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SERVICE MANUAL - Martin Diesel Inc

1. OB I NM G00100 PRINTED IN JAPAN
2. 2 3 What is Covered by this Warranty 2 3 How Long is the Warranty Period 2 8 What the Engine Owner Must Do 2 3 To Locate an Authorized Yanmar Industrial Engine Dealer OM eere rae eer eh ene 2 4 What Yanmar Will 2 4 What is Not Covered by this Warranty 2 4 Warranty eee 2 5 Warranty Modifications 222 46 2 5 QUESSU 2 5 Retail Purchaser 11 2 5 Emission System Warranty 2 6 Yanmar Co Ltd Limited Emission Control System Warranty 0 steh aate erba s o t cede a pa P Ut 2 6 Your Warranty Rights and Obligations 2 6 Manufacturer s Warranty 4 4 2 49 28 4 2 6 Warranty Coverage 01 2 7 Warranted 2 7 imo Ue P 2 8 Owner s Warranty Responsibilities sess 2 8 TNM Series Service Manual 2 1 WARRANTIES This Page Intentionally Left Blank 2 2 TNM Series Service Manual Yanmar Limited Warranty YANMAR WARRANTIES YANMAR LIMITED WARRANTY What
3. 7 22 Removal of Fuel 0 7 22 Testing of Fuel Injectors 7 22 TNM Series Service Manual 7 1 FUEL SYSTEM 7 2 Disassembly and Inspection of Fuel Injectors 7 25 Adjusting Fuel Injector Pressure 2 7 26 Reassembly 4 7 27 Installation of the Fuel 0 00 7 27 TNM Series Service Manual Before You Begin Servicing BEFORE YOU BEGIN SERVICING ENTANGLEMENT HAZARD Stop the engine before you begin to service it NEVER leave the key in the key switch when you are servicing the engine Someone may accidentally start the engine and not realize you are servicing it This could result in a serious injury If you must service the engine while it is operating remove all jewelry tie back long hair and keep your hands other body parts and clothing away from moving rotating parts Failure to comply could result in death or serious injury 0000010en FUME BURN HAZARD Always read and follow safety related precautions found on containers of hazardous substances like parts cleaners primers sealants and sealant removers Failure to comply could result in death or serious injury 0000014en e Series Service Manual FUEL SYSTEM To prevent possible
4. 11 11 Alterniator 11 12 Removal of 11 12 Disassembly of 11 12 Reassembly of 222 11 14 Installation Of 0 11 16 Dynamo Component 2 11 17 Dynamo Wiring 11 18 Operation Of Dynamo d o ae x Pax 11 18 Dynamo Standard 11 19 Testing of Dynamo ved coded vedrai 11 20 Testing Stator Coil Continuity 2 11 20 Testing Stator Coil 222 4 1400 11 20 Testing Dynamo Regulated 11 20 TNM Series Service Manual 11 1 ALTERNATOR EE 11 20 Removal of 11 20 Disassembly of 11 21 Reassembly of 11 21 11 22 Installation of Dynamo eese TNM Series Service Manual Before You Begin Servicing BEFORE YOU BEGIN SERVICING ENTANGLEMENT HAZARD Stop the engine before you begin to service it NEVER leave the key in the key switch when you are servicing the engine Someone may accidentally start the engine and not realize you are servicing it This could result in a serious injury If you must servi
5. TNM Series Service Manual Periodic Maintenance Procedures 4 Reinstall the diaphragm diaphragm plate spring and diaphragm cover Tighten the diaphragm bolts to the specified torque See Tightening Torques for Standard Bolts and Nuts on page 4 24 Failure of the diaphragm and or spring will cause the loss of pressure control and allow an excessive amount of crankcase fumes to be routed to the intake manifold This could result in excessive deposits in the intake system high engine exhaust smoke levels excessive engine oil consumption and or engine run on due to the burning of the engine oil e Series Service Manual PERIODIC MAINTENANCE Every 2000 Hours of Operation Perform the following maintenance every 2000 hours of operation Check and Replace Fuel Hoses and Engine Coolant Hoses Lap the Intake and Exhaust Valves Check and Replace Fuel Hoses and Engine Coolant Hoses ALWAYS environmentally responsible Follow the guidelines of the EPA or other governmental agencies for the proper disposal of hazardous materials such as engine oil diesel fuel and engine coolant Consult the local authorities or reclamation facility NEVER dispose of hazardous materials irresponsibly by dumping them into a sewer on the ground or into ground water or waterways Failure to follow these procedures may seriously harm the environment 0000013en Regularly
6. 0000234A R Figure 6 75 R Inspection of Camshaft 1 Use V blocks and a dial indicator to check camshaft bend Figure 6 76 Place the indicator on the center bearing journal 1 2 0001733A Figure 6 74 Reconditioning the Crankshaft If any of the crankshaft journals do not meet the specifications it may be possible to grind any or all of them to an undersize The connecting rod bearings main bearings and thrust bearing inserts are available as 0 010 in 0 25 mm undersize If 0002196 the journals are ground undersize the following Figure 6 76 plandards higuie 6 15 mustbe adhere 2 Rotate the camshaft and observe the runout to Record the measurements See Camshaft on page 6 7 for specifications 3 Measure the height of each lobe Figure 6 77 1 Record the measurements See Camshaft on page 6 7 for specifications 0001712A Figure 6 77 e Series Service Manual 6 49 4 Measure the diameter of the gear end Figure 6 78 1 intermediate Figure 6 78 2 and flywheel end Figure 6 78 3 bearing journals Record the measurements See Camshaft on page 6 7 for specifications 0001713A Figure 6 78 Inspection of Camshaft Insert Bores Camshaft bushing is not applicable in TNM Therefore measure the bore ID of the camshaft insertion portion in the cylinder block If the bore ID is out of the specification it is requi
7. 15 41 1010JN YOLOW YALYVLS STARTER MOTOR Starter Motor Components STARTER MOTOR COMPONENTS 0002486 Figure 10 1 10 8 TNM Series Service Manual Starter Motor 1 Nut 2 Needle Bearing 3 Pinion Housing 4 Pinion Retaining Ring 5 Stop 6 Pinion 7 Shift Lever 8 Solenoid Switch Assembly 9 Snap Ring 10 Washer 11 Bushing 12 Intermediate Housing 13 Reduction Gear 14 Washer 15 Through Bolt 16 End Housing 17 Brush Plate and Holder 18 Field Assembly 19 Armature 20 Bushing 21 Plate 22 Planetary Gear 3 used 23 Washer 3 used 24 Pinion Shaft 4 Series Service Manual STARTER MOTOR STARTER MOTOR SHOCK HAZARD Turn off the battery switch if equipped or disconnect the negative battery cable before servicing the electrical system Check the electrical harnesses for cracks abrasions and damaged or corroded connectors ALWAYS keep the connectors and terminals clean Failure to comply could result in death or serious injury 0000009en Note While starter motor design varies between models the basic repair procedures are the same The following procedures are typical and may differ from the starter being serviced STARTER MOTOR Removal of Starter Motor 1 Disconnect the battery cables at the battery negative cable
8. and engine oil filter replacement procedures OIL PUMP SERVICE INFORMATION Engine Oil Pressure Medd at Rated Engine rpm at Low Idle Speed 3TNM68 VM VH 42 64 psi 0 29 0 44 MPa 2 96 4 49 3TNM72 VM VH kgf cm 8 8 psi 0 06 MPa 0 6 or greater 3TNM68 CL 35 51 psi 0 24 0 35 MPa 2 44 3 57 3TNM72 CL kgf cm Outer Rotor Outside Clearance 0 0039 0 0063 in 0 0098 in 3TNM72 0 10 0 16 mm 0 25 mm Outer Rotor Side Clearance mt 68 0 0019 0 0039 in 0 0059 3TNM72 0 05 0 10 mm 0 15 mm Outer Rotor to Inner Rotor Tip Clearance Sm d 3TNM68 0 0063 in 3TNM72 0 16 mm e Series Service Manual 9 5 LUBRICATION SYSTEM Lubrication System Diagram LUBRICATION SYSTEM DIAGRAM Oil Filter Bypass Valve Fuel Injection Pump Oil Pressure Switch Cylinder Body Main Gallery Crank Journal Pressure Regulator Valve T Idle Gear Camshaft Oil Pump Shaft Bearing Rocker Arm Oil Suction Pipe Bearing Strainer Tappet Cam Face 0001624 Figure 9 1 9 6 TNM Series Service Manual Trochoid Oil Pump TROCHOID OIL PUMP Components The oil pump on these model engines is located in the front gear case and is driven by the same gear train that drives the camshaft and fuel injection pump You must remove the front gear case cover to gain access t
9. cp m 6 8 Crankshaft Reconditioning 0 6 9 Thrust BearlriQg 6 9 6 10 Piston RING da ul enda 6 10 ER 6 11 6 11 Cylinder Block Specifications 6 12 Cylinder BOCK a 6 12 Special Torque 6 13 Tightening Torque for Special Bolts 6 13 Special Service 0 6 14 Measuring 6 16 TNM Series Service Manual 6 1 VMAS I EC 6 18 Cylinder Head Components essen 6 18 Disassembly of Cylinder 6 19 Cleaning of Cylinder Head 6 23 Inspection of Cylinder Head Components 6 23 Reassembly of Cylinder 6 27 Measuring and Adjusting Valve Clearance 6 32 6 34 Crankshaft and Camshaft Components 6 34 Disassembly of Cylinder Block Components 6 35 Disassembly of Camshaft and Timing Components 6 36 Disassembly of Crankshaft and Piston Componen
10. 0 034 mm Ring Groove 0 0622 0 0628 in 0 0667 in Width 1 580 1 595 mm 1 695 mm 45 0 0579 0 0587 0 0571 Inspection of Ring Width 1 470 1 490 mm 1 450 mm Pistons Second Ring Side Clearance 0 0035 0 0049 in 0 0096 in Piston Rings 0 090 0 125 mm 0 245 mm and Wrist Pin 0 0098 0 0157 in 0 0193 in 6 45 0 250 0 400 mm 0 490 mm Ring Groove 0 1185 0 1191 in 0 1232 in Width 3 010 3 025 mm 3 130 mm 0 1170 0 1177 in 0 1161 in Bing width 2 970 2 990 mm 2 950 mm Oil Ring Side Sie Clesrance 0 0008 0 0022 in 0 0071 in 0 020 0 055 mm 0 180 mm End Clearance 0 0059 0 0138 in 0 0079 0 0177 in 0 0173 in 0 0217 in 0 150 0 350 mm 0 200 0 450 mm 0 440 mm 0 550 mm 6 10 TNM Series Service Manual Crankshaft and Pistons Specifications ENGINE Connecting Rod Connecting Rod Small End Inspection Item 3TNM68 3TNM72 3TNM68 3TNM72 Page Wrist Pin Bushina Inside Diameter 0 7884 0 7891 in 0 8671 0 8678 in 0 7902 in 0 7902 in 9 20 025 20 042 mm 22 025 22 042 mm 20 072 mm 20 072 mm See ENTE 0 7872 0 7874 in 0 8659 0 8661 in 0 7861 in 0 7861 in 19 995 20 000 mm 21 995 22 000 mm 19 967 mm 19 967 mm 7757 9 0 0010 0 0019 in 0 0041 in page 6 47 0 025 0 047 0 105 Connecting Rod Big End Inspection Item 3TNM68 3T
11. 5 After draining the engine coolant flush the radiator and engine block to remove any rust scale and contaminants 6 Reinstall and tighten the drain plug or close the drain cock at the radiator Reinstall and tighten the engine block drain plug 7 Fill radiator and engine with engine coolant See Filling Radiator with Engine Coolant on page 4 17 e Series Service Manual PERIODIC MAINTENANCE Adjust Intake Exhaust Valve Clearance Proper adjustment is necessary to maintain the correct timing for opening and closing the valves Improper adjustment will cause the engine to run noisily resulting in poor engine performance and engine damage See Measuring and Adjusting Valve Clearance on page 6 32 PERIODIC MAINTENANCE Every 1500 Hours of Operation Perform the following maintenance every 1500 hours of operation Inspect Clean and Test Fuel Injectors if necessary Inspect Crankcase Breather System Inspect Clean and Test Fuel Injectors HIGH PRESSURE HAZARD Avoid skin contact with the high pressure diesel fuel spray caused by a fuel system leak such as a broken fuel injection line High pressure fuel can penetrate your skin and result in serious injury If you are exposed to high pressure fuel spray obtain prompt medical treatment NEVER check for a fuel leak with your hands ALWAYS use a piece of wood or cardboard Have your authorized Yanmar industrial engine dealer
12. NEVER overfill the engine with engine inner rotors To inspect this insert a feeler gauge oil between the inner rotor tooth tip Figure 9 6 1 and the outer rotor tooth tip Figure 9 6 2 and measure the clearance ALWAYS keep the oil level between the upper and lower lines on the oil cap dipstick 0000015en Check Outer Rotor Outside Clearance Inspect the outside diameter clearance of the outer rotor To inspect this insert a feeler gauge between the outer rotor Figure 9 5 1 and the lubricating oil pump body Figure 9 5 2 Figure 9 6 9 8 TNM Series Service Manual Trochoid Oil Pump Record the measurement s and see Outer Rotor to Inner Rotor Tip Clearance on page 9 5 for the service limits Check Outer Rotor Side Clearance Inspect the side clearance between the lubricating oil pump body and the outer rotor To measure the side clearance use a straight edge and feeler gauge as shown in Figure 9 7 or a depth micrometer 2 3 4 Figure 9 7 5 Record the measurement s and see Outer Rotor Outside Clearance on page 9 5 for the service limits 6 Check Rotor Shaft Clearance 7 Inspect the rotor shaft clearance Measure the outside diameter of the rotor shaft Figure 9 8 1 and the inside diameter of the cover Determine the clearance by subtracting the outside diameter of the rotor from the inside diameter of the cover e Series Ser
13. NEVER remove or attempt to remove the tamper proof devices from the full load fuel adjusting screw or the high speed throttle limit screw on the fuel injection pump and governor assembly These adjustments have been made at the factory to meet all applicable emissions regulations and then sealed NEVER attempt to make any adjustments to these sealed adjustment screws If adjustments are required they can be made only by a qualified fuel injection shop that will ensure the injection pump continues to meet all applicable emissions regulations and then replace the tamper proof seals Tampering with or removing these devices may void the Yanmar Limited Warranty 0000146en CAUTION The fuel return line is a one piece assembly Use care not to bend or twist the fuel return line 0000171 3 20 TNM Series Service Manual Section 4 GENERAL SERVICE INFORMATION Page Component 1 4 3 Werezue qeu HK 4 4 EPA CARB Emission Control Regulations USA Only 4 4 Emission Control teet ae endete br re 4 5 EPA CARB Labels 4 5 The 97 68 EC Directive Certified 4 5 ENQING Family 4 6
14. Output Surging Engine Starts but Stops Soon Exhaust TROUBLESHOOTING Engine Air Coolant Intake Corrective Action Reference Page Check and Adjust See Checking and Adjusting Fuel Injection Timing on page 7 19 Check and Adjust See Checking and Adjusting Fuel Injection Timing on page 7 19 Use Correct Fuel See Diesel Fuel Specifications on page 4 10 rae See Drain Fuel Filter Water Draining the Fuel Filter Separator on page 5 22 See Drain Fuel Filter Water P Separator on page 5 22 5 i a oro TTT forte TFs ss SN Exhaust Temperature Rise 13 13 TROUBLESHOOTING Troubleshooting Charts This Page Intentionally Left Blank 13 14 TNM Series Service Manual Troubleshooting Charts TROUBLESHOOTING Poor Exhaus t Color Insufficient Trouble Symptom Starting Problem Engine Output Engine Air Coolant Intake Engine Surging Engine Oil Engine Starts but Stops Soon Corrective Action Reference Pages Bleed the Air See Priming the Fuel System on page 4 13 5 E 2 2 Air in Fuel System See Check Replace Fuel Clean or Replace Hoses and Engine Coolant Clogged or Cracked Fuel Line Hoses on page 5 37 Check the Fuel Tank Cock Fuel Filter Fuel Line and Fuel Feed Pump Check and Adjust S
15. 1 Be sure not to exceed the maximum cylinder bore specification Deglazing A used cylinder that did not require boring orhoning should always be deglazed with a ball hone Figure 6 81 2 before installing new piston rings This will properly prepare the cylinder surface to allow new piston rings to seat properly Note When honing a cylinder with either a ridged hone or a ball hone Figure 6 80 1 move the rotating hone up and down in the cylinder bore to accomplish a 30 to 40 crosshatch pattern Figure 6 80 This will provide the ideal surface for the proper seating of new piston rings TNM Series Service Manual Cylinder Block CAUTION Do not allow the honing tool to operate in one position for any length of time Damage to the cylinder wall will occur Keep the tool in constant up and down motion 0000090en MM Y SA M MAMIE 0000248 6 80 Use a 50 50 mixture of diesel fuel and engine oil as a honing fluid Use a 300 grit hone at 300 1200 rpm Figure 6 81 1 00002498 6 81 IMPORTANT Solvents will not adequately remove honing residue resulting in premature piston and ring wear Always wash cylinders using hot soapy water e Series Service Manual ENGINE When honing is completed wash the cylinder block with hot water and soap The cylinder wall is adequately cleaned when a white rag
16. Although atomized burner like shape the needle does not pulsate Caused by excessive carbon contamination of the nozzle tip Sometimes caused by internal contamination 0001750 Although the gauge needle reaches the valve opening pressure the pressure drop is large Bar shape with excessive after drops Damage to the seat Contamination of seat by fine foreign particles Excessively worn seat Fuel Injectors 0001751 Pressure does not increase even when the tester lever is operated Sticking of needle Excessively damaged or worn seat Contamination of seat by foreign matter Damaged or broken internal parts or nozzle case nut Note If the fuel injector fails any tests it should be serviced or replaced as necessary If the pressure is outside specified limits adjust the pressure See Adjusting Fuel Injector Pressure on page 7 26 7 24 TNM Series Service Manual Fuel Injectors FUEL SYSTEM Disassembly and Inspection of Fuel 5 Turn the injector over and remove the nozzle Injectors body nozzle valve valve stop spacer nozzle spring seat nozzle spring and shims CAUTION 6 Inspect the sealing surfaces Figure 7 30 2 between the valve stop spacer and nozzle body Never use a steel wire brush to clean for nicks or scratches Check the contact area fuel injectors Damage to the nozzle and between the valve stop spacer and the nozzle other components is lik
