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TP-6382 - Atlantis Marine Power

1. FUSE 712372128 11022128 ELECTRICAL FEED PUMP R R 154 MARK COLOR INE a B B 119225 52102 0 8 D ui cop AE t hite Pigg 104 eremo E p o 0 0 5 OFF R Red X PILOT LAMP 4 1 114250739450 i Bius 10012 LESS THAN 3 40 RETE XCB104 ME SS LEM G Green CHARGE LAMP f 0 po 121250 44901 Y Yellow GENERATOR DCiev 3 4W PILOT LAMP DC12V 40A 12 LESS THAN 3 4W Brown 129423 77200 EXTAT E RU Lg Light Green g pm Sb Sky blue gt g S as 8 NM IC S amp gt Le TIMER 12182 o gt TUS qe L Pink QU SOLENOID DCI2V YAZAKI NO YAZAKI 129211 77920 Q 252 5 v Pall HOLD 0 49A 7828 0446 7322 2446 Gr Gray 92 sw no EG 1 PULL 36 54 R 7 6195 0024 SO 11 R R W Red White z n ES DT z i 0195 002 115802 77200 77 7 5 5 77 E 3215 OR
2. Engine name Unit 3TNV76 Engine specification class VM Type Vertical in line 4 cycle water cooled diesel engine Combustion chamber Indirect injection Number of cylinders 3 Cylinder borexstroke jos 76x82 Displacement L 1 115 Revolving Continuous speed tang Output NET S Ree 2000 2100 2200 2300 2400 2500 2600 2700 2800 2900 3000 Rated Outout NET kW 118 125 132 138 143 149 155 16 1 167 173 179 ps 161 170 179 187 195 203 21 1 219 027 235 043 Max no load speed 25 min 2160 2250 2355 2460 2570 2675 2780 2890 2995 3100 3210 Ignition order 1 3 2 1 No 1 cylinder on flywheel side Power take off Flywheel Direction of rotation Counterclockwise viewed from flywheel Cooling system Radiator Lubrication system Forced lubrication with trochoid pump Starting system Electric Applicable fuel j Diesel oil BS 2869 A1 or A2 cetane No 45 Applicable lubricant API grade class CD or CF Lubricant capacity Total L 3 5 Vell pan Effective L 1 6 Cooling water capacity L 0 9 engine only i Engine Overall length mm 485 Dimensions with flywheel Overall width mm 436 housing Overall height 535 Engine mass dry with flywheel housing kg Te Cooling fan
3. 45 3 Troubleshooting 3 3 Troubleshooting by measuring Compression Pressure Compression pressure drop is one of major causes of increasing blowby gas lube oil contamination or increased lube oil consumption 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 Gas leak from nozzle gasket or cylinder head gasket In other words the pressure drops due to increased parts wear and reduced durability resulting from long use 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 diagnose presence of any abnormality in the engine 1 Compression pressure measurement method 1 After warming up the engine remove the fuel injection pipe and valves from the cylinder to be measured Compression 2 Crank the engine before installing the compression gage adapter 1 Perform cranking with the stop handle at the stop position no injection state 2 See 4 1 2 2 No 18 in Chapter 4 for the compression gage and compression gage adapter Measurement of the compression pressure 3 Install the compression
4. 46 4 Disassembly Inspection and Reassembly of Engines 48 4 1 Complete disassembly and reassembly 02202422 0 48 Atl Introduction coute dee E 48 4 1 2 Special service 49 44 3 Complete disassembly ete trant ih eer oy ae dac e o dope de Or aed een dee cet 54 4 1 4 Precautions before and during reassembly sssssssssseeee 58 41 5 Adjusting operation eere ce dee ee ae egre eed ne tere Ed ee pie e n dd 58 4 2 Cylinder Head Disassembly Inspection and 59 4 2 1 Components 2 valve cylinder mener enne 59 4 2 2 Disassembly procedure san fade ie testet i o e ped 59 4 2 3 Reassembly procedure 59 4 2 4 Servicing points Ce Ey a pen eddie Legenda KO ELE ERR eate ea 60 4 2 5 Parts Inspection and seen sees nenne nenne nnne nnne nnn 63 4 2 6 Valve s at COMECUOM sch c tee ee cr p e Pesce e dte ede 66 4 2 7 Valve guide 67 4 2 8 Valve stem seal nene nn nennen nnn 67 4 3 Gear Train and
5. 18 2 2 3 Inspection every 50 eene een 21 2 2 4 Inspection every 250 hours or 25 2 2 5 Inspection every 500 hours or 6 months sssssssseeee een 28 2 2 6 Inspection every 1 000 hours or one 30 2 2 7 Inspection every 2000 hours or 2 36 2 3 Adjusting the no load maximum or minimum 38 2 4 Sensor Inspection rer tcr bec Ete Det tee re eve eta ee Eu eL thug 39 244 1 Oll pressure Switch ssa cete ep ete aite ds 39 2 42 Thermo SWIECDY ocio rera tee zd ta Ret feto prete Mete fosa e ES ER et 39 2 5 Water leak check in cooling water 12 22 211 2 4 2 1444 nnn 39 2 6 Radiator Cap inspection e ette irr EE Rr TUE OFEN ERR RU 39 2 L aermostatilisDectiOnia ucc tte 40 ZO oT ge QUE TALON REDEUNDO Tm 40 29 Long Storage iaat 41 ox TROUBLESHOOTING dirae t decorates E s bud 42 3 1 Preparation before troubleshooting etae 42 3 2 Quick Reference Table for Troubleshooting eese 43 3 3 Troubleshooting by measuring Compression
6. 68 4 3 1 Components rite put spia Fri 68 4 3 2 Disassembly nennen nen nnn 68 4 3 3 Reassembly procedure nennen nsn nnns nnns nns nnns 68 4 3 4 Servicing POM e eee ree e iere dodo Oise adt ive AMG eee 69 4 3 5 Parts inspection and measurement rne nnne nnne nnne nnne 71 4 3 6 Oil seal aa 72 4 3 7 Camshaft bushing 2 1 27 11 0000 000000000006 72 4 4 Cylinder 4 73 4 41 Components bte but erbe dee ite eed autos 73 4 4 2 Disassembly 74 4 4 3 Reassembly procedure 74 AAA Servicing POMS sero e pete t te e Me ee 75 4 4 5 Parts inspection and 78 4 4 6 Cylinder bore correction emen nenne 87 4 4 7 Piston pin bushing replacement 87 4 4 8 Oil seal replacement Flywheel housing 5 2
7. 116 11 3 Lubricating Oil System Trochoid Pup eate oda edet eaae tede cite tti abes 118 12 Tightening Torque for Bolts and 119 12 1 Tightening Torques for Main Bolts and Nuts sse m 119 12 2 Tightening Torques for Standard Bolts and 120 1 General 1 General 1 1 Engine Nomenclature 3 TNV OO O OO o Destination code Nominal engine speed or output code Cylinder bore in mm Model series Number of Cylinders The engine specification class Available engine speed at nominal output Classification Load Engine speed CL Constant load Constant speed 1500 1800 CH Constant load Constant speed 3000 3600 VM Variable load Variable speed 2000 3000 VH Variable load Variable speed 3000 3600 The engine specification class VM CHor VH is described in the specifications table 1 2 Specifications NOTE 1 The information described in the engine specifications tables the next page and after is for standard engine To obtain the information for the engine installed in each machine unit refer to the manual provided by the equipment manufacturer 2 Engine rating conditions are as follows SAE J1349 ISO 3046 1 Atmospheric condition Room temp 25 C Atmospheric press 100 kPa 750mm Hg Relative
8. sssssssssssssssssssseeeen eene enne 102 9515 InspectiOmnz e oU erepta aea e e 103 9 2 40A Alternator retreat oen Le ase Co e ub Air c ER d 104 9 2 Components ter ri pe ree d t ee Er n EAR HO ERE DR nd ARR 104 9 2 2 5 PT 105 9 2 3 Wiring dlagralm oit trn e obire bio tnit ehe tae 105 9 2 4 Standard output 106 9 2 5 Inspections e eR e 106 9 3 TroubleshootiNg m HP 107 TO 2 C 108 10 1 Electric Wiring Diagram uiii E e Peg ette ette x Rr uo 108 teet tte etta me cet 109 SHAMS RE D E 110 10 1 3 Current limiter iicet acc 111 10 1 4 Section area and resistance of electric wire 002 2 10000 00000000 112 THe SERVICE STANDARDS siae er exe dre 113 quA Re S 113 11 2 Engine BOG 114 11 2 1 Gylinider head paient t nr REOR ER ceased dies 114 11 2 2 Gear train and camshaft et boe e eet nera Ote eua Feet Lu dH t E 115 11 2 3 Cylinder block itc et e bis etes e etait spa ia
9. 1 Remove a starting motor from flywheel housing 55 4 Disassembly Inspection and Reassembly of Engines Removal Parts Remarks 1 Remove flywheel mounting bolts 2 Remove a flywheel 1 Carefully protect the ring gear from damage 1 Remove a flywheel housing 2 Remove a oil seal 1 Carefully protect the oil seal from damage 1 Put a cylinder block upside down and remove a oil pan and a spacer 1 Carefully protect the combustion surface of the cylinder block from damage 2 Be careful not to drop tappets off when the cylinder block is turned upside down because the tappet is cylindrical in shape 1 Remove a idle gear shaft and then remove a idle gear 2 Remove a mounting bolt of thrust bearing through the hole of the camshaft gear Remove camshaft assembly 1 Turn the cylinder block aside and carefully prevent tappet from jamming on the cam 2 Preheat a camshaft gear and a camshaft assembly to 180 200 before removing them because they are shrink fitted 1 Remove a gear case flange 1 Remove a lube oil strainer 1 While turning a crankshaft place piston at the bottom dead center BDC 2 Remove the crankpin cap of a connecting rod 1 Remove carbon deposits from the upper wall of the cylinder using fine sandpaper before extracting pistons Take care not to damage the inner surface of the cylinder 2 Make sure that the cap No of connecting
10. 4 Inspection and adjustment of governor lever and accelerator The governor lever and accelerating devices accelerating lever pedal etc of the machine unit are connected by an accelerating wire or rod If the wire becomes stretched or the connections loose the High idling speed limiting bolt Governor lever deviation in the position may result and make Accelerating wire bracket operation unsafe Check the wire periodically and A x Low idling speed adjust if necessary limiting bolt Do not strongly move the accelerating wire or accelerating pedal It may deform the governor lever 26 2 Inspection and Adjustment or stretch the wire to cause irregular engine speed control Checking and adjusting procedure are as follows 1 Check that the governor lever of the engine makes uniform contact with the high idling and low idling limiting bolt when the accelerating devices is in the high idling speed or low idling speed position 2 If either the high or the low idling speed side does not make contact with the limiting bolt adjust the accelerating wire Loosen the accelerating wire fixing nut and adjust the wire to contact with the limiting bolt A CAUTION Never release the limiting bolts It will impair the safety and performance of the product and functions and result in shorter engine life 5 Air cleaner cleaning and element replacement CAUTION Beware of dirt from air blowing Da Wear protecti
11. Leakage from lube oil piping system Repair Insufficient delivery capacity of trochoid pump Check and repair See 5 5 in Chapter5 Clogged lube oil filter Clean or replace Defective pressure regulating valve Clean adjust or replace Insufficient lube oil level Add proper lube oil See 2 2 1 3 in Chapter2 Fuel system Too early timing of fuel injection pump Check and adjust See 2 2 7 4 in Chapter2 Too late timing of fuel injection pump Check and adjust See 2 2 7 4 Chapter2 Improper properties of fuel oil Use proper fuel oil See 1 3 1 in Chapter1 Water entrance in fuel system Drain from the fuel system See 2 2 3 1 2 and 2 2 5 1 2 in Chapter2 Clogged fuel filter Clean or replace See 2 2 5 2 in Chapter2 Air entrance in fuel system Perform air bleeding See 2 2 3 3 in Chapter2 Clogged or cracked fuel pipe Clean or replace Insufficient fuel supply to fuel injection pump Check the fuel tank cock fuel filter fuel pipe and fuel feed pump Uneven injection volume of fuel injection pump Check and adjust Excessive fuel injection volume Check and adjust Poor spray pattern from fuel injection nozzle Check and adjust See 2 2 6 4 in Chapter2 Priming failure Foreign matter trapped in the valve inside the priming pump Disassemble and clean Clogged strainer at feed pum
12. Intake PS Output metric horsepower Exhaust T Bolt nut tightening torque CONTENTS jeep 1 ot carton antacid ares 1 12 SPeCiCAtONS 1 1 3 Fuel Oil Lubricating Oil and Cooling 7 1 351 RUCK oll tore tta tton tbe ttem ibus 7 t32 L bricating OM EE 8 1 3 3 Cooling ue E 8 1 4 Engine External Faro Ese eed E r 9 1 5 Structural Description oett tre e e t ode poU Re A a 10 1 6 Exhaust gas emission regulallOri soie c etd ent inte a Ente bbc nudos 11 1 6 1 The Emission Standard in 0 5 11 1 6 2 Engine identification 12 1 6 3 Guarantee Conditions for the EPA Emission 13 2 Inspection Ad Uustlrerit usi side durer kat ed pe tee eae uud au et 15 2 1 Periodic Maintenance eere 15 2 2 Periodic Inspection and Maintenance Procedure 16 2 2 1 Check before Daily Operation 16 2 2 2 inspection after initial 50 hours
13. A Crankshaft gear f Ae gt Pr yi fe ji PAN Don t disassemble Fuel pump drive gear Flange bolt Note This figure shows the 3TNV76 Crankshaft pulley Disassembly procedure 1 Follow steps 1 to 15 of the cylinder head disassembly procedure 2 Remove the cooling water pump 3 Remove the crankshaft pulley Point 1 Operation point to be explained on a later page Operation points Disassemble Service point for removal Reassemble Service point for installation Disassemble Reassemble Service point required in both removal and installation Contents omitted in this manual Though the following jobs are omitted in the explanation in this manual they should be conducted in actual work 3 Jacking up and lifting 4 Cleaning and washing of removed parts as required 5 Visual inspection 3 Definition of Terms NOTICE Instruction whose negligence is very likely to cause an accident Always observe it Standard Allowable range for inspection and adjustment Limit The maximum or minimum value that must be satisfied during inspection or adjustment 4 Abbreviations Abbreviation Meaning Abbreviation Meaning Assy assembly T D C top dead center Sub Assy sub assembly B D C bottom dead center a T D C after top dead center OS oversize b T D C before top dead center US undersize Standard Min revolutions per minute
14. Check to see that the cooling water pump bearing is free from abnormal noise sticking or play and water leakage from the bearing If replacement is necessary replace the whole cooling water pump assy NOTICE Replace the O ring of the installation part to the cylinder block of the cooling water pump with new one when disassembling And be sure to use the special O ring for each engine model because the material is different although the dimension is the same as a commercial part Refer to the right figure Point2 Disassemble Check the thermostat function See 2 7 in Chapter 2 for the inspection method 92 Cooling water pump 7 Fuel Injection Pump Governor 7 FUEL INJECTION PUMP GOVERNOR 7 1 Introduction A fuel injection pump is the most important device which adjusts an injection quantity precisely corresponding to the change of engine load Fuel injection pum Therefore not only a very precise machining should be necessary all parts but also the assembling adjustment which top level is excellent in should be necessary The careful consideration to avoid dust and rust at the time of disassembly adjustment reassembly of the fuel injection pump in the market is necessary Fuel injection pumps manufactured by Yanmar YPES ML type series are inline type A cam shaft is driven through the timing gear and mechanical type fuel feed pump driven by a cam shaft sends fuel to the fuel filter f
15. Apply sealant to packings depending on the place where they are used Apply of grease to sliding contact portions and apply grease to oil seal lips 7 Precautions for Adjustment and Check Use measuring instruments for adjustment to the specified service standards How to Read this Manual 1 Range of Operation Explanation This manual explains the troubleshooting installation removal replacement disassemble reassembly inspection adjustment and adjusting operation procedures for the TNV series engines with direct injection system Refer to the manufacturer s manual for each of the fuel injection pump governor starting motor and alternator except for their installation 2 How to Read the Explanations An exploded view sectional views a system diagram etc are shown at the beginning of each section as required for easy understanding of the mounted states of the components For the removal installation of each part the procedure is shown with the procedural step No in the illustration Precautions and key points for disassembly and reassembly of parts are described as points the explanation for each point detailed operation method information standard and precautions are described Description Example Flywheel Flywheel hausing Gear case flange amp dle gear o Camshaft ub 4 ATA Camshaft driving ge m QA iving gear Fuel injection pump eT 227 bo 4 EG
16. O O Abnormal engine sound O IO O Pressure drop Correct or replace Blowout from cylinder head gasket IO Ordinary Replace the gasket See 4 2 2 11 in Chapter4 Seized or broken piston ring O Replace the piston ring See 4 4 2 5 10 in Chapter4 Worn piston ring piston or cylinder Perform honing and use oversize parts See 4 4 5 1 4 and 4 4 6 in Chapter4 Seized crankpin metal or bearing O Repair or replace Improper arrangement of piston ring joints Correct the ring joint positions See 4 4 4 point 6 in Chapter4 Reverse assembly of piston rings Reassemble correctly See 4 4 4 point 6 in Chapter4 Worn crankpin and journal bearing Measure and replace See 4 4 5 2 in Chapter4 Loosened connecting rod bolt Tighten to the specified torque See 4 4 4 point 2 in Chapter4 Foreign matter trapped in combustion chamber Disassemble and repair Excessive gear backlash Adjust gear meshing See 4 3 4 point 2 in Chapter4 Worn intake exhaust valve guide Measure and replace See 4 2 5 2 4 2 7 Chapter4 Defective governor Make adjustment Improper open close timing of intake exhaust valves Adjust the valve clearance See 2 2 6 3 in Chapter2 43 3 Troubleshooting
17. terminal and black clip to the battery negative terminal by pinching them securely and judge the battery charge level from the indicator position Green zone Normal Yellow zone Slightly discharged Red zone Defective or much discharged Battery charge measurement with battery tester 24 2 Inspection and Adjustment b Measurement with hydrometer When using a hydrometer the measured specific gravity must be corrected according to the temperature at the time of measurement The specific gravity of battery electrolyte is defined with 209 as the standard Since the specific gravity increases or decreases by 0 0007 when the temperature varies by 1 correct the value according to the equation below S20 St 0 007 t 20 Measured electrol temperature Measured specific Specific gravity co to 20 C oy Specific gravity and remaining battery charge Remaining charge Specific Discharged quantity gravity of electricity 20 C 1 28 0 100 1 26 10 90 1 24 20 80 1 23 25 75 3 Terminals Clean if corroded or soiled 4 Mounting bracket Repair or replace it if corroded Retighten if loosened 5 Battery appearance Replace the battery if cracked or deformed Clean with fresh water if contaminated 25 Battery charge measurement with a hydrometer Rubber bulb Glass tube Hydrometer structure How to read hydrometer 2 Inspection and Adjustmen
18. As a representative example of alternator the alternators of 20A and 40A are shown in this chapter 9 1 20A Alternator 9 1 1 Specifications Manufacturer s model Kokusan GP9191 Yanmar code 119910 77200 Rating Continuous Battery voltage V 12 Nominal output 20 Rated revolution 3 500 Operating revolution min 1 400 6 600 Grounding characteristics Minus side grounding Direction of revolution viewed from pulley Clockwise Integrated regulator IC regulator Weight kg 1 8 Pulley outside diameter mm 65 for A belt or 58 for special M belt Belt shape Type A or type special M 100 9 Alternator 9 1 2 Structure Coil Plate CICLOS Spring washer zen ml oS red Coupler 101 9 Alternator 9 1 3 Wiring diagram Standard circuit composition for output confirmation Load 2V Battery SW 1 1 Charge lamp IC Regurator Generator NOTICE connecting and short circuit of each terminal t remove a battery terminal and a B terminal when rotating t do mis 3 Shut out a battery switch during the alternator stop 1 Don 2 Don 9 1 4 Standard output characteristics The standard output characteristics of this alternator are shown as the below figure gt N o 9 v x 5 lt 2 a lt
19. b While turning the crankshaft with the crankpin cap removed raise the piston up to the top dead center TDC c Extract the piston connecting rod assembly while tapping the connecting rod at the large end with the handle of a plastic hammer or the like 1 Remove tappets 57 4 Disassembly Inspection and Reassembly of Engines 4 1 4 Precautions before and during reassembly To reassemble engine components reverse the procedure of disassembly However follow the precautions below and the precautions from chapter 4 to chapter 7 particularly before and during reassembly 1 Cleaning the component Use particular care to clean the cylinder block cylinder head crankshaft and camshaft Ensure that they are free from chips dust sand and other foreign matter 2 Parts to be replaced during reassembly Be sure to replace the following parts with new ones during assembly Valve stem seal Head gasket packing Various copper packing O rings and gasket packing 4 1 5 Adjusting operation Make sure to perform adjusting operation after completing reassembly Refer to section 2 8 in chapter 2 for the operation procedure 58 4 Disassembly Inspection and Reassembly of Engines 4 2 Cylinder Head Disassembly Inspection and Reassembly 4 2 1 Components 2 valve cylinder head 2 7 Rocker arm cover Kuss manifold f N NRI rw L a Ni V pulle
20. ps 22 129 135 143 149 155 161 168 174 180 186 Max no load speed 25 min 2160 2250 2355 2460 2570 2875 2780 2890 2995 3100 3210 Ignition order 1 3 2 1 No 1 cylinder on flywheel side Power take off Flywheel Direction of rotation Counterclockwise viewed from flywheel Cooling system Radiator Lubrication system Forced lubrication with trochoid pump Starting system Electric Applicable fuel Diesel oil BS 2869 A1 or A2 Cetane No 45 Applicable lubricant API grade class CD Lubricant capacity Total L 2 8 Vell pan Effective L 13 Cooling water capacity L 09 engine only Engine Overall length mm 504 Dimensions with flywheel Overall width mm 427 housing Overall height 506 Engine mass dry with flywheel housing Kg i Cooling fan std mm 310 mm O D 5 blades pusher type F Crankshaft V pulley diameter aim 6110 amp 100 amp Fun V pulley diameter std Items marked may differ from the above depending on an engine installed on a machine unit Engine mass and dimensions without radiator 1 General 3 3TNV76 Engine name Unit 3TNV76 Engine specification class CH VH Type Vertical in line 4 cycle water cooled diesel engine Combustion chamber Indirect inject
