using compressed air or high pressure water Dust flying debris compressed air pressurized water or steam may injure your eyes Failure to comply may result in minor or moderate injury 0000003en FUEL SYSTEM E PINCH HAZARD Carefully rotate the alternator toward the cylinder block while loosening the V belt Failure to comply may result in minor or moderate injury 0000014en NEVER remove or attempt to remove the tamper proof devices from the full
252. t Failure to comply will result in death or DANGER serious injury fj 0000009en 0000012en FIRE AND EXPLOSION HAZARD Only use the key switch to start the engine NEVER jump start the engine Sparks caused by jumping the battery to the starter terminals may cause a fire or explosion Failure to comply will result in death or serious injury 0000004en YANMAR TNV IDI Service Manual 3 5 SAFETY A DANGER Chi FIRE AND EXPLOSION HAZARD Diesel fuel is extremely flammable and explosive under certain conditions Only fill the fuel tank with diesel fuel Filling the fuel tank with gasoline may result in a fire and will damage the engine NEVER refuel with the engine running Wipe up all spills immediately Keep sparks open flames or any other form of ignition match cigarette static electric source away when fueling refueling NEVER overfill the fuel tank Fill the fuel tank Store any containers containing fuel in a well ventilated area away from any combustibles or sources of ignition Failure to comply will result in death or serious injury 0000005en A DANGER Gh FIRE AND EXPLOSION HAZARD Diesel fuel is extremely flammable and explosive under certain conditions Be sure to place the diesel fuel container on the ground when transferring the diesel fuel from the pump to the container Hold the hose
253. t rotate crankshaft when using PLASTIGAGE A false reading may result 7 Reinstall the bearing cap and tighten to specification See Special Torque Chart on page 6 15 8 Remove the bearing cap ENGINE 0001899 Figure 6 58 9 Compare the width of the flattened PLASTIGAGE to the graduation marks on the package Figure 6 52 1 The mark that most closely matches the width of the flattened PLASTIGAGE will indicate the bearing oil clearance Record the measurement See Crankshaft on page 6 9 for clearance specifications 10 Repeat with the remaining main bearings Note Be sure to note the markings on the main bearing caps or make marks so they can be reinstalled in the same order as they were removed The arrows on the main bearing caps point to the flywheel end of the engine 0002189 Figure 6 59 11 Remove the crankshaft from the engine 12 Remove the bearing inserts Figure 6 59 1 and thrust bearings Figure 6 59 2 6 45 ENGINE Note Do not remove the crankshaft gear unless the gear or crankshaft are damaged and require replacement 13 If necessary remove the crankshaft gear Figure 6 60 1 and key Figure 6 60 2 If using a gear puller be careful not to damage the threads in the end of the crankshaft 0002193 Figure 6 60 Inspection of Crankshaft and Camshaft Components FUME BURN HAZARD Always read and follow safety related
254. t side faces down Remove the intake and exhaust valves Figure 6 9 6 from the cylinder head Remove the valve stem seals Figure 6 9 5 Removal of Valve Guides Note Removal of valve guides should be postponed until inspection and measurement procedures have been performed See Inspection of Valve Guides on page 6 26 If the valve guides are not within specifications use a drift pin and hammer to drive the valve guides Figure 6 10 1 out of the cylinder head 0002152 Figure 6 10 Cleaning of Cylinder Head Components DE FUME BURN HAZARD Always read and follow safety related precautions found on containers of hazardous substances like parts cleaners primers sealants and sealant removers Failure to comply could result in death or serious injury 0000014en Thoroughly clean all components using a non metallic brush and an appropriate solvent Each part must be free of carbon metal filings and other debris Inspection of Cylinder Head Components Visually inspect the parts Replace any parts that are obviously discolored heavily pitted or otherwise damaged Discard any parts that do not meet its specified limit Any part which is found defective as a result of inspection or any part whose measured value does not satisfy the standard or limit must be replaced 00001 19 ENGINE Any part determined to not meet