17. D E e c En 2 c LL miS o 2 n hi x Lu a Series Service Manual 13 7 TROUBLESHOOTING Troubleshooting Charts This Page Intentionally Left Blank 13 8 TNM Series Service Manual Troubleshooting Charts TROUBLESHOOTING Insufficient Trouble Symptom Starting Problem Engine Output Engine Surging Engine Oil Engine Starts But Stops Soon Exhaust During Color Work Corrective Action Reference Page Reverse Assembly of Piston Rings Worn Crankpin and Journal Bearing Loose Connecting Rod Bolt Foreign Matter Trapped in Combustion Chamber Excessive Gear Backlash Worn Intake Exhaust Valve Guide See Inspection of Crankshaft and Measure and Replace Camshaft Components on page 6 44 api Tighten to the Specified Torque See page 6 13 See Disassembly of Cylinder Block Components on page 6 35 4 See Checking Timing Gear aa Adjust Gear Meshing Backlash on page 6 36 Measure and Replace See Inspection of Valve Guides on page 6 24 See Check and Adjust the Make Adjustment Governor Lever and Engine Speed Control on page 5 27 See Measuring and Adjusting ERN Adjust the Valve Clearance Valve Clearance on page 6 32 o 5 2 Reassemble Correctly See Reassembly of Pistons on page 6 53 Disassemble and Repair
18. Figure 6 55 1 along the full width of the bearing insert 026980 00X Figure 6 55 IMPORTANT Do not rotate crankshaft when using PLASTIGAGE A false reading may result TNM Series Service Manual Cylinder Block 7 Reinstall the ladder frame and tighten to specification See Special Torque Chart on page 6 13 027139 00X 1 Gear Case Side 2 Flywheel Side Figure 6 56 8 Remove the ladder frame Ry wie xD CN Figure 6 57 9 Compare the width of the flattened PLASTIGAGE Figure 6 57 1 to the graduation marks on the package The mark that most closely matches the width of the flattened PLASTIGAGE will indicate the bearing oil clearance Record the measurement See Crankshaft on page 6 8 for clearance specifications e Series Service Manual ENGINE 10 Repeat with the remaining main bearings Note Be sure to note the markings on the main bearing or make marks so they can be reinstalled in the same order as they were removed Figure 6 58 11 Remove the crankshaft from the engine Note Do not remove the crankshaft gear unless the gear or crankshaft are damaged and require replacement 12 If necessary remove the crankshaft gear Figure 6 59 1 and key Figure 6 59 2 If using a gear puller be careful not to damage the threads in the end of the crankshaft 1 0002193 6 59 6 4
19. Series Service Manual 6 9 Crankshaft and Pistons Specifications Piston Inspection 3TNM68 3TNM72 3TNM68 3TNM72 Page Sfc EM 2 6756 2 6768 2 8331 2 8343 in 3 8550in 2 8313 in 67 961 67 991 mm 71 960 71 990 mm 97 916 mm 71 915 mm Piston Diameter Measurement 0 3937 0 5118 in Location 10 18 mm See 0 0004 0 0027 in 0 0004 0 0028 in Inspection of Pistonto Cyinder Clearance to Pistonto Cyinder Clearance Clearance 0 009 0 069 mm 0 010 0 070 mm Pistons Hole Inside 0 7874 0 7877 in 0 8661 0 8665 0 7889 in 0 8677 in Piston Rings Diameter 20 000 20 008 mm 22 000 22 009 mm 20 039 mm 22 039 mm Wrist Pin West Pin Outside 0 7872 0 7874in 0 8659 0 8661in 0 7860in 0 8648 in 27 age 6 45 Diameter 19 995 20 000 mm 21 995 22 000 mm 19 965 mm 21 965 mm Oil Clearance 0 0000 0 0005 in 0 0000 0 0006 in 0 0029 in 0 0029 in 0 000 0 013 0 000 0 014 0 074 mm 0 074 mm Piston Ring Inspection Item 3TNM68 3TNM72 3TNM68 3TNM72 Page Ring Groove 0 0610 0 0618 in Width 1 550 1 570 mm 0 0579 0 0587 in 0 0571 in 1 470 1 490 1 450 Rin Side Clearance 0 060 0 100 mm End 0 0059 0 0118 in 0 0039 0 0098 in 0 0154 in 0 0013 in 0 150 0 300 mm 0 100 0 250 mm 0 390 mm
20. The engine cooling fan is driven by a V belt which is powered by the Engine Cooling Fan crankshaft V pulley The purpose of the engine cooling fan is to circulate air through the radiator The engine coolant pump circulates the engine coolant through the Engine Coolant Pump cylinder block and cylinder head and returns the engine coolant to the radiator The radiator acts as a heat exchanger As the engine coolant circulates through the cylinder block it absorbs heat The heat in the Radiator engine coolant is dissipated in the radiator As the engine cooling fan circulates air through the radiator the heat is transferred to the air Cooling System The radiator cap controls the cooling system pressure The cooling system is pressurized to raise the boiling point of the engine coolant As the engine coolant temperature rises the system pressure and the coolant volume increases When the pressure Radiator Gap reaches a preset value the release valve in the radiator cap opens and the excess engine coolant flows into the reserve tank As the engine coolant temperature is reduced the system pressure and volume is reduced and the vacuum valve in the radiator cap opens allowing engine coolant to flow from the reserve tank back into the radiator The reserve tank contains the overflow of engine coolant from the Reserve Tank radiator If you need to add engine coolant to the system add it to the reserve tank not to the radiator A thermos
21. 0006458 14 Oil Pressure Switch 15 Dipstick engine oil 16 Governor Lever 17 Fuel Injection Pump 18 Top Filler Port engine oil 19 Intake Manifold 20 Air Intake Port from air cleaner 21 Lifting Eye flywheel end 22 Rocker Arm Cover 23 Stop Solenoid 24 Flywheel 25 Starter Motor 26 Exhaust Manifold Engine oil drain plug location may vary based on oil pan options e Series Service Manual 4 3 GENERAL SERVICE INFORMATION LOCATION OF LABELS Figure 4 2 shows the location of regulatory emission control Figure 4 2 1 and engine nameplate Figure 4 2 2 labels on Yanmar TNM series engines In addition to the engine nameplate the engine model and serial numbers are stamped on flat pads on the left side of the crankcase 2 0006459 Figure 4 2 Engine Nameplate Typical MODEL DISPLACEMENT ENGINE NO YANMAR YANMAR CO LTD MADE IN JAPAN 0003852 4 4 Location of Labels EPA CARB EMISSION CONTROL REGULATIONS USA ONLY Yanmar TNM engines meet Environmental Protection Agency EPA U S Federal emission control standards as well as the California Air Resources Board CARB regulations Only engines that conform to CARB regulations can be sold in the State of California Refer to EPA CARB Emission Control Regulations USA Only on page 4 4 and Required EPA ARB Maintenance USA Only on page 5 16 in the Pe
22. Engine System Continued Co Os EST T Fe TTT To perro to Ll 2 D 2 2 2 x 8 z g s z o 2 2 a Series Service Manual 13 9 TROUBLESHOOTING Troubleshooting Charts This Page Intentionally Left Blank 13 10 TNM Series Service Manual Troubleshooting Charts Engine Coolant System Engine Oil System Insufficient Starting Problem Engine Output Trouble Symptom Engine Starts but Stops Soon Excessive Radiator Cooling Incorrect Engine Oil Engine Oil System Leakage ie Insufficient Delivery Capacity of Trochoid Pump Clogged Engine Oil Filter BENESSERE Defective Pressure Regulating Valve Poor Exhaus t Color mae el prr Series Service Manual Engine Surging Engine Cil D wn 2 814 5 8 8 Jt Ww O xl o TROUBLESHOOTING Engine Air Coolant Intake Corrective Action Reference Page See Disassembly of Engine Coolant Pump on page 8 7 Replace Thermostat Replace Thermostat or Check for Loose Fan Belt See Disassembly of Engine Coolant Pump on page 8 7 or Check and Adjust Cooling Fan V Belt on page 5 27 Check Water Leakage fr
23. L cu in 16 38700 mL floz U S x 0 02957 L floz U S x 29 57000 mL cm X 1 00000 mL x 0 03382 fl oz U S Units of Mass Ib X 0 45360 kg OZ X 28 35000 g kg X 2 20500 1 9 X 0 03527 07 Units of Force Ibf x 4 4480 Ibf x 0 4536 kgf N X 0 2248 Ibf N x 0 1020 kgf kgf x 2 2050 kof x 9 8070 N e Series Service Manual GENERAL SERVICE INFORMATION Units of Torque ft lb x 1 3558 ft Ib x 0 1383 in Ib X 0 1130 in Ib 0 0115 kgf m x 7 2330 kgf m x 86 8000 kgf m x 9 8070 N m x 0 7376 8 8510 x 0 1020 Units of Pressure psi x 0 0689 psi x 6 8950 psi x 0 0703 bar x 14 5030 bar x 100 0000 bar x 29 5300 kPa x 0 1450 kPa x 0 0100 kPa x 0 0102 kg cm x 98 0700 kg cm x 0 9807 kg cm x 14 2200 Hg 60 x 0 0333 Hg 60 3 3770 Hg 60 x 0 0344 Units of Power hp metric or Ps 0 9863201 9r 0 7354988 hp SAE x 1 0138697 hp SAE x 0 7456999 kw x 1 3596216 kw x 1 3410221 Units of Temperature F 1 8 x C 32 C 0 556 x F 32 N m kgf m N m kgf m ft lb in lb N m ft lb in lb kgf m bar kPa kg cm psi kPa in Hg 60 F psi bar kg cm psi bar kPa bar kPa kg cm hp SAE kW hp metric or PS kW hp metric or PS hp SAE 4 27 GENERAL SERVICE INFORMATION This Page Intentionally Left
24. and for proper operation of the indicators and or gauges During the first hour of operation vary the engine speed and the load on the engine Short periods of maximum engine speed and load are desirable Avoid prolonged operation at minimum or maximum engine speeds and loads for the next four to five hours During the break in period carefully observe the engine oil pressure and engine temperature During the break in period check the engine oil and coolant levels frequently 000001 ten CAUTION NEVER engage the starter motor while the engine is running This may damage the starter motor pinion and or ring gear 0000012en e Series Service Manual SAFETY CAUTION NEVER attempt to modify the engine s design or safety features such as defeating the engine speed limit control or the fuel injection quantity control Failure to comply may impair the engine s safety and performance characteristics and shorten the engine s life Any alterations to this engine may affect the warranty coverage of your engine Yanmar Limited Warranty on page 2 3 0000044TNVIDISM CAUTION NEVER use high pressure water or compressed air at greater than 28 psi 193 kPa 19 686 mmAq or a wire brush to clean the radiator fins Radiator fins damage easily 0000016en CAUTION NEVER attempt to adjust the low or high idle speed limit screw This may impair the safety and performance of the
25. contaminating the engine oil Carefully clean the oil cap dipstick and the surrounding area before you remove the cap NEVER mix different types of engine oil This may adversely affect the lubricating properties of the engine oil NEVER overfill Overfilling may result in white exhaust smoke engine overspeed or internal damage 0000005en CAUTION ALWAYS be environmentally responsible Follow the guidelines of the EPA or other governmental agencies for the proper disposal of hazardous materials such as engine oil diesel fuel and engine coolant Consult the local authorities or reclamation facility NEVER dispose of hazardous materials irresponsibly by dumping them into a sewer on the ground or into ground water or waterways Failure to follow these procedures may seriously harm the environment 0000013en TNM Series Service Manual Periodic Maintenance Procedures PERIODIC MAINTENANCE The engine oil on a new engine becomes 6 Remove the oil drain plug Figure 5 2 1 contaminated from the initial break in of internal Allow oil to drain parts It is very important that the initial oil and filter 7 After all oil has been drained from the engine change is performed as scheduled reinstall the oil drain plug Figure 5 2 1 and tighten to 39 8 47 0 ft lb 53 9 63 7 N m 5 5 Note The oil drain plug may be in another location if an optional oil pan is used 6 5 kgf m 8 D
26. machine and shorten its life If the idle speed limit screws require adjustment see your authorized Yanmar industrial engine dealer or distributor 0000017en CAUTION The starter motor can be damaged if operated continuously longer than 10 seconds while performing the no load test 0000034en SAFETY CAUTION The tightening torque in the Standard Torque Chart in General Service Information should be applied only to the bolts with a 7 head JIS strength classification 7T Apply 60 torque to bolts that are not listed Apply 80 torque when tightened to aluminum alloy 0000023enTNVIDISM CAUTION Establish a periodic maintenance plan according to the engine application and make sure you perform the required periodic maintenance at intervals indicated Failure to follow these guidelines will impair the engine s safety and performance characteristics shorten the engine s life and may affect the warranty coverage on your engine See Yanmar Warranties section Consult your authorized Yanmar dealer or distributor for assistance when checking items marked with e 0000024enTNVIDISM CAUTION If the fuel filter water separator is positioned higher than the fuel level in the fuel tank water may not drip out when the fuel filter water separator drain cock is opened If this happens turn the air vent screw on the top of the fuel filter water separator 2 3 turns counterclockwise Be sur
27. 0 26 gal 1 0 L Engine Only e Series Service Manual 4 21 GENERAL SERVICE INFORMATION Principal Engine Specifications 72 EPA Tier 4 Engine Model 3TNM72 Version e E o ype ay Vertical In line Diesel Engine Combustion System Ball Type Swirl Chamber Aspiration Natural No of Cylinders 57 3 3 Bore x Stroke 2 83 x 2 91 in 72 x 74 Displacement 55 1 cu in 0 904 L RA in CE SAE 8871404 10 1 20 Pw E Ep 106 179 216 1500 1800 2000 s 2400 s s 3000 3000 1 1 3600 142 156 168 182 197 194 234 209 221 236 e DECR ETAR THESE RECS 239 High Idling 1600 1900 2185 2380 2595 2805 3020 3235 3175 3770 3415 3630 3840 Engine Weight Dry with Flywheel 21 kg 205 Ib 93 kg ene CAU kg 187 Ib 85 kg Housing PTO Position Flywheel End Direction of Rotation Counterclockwise Viewed from Flywheel End Cooling System SS Liquid Cooled with Radiator Lubricating System Forced Lubrication with Trochoid Pump Normal Oil Pressure at Rated Engine Speed 34 8 63 8 psi 0 240 0 440 MPa 2 4 4 4 kgf cm N Oil P t s Speed d 8 5 psi 0 06 MPa 0 6 kgf cm or greater Electric Starting Starter Motor DC12V 1 6 hp 1 2 kW Starting System Dynamo DC12V 20A
28. 0002487 Figure 10 28 3 Reinstall the pinion clutch assembly Figure 10 29 2 return spring if equipped and pinion stop Figure 10 29 3 onto the pinion shaft Figure 10 29 1 Reinstall the retaining ring Figure 10 29 4 in the groove in the pinion shaft Slide the pinion stop over the retaining ring e Series Service Manual STARTER MOTOR 2 ES 3 Figure 10 29 0000152B 4 Apply a small amount of high temperature lithium grease obtain locally to the contact surfaces of the shift lever Reassemble the shift lever Figure 10 30 2 spacer if equipped Figure 10 30 1 and pin 5 Reinstall the pinion shaft assembly Figure 10 30 4 in the pinion housing Figure 10 30 3 Be sure the shift lever properly engages the pinion 1 2 0000148 10 30 6 Apply a small amount of high temperature lithium grease obtain locally to the surface of the plunger and the hole that engages the shift lever 7 Attach the plunger to the shift lever 10 17 STARTER MOTOR Starter Motor 8 Reinstall the plate onto the intermediate 13 Reinstall the two through bolts and tighten housing and carefully reinstall the armature securely assembly Figure 10 31 2 into the pinion 14 Reinstall the return spring if equipped shaft assembly Figure 10 33 3 on the solenoid plunger Figure 10 33 4 Reinstall the solenoid switch coil Figure
29. 11 24 1 2 Remove the nut Figure 11 23 2 lock washer Figure 11 24 3 and flat washer Figure 11 24 4 1 0002143 Figure 11 24 3 Remove the through bolt Figure 11 25 1 pulley half Figure 11 25 2 flywheel Figure 11 25 3 flat washer Figure 11 25 4 bearings Figure 11 25 5 and spacer Figure 11 25 6 0002144 Figure 11 25 4 Remove the screws Figure 11 26 1 and the stator assembly Figure 11 26 2 5 Remove the rear bearing Figure 11 26 3 e Series Service Manual ALTERNATOR 0002145 Figure 11 26 Reassembly of Dynamo Reinstall the rear bearing Figure 11 26 3 Reinstall the stator Figure 11 26 1 Reinstall screws Figure 11 26 1 Reinstall the front bearings Figure 11 27 5 and spacer Figure 11 27 6 5 Reinstall the flat washer Figure 11 27 4 flywheel Figure 11 27 3 pulley half Figure 11 27 2 and through bolt Figure 11 27 1 ce 0002144 Figure 11 27 11 21 ALTERNATOR 6 Reinstall the flat washer Figure 11 28 4 lock washer Figure 11 28 3 and nut Figure 11 28 2 Tighten the nut to the specified torque 7 Reinstall the rear cap Figure 11 28 1 1 0002143 Figure 11 28 11 22 Dynamo Installation of Dynamo Position the dynamo on the gear case Loosely reinstall the nut Figure 11 29 2 on