21. humidity 3096 Fuel temp 40 C Fuel injection pump inlet With cooling fan air cleaner exhaust silencer Yanmar standard parts After running in hours Output allowable deviation 3 1 General 1 2TNV70 Engine name Unit 2TNV70 Engine specification class VM Type Vertical in line 4 cycle water cooled diesel engine Combustion chamber Indirect injection Number of cylinders 2 Cylinder borexstroke Mis 70 74 Displacement L 0 570 Revolving min Continuous speed rating Output NET 5 Revolving 2000 2100 2200 2300 2400 2500 2600 2700 2800 2900 3000 Rated output speed Output NET kW 60 63 68 70 73 76 79 82 85 88 91 put NET ps 81 86 90 95 99 103 107 11 1 116 120 124 Max no load speed 25 2160 2250 2355 2460 2570 2675 2780 2890 2995 3100 3210 Ignition order 1 2 1 No 1 cylinder on flywheel side Power take off Flywheel Direction of rotation Counterclockwise viewed from flywheel Cooling system Radiator Lubrication system Forced lubrication with trochoid pump Starting system Electric f Diesel oil BS 2869 A1 or A2 Applicable fuel Cetane No 45 Applicable lubricant API grade class CD or CF Lubricant capacity Total L 14 Effective L 0 7 Cooling wa
22. o obs 1 EIS 1 1 1 12774 tot Pg Roe bin et eee eee een 1 v LNSYYND LAdLNO ALTERNATOR SPEED mir 102 9 Alternator 9 1 5 Inspection 1 V belt inspection 4 Inspect the matter whether there are not crack stickiness and wear on the belt visually Check that a belt doesn t touch the bottom part of the pulley groove If necessary replace the V belt set 5 V belt tension Clearance Refer to 2 2 2 2 in Chapter 2 2 Visual check of wiring and check of unusual Inspection of V pulley sound 1 Confirm whether wiring is right or there is no looseness of the terminal part 2 Confirm that there is no unusual sound from the alternator during the engine operation 3 Inspection of charge lamp circuit 1 Move a start switch to the position of on Confirm lighting of the charge lamp 2 Start an engine and confirm the lights out of the lamp Repair a charge lamp circuit when a lamp doesn t work 103 9 Alternator 9 2 40A Alternator 9 2 1 Components 1 Parts related to the alternator 2 Alternator components of disassembly and assembly Rotor Assy Flame Assy Rear flame Assy 104 9 Alternator 9 2 2 Specifications Manufacturer s model Denso ACFA68 Yanmar code 129423 77200 Rating Continuous Battery voltage 12 No
23. 2 Side clearance of outer rotor mm Standard Limit Reference page 0 02 0 07 0 12 5 5 1 3 Outside clearance of inner rotor centering location part mm Standard Limit Reference page 0 13 0 20 0 25 5 5 1 118 12 Tightening Torque for Bolts and Nuts 12 Tightening Torque for Bolts and Nuts 12 1 Tightening Torques for Main Bolts and Nuts Part and engine model Thread diameter x pitch mm Tightening torque N m kgf m Lube oil application thread portion and seat surface Reference page Cylinder head bolt M9x1 25 53 9 57 9 5 5 5 9 Applied 4 2 4 Connecting rod bolt M7x1 0 22 6 27 5 2 3 2 8 Applied Flywheel set bolt M10x1 25 80 4 86 4 8 2 8 8 Applied Bearing cap set bolt M10x1 25 75 5 81 5 7 7 8 3 Applied Crankshaft FC250 pulley set bolt SABC M12x1 25 83 3 93 3 8 5 9 5 11344123 11 5 12 5 Applied Fuel pump drive gear nut M12x1 75 58 8 68 8 6 0 7 0 Applied Fuel pump gear bolt M8x1 0 32 3 36 3 3 3 3 7 Not applied Fuel injection pipe sleeve nut M12x1 25 29 4 34 4 3 0 3 5 Not applied Fuel injection nozzle nut M20x1 5 49 0 53 0 5 0 5 4 Not applied Governor weight suport nut M12x1 25 68 7 73 7 7 0 7 5 Applied Glow plug M10x1 25 14 7 19 6 1 5 2 0 119 Not applied 12 Tightening Torque for Bolts
24. 2222 12 00 87 5 LUBRICATION SYSTEM 88 5 1 Lubrication System eR EHE erri 88 5 2 Trochoid Pump 88 5 3 Disassembly Reverse the below procedure for 89 5 4 Servicing ERR DER DE 89 5 5 Parts Inspection and 90 5 5 1 Trochoid pump inspection and 90 6 COOLING SYSTEM 91 6 1 Goolind Water Syste Misirin ge dad Tode Rumes ele 91 6 2 Cooling Water Pump 8 91 6 3 Disassembly Reverse the below procedure for 92 6 4 POMS as oie tenebit eo tes Ur ate ute Mose DU ee oa pep b e Dd eta 92 7 FUEL INJECTION PUMP 93 1 46 6 93 Z2 Fuel SCHON LI Dp ote dt Gone eodd cm rst tI 93 7 2 Fuel system diagram o Le eene ce 93 7 2 2 External view and 94
25. 3 Check the inside diameter and finish to the standard inside diameter as required with a reamer 4 Check the projection from the cylinder head Valve guide replacement Projection mm 9 8 10 0 Valve stem seal inserting tool 4 2 8 Valve stem seal replacement V Always use a new valve stem seal after the intake exhaust valve or valve stem seal is disassembled Since the one for the exhaust valve is marked with yellow paint do not confuse the intake and exhaust valves Stem seal NOTICE Valve guide Painting is applied to the springs of both M Cylinder head intake exhaust valve stem seals for the distinction because both parts are different Be careful because it causes oil down when the attachment of intake exhaust is mistaken Distinction coloration for the intake is white and for the exhaust black Stem seal insertion 1 Apply lube oil to the lip 2 Push with the inserting tool Refer to No 5 of Stem seal 4 1 2 1 in Chapter 4 for installation 3 Measure and check the projection of valve stem seal to keep proper clearance between valve guide and stem seal Clearance Projection mm 10 9 11 2 E Valve guide lt VY 2 Valve guide projection Stem seal proiection 67 4 Disassembly Inspection and Reassembly of Engines 4 3 Gear Train and Camshaft 4 3 1 Components Flywheel Flywheel hausing Gear case flange amp dle ge
26. 3TNV76 Top ring Ring groove width 1 550 1 570 Ring width 1 470 1 490 Side clearance 0 060 0 100 End clearance 0 15 0 30 Second ring Ring groove width 1 580 1 595 Ring width 1 430 1 450 Side clearance 0 013 0 165 End clearance 0 18 0 33 Oil ring Ring groove width 3 010 3 025 Ring width 2 970 2 990 Side clearance 0 020 0 055 End clearance 84 0 20 0 45 4 Disassembly Inspection and Reassembly of Engines 5 Connecting rod a Appearance inspection Inspect the portion near the boundary of the chamfered portion and I beam section of the big and small ends of the connecting rod as well as the portion near the oil hole of the bushing at the small end for cracks deformation and discoloration b Twist and parallelism measurement Use a connecting rod aligner and measure the twist and bend Standard Limit dimension dimension Twist and 0 03 or less 0 08 parallelism per 100mm Item c Rod small end measurement Measure the pin outside diameter according to 4 4 5 4 b described above Item Standard Piston pin metal 1 0 22 025 22 038 Pin O D 21 991 22 000 Clearance 0 025 0 047 If the metal is to be replaced because the oil clearance exceeds the limit use spare part Service part code 119717 23910 85 Parallelism Connecting rod aligner Twist meas
27. 850 If the side gap is exceeded use an oversized thrust metal Oversized metal 0 25mm mm Code No assy Standard thickness 119810 02940 2 055 2 105 81 Super polishing Ry 0 8S Crank Pin Crank Journal Crankshaft R machining 4 Disassembly Inspection and Reassembly of Engines 4 Piston Especially clean the combustion surface circumference ring grooves and piston pin bosses and check after removing any carbon deposit Any burr at a ring groove or snap ring groove shall be removed If crack is suspected inspect by color check a Piston outside diameter measurement Measure the long diameter at H mm from the bottom end of the piston of the oval hole in the vertical direction to the piston pin hole v Measurement 172 M position lt gt i H mm Piston outside diameter The clearance between a piston and a cylinder is calculated by using a measured piston outside diameter and a cylinder inside diameter measured according to 4 4 5 1 b Clearance between Measurement position piston and cylinder H 0 030 0 050 22 25 Model Piston outside diameter 2 3TNV70 3TNV76 69 960 69 990 75 955 75 985 0 035 0 055 22 25 If the piston outside diameter exceeds the limit replace the piston with new one If necessary use an oversized piston Refer to the tables of oversized pistons oversized piston rings and cylinder boring
28. Cooling water System Trouble symptom Excessive cooling effect of radiator Starting failure Insufficient engine output Poor exhaust color Engine does not start Engine starts but stops soon Exhaust color During work Exhaust smoke Ordinary High knocking sound during combustion Abnormal engine sound Uneven combustion sound Hunting During idling During work Large engine vibration Difficulty in returning to low speed Cooling water Excessive consumption Dilution by fuel oil Mixture with water Low L O pressure Much blow by gas Overheat Pressure drop Pressure rise Exhaust temperature rise Corrective action Excessive fuel consumption O Low water temperature Defective thermostat kept closed See 2 7 in Chapter2 Insufficient cooling effect of radiator Defective thermostat kept opened See 2 7 in Chapter2 or slipping fan belt See 2 2 2 2 in Chapter2 Insufficient cooling water level Check water leakage from cooling water system See 2 2 1 1 4 5 in Chapter2 Cracked water jacket Repair or replace Slackened fan belt Adjust the belt tension See 2 2 2 2 in Chapter2 Defective thermostat Check or replace See 2 7 in Chapter2 E 9 gt o 5 5 a Improper properties of lube oil Use proper lube oil See 1 3 2 in Chapter1
29. Disconnect the connector from the oil pressure switch p flywheel side Keep the voltammeter probes in contact with the switch terminal and cylinder block while operating the engine Itis abnormal if circuit is closed Tester probes Continuity test 2 4 2 Thermo switch Place the thermo switch in a container filled with antifreeze or oil Heat it while measuring the fluid temperature The switch is normal if the voltammeter f Tester probes shows continuity when the fluid temperature is 107 113 deg C 2 5 Water leak check in cooling water system Check cooling water leakage from the cooling water system visually If any problem is found Inspect as follows 1 Fill cooling water to the normal level in the radiator and install the cap tester on the radiator 2 Operate the manual pump to set the pressure to 0 09 0 015 0 9 0 15kgf cm If the cap tester pressure gage reading drops then water is leaking from the cooling water system Check Cap tester the water leaking point Water leak check in cooling water system 2 6 Radiator cap inspection Spread water on the seal surface of the radiator cap fully and install the cap to a cap tester Raise the pressure of the tester and check that the valve of the cap opens by the standard pressure 0 092 0 015MPa Standard pressure 0 92 0 15kgf cm Radiator cap When the cap doesn t open it is abnormal Replace the cap with new one Radiator cap in
30. PER SCREW SETTING BE ENSURED PAINTED SURFACE MAY NOT BE USED COUPLER RESISTANCE OF SOLENOID DOESN T NEED TO BE COUNTED SE P A DING THE MISS CONTAC RET REFERENCE 2 0 00880 lt 8 WITHOUT TERMINAL RESISTANCE 2 BATTER UST BE OBSERVED AS FOLLOWS 0 O056Q m 12 5m SAME AS ABOVE OTHERWISE IT MAY CAUSE BURNING OF ELECTRIC WHEN YOU EXCEED PERMISSIBLE RESISTANCE ADOPT THE CIRCUIT EQUIPMENTS OR COMPONENTS ALTERNATOR DIODES IMPRESSED FROM THE POWER SUPPLY TO THE SOLENOID DIRECTLY BURNING CAUSED BY BATTERY CABLE CONNECTIO USING A RELAY REVERSELY 1S WARRANTED 2 HIGH TEMPERATURE PARTS SUCH AS AN EXHAUST PIPE SHOULD NOT APPROACH 2 1 BATTERY SHOULD BE FIXED BY FITTING NOT FOR THE PULL POWER FALL OF SOLENOID AND HEATING PREVENTION OF TO MOVE INNER COIL TEMPERATURE PERMISSIBLE AMBIENT TEMPERATURE 30 1000 2 2 BATTERY CABLE LENGTH SHOULD BE ADJUSTED 3 INSTALL FUSE TO PROTEC HE HARNESS AGAINST TROUBLES SUCH AS PROPERLY AND CLAMPED NOT TO BE CONNECTED SHORT CIRCUIT OR CONTINUOUS DRIVE OF PULL COIL REVERSELY 4 THE POWER SUPPLY DF S E ID MAY NOT BE COMMON WITH THE LINE OF 2 3 LOOSE THE BATTERY CABLE TERMINAL ALTERNATOR INITIAL EXCITATOR AS SHOWN IN THIS DRAWING NOR TURN THE BATTERY SWITCH OFF DURING THE COTHERWISE SOLENOID MAY SE STOP FUNCTION DUE TO THE POWER ENGINE RUNNING SUPPLY FROM A L TERMINAL 3 ONLY THE SPECIFIED LOAD SHOULD B
31. Shae 9 Oil pressure switch operating pressure 0 05 0 01 MPa kgf cm 0 5 0 1 valve opening Full opening lift temperature mm 10 Thermostat deg C temperature 2 7 8 or above 69 5 72 5 85 deg C 11 Thermo switch actuating temperature 1074413 _ 24 2 deg C Lube oil capacity may differ from the above depending on an engine installed on a machine unit 113 11 Service Standards 11 2 Engine Body 11 2 1 Cylinder head 1 Cylinder head Inspection item Standard Limit Reference page Combustion surface distortion 0 05 or less 0 15 mm Valve sink Intake 0 4 0 6 0 9 4 2 5 1 mm Exhaust 0 4 0 6 0 8 Intake 120 Seat angle Deg Valve seat Exhaust 90 4 2 6 Seat correction angle deg 40 150 2 Intake exhaust valve and guide Inspection item Standard Reference page Guide inside diameter 6 000 6 012 Intake Valve stem outside diameter 5 960 5 975 Clearance 0 025 0 052 Guide inside diameter 6 000 6 012 Exhaust Valve stem outside diameter 5 945 5 960 Clearance 0 040 0 067 Valve guide projection from cylinder head 9 8 10 0 Valve guide driving in method Cold fitted 3 Valve spring Inspection item Standard Reference page Free length 37 8 4 2 5 4 Inclination 4 Rocker arm and shaft Inspection item Standard Reference page Arm shaft hole diameter 12 000 12 020 Shaft outside diameter
32. and Nuts 12 2 Tightening Torques for Standard Bolts and Nuts Nominal thread diameter x pitch mm Tightening torque Nm kgf m Remarks Hexagon bolt 7T and nut M6x1 9 8 11 8 1 0 1 2 M8x1 25 22 5 28 4 2 3 2 9 10 1 5 44 1 54 1 4 5 5 5 M12x1 75 78 3 98 3 8 0 10 Use 80 of the value at left when the tightening part is aluminum Use 60 of the value at left for AT bolts and lock nuts 1 8 9 8 1 0 1 4 19 6 2 0 3 8 29 4 3 0 1 2 58 8 6 0 Pipe joint bolt M8 12 7 16 7 1 3 1 7 24 5 34 4 2 5 3 5 39 1 49 1 4 0 5 0 48 9 58 9 5 0 6 0 Note Lube oil is not applied to threaded portion and seat surface 120 YANMAR DIESEL AMERICA CORP 951 CORPORATE GROVE DRIVE BUFFALO GROVE IL 60089 4508 U S A TEL 1 847 541 1900 FAX 1 847 541 2161 YANMAR EUROPE B V P O BOX 30112 1303 AC ALMERE NL BRUGPLEIN 11 1332 BS ALMERE DE VAART THE NETHERLANDS TEL 31 36 5493200 FAX 31 36 5493209 YANMAR ASIA SINGAPORE CORPORATION PTE LTD 4 TUAS LANE SINGAPORE 638613 TEL 65 6861 3855 FAX 65 6862 5195 YANMAR CO LTD HEAD OFFICE 1 32 CHAYAMACHI KITA KU OSAKA 530 8311 JAPAN SMALL ENGINES FACTORY ENGINE PRODUCT OPERATIONS DIVISION 1009 2 Kawamichi Biwa cho Higashiazai Gun Shiga JAPAN TEL 81 749 72 5195 FAX 81 749 72 5158 Printed in Japan September 2003
33. and a gear case Or put a mark on the gear case at the position to agree the timing mark of a fuel pump 3 Remove a pump cover from the gear case 4 Give the marks on a fuel injection pump drive gear and a idle gear with paint or the like 5 Loosen fuel injection pump installation nuts three nuts 6 Loosen a installation nut of a fuel injection pump drive gear 7 Move a pump drive gear and a flange with a pair to your side by gear puller 8 Remove an installation nut and a washer 9 Remove a fuel injection pump Leave the pump drive gear in the gear case Fuel injection pump drive gear Pump drive gear nut 7 2 4 Reassembly procedure NOTICE Use a new O ring on the fuel pump flange and apply grease Confirm whether the marks 7 2 3 4 of the pump drive gear and the idle gear is correct 1 Turn a cam shaft so that the key of the pump cam shaft may almost agree in a position of the key groove of a pump drive gear 2 Insert a fuel injection pump into the installation hole of the gear case straight to prevent the damage of the O ring Insert a fuel pump with confirming whether the key of a camshaft and the key groove of a drive gear agree 3 Assemble a pump drive gear installation nut and a washer together temporarily 4 Turn a fuel injection pump to the position where the marks 7 2 3 2 of the fuel injection pump and the gear case agrees 5 Fasten pump installation nuts three nuts 6 Ti
34. and the gear case cover and measure outside diameter gap Put a ruler on the end face of the gear case cover and insert a gap gauge between rotor and measure a side gap Outside clearance mm Standard Limit 0 12 0 21 0 30 nner rotor Outer diameter clearance Side clearance mm Standard Limit 0 02 0 07 0 12 Outer rotor Side clearance 2 Outside diameter clearance of inner rotor centering location part Measure the outside diameter of inner rotor centering location part and the hole diameter of gear case cover Calculate the clearance from that difference Inspection item Standard Gear case cover 46 13 46 18 Inner rotor O D 45 98 46 00 Rotor clearance 0 13 0 20 90 6 Cooling System 6 COOLING SYSTEM 6 1 Cooling water System Thermostat Cylinder head Sub tank Radiator Cylinder block Thermostat cover 9 C Thermostat eC SZ Cooling water pump Thermo switch Note This figure shows the 3TNV76 91 6 Cooling System 6 3 Disassembly Reverse the below procedure for reassembly 1 Remove the alternator See 4 2 2 1 in Chapter 4 2 Remove the fan V belt and pulley See 4 2 2 2 in Chapter 4 4 Remove the cooling water pump Point 1 in 6 4 5 Remove the thermostat Point 2 in 6 4 6 4 Servicing Points Point1 Disassemble Reassemble 3 Remove the thermostat case See 4 2 2 3 in Chapter 4
35. at specified intervals before it is clogged with dust to advesely affect the fuel flow Do this work after an engine gets cold fully 1 Close the fuel filter cock 2 Loosen the retainer ring and replace the fuel filter element Take the water and trash in the cup out When removing the fuel filter hold the bottom of the fuel filter with a piece of rag to prevent the Mechanical EIOS water Fuel injection fuel oil from dropping If you spill fuel wipe such Fuel feeding pump separatr pump spillage carefully 3 Install a new fuel filter element and tighten the retainer ring Tightening torque 13 16N m 1 3 1 6kgf m Fuel filter element Part No irm 119740 55650 g f NI ightning Retaining ring Fuel cock Priming lever Joint for fuel return Fuel filter 28 2 Inspection and Adjustment 4 Bleed the fuel system Refer to 2 2 3 3 IMPORTANT Be sure to use genuine Yanmar part Otherwise it results in engine damage uneven engine performance and decline of engine life And these troubles are outside the guarantee 3 Air cleaner cleaning and element replacement Refer to 2 2 4 5 Replace the air cleaner element periodically even if it is not damaged or dirty When replacing the element clean inside of the dust pan at the time If having the air cleaner with double elements do not remove the inner element If the engine output is still not recover or the dust indicator still actua
36. gage and compression gage adapter at the cylinder to be measured 1 Never forget to install a gasket at the tip end of the adapter 4 With the engine set to the same state as in 2 1 crank the engine by the starter motor until the compression gage reading is stabilized 2 Standard compression pressure Engine compression pressure list reference value Compression pressure Deviation among cylinders at 250 MPa kgf cm Standard Limit MPa kgf cm 2 3TNV70 3 24 0 1 3341 2 55 0 1 26 1 0 2 0 3 2 3 Engine mode 3TNV76 3 43 0 1 3541 2 75 0 1 28 1 0 2 0 3 2 3 46 3 Troubleshooting 3 Engine speed and compression pressure for reference 3TNV76 em E 3 92 9 3 43 5 i 2 9 1 2 94 2 2 3TNV7O 5 MES E erp one ore 2 45 5 E aS E M MM FILE e 1 96 __ MPa 200 250 300 350 400 Engine speed min 4 Measured value and troubleshooting When the measured compression pressure is below the limit value inspect each part by referring to the table below Item Cause Corrective action Air cleaner element Clogged element Clean the element Broken element Replace the element Defect at element seal portion Valve clearance Excessive or no clearance Adjust the valve clearance See 2 2 6 3 in Chapter 2 valve timing Incorrect valv
37. improvement of fuel injection quantity in production Precision improvement of fuel injection timing in production Noise Reduction LO pump with more teeth Quality improvement Governor performance up Noise Reduction Cylinder block of higher stiffness Noise Reduction Gear with smaller module m 1 5 Ed ANT LAN XT e il fee EX Noise Reduction Molybdenum coated piston Durability improvement uondiosog JeINJONAS JelQUay 1 General 1 6 Exhaust gas emission regulation The engines in this manual have been certified by the US EPA and or California California Proposition 65 Warning Diesel engine exhaust and some of its constitutions are known to the State of California to cause cancer birth defects and other reproductive harm California Proposition 65 Warning Battery posts terminals and related accessories contain lead and lead compounds chemicals known to the State of California to cause cancer and reproductive harm Wash hands after handling 1 6 1 The Emission Standard in USA 1 EPA Nonroad Diesel Engine Emission Standards g kW hr g bhp hr Engine Power Model Year NMHC NOx PM TAM 2000 10 5 7 8 1 0 0 75 hp lt 11 2005 7 5 5 6 0 80 0 60 2000 9 5 7 1 0 80 0 60 11 lt lt 25 2005 7 5 5 6 0 80 0 60 Note1 The EPA emission regulation under 19kW is mentioned abov
38. maintenance Rust and water scale will accumulate in the cooling system through many hours of operation This lowers the engine cooling effect Oil coolers attached to turbocharged engines and some of naturally aspirated engines guickly deteriorate the lube oil The cleaning and maintenance of the following parts are necessary in accordance with the cooling water replacement Cooling system parts radiator cooling water pump thermostat cylinder block cylinder head oil cooler 2 Fuel pipe and cooling water pipe inspection and maintenance Regularly check the rubber hoses of the fuel system and cooling water system If cracked or degraded replace them with new one Replace the rubber hoses at least every 2 years even if 2 000 hours doesn t come 3 Intake exhaust valve seat lapping The adjustment is necessary to maintain proper contact of the valves and seats Refer to 4 2 6 in Chapter 4 4 Fuel injection timing adjustment Fuel injection pump inspection and adjustment The fuel injection timing and the fuel injection pump are adjusted so that engine performance may become Fiywhesi the best condition As for the inspection and housing adjustment of the fuel pump it is based on the service N manual of the ML pump of the separate volume The fuel injection timing is adjusted by the following procedure 1 Complete air bleeding from the fuel line and set the engine ready for starting 2 See that the timing marks on fuel pump mountin