255. t types of engine oil This may adversely affect the lubricating properties of the engine oil NEVER overfill Overfilling may result in white exhaust smoke engine overspeed or internal damage 0000005en YANMAR TNV IDI Service Manual 5 11 PE RIODIC MAINTENANCE Only use the engine coolant specified Other engine coolants may affect warranty coverage cause an internal buildup of rust and scale and or shorten engine life Prevent dirt and debris from contaminating the engine coolant Carefully clean the radiator cap and the surrounding area before you remove the cap NEVER mix different types of engine coolants This may adversely affect the properties of the engine coolant 0000006en NEVER attempt to modify the engine s design or safety features such as defeating the engine speed limit control or the diesel fuel injection quantity control Modifications may impair the engine s safety and performance characteristics and shorten the engine s life Any alterations to this engine may void its warranty Be sure to use Yanmar genuine replacement parts 0000079en Observe the following environmental operating conditions to maintain engine performance and avoid premature engine wear Avoid operating in extremely dusty conditions Avoid operating in the presence of chemical gases or fumes Avoid operating in a corrosive atmosphere such as salt water spray NEV
256. tem or electrical components remaining on the engine 7 Drain the engine oil into a suitable container Remove oil filter 8 Remove the cylinder head See Disassembly of Cylinder Head on page 6 21 9 Remove the fuel injection pump from the gear case only if it must be sent out for repair or will interfere with other procedures such as hot tank cleaning See Removal of Fuel Injection Pump on page 7 15 10 Remove the starter motor See Removal of Starter Motor on page 10 9 Disassembly of Camshaft and Timing Components Discard all gaskets O rings and seals Use new gaskets O rings and seals on reassembly of camshaft and timing components Removal of Timing Gear Case Cover 1 Remove the bolt and washer retaining the crankshaft pulley IMPORTANT Use care not to damage the threads in the end of the crankshaft when removing the crankshaft pulley 2 Remove the crankshaft pulley using a gear puller 3 Remove the bolts that retain the gear case cover to the cylinder block and oil pan 4 Remove the gear case cover Figure 6 39 1 6 38 5 Remove the dowel pins Figure 6 39 3 and O ring Figure 6 39 2 0002181 Figure 6 39 Checking Timing Gear Backlash Prior to removing the timing gears measure the gear backlash and determine the gear wear Note Check the backlash between each pair of mating gears If not within specification replace both mating gears Do not allow the gear being ch
257. the fuel tank to drain the contaminates water dirt etc from the bottom of the tank 4 Drain the tank until clean diesel fuel with no water and dirt flows out Reinstall and tighten the drain plug firmly 5 Reinstall the fuel cap 6 Check for fuel leaks TNV IDI Service Manual YANMAR PERIODIC MAINTENANCE CAUTION CE Be environmentally responsible Follow these procedures for hazardous waste disposal Failure to follow these procedures may seriously harm the 70000558 environment Figure 5 9 Follow the guidelines of the EPA or _ _ other governmental agency for the Replace Engine Oil and Engine Oil proper disposal of hazardous Filter materials such as engine oil diesel fuel and engine coolant Consult the Only use the engine oil specified NEVER dispose of hazardous Other engine oils may affect warranty materials irresponsibly by dumping coverage cause internal engine them into a sewer on the ground or components to seize and or shorten into ground water or waterways engine life 0000013en Prevent dirt and debris from Change the engine oil every 250 hours of operation contaminating the engine oil Carefully after the initial change at 50 hours Replace the clean the oil cap dipstick and the engine oil filter at the same time See Replace e area before you remove Engine Oil and Engine Oil Filter on page 5 19 e cap NEVER mix different types of engine oil Thi