30. 2 then full torque See Special Torque Chart on page 6 13 IMPORTANT Application method of liquid packing Apply plenty of liquid packing to these portions in the flywheel side in particular until protruding to the oil seal insertion hole and wipe off the protruded liquid packing 027654 00X Figure 6 92 Cylinder Block 7 The surface difference between the surfaces on Installation of Pistons the flywheel side and the gear case side and the ladder frame surface shall be 0 1 or IMPORTANT less Do not allow the connecting rod to contact the crankshaft journal during piston installation Damage to the crankshaft bearing journal may result o of Sal NO NO Ox E 99 oo 1 Lubricate piston piston rings and cylinder with 2 clean engine oil or assembly lubricant 2 Rotate the crankshaft so the crankpin for the piston being installed is near bottom dead center 1 Gear Case Side 2 Flywheel Side Figure 6 93 8 Rotate the crankshaft to ensure it turns freely 9 Apply ThreeBond Liquid Gasket No 1212 Yanmar Part No 977770 01212 to the mounting flange of the flywheel housing Figure 6 94 2 10 Align the flywheel housing with the two dowel pins Figure 6 94 3 11 Reinstall flywheel housing and seal assembly 12 Reinstall the flywheel Figure 6 94 1 and tighten the bolts to the specified torque See Special Torque Chart
31. 29 4 N m 3 0 kgf m 43 ft lb 4 24 TNM Series Service Manual Tightening Torques for Standard Bolts and Nuts GENERAL SERVICE INFORMATION Nominal Thread 112 148 in lb M8 12 7 16 7 N m 1 3 1 7 kgf m 173 225 in lb 19 6 18 734 N m 2 0 3 5 kgf m 18 25 ft lb Pipe Joint Bolt M12 24 5 34 3 N m 2 5 3 5 kgf m 29 36 ft lb M14 39 2 49 0 N m 4 0 5 0 kgf m 36 43 ft lb M16 49 0 58 8 N m 5 0 6 0 kgf m Note Torque values shown in this manual are for clean non lubricated fasteners unless otherwise specified 4 Series Service Manual 4 25 GENERAL SERVICE INFORMATION ABBREVIATIONS AND SYMBOLS Abbreviations A ampere AC alternating current Association des Constructeurs BOER Europ ens d Automobilies Ah ampere hour approx approximately API American Petroleum Institute ARB Air Resources Board ATDC after top dead center BTDC before top dead center C degree Celsius CARB California Air Resources Board CCA cold cranking amp cm centimeter cm cubic centimeter cm min cubic centimeter per minute cu in cubic inch DC direct current DI direct injection DVA direct volt adapter EPA Environmental Protection Agency ESG electronic speed governor E degree Fahrenheit fl oz fluid ounce U S fl oz min fluid ounce U S per minute ft foot ft Ib foot pound ft Ibf min foot pound force per minute g gram ga
32. 6 101 2 e Series Service Manual Cpu OD ENGINE IMPORTANT Be sure to align the flats on the oil pump with the flats on the crankshaft gear Reinstall the timing gear case cover Reinstall and tighten the gear case cover bolts Reinstall the crankshaft pulley Reinstall the washer and bolt Tighten to the specified torque See Special Torque Chart on page 6 13 for specifications Installation of Oil Pan T Reinstall the oil pickup tube Figure 6 102 1 and a new O ring Figure 6 102 2 Q Figure 6 102 Apply a continuous bead of ThreeBond Liquid Gasket No 1212 Yanmar Part No 977770 01212 to the mounting surface of the oil pan Figure 6 103 2 and crankcase extension if equipped Figure 6 103 1 Be sure to circle each bolt hole If equipped reinstall the crankcase extension Figure 6 103 1 Reinstall the oil pan and tighten the bolts securely 6 103 Final Assembly of Engine 1 2 p o oe eS 6 60 Reinstall the starter motor Reinstall the cylinder head See Heassembly of Cylinder Head on page 6 29 Reinstall the engine in the machine Reconnect the fuel and coolant lines Reinstall the alternator Reconnect and adjust the throttle cable Reconnect all electrical connections Fill the engine with oil and coolant Reconnect the battery cables negative cable last TNM Series Service Manual
33. 8 3 1 1 0000577 8 3 2 Apply 10 8 14 8 psi 75 105 kPa 0 75 1 05 kgf cm to the cooling system If the pressure reading drops the engine coolant system is leaking Identify the source of the leak and repair ENGINE COOLANT PUMP Disassembly of Engine Coolant Pump Verify the condition of the engine coolant pump before disassembling it from the engine Check the engine coolant pump shaft bearing for abnormal noise sticking excessive play and water leakage Replace the coolant pump if any of these conditions are present CAUTION If the engine coolant pump must be replaced replace the engine coolant pump as an assembly only Do not attempt to repair the engine coolant pump or replace individual components 0000041en 1 Make sure the engine and engine coolant are not hot e Series Service Manual COOLING SYSTEM Before removing the engine coolant pump or thermostat it will be necessary to drain the engine coolant Drain the coolant into a clean container if the coolant is to be reused Otherwise properly dispose of the coolant Drain the coolant from the radiator See steps 1 4in Drain Flush and Hefill Cooling System with New Coolant on page 5 33 Loosen the alternator mounting bolts Loosen and remove the V belt and rotate the alternator away from the engine and out of the way PINCH HAZARD Carefully rotate the a
34. 9 1 Starter Pn 10 1 Alternator 5 2 dee c E rr ust d 11 1 Electric Wiring be nid 12 1 Troubleshooting 13 1 Series Service Manual TABLE CONTENTS This Page Intentionally Left Blank iv TNM Series Service Manual Section 1 INTRODUCTION This Service Manual describes the service procedures for the TNM series indirect injection engines These engines are certified by the U S EPA California ARB and or the 97 68 EC Directive for industrial use Please use this manual for accurate quick and safe servicing of the engine Since the directions in this manual are for a typical engine some specifications and components may be different from your engine Refer to the documentation supplied by the optional equipment manufacturer for specific service instructions Yanmar products are continuously undergoing improvement This Service Manual might not address possible field modifications to the equipment Contact an authorized Yanmar industrial engine dealer or distributor for answers to any questions relating to field modifications e Series Service Manual 1 1 INTRODUCTION This Page Intentionally Left Blank 1 2 TNM Series Service Manual Section 2 YANMAR WARRANTIES Page Yanmar Limited
35. CAUTION OP MOOSA I UEY Use a new special O ring between the engine coolant pump the joint sure to use the special O ring for each CAUTION engine model Although the O ring If the engine coolant pump must be dimensions are the same as a replaced replace the engine coolant commercially available O ring the pump as an assembly only Do not material is different attempt to repair the engine coolant 0000042en pump or replace individual components 000004 1en 8 4 TNM Series Service Manual Introduction COOLING SYSTEM INTRODUCTION This section of the Service Manual describes the procedures necessary to service the 3TNM68 and 2 engine coolant pump COOLING SYSTEM DIAGRAM Figure 8 1 1 Cylinder Head 4 Radiator 2 Thermostat 5 Coolant Recovery Tank 3 Engine Coolant Pump 6 Cylinder Block e Series Service Manual 8 5 COOLING SYSTEM Engine Coolant Pump Components ENGINE COOLANT PUMP COMPONENTS Figure 8 2 1 Thermostat Cover 6 Engine Coolant Pump Gasket 2 Thermostat 7 V Belt 3 Engine Coolant Pump 8 Engine Coolant Pump V Pulley 4 Temperature Switch 9 Spacer 5 Gasket 10 Engine Coolant Fan 8 6 TNM Series Service Manual Engine Coolant System Check ENGINE COOLANT SYSTEM CHECK Check the engine coolant system for leakage 1 With the radiator properly filled install a cooling system tester Figure
36. Intentionally Left Blank 13 6 TNM Series Service Manual Troubleshooting Charts TROUBLESHOOTING Troubleshooting Charts Insufficient Poor Trouble Symptom Starting Problem Engine Exhaus Output t Color Engine Surging Engine Oil Engine Starts But Stops Soon Exhaust Color Corrective Action Reference Page Improper Intake Exhaust Valve Clearance Compression Leakage from Valve Seat Intake Exhaust Valve Seizure L 2 8 2 2 uj See Measuring and Adjusting o Adjust the Valve Clearance Valve Clearance on page 6 32 Lap the Valve Seat See Valve Face and Valve Seat on page 6 26 Correct or Replace Intake See Inspection of Intake and Exhaust Valve Exhaust Valves on page 6 25 Cylinder Head Gasket Blowout Replace the Gasket See Disassembly of Cylinder Seized or Broken Piston Ring CH Worn Piston Ring Piston or Cylinder BEN Seized Crankpin Metal or Bearing ee Improper Arrangement of Piston Ring Gaps Head on page 6 19 See Reassembly of Cylinder Head on page 6 29 Perform Honing and Use Oversize See Honing and Boring on Parts page 6 51 See Inspection of Crankshaft and Repair or Replace Camshaft Components on page 6 44 Correct the Ring Joint Positions 6 53 Replace the Piston Ring Engine System 75 mM i
37. Quiet CO vector RUD tae 10 9 Removal of Starter 1 10 10 Disassembly of Starter 2 2 10 10 Cleaning and Inspection 10 12 Reassembly of Starter 0 10 17 Check Pinion Projection Length 2 10111 10 19 ier eee d 10 19 Installation of Starter 2 0 10 20 TNM Series Service Manual 10 1 STARTER MOTOR This Page Intentionally Left Blank 10 2 TNM Series Service Manual Before You Begin Servicing BEFORE YOU BEGIN SERVICING ENTANGLEMENT HAZARD Stop the engine before you begin to service it NEVER leave the key in the key switch when you are servicing the engine Someone may accidentally start the engine and not realize you are servicing it This could result in a serious injury If you must service the engine while it is operating remove all jewelry tie back long hair and keep your hands other body parts and clothing away from moving rotating parts Failure to comply could result in death or serious injury 0000010en e Series Service Manual STARTER MOTOR SHOCK HAZARD Turn off the battery switch if equipped or disconnect the negative battery cable before servicing the electrical system Check the ele
38. SPECIAL SERVICE TOOLS Compression Gauge Kit For measuring compression pressure Yanmar Part No TOL 97190080 TROUBLESHOOTING 4 Series Service Manual 13 3 TROUBLESHOOTING TROUBLESHOOTING BY MEASURING COMPRESSION PRESSURE Compression pressure drop is one of major causes of increasing blow by gas engine oil contamination or increased engine oil 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 The pressure will drop due to increased parts wear Pressure drop reduces the durability of the engine A pressure drop may also be caused by scratched cylinder or piston by dust entrance from the dirty air cleaner element or worn or broken piston ring Measure the compression pressure to determine the condition of the engine Compression Pressure Measurement Method 1 Warm up the engine 2 Stop the engine Remove the high pressure fuel injection lines as an assembly from the engine See Removal of High Pressure Fuel Injection Lines on page 7 11 Remove the fuel injector from the cylinder to be measured See Removal of Fuel Injectors on page 7 22 CAUTION Remove or install the high pressure fuel injection lines as an assembly whenever possible Disasse
39. an electric fuel pump when you prime the fuel system turn the key switch to the ON position for 10 to 15 seconds to allow the electric fuel pump to prime the system If the unit has a mechanical fuel pump when you prime the fuel system operate the fuel priming lever of the mechanical fuel pump several times until the fuel filter cup is filled with fuel Failure to comply will result in death or serious injury 0000010en Safety Precautions DANGER UA FIRE AND EXPLOSION HAZARD Diesel fuel is flammable and explosive under certain conditions Be sure to place the diesel fuel container on the ground when transferring the diesel fuel from the pump to the container Hold the hose nozzle firmly against the side of the container while filling it This prevents static electricity buildup which could cause sparks and ignite fuel vapors NEVER place diesel fuel or other flammable material such as oil hay or dried grass close to the engine during engine operation or shortly after shutdown Failure to comply will result in death or serious injury 0000014en TNM Series Service Manual Safety Precautions DANGER CRUSH HAZARD When you need to transport an engine for repair have a helper assist you to attach it to a hoist and load it on a truck NEVER stand under a hoisted engine If the hoist mechanism fails the engine will fall on you causing death or serious injury
40. bushing Figure 6 99 2 and idler gear shaft Figure 6 99 1 with clean engine oil or assembly lube Figure 6 98 4 Lubricate the camshaft lobes and tappets with clean oil or assembly lube Reinstall the tappets in their respective locations in the cylinder block Push the tappets fully into the tappet bores until they make solid contact with the camshatt 5 If removed reinstall the fuel injection pump Adjust the fuel injection timing after installation See Checking and Adjusting Fuel Injection Timing on page 7 18 Figure 6 99 4 Align the timing gears as shown in Figure 6 100 5 Reinstall the idler gear and idler gear shaft Be sure the oil hole in the bushing is facing toward the top of the engine 6 Ensure all three timing marks Figure 6 100 A B and C are aligned 6 58 TNM Series Service Manual Cylinder Block 3 026975 00X 1 Fuel Injection Pump Gear 2 Camshaft Gear 3 Crankshaft Gear 4 idler Gear Figure 6 100 When all gears are properly aligned tighten the idler gear retaining bolts to specified torque See Special Torque Chart on page 6 13 for specifications Installation of Gear Case Cover 1 Apply a continuous bead of ThreeBond Liquid Gasket No 1212 Yanmar Part No 977770 01212 to the mounting area of the gear case cover Figure 6 101 1 Be sure to circle the bolt holes 026974 00X Figure 6 101 2 Reinstall the dowels Figure
41. drive the valve guides compress one of the valve springs Figure 6 8 Figure 6 10 1 out of the cylinder head 4 Remove the valve keepers Figure 6 9 2 5 Slowly release the tension on the valve spring 6 Remove the spring retainer Figure 6 9 3 and valve spring Figure 6 9 4 1 e Figure 6 10 6 CD 026972 00X Figure 6 9 7 Repeat procedure with all remaining valves 6 22 TNM Series Service Manual Cylinder Head Cleaning of Cylinder Head Components FUME BURN HAZARD Always read and follow safety related precautions found on containers of hazardous substances like parts cleaners primers sealants and sealant removers Failure to comply could result in death or serious injury 0000014en Thoroughly clean all components using a non metallic brush and an appropriate solvent Each part must be free of carbon metal filings and other debris Inspection of Cylinder Head Components Visually inspect the parts Replace any parts that are obviously discolored heavily pitted or otherwise damaged Discard any parts that do not meet its specified limits CAUTION Any part which is found defective as a result of inspection or any part whose measured value does not satisfy the standard or limit must be replaced 0000119en e Series Service Manual ENGINE CAUTION Any part determined to not meet the service sta
42. engine Your emission control system may include parts such as the fuel injection system and the air induction system Also included may be hoses belts connectors and other emission related assemblies Where a warrantable condition exists Yanmar will repair your non road compression ignition engine at no charge to you including diagnosis parts and labor Manufacturer s Warranty Period The model year 1998 or later certified and labeled non road compression ignition engines are warranted for the periods listed below If any emission related part on your engine is found to be defective during the applicable warranty period the part will be replaced by Yanmar Engine Type Warranty Period by Number of Years or Hours of Operation The warranty period is five 5 years or 3 000 hours of use whichever occurs first In the absence of a device to measure the hours of use the engine has a warranty period of five 5 years Constant speed engines rated at or above 50 hp SAE 37 kW Constant speed engines rated under 50 hp The warranty period is two 2 years or 1 500 hours of use whichever occurs first SAE 37 kW with rated speeds greaterthan In the absence of a device to measure the hours of use the engine has a or equal to 3 000 rom warranty period of two 2 years Constant speed engines rated under 50 hp SAE 37 kW and engines rated at or above 26 hp SAE 19 kW with rated speeds less than 3 000 rpm The warranty period is f