39. of oil mist may be inducted in the combustion chamber and the oil hammer sometimes may occur 3 Intake exhaust valve clearance adjustment Make measurement and adjustment while the engine is cold a Valve clearance measurement 1 Remove the rocker arm cover above cylinder head 2 Set the No 1 cylinder in the compression TDC Turn the crankshaft to bring the piston of the No 1 cylinder to its compression top dead center while watching the rocker arm motion timing scale and the top mark position of the crankshaft pulley Position where both the intake and exhaust valves are closed Notes The crankshaft shall be turned clockwise as seen from the radiator side The No 1 cylinder position is on the opposite side of the radiator Since there is a clearance between the rocker arm and valve at the compression top dead center the position of TDC can be checked by hand Also see that the top mark on the crankshaft pulley aligns with the mark on the gear case If there is no valve clearance disassemble and inspect around the valve seat since the valve seat may be worn abnormally 31 2 Inspection and Adjustment 3 Valve clearance measurement Insert a thickness gage between the rocker arm and valve cap and record the measured valve Adjusting screw clearance Use it as data for estimating the wear state Valve clearance 4 Adjusting other cylinders Then in case of 3 cylinder engines turn the crankshaft clockwise viewed f
40. periphery of the revolving shaft Photoelectric type i 16 Speedometer Reflection mark For measuring the revolution regardless of the center or periphery of 257 the revolving object Fuel id high pressure aD pipe clamp Een For measuring resistance voltage and continuity of electrical circuits 17 Circuit tester 18 Compression gage kit For measuring compression pressure Yanmar code No TOL 97190080 53 4 Disassembly Inspection and Reassembly of Engines 4 1 3 Complete disassembly Peripheral parts such as air cleaner muffler and radiator differ in installation and types for each application Therefore description in this Chapter is started with the steps to be taken just after the peripheral parts have been removed Removal Parts Remarks 1 Thoroughly remove sand dust dirt and soil from the surface of the engine 2 Drain cooling water and lube oil from the engine 1 Remove exhaust manifold 2 Remove intake manifold Close the fuel cock valve of the fuel tank Remove high pressure fuel pipes Remove fuel return pipe Remove fuel injection nozzles Fuel injection nozzle for Indirect injection System is screwed type 1 If nozzle seat is left in the cylinder head remove the cylinder head before extracting nozzle seat 2 To prevent dust from entering fuel injection nozzles fuel injection pump and high pressure fuel pipes seal their respective thread
41. specified lube oil may cause inner parts seizure or early wear leading to shorten the engine service life Selection of viscosity 1 lection of i Se ISAE Service grade API classification CD or CF e HOW gt Standards of America Petroleum Institute i W x i SAE viscosity 10W 30 or 15W 40 PAS susce 21 Standard of Society of Automotive Engineering lt cce dae TUI 20 gt e 30 gt Lube oil with 10W30 or 15W40 be used throughout the year Refer to the right figure 2 Handling of lube oil 20 10 0 10 20 30 40 50 Carefully store and handle the oil so as to prevent Atmospheric temperature C dust or dirt entrance When supplying the oil pay attention and clean around the filler port 15W 40 10W 30 can be used almost throughout the year Do not mix different types of oil as it may adversely affect the lubricating performance When touching lube oil by hand the skin of the hand may become CAUTION rough Be careful not to touch oil with your hands without protective gloves If touch wash your hands with soap and water thoroughly 1 3 3 Cooling water Use clean soft water and be sure to add the Long Life Coolant Antifreeze LLC in order to prevent rust built up and freezing If there is any doubt over the water quality distilled water or pre mixed coolant should be used The coolants antifreezes which ar
42. the entry of water The water proofing of the starting motor is equivalent to R2 of JIS D 0203 This guarantees that there will be no damage from the sort of exposure encountered in rain or when water is poured on from a bucket You should however avoid the use of high pressure washing and steeping in water 6 Regarding the heat resistance of the starter motor The starting motor has heat resistance for an ambient temperature of 80 C and surface temperature of 100 C Insulators must be installed to prevent overheating when used near high temperature parts such as the exhaust system 7 Corrosion of magnet switch contact point by corrosive gas When using equipment with a dry clutch ammonium gas generated by friction is liable to corrode the contact of the magnet switch sure to install a vent in the clutch case 110 10 Electric Wiring 10 1 3 Current limiter In the cases listed below the warranty shall not be deemed to apply Please be sure to read these conditions carefully when planning to use it with other equipment Also be certain to give appropriate guidance on usage to the user 1 When an over discharged battery is used Use of booster starting with an over discharged battery when the voltage has dropped to 8V or less will destroy other electrical equipment by generating an abnormally high voltage specialized battery charger should be used to recharge such an over discharged battery when the voltage has droppe
43. water Radiator cap 3 After draining the cooling water tighten the drain Radiator plug Nes Option 4 Fill radiator and engine with cooling water Refer to 3 4 Rubber hose a Before filling check to be sure the drain plug is closed b Remove the radiator cap of the radiator by turning the radiator cap counter clockwise about 1 3 of a turn c Pour the cooling water slowly into the radiator up to the lip of the filler port so that air bubbles do not develop d After supplying the cooling water surely tighten the radiator cap fasten the radiator Ww cap align the detents on the back face of the Drain plug Min limit radiator cap with the slot of the filler port and Drain plug location depends on the machine unit turn clockwise pushing it downward approx 1 3 of a turn until contact with each other e Remove the cap of the coolant recovery tank supply the cooling water to the FULL mark and fasten the cap f Check the rubber hose connecting the coolant recovery tank to the radiator Be sure the rubber is securely connected and there is no looseness or damage When the rubber hose is not water tight an excessive amount of cooling water will be consumed 30 2 Inspection and Adjustment g When filling with the cooling water for the first time or replacing the air contains in the cooling water system So as the air in the cooling water system is made self bleeding during engine operation the cool
44. with the with inner and outer element latches IMPORTANT When the engine is operated in dusty conditions clean the element more frequently Do not run the engine with removed air cleaner or element as this may cause foreign material to enter and damage the engine 27 2 Inspection and Adjustment 2 2 5 Inspection every 500 hours or 6 months Be sure to check the following points every 500 hours or 6 months operation whichever comes first Inspection Item Water separator cleaning Fuel filter element replacement Air cleaner cleaning and element replacement 1 Air cleaner element replacement The cup of an water separator is translucent and the inside can be seen The floate ring rises when water collects at the bottom of the cup _ Outlet Periodically wash the water separator element and inside cup with clean fuel oil 1 Close the fuel cock 2 Loosen the retaining ring and remove the cup Take the water and trash in the cup out 3 Wash the element with clean fuel oil Replace the element with new one if any damaged Element Part No 129335 55700 Air bleeding bolts Water separator 4 Insert the element to the bracket and put the float ring and spring in the cup Tighten the retaining ring Tightening torque 13 16Nm 1 3 1 6kgf m 5 Bleed the fuel system Refer to 2 2 3 3 2 Fuel filter element replacement E ruel retum Nose Replace the fuel filter element
45. 0 15 0 30 Ring groove width 1 540 1 560 Ring width 1 470 1 490 2 3TNV70 Second ring Side clearance 0 050 0 090 End clearance 0 18 0 33 Ring groove width 3 010 3 030 Ring width 2 970 2 990 Oil ring Side clearance 0 020 0 060 End clearance 0 20 0 45 Ring groove width 1 550 1 570 Ring width 1 470 1 490 Top ring Side clearance 0 060 0 100 End clearance 0 15 0 30 Ring groove width 1 580 1 595 Ring width 3TNV76 Second ring 1 430 1 450 Side clearance 0 013 0 165 End clearance 0 18 0 33 Ring groove width 3 010 3 025 Ring width 2 970 2 990 Oil ring Side clearance 0 020 0 055 End clearance 0 20 0 45 117 11 Service Standards 5 Connecting rod mm Inspection item Standard Limit Reference page Thrust clearance 0 2 0 4 4 4 4 Rod small end Item Standard Reference page Bushing inside diameter 22 025 22 038 Pin outside diameter 21 991 22 000 4 4 5 5 Clearance 0 025 0 047 6 Tappet Inspection item Standard Reference page Tappet hole block inside diameter 21 000 21 021 Tappet stem outside diameter 20 927 20 960 4 4 5 6 Clearance 0 040 0 094 11 3 Lubricating Oil System Trochoid Pump 1 Outside clearance of outer rotor mm Standard Limit Reference page 0 12 0 21 0 30 5 5 1
46. 1 2 3 Disassembly procad re i itio nte dee c ERE Re 95 7 2 4 Reassembly 44404440 n nnnn nns nnhsn nnns nnns nnn 95 7 2 5 Confirmation and adjustment of the fuel injection timing 96 7 2 6 Confirmation and adjustment of the no load maximum minimum engine speed 96 8 The specifications of a starting motor and the characteristics 97 8 1 The specifications and the 97 1 SpecifICatiOnis d iei e ye e eee eet ies 97 8 1 2 CharacteriStiCS 2 i ee ete E Ee Ke ERE eR ER FRE XE KR ER 97 8 2 The structure of a starting motor and the wiring diagram sse 98 9 2 1 Structure dedidit Heo b Oe bts 98 8 2 2 Wiring diagram of a starting 99 Oi SP OMOMMAN CS 2 2 certes en E ERSTER RR ERE 99 SCALT EIR INA OR Cc 100 9 1 20A Alternator cc tre en eta et e Y Re VE VeL E E e perde vu E ERR 100 9 4 1 Specifications etr tes e f itta teta ied i He taba rt e 100 9 1 2 Str etUre etes tet Eee ol or e utitur did Haase ui feret 101 91 3 Wirlnig dlagralTis E tete HR E Bee LEX aen 102 9 1 4 Standard output characteristics
47. 1 3 Valve spring Inclination 2 Valve rocker arm Mainly inspect valve head cap contact surface inside surface defects and wear Slight surface defects shall be corrected with an oilstone Items Standard Arm hole diameter 12 000 12 020 Shaft O D 11 966 11 984 Clearance 0 016 0 054 3 Rocker arm shaft Mainly inspect seizure and wear at the surface in sliding contact with the arm The rocker shaft diameter shall be as specified in 5 above Rocker arm shaft outside diameter 65 4 Disassembly Inspection and Reassembly of Engines 7 Push rod Mainly inspect the surface in contact with the tappet and adjusting screw Slight defects shall be corrected with an oilstone Bend limit 0 03mm or less 8 Valve clearance adjusting screw Mainly inspect the surface in contact with the push rod Slight defects shall be corrected with an oilstone Thickness gage 9 Rocker arm spring Push rod bend Mainly inspect surface defects and corrosion 4 2 6 Valve seat correction NOTICE Always check the oil clearance between the valve and valve guide before correcting the valve seat If it exceeds the limit replace the valve or valve guide first to make the clearance satisfy the standard After correction wash the valve and the cylinder head sufficiently with diesel fuel oil to remove all grinding powder or compound 1 If the seat surface is slightly roughened perform A and B
48. 11 966 11 984 4 2 5 5 Clearance 0 016 0 054 5 Push rod mm Inspection item Standard Limit Reference page Bend 8 0 03 4 2 5447 114 11 Service Standards 11 2 2 Gear train and camshaft 1 Camshaft Inspection item Standard Reference page Side gap 0 05 0 15 4 3 4 Bending 1 2 the dial gage reading 0 0 02 Cam height 34 135 34 265 Shaft outside diameter Metal inside diameter Bushing inside diameter 40 000 40 075 Gear side Camshaft outside diameter 39 940 39 960 Clearance 0 040 0 135 Bushing inside diameter 40 000 40 025 us a Camshaft outside diameter 39 910 39 935 Clearance 0 065 0 115 Bushing inside diameter 40 000 40 025 Camshaft outside diameter 39 940 39 960 Clearance 0 04 0 085 4 3 5 1 Wheel side No bushing 2 Idle gear shaft and bushing mm Inspection item Standard Limit Reference page Shaft outside diameter 45 950 49 975 45 900 Bushing inside diameter 46 000 46 025 46 075 4 3 5 2 Clearance 0 025 0 075 0 175 3 Backlash of each gear Inspection item Standard Reference page Crank gear cam gear idle gear fuel injection pump gear and PTO gear 0 06 0 12 4 3 4 115 11 Service Standards 11 2 3 Cylinder block 1 Cylinder block Inspection item Standard Reference page 2 3TNV70 70 010 70 020 Cylinder inside diameter 3TNV76 76 010 76 020 Rou
49. 4 0 84 Loaded Clutch system Overrunning Pinion projection voltage at 100 C 8 0 or less Pinion DP or module number of teeth M2 54 9 Application Standard 8 1 2 Characteristics e E 2 STARTER t lt STANDARD PERFORMANCE 12V 1 1kW LLI a 2 5 9 amp a a 5 e gt 6000 24 12 12 y m 5000 20 1 0 10 Tim 4000 16 2 08 8 3000 124 06 6 2000 84 04 4 11 1000 4 0 2 2 HL 0 0 0 0 0 100 200 300 400 500 CURRENT A 8 The specifications of a starting motor and the characteristics 8 2 The structure of a starting motor and the wiring diagram 8 2 1 Structure 1 Disassembly drawing 2 Structure When the starting switch is turned on a magnet switch takes a voltage and a pinion projects The pinion engages with the ring gear of a engine and the engine is started Magnetic switch Shift lever EZ 2 AY S Yoke Assy End flame cover 98 8 The specifications of a starting motor and the characteristics 8 2 2 Wiring diagram of a starting motor 1 When a starting switch is turned on a magnet switch is charged and a moving core is absorbed Starting switch and a pinion clutch is moved forward through a lever and the
50. E APPLIED 5 IN CASE OF WATERPROOF CONNECT OR APPLICATION CONNECTOR SHOULD THE ALTERNATOR L AND P LINE BE FIXED BY FITTING TO PREVENT LEAD WIRE BREAK IT 18 NOT ALLOWED TO CONNECT ANY LOAD 6 IN CASE OF EMARGENCY STOP OF MACHINE FOR SAFETY WILL BE APPLIED UNSPECIFIED WITHOUT YANMAR APPROVAL SWITCH LOCATION SHOULD BE SHUWN AS A 4 SESE ESTEE ee 7 IN CASE OF THE SOLENOID CIRCUIT RESISTANCE WOULD BE LIMIT Es WIRING IS APPLICABLE ERRONEOUS OPERATIONS AND CONFIRM THE CIRCUIT NO SURGE OCCURS ESPECIALLY PROVIDE THE FLYWHEEL DIODE FOR REMARKS G LOAD AND ALODE FOR 1 1 0AN 1 X MARKED PARTS NOT PROVIDED BY YANMAR 108 10 Electric Wiring 10 1 1 Alternator In the cases listed below the warranty shall not be deemed to apply Please be sure to read these conditions carefully when planning to use it with other equipment Also be certain to give appropriate guidance on usage to the user 1 When the battery cable can be connected backwards The alternator diode will be damaged and recharging made impossible if the plus and minus ends of the battery cable are confused The stator coil will also be burned as a result To prevent this supply the user with a cable of such a length or structure that the plus and minus ends cannot be confused Also warn the user not to connect the cable backwards 2 When charging output voltage is used for control purposes The engine speed at starting is not proportional to th
51. ES RELAY n X 11208 YAZAKI NO 406 B IRIRE C 1123 2228 KEENE PRE HEATING O O FUSIBLE LINK 5 FOR 3TNV82A 0 850 FF FOR 4 84 lt 88 84 T gt 88 n STARTER MOTUR STARTER MOTOR N O DC12V_1 4KW DC12V_1 2KW z 2 129407 77010 129129 77010 NIAZAKI WO START I6 208 GROUND SHOULD BE 20A KEY SW DIAGRAM AEN CONNECTED TO ekinen FUSE DC12V DIRECTLY NOTES A RM E m 1 WIR 1 F S ER MUST BE BS RVE AS F LI WS TIMER H x pii YAZAKI NO YAZAKI NO avs IHERWISE CAUSES MISS STARTING DAMAGE ea TUSOD T YAZAKI YAZAKI NO X L 7123 2037 00 7122 22370 B F S R UM UC BA 7122 2046 7123 2249 1 1 1 TOTAL ELECTRIC RESISTANCE OF BATTERY HE mn x ur SOLENOID DCi2V CABLE D4Q SHOULD BE LESS THAN 2 10000 B R DETAIL A YAZAKI NO 119643 66900 HDD 0225 REFERENCE BE 1123 22208 OTS ES CURRENT Ov 9653 77950 25 53 m 254 m 1 2 TOTAL ELECTRIC RESISTANCE OF WIRING FOR 15sec IFD NOTES FOR ENGINE STOP SOLENOID STARTER 9 0 SHOULD BE LESS THAN 5 1000 1 PERMISSIBLE RESISTANCE OF SOLENOID CIRCUIT REFERENCE OF TER AL RESISTANCE SHOULD BE LESS THAN 0 070 TO GUARANTEE PERMISSIBLE PALE ee Tn LOWEST VOLTAGE 9V TO WORK SOLENOID PULL COIL E RS E EET ENTE Th CORRECTION SHALL ava TERMINAL RESISTANCE 15 10000 PER COUPLER 3 L 00
52. IV lf 9961 02 070 YANMAH SERVICE MANUAL INDUSTRIAL DIESEL ENGINE Z2TNV STNV series Indirect Injection System MODEL 2TNV7O 3TNV7O 3TNV76 YANMAR CO LTD Publication No M9961 02E070 History of Revision Manual Name Service Manual for Industrial Diesel Engine Engine Model 2TNV 3TNV series Indirect Injection System Number Date Reason for Correction item Corrected of il 1 1 revision revision correction Outline of correction No page by New edition September 2003 Printed in Japan M9961 02E070 PREFACE This manual describes the service procedures for the TNV series engines of indirect injection system that have been certified by the US EPA California ARB and or the 97 68 EC Directive for industrial use Please use this manual for accurate quick and safe servicing of the said engine Since the explanation in this manual assumes the standard type engine the specifications and components may partially be different from the engine installed on individual work equipment power generator pump compressor etc Please also refer to the service manual for each work equipment for details The specifications and components may be subject to change for improvement of the engine quality without notice If any modification of the contents described herein becomes necessary it will be notified in the form of correction information eac
53. N CONTROL SYSTEM EM FUEL RATE CE MM STROKE RPM EFER TO OWNERS MANUAL FOR MAINTENANCE SPECIFICATIONS AND ADJUSTMENTS YANMAR CO LTD 12 IMPORTANT ENGINE INFORMATION THIS ENGINE CONFORMS TOCA MODEL YEAR U 5 EPA REGULATIONS NONROAD COMPRESSION IGNITION ENGINES THIS ENGINE 5 CERTIFIED TO OPERATE ON US 2D FUEL ENGINE FAMILY _____C____ DISPLACEMENT LD LITERS ENGINE MODEL ____E____ EMISSION CONTROL SYSTEM FUEL RATE CG MM STROKE REFER TO OWNERS MANUAL FOR MAINTENANCE SPECIFICATIONS AND ADJUSTMENTS YANMAR CO LTD EPA label for variable speed engines 1 General 1 6 3 Guarantee Conditions for the EPA Emission Standard The following guarantee conditions are set down in the operation manual addition to making sure that these conditions are met check for any deterioration that may occur before the required periodic maintenance times 1 Requirement on engine operation condition a Intake air depression kPa mmAq Initial Permissible lt 2 94 300 lt 6 23 635 b Exhaust gas back pressure kPa mmAq Initial Permissible lt 12 75 1300 lt 15 30 1560 2 Fuel oil The diesel fuel oil US No 2 diesel fuel oil 3 Tamper resistance Sealing cap Do not remove the seals rest
54. Radiator Lubrication system Forced lubrication with trochoid pump Starting system Electric Diesel oil BS 2869 A1 or A2 Applicable fuel Cetane No 45 min Applicable lubricant API grade class CD Lubricant Total L 3 8 2 8 capacity oil pan Effective L 1 7 1 3 Cooling water capacity L 0 9 engine only Engine Overall length mm 463 Dimensions with flywheel Overall width mm 436 housing Overall height 536 506 Engine mass dry with flywheel housing kg 2p Cooling fan std mm 310 mm O D 5 blades pusher type Crankshaft V pulley diameter mm 110 amp 100 amp Fun V pulley diameter std tems marked may differ from the above depending on an engine installed on a machine unit Engine mass and dimensions without radiator 1 General 3TNV70 continue Engine name Unit 70 Engine specification class VM Type Vertical in line 4 cycle water cooled diesel engine Combustion chamber Indirect injection Number of cylinders 3 Cylinder borexstroke 70x74 mm Displacement L 0 854 Revolving min _ Continuous speed rating kW Output NET utput NET ps 2000 2100 2200 2300 2400 2500 2600 2700 2800 2900 3000 Rated Outout NET kW 90 95 100 105 110 114 118 124 128 132 137 put NET
55. TIONS A WARNING WARNING p WARNING A WARNING If rn e Fueling Refueling Keep sparks open flames or any other form of ignition match cigarette etc away when fueling refueling the unit Fire and or an explosion may result e Hot Surfaces Do NOT touch the engine or any of its components during running or shortly after shutting it down Scalding serious burns may result Allow the engine to cool down before attempting to approach the unit e Rotating Parts Be careful around moving rotating parts Loose clothing jewelry ties or tools may become entangled causing damage to the engine and or severe personal injury Preventing burns from scalding 1 Never open the radiator filler cap shortly after shutting the engine down Steam and hot water will spurt out and seriously burn you Allow the engine to cool down before attempt to open the filler cap 2 Securely tighten the filler cap after checking the radiator Steam can spurt out during engine running if tightening loose Precautions for Service Work 1 Precautions for Safety Read the safety precautions given at the beginning of this manual carefully and always mind safety in work 2 Preparation for Service Work Preparation is necessary for accurate efficient service work Check the customer ledger file for the history of the engine Preceding service date Period operation hours after preced