258. tween the ring and the piston Record the measurements See Piston Ring on page 6 12 for specifications Replace the piston if not within specification 6 48 0001892 Figure 6 67 10 Insert each piston ring Figure 6 68 1 one at a time into the cylinder Use a piston with the piston rings removed to slide the ring into the cylinder bore until it is approximately 1 18 in 80 mm Figure 6 68 2 from the bottom of the bore Remove the piston Measure the end gap Figure 6 68 3 of each piston ring Record the measurements See Piston Ring on page 6 12 for specifications ast OM 0001964 Figure 6 68 11 Repeat the above steps for each of the cylinders and the piston rings for that specific cylinder YANMAR Inspection of Connecting Rod 1 Measure the wrist pin bushing bore using a bore gauge Figure 6 69 1 Replace the bushing if not within specifications If the bushing has been removed measure the inside diameter of the connecting rod small end Figure 6 69 2 Record the measurements See Connecting Rod on page 6 13 for specifications 0001724A Figure 6 69 Measure the connecting rod twist Figure 6 70 1 and bend Figure 6 70 2 using a connecting rod alignment tool Figure 6 71 Record the measurements See Connecting Rod on page 6 13 for specifications 0001849 Figure 6 70 ENGINE 0000242 Figure 6 71 Place the connectin
259. ue See Special Torque Chart on mark Figure 6 93 2 stamped into the piston page 6 15 for specifications top is facing the camshaft side Figure 6 93 1 The embossed mark cast into the connecting rod beam Figure 6 93 3 will be facing the flywheel end of the engine Figure 6 93 5 6 th 2 Ne 5 0001965 Figure 6 94 8 Reinstall the remaining pistons in their respective cylinders Reassembly of Camshaft and Timing Components Installation of Gear Case 1 If removed install a new camshaft bushing Figure 6 95 3 using the appropriate service 0000227A 1 Fuel Injection Pump Side of Engine tool 2 Piston Identification Mark 2 Apply a continuous bead of ThreeBond Liquid 3 Embossed Mark on Connecting Rod Gasket No 1212 Yanmar Part No 977770 4 Rod and Cap Match Marks 01212 to the mounting area of the gear case 5 Flywheel End of Engine Be sure to circle each bolt hole 6 Camshaft Side of Engine 3 Reinstall dowels and new O rings Figure 6 95 Figure 6 93 2 5 Reinstall the bearing inserts Figure 6 94 1 in the connecting rod and cap 6 Apply a liberal coat of clean engine oil to the bearing inserts and crankshaft journal 6 58 0002187 Figure 6 95 4 Reinstall the gear case Figure 6 95 1 Tighten the bolts Figure 6 95 4 to the specified torque Installation of Camshaft Note The gear housing must be installed
260. ue does not satisfy the standard or limit must be replaced 00001 19 Any part determined to not meet the service standard or limit before the next service as determined from the state of current rate of wear should be replaced even though the part currently meets the service standard limit 0000120en NEVER remove or attempt to remove the tamper proof devices from the full load fuel adjusting screw or the high speed throttle limit screw on the fuel injection pump and governor assembly These adjustments have been made at the factory to meet all applicable emissions regulations and then sealed NEVER attempt to make any adjustments to these sealed adjustment screws If adjustments are required they can be made only by a qualified fuel injection shop that will ensure the injection pump continues to meet all applicable emissions regulations and then replace the tamper proof seals Tampering with or removing these devices may void the Yanmar Limited Warranty 0000146en The fuel return line is a one piece assembly Use care not to bend or twist the fuel return line 0000171en Never use a steel wire brush to clean fuel injectors Damage to the nozzle and other components is likely to result 0000172en TNV IDI Service Manual Section 4 GENERAL SERVICE INFORMATION Page Component Identification 4 3 Location of Labels c 4 4
261. xpander 0001705A Figure 6 53 14 Remove the circlips Figure 6 53 5 from the wrist pin 15 Remove the wrist pin Figure 6 53 6 and connecting rod Figure 6 53 8 from the piston Figure 6 53 9 16 Repeat steps until all pistons are removed and dissembled 6 44 Removal of Crankshaft 1 Remove the flywheel Figure 6 54 1 from the crankshaft Remove the bolts from the flywheel housing assembly Figure 6 54 2 3 Remove the flywheel housing from the engine 0002188 Figure 6 54 Before removing the main bearing caps measure the crankshaft end play Use either of the following two methods Method A Install a dial gauge Figure 6 55 1 on the cylinder block Move the crankshaft Figure 6 55 2 back and forth to measure the end play Record the measurement 0001961 Figure 6 55 YANMAR Method B Use a feeler gauge to measure the clearance Figure 6 56 3 between the thrust bearing Figure 6 56 1 and crankshaft Figure 6 56 2 Record the measurement See Thrust Bearing on page 6 10 for the service limit 1 2 3 0001962 Figure 6 56 4 Remove the bearing cap Do not remove the bearing inserts at this time 5 Wipe oil from the bearing insert and crankshaft journal surfaces 6 Place a piece of PLASTIGAGE Figure 6 51 1 along the full width of the bearing insert a 0001898 Figure 6 57 IMPORTANT Do no