43. eye injury always wear SAFETY GLASSES while servicing the engine 0000013en FLYING OBJECT HAZARD ALWAYS wear eye protection when servicing the engine and when using compressed air or high pressure water Dust flying debris compressed air pressurized water or steam may injure your eyes Failure to comply may result in minor or moderate injury 0000003en A CAUTION E PINCH HAZARD Carefully rotate the alternator toward the cylinder block while loosening the V belt Failure to comply may result in minor or moderate injury 0000014en 7 3 FUEL SYSTEM CAUTION NEVER remove or attempt to remove the tamper proof devices from the full load fuel adjusting screw or the high speed throttle limit screw on the fuel injection pump and governor assembly These adjustments have been made at the factory to meet all applicable emissions regulations and then sealed NEVER attempt to make any adjustments to these sealed adjustment screws If adjustments are required they can be made only by a qualified fuel injection shop that will ensure the injection pump continues to meet all applicable emissions regulations and then replace the tamper proof seals Tampering with or removing these devices may void the Yanmar Limited Warranty 0000146en CAUTION Never use a steel wire brush to clean fuel injectors Damage to the nozzle and other components is likely to result 000
44. for the service limit 0001952 Figure 6 13 6 24 Cylinder Head Inspection of Valve Guides Visually inspect the valve guides for distortions scoring or other damage Note Measure valve guides while they are installed in cylinder head Use a telescoping gauge and micrometer to measure the inside diameter of the valve guide Measure in three places and 90 apart Figure 6 14 Record the measurements See Intake Exhaust Valve and Guide on page 6 6 for the service limit Replace valve guides if not within specification 0001869 Figure 6 14 Inspection of Cylinder Head Cylinder Head Distortion Put the cylinder head flat and inverted combustion side up on the bench Use a straightedge and feeler gauge to measure cylinder head distortion Figure 6 15 Measure diagonally and along each side Record the measurements See Cylinder Head on page 6 5 for the service limit 0000192 Figure 6 15 TNM Series Service Manual Cylinder Head If distortion exceeds the service limit resurface or replace the cylinder head Remove only enough material to make the cylinder head flat but do not remove more than 0 008 in 0 20 mm Inspection of Intake and Exhaust Valves Visually inspect the intake and exhaust valves Replace any valves that are obviously discolored heavily pitted or otherwise damaged Valve Stem Diameter Use a micrometer to measure the valve
45. from the gear case however it is best to let it remain in the gear case 18 Once the fuel injection pump drive gear and hub assembly have popped loose from the tapered fuel injection pump drive shaft carefully remove the drive gear nut Figure 7 14 2 and lock washer Figure 7 14 1 027021 00X Figure 7 14 7 15 FUEL SYSTEM 19 Remove the four bolts fastening the fuel injection pump to the cylinder block Remove the fuel injection pump Leave the fuel injection pump drive gear in the gear case and meshed with the idler gear CAUTION Do not rotate the crankshaft with the injection pump removed 0000083en 20 If the fuel injection pump requires servicing it must be sent to an authorized Yanmar FIE repair facility for repair and calibration or replaced with a new fuel injection pump CAUTION NEVER remove or attempt to remove the tamper proof devices from the full load fuel adjusting screw or the high speed throttle limit screw on the fuel injection pump and governor assembly These adjustments have been made at the factory to meet all applicable emissions regulations and then sealed NEVER attempt to make any adjustments to these sealed adjustment screws If adjustments are required they can be made only by a qualified fuel injection shop that will ensure the injection pump continues to meet all applicable emissions regulations and then replace the tamper proof seals Tamp
46. gear nut to the specified torque See Special Torque Chart on page 7 7 027021 00X Figure 7 17 Reconnect the fuel supply and return lines to the fuel injection pump Reconnect the throttle linkage and stop solenoid connector If installing a new or recalibrated fuel injection pump check the fuel injection timing before completing the installation of the fuel injection pump See Checking and Adjusting Fuel Injection Timing on page 7 18 Note While it is not required to check the 9 10 injection timing when reinstalling the original fuel injection pump it is recommended that it be done Apply ThreeBond Liquid Gasket No 1212 Yanmar Part No 977770 01212 or equivalent sealant to the sealing surface of the fuel injection pump drive gear access cover Reinstall the cover on the front of the gear case and tighten the bolts However install the cover after adjusting the fuel injection timing Reinstall the fuel injection high pressure lines See Installation of High Pressure Fuel Injection Lines on page 7 12 e Series Service Manual 11 12 13 14 15 FUEL SYSTEM IMPORTANT When installing a new or repaired fuel injection pump add 5 7 oz 150 200 cc of new clean engine oil to the fuel injection pump at the fill plug located in the upper outside section of the governor housing Reinstall the coolant pump V pulley Figure 7 18 4 spacer Figure 7 18
47. if contaminants are discovered TNM Series Service Manual Periodic Maintenance Procedures The cup of the separator is made from semi transparent material In the cup is a red colored float ring The float ring will rise to the surface of the water to show how much needs to be drained Also some optional fuel filter water separators are equipped with a sensor to detect the amount of contaminants This sensor sends a signal to an indicator to alert the operator Drain the fuel filter water separator as follows 1 Position an approved container under the fuel filter water separator Figure 5 7 1 to collect the contaminants 0000590A Figure 5 7 2 Close Figure 5 7 2 the fuel cock Figure 5 7 3 3 Turn the retaining ring Figure 5 7 4 to the left Figure 5 7 9 4 Carefully remove the cup Figure 5 7 1 Remove the retaining spring Figure 5 7 6 and float Figure 5 7 7 from the cup Pour the fuel into an approved container and dispose properly Hold the bottom of the cup with a shop towel to prevent the fuel from dripping Wipe up any spills immediately 5 Clean the inside of the cup 6 Inspect the condition of the mesh filter Figure 5 7 10 Clean the mesh filter if necessary 7 Inspect the condition of the O ring Figure 5 7 11 Replace the O ring if necessary e Series Service Manual PERIODIC MAINTENANCE 8 P
48. if worn or damaged Cleaning and Inspection Armature Commutator Surface Inspection If the commutator surface is rough polish the surface with a 500 to 600 emery cloth 0000117 Figure 10 12 Measure Commutator Outside Diameter Measure the commutator outside diameter Replace the armature if the measurement is less than the limit See Starter Motor Specifications on page 10 6 0000113 Figure 10 13 TNM Series Service Manual Starter Motor Measure Commutator Insulation Depth Measure the depth of the insulating material Figure 10 14 1 between commutator segments Figure 10 14 2 If the depth measures less than the limit use a hacksaw blade Figure 10 14 3 to remove the insulating material until the depth is within the limit See Starter Motor Specifications on page 10 6 for service limit A normal commutator condition is indicated in Figure 10 14 4 An abnormal commutator condition is indicated in Figure 10 14 5 3 0000118 Figure 10 14 Armature Coil Continuity Test Check for continuity between the commutator segments using a multimeter Figure 10 15 The multimeter should indicate continuity If the multimeter does not indicate continuity replace the armature 4 Series Service Manual STARTER MOTOR 0000114 10 15 Armature Coil Insulation Test Check for continuity between a commut
49. inclination of the valve cap entrance of dirt or wear 0001782A Figure 6 37 7 Apply oil to the contact surface between adjusting screw and push rod 8 Rotate the crankshaft and measure the next cylinder Continue until all valves are adjusted 0001783A Figure 6 36 e Series Service Manual 6 33 CYLINDER BLOCK Crankshaft and Camshaft Components Cylinder Block Figure 6 38 6 34 TNM Series Service Manual Cylinder Block 1 Flywheel Housing 2 Dowel 2 used 3 Crankshaft Rear Seal 4 Tappets 5 Camshaft 6 Camshaft Gear Key 7 Camshaft End Plate 8 Camshaft Gear 9 Gear Case Cover 10 Front Crankshaft Seal 11 Fuel Injection Pump Gear Cover 12 Idler Gear Shaft 13 Idler Gear Bushing 14 Idler Gear 15 Top Compression Ring 16 Second Compression Ring 17 Oil Ring 18 Piston 19 Wrist Pin 20 Circlip 21 Wrist Pin Bushing 22 Connecting Rod 23 Connecting Rod Bearing Inserts 24 Connecting Rod Cap 25 Flywheel 26 Ring Gear 27 Flywheel 28 Crankshaft Gear Key 29 Crankshaft Gear 30 Crankshaft Pulley 31 Thrust Bearings 32 Main Bearing Inserts 33 Oil Pickup O Ring 34 Oil Pickup 35 Oil Pan e Series Service Manual ENGINE Disassembly of Cylinder Block Components Prepare a clean flat working surface on a workbench large enough to accommo
50. is Covered by this Warranty Yanmar warrants to the original retail purchaser that a new Yanmar TNM Series Industrial Engine will be free from defects in material and or workmanship for the duration of the warranty period Note Yanmar engines may be equipped with external components including but not limited to wiring harnesses electrical devices control panels radiators air filters fuel filters and or exhaust systems that are supplied and or installed by manufacturers other than Yanmar For warranty information on such external components please contact the machine or component manufacturer directly or see your authorized Yanmar dealer or distributor THIS WARRANTY IS PROVIDED IN LIEU OF ALL OTHER WARRANTIES EXPRESSED OR IMPLIED YANMAR SPECIFICALLY DISCLAIMS ANY IMPLIED WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE except where such disclaimer is prohibited by law IF SUCH DISCLAIMER IS PROHIBITED BY LAW THEN IMPLIED WARRANTIES SHALL BE LIMITED IN DURATION TO THE LIFE OF THE EXPRESSED WARRANTY How Long is the Warranty Period The Yanmar standard limited warranty period runs for a period of twenty four 24 months or two thousand 2000 engine operation hours whichever occurs first An extended limited warranty of thirty six 36 months or three thousand 3000 engine operating hours whichever occurs first is provided for these specific parts only the cylinder block cylinder head crankshaft forging co
51. on the dipstick 5 Fully reinsert dipstick e Series Service Manual GENERAL SERVICE INFORMATION vA 9 I v6 7 Wa WA E 0006463 Figure 4 6 Adding Engine Oil Make sure engine is level 2 Remove oil cap Figure 4 6 4 3 Add indicated amount of engine oil at the top or side engine oil filler port Figure 4 6 5 4 Wait three minutes and check oil level 5 Add more oil if necessary 6 Replace oil cap Figure 4 6 4 and hand tighten Over tightening may damage the cap 4 15 GENERAL SERVICE INFORMATION Engine Oil Capacity Typical Note These are the engine oil capacities associated with a deep standard oil pan Oil capacity will vary dependant upon which optional oil pan is used Refer to the operation manual provided by the driven machine manufacturer for the actual engine oil capacity of your machine The following are the engine oil capacities for various Yanmar TNV engines Dipstick Upper Engine Model Limit Lower Limit 26 14 at SUDO 2 51 1 8 L 3 1 1 7 at SUNMA 2 9 1 6 L Engine Coolant ENGINE COOLANT DANGER SCALD HAZARD NEVER remove the radiator cap if the engine is hot Steam and hot engine coolant will spurt out and seriously burn you Allow the engine to cool down before you attempt to remove the radiator cap Tighten the radiator cap securely after you check the radiator Steam can s
52. operate to prevent any foreign matter or fluids from entering the engine fuel system or electrical components remaining on the engine 7 Drain the engine oil into a suitable container Remove oil filter 8 Remove the cylinder head See Disassembly of Cylinder Head on page 6 19 9 Remove the fuel injection pump from the gear case only if it must be sent out for repair or will interfere with other procedures such as hot tank cleaning See Removal of Fuel Injection Pump on page 7 13 10 Remove the starter motor See Removal of Starter Motor on page 10 10 Disassembly of Camshaft and Timing Components Discard all gaskets O rings and seals Use new gaskets O rings and seals on reassembly of camshaft and timing components Removal of Timing Gear Case Cover 1 Remove the bolt and washer retaining the crankshaft pulley IMPORTANT Use care not to damage the threads in the end of the crankshaft when removing the crankshaft pulley 2 Remove the crankshaft pulley with a gear puller 3 Remove the bolts that retain the gear case cover to the cylinder block and oil pan 4 Remove the gear case cover Figure 6 39 1 5 Remove the dowel pins Figure 6 39 2 6 36 Cylinder Block Figure 6 39 Checking Timing Gear Backlash Prior to removing the timing gears measure the gear backlash and determine the gear wear Note Check the backlash between each pair of mating gears If not within specification r
53. or submerse the starter motor in water 0000055en Use a specialized battery charger to recharge a battery with a voltage of 8 volts or less Booster starting a battery with a voltage of 8 volts or less will generate an abnormally high voltage and destroy electrical equipment 0000056en TNM Series Service Manual Introduction STARTER MOTOR INTRODUCTION This section of the Service Manual covers the servicing of starter motor Yanmar Part No 119717 77010 is standard equipment on 3TNV76 model engines and is used in this section to show the service procedures for a representative starter motor For specific part detail see the Yanmar Parts Catalog for the engine being serviced STARTER MOTOR INFORMATION Part Model Specification Terminal Amperage Terminal Amperage Number Number Voltage Draw Voltage Draw q 2 np 119515 428000 PE TOR 1 hp Min Min 6 mS era em m PAE it e om E 77010 3310 1 4 kW Min 38 ihm Min oven aan oe ome i 77010 1 2 kW Min d 59 e Series Service Manual 10 5 STARTER MOTOR Starter Motor Specifications STARTER MOTOR SPECIFICATIONS Nominal Output 1 5 hp 1 1 kW 1 34 hp 1 0 kW 6 6 lb 6 3 lb Weight 3 0 kg 2 85 kg Revolution Direction As Viewed From Pinion 3000 rpm 3000 rpm Loaded 61 in lb 6 9 N m 0 70 kgf m 4
54. so they can be reinstalled on the same rocker arm e Series Service Manual ENGINE Removal of Cylinder Head 1 Loosen the cylinder head bolts following the sequence shown in Figure 6 6 2 1 Cooling Fan End 2 Camshaft Side Figure 6 6 2 Remove the cylinder head bolts Figure 6 7 1 3 Lift the cylinder head away from the cylinder block Discard the cylinder head gasket Figure 6 7 2 Position the cylinder head on the work bench to prevent damage to the combustion surface 1 2 Figure 6 7 Cylinder Head Removal of Intake Exhaust Valves Note If the valves are to be reused identify them so they can be reinstalled in their 1 Put the cylinder head on the work bench with E original location the combustion side down Figure 6 8 8 Turn the cylinder head so the exhaust port side faces down Remove the intake and exhaust valves Figure 6 9 6 from the cylinder head 9 Remove the valve stem seals Figure 6 9 5 Removal of Valve Guides Note Removal of valve guides should be 0000191 postponed until inspection and measurement procedures have been performed See Inspection of Valve 2 Remove the valve stem cap Figure 6 9 1 Guides on page 6 24 and keep with the valve it was installed on Figure 6 8 If the valve guides are not within specifications use 3 Using the valve spring compressor tool a drift pin and hammer to
55. start and the engine oil may not flow easily Contact your authorized Yanmar industrial engine dealer or distributor if the engine will be operated outside of this standard temperature range 0000065en e Series Service Manual SAFETY CAUTION If any indicator illuminates during engine operation stop the engine immediately Determine the cause and repair the problem before you continue to operate the engine 0000029en specified Other engine oils may affect warranty coverage cause internal engine components to seize and or shorten engine life Prevent dirt and debris from contaminating the engine oil Carefully clean the oil cap dipstick and the surrounding area before you remove the cap NEVER mix different types of engine oil This may adversely affect the lubricating properties of the engine oil NEVER overfill Overfilling may result in white exhaust smoke engine overspeed or internal damage 0000005 CAUTION Only use the engine coolant specified Other engine coolants may affect warranty coverage cause an internal buildup of rust and scale and or shorten engine life Prevent dirt and debris from contaminating the engine coolant Carefully clean the radiator cap and the surrounding area before you remove the cap NEVER mix different types of engine coolants This may adversely affect the properties of the e