56. ace the stem seal with a new one when an intake exhaust valve is disassembled Carefully install each valve after oil application so as not to damage the stem seal Different stem seals are provided for the intake and exhaust valves Do not confuse them since those for exhaust valves are marked with yellow paint After assembling the intake exhaust valve stem seal valve spring seat and cotter tap the head of the valve stem lightly for settling Do not forget to install the valve cap Camshaft side Fan side 62 4 Disassembly Inspection and Reassembly of Engines 4 2 5 Parts Inspection and measurement 1 Cylinder head Clean the cylinder head mainly the combustion surface valve seats and intake exhaust ports remove carbon deposit and bonding agent and check the surface state a Appearance check Check mainly discoloration and crack If crack is suspected perform color check b Combustion surface distortion Apply a strait edge in two diagonal directions and on four sides of the cylinder head and measure distortion with a thickness gage Standard Limit Distortion 0 05 or less 0 15 c Valve sink Measure with the valve inserted to the cylinder head mm Standard Limit Intake 0 4 0 6 0 8 Exhaust 0 4 0 6 0 8 d Seat contact Apply a thin coat of minium on the valve seat Insert the valve in the cylinder and push it against the seat to check seat contact S
57. aft Journal machining dimension mm Journal machining dimension 46 702 46 712 80 4 Disassembly Inspection and Reassembly of Engines Dimension R and finishing precision of crankshaft journal and pin As for grinding processing of journal and pin machine it by using the grinding wheel of the dimension R of below table mm Finishing precision standard of dimension R 35 Surface finishing precision standard on journal pin Ry 0 8S super polishing Surface finishing precision standard on the thrust 1 6 side of crankshaft arm NOTICE 1 If the oil clearance is excessive though the thickness of the journal and crankpin metals are normal or if partial uneven wear is observed re grind the crankshaft and use an undersized metals 2 If rust or surface roughening exists on the rear side of the metals coat it with blue or minimum Then assemble the crankpin metal to the connecting rod and tighten the rod bolt to the specified torque to check the metal for contact If the contact surface occupies 75 or more the metal is normal If the contact surface is insufficient the metal interference is insufficient Replace the metal with a new standard one 3 Thrust metal inspection a Inspect any damage or wear b Measure side gap and thrust metal thickness Side gap and thrust metal thickness mm Side gap Thrust metal thickness Standard Limit Standard Limit 0 111 0 250 1 930 1 980 1
58. age the bearing bushing Rotate the camshaft a few turns before extracting it to prevent the tappet from being caught by the cam After removing the camshaft set the engine horizontal and fix it on the base A CAUTION Unforeseen injury may arise due to falling of slipping when raising the engine vertically or returning it to the horizontal position Proceed carefully so as not to lose balance Camshaft side gap Points Reassemble Do not forget to install the oil pan mounting bolts on the bottom side when installing the gear case Apply sealant code No 977770 01212 and install the gear case by matching the two dowel pints 70 4 Disassembly Inspection and Reassembly of Engines 4 3 5 Parts inspection and measurement 1 Camshaft Mainly check the contact between the tappet and cam contact surface bearing seizure and wear and gear damage a Shaft bend measurement Support the camshaft with V blocks Rotate the camshaft and measure the distortion at the center of the camshaft and at each journal with a dial gage Half of the distortion is the bend Item Standard Limit Bend 0 0 02 0 05 b Intake exhaust cam height measurement Model Standard 2 3TNV70 34 535 34 665 3TNV76 34 135 34 265 Cam height c Camshaft outside diameter and bearing hole diameter measurement Measure the camshaft outside diameter with a micrometer The oil clearance shall be calculated by su
59. ally a terminal resistance is 15mQ per coupler and 0 per screw setting This resistance should be included in allowable maximum resistance when the cable length is planned 112 11 Service Standards 11 SERVICE STANDARDS 11 1 Engine Tuning No Inspection item Standard Limit Reletence page 1 Gap at intake exhaust valve heads 0 15 0 25 _ 2 2 6 3 Between alternator Used part 10 14 and crank pulley Direction A New part 8 12 S V belt tension Between alternator Used part 7 40 z 2 mm and radiator fan 2 2 2 2 at 98N 10kgf Direction S New part 5 8 Between radiator Used part 90 43 5 fan and crank pulley Direction C New part 7441 Fuel injection pressure 11 8 12 8 MPa kgf cm 120 130 2 2260 Fuel injection timing FID Refer to 2 2 7 4 z 1 degrees bTDC in chapter 2 22100 Compression pressure 2 3TNV70 3 24 33 0 1 1 2 55 26 0 1 1 5 at 250 3 3 MPa kgf cm 3TNV76 3 43 35 0 1 1 2 75 28 0 1 1 Cooling water Capacity 2TNV70 0 6 P 6 Only engine body 2 2 1 4 Liter 3TNV70 76 0 9 Model Total Effective 2TNV70 VM 1 7 0 7 Lube oil capacity 3TNV70 VH VM 2 8 1 3 7 oil pan 2 2 1 3 Liter 3TNV70 CH 3 8 1 7 3TNV76 VM VH 3 5 1 6 3TNV76 CH 4 4 2 1 at low idle 8 Lube oil pressure speed speed j MPa kgf cm 0 06 0 6 or 0 29 3 0 0 44 4 5
60. ar Camshaft Tj 23 Cool t oolng water pump gt XY Sey Camshaft driving gear YO Fuel injection pump 459 6 ZRI Pump flange Don t disassemble Fuel pump drive gear Flange bolt Note This figure shows the 3TNV76 Crankshaft pulley 4 3 2 Disassembly procedure Disassemble in the order of the numbers in the illustration 1 Perform steps 1 to 12 of the cylinder head disassembly procedure 2 Remove the cooling water pump 3 Remove the crankshaft pulley See Point 1 of 4 3 4 4 Remove the gear case See Point 2 of 4 3 4 5 Remove the fuel injection pump See Point 3 of 4 3 4 6 Remove the idle gear assy See Point 4 of 4 3 4 7 Remove the PTO drive gear See Point 5 of 4 3 4 8 Remove the starting motor 9 Remove the flywheel See Point 6 of 4 3 4 10 Remove the camshaft assy See Point 7 of 4 3 4 11 Remove the gear case flange See Point 8 of 4 3 4 12 Remove the oil seal from the gear case See 4 3 6 4 3 3 Reassembly procedure Reverse of the disassembly procedure 68 4 Disassembly Inspection and Reassembly of Engines 4 3 4 Servicing points Point1 Disassemble Remove the crankshaft pulley using a gear puller after removing the crankshaft pulley set bolt When removing the pulley using the gear puller use a pad and carefully operate so as not to damage the thread Set the gear puller securely to prevent the pulley from being
61. ard level replace the pressure adjusting shim with a thicker one Thickness of pressure adjusting shims Injection pressure adjustment mm The injection pressure is increased by approx 0 1 0 2 0 3 0 4 0 5 6 9 9 8MPa 7 10kgf cm when the adjusting shim thickness is increased by 0 1 mm 33 2 Inspection and Adjustment Informative Fuel injection valve structure Nozzle holder Pressure adjusting shim Ene spring spring seat Valve stop spacer in Nozzle valve Nozzle E Nozzle body Nozzle case nut b Spray pattern inspection After adjustment to the specified valve opening pressure use a nozzle tester and check the spray pattern and seat oil tightness Seat oil tightness check After injecting a few times increase the pressure gradually Hold the pressure for about 5 seconds at a little before the valve opening pressure of 1 96 Mpa 20kgf cm and check to see that oil does not drip from the tip end of the nozzle f extreme oil leak from the overflow joint exists during injection by the nozzle tester check after retightening If much oil is leaking replace the nozzle assembly 34 2 Inspection and Adjustment Spray and injection states Operate the nozzle tester lever at a rate of once or twice a second and check no abnormal injection If normal injection as shown below cannot be obtained replace the fuel injection valve No extreme diffe
62. aust color and starting failure at the same time 4 After presuming a probable cause based on the above investigation investigate a cause systematically by the next troubleshooting guide and find out the cause of sincerity 42 3 Troubleshooting 3 2 Quick Reference Table for Troubleshooting The following table summarizes the general trouble symptoms and their causes Engine system Trouble symptom Improper clearance of intake exhaust valve Starting failure Insufficient engine output Poor exhaust color Engine starts but stops soon Exhaust color During work Exhaust smoke High knocking sound during combustion Uneven combustion sound Hunting During idling During work Large engine vibration Difficulty in returning to low speed Excessive fuel consumption Lube oil Cooling water Air intake Excessive consumption Dilution by fuel oil Mixture with water Low L O pressure Much blow by gas Low water temperature Overheat Pressure rise If any trouble symptom occurs take corrective action before it becomes a serious problem so as not to shorten the engine service life Corrective action O Engine does not start Adjust the valve clearance See 2 2 6 3 in Chapter2 Compression leakage from valve seat O Exhaust temperature rise Lap the valve seat See 4 2 6 in Chapter4 Seizure of intake exhaust valve
63. below A Lap the valve and seat with a mixture of valve compound and lube oil y x 40 Seat width 8 with lube oil only Seat angle 2 If the seat is heavily roughened but the width is almost normal correct with a seat grinder or seat cutter first Then perform lapping A and B xin Seat cutter intake Exhaust Seat cutter angle Cylinder head correction angle 3 If the seat is heavily roughened and the width is much enlarged grind the seat inner surface with a seat grinder whose center angle is 40 then grind the seat outer surface with a grinder whose center angle is 150 to make the seat width match the standard Then perform seat correction as described in 2 and then carry out lapping A and B 01 02 40 150 Grindstone Grinding wheel angle Seat grinder 4 Disassembly Inspection and Reassembly of Engines 4 2 7 Valve guide replacement 1 Use a valve guide extraction tool 4 1 2 1 No 1 in Chapter 4 and extract the valve guide from the Valve guide extracting cylinder head amp inserting tool 2 Put liquid nitrogen or ether or alcohol with dry ice added in a container and put the valve guide for replacement in it for cooling Then insert it in with a valve guide inserting tool Refer to No 2 of Cylinder head 4 1 2 1 in Chapter 4 A CAUTION Do not touch the cooled valve guide with bare hands to avoid skin damage Valve guide Projection
64. btracting the measured camshaft outside diameter from the camshaft metal inside diameter after insertion to the cylinder measured with a cylinder gage Place Item Standard Metal I D 40 000 40 075 Gear side Camshaft O D 39 940 39 960 Oil clearance 0 040 0 135 Metal I D 40 000 40 025 Intermediate position Camshaft O D 39 910 39 935 Oil clearance 0 065 0 115 Metal I D 40 000 40 025 Wheel side Camshaft O D 39 940 39 960 Oil clearance 0 04 0 085 71 4 Disassembly Inspection and Reassembly of Engines 2 Idle gear Mainly check the metal seizure and wear and gear damage Shaft outside diameter and metal inside diameter measurement Idle gear Shaft outside diameter Metal inside diameter Idle gear Item Standard Shaft outside diameter 44 950 44 975 Metal inside diameter 45 000 45 025 Clearance 0 025 0 075 3 PTO drive gear Mainly check sticking of bearings on both sides gear damage and looseness and gear shaft damage and wear 4 3 6 Oil seal replacement 1 Replace the oil seal with a new one when the gear case is disassembled Crankshaft Gear case Extract the used oil seal pulley 2 Insert a new oil seal by using the oil seal insertion tool on the position of the gear case end face Refer to the right figure 3 Apply lithium grease to the oil seal lips 4 When wear is found on the oil seal contact part of a crankshaft pull
65. clearance measurement Except for the top ring to measure the piston ring Top ring groove width first measure the width of the piston ring Then insert the piston ring into the ring Then insert the piston ring into the ring groove Insert a thickness gage in between the piston ring and groove to measure the gap between them Obtain the ring groove width by adding ring width to the measured side clearance To measure the end clearance push the piston ring into the sleeve using the piston head insert a thickness gage in end clearance to measure The ring shall be pushed in to approx 30 mm above the bottom end of the cylinder For the top ring measure only the piston ring joint end clearance in normal state Second ring Oil ring Pistonring Approx 30mm Thickness Measuring side clearance Joint end clearance Ring joint end clearance measurement 83 4 Disassembly Inspection and Reassembly of Engines Piston ring dimension Item Standard 2 3TNV70 Top ring Ring groove width 1 550 1 570 Ring width 1 470 1 490 Side clearance 0 060 0 100 End clearance 0 15 0 30 Second ring Ring groove width 1 540 1 560 Ring width 1 470 1 490 Side clearance 0 050 0 090 End clearance 0 18 0 33 Oil ring Ring groove width 3 010 3 030 Ring width 2 970 2 990 Side clearance 0 020 0 060 End clearance 0 20 0 45
66. d the wrong way around This causes charging malfunctioning and burns the harness Give the user a cable of such a length that it cannot be connected the wrong way and warn the user against connecting the cable backwards 5 Non use of the Yanmar wiring diagram Use without prior consultation of any wiring diagram other than that provided by Yanmar removes any breakdown of any electrical equipment from the warranty 6 Installation environment Observe the following when installing the current limiter 1 Do not install it on the engine 2 Place it in a well ventilated place with an ambient temperature of 65 C or less 3 Ensure that the cooling air flows in the right direction for the current limiter s cooling fins 4 Do not use the earth wire of the current limiter to earth any other electrical equipment 111 10 Electric Wiring 10 1 4 Section area and resistance of electric wire 1 Allowable maximum cable length Terminal resistance is not included bl tructi Cable size Resistance 2 mm Element No Cable dia 41 0 32 0 005590 65 0 32 0 003520 50 0 45 0 002320 84 0 45 0 001380 41 0 80 0 000887 70 0 80 0 000520 85 0 80 0 000428 0 80 0 000337 0 000287 0 000215 0 000168 Note1 Allowable maximum resistance of Battery cable Note2 Allowable maximum resistance of Starting motor circuit 2 Terminal resistance Gener
67. d to 8V or less 2 When checks for malfunctioning are not performed When high voltage noise from other electrical equipment is impressed on the current limiter upon turning off the key switch the current limiter can be damaged and cause loss of control over the output voltage Other electrical equipment may also be damaged if this happens so surge killers should be fitted to the electrical equipment whenever necessary Be sure to check prior to mass production whether electrical noise might damage the current limiter by turning the key switch and other electrical equipment on and off while the engine is running using both the vehicle and the wire harness that will be used in mass production 3 Removal of the battery cable during operation The current limiter may malfunction if the battery cable and or battery are removed during operation depending on the kind of electrical equipment being used causing loss of control over the output voltage In such cases the current limiter and other electrical equipment will be damaged by the generation of a continuous high voltage of 24 43V for 5 000rpm dynamo electrical equipment falls outside the scope of the warranty under these circumstances Be sure to warn the user not to remove the battery cable and or battery during operation 4 If the battery cable can be attached in reverse The current limiter s SCR diode will be destroyed if the plus and minus ends of the battery cable are connecte
68. damaged Reassemble When installing the crankshaft pulley apply lube oil to the set bolt to tighten and carefully assemble so as not to damage the oil seal NOTICE Clean by wiping off any oil on both taper surfaces of crankshaft and pulley using detergent N m kgf m Tightening torque 83 3 93 3 8 5 9 5 Material of pulley FC250 S48C 1134123 11 5 12 5 Point2 Reassemble Fuel injection pump drive gear When installing the gear case do not forget to install the two reinforcing bolts at the center Measure the backlash of each gear Camshaft gear Standard Crankshaft gear Camshaft gear 0 06 0 12 Fuel injection pump gear Idle gear PTO gear See ot Direction of rotation Apply sealant after checking that oil doesn t stick on either surface of the cylinder block and the gear case flange and also the gear case flange and the gear case Install the gear case by correctly positioning the two dowel pins Point3 Refer to 7 2 5 in chapter 7 Disassemble Gear train Remove the mounting nut of the fuel injection pump drive gear remove the gear using the gear puller and remove the fuel injection pump When extracting the gear using the gear puller use a 16 e Fuel injection pump pad at the shaft and carefully operate so as not to eS Ani damage the thread NOTICE Be sure to remove a flange and a drive gear with a pair without loose
69. dimension in 4 4 5 1 c Selective pairing of cylinder and piston Piston must be paired with cylinder according to the below table The size mark of a piston is shown on the top surface of the piston and the size mark of a cylinder block is shown on the non operating side of the cylinder block The service parts of pistons are provided mm Piston outside diameter D2 T lerarice 0 015 max below 0 005 below 0 below 0 005 0 005 min 0 min 0 005 min 0 015 min Size mark L ML MS S 0 030 max Cylinder 0 020 min L O O 2 di inside below 0 020 diameter 0 010 min O i D1 below 0 010 S x O O 0 min mm Model Cylinder inside diameter Piston outside diameter D1 D2 2 3TNV70 70 69 975 3TNV76 76 75 970 82 4 Disassembly Inspection and Reassembly of Engines b Piston pin and piston pin hole measurement Measure the outside diameter of piston pin and the Measure at positions a b and c inside diameter of piston pin hole Calculate the in directions A and B clearance between piston pin and piston pin hole If a b A 4 EE j t i any data exceeds the limit replace the part with a new Piston pin outside diameter one Standard 22 000 22 009 Pin O D 21 995 22 000 Measure at positions and b in directions A and B Clearance 0 000 0 014 Piston pin hole c Piston ring ring groove and end
70. e Note2 As for Model year the year which a regulation is applicable to is shown Transient smoke standards opacity Engine cassification acceleration lug peak modes Constant speed engine Not regulated Variable speed engine 20 15 50 or less 2 California ARB Emission Regulation The ARB emission standard is based on that of the EPA 11 1 General 1 6 2 Engine identification To identify the engines the following emission control labels are affixed on the engines 1 Emission control labels of US EPA IMPORTANT ENGINE INFORMATION THIS ENGINE CONFORMS TOCA MODEL YEAR U S REGULATIONS NONROAD C 1 ENGINES CONSTANT SPEED ONLY THIS ENGINE 5 CERTIFIED TO OPERATE ON US 2D FUEL ENGINE FAMILY C DISPLACEMENT 77 LITERS ENGINE MODEL E EMISSION CONTROL SYSTEM FUEL TRPM REFER TO OWNERS MANUAL FOR MAINTENANCE SPECIFICATIONS AND ADJUSTMENTS YANMAR CO LTD EPA label for constant speed engines 2 Emission control label for both EPA and ARB IMPORTANT ENGINE INFORMATION HIS ENGINE CONFORMS TOCH Y CALIFORNIA AND U S EPA REGULATIONS FOR OFFROAD C 1 ENGINES THIS ENGINE IS CERTIFIED TO OPERATE ON Type 2 D FUEL ENGINE FAMILY _____B____ DISPLACEMENT C LITERS ENGINE MODEL EMISSIO
71. e clearance Adjust the valve clearance See 2 2 6 3 in Chapter 2 Cylinder head gasket Gas leak from gasket Replace the gasket e Retighten the cylinder head bolts to the specified torque See 4 2 4 point 8 in Chapter 4 Intake exhaust valve Gas leak due to worn valve the valve seat Valve seat seat or foreign matter See 4 2 6 in Chapter 4 trapping Replace the intake exhaust valve e Sticking valve Piston Gas leak due to scratching Perform honing and use an oversized Piston ring or wear part Cylinder See 4 4 5 and 4 4 6 in Chapter 4 47 4 Disassembly Inspection and Reassembly of Engines 4 Disassembly Inspection and Reassembly of Engines 4 1 Complete disassembly and reassembly 4 1 1 Introduction Make preparation as follows before starting engine inspection and service 1 Fix the engine on a horizontal base A WARNING Be sure to fix the engine securely to prevent injury or damage to parts due to falling during the work 2 Remove the cooling water hose fuel oil pipe wire harness control wires etc connecting the driven machine and engine and drain cooling water lube oil and fuel 3 Clean soil oil dust etc from the engine by washing with solvent air steam etc Carefully operate so as to prevent any foreign matter from entering the engine A WARNING Always wear glasses or other protectors when using compressed a
72. e good performance for example are shown below TEXACO LONG LIFE COOLANT ANTIFREEZE both standard and pre mixed Product codes 7997 and 7998 HAVOLINE EXTENDED LIFE ANTIFREEZE COOLANT Product code 7994 IMPORTANT e Be sure to add Long Life Coolant Antifreeze LLC to soft water In cold season the LLC is especially important Without LLC cooling performance will decrease due to scale and rust in the cooling water line Without LLC cooling water will freeze and expand to break the cooling line e Be sure to use the mixing ratios specified by the LLC manufacturer for your temperature range Do not mix different types brand of LLC chemical reactions may make the LLC useless and engine trouble could result e Replace the cooling water every once a year When handling Long Life Coolant Antifreeze wear protective rubber A CAUTION gloves not to touch it If LLC gets eyes or skin wash with clean water at once 1 General 1 4 Engine External Views Lifting eye Cooling water pump Fuel filter Air intake port from air cleaner Intake manifold Fuel injection pump Governor lever Fuel oil inlet Bonnet Rocker arm cover Exhaust manifold Starter motor 0l Starting performance improvement Applying super quick glow plug Emission Reduction Noise Reduction New combustion chamber Taper throttle nozzle Emission Reduction New small in line fuel pump Revised ML type Precision