262. y If you must service the engine while it is operating remove all jewelry tie back long hair and keep your hands other body parts and clothing away from moving rotating parts Failure to comply could result in death or serious injury 0000010en YANMAR TNV IDI Service Manual ALTERNATOR ili SHOCK HAZARD Turn off the battery switch if equipped or disconnect the negative battery cable before servicing the electrical system Check the electrical harnesses for cracks abrasions and damaged or corroded connectors ALWAYS keep the connectors and terminals clean Failure to comply could result in death or serious injury 0000009en Lm p BURN HAZARD Keep your hands and other body parts away from hot engine surfaces such as the muffler exhaust pipe turbocharger if equipped and engine block during operation and shortly after you shut the engine down These surfaces are extremely hot while the engine is operating and could seriously burn you Failure to comply could result in death or serious injury 0000015en 11 3 ALTERNATOR O ab ue FUME BURN HAZARD Always read and follow safety related precautions found on containers of hazardous substances like parts cleaners primers sealants and sealant removers Failure to comply could result in death or serious injury 0000014en FLYING OBJE
263. y Every Every Every Every 50 250 500 1000 1500 2000 hours hours hours hours hours hours Check amp Refill Engine Coolant Check amp Clean Radiator Fins Check amp Adjust Cooling Fan V belt 1st time pica after Cooling System Drain Flush and Refill Cooling System With or New Coolant every 1 yr which ever comes first Cylinder Adjust Intake Exhaust Valve Clearance e Head Lap Intake Exhaust Valve Seats e Electrical Check Indicators Equipment Check Battery O Check Engine Oil Level O Engine Oil Drain amp Fill Engine Oil o o 3 mem 2nd amp Replace Engine Oil Filter isttime otter Engine Check amp Adjust Governor Lever amp Speed Engine Speed Control O Control Emission Inspect Clean amp Test Fuel Injectors e Control Warranty Inspect Crankcase Breather System Check amp Refill Fuel Tank Level Drain Fuel Tank E Drain Fuel Filter Water Separator Check Fuel Filter Water Separator Clean Fuel Filter Water Separator Replace Fuel Filter o Replace Fuel System amp e Hoses Cooling System Hoses or every 2 yrs Intake amp Clean or Replace Air Cleaner Element o Exhaust Complete Overall Visual Check Daily Note These procedures are considered normal maintenance and are performed at the owner s expense 5 18 TNV IDI Service Manual YANMAR PERIODIC MAINTENANCE PERIODIC MAINTENANCE ES PROCEDURES Only use the engine oil specifi
264. y cause poor engine performance Consult your Yanmar representative for more information Ash content not to exceed 0 0196 by volume Carbon residue content not to exceed 0 3596 by volume Less than 0 196 is preferred YANMAR TNV IDI Service Manual GENERAL SERVICE INFORMATION Total aromatics content should not exceed 35 by volume Less than 30 is preferred PAH polycyclic aromatic hydrocarbons content should be below 10 by volume Metal content of Na Mg Si and Al should be equal to or lower than 1 mass ppm Test analysis method JPI 5S 44 95 Lubricity Wear mark of WS1 4 should be Max 0 018 in 460 at test Bio Diesel Fuels In Europe and in the United States as well as some other countries non mineral oil based fuel resources such as RME Rapeseed Methyl Ester and SOME Soybean Methyl Ester collectively known as FAME Fatty Acid Methyl Esters are being used as extenders for mineral oil derived diesel fuels Yanmar approves the use of bio diesel fuels that do not exceed a blend of 5 by volume of FAME with 9596 by volume of approved mineral oil derived diesel fuel Such bio diesel fuels are known in the marketplace as B5 diesel fuels These B5 diesel fuels must meet certain requirements 1 The bio fuels must meet the minimum specifications for the country in which they are used n Europe bio diesel fuels must comply with the European Standard EN14214 n the U

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