56. that the word diesel is implied throughout this manual when the word fuel is used The fuel filter water separator removes contaminants sediments and water from diesel fuel going to the fuel filter This is a required component of the fuel system This is standard equipment with every engine The separator is installed between the fuel tank and the fuel pump Periodically drain the water from the fuel filter water separator using the drain cock at the bottom of the separator If the unit has a mechanical fuel pump a fuel priming lever on the mechanical fuel pump primes the fuel system The fuel system needs to be primed before you start the engine for the first time if you run Out of fuel or if fuel system service is performed To prime the fuel system operate the fuel priming lever until the cup in the fuel filter is full of fuel anual 4 7 GENERAL SERVICE INFORMATION Fuel Tank Mechanical Fuel Pump Side and Top Filler Port Engine Oil Starter Motor 4 8 Function of Major Engine Components The fuel tank is a reservoir that holds diesel fuel When fuel leaves the fuel tank it goes to the fuel filter water separator Next fuel is pumped to the fuel filter by the fuel pump Next the fuel goes to the fuel injection pump Since fuel is used to keep the fuel injection pump cool and lubricated more fuel than necessary enters the injection pump When the injection pump pressure reaches a preset value a relief
57. the valve seat do not contact correctly Check the valve recession after grinding If the valve or seat require grinding lap the valve after grinding Lap the valve face to the valve seat using a mixture of valve lapping compound and engine oil Be sure to thoroughly wash all parts to remove all grinding powder or compound Inspection of Valve Springs Inspect the valve springs If damage or corrosion is seen or if measurements exceed the specified limits replace the springs Record the measurements Fractures Check for fractures on the inside and outside portions of the springs If the valve spring is fractured replace the valve spring Corrosion Check for corrosion of spring material caused by oxidation TNM Series Service Manual Cylinder Head Squareness Use a flat surface and a square to check each spring for squareness Figure 6 22 See Valve Spring on page 6 6 for the service limit 0000201 Figure 6 22 Free Length Use a caliper to measure the length of the spring Figure 6 23 See Valve Spring on page 6 6 for the service limit 0000200 Figure 6 23 e Series Service Manual ENGINE Reassembly of Cylinder Head Use new gaskets O rings and seals on reassembly of cylinder head IMPORTANT Liberally oil all components during assembly to prevent premature wear or damage Reassembly of Valve Guides 1 The valve guides are install
58. use diesel fuel as a cleaning agent Failure to comply will result in death or serious injury 0000012en DANGER ag ALWAYS be environmentally responsible Follow the guidelines of the EPA or other governmental agencies for the proper disposal of hazardous materials such as engine oil diesel fuel and engine coolant Consult the local authorities or reclamation facility NEVER dispose of hazardous materials irresponsibly by dumping them into a sewer on the ground or into ground water or waterways Failure to follow these procedures may seriously harm the environment 0000013en Gh FIRE AND EXPLOSION HAZARD Diesel fuel is flammable and explosive under certain conditions Periodically clean the fuel filter water separator element and inside the cup 1 Position an approved container under the cup Figure 5 15 1 of the fuel filter water separator to collect the contaminants When you remove any fuel system component to perform maintenance such as changing the fuel filter place an approved container under the opening to catch the fuel NEVER use a shop rag to catch the fuel Vapors from the rag are flammable and explosive Wipe up any spills immediately Wear eye protection The fuel system is under pressure and fuel could spray out when you remove any fuel system component 0000590B Failure to comply will result in death or serious injury Figure 5 15 00000
59. using compressed air or high pressure water Dust flying debris compressed air pressurized water or steam may injure your eyes Failure to comply may result in minor or moderate injury 0000003en Before You Begin Servicing CAUTION PINCH HAZARD Carefully rotate the alternator toward the cylinder block while loosening the V belt Failure to comply may result in minor or moderate injury 0000014en CAUTION ra NEVER permit anyone to operate the engine or driven machine without proper training Read and understand this Operation Manual before you operate or service the machine to ensure that you follow safe operating practices and maintenance procedures Machine safety signs and labels are additional reminders for safe operating and maintenance techniques See your authorized Yanmar industrial engine dealer or distributor for additional training 0000002en CAUTION Do not short circuit the charging system between alternator terminals IG and L Damage to the alternator will result 0000035en TNM Series Service Manual Before You Begin Servicing CAUTION Do not connect a load between alternator terminals L and E Damage to the alternator will result 0000036en CAUTION Do not operate the engine if the alternator is producing unusual sounds Damage to the alternator will result 0000039en CAUTION Do not remove the positive
60. warranty period Yanmar is liable for damages to other engine components caused by the failure of any warranted part during the warranty period Any replacement part which is functionally identical to the original equipment part in all respects may be used in the maintenance or repair of your engine and shall not reduce Yanmar s warranty obligations Add on or modified parts that are not exempted may not be used The use of any non exempted add on or modified parts shall be grounds for disallowing a warranty Warranted Parts This warranty covers engine components that are a part of the emission control system of the engine as delivered by Yanmar to the original retail purchaser Such components may include the following Fuel Injection System Cold Start Enrichment System Intake Manifold Turbocharger Systems Exhaust Manifold Positive Crankcase Ventilation System Hoses belts connectors and assemblies associated with emission control systems Since emissions related parts may vary slightly between models certain models may not contain all of these parts and other models may contain the functional equivalents e Series Service Manual 2 7 YANMAR WARRANTIES Emission System Warranty Limited Emission Control System Warranty USA Only Continued Exclusions Failures other than those arising from defects in material and or workmanship are not covered by this warranty The warranty does no
61. wiped in cylinder comes out clean Use brushes to clean all passages and crevices Rinse with hot water and dry with compressed air Apply clean engine oil to all steel surfaces to prevent rusting Reassembly of Crankshaft and Piston Components Notes Proceed slowly Make no forced assemblies unless a pressing operation is called for All parts must be perfectly clean and lightly lubricated when assembled Use new gaskets seals and O rings during assembly Liberally apply clean engine oil to all internal parts during assembly All fasteners should be tightened to a given torque If a special torque is not provided in the Special Torque Chart on page 6 13 tighten to standard torque specifications See Tightening Torques for Standard Bolts and Nuts on page 4 24 Reassembly of Pistons 1 3 6 52 Select the parts needed to assemble the piston and connecting rod for one cylinder If removed install a new wrist pin bushing Figure 6 82 7 using a press and the appropriate service tool Be sure to align the oil holes 027272 00X Figure 6 82 Reinstall one circlip Figure 6 82 5 into the piston Ensure the circlip is securely seated in the groove IMPORTANT The piston and connecting rod must be assembled with the correct orientation When correctly assembled the piston identification mark Figure 6 83 1 stamped into the top of the piston will be on the opposite side of
62. xhaus Clearance 0 0016 0 0028 in 0 0012 0 0026 in 0 0067 in 0 0067 in 0 040 0 071 mm 0 030 0 067 mm 0 17 mm 0 17 mm 0 0004 in Valve Guide Projection From Cylinder 0 3268 0 3445 0 3858 0 3937 in See Head 8 30 8 75 mm 9 8 10 0 mm Reassembly Valve Stem Seal Projection From 0 484 in 0 543 in of Valve Cylinder Head 12 3 13 8 mm Guides on Valve Stem Bend Valve Guide Installation Method Cold fitted page 6 27 Push Rod Inspection 3TNM68 3TNM72 3TNM68 3TNM72 Page See Push Push Rod Bend Less than 0 0012 in 0 0012 in Rod Bend on 0 03 mm 0 03 mm page 6 23 Valve Spring Inspection Item 3TNM68 3TNM72 3TNM68 3TNM72 Page mem 1 3268 in 1 4882 9 33 7 37 8 mm See Inspection of 0 0512 i vate Squareness ui Springs on 1 3 mm page 6 26 6 6 TNM Series Service Manual Camshaft and Timing Gear Train Specifications ENGINE Rocker Arm and Shaft Inspection Item 3TNM68 3TNM72 3TNM68 3TNM72 Page 0 3937 0 3945 in 0 4724 0 4732in 0 3965in 0 4752 in 10 000 10 020 12 000 12 020 mm 10 07 mm 12 07 mm See 7 Inspection of E 0 3925 0 3933 in 0 4711 0 4718 in 0 3913 in 0 4701 in 9 97 9 99 mm 11 966 11 984 9 94 11 94 ocker Arm Assembly on mon 0 0004 0 0020 in 0 0006 0 0021 in 0 0051 i
63. 0 3415 3630 3840 Engine Weight Dry 229 Ib 104 kg with Flywheel urs 174 Ib 79 kg 229 16 104 kg 174 Ib 79 kg Housing PTO Position Flywheel End Direction of Rotation Counterclockwise Viewed from Flywheel End Cooling System Liquid Cooled with Radiator Lubricating System Forced Lubrication with Trochoid Pump Normal Oil Pressure at Rated Engine Speed 34 8 63 8 psi 0 240 0 440 MPa 2 4 4 4 kgf cm 8 5 psi 0 06 MPa 0 6 kgf cm or greater Electric Starting Starter Motor DC12V 1 6 hp 1 2 kW Dynamo DC12V 20A Recommended Battery Capacity 12V 36 Amp Hour 5h rating 20 4 16 3 19 6 20 4 x 16 3 x in 19 0 x 16 3 x 19 6 in 20 7 in 16 9 x 16 3 x 19 6 in 520 x 416 x 500 483 x 416 x 500 mm 520 x 416 x 431 x 416 x 500 mm mm 528 mm 8411 8qt 3 27 Engine Oil Pan 2 6 1 4 qt 2 5 1 3 L 170 2 6 1 4 qt 2 5 1 3 L Starting System Dimensions Lx Wx Capacity Dipstick Upper Limit Lower Limit Dipstick Upper Dipstick Upper Limit Limit Lower Lower Limit Engine Coolant Capacity Limit Cooling 11 4 in 290 mm O D 5 Blade Pusher Type 3 9 3 5 in 100 mm 90 mm Engine specifications without radiator Engine oil capacity for a Deep Standard pan Refer to the Operation Manual provided by the driven machine manufacturer for the actual engine oil capacity of your machine May vary depending on application
64. 000004en TNM Series Service Manual Safety Precautions DANGER UA FIRE AND EXPLOSION HAZARD Diesel fuel is flammable and explosive under certain conditions NEVER remove the fuel cap with the engine running Failure to comply will result in death or serious injury DANGER VA Y FIRE AND EXPLOSION HAZARD Diesel fuel is flammable and explosive under certain conditions NEVER use diesel fuel as a cleaning agent Failure to comply will result in death or serious injury 0000012en 4 Series Service Manual SAFETY DANGER UA FIRE AND EXPLOSION HAZARD Diesel fuel is flammable and explosive under certain conditions Only fill the fuel tank with diesel fuel Filling the fuel tank with gasoline may result in a fire and will damage the engine NEVER refuel with the engine running Wipe up all spills immediately Keep sparks open flames or any other form of ignition match cigarette static electric source well away when refueling NEVER overfill the fuel tank Fill the fuel tank Store any containers containing fuel in a well ventilated area away from any combustibles or sources of ignition Failure to comply will result in death or serious injury 0000005en 3 5 SAFETY 3 6 DANGER GL FIRE AND EXPLOSION HAZARD Diesel fuel is flammable and explosive under certain conditions If the unit has
65. 0000237 Figure 6 64 Measure the outside diameter of the wrist pin in three places and at 90 Figure 6 65 See Piston on page 6 10 for specifications Record the measurements 0001889 Figure 6 65 Using a micrometer measure the thickness of each piston ring See Piston Ring on page 6 10 for specifications Record the measurements Notes Onan engine with low hours the pistons piston rings and cylinders may be reused if they are found to be within specifications 10 Cylinder Block Onan engine with high hours the pistons rings should be replaced and the cylinder honed See Honing and Boring on page 6 50 or replaced The piston should be replaced as necessary Place each compression piston ring in the groove as shown Figure 6 66 Use a feeler gauge to measure the clearance between the piston ring and the piston ring land Record the measurements See Piston Ring on page 6 10 for specifications Replace the piston if not within specification 0001892 Figure 6 66 To measure piston ring end gap insert each compression piston ring Figure 6 67 1 one at a time into the cylinder Use a piston with the piston rings removed to slide the ring into the cylinder bore until it is approximately 1 18 in 30 mm Figure 6 67 2 from the bottom of the bore Remove the piston Measure the end gap Figure 6 67 3 of each piston ring Record the measurements See Piston Ring on page 6 10 for specific
66. 00X Figure 6 2 3 Remove the exhaust manifold bolts Figure 6 2 5 and nuts Figure 6 2 6 Remove the exhaust manifold Figure 6 2 7 and the exhaust manifold gasket Figure 6 2 8 Removal of Glow Plugs 1 Disconnect the glow plug harness Figure 6 3 2 from the glow plugs Figure 6 3 1 2 Remove the glow plugs from the cylinder head 026969 00 6 4 6 20 TNM Series Service Manual Cylinder Head Disassembly of Rocker Arm Assembly 1 Remove the rocker arm shaft alignment set screw Figure 6 5 6 from support Figure 6 5 5 Figure 6 5 Note On 3 cylinder models the set screw is located in the center support On 2 cylinder models the set screw is located in the front cooling fan end support 2 Remove two circlips Figure 6 5 8 Note The rocker arm shaft fits tightly in the rocker arm supports Clamp the support in a padded vise Twist and pull out on the rocker arm shaft to remove Reverse this process when installing the rocker arm shaft into the supports 3 Slide the rocker arm shaft Figure 6 5 7 out of the rocker arm supports Figure 6 5 5 springs Figure 6 5 4 and rocker arms Figure 6 5 1 Note Mark the rocker arms so they can be reinstalled with the original matching valve and pushrod 4 Remove the valve adjusting screw Figure 6 5 3 and lock nut Figure 6 5 2 from the rocker arms Mark parts
67. 0172en CAUTION Do not loosen or remove the four bolts retaining the fuel injection pump drive gear to the fuel injection pump hub Do not disassemble the fuel injection pump drive gear from the hub Correct fuel injection timing will be very difficult or impossible to achieve 0000031en 7 4 Before You Begin Servicing CAUTION Remove or install the high pressure fuel injection lines as an assembly whenever possible Disassembling the high pressure fuel injection lines from the retainers or bending any of the fuel lines will make it difficult to reinstall the fuel lines 0000047en After marking the position of the pump drive gear do not rotate the engine crankshaft Rotating the crankshaft will cause the fuel injection pump to become misaligned 0000048en CAUTION Do not rotate the crankshaft with the injection pump removed 0000083en CAUTION The fuel return line is a one piece assembly Use care not to bend or twist the fuel return line 0000171en TNM Series Service Manual Introduction FUEL SYSTEM INTRODUCTION Figure 7 1 This section of the Service Manual describes the procedures necessary to remove install and time the MC fuel injection pump and its associated system components Fuel Injection Pump Note If the MC fuel injection pump itself requires servicing it must be taken to an authorized Yanmar FIE Fuel Injection Equipment repair
68. 062 0001873 6 26 Measure the distance Figure 6 27 1 from the cylinder head to valve stem seal to ensure proper clearance Figure 6 27 2 between the valve guide and seal See valve stem seal projection specification on page 6 6 Figure 6 27 Put the cylinder head assembly on its exhaust port side Install all the valves Figure 6 28 6 in their proper location in the cylinder head TNM Series Service Manual 026972 00 6 28 5 Put the cylinder head on the workbench with the combustion side down to install the valve springs Reinstall the valve spring Figure 6 28 4 and spring retainer Figure 6 28 5 Using a valve spring compressor tool compress the valve spring Insert the valve keeper Figure 6 28 2 and slowly release the tension in the valve spring Reinstall the valve cap Figure 6 28 1 Repeat steps on all remaining valves Reassembly of Cylinder Head 1 Carefully clean both the combustion surface of the cylinder head and the top surface of the cylinder block Install a new cylinder head gasket Figure 6 29 2 on the cylinder block Position the cylinder head on the cylinder head gasket e Series Service Manual Cylinder Head ENGINE Figure 6 29 3 Lightly oil the threads of the cylinder head bolts Figure 6 29 1 Tighten the bolts to the specified torque shown in the chart