73. e oil filler cap to drain easily while drainig the lube oil Loosen the drain plug using a wrench customer procurec 8 lube on The location depends the engine Securely tighten the drain plug after draining the installed on the machine unit lube oil NOTICE Use a socket wrench or a closed wrench when removing or tightening a drain plug Don t use a spanner because it has the possibility that the spanner will slip and it will get hurt b Replacing oil filter Turn the lube oil filter counter clockwise using filter wrench customer procured to remove it Clean the mounting face of the oil filter Moisten the new oil filter gasket with the lube oil and install the new lube oil filter manually turning it clockwise until it comes into contact with the mounting surface and tighten it further to 3 4 of a turn with the filter wrench Tightening torque 20 24N m 2 0 2 4kgf m Applicable oil filter Part No 119305 35150 19 2 Inspection and Adjustment c Filling oil and inspection Fill with new lube oil until it reaches the specified level IMPORTANT Do not overfill the oil pan with lube oil Be sure to keep the specified level between upper and lower limit on the dipstick Warm up the engine by running for 5 minutes while checking any oil leakage Stop the engine after warming up and leave it stopping for about 10 minute to recheck the lube oil level with dipstic
74. e output voltage of the alternator so this output voltage must not be used for any control systems It is especially wrong to use it for the control signal of the safety relay for cutting the starting motor because this will damage the starting motor and cause engine starting failure 3 When the L line is used for control purposes Consult with Yanmar first before connecting any load other than the charge lamp to the L line Damage to the alternator and related equipment will not be warranted without such prior consultation 4 Non use of the Yanmar wiring diagram Use without prior consultation of any wiring diagram other than that provided by Yanmar removes any breakdown of any electrical equipment from the warranty 5 Regarding lamp control Once the charge lamp goes out after the start of charging it does not come on again even if the engine speed falls and charging is insufficient The lamp will not light again if the charging circuit is normal The lamp only comes on during operation if the alternator itself is broken or the drive V belt breaks However when an LED is used for the charge lamp the LED will shine faintly even during normal operation This is due to the control system for the alternator lamp and is not an abnormality 6 Use of a non specified V belt Use of a non specified V belt will cause inadequate charging and shorten the life of the belt Usea belt of the specified type 7 Direct high pressure washing is prohibit
75. e the combustion surface 2 The order of loosening the cylinder head tightening bolts Disassembly Camshaft side 2 oL e oso 8 es 6 38 Head bolt disassembly order 3 cylinder head Fan side Disassembly Camshaft side 2 2 Head bolt disassembly order 2 cylinder head 3 To remove the intake exhaust valves from cylinder head assembly take the following steps 8 Using a valve spring compressor see 4 1 2 1 No 4 in Chapter 4 compress a valve spring and remove a valve cotter b Remove valve retainer and valve spring c Remove intake valve and exhaust valve 1 Remove crankshaft V pulley clamping bolt 2 Using a puller extract crankshaft V pulley 1 Extract crankshaft V pulley by hitting the bolt of the puller using a plastic hammer or the like 1 Remove oil pan mounting bolts under a gear case 2 Remove gear case mounting bolts 3 Remove a gear case 1 Never fail to removes stiffner bolt at the center of the gear case 2 When removing the gear case carefully protect oil seal from damage 1 Remove the nut from fuel injection pump drive gear Extract the fuel injection pump drive gear using a puller 1 Before removing fuel injection pump make sure of the position of the arrow on the pump body for adjusting fuel injection timing as well as the position of the scribed line of the gear case flange 1 Remove a lube oil pump
76. ead bolts in two steps in the Camshaft side illustrated order e a Place the cylinder head assy a paper board to _ prevent the combustion face from any damage 4 42 5 Reassemble 9 Remove the head gasket with a new one Uniformly install the head bolts manually after applying oil on the threaded and seat portions They shall be tightened in two steps in the reverse Disassembly Camshaft side of the order for disassembly Head bolt tightning order 3 cylinder head Nm kgf m Tightening torque First step 26 0 30 0 2 7 3 1 Fan side Head bolt disassembly order 2 cylinder head Second step 53 9 57 9 5 5 5 9 Point 9 Assembly Disassemble Carefully remove the fuel injection valve so as not to leave the top end protector from being left inside the cylinder Reassemble Replace the fuel injection valve protector with Head bolt tightning order new one 2 cylinder head Point 10 Disassemble When removing each intake exhaust valve from the cylinder head use a valve spring compressor see 4 1 2 No 4 in Chapter 4 and compress the valve spring and remove the valve cotter Keep each removed intake exhaust valve after attaching a tag showing the corresponding cylinder No If cotter burr is seen at the shaft of each spring Compressor intake exhaust valve stem remove it with an oilstone and extract the valve from the cylinder head Reassemble Repl
77. ed Water will enter the brush if the alternator is washed directly at high pressure causing inadequate charging Warn users not to use direct high pressure washing 8 Adhesion of agricultural and other chemicals direct contact or airborne Adhesion of agricultural and other chemicals especially those with high sulfur content to the IC regulator corrodes the conductor on the substrate leading to over charging battery boiling and charging malfunctions Consult with Yanmar prior to using the engine in such an environment Use without prior consultation removes any breakdown from the warranty 109 10 Electric Wiring 10 1 2 Starting motor In the cases listed below the warranty shall not be deemed to apply Please be sure to read these conditions carefully when planning to use it with other equipment Also be certain to give appropriate guidance on usage to the user 1 Starting performance in the case of using an untested battery The starting performance of the engine is closely dependent on the battery capacity This battery capacity is itself affected by the climate and the type of equipment installation details regarding ambient temperature and equipment installation vary depending on the OEM so Yanmar cannot decide the battery capacity on its own Confer with Yanmar in advance after checking these conditions and fix the battery capacity on the basis of confirmatory tests 2 When the resistance of the battery cable e
78. ee 4 2 2 2 in Chapter 4 2 Remove the crankshaft pulley See 4 3 2 3 in Chapter 4 3 Remove the gear case cover See 4 3 2 4 in Chapter 4 4 Remove the lube oil pump cover from the gear case cover Point 1 in 5 4 5 Remove the pressure regulating valve from the lube oil pump cover Point 2 in 5 4 5 4 Servicing Points Point 1 Disassemble Check if the pump rotates smoothly and see that there is no play between the shaft and gear and inner rotor Reassemble Rotor outer inner insertion part is to apply lube oil For installation on the gear case cover tighten the lube oil pump cover by the standard torque Nm kgf Lube oil application Tightening torque threaded portion and bearing seat surface 5 9 7 9 0 6 0 8 Lube oil applied When replacing the lube oil pump replace the whole assy including the outer inner rotor NOTICE Always check if the pump rotates smoothly after installation on the gear case cover Running the engine when the pump rotation is heavy may cause the pump to be burnt Point 2 Disassemble Reassemble Only wash the pressure regulating valve Disassembly is unnecessary unless any abnormality in operation is detected 89 5 Lubrication System 5 5 Parts Inspection and Measurement 5 5 1 Trochoid pump inspection and measurement 1 Outside diameter clearance and side clearance of outer rotor Gear case Insert a gap gauge between the outer rotor
79. er journal while rotating the shaft to inspect the bend The bend is half of the run out value 0 01mm or less Deflection Dial gage L V block V block Crankshaft bend measurement 79 4 Disassembly Inspection and Reassembly of Engines c Crankpin and journal measurement Measure the outside diameter roundness and taper at each crankpin and journal Correct by grinding if unevenly wear roundness exceeding the limit or insufficient outside diameter is found Replace if the defect is excessive Crankpin If a clearance is necessary measure the inside diameter by following 5 d Rod big end measurement and calculate it Item Standard Pin outside diameter 41 952 41 962 0 020 0 050 Oil clearance Roundness 0 01 or less If the oil clearance exceeds the limit use an undersized bearing Undersized bearing 0 25 mm Code No assy 119717 23610 Pin machining dimension mm Pin machining dimension 41 702 41 712 Crank journal Item Standard Crankshaft Journal Crankpin Measuring position of the crankpin and crank journal Journal O D 46 952 46 962 0 020 0 050 Oil clearance Roundness 0 01 or less If the clearance limit is exceeded use an undersized bearing and machine the crank journal into the value of the below table Undersized bearing 0 25mm Code No assy 119717 02870 Cranksh
80. er may be checked 9 If the injection timing is out of the standard value loosen the fuel pump mounting nut and incline the fuel injection pump toward or away from the engine for adjustment Incline toward the engine to delay the timing and away from the engine to advance it One graduation of the timing scale on gear case corresponds to two degrees in injection timing 37 2 Inspection and Adjustment 2 3 Adjusting the no load maximum or minimum speed 1 After warming the engine up gradually raise the speed and set it at the no load maximum speed 2 If the no load maximum revolution is out of the standard adjust it by turning the high idle limiting bolt 3 Then set the no load minimum speed by Tene adjusting the low idle limiting bolt High idling speed limiting bolt NS B Governor lever Accelerating wire bracket Low idling speed limiting bolt Standards Unit min Engine application class Rating speed minimum 2000 2160 2100 2250 2200 2355 2300 2460 2400 2570 2500 2675 2600 2780 2700 2890 2800 2995 2900 3100 3000 3210 3000 3600 3100 3200 3300 3400 3500 3600 Note The engine speed may differ from the above standard depending on an engine installed a machine unit 38 2 Inspection and Adjustment 2 4 Sensor Inspection 2 4 1 Oil pressure switch f Oil pressure switch Cylinder block
81. eshooting If the signs of a trouble appear it is important to lecture on the countermeasure and treatment before becoming a big accident not to shorten the engine life When the signs of a trouble appear in the engine or a trouble occurs grasp the trouble conditions fully by the next point and find out the cause of sincerity according to the troubleshooting Then repair the trouble and prevent the recurrence of the trouble 1 What s the occurrence phenomenon or the trouble situation e g Poor exhaust color 2 Investigation of the past records of the engine Check a client control ledger and examine the history of the engine Investigate the engine model name and the engine number Mentioned in the engine label Examine the machine unit name and its number in the same way When was the engine maintained last time How much period and or time has it been used after it was maintained last time What kind of problem was there on the engine last time and what kind of maintenance was done 3 Hear the occurrence phenomenon from the operator of the engine in detail 5WAH of the occurrence phenomenon the investigation of when when where where who who what what why why and how how When did the trouble happen at what kind of time Was there anything changed before the trouble Did the trouble occur suddenly or was there what or a sign Was there any related phenomenon ee e g Poor exh
82. et bolt and move the alternator to tighten the V belt 3 After replacing with a new V belt and adjusting it run the engine for 5 minutes and readjust the deflection to the value in the table above 4 Visually check the V belt for cracks oiliness or wear If any replace the V belt with new one 21 2 Inspection and Adjustment 2 2 3 Inspection every 50 hours Be sure to check the following points every 50 hours operation Inspection Item Fuel tank draining Water separator draining Bleeding the fuel system Battery electrolyte level check and battery recharging 1 Fuel tank draining 1 Prepare a waste oil container 2 Remove the drain plug of the fuel tank to drain Fuel tank water dust etc from the fuel tank bottom OPTION 3 Drain until fuel with no water and dust flow out Then tighten the drain plug firmly Drain plug 2 Water separator draining Drain off the water separator whenever there is a lot of drain collected in the water separator at the bottom of the cup even if not the time for periodic inspection hour The cup of the water separator is made from semi transparency material and in the cup the red colored float ring which rises on the surface of the drain is installed to visualize the amount of drain Drain off the water separator in the following manner P FORE 1 Close the fuel cock Fuel Sock 2 Loosen the retainer ring and remove the cup Retaining t
83. ey replace the pulley with a new one Carefully install the pulley so as not to damage the oil seal Oil seal Replacement of a gear case oil seal 4 3 7 Camshaft bushing replacement Replace the bushing using the special service tool Refer to No 7 of 4 1 2 1 in Chapter 4 72 4 Disassembly Inspection and Reassembly of Engines 4 4 Cylinder Block 4 4 1 Components a i Piston ring Flywheel 7 Piston amp Connecting rod Flywheel hausing Ring gear Bearing amp Crankshaft Crankshaft gear Note This figure shows the 3TNV76 73 4 Disassembly Inspection and Reassembly of Engines 4 4 2 Disassembly procedure Disassemble in the order of the numbers in the illustration 1 Perform steps 1 to 15 in the cylinder head disassembly procedure 2 Perform steps 1 to 12 in the gear train disassembly procedure Remove the oil pan and the spacer See Point 1 of 4 4 6 Remove the lube oil suction pipe Remove the piston w rod See Point 2 of 4 4 6 Remove the mounting flange See Point 3 of 4 4 6 Remove the bearing metal caps See Point 4 of 4 4 6 Remove the crankshaft See Point 5 of 4 4 6 Remove the tappets Remove the rings from the piston See Point 6 of 4 4 6 Remove the oil seal from the flywheel housing See 4 4 8 2 a SOS 3 4 5 6 7 8 9 10 11 4 4 3 Reassembly procedure Reverse of the disassembly procedure 74 4 Disassemb
84. g flange and gear case are aligned 3 Set the speed control lever at the operating position 4 Disconnect the injection pipe on the fuel pump side for the No 1 cylinder Do not remove the delivery holder 5 Check the fuel discharge from the delivery holder while turning the crankshaft clockwise as seen from the radiator and stop turning it at the same time when the fuel comes out Wipe out the fuel of the delivery holder exit Next turn the crankshaft in the opposite direction counterclockwise and return it to about 20 degrees before top dead center 6 Check again the fuel discharge from the delivery holder while turning the crankshaft clockwise and stop turning it at the same time when the fuel comes out Inspection hole 36 2 Inspection and Adjustment 7 Read the timing scale on the flywheel from the hole on the flywheel housing It is standard fuel injection timing if the timing mark position meets the fuel injection timing of the below table Model name Engine speed 2TNV70 Injection timing 3TNV70 FID bTDC 1 deg 3TNV76 8 Repeat steps 5 to 7 a few times Note Injection timing check for one cylinder is generally sufficient If it is to be checked for all cylinders of 3 cylinder engine check each cylinder in the ignition order of 1 3 2 1 by turning at each 240 degrees The cylinder to be checked is not limited to the No 1 cylinder and any cylind
85. ghten the pump installation nut which was assembled temporarily by the specified standard torque Tightening torque of the gear installation nut with lube oil N m kgf m Tightening torque 58 8 68 8 6 7 95 7 Fuel Injection Pump Governor 7 2 5 Confirmation and adjustment of fuel injection timing Refer to 2 2 7 in Chapter 2 7 2 6 Confirmation and adjustment of no load maximum and minimum speed Refer to 2 3 in Chapter 2 And fuel injection pipes fuel pipes and a remote control wire are installed in the former condition NOTICE Monitor the oil and fuel leakage from the fuel pump system or the oil leakage from the fuel pump flange during the engine running 96 8 The specifications of a starting motor and the characteristics 8 The specifications of a starting motor and the characteristics 8 1 The specifications and the characteristics A starting motor turns the ring gear installed on a engine flywheel by the pinion while overcoming resistance such as the compression pressure and the friction loss of the engine and makes the engine start 8 1 1 Specifications Manufacturer s model Denso P1 1 Yanmar code 119717 77010 Nominal output 1 1 Weight 3 0 Revolution direction as viewed from pinion Clockwise Engagement system Magnetic shift Terminal voltage current 11 5 90 or less No load Revolution in 3000 or above Terminal voltage current 2 5 325 or less Torque 8 2
86. h time California California Proposition 65 Warning Proposition 65 Warning Diesel engine exhaust and some of its Battery posts terminals and related constituents are known to the State of accessories contain lead and lead California to cause cancer birth defects compounds chemicals known to the and other reproductive harm State of California to cause cancer and reproductive harm Wash hands after handling SAFETY LABELS Most accidents are caused by negligence of basic safety rules and precautions For accident prevention it is important to avoid such causes before development to accidents Please read this manual carefully before starting repair or maintenance to fully understand safety precautions and appropriate inspection and maintenance procedures Attempting at a repair or maintenance job without sufficient knowledge may cause an unexpected accident It is impossible to cover every possible danger in repair or maintenance the manual Sufficient consideration for safety is required in addition to the matters marked A CAUTION Especially for safety precautions in a repair or maintenance job not described in this manual receive instructions from a knowledgeable leader Safety marks used in this manual and their meanings are as follows DANGER DANGER indicates an imminently hazardous situation which if not avoided WILL result in death or serious injury WARNING WARNING indicates a potentially haza
87. he grooved one is positioned away from the cap Reassemble Do not confuse the upper and lower main bearing metals The upper main bearing metal block side has an oil hole and the lower one does not The wheel and arrow marks on the cap shall face the flywheel Main bearing cap bolt tightening torque apply lube oil N m kgf m Standard 75 5 81 5 7 7 8 3 Point5 Crankshaft Disassemble Remove the crankshaft Remove each main bearing metal upper block side and pair it with the metal cap side lower metal A CAUTION Carefully prevent the bearing from being damaged or finger injury when removing the crankshaft because it is heavy 76 4 Disassembly Inspection and Reassembly of Engines Point 6 Piston pin and rings Disassemble Using the piston ring replacer see 4 1 2 1 No 10 in Chapter 4 remove the piston rings Remove the circlip and remove the piston by pushing it out Reassemble Install each piston ring on the piston with the punched manufacturer s mark facing upward Reassemble The piston ring joints shall be staggered at by 120 C intervals Do not position the top ring joint vertical to the piston pin The coil expander joint shall be opposite to the oil ring joint Reassemble When installing the piston pin to the rod and piston the punched match mark on the big end of the connecting rod shall be opposite to the size mark on the piston top Reassemb
88. he following Refuel if S From oil water Fuel injection separator pump Mechanical Fuel feed pump Priming lever Close Air bleeding bolts hand up and down surface inside the fuel Water separator On the piping line Tightning Retainer ring Fuel cock c Loosening pump for 10 15 Fuel filter a starting motor 4 Battery electrolyte level check and battery recharging WARNING r Fire due to electric short circuit Make sure to turn off the battery switch or disconnect the negative cable before inspecting the electrical system Failure to do so could cause short circuiting and fires Always disconnect the Negative battery cable first before disconnecting the battery cables from battery accidental Short circuit may cause damage fire and or personal injury And remember to connect the Negative battery cable back onto the battery last Proper ventilation of the battery area Keep the area around the battery well ventilated paying attention to keep away fire source During operation or charging hydrogen gas is generated from the battery and can be easily ignited Do not come in contact with battery electrolyte Pay sufficient attention to avoid your eyes or skin from being in contact with the fluid The battery electrolyte is dilute sulfuric acid and causes burns Wash it off immediately with a large amount of fresh water if you get any
89. hen throw collected water and trash away spring qos Float ring 3 Put a float ring and a spring in the cup and tighten the retainer ring Tightening torque 13 16Nm 1 3 1 6kgf m 4 Be sure to bleed air in the fuel system Water separator 22 2 Inspection and Adjustment 3 Bleeding the fuel system Bleed the fuel system according procedures insufficient 2 Open the fuel cocks of the water separator and the fuel filter 3 Loosen the air bleeding bolt on the water separator by turning 2 3 turns to the counter clockwise by using a screw driver 4 When the fuel coming out is clear and not mixed with any bubble tighten the air bleeding bolt 5 Feed the fuel with the fuel priming pump or electro magnetic fuel feed pump In case of an engine installed with a fuel priming pump Move the priming lever by and feed fuel until the fuel filter cup goes up and the air disappears inside Move the lever until feeling your hand slightly heavy In case of an engine using the electro magnetic fuel feed pump Turn the starter switch to the ON position and hold it in the position and operate the electro magnetic fuel feed seconds to bleed the fuel system automatically Note Don t do air bleeding by When there is air in the fuel system the fuel injection pump will not be able to function 1 Check the fuel oil level in the fuel tank Fuel filter Fuel return hose lt AN to t