69. 0832 0000833 0000834 0000835 0000836 0000837 0000838 Measuring Instruments Measuring instruments Cont Instrument Name Application V Block Available Locally Torque Wrench Available Locally Feeler Gauge Available Locally a TNM Series Service Manual ENGINE For measuring shaft bend 0000839 For tightening nuts and bolts to the specified torque goo 0000840 For measuring piston ring gaps piston ring clearance and valve adjustment clearance Cylinder Head CYLINDER HEAD Cylinder Head Components 11 e 5 ar 2 15 8 04 21 6 1 6 18 TNM Series Service Manual Cylinder Head 1 Baffle Plate 2 Oil Fill Cap 3 Valve Cover Intake Manifold 4 Gasket 5 Rocker Arm Shaft 6 Rocker Arm Shaft Support 7 Adjuster Lock Nut 8 Valve Adjuster Screw 9 Rocker Arm 10 Circlip 11 Valve Cap 12 Keeper 13 Valve Spring Retainer 14 Valve Spring 15 Valve Stem Seal 16 Valve Guide 17 Cylinder Head 18 Exhaust Valve 19 Intake Valve 20 Cylinder Head Gasket 21 Push Rod 2 per cylinder 22 Glow Plug 23 Glow Plug Wiring Harness 24 Cylinder Head Bolt 4 Series Service Manual ENGINE Disassembly of Cylinder Head Prepare a clean flat working surface on a workbench large enough to acco
70. 09 2 Close Figure 5 15 2 the fuel cock Figure 5 15 3 5 32 TNM Series Service Manual Periodic Maintenance Procedures 3 Turn the retaining ring Figure 5 15 4 to the left Figure 5 15 10 4 Carefully remove the cup Figure 5 15 1 and pour the fuel into an approved container and dispose of properly Hold the bottom of the cup with a shop towel to prevent the fuel from dripping Wipe up any spills immediately 5 Keep the retaining spring Figure 5 15 6 and float Figure 5 15 7 handy for reassembly 6 Remove the element Figure 5 15 8 by pulling it down 7 Replace the element with a new one Applicable Element Part No 3TNM68 3TNM72 119810 55650 8 Wash the inside of the cup with clean diesel fuel 9 Check the condition of the cup O ring Replace if necessary 10 Put the float Figure 5 15 7 and retaining spring Figure 5 15 6 inside the cup 11 Reinstall the cup to the mounting flange Figure 5 15 9 and turn the retaining ring Figure 5 15 4 to the right Figure 5 15 5 Hand tighten only 12 Open the fuel cock Figure 5 15 3 13 Prime the fuel system See Priming the Fuel System on page 4 13 14 Check for fuel leaks e Series Service Manual PERIODIC MAINTENANCE Every 1000 Hours of Operation Perform the following maintenance every 1000 hours of operation Drain Flush and Refill C
71. 1 7 in lb 4 7 N m 0 48 kgf m 1130 rpm min 1240 rpm min Stalled Torque 73 in Ib 43 5 in Ib 3 8 24 N m 0 84 kgf m minimum 4 9 N m 0 5 kgf m minimum Pinion Projection Voltage at 212 F 100 C 13 7 17 6 N 1 4 1 8 kgf 13 7 17 6 N 1 4 1 8 kgf Brush 0 55 in 14 mm 0 55 in 14 mm 0 44 in 11 1 mm 0 44 in 11 1 mm Solenoid 0 484 W at 68 F 20 C 0 484 W at 68 F 20 C Switch 1 055 W at 68 F 20 C 1 055 W at 68 F 20 C Outside Standard 1 102 in 28 0 mm 1 102 in 28 0 mm Diameter 1 063 in 27 0 mm 1 063 in 27 0 mm Standard 0 001 in 0 02 mm 0 001 in 0 02 mm Commutator Run Out 0 002 in 0 05 mm 0 002 in 0 05 mm Insulation Standard 0 024 in 0 6 mm 0 024 in 0 6 mm Depth 0 008 in 0 2 mm 0 008 in 0 2 mm 10 6 TNM Series Service Manual 2 enuey aoas sanes WNL 2 01 15 the shift lever at NO Move shift lever to is battery fully charged NO Charge or replace battery NEUTRAL position NEUTRAL position and terminals clean Clean terminals Y pes Engine does not start Inspect wiring up to solenoid switch Is starter motor solenoid NO erie tepals if necessary switch actuating sound Key switch heard Safety relay Solenoid switch assembly NO NO Electrical connections Does engine crank Is starter motor operating YES pres Adjust pinion projection le
72. 10 33 1 and dust covers Figure 10 33 2 Secure with nuts or bolts 0000144 10 31 9 Reinstall the field assembly Figure 10 31 3 over the armature assembly and align to the pinion housing Figure 10 33 10 Position the brush springs in brush holders Reinstall the brushes in the brush holders Reversing the brushes will cause the starter motor to turn backwards 11 Carefully reinstall the brush holder Figure 10 32 3 assembly 12 Reinstall the rear cover Figure 10 32 2 and Va 3 0000140 15 Reconnect the wire to the solenoid switch assembly Tighten the nut Reinstall the cover over the connection secure with two bolts Figure 10 32 1 000013 0000142A Figure 10 34 Figure 10 32 10 18 TNM Series Service Manual Starter Motor Check Pinion Projection Length 1 Connect the positive lead from a battery to the S terminal Connect the negative lead to the terminal Lightly pull the pinion away from the gear housing Turn the switch ON and measure the pinion moving distance L in the thrust direction Figure 10 35 Perform this test within 10 seconds 0000132 Figure 10 35 See Starter Motor Specifications on page 10 6 for service limit 5 If the measured L dimension is outside the standard range adjust the dust covers to obtain the standard range Dust covers Figure 10 36 1 are avai
73. 11 14 3 0000258 11 16 100266 11 14 7 Reassemble the regulator assembly Figure 11 16 1 to the holder 5 Align the front frame housing with the rear Figure 11 16 2 frame housing Reinstall the two bolts 8 Reinstall the brush holder Figure 11 17 3 Figure 11 15 1 and two nuts springs Figure 11 17 4 and brushes Figure 11 15 2 Figure 11 17 5 9 Reattach the regulator assembly and holder to the rear frame housing 0000265A Figure 11 15 6 Reinstall the insulation bushing Figure 11 16 4 and nut Figure 11 16 3 0000257A Figure 11 17 10 Reinstall the rear cover Figure 11 17 2 to the rear frame housing with three bolts Figure 11 17 1 e Series Service Manual 11 15 ALTERNATOR 5 Alternator 4 Start the engine Listen for any unusual sounds from the alternator CAUTION Do not operate the engine if the alternator is producing unusual sounds Damage to the alternator will result 0000039en 5 Verify that the charge indicator is ON while the engine is operating If the charge indicator is not ON repair the problem before operating the engine 1 0000256 Figure 11 18 11 Reassemble the pulley Figure 11 18 2 and nut Figure 11 18 1 to the shaft of the rotor assembly Tighten the nut Installation of Alternator 1 Position the alternator on the gear
74. 3 Inspection of Crankshaft and Camshaft Components FUME BURN HAZARD Always read and follow safety related precautions found on containers of hazardous substances like parts Cylinder Block 3 Remove the rear oil seal Figure 6 61 1 from the flywheel housing Figure 6 61 2 cleaners primers sealants and sealant removers Failure to comply could result in death or serious injury 0000014en Thoroughly clean all components using a brush and appropriate solvent Each part must be free of carbon gasket material metal filings and other debris Note Record all measurements taken during inspection Replacement of Crankshaft Oil Seals 1 Remove the seal Figure 6 60 2 from the gear case cover Figure 6 60 1 2 Install a new seal in the gear case cover with the lip facing in away from the crankshaft pulley Apply lithium grease to the lip of the seal 026982 00X Figure 6 60 6 44 Figure 6 61 4 Install a new seal in the flywheel housing Figure 6 61 2 with the lip facing in away from the flywheel Apply lithium grease to the lip of the seal Crankshaft Bearing Oil Clearance Oil clearance should be checked during disassembly to determine the extent of wear and during assembly to ensure long engine life The same procedure is done for both connecting rods and main bearings See Removal of Pistons on page 6 40 or Removal of Crankshaft on page 6 41 for s
75. 3 if equipped and engine cooling fan Figure 7 18 2 Figure 7 18 Reinstall the cooling fan V belt Figure 7 18 1 Adjust as described in Check and Adjust Cooling Fan V Belt on page 5 27 Reinstall the cooling fan guard if equipped Prime the fuel system See Priming the Fuel System on page 4 13 Operate the engine and check for fuel and lube oil leaks 7 17 FUEL SYSTEM CHECKING AND ADJUSTING FUEL INJECTION TIMING Note The following procedure is performed on the No 3 cylinder While checking and adjusting the timing on only No 3 cylinder is usually sufficient the same procedure can be performed on any or all cylinders Checking Fuel Injection Timing Note Some fuel may drain from the fuel injection pump during this process Make provisions to contain and dispose of any such spillage 1 Ensure the fuel injection pump is primed with fuel See Priming the Fuel System on page 4 13 2 Clean the area around the fuel injection pump Note The stop solenoid must be removed to allow fuel to flow through the fuel injection pump 3 Remove two screws Figure 7 19 1 Remove the stop solenoid Figure 7 19 2 and O ring Figure 7 19 3 Figure 7 19 4 Setthe throttle to the HIGH IDLE position Checking and Adjusting Fuel Injection Timing 5 Using a wrench on the crankshaft pulley bolt rotate the crankshaft in a clockwise direction while looking through the flywheel insp
76. 3 in 0 1 mm Locally Manufactured Stem Seal Tool for Installing Stem Seals Flex Hone 129400 92410 22 2 in For Preparing 70 76 mm Cylinder Walls 0000823 Piston Ring Compressor For Installing Pistons Yanmar Part No 955500 02476 The Piston Insertion Tool is Applicable for 2 362 4 921 in 60 125 mm Diameter Pistons Piston Ring Tool For Removing Installing of Piston Rings Available Locally 0000825 e Series Service Manual 6 15 Measuring Instruments MEASURING INSTRUMENTS No Instrument Name Application Dial Indicator Available Locally Measure shaft bend and end play Measurements of narrow or deep portions that Test Indicator Available Locally cannot be measured by dial gauge Magnetic Stand Available Locally For holding the dial gauge when measuring For measuring the outside diameters of Micrometer Locally crankshaft pistons piston pins etc For measuring the inside diameters of cylinder Cylinder Bore Gauge Available Locally liners bearing bores etc For measuring outside diameters depth Calipers Available Locally thickness and width Depth Micrometer Available Locally For measuring of valve recession For measuring valve spring inclination and Square Available Locally straightness of parts 6 16 TNM Series Service Manual G2 We 0000831 x 000
77. 7 2 assembly out of the engine being careful not to damage the front camshaft bushing Remove the camshaft gear Figure 6 47 4 only if the gear or camshaft require replacement Use a knife edge puller and a press to remove the gear The gear is a shrink fit and will need to be heated to 356 392 F 180 200 C to remove Disassembly of Crankshaft and Piston Components Removal of Pistons CAUTION Keep the piston pin parts piston assemblies and connecting rod assemblies together to be returned to the same position during the reassembly process Label the parts using an appropriate method 0000088en IMPORTANT Engines with high operating hours may have a ridge near the top of the cylinders that will catch the piston rings and make it impossible to remove the pistons Use a suitable ridge reamer to remove ridges and carbon prior to removing pistons Note Pistons can fall from cylinder block if engine is inverted Rotate the engine so the connecting rods are horizontal before removing the connecting rod caps 6 40 Cylinder Block Using a feeler gauge measure the connecting rod side clearance Figure 6 48 See Connecting Rod on page 6 11 for the standard limit lf the measurement is out of specification replace the crankshaft connecting rod or both 0000219 Figure 6 48 IMPORTANT Mark the connecting rod caps and connecting rods so the caps and connecting rods stay toget
78. Blank 4 28 TNM Series Service Manual Unit Conversions Section 5 PERIODIC MAINTENANCE Page LE 5 3 ure Wupeafep 5 15 The Importance of Periodic 5 15 Performing Periodic 5 15 Yanmar Replacement 5 16 Required EPA ARB Maintenance USA Only 5 16 ARB Installation Requirements USA Only 5 16 Periodic Maintenance 5 16 Periodic Maintenance Procedures 5 18 After Initial 50 Hours of Operation 4 204422 5 18 Every 50 Hours of 2 04 00 5 22 Every 250 Hours of 5 25 Every 500 Hours of 5 30 Every 1000 Hours of 5 33 Every 1500 Hours of 5 36 Every 2000 Hours of Operation eese 5 37 TNM Series Service Manual 5 1 PERIODIC MAINTENANCE This Page Intentionally Left Blank 5 2 TNM Series Service Manual Introduction INTRODUCTION This section of the Service Manual describes the procedures for proper car
79. CIFICATIONS Special Torque Chart Lubricating Oil Application Fuel Injector Fuel Pump Drive Gear Nut High Pressure Fuel Injection Line Nuts Fuel Return Line Nuts Fuel Injection Pump Mounting Nuts Fuel Injector Nozzle Case Nut Test and Adjustment Specifications 36 1 39 1 ft lb 49 53 N m 5 0 5 4 kgf m 44 51 ft lb B9 69 N m 6 7 kgf m 22 25 ft lb 29 34 N m 3 0 3 5 kgf m 18 24 ft lb 24 33 2 5 3 3 kgf m 17 21 ft lb 23 28 N m 2 3 2 9 kgf m 21 4 36 1 ft lb 29 49 N m 3 0 5 0 kgf m FUEL SYSTEM Fuel Injector Pressure Fuel Injection Timing 1784 1929 psi 12 3 13 3 MPa See Checking and Adjusting Fuel Injection Timing on page 7 18 125 136 kgf cm Note Fuel injector pressures given are for used parts New injectors 5 hours operation or less will read approximately 72 5 psi 0 5 MPa 5 kgf cm higher a TNM Series Service Manual FUEL SYSTEM Special Service Tools SPECIAL SERVICE TOOLS Note Tools not having Yanmar part numbers must be acquired locally For tightening nuts and bolts to the specified torque oo 0000840 Torque Wrench Locally Available MEASURING INSTRUMENTS No _ Aeon For observing injection spray pattern of fuel Fuel Injector Tester Locally Available injection nozzle and measuring injection pressure Spill Timing Tool Shop Fabricated U
80. Clean Air Cleaner Element Clean Air Filter on page 5 28 S 9 2 o c Clogged Air Filter Engine Used at High Temperatures or at High Altitude Clogged Exhaust Pipe 5 E 2 2 Study Output Drop and Load Matching Repair or Replace Stater Motor See Starter Motor on page 10 9 See Removal of Alternator on Repair or Replace Alternator page 11 12 or Removal of Dynamo on page 11 20 ie aii ee Inspect and Change the Battery 989 pus ve Air Exhaust Gas System o x 2 o o i ou are Alternator Defect of 40 22 Battery Voltage Drop BEND Electrical System pm gt S gt z 2 o o o i Eg JL ww LI d e eee ee en I NEN Series Service Manual 13 17 TROUBLESHOOTING Troubleshooting Charts This Page Intentionally Left Blank 13 18 TNM Series Service Manual YANMAR Head Office Yanmar Co Ltd 1 32 Chayamachi Kita ku Osaka Japan http Awww yanmar co jp Yanmar America Corporation 951 Corporate Grove Drive Buffalo Grove IL 60089 4508 U S A TEL 1 847 541 1900 FAX 1 847 541 2161 http www yanmar com Yanmar Europe B V Bru
81. Cylinder Block Section 7 FUEL SYSTEM Page Before You Begin 7 3 INTO GU CHOM AT 7 5 Fuel Injection 7 5 Stop Solenoid swiss 7 6 Fuel System Specifications 7 7 Special Torque Chart iei 7 7 Test and Adjustment Specifications 7 7 Special Service LOOMS vis ucc ere aatia imis Dn s 7 8 Measuring 7 8 Fuel System 444 4444440 0 7 9 Fuel System Components 7 10 Fuel Injection mm 7 11 Removal of High Pressure Fuel Injection Lines 7 11 Installation of High Pressure Fuel Injection Lines 7 12 Removal of Fuel Return 7 12 Installation of Fuel Return 2 7 18 Fuel Injection 7 13 Removal of Fuel Injection 7 13 Installation of Fuel Injection Pump esses 7 16 Checking and Adjusting Fuel Injection Timing 7 18 Checking Fuel Injection Timing 2 22 7 18 Adjusting Fuel Injection 7 21 Fuel 0
82. ENTS YAN YANMAR CO LTD 021752 00 EPA amp CARB 4 Series Service Manual GENERAL SERVICE INFORMATION THE 97 68 EC DIRECTIVE CERTIFIED ENGINES The engines described in this manual have been certified by the 97 68 EC Directive To identify the engines that meet this certification the 97 68 EC emission control label is affixed on the engines IMPORTANT ENGINE INFORMATION THIS ENGINE CONFORMS TO 97 68 EC DIRECTIVE ENGINE FAMILY ENGINE MODEL 1 APPROVAL NUMBER nnn ened YANMAR CO LTD 97 68 EC 4 5 GENERAL SERVICE INFORMATION Engine Family ENGINE FAMILY The EPA ARB labels and the 97 68 EC label all have an Engine Family field The following is an explanation of the Engine Family designation 8 YDX L 0 78 V 3 SES of air aspiration Number of cylinders Engine speed specifications Displacement liter Non road Off road engine Yanmar Diesel 2008 Model Year 8 2008 9 2009 10 2010 etc 4 6 TNM Series Service Manual Function of Major Engine Components GENERAL SERVICE INFORMATION FUNCTION OF MAJOR ENGINE COMPONENTS Air Cleaner Dipstick Engine Oil Electric Fuel Pump Engine Oil Filter Fuel Filter Fuel Filter Water Separator Fuel Priming Lever 4 Series Service M The air cleaner prevents airborne contaminants fro