90. ifreeze LLC in the cooling water system and do not drain the coolant before long term storage If drain the cooling water it will cause to built up rust due to the residual water in the cooling water system 2 Remove the mud dust and oil deposit and clean the outside 3 Perform the nearest periodic inspection before the storage 4 Drain or fill the fuel oil fully to prevent condensation in the fuel tank 5 Disconnect the battery cable from the battery negative terminal 6 Cover the silencer air cleaner and electric parts with PVC cover to prevent water and dust from depositing or entrance 7 Select a well ventilated location without moisture and dust for storage 8 Perform recharging once a month during storage to compensate for self discharge 9 When storing an engine for long time run the engine or do motoring periodically according to the following procedure because the rust occurrence inside the engine the rack agglutination of the fuel pump and so on are likely to occur In case that the engine is equipped with a machine unit a Replace the lube oil and the filter before the engine running b Supply fuel if the fuel in the fuel tank was removed and bleed the fuel system c Confirm that there is the coolant in the engine d Operate the engine at the low idling speed for about five minutes If it can be done one a month 41 3 Troubleshooting 3 TROUBLESHOOTING 3 1 Preparation before troubl
91. ing service Problems and actions in preceding service Replacement parts expected to be required for service Recording form check sheet required for service 3 Preparation before Disassembly Prepare general tools special service tools measuring instruments oil grease nonreusable parts and parts expected to be required for replacement When disassembling complicated portions put matchmarks and other marks at places not adversely affecting the function for easy reassembly 4 Precautions in Disassembly Each time a parts is removed check the part installed state deformation damage roughening surface defect etc Arrange the removed parts orderly with clear distinction between those to be replaced and those to be used again Parts to be used again shall be washed and cleaned sufficiently Select especially clean locations and use clean tools for disassembly of hydraulic units such as the fuel injection pump 5 Precautions for Inspection and Measurement Inspect and measure parts to be used again as required to determine whether they are reusable or not 6 Precautions for Reassembly Reassemble correct parts in correct order according to the specified standards tightening torques and adjustment standards Apply oil important bolts and nuts before tightening when specified Always use genuine parts for replacement Always use new oil seals O rings packings and cotter pins
92. ing water level in the radiator and coolant recovery tank will be lowered Replenish the cooling water into the radiator and coolant recovery tank until it reaches the FULL mark of the coolant recovery tank A CAUTION Beware of scalding by hot water Wait until the temperature goes down before draining the cooling water St Otherwise hot water may splash to cause scalding 2 Diaphragm assy inspection Inspect the diaphragm assy on the rocker arm cover every 1000 hours 2 years whichever comes first Diaphragm cover Sp Refer to 4 2 4 point 6 for the function of the diaphragm Spring amp Rocker arm cover 1 Loosen screws and remove a diaphragm assy Center plate and check whether oil and so on doesn t enter Diaphragm between the diaphragm and the cover If oil and so on enters into the diaphragm assy the diaphragm doesn t work well 2 Check the damages of the diaphragm rubber and Baffle plate the spring If necessary replace with new ones Intake maniforld NOTICE Breather system componert When a diaphragm is damaged pressure control inside the crankcase becomes insufficient and troubles such as combustion defect and so on occur At lube oil replacement or lube oil supply the amount of lube oil isn t to be beyond the standard upper limit If the lube oil quantity is beyond the upper limit or an engine is operated beyond the allowable maximum angle of an engine the amount
93. ion Number of cylinders 3 Cylinder borexstroke jue 76x82 Displacement L 1 115 3000 3600 Continuous speed rating kW 151 177 Output NET 05 41 rod 3000 3600 3100 3200 3300 3400 3500 3600 Rated output Speed Output NET kW 165 195 177 182 187 193 193 195 P ps 25 65 240 048 254 62 263 265 no load speed 25 3800 3290 3400 3500 3600 3710 3815 Ignition order 1 3 2 1 No 1 cylinder on flywheel side Power take off Flywheel Direction of rotation Counterclockwise viewed from flywheel Cooling system Radiator Lubrication system Forced lubrication with trochoid pump Starting system Electric f Diesel oil BS 2869 A1 or A2 Applicable fuel cetane No 45 min Applicable lubricant API grade class CD or CF Lubricant capacity Total L 4 4 3 5 tol pan Effective L 21 1 6 Cooling water capacity L 0 9 engine only Engine Overall length mm 485 Dimensions with flywheel Overall width mm 436 housing Overall height mm 559 535 Engine mass dry with flywheel housing kg Tie Cooling fan std mm 335 mm O D 5 blades pusher type F Crankshaft V pulley diameter amp Fun V pulley diameter std s 110 amp 100 Items marked may differ from the above depending on an engine installed on a machine unit Engine mass and dimensions without radiator 1 General 3TNV76 continue
94. ir or steam to prevent any foreign matter from getting in the eyes NOTICE e Any part which is found defective as a result of inspection or any part whose measured value does not satisfy the standard or limit shall be replaced e Any part predicted to dissatisfy the standard or limit before the next service as estimated from the state of use should be replaced even when the measured value then satisfies the standard or limit 48 4 Disassembly Inspection and Reassembly of Engines 4 1 2 Special service tools Although main engine parts can be disassembled and reassembled only with standard service toots is recommended to provide the following special service tools and measuring instruments for more efficient and accurate work correct measurement diagnosis and troubleshooting 1 Special Tools Tool name Applicable model and tool size Illustration Valve guide tool for extracting valve guide L1 L2 1 20 75 5 5 Locally manufactured Valve guide tool for inserting valve guide mm L2 d1 d2 10 60 11 17 22 40 Tolerance 1170 Locally manufactured Connecting rod bushing replacer for removal installation of connecting rod bushing mm L1 L2 1 2 25 85 22 25 Tolerance di d2 0 6 0 3 Locally manufactured Valve spring compressor for removal installation of valve spring yanmar code No 129100 92630 Stem seal inserter for inserting s
95. just the valve clearance Tighten the adjusting screw mm Standard valve clearance 0 15 0 25 3 Apply oil to the contact surface between adjusting screw and push rod 4 Adjust the other cylinder s in the order Valve clearance adjustment 32 2 Inspection and Adjustment 4 Fuel injection nozzle pressure inspection A WARNING Wear protective glasses when testing injection from the fuel injection valve Never approach the injection nozzle portion with a hand The oil jetting out from the nozzle is at a high pressure to cause loss of sight or injury if coming into careless contact with it a Injection pressure measurement Standard Mpa kgf cm 11 8 12 8 120 130 NOTICE EJ Nozzle tester As for the opening pressure of the brand new fuel p nozzle about 0 5MPa 5kgf cm declines by the engine operation for about 5 hours because of the initial wear out of a spring etc Therefore adjust 0 5MPa 5kgf cm higher than the standard value of the above table when adjusting a new fuel nozzle of Injection pressure measurement a spare part with nozzle tester Remove carbon deposit at the nozzle hole thoroughly before measurement 1 Connect the fuel injection valve to the high pressure pipe of the nozzle tester 2 Operate the nozzle tester lever slowly and read the pressure at the moment when the fuel injection from the nozzle starts 3 If the measured injection pressure is lower than the stand
96. k and replenish the lube oil If any oil is spilled wipe it away with a clean cloth 2 V belt tension check When there is not enough tension in the V belt the V belt will slip making it impossible for the alternator to generate power and cooling water pump and cooling fan will not work causing the engine to overheat Check and adjust the V belt tension deflection in the following manner NOTICE Be especially careful not to splash lube oil on the V belt because it will cause slipping stretching and aging of the belt 1 Press the V belt with your thumb approx 98N 10kgf at the middle of the V belt span to SE check the tension deflection Available positions to check and adjust the V belt tension deflection are at the A B or C direction as shown in the illustration right You may choose a position whichever you can easily carry out the check and adjustment on the machine unit New V belt refers to a V belt which has been used less than 5 minutes on a running engine Used V belt refers to a V belt which has been used on a running engine for 5 minutes or more The specified deflection to be measured at each position should be as follows Unit mm Direction For used V belt For new V belt 20 2 Inspection and Adjustment 2 If necessary adjust the V belt tension deflection a adjust the V belt tension Adjust the V belt tension inserting a bar loosen the s
97. le Install the piston in the cylinder block The embossed mark on the connecting rod shall be on the flywheel side 77 the punched manufacturer s mark face upward 2 Piston ring Oil ring joint Second ring joint Top ring joint Camshaft side Nozzle side Embossed mark Flywheel side 4 Disassembly Inspection and Reassembly of Engines 4 4 5 Parts inspection and measurement 1 Cylinder block Especially clean head surface cylinder bores and oil holes and check the below items after removing any carbon deposit and bonding agent a Appearance inspection Check if there is any discoloration or crack crack is suspected perform color check Sufficiently clean the oil holes and check they are not clogged b Cylinder bore and distortion Measure at 20 mm below the crest of the liner at 20 mm from the bottom end and at the center in two directions A and B as shown in the below figure Roundness Roundness is found as follows though it is the simple method Measure cylinder diameters of the A direction and the B direction on each section of a b and c Roundness is the maximum value among those difference values Cylindricity Cylindricity is found as follows though it is the B DONO D dh o simple method Measure cylinder diameters of a b and c sections in the A direction and calculate the difference in Cylinder bore measurement positions maximum value and minimum
98. lve or the urgent rotation of the engine by the oil burning When pressure progresses in the crank case too much due to the wrong operation of the diaphragm and so on it is considered that oil leakage from the joint of a oil pan a oil seal and so on will occur When a diaphragm is damaged blowby is discharged from the breathing hole on the side of diaphragm cover and not reduced in the intake manifold Therefore be careful of the diaphragm trouble 2 At lube oil replacement or lube oil supply The amount of lube oil isn t to be beyond the standard upper limit in the engine horizontality the upper limit mark of the dip stick Since the blowby gas reductor is adopted be careful that the amount of oil mist may be inducted in the combustion chamber and the oil hammer sometimes may occur when the lube oil quantity is beyond the upper limit or an engine is operated beyond the allowable maximum angle of an engine Reassembly Replace the diaphragm with new one when it is damaged 61 4 Disassembly Inspection and Reassembly of Engines Point 7 Disassemble Camshaft side Keep the removed push rods by attaching tags 5 2 showing corresponding cylinder Nos 2 2 9 Reassemble 7 i Always apply oil to the contact portions of the 6 B push rods and clearance adjusting screws Point 8 Head bolt disassembly order Di bl 3 cylinder head Disassemble Assembly Loosen the cylinder h
99. ly Inspection and Reassembly of Engines 4 4 4 Servicing points Point1 Oil pan Disassemble Sealant is applied to the oil pan mounting surface on the block Carefully operate so as not to damage or distort the bonding surface Reassemble Apply sealant code No 977770 01212 before reassembly Point2 Piston w rod Disassemble Tu Crankshaft Measure the connecting rod side gap Thickness gage mm Standard 0 20 0 40 Connecting rod side gap Carefully remove the carbon deposit on top of the cylinder so as not to damage the inner side of the cylinder Set the piston at the BDC position and remove the connecting rod cap Then set the piston at the TDC position and push the connecting rod big end with the wooden shaft of a hammer Proceed carefully so as not to cause the cylinder block catch the rod big end Set the rod caps and crankpin metals in their correct combinations Reassemble Apply oil especially carefully to the sliding contact surfaces of the pistons rods and rings Use the piston insertion tool see 4 1 2 1 No 9 in Chapter 4 to insert each piston w rod in the cylinder block and install the bearing metal cap Rod bolt tightening torque N m kgf m Standard apply lube oil 22 6 27 5 2 32 8 Point3 flywheel housing Disassemble Place the engine on a stable base with the cylinder block upper surface facing down and remove the flywheel housing carefull
100. minal output 13 5V heat 40 Rated revolution 5 000 Operating revolution 1 350 18 000 Grounding characteristics Minus side grounding Direction of revolution viewed from pulley Clockwise Integrated regulator IC regulator Weight 2 8 Pulley outside diameter 69 2 Belt shape 9 2 3 Wiring diagram WIRING DIAGRAM ae ASSY NOTICE IC REGURATOR 1 Don t do mis wiring and short circuit of each terminal 2 Don t remove a battery terminal and a B terminal when rotating 3 Shut out a battery switch during the alternator stop 105 Type A Charge lamp Max 3 4W BT Battery ry Ta 77 9 Alternator 9 2 4 Standard output characteristics The standard output characteristics of this alternator are shown as the right figure STANDARD CHARACTERISTICS CONSTANT 60 AMBIENT 25 MEREZA ooa leo Ge i ELE 0 23 45 6 7 8 ALTERNATOR SPEED X10 min Z x a i 2 E D gt 9 2 5 Inspection Perform the same procedure as that of 9 1 5 in Chapter 9 106 201 L IG Turn key switch to ON OFF Does the charge lamp cio GN coupler come ON Ground L terminal of the driven machine side coupler Does
101. ndness Cylinder bore Cylindricity 2 Crankshaft Inspection item 0 01 or less Standard 4 4 5 1 Reference page Bending 1 2 the dial gauge reading Roundness 0 01 or less Pin outside diameter 41 952 41 962 Metal inside diameter 41 982 42 002 Metal thickness 1 503 1 509 Clearance 0 020 0 050 Journal outside diameter 46 952 46 962 Metal inside diameter 46 982 47 002 Crank journal Metal thickness 2 009 2 014 Clearance 3 Thrust bearing Inspection item 0 020 0 050 Standard Reference page Crankshaft side gap 0 111 0 250 Metal thickness 1 930 1 980 116 4 4 5 3 11 Service Standards 4 Piston and ring Piston Inspection item Standard Reference page Piston outside diameter 2 3 70 69 960 69 990 Measure in the direction vertical to the piston pin 3TNV76 75 955 75 985 Piston diameter measure position 2 3TNV70 Upward from the bottom 3TNV76 end of the piston 22 25 Hole inside diameter 22 000 22 009 Piston pin Pin outside diameter 21 995 22 000 Clearance Piston ring Inspection item 0 000 0 014 Standard Reference page Ring groove width 1 550 1 570 Ring width 1 470 1 490 Top ring Side clearance 0 060 0 100 End clearance
102. ning flange installation bolts Reassemble Pump drive gear nut Tightening torque for fuel pump drive gear nut with lube Oil N m kgf m Tightening torque 58 8 68 8 6 7 69 4 Disassembly Inspection and Reassembly of Engines Point4 Reassemble Assemble crankshaft gear A fuel injection pump drive gear B and camshaft gear C at the same time by aligning with idle gear A B and C marks Install the idle gear shaft with the oil hole facing upward Point5 Reassemble Idle gear Install the PTO drive gear with its inner spline side facing the flywheel Crankshaft gear Point6 Disassemble Install a bolt as a handle in the hole at the end face of the flywheel and remove carefully so as not to damage the ring gear Reassemble Flywheel mounting bolt apply lube oil N m kgf m Tightening torque 80 4 86 4 8 2 8 8 Fuel injection pump drive gear Camshaft gear Point7 Disassemble Measure the camshaft side gap Camshaft gear i mm Item Standard Limit Side gap 0 05 0 15 0 25 f the measured side gap exceeds the limit replace the thrust metal Disassemble Since the camshaft gear is shrink fit heat it to 180 C 200 C for extraction For camshaft removal raise the engine with its mounting flange at the bottom After removing the thrust metal mounting bolt from the camshaft gear hole extract the camshaft carefully so as not to dam
103. nishment Daily inspection of cooling water should be done only by coolant recovery tank Never open the radiator filler cap while the engine and radiator are WARNING still hot Steam and hot water will spurt out and seriously burn you Wait until the radiator is cooled down after the engine has stopped wrap the filler cap with a rag piece and turn the cap slowly to gently e release the pressure inside the radiator Securely tighten the filler cap after checking the radiator Steam can spurt out during operation if the cap is tightened loosely a Checking cooling water volume Check the cooling water level in the coolant recovery tank Ifthe water level is close to the LOW mark open the coolant recovery tank cap and replenish the coolant recovery tank with clean soft water to the FULL mark Standard The water level of the coolant recovery tank shall be between the upper and lower limit lines T Coolant 22 b Replenishing engine with water recovery tank If the coolant recovery tank water level is lower than the LOW mark open the radiator cap and check the cooling water level in the radiator Replenish the radiator with the cooling water if the level is low Check the cooling water level while the engine is cool Checking when the engine is hot is dangerous And the water volume is expanded due to the heat Daily cooling water level check and replenishing shall be done only at the coolant
104. on you 23 2 Inspection and Adjustment Battery structure 2 SUUS Separator Glass mat NV LN Battery case Anode plate 1 Electrolyte level Check the level of fluid in the battery When the amount of fluid nears the lower limit fill with battery fluid available in the market to the upper limit If operation continues with insufficient battery fluid the battery life is shortened and the battery may overheat and explode Upper limit UPPER LEVEL Battery fluid tends to evaporate more quickly in the ROWER LEVEL summer and the fluid level should be checked earlier than the specified times f the engine cranking speed is so slow that the engine does not start up recharge the battery If the engine still will not start after charging replace the battery Remove the battery from the battery mounting of Electrolyte level the machine unit after daily use if letting the machine unit leave in the place that the ambient temperature could drop at 15 C or less store the battery in a warm place until the next use the unit to start the engine easily at low ambient temperature 2 Battery charge Use a battery tester or hydrometer and check the battery condition If the battery is discharged recharge it a Measurement with a battery tester When checking the battery with the batter tester connect the red clip of the tester to the battery positive
105. oning Pees osses LS SS Sacs SSS SSS 52 gt 252 gt 2 gt 22525543 Honing cross hatch Replace metal by using the special service tool see No 3 of 4 1 2 in Chapter 4 4 4 8 Oil seal replacement Flywheel housing side 1 Replace an oil seal with new one when a flywheel housing is removed Extract the used oil seal 2 Insert a new oil seal by using the oil seal insertion tool on the position of the flywheel housing end face Refer to the right figure 3 Apply lithium grease on the lip 4 Install the flywheel housing on the cylinder block with being careful not to damage the oil seal 87 Cylinder block Flywheel housing Cil seal Crank shaft Replacement of a flywheel housing oil seal 5 Lubrication System 5 LUBRICATION SYSTEM 5 1 Lubrication System Diagram Lube oil filter Bypass valve Fuel injection pump Hydraulic swich Cylinder block Main gallery Regulator 1 valve pinnae EP Intermediate Camshaft Crank Lube oil pump gear shaft metal journal metal Rocker arm Crank Oil suction pipe metal pin metal strainer I Rocker arm HM N Tappet Cam face X Oil pan 5 2 Trochoid Pump Components Trochoid pump 88 5 Lubrication System 5 3 Disassembly Reverse the below procedure for reassembly 1 Loosen the belt and remove the radiator pulley fan and V belt S
106. ot abnormal 6 2 6 10 Electric Wiring 10 Electric Wiring 10 1 Electric Wiring Diagram This is a typical example X YAZAKI No YAZAKI NO