83. End Gap 3 Oil Ring End Gap Figure 6 88 Installation of Crankshaft 1 If removed reinstall the key and timing gear on crankshaft Install new bearing inserts Figure 6 89 1 and thrust bearing Figure 6 89 2 in the cylinder block and main bearing caps Be sure the oil holes in the upper bearing shells align with the oil ports in the cylinder block Apply a liberal coat of clean engine oil to the bearings and crankshaft journals TNM Series Service Manual Cylinder Block 027073 00X Figure 6 89 3 Install the thrust metal side gap Install the thrust metal on the flywheel side The installation procedure is indicated as follows the same procedure for both sides 1 Install the thrust metal without a tab to the cylinder block after the crankshaft assembly the crankshaft is omitted 027483 00X Figure 6 90 2 Mount the thrust metal with a tab and turn it 90 degrees counterclockwise e Series Service Manual ENGINE Figure 6 91 Install the upper main bearing thrust bearing and crankshaft into the engine IMPORTANT The main bearing are numbered and have arrows for proper positioning The No 1 bearing is at the flywheel end Reinstall the lower main bearing into the ladder frame Apply a light coat of clean engine oil to the ladder frame mounting bolts and tighten the bolts to the specified torque in two stages 1
84. Engines fire every 240 of crankshaft rotation Valve clearance of both the intake and exhaust valves can be checked with the piston for that cylinder at top dead center TDC of the compression stroke When a piston is at TDC of the compression stroke both rocker arms will be loose and the cylinder TDC mark on the flywheel will be visible in the timing port of the flywheel housing If there is no valve clearance and the piston is at TDC of the compression stroke extreme wear or damage to the cylinder head or valves may be possible 3 Cylinder Engines Cylinder Head If adjusting each cylinder individually the cylinder to be adjusted first does not have to be the No 1 cylinder Select and adjust the cylinder where the piston is nearest to the top dead center after turning Adjust the remaining cylinders in the order of firing by turning the crankshaft each time To decrease the number of rotations required to check all cylinders of a 3 cylinder engine other cylinders can also be checked as indicated in the chart below Example On a 3 cylinder engine with the No 1 piston at TDC on the compression stroke both valves closed the valves indicated on the top line of the chart can be adjusted without rotating the crankshaft To adjust the remaining two valves rotate the crankshaft until the No 1 piston is at TDC on the exhaust stroke exhaust valve only open No 1 Cylinder at TDC Compression 1 Remove the inta
85. Failure to comply will result in death or serious injury 0000008en DANGER EXPLOSION HAZARD NEVER check the remaining battery charge by shorting out the terminals This will result in a spark and may cause an explosion or fire Use a hydrometer to check the remaining battery charge If the electrolyte is frozen slowly warm the battery before you recharge it Failure to comply will result in death or serious injury 0000007en e Series Service Manual SAFETY SEVER HAZARD Keep hands and other body parts away from moving rotating parts such as the cooling fan flywheel or PTO shaft Wear tight fitting clothing and keep your hair short or tie it back while the engine is running Remove all jewelry before you operate or service the machine NEVER start the engine in gear Sudden movement of the engine and or machine could cause death or serious personal injury NEVER operate the engine without the guards in place Before you start the engine make sure that all bystanders are clear of the area Keep children and pets away while the engine is operating Check before starting the engine that any tools or shop rags used during maintenance have been removed from the area Failure to comply could result in death or serious injury 0000002en 3 7 SAFETY EXHAUST HAZARD NEVER operate the engine in an enclosed area such as a garage tunnel undergroun
86. Function of Major Engine 4 7 Function of Cooling System 4 9 Diesel Eel a erre pp e a deb e EC CER PAR 4 10 Diesel Fuel Specifications 2 0200 4 10 Filing the 4 11 Priming the Fuel 40 4 13 ize 29 rr T 4 14 Engine Oil Specifications 2 4 4 14 Service Categories 4 14 Engine Oil Viscosity aeu d neenon 4 15 Checking Engine 2 44 0 0 4620 4 1 4 15 Adding Engine Oil eicere t rnc toten e peg 4 15 Engine Oil Capacity Typical 4 16 Engine Caolarib ARP oa 4 16 Engine Coolant 4 17 Filling Radiator with Engine 4 17 Engine Coolant Capacity 4 18 Specifications a reironta exea rd 4 19 Description of Model 4 19 Engine Speed Specifications 4 19 Engine General Specifications esses 4 20 TNM Series Service Manual 4 1 GENERAL SERVICE INFORMATION 4 2 Principal Engine Specifications 2 4 21 STNMGS EPA IgE tex ct
87. NM72 3TNM68 3TNM72 Page 0 20 0 40 mm Inspection of f 1 Connecting page 6 47 Connecting Rod Distortion Inspection Item 3TNM68 3TNM72 3TNM68 3TNM72 Page See Less than f Inspection of Twist and Bend per 3 937 in 100 mm 0 001 in 0 03 mm Rod on page 6 47 Tappet Inspection Item 3TNM68 3TNM72 3TNM68 3TNM72 Page Tappet Bore Block Inside Diameter 0 7087 0 7094 in 0 8268 0 8276 in 0 7102 in 0 8284 in 18 000 18 018 mm 21 000 21 021 mm 18 038 mm 21 041 mm See Stem Outside Diameter 0 7067 0 7074in 0 8239 0 8252 in 0 7059 in 0 8231 in nspection of 17 950 17 968 mm 20 927 20 960 mm 17 930mm 20 907 Tappets Ga 0 0013 0 0027 in 0 0016 0 0037 in 0 0043in 0 0053 in Page 6 48 0 032 0 068 mm 0 040 0 094 mm 0 108 mm 0 134 mm e Series Service Manual 6 11 Cylinder Block Specifications CYLINDER BLOCK SPECIFICATIONS Cylinder Block mM Stndad 3TNM68 3TNM72 3TNM68 3TNM72 Page Cylinder Inside Bore 2 6772 2 6783 in 2 8346 2 8358 in 2 6850 in 2 8425 in See y 68 000 68 030 mm 72 000 72 030 mm 68 200 mm 72 200 mm Inspection of Cylinder Roundness 0 0004 in 0 01 mm 0 0012 in Cylinder Bore 6 12 TNM Series Service Manual SPECIAL TORQUE CHART T
88. Not abnormal ONILOOHSATENOUL HOLVNH3I TIV YOLVNYALIV 41 Alternator Components ALTERNATOR ALTERNATOR COMPONENTS Yanmar Part No 129423 77200 alternator is used in this section to show the service procedures for the representative alternator For specific part detail see the Parts Catalog for the engine you are working on 0000255 Figure 11 1 1 Nut 20 Rear Frame Housing 2 Pulley 21 Bolt 2 used 3 Collar 22 Holder 4 Front Frame Housing 23 IC Regulator Assembly 5 Stator Assembly 24 Bolt 2 used 6 Stud 2 used 25 Bolt 7 Front Frame Housing Bearing 26 Brush 2 used 8 Bearing Cover 27 Bolt 9 Bearing Cover Bolt 4 used 28 Rear Cover 10 Rotor Assembly 29 Bolt 3 used 11 Rear Frame Housing Bearing 12 Bearing Cover 13 Thrust Washer 14 Thrust Washer 15 Nut 2 used 16 Nut 17 Insulation Bushing 18 Spring 2 used 19 Brush Holder e Series Service Manual 11 9 ALTERNATOR Alternator Wiring Diagram ALTERNATOR WIRING DIAGRAM 1 Key Switch 4 Battery 2 Charge Lamp 3 4 Watts Max 5 Alternator Assembly 3 Load 6 IC Regulator Assembly Figure 11 2 CAUTION CAUTION Do not short circuit the charging system Do not remove the positive battery between alternator terminals IG and L cable from alternator terminal B while Damage to the alternator will result the en
89. Note The information described in Principal Engine Specifications is for a standard engine To obtain the information for the engine installed in your driven machine please refer to the manual provided by the driven machine manufacturer Engine rating conditions are as follows SAE J1349 ISO 3046 1 Atmospheric Condition Room temperature 77 F 25 C Atmospheric pressure 29 53 in Hg 100 kPa 750 mm Hg Relative humidity 30 Fuel Temperature at Fuel Injector Pump Inlet 104 F 40 C With Cooling Fan Air Cleaner Muffler Yanmar Standard After Engine Break In Period Output Allowable Deviation 3 1 5 0 7355 kW 1 hp SAE Society of Automotive Engineers 0 7457 kW 4 20 TNM Series Service Manual Principal Engine Specifications GENERAL SERVICE INFORMATION PRINCIPAL ENGINE SPECIFICATIONS 3TNM68 EPA Tier 4 Engine Model 3TNM68 Type Vertical In line Diesel Engine System Ball Type Swirl Chamber Natura No of Cylinders 3 Borex Stake BET REG STET Displacement RA 47 8 cu in 0 784 L a Rated n 148 8 178 8 utput Pw SETTE E ECEE E E S E S eS 1500 1800 2000 2200 2400 2600 2800 3000 3000 3600 3200 3400 3600 Rated Output High Idling 1600 1900 2185 2380 2595 2805 3020 3235 3175 377
90. Recommended Battery Capacity 12V 36 Amp Hour 5h rating Dimensions 19 5 x 16 8 x 21 3 in Lx Wx Hy 497 x 427 x 542 mm 4 1 2 3 9 3 3 1 9 qt 3 1 1 8 L Upper Dipstick Upper Limit Limit Lower Lower Limit Limit Engine Oil Pan 3 1 1 7 qt 2 9 1 6 L Capacity Dipstick Upper Limit Lower Limit ae 0 26 gal 1 0 L Engine Only Cooling imn 12 2 in 310 mm O D 5 Blade Pusher Type 0222 000000 2 Engine specifications without radiator Engine oil capacity for a Deep Standard oil pan Refer to the Operation Manual provided by the driven machine manufacturer for the actual engine oil capacity of your machine vary depending on application 4 22 TNM Series Service Manual Engine Service Information GENERAL SERVICE INFORMATION ENGINE SERVICE INFORMATION Inspection Item Standard 0 006 0 010 in Intake Exhaust Valve Gap 0 15 0 25 mm EHI Fuel Injection Timing See Checking and Adjusting Fuel Injection Timing on page 7 18 1784 1929 psi Fuel Injection Pressure 12 3 13 3 MPa 125 136 kgf cm Compression Pressure at 3TNM68 470 15 psi 370 15 psi 250 rpm 250 min 3TNV72 3 24 0 1MPa 2 55 0 1 MPa 33 1 kgf cm 26 1 kgf cm 41 55 psi 0 28 0 38 MPa Lubricating Oil Pressure When idlin 8 5 psi 0 06 MPa 9 0 6 kgf cm or greater Full Opening Lift Valve Opening Tem
91. SYSTEM 11 Remove all high pressure fuel injection lines See Removal of High Pressure Fuel Injection Lines on page 7 11 12 Turn on all fuel supply valves Note As the injection pump injects fuel to a cylinder only once every two engine revolutions it may be necessary to rotate the crankshaft twice to see fuel being pumped from the timing tool or delivery valve of the cylinder you are using to check injection timing 13 Install the spill timing tool Figure 7 24 1 onto the delivery valve for the cylinder being checked See Measuring Instruments on page 7 8 Note If a timing tool is not available timing can be checked by watching the fuel in the delivery valve itself 0000592A Figure 7 24 Note The following references to the direction of rotation are made facing the cooling fan end of the engine and are adjusted by turning the crankshaft 14 Slowly rotate the crankshaft clockwise using a wrench on the crankshaft pulley bolt until fuel is pumped from the nozzle of the spill timing tool or delivery valve 7 20 Checking and Adjusting Fuel Injection Timing 15 Slowly rotate the crankshaft clockwise approximately two more revolutions until the timing grid on the flywheel for the cylinder being checked is at approximately 30 BTDC Note The fuel injection pump injects fuel to a 16 17 18 19 20 21 22 23 24 cylinder only once every two engine revolutions F
92. YANMAR SERVICE MANUAL STNMGS STNM72 California Proposition 65 Warning Diesel engine exhaust and some of its constituents 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 TNM series 3TNM68 3TNM72 P N OBTNM GO00100 This Service Manual has been developed for the exclusive use of service and repair professionals such as Yanmar authorized Distributors and Yanmar authorized Dealers It is written with these professionals in mind and may not contain the necessary detail or safety statements that may be required for a non professional to perform the service or repair properly and or safely Please contact an authorized Yanmar repair or service professional before working on your Yanmar product Disclaimers All information illustrations and specifications in this manual are based on the latest information available a
93. ZARD NEVER operate the engine an enclosed area such as a garage tunnel underground room manhole or ship s hold without proper ventilation NEVER block windows vents or other means of ventilation if the engine is operating in an enclosed area All internal combustion engines create carbon monoxide gas during operation Accumulation of this gas within an enclosure could cause illness or even death Make sure that all connections are tightened to specifications after repair is made to the exhaust system Failure to comply could result in death or serious injury 0000003en e Series Service Manual PERIODIC MAINTENANCE SEVER HAZARD Keep hands and other body parts away from moving rotating parts such as the cooling fan flywheel or PTO shaft Wear tight fitting clothing and keep your hair short or tie it back while the engine is running Remove all jewelry before you operate or service the machine NEVER start the engine in gear Sudden movement of the engine and or machine could cause death or serious personal injury NEVER operate the engine without the guards in place Before you start the engine make sure that all bystanders are clear of the area Keep children and pets away while the engine is operating Check before starting the engine that any tools or shop rags used during maintenance have been removed from the area Failure to comply could
94. a SUR anc iR 4 21 STNM72 EPA uide copa Moo ext RO RR 4 22 Engine Service Information 0 000 4 23 Tightening Torques for Standard Bolts and Nuts 4 24 Abbreviations and 4 26 nnnm nnne nen 4 26 uolo EN 4 26 Unit CONVERSIONS ausser aae a 4 27 Unit Prefixes 4 27 Units of 4 27 Units of 12 nennen 4 27 URIS OPW SS sate 4 27 UNIS of ERR Ee Rx v o EUR EPA RR RR 4 27 tS OF LOIque scd op verita ne Eri Fee e 4 27 Units 4 27 Units 4 27 OF T 4 27 Series Service Manual Component Identification COMPONENT IDENTIFICATION GENERAL SERVICE INFORMATION Figure 4 1 shows where major engine components are located 1 Coolant Temperature Sensor 2 Lifting Eye engine cooling fan end 3 Engine Cooling Fan 4 V Belt 5 Engine Coolant Pump 6 Fuel Return to Fuel Tank 7 Crankshaft V Pulley 8 Side Filler Port engine oil 9 Drain Plug engine 10 Engine Oil Filter 11 Fuel Inlet 12 Mechanical Fuel Pump 13 Fuel Priming Lever
95. ace the bearing Figure 11 10 2 in the front frame housing remove the four bolts Figure 11 10 3 securing the plate Figure 11 10 4 to the front frame housing Remove the plate Use a puller to remove the bearing Discard the bearing 11 If itis necessary to replace the bearing Figure 11 11 1 in the rear frame housing use a puller to remove Discard the bearing Remove the bearing cover Figure 11 11 2 and two thrust washers Figure 11 11 3 0000260A Figure 11 11 11 14 m Alternator Reassembly of Alternator 1 If removed reinstall the two thrust washers Figure 11 12 3 and bearing cover Figure 11 12 2 in the rear frame housing Lubricate the outside diameter of a new bearing Figure 11 12 1 Press the bearing into the rear frame housing 0000260A Figure 11 12 If removed lubricate the outside diameter of a new front frame housing bearing Press the bearing Figure 11 13 2 into the front frame housing Reinstall the plate Figure 11 13 4 to the front housing Tighten the four bolts Figure 11 13 3 0000259A Figure 11 13 TNM Series Service Manual Alternator ALTERNATOR 3 Position the stator assembly Figure 11 13 1 on the front frame housing studs 4 Lubricate the shaft of the rotor assembly Figure 11 14 1 Press the rotor assembly into the front frame housing Figure 11 14 2 and rear frame housing Figure
96. ach of the following shims 0 0197 in 0 50 mm 114250 53560 0 0394 in 1 00 mm 7 26 Fuel Injectors 1 Return Fuel Fitting Nut 2 Return Fuel Fitting 3 Seal PK 4 Injector Body 5 Pressure Adjusting Shims 6 Spring 7 Spring Seat 8 Valve Stop Spacer 9 Nozzle Valve 10 Nozzle Body 11 Nozzle Case Nut Figure 7 32 The injection pressure will change by approximately 100 142 psi 0 69 0 98 MPa 7 10 kgf cm for every 0 004 in 0 1 mm shim thickness See the parts catalog for available shims 1 Disassemble the fuel injector assembly See Disassembly and Inspection of Fuel Injectors on page 7 25 2 Remove or add adjusting shims as needed 3 Reassemble the fuel injector assembly See Heassembly of Fuel Injectors on page 7 27 4 Retest the fuel injector See Testing of Fuel Injectors on page 7 22 If the injector cannot be adjusted to the appropriate pressure discard the fuel injector TNM Series Service Manual Fuel Injectors Reassembly of Fuel Injectors 1 Secure the injector in a soft jawed vise with the nozzle end up Reinstall the shims nozzle spring nozzle spring seat valve stop spacer nozzle valve and nozzle body Reinstall the nozzle case nut Tighten it to specification Installation of the Fuel Injectors 1 Insert the nozzle gaskets Figure 7 33 5 and nozzle protector Figure 7 33 6 in the cylinder h