107. p inlet Clean the strainer 44 3 Troubleshooting Air Exhaust Gas System Trouble symptom Clogged air filter Starting failure Insufficient engine output Poor exhaust color Engine does not start Engine starts but stops soon Exhaust color During work Exhaust smoke Ordinary High knocking sound during combustion Abnormal engine sound Hunting During idling During work Large engine vibration Difficulty in returning to low speed Excessive fuel consumption Cooling water Excessive consumption Dilution by fuel oil Mixture with water Low L O pressure Much blow by gas Overheat Low water temperature Pressure rise Exhaust temperature rise Corrective action Uneven combustion sound Clean See 2 2 4 5 and 2 2 5 3 in Chapter2 Engine used at high temperatures or at high altitude O Pressure drop Study output drop and load matching Clogged exhaust pipe O Black O Black Clean Electrical System Starting motor defect Repair or replace See Chapter8 Alternator defect Repair or replace See Chapter9 Open circuit in wiring Repair See Chapter10 Battery voltage drop Inspect and change the battery See 2 2 3 4 in Chapter2
108. passes through the clearance between the cylinder and the piston piston ring and flows to the crankcase This is said as blowby gas While it passes into the cylinder Breather system componert head and the rocker arm cover the blowby gas mixes with splash oil and becomes oil mist blowby gas Next oil is separated from mist blowby gas with passing through the baffle plate inside a rocker arm cover And it passes through a diaphragm assy and a intake manifold and is reduced in the combustion chamber Pressure inside a crankcase is controlled by the function of the diaphragm assy and suitable amount of blowby gas is reduced in 6 intake air system Baffle plate 4 Intake maniforld Diaphragm Disassembly Spring When a rocker arm cover is taken off check LP Diaphragm cover whether oil or the like enter the diaphragm space Gi Er Baffle plate 4 Rocker from a small hole on the side of a diaphragm cover cover or not without disassembling the diaphragm TRA E IT Yo Cylinder heac Blowby gas flow NOTICE 1 When a diaphragm is damaged pressure control inside the crankcase becomes insufficient and troubles occur When the internal pressure of the crankcase decreases too much due to the damage of a spring much blowby gas containing oil is reduced in intake air system and it may cause the combustion defect by the early dirt of the intake va
109. pinion engages with a ring gear 2 When the pinion engages the ring gear because a main contact point is closed and the main electric current flows and a pull coil is short circuited by the main contact point and it stops being charged with electricity the pinion is kept at the position by a holding coil during the start 3 When the starting switch is turned off the main contact point becomes open and the pinion clutch is returned to the stop position by a return Starter spring Dg Magnetic switch 8 3 Performance The specified characteristics of a starting motor at 20 deg C 1 No load Less than electric current 90A more than rotation speed 3000min at voltage 11 5V 2 Load More than rotation speed 1130 min 1 torque 6 86 N m 0 70kg f m at voltage 8 7V and electric current 230A 3 Restraint Less than electric current 325A torque 8 2 0 84 kgf m at voltage 2 5V 4 Operation voltage In the position of a ring gear less than 8V Since the characteristics of a starting motor can be confirmed easily in the no load test comparatively perform the test by the next point No load test Fix the starting motor on a test bench and connect wiring When the switch is closed a current flows in the starting motor which is rotated at no load Measure the current voltage and number of revolutions then and check if they satisfy the specified characteristics 99 9 Alternator 9 ALTERNATOR
110. pump and Fuel injection timing adjustment nozzle Fuel pump inspection and adjustment EPA allows to maintain the emission related parts as shown in 1 6 3 of chapter1 15 2 Inspection and Adjustment 2 2 Periodic Inspection and Maintenance Procedure 2 2 1 Check before Daily Operation Be sure to check the following points before starting an engine every day Inspection Item Visual check around engine Fuel tank level check and fuel supply Lube oil level check and replenishment Cooling water level check and replenishment Fuel pipe and cooling water pipe inspection and maintenance Inspection and adjustment of governor lever and accelerator Warning lamp amp instruments function check 1 Visual check around engine If any problem is found do not use before the engine repairs have been completed Oil leak from the lubrication system Fuel leak from the fuel system Cooling water leak from the cooling water system Damaged parts Loosened or lost bolts Fuel radiator rubber hoses V belt cracked loosened clamp 2 Fuel tank level check and fuel supply Check the remaining fuel oil level in the fuel tank and refuel the recommended fuel if necessary Refer to 1 3 1 3 Lube oil level check and replenishment a Checking oil level Check the lube oil level with the dipstick after N adjusting the posture of the machine unit so that an l
111. r For measuring the outside diameters of crankshaft pistons piston pins etc Cylinder gage For measuring the inside diameters of cylinder liners rod metal etc Vernier Calipers For measuring outside diameters depth thickness and width Depth micrometer For measuring of valve sink 51 4 Disassembly Inspection and Reassembly of Engines No Instrument name Application Illustration For measuring valve spring inclination and straightness of parts 8 Square For measuring shaft bend 9 V block For tightening nuts and bolts to the specified torque a 10 Torque wrench For measuring gaps between ring and ring groove and shaft joints during assembly 11 Thickness gage Z For checking water leakage 12 Cap tester For checking concentration of antifreeze and the battery electrolyte charge status 13 Battery coolant tester For measuring injection spray pattern of fuel injection nozzle and injection pressure 14 Nozzle tester For measuring temperatures 15 Digital thermometer 52 4 Disassembly Inspection and Reassembly of Engines No Instrument name Application Illustration For measuring revolution by contacting the mortise in the revolving shaft Contact type CIT i For measuring revolution by sensing the reflecting mark the outer Revolving shaft
112. rdous situation which if not avoided COULD result in death or serious injury A CAUTION CAUTION indicates a potentially hazardous situation which if not avoided MAY result in minor or moderate injury e NOTICE indicates that if not observed the product performance or quality may not be guaranteed 1 SERVICE AREA WARNING CAUTION A CAUTION A CAUTION Safety Precautions e Sufficient ventilation Inhalation of exhaust fumes and dust particles may be hazardous to ones health Running engines welding sanding painting and polishing tasks should be only done in well ventilated areas e Safe Adequate Work Area The service area should be clean spacious level and free from holes in the floor to prevent slip or trip and fall type accidents e Bright Safely Illuminated Area The work area should be well lit or illuminated in a safe manner For work in enclosed or dark areas a drop cord should be utilized The drop cord must have a wire cage to prevent bulb breakage and possible ignition of flammable substances e Safety Equipment Fire extinguisher s first aid kit and eye wash shower station should be close at hand or easily accessible in case of an emergency 2 WORK WEAR GARMENTS A CAUTION e Safe Work Clothing Appropriate safety wear gloves special shoes boots eye ear protection head gear harness clothing etc should be used worn to ma
113. recovery tank Usually do not open the radiator cap to check or replenish Radiator cap 17 2 Inspection and Adjustment IMPORTANT If the cooling water runs short quickly or when the radiator runs short of water with the coolant recovery tank level unchanged water may be leaking or the air tightness may be lost Increase in the coolant recovery tank water level during operation is not abnormal The increased water in the coolant recovery tank returns to the radiator when the engine is cooled down If the water level is normal in the coolant recovery tank but low in the radiator check loosened clamping of the rubber hose between the radiator and coolant recovery tank or tear in the hose Standard Engine The radiator shall be filled up Unit liter Model Cooing water volume in an engine 2TNV70 0 6 3TNV70 3TNV76 Engine cooling water capacity may differ from the above volume depending on an engine installed on a machine unit 0 9 5 Fuel pipe and cooling water pipe inspection and maintenance Check the rubber hoses for fuel and cooling water pipes cracked If the cracked hose is found replace it with new one Check the loosened clamp If found tighten it 6 Inspection and adjustment of governor lever and accelerator Make sure the accelerator of the machine unit can be operated smoothly before starting the engine If it feels heavy to manipulate lubricate the accelerator cable joints and pivots Adj
114. rence in angle 0 e Finely atomized spray Excellent spray departure 5 40 gt 2 Ut Normal spray pattern c Nozzle valve sliding test Wash the nozzle valve in clean fuel oil Place the nozzle body vertically and insert the nozzle into the body to about 1 3 of its length The valve is normal if it smoothly falls by its own weight into the body In case of a new nozzle remove the seal peel and immerse it in clean diesel oil or the like to clean the inner and outer surfaces and to thoroughly remove rust preventive oil before using the nozzle Note that a new nozzle is coated with rust preventive oil and is pasted with the seal peel to shut off outer air d Nozzle punch mark 35 Nozzle valve sliding check by gravity Y DN OS D YD1 Design code No code pintle type D throttle type Size size P size S Injection angle Type pintle type YANMAR Identification number 2 Inspection and Adjustment 2 2 7 Inspection every 2000 hours or 2 years Be sure to check the following points every 2 000 hours or two years operation whichever comes first Inspection Item Cooling water path flushing and maintenance Fuel pipe and cooling water pipe inspection and maintenance Intake exhaust valve seat lapping Fuel injection timing adjustment Fuel injection pump inspection and adjustment 1 Cooling water path flushing and
115. ricting injection quantity Gasket and engine speed Injection quant limit bc Tamper Seal washer resistance Assy Tamper resistance device for engines certified by ARB EPA 13 1 General 4 Perform maintenance without fail Note Inspections to be carried out by the user and by the maker are divided and set down in the List of Periodic Inspections and should be checked carefully 5 Maintenance period and Quality guarantee period for exhaust emission related parts The maintenance of the parts related to the exhaust emission must be carried out in the maintenance period as shown in the below table A guarantee period is that either the operation hours or years shown in the table come first in the condition that the maintenance inspection was carried out based on the List of Periodic Maintenance Schedule PERENNE Maintenance period Quality Guarantee Period Fuel nozzle cleaning Adjustment cleaning For nozzle fuel pump repairs for fuel nozzle turbocharger fuel pump turbocharger electronic control unit etc Every 1500 hours Every 3000 hours 1500 hours 2 years Power Rating kW 19 And constant speed engines beyond 3000 under 37kW 14 2 Inspection and Adjustment 2 Inspection and Adjustment 2 1 Periodic Maintenance Schedule The engine periodic inspection timing is hard to determine as it varies with the application load status qualities of the fuel and lube oil
116. rod meets the cylinder No 3 Take care not to drop the crankpin metal when removing the crankpin cap of the connecting rod 1 Remove main bearing cap bolts While shaking a main bearing cap remove it together with the lower main bearing metal 2 Extract a crankshaft taking care not to damage it 3 Remove upper main bearing metal 56 1 Before extracting a crankshaft measure the side gap of it Dial gauge Crankshaft Apply a dial gauge to the end of crankshaft Force the crankshaft on both sides in the axial direction to measure the thrust gap 4 Disassembly Inspection and Reassembly of Engines Removal Parts Remarks Alternatively insert a thickness gauge directly between the base thrust metal and the thrust surface of the crankshaft to measure the gap Refer to 4 4 4 in Chapter 4 If the measured gap exceeds the limit replace the thrust metal with a new one 2 Notice on the removal of thrust metal a When removing thrust metal ascertain the position and direction of thrust metal in relation to the cap b Make sure that the thrust metal groove is outward to the cap 1 Remove pistons and connecting rod 1 To selectively remove a desired piston and assemblies connecting rod assembly without extracting crankshaft take the steps itemized below a Remove carbon deposits from the upper wall of the cylinder using fine sandpaper taking care not to damage the inner surface of the cylinder
117. rom radiator side at 240 degree and adjust the valve clearance for the No 3 cylinder Then adjust the No 2 cylinders in this order Valve cap In case of 2 cylinder engines turn the crankshaft clockwise at 180 degree with 1 turn after the No 1 cylinder s adjustment The cylinder to be adjusted first does not have to be the No 1 cylinder Select and adjust the cylinder where the piston is the nearest to the top dead center after turning and make adjustment for other cylinders in the order of ignition by turning the crankshaft A adjustment method of reducing the flywheel turning numbers for 3 cylinder engines for reference Set No 1 cylinder to the compression T D C and adjust the clearance of the mark of the bottom table Next turn the flywheel once the suction exhaust valve of No 1 cylinder is in the position of the overlap T D C at this time and adjust the clearance of the O mark Ignition order of cylinder engines 1 gt 3 gt 2 Cylinder No 1 2 3 Valve Suction Exhaust Suction Exhaust Suction Exhaust No 1 compression T D C The first time No 1 overlap T D C The second time b Valve clearance inspection and adjustment 1 Loosen the lock nut and adjusting screw and check the valve for any inclination of valve cap dirt or wear Valve cap E Abnormal 2 Insert a 0 2 mm thickness gage between the rocker arm and valve cap and ad
118. rom the fuel tank The fuel which passed through the fuel filter is supplied to the storeroom of the pump housing and the pressure of the fuel rises by the plunger The fuel passes through the fuel high pressure pipe and the fuel is injected to each cylinder from the fuel injection nozzle The manual of the separate volume is referred to for the disassembly and assembly adjustment procedure of only the YPES ML type fuel pump 7 2 Fuel Injection Pump 7 2 1 Fuel system diagram Fuel injection valve Fuel injection pipe Fuel return pipe To fuel tank Fuel injection pump Fuel filter Oll water separatoi Option From fuel tank Feed pump 93 7 Fuel Injection Pump Governor 7 2 2 External view and components Exhaust manifold Fuel filter ole Pump flange Don t disassemble ji 9 Fuel pump drive gear Drive gear nut Note This figure shows the 3TNV76 94 7 Fuel Injection Pump Governor 7 2 3 Disassembly procedure The procedure to remove a fuel injection pump from the gear case is shown NOTICE Be sure to remove a flange and a fuel injection pump drive gear with a pair without loosening the flange installation bolts 1 Remove fuel injection pipes fuel pipes and a remote control wire Block the entrance with tape so that trash may not enter the fuel injection pipes and the fuel injection pump 2 Mark the position of the timing marks of a fuel pump
119. s measured by a micrometer The clearance is calculated from the measured tappet hole and the measured stem diameter Abnormal contact Normal contact Item Standard surface surface Tappet hole I D 21 000 21 021 Tappet Stem O D 20 927 20 960 Clearance 0 040 0 094 Tappet stem O D measurement 86 4 Disassembly Inspection and Reassembly of Engines 4 4 6 Cylinder bore correction a Slight uneven worn flawed etc shall be corrected by honing only If the cylinder is unevenly worn partially flawed or otherwise damaged and cannot be repaired simply by honing rebore the cylinder first and then hone See 4 4 5 1 c for the boring dimension b Items to be prepared for honing e Flex Hone see No 8 of 4 1 2 in Chapter 4 Electric drill Honing fluid 50 50 mixture of lube oil and diesel oil c Apply the honing fluid to the Flex Hone and turn the electric drill at 300 to 1200 min Then insert the Flex Hone into the cylinder bore while turning it and move it up and down for about 30 sec to obtain a honing mark with a cross hatch angle of 30 to 40 NOTICE 1 Avoid faster revolution than 1200 min since it may cause breakdown 2 Do not insert or extract the Flex Hone in stopped state because the cylinder will be damaged 4 4 7 Piston pin metal replacement Flex Hone Z Electric drill Lube oil Diesel oil t 50 50 ero Flex Hone Honing fluid Items to be prepared for h
120. s used and handling status General rules are described here O User maintenance Parts replacement Shop inspection Maintenance period Every Every Every 250 500 1000 hours hours hours or 3 or 6 or one months months year Classification Visual check around engine Fuel tank level check and fuel supply Fuel tank draining Fuel oil Bleeding the fuel system system Water separator draining Water separator cleaning Fuel filter element replacement Lube oil level check and replenishment Lubricating oil system Lube oil replacement 2 time and thereafter Lube oil filter replacement Cooling water level check and replenishment Radiator fin cleaning Cooling water Cooling fan V belt tension check M system thereafter Cooling water replacement Cooling water path flushing and maintenance Rubber Fuel pipe and cooling water pipe house inspection and maintenance Inspection and adjustment of governor lever and accelerator Air cleaner cleaning and element Air intake replacement system Governor Diaphragm assy inspection 2 years Warning lamp amp instruments function Electrical check system Battery electrolyte level check and battery recharging Intake exhaust valve clearance Cylinder adjustment head Intake exhaust valve seat lapping Fuel Fuel injection nozzle pressure injection inspection
121. s with a tape or the like 3 Whenever extracting fuel injection nozzle replace nozzle protector with a new one 1 Remove rocker arm cover assembly 1 Remove valve rocker arm shaft assembly 2 Remove push rods 1 Attach a tag to a push rod for each cylinder No to put the push rods in order 2 Remove valve cap from the intake exhaust valve head 3 Tappet can be removed at the same time when push rod is extracted 4 Attach a tag to a tappet for each cylinder No to put the tappets in order 1 Remove fan mounting bolt and then remove fan 2 Loosen a adjusting bolt for the V belt adjuster and then remove V belt 3 Remove alternator 4 Remove the spacer for cooling fan and V pulley 1 Never turn down alternator vigorously toward the cylinder block Otherwise your finger may be nipped and alternator broken 1 Remove lube oil filter assembly 2 Extract a dipstick from the oil dip stick hole 1 Disconnect fuel return pipes 2 Remove fuel filter 1 Disconnect cooling water pipe from the cooling water pump 2 Remove thermostat assembly 3 Remove cooling water pump 54 4 Disassembly Inspection and Reassembly of Engines Removal Parts Remarks 1 Remove cylinder head tightening bolts 2 Remove a cylinder head assembly 3 Remove a cylinder head gasket 1 Lay a cardboard or the like on the floor and place a cylinder head assembly on it so as not to damag
122. service manual Incorrect values procedures and or tools may cause damage to the engine and or personal injury e Short Circuits Always disconnect the Negative battery cable before working on the electrical system An accidental short circuit may cause damage fire and or personal injury Remember to connect the Negative battery cable back onto the battery last Fasten the terminals tightly e Charging Batteries Charging wet celled batteries produces hydrogen gas Hydrogen gas is extremely explosive Keep sparks open flame and any other form of ignition away Explosion may occur causing severe personal injury e Battery Electrolyte Batteries contain sulfuric acid Do NOT allow it to come in contact with clothing skin and or eyes severe burns will result 7 WASTE MANAGEMENT CAUTION Observe the following instructions with regard to hazardous waste disposal Negligence of these will have a serious impact on environmental pollution concerns 1 Waste fluids such as lube oil fuel and coolant shall be carefully put into separate sealed containers and disposed of properly 2 Do NOT dispose of waste materials irresponsibly by dumping them into the sewer overland or into natural waterways 3 Waste materials such as oil fuel coolant solvents filter elements and batteries must be disposed of properly according to local ordinances Consult the local authorities or reclamation facility 8 FURTHER PRECAU
123. spection 39 2 Inspection and Adjustment 2 7 Thermostat inspection Place the thermostat in a container filled with water Heat it while measuring the water temperature and see that the thermostat is actuated at temperature of following table Valve opening Full open lift Temperature Temperature deg C mm 69 5 72 5 8 or more 85deg C Valve opening temperature is carved on the flange Thermometer Thermo switch Cooling water pump Thermostat 2 8 Adjusting Operation Perform the adjusting operation of a engine as follows after the maintenance job 1 Supply the fuel oil lube oil and cooling water Note Check the levels of the lube oil and cooling water again after test running for about 5 minutes and add as required 2 Start the engine and carry out idling at the low speed 700 to 900 rpm for a few minutes 3 Run in the engine for about five minutes at the rated revolution no load Check any water fuel or oil leak and existence of abnormal vibration or noise Also check the oil pressure cooling water temperature and exhaust gas color 4 Adjust the no load minimum and maximum revolutions Refer to 2 3 in chapter 2 5 Perform loaded operation as required 40 2 Inspection and Adjustment 2 9 Long storage Observe the following instructions when the engine is to be stored for a long period without operation 1 Be sure to use clean soft water added Long Life Coolant Ant
124. std mm 335 mm O D 6 blades pusher type F Crankshaft V pulley diameter amp Fun V pulley diameter std 110 amp 100 tems marked may differ from the above depending on an engine installed on a machine unit Engine mass and dimensions without radiator 1 General 1 3 Fuel Oil Lubricating Oil and Cooling water 1 3 1 Fuel oil IMPORTANT Only use the recommended fuel to obtain the best engine performance and prevent damage of parts also prevent air pollution 1 Selection of fuel oil Use the following diesel fuels for best engine performance BS 2869 A1 or A2 Fuels equivalent to Japanese Industrial Standard JIS No K2204 2 Fuel cetane number should be 45 or greater 2 Fuel handling Water and dust in the fuel oil can cause operation failure Use containers which are clean inside to store fuel oil Store the containers away from rain water and dust Pump up only the fuel Before supplying fuel let the fuel container rest for in the upper half to leave dregs near the bottom several hours so that water and dust in the fuel are deposited on the bottom Pump up only the clean fuel 3 Fuel tank Be sure to attach a drain cock precipitation trap and primary strainer to the fuel tank as shown illustration right Filler port Fuel return connection strainer Outlet to engine Drain cock 1 General 1 3 2 Lubricating oil IMPORTANT Use of other than the
125. t 2 2 4 Inspection every 250 hours or 3 months Be sure to check the following points every 250 hours or 3 months operation whichever comes first Inspection Item Lube oil and filter replacement Radiator fin cleaning V belt tension check Inspection and adjustment of governor lever and accelerator Air cleaner cleaning and element replacement 1 Lube oil and filter replacement The second replacement and after Replace the lube oil every 250 hours operation from 2nd time and on Replace the lube oil filter at the same time Refer to 2 2 2 1 2 Radiator fin cleaning A CAUTION Beware of dirt from air blowing Wear protective equipment such as goggles to protect your eyes when blowing compressed air Dust or flying debris can hurt eyes Dirt and dust adhering on the radiator fins reduce the cooling performance causing overheating it a rule to check the radiator fins daily and clean as needed Blow off dirt and dust from fins and periphery with compressed air 0 19MPa 2kgf cm or less not to damage the fins with compressed air If contaminated heavily apply detergent thoroughly clean and rinse with tap water shower IMPORTANT Never use high pressure water or air from close by fins or never attempt to clean using a wire brush Radiator fins can be damaged 3 V belt tension check The second time and after Check and adjust the V belt tension Refer to 2 2 2 2
126. tandard Continuous contact all around 63 Strait edge Thickness gage Distortion at combustion surface Valve sink Valve sinking depth Valve sink depth Valve seat contact 4 Disassembly Inspection and Reassembly of Engines 2 Valve guide Measuring positions Mainly check damage and wear on the inside wall PA DM a b C B Apply supply part code when replacing the part Valve guide inside diameter Service part code 119717 11800 Valve stem clearance Part name Place Standard Limit Guide I D 6 000 6 012 6 08 Intake valve Stem O D 5 960 5 975 5 90 Clearance 0 025 0 052 0 16 Guide I D 6 000 6 012 6 08 Exhaust valve Stem O D 5 945 5 960 5 90 Clearance 0 040 0 067 0 17 3 Intake exhaust valve Mainly clean and check damage and wear at the valve stem and seat a Seat contact See 1 d above Measuring positions b Stem outside diameter See 2 above Valve stem outside diameter c Valve head thickness Part Standard Intake 0 9 1 1 Exhaust 1 0 1 2 d Valve stem bend Thickness Overall length Valve head thickness mm Standard Limit Intake Exhaust 86 8 87 2 86 6 Valve bend and length 64 4 Disassembly Inspection and Reassembly of Engines 1 Valve spring Mainly inspect damage and corrosion mm Free length standard Inclination limit 37 8
127. tch the task at hand Avoid wearing jewelry unbuttoned cuffs ties or loose fitting clothes around moving machinery A serious accident viii may occur if caught in moving rotating machinery 3 TOOLS WARNING Appropriate Lifting Holding When lifting an engine use only a lifting device crane jack etc with sufficient lifting capacity Do not overload the device Use only a chain cable or lifting strap as an attaching device Do not use rope serious injury may result To hold or support an engine secure the engine to a support stand test bed or test cart designed to carry the weight of the engine Do not overload this device serious injury may result Never run an engine without being properly secured to an engine support stand test bed or test cart serious injury may result A CAUTION Appropriate Tools Always use tools that are designed for the task at hand Incorrect usage of tools may result in damage to the engine and or serious 9 personal injury 4 GENUINE PARTS and MATERIALS Genuine Parts A CAUTION Always use genuine YANMAR parts or YANMAR recommended parts and goods Damage to the engine shortened engine life and or personal injury may result 5 FASTENER TORQUE A WARNING v kg 6 Electrical WARNING e A WARNING e Torqueing Fasteners Always follow the torque values and procedures as designated in the
128. tem seal mm d1 d2 d3 L1 L2 L3 15 0 21 12 11 0 65 4 or more Tolerance d1 0 2 11 0 1 XLocally manufactured 49 4 Disassembly Inspection and Reassembly of Engines No Tool name Applicable model and tool size Illustration Filter wrench for removal installation of 6 L O filter Available on the market ym Camshaft bushing tool for extracting mm camshaft bushing L1 L2 91 92 18 70 45 48 7 Tolerance 0193 d2 0 Locally manufactured Flex Hone iim For re honing of ParsNo Oylnderbee cylinder liner Parts No Cylinder bore 129400 92410 70 76 8 Piston insertion tool for inserting piston Yanmar code No 955500 02476 above piston insertion tool is applicable to 60 125 mm diameter pistons Piston ring replacer for removal installation of piston ring 10 Available on the market Crankshaft pulley installing tool Locally manufactured 11 for 4TNV94L Refer to 4 3 6 in detail 50 4 Disassembly Inspection and Reassembly of Engines 2 Measuring instruments Instrument name Dial gage Application Measurements of shaft bending and strain and gap of surfaces Illustration Test indicator Magnetic stand Measurements of narrow or deep portions that cannot be measured by dial gage For holding the dial gage when measuring using a dial gage standing angles adjustable Micromete
129. ter capacity L 0 6 engine only i Engine Overall length mm 415 Dimensions with flywheel Overall width mm 427 housing Overall height mm 484 Engine mass dry with flywheel housing kg Cooling fan std mm 260 mm O D 5 blades pusher type Crankshaft V pulley diameter 6110 amp 110 amp Fun V pulley diameter std tems marked may differ from the above depending on an engine installed on a machine unit Engine mass and dimensions without radiator 1 General 2 3TNV70 Engine name Unit 70 Engine specification class CH VH Type Vertical in line 4 cycle water cooled diesel engine Combustion chamber Indirect injection Number of cylinders 3 Cylinder borexstroke 70x74 mm Displacement L 0 854 E vo Ming min 3000 3600 Continuous speed rating kW 121 145 Output NET ps 165 197 1 min 3000 3600 3100 3200 3300 3400 3500 3600 Rated output kW 133 160 135 140 143 147 150 154 utput NET 5s 81 217 asa 190 194 QoO Qo4 010 Max no load speed 25 min 3800 3290 3400 3500 3600 3710 3815 Ignition order 1 3 2 1 No 1 cylinder on flywheel side Power take off Flywheel Direction of rotation Counterclockwise viewed from flywheel Cooling system
130. tes if having the air cleaner with a dust indicator even though the outer element has replaced with new one replace the inner element with new one 29 2 Inspection and Adjustment 2 2 6 Inspection every 1 000 hours or one year Be sure to check the following points every 1 000 hours or one year operation whichever comes first Inspection Item Cooling water replacement Diaphragm assy inspection Intake exhaust valve clearance adjustment Fuel injection nozzle pressure inspection 1 Cooling water replacement Cooling water contaminated with rust or water scale reduces the cooling effect Even when antifreeze agent LLC is mixed the cooling water gets contaminated due to deteriorated ingredients Replace the cooling water at least once a year Fill the radiator and coolant recovery tank with the cooling water as following 1 Remove the radiator cap Never open the radiator filler cap while the engine and radiator are A WARNING still hot Steam and hot water will spurt out and seriously burn you Wait until the radiator is cooled down after the engine has stopped wrap the filler cap with a rag piece and turn the cap slowly to gently release the pressure inside the radiator Securely tighten the filler cap after checking the radiator Steam can spurt out during operation if the cap is tightened loosely 2 Loosen the drain plug at the lower portion of the radiator and drain the cooling
131. the charge lamp come ON Replace the charge lamp The charge lamp is available from y 9N Turn the key switch to START The engine starts ON the driven machine manufacturer Inspect the rotor coil and brush IC RG At idling Does the charge lamp Inspect or replace the fan belt and inspect the alternator The lamp flashes The lamp is lit dimly goes OFF m Increase the engine speed to 1500 rpm and turn the light Switch to ON The lamp is lit dimly Measure VB and VL at BAT L terminal during idling Does the charge lamp come ON Measure VB at BAT terminal with the engine running at Excessive voltage drop between VB VL gt 0 5V BAT and batt amp side terminal L terminal defective conduction VB VL lt 0 5V Inspect the diode side gt Inspect the diode side VB gt 15 5 VB 13 15 1500 Turn the light switch to ON during idling the bench test Remarks Explanation on abbreviations 1 Use a fully charged battery GN Alternator i 2 DC voltmeter 0 to 30 V 0 5 class IC RG IC regulator i 3 The check method is also applicable to VB BAT terminal voltage VL L terminal voltage Does the charge lamp come ON gt Replace IC RG Inspect the auxiliary diode ON OFF N
132. the cylinder block in haste since it may damage the alternator or pinch a finger Reassemble The belt deflections A B amp C shall be checked according to 2 2 2 2 in Chapter2 Reassemble Replace the belt with a new one if cracked worn or damaged Carefully prevent the belt from being smeared with oil or grease Point 2 Reassemble Check the thermostat function See 2 7 in Chapter 2 for the check procedure Point 3 Reassemble Replace the fuel filter element with a new one Disassemble Cover the fuel pipe opening with tape to prevent intrusion of foreign matters Point 4 Reassemble Replace the oil filter with a new one After fully tightening the filter manually retighten it with a filter wrench see 4 1 2 1 No 6 in Chapter 4 by 3 4 turn Point 5 Disassemble Cover the fuel injection pipe and pump inlets and outlets with tape or the like to prevent intrusion of foreign matters 60 4 Disassembly Inspection and Reassembly of Engines Point 6 Breather system A reductor to intake air system of Diaphragm cover Sp blowby gas Spring amp Rocker arm cover Emitting blowby gas is harmful to natural Center plate environment Therefore blowby gas reductor is Diaphragm adopted to TNV series engines as breather system The system of model 3TNV76 is shown as a representative of that breather system in the right figure Some of the combustion gas
133. ube oil engine may become a horizontality Insert the dipstick fully and check the oil level The oil shall not be contaminated heavily and have appropriate viscosity No Cooling water or diesel fuel shall be mixed When lube oil is supplied after the engine running check the lube oil level after about 10 minutes pass after the engine shutdown so that the lube oil inside may be returned to the oil pan Standard The level shall be between the upper and lower limit lines on the dipstick Dipstick Dipstick Upper limit Lower limit 16 2 Inspection and Adjustment Unit liter Model Total volume Effective volume 2TNV70 1 7 0 7 2 8 1 3 3TNV70 3 8 1 7 3 5 1 6 3TNV76 4 4 2 1 Lube oil capacity may differ from the above volume depending on an engine installed on a machine unit b Replenishing oil pan with lube oil If the remaining lube oil level is low fill the oil pan with the specified lube oil to the specified level through the filler port NOTICE The oil should not be overfilled to exceed the upper limit line Otherwise a naturally aspirated engine may intake lube oil in the combustion chamber during the operation then white smoke oil hummer or urgent rotation may occur because the blowby gas is reduced in the suction air flow In case of turbo charged engine oil may jet out from the breather or the engine may become faulty 4 Cooling water level check and reple
134. urement using a connecting rod aligner Cylinder gage Connecting rod small end 4 Disassembly Inspection and Reassembly of Engines d Rod big end measurement Measure the crankpin outside diameter The oil clearance is calculated as the difference in the crankpin outside diameter and the crank pin metal inside diameter refer to 4 4 5 2 c Replace the crankpin metal if a clearance becomes close to the limit value in the table below If wear and unevenly wear on the crankpin is found correct by grinding the crankpin and apply the undersized bushing refer to 4 4 5 2 c NOTICE When measuring the inside diameter of the rod big Cylinder gage end install the bushing in the rod big end not to mistake top and bottom of the crankpin metal and fasten the rod bolts by the standard torque shown in the table Tightening torque of rod bolt N m kgf m Lube oil application Tightening torque threaded portion and bearing seat surface Crankpin metal I D measurement 22 6 27 5 2 3 2 8 Lube oil applied Standard of rod big end mm Item Standard Crankpin O D 41 952 41 962 Metal I D 41 982 42 002 Metal thickness 1 503 1 509 Clearance 0 020 0 058 6 Tappet Mainly check the tappet contact surface with the cam and push rod Slight surface defects shall be corrected with an oilstone Tappet stem outside diameter measurement The outside diameter of the tappet stem i
135. ust the accelerator cable if there is a dislocation or excessive play between the accelerator and the governor lever Refer to 3 2 3 7 Warning lamp amp instruments function check Before and after starting the engine check to see that the alarm function normally Failure of alarm cannot warn the lack of the lube oil or the cooling water Make it a rule to check the alarm operation before and after starting engine every day Refer to each manual for machine units in details 18 2 Inspection and Adjustment 2 2 2 inspection after initial 50 hours operation Be sure to check the following points after initial 50 hours operation thereafter every 250 hours or 3 months operation Inspection Item Lube oil and filter replacement V belt tension check 1 Lube oil and filter replacement CAUTION When engine is still hot be careful with a splash of lube which may cause burns Replace lube oil after the lube oil becomes warm S It is most effective to drain the lube oil while the engine is still warm In early period of use the lube oil gets dirty rapidly because of the initial wear of internal parts Replace the lube oil earlier Lube oil filter should also be replaced when the lube oil is replaced The procedure of lube oil and lube oil filter replacement is as follows a Drain lube oil Remove the oil filler cap to drain easily while drainig the lube oil Remove th
136. value of the measured diameters In the same way measure and calculate the difference in the B direction Cylindricity is the maximum value between those difference values Item Model Standard M size 2 3TNV70 70 000 70 030 3TNV76 76 000 76 030 Cylinder inside diameter Roundness Cylinder bore all TNV 0 01 or less Cylindricity 78 4 Disassembly Inspection and Reassembly of Engines c Ifthe limit is exceeded or any surface defect is found repair by boring and honing Use oversized piston and new piston rings as required Oversized piston 0 25 mm mm Model Code No Standard 2 3 70 70 250 3TNV76 119717 22090 76 250 Piston ring for oversized 0 25mm Model Piston ring code No Assy 2 3TNV70 3TNV76 119717 22550 Cylinder boring dimension mm Model Boring dimension 2 3 70 70 250 70 280 3TNV76 76 250 76 280 2 Crankshaft Mainly check seizure and wear of the crankpins and journals Since the crankshaft gear is shrink fitted heat to 180 to 200 C when extraction is necessary a Shaft portion color check After washing the crankshaft inspect it by means of color check or a magnaflux inspector Replace it if cracked or heavily damaged Slight defects shall be corrected by grinding b Crankshaft bend Support the crankshaft journals at both ends with V blocks Use a dial gage and measure the run out at the cent
137. ve equipment such as goggles to protect your eyes when blowing compressed air Dust or flying debris can hurt eyes The engine performance is adversely affected when the air cleaner element is clogged by dust So periodical cleaning after disassembly is needed 1 Undo the latches on the dust pan and remove the dust pan 2 And pull out the element 3 Blow air 0 29 0 49MPa 3 0 5 0kgf cm from inside the element to blow dust off as shown in 4 22 the illustration right Air blow Apply the air blowing pressure as low as possible latch Dust so as not to damage the element If having the air cleaner with double elements never remove and clean the inner element The aim of installing the inner element is for back up protecting from intaking dust during engine running when leaving the outer element to Element A s mark Dust indicator optional Air cleaner case reinstall after removing it or when damaging the outer element unexpectedly during engine lf Outer element running gt 4 Replace the element with new if the element 4 i is damaged excessively dirty or oily 5 Clean inside of the dust pan 6 Reinstall the element inserting into the air cleaner XG And install the dust pan to the air cleaner case latch 2 matching the arrow marks or the dust pan and air Double elements type air cleaner cleaner case then fasten the dust pan
138. xceeds the specified value The combined total resistance of the battery cable in both directions between the starting motor and battery should be within the value indicated on the wiring diagram The starting motor will malfunction or break down if the resistance is higher than the specified value 3 When the resistance of the starting motor circuit exceeds the specified value The combined total resistance of the wiring between the starting motor and key switch or power relay or safety relay depending on the application should be within the value indicated on the wiring diagram Engine starting will be difficult if the resistance is higher than the specified value This can also cause welding of the magnet switch at the point of contact and resultant burning of the armature coil 4 When there is no safety relay Over running when the electric current flows for too long is a major cause of starting failure This burns the armature coil and causes clutch failure Excessive work and failure of the key switch to return properly are the main causes of over running The user must be given sufficient warning about this Be sure to use the safety relay to prevent over running This safety relay is supplied as an option Consult Yanmar first when planning to install a safety relay at your own company In the case of failure to consult with Yanmar our warranty will not be applied to all the electrical equipment 5 When there is too much rust due to
139. y Fuel filter Oil filter Note This figure shows the 3TNV76 4 2 2 Disassembly procedure Disassemble in the order of the numbers shown in the Rocker arm cover illustration 1 Remove the alternator assy Point1 of 4 2 4 2 Remove the fan pulley and V belt 3 Remove the thermostat case Point2 4 Remove the fuel filter and fuel oil piping Point3 5 Remove the oil level gage 6 Remove the oil filter Point4 7 8 9 0 2 Valve cylinder head the fuel injection pipes Point5 Remove the exhaust manifold assy Remove the rocker arm cover Assy Point6 in 24 10 Remove the rocker shaft assy push rods and b ig valve caps Point7 PIC cap 11 Remove the cylinder head assy and head gasket E Cotter v Point8 8 amp Spring holder AE Valve spring 12 Remove the fuel injection valves and fuel return e Stem seal pipe Point9 13 Remove the intake exhaust valves stem seals and valve springs Point10 14 Remove the rocker arms from the rocker shaft 4 2 3 Reassembly procedure Reverse order of the disassembly procedure Exhaust valve Suction valve 59 4 Disassembly Inspection and Reassembly of Engines 4 2 4 Servicing points Point 1 Disassemble Adjust the V belt tension Loosen the mounting bolt while supporting the S inserting a bar alternator A CAUTION Do not tilt the alternator toward
140. y so as not to damage the combustion surface Reassemble Apply sealant code No 977770 01212 and install flywheel housing by matching the two dowel pins After assembly raise the engine with its flywheel housing on the bottom side A CAUTION Unforeseen injury may arise due to falling of slipping when raising or reversing the engine Carefully operate so as not to lose balance 75 4 Disassembly Inspection and Reassembly of Engines Point 4 Journal bearing cap Disassemble Before removing the journal bearing measure the crankshaft side gap Measure it in either method because there are the next two methods 1 Install a dial gage on the cylinder block and move a crankshaft in front and back and measure the side gap as shown in the right figure 2 Put a thickness gauge in the clearance between thrust metal and crankshaft directly and measure it mm Crankshaft Side gap standard Limit A 0 111 0 250 Thrust metal Reassemble Bearing cap f the side gap exceeds the standard replace the thrust metal with an oversized one 0 25mm Oversized thrust metal 0 2505 Thickness gauge mm Thrust metal assy code Standard thickness 119810 02940 2 055 2 105 Side gap measurement2 Disassemble Remove the bearing caps cap bearings and thrust metals Place each thrust metal with identification of the position and direction Carefully install each thrust metal so that t

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