97. ailure of an electrical component and the loss of warranty coverage on that item as well as related items Make sure that all users read and understand these precautions 1 AD Do not reverse the positive and negative ends of the battery cable The alternator diode and stator coil will be damaged 0000050en CAUTION When the battery indicator goes out it should not come on again The battery indicator only comes on during operation if the alternator fails However if an LED is used in the battery indicator the LED will shine faintly during normal operation 0000051en CAUTION Make sure that the combined total resistance of the battery cable in both directions between the starter motor and the battery is within the value indicated in the Battery Cable Resistance chart in the Electric Wiring Section of this manual The starter motor will malfunction and fail if the resistance is higher than the specified value 0000057en e Series Service Manual ELECTRIC WIRING CAUTION Removing the battery cables or the battery while the engine is operating may cause damage to the current limiter depending on the electrical equipment being used This situation could cause loss of control of output voltage The continuous high voltage of 23 24 volts for 5000 rpm dynamo will damage the current limiter and other electrical equipment 0000058en CAUTION Reversing the battery ca
98. anese Automobile Standards Organization Note 1 Be sure the engine oil engine oil storage containers and engine oil filling equipment are free of sediments and water TNM Series Service Manual Engine Oil 2 Change the engine oil after the first 50 hours of operation and then every 250 hours thereafter 3 Select the oil viscosity based on the ambient temperature where the engine is being operated See the SAE Service Grade Viscosity Chart Figure 4 5 4 Yanmar does not recommend the use of engine oil additives Additional Technical Engine oil Requirements The engine oil must be changed when the Total Base Number TBN has been reduced to 1 0 mgKOH g test method JIS 201 5 2 2 ASTM D4739 Engine Oil Viscosity Select the appropriate engine oil viscosity based on the ambient temperature and use the SAE Service Grade Viscosity Chart in Figure 4 5 i H SAE 10W p ESAE 20W gt i i SAE 10W 30 30 M SAE 40 SAE 20W 50 bmp PF 14 F 32 F 50 F 68 F 86 F 104 122 F 20 C 10 C 0 C 10 C 20 C 30 40 C 50 0000005 4 5 Checking Engine Oil Make sure engine is level 2 Remove dipstick Figure 4 6 1 and wipe with clean cloth 3 Fully reinsert dipstick 4 Remove dipstick The oil level should be between upper Figure 4 6 2 and lower Figure 4 6 3 lines
99. assembly make reference marks Figure 7 11 1 2 on the drive gear and idler gear CAUTION After marking the position of the pump drive gear do not rotate the engine crankshaft Rotating the crankshaft will cause the fuel injection pump to become misaligned 0000048en TNM Series Service Manual Fuel Injection Pump CAUTION 15 Figure 7 11 Do not loosen or remove the four bolts retaining the fuel injection pump drive gear to the fuel injection pump hub Do not disassemble the fuel injection pump drive gear from the hub Correct fuel injection timing will be very difficult or impossible to achieve 0000031en Do not loosen or remove the four bolts Figure 7 12 3 holding the pump drive gear to the hub Only remove the single drive gear nut Figure 7 12 1 and washer Figure 7 12 2 leaving the hub attached to the gear 927020 00 7 12 TNM Series Service Manual FUEL SYSTEM 16 Hold the gear train stationary using a large socket wrench on the crankshaft pulley bolt Loosen the fuel injection pump drive gear retaining nut Figure 7 12 1 and turn it out to the end of the fuel injection pump shaft 17 Remove the injection pump drive gear and hub from the injection pump drive shaft as an assembly using an appropriate gear puller Figure 7 13 Figure 7 13 Note The injection pump drive gear can be removed
100. at all times Poor quality fuel can reduce engine performance and or cause engine damage Fuel additives are not recommended Some fuel additives may cause poor engine performance Consult your Yanmar representative for more information Ash content not to exceed 0 0196 by volume Diesel Fuel Carbon residue content not to exceed 0 3596 by volume Less than 0 196 is preferred Total aromatics content should not exceed 3596 by volume Less than 3096 is preferred PAH polycyclic aromatic hydrocarbons content should be below 1096 by volume Metal content of Na Mg Si and AI should be equal to or lower than 1 mass ppm Test analysis method JPI 5S 44 95 Lubricity Wear mark of WS1 4 should be Max 0 018 in 460 um at HFRR test Bio Diesel Fuels In Europe and in the United States as well as some other countries non mineral oil based fuel resources such as RME Rapeseed Methyl Ester and SOME Soybean Methyl Ester collectively known as FAME Fatty Acid Methyl Esters are being used as extenders for mineral oil derived diesel fuels Yanmar approves the use of bio diesel fuels that do not exceed a blend of 596 by volume of FAME with 9596 by volume of approved mineral oil derived diesel fuel Such bio diesel fuels are known in the marketplace as B5 diesel fuels These B5 diesel fuels must meet certain requirements 1 The bio fuels must meet the minimum specifications for the country in which
101. ations TNM Series Service Manual Cylinder Block pik 3 Figure 6 67 2 0001964 Note Always check the piston ring end gap when installing new piston rings See Piston Ring on page 6 10 for specifications Use a piston ring end gap filing tool to adjust the piston ring end gap on new piston rings 11 Repeat the above steps for each cylinder and piston assembly Inspection of Connecting Rod 1 Measure the wrist pin bushing bore using a bore gauge Figure 6 68 1 Replace the bushing if not within specifications If the bushing has been removed measure the inside diameter of the connecting rod small end Figure 6 68 2 Record the measurements See Connecting Rod on page 6 11 for specifications e Series Service Manual ENGINE 1 2 0001724A Figure 6 68 Measure the connecting rod twist Figure 6 69 1 and bend Figure 6 69 2 using a connecting rod alignment tool Figure 6 70 Record the measurements See Connecting Rod on page 6 11 for specifications 0001896 0000242 Figure 6 70 6 47 Cylinder Block 3 Place the connecting rod bearing inserts into Inspection of Crankshaft the connecting rod and connecting rod cap 1 Install the rod cap and tighten the bolts to the specified torque 4 Measure the inside diameter Record the measurements See Crankshaft
102. ator segment and the shaft or armature using a multimeter Figure 10 16 The multimeter should not indicate continuity If the multimeter indicates continuity replace the armature 0000115 Figure 10 16 10 13 STARTER MOTOR Measure Armature and Commutator Run Out Measure the armature core run out and the commutator run out using a dial indicator Figure 10 17 Replace the armature if either of the measurements is not within specifications See Starter Motor Specifications on page 10 6 for service limit 0000116 Figure 10 17 Field Coil Field Coil Continuity Test Check for continuity between the field coil terminals using a multimeter Figure 10 18 The multimeter should indicate continuity If the multimeter does not indicate continuity replace the field coil assembly 0000119 10 18 10 14 Starter Motor Field Coil Insulation Test Check for continuity between either field coil terminal and the yoke using a multimeter Figure 10 19 The multimeter should not indicate continuity If the multimeter indicates continuity replace the field coil assembly 0000120 Figure 10 19 Measure Brush Length Measure the length of the brush Figure 10 20 Replace the brush if the length is less than the limit See Starter Motor Specifications on page 10 6 for service limit 0000121 Figure 10 20 TNM Series Service Manual Starter Motor Brush H
103. battery cable from alternator terminal B while the engine is operating Damage to the alternator will result 0000037en CAUTION Do not turn the battery switch OFF while the engine is operating Damage to the alternator will result 0000038en CAUTION Do not reverse the positive and negative ends of the battery cable The alternator diode and stator coil will be damaged 0000050en CAUTION When the battery indicator goes out it should not come on again The battery indicator only comes on during operation if the alternator fails However if an LED is used in the battery indicator the LED will shine faintly during normal operation 0000051en e Series Service Manual ALTERNATOR CAUTION Using a non specified V belt will cause inadequate charging and shorten the belt life Use the specified belt 0000052en CAUTION Agricultural or other chemicals especially those with a high sulfur content can adhere to the IC regulator This will corrode the conductor and result in battery over charging boiling and charging malfunctions Consult Yanmar before using the equipment in such an environment or the warranty is voided 0000053en CAUTION Do not use a high pressure wash directly on the alternator Water will damage the alternator and result in inadequate charging 0000049en ALTERNATOR Introduction INTRODUCTION This section of the Service Manual describe
104. below Tighten in the sequence shown in Figure 6 30 See Tightening Torque for Special Bolts on page 6 13 1 2 of final torque Second Step 2 1 027135 00X 1 Cooling Fan End 2 Camshaft Side Figure 6 30 4 Insert the push rods in their respective positions Cylinder Head Reassembly of Rocker Arm Assembly 2 Align the hole in the rocker arm shaft Figure 6 32 7 and the hole in the rocker arm support Figure 6 32 5 Reinstall the alignment set screw Figure 6 32 6 3 Place the rocker arm shaft assembly onto the cylinder head 4 f removed reinstall the valve adjusting screws Figure 6 32 3 and lock nuts Figure 6 32 2 5 Align the push rods with their respective rocker arms 6 Reinstall and tighten the rocker arm shaft retaining bolts to the specified torque IMPORTANT 7 Tighten the rocker arm shaft alignment screw Ensure the lubrication holes in the rocker 8 Adjust the valve clearance See Measuring F igure 6 31 1 are oriented Adjusting Valve Clearance on page 6 32 correctly with respect to the rocker arms Figure 6 31 2 1 Lubricate the rocker arm shaft Slide the rocker arm supports Figure 6 32 5 springs Figure 6 32 4 and rocker arms Figure 6 32 1 onto the shaft 1 0001914 Figure 6 31 026970 00X Figure 6 32 Note The rocker arm shaft fits tightly in the rocker arm supports Clamp the su
105. ble connections at the battery or on the engine will destroy the SCR diode in the current limiter This will cause the charging system to malfunction and may cause damage to the electrical harnesses 0000059 ELECTRIC WIRING Electric Wire Resistance ELECTRIC WIRE RESISTANCE C e o 8 f e sewer s 8 cese eo 0 000087 Wiring voltage drop should not exceed 5 0 05 x 12 Volts 0 6 Volts Voltage Drop Current Amps x Length of Wire Feet x Resistance per Foot Ohms Example Current draw of 100 Amps x 3 feet of 4 AWG wire 100 Amps x 3 Feet x 0 000270 0 08 Volts Voltage Drop 12 4 TNM Series Service Manual Battery Cable Resistance ELECTRIC WIRING BATTERY CABLE RESISTANCE Maximum Total Battery Cable Length Positive Cable Negative Cable 12V Starter Motor Output 0 9 m n 4 r me e LE e 3000 a Note Total allowable resistance of the complete battery cable circuit positive cable negative cable a Resistance of a battery switch or other electrical equipment having high resistance Note For starter motors of less than 2 68 HP 2 kW the total resistance must be less than 0 002 For starter motors of greater than 2 68 HP 2 kW the total resistance must be less than 0 0012 e Series Service Manual 12 5 ELECTRIC WIRING Electrical Wir
106. by rotating the pump drive gear flywheel 1 Leave the spill timing tool installed in the fuel injection pump 2 Determine if the timing is advanced or retarded by comparing the position of the target timing mark on the flywheel grid ii Figure 7 25 1 with the timing mark on the flywheel housing or back plate Figure 7 25 2 2 4 0002469 7 7 25 8 3 Puton the timing grid sticker on the drive gear 9 align the timing mark on the block then loosen the bolts fastening the fuel injection pump drive gear to the pump flange Figure 7 26 16 11 e Series Service Manual FUEL SYSTEM 4 027019 00 7 26 If the injection timing was less than the target timing the injection timing is retarded and will need to be advanced To advance the injection timing Rotate the pump drive gear crankshaft towards counterclockwise If the injection timing was greater than the target timing the injection timing is advanced and will need to be retarded To retard the injection timing Rotate the pump drive gear crankshaft towards clockwise Tighten the pump drive gear mounting bolts Recheck the fuel injection timing Repeat the fuel injection timing and adjustment procedures until the timing is correct Remove the spill timing tool Reinstall the shut off solenoid Reinstall the high pres
107. cap Figure 4 7 2 by turning it counterclockwise about 1 3 of a turn Pour the engine coolant s owly into the radiator until it is even with the lip of the engine coolant filler port Make sure that air bubbles do not develop as you fill the radiator Engine Coolant 4 Reinstall the radiator cap Figure 4 7 2 Align the tabs on the back of the radiator cap with the notches on the engine coolant filler port Press down and turn the cap clockwise about 1 3 of a turn 5 Remove the cap of the reserve tank Figure 4 7 3 and fill it to the LOW COLD mark Figure 4 7 4 with engine coolant Reinstall the cap 6 Check the hose Figure 4 7 5 that connects the reserve tank Figure 4 7 3 to the radiator Be sure it is securely connected and there are no cracks or damage If the hose is damaged engine coolant will leak out instead of going into the reserve tank 7 Run the engine until it is at operating temperature Check the level of engine coolant in the reserve tank When the engine is running and the engine coolant is at normal temperature the coolant level in the tank should be at or near the FULL HOT mark Figure 4 7 6 If the engine coolant is not at the FULL HOT mark Figure 4 7 6 add additional engine coolant to the reserve tank to bring the level to the FULL HOT mark Engine Coolant Capacity Typical Note Capacities listed are for engine only without a radiator Refer to the operati
108. case Loosely reinstall the nut Figure 11 19 2 on the gear case stud and the V belt adjuster bolt Figure 11 19 1 0000264 Figure 11 19 2 Reconnect the electrical wires to the alternator Tighten the nuts to 15 20 in Ib 1 7 2 3 17 23 kgf m Reinstall the V belt Tighten the V belt to the proper tension See Check and Adjust Cooling Fan V Belt on page 5 27 11 16 TNM Series Service Manual Dynamo Component Location ALTERNATOR DYNAMO COMPONENT LOCATION Yanmar Part No 171301 77201 dynamo is used in this section to show the service procedures for the representative dynamo For specific part detail see the Parts Catalog for the engine you are working on 1 Rear Cover 2 Nut 3 Lock Washer 4 Flat Washer 5 Rear Bearing 6 Output Wire and Connector 7 Plate e Series Service Manual A Pp 12 0002140 Figure 11 20 8 Spacer 9 Stator Assembly 10 Front Bearing 2 used 11 Flat Washer 12 Flywheel Assembly 13 Pulley Half 14 Through Bolt 11 17 ALTERNATOR Dynamo Wiring Diagram DYNAMO WIRING DIAGRAM 3 Qi Q 4 1 77 ZUM 77 7 11 21 1 4 Charge Lamp 3 4 Watts Max 2 Current Limiter Assembly 5 Battery 3 Key Switch 6 Load OPERATION OF DYNAMO The dynamo consists of a series of permanent mag
109. ce as necessary Note Test the fuel injector using an injection nozzle tester Operate the tester following the information provided by the tester manufacturer Use clean filtered fuel or FIE calibration fluid for the test 3 Using the correct adapter connect a fuel injector to a nozzle tester Aim the fuel injector into a suitable container to catch the fuel spray Figure 7 28 Figure 7 28 TNM Series Service Manual Fuel Injectors HIGH PRESSURE HAZARD Avoid skin contact with the high pressure diesel fuel spray caused by a fuel system leak such as a broken fuel injection line High pressure fuel can penetrate your skin and result in serious injury If you are exposed to high pressure fuel spray obtain prompt medical treatment NEVER check for a fuel leak with your hands ALWAYS use a piece of wood or cardboard Have your authorized Yanmar industrial engine dealer or distributor repair the damage Failure to comply could result in death or serious injury 0000008en To prevent possible eye injury always wear SAFETY GLASSES while servicing the engine 0000013en 4 Pump the operating lever of the tester slowly observing the pressure reading at the point where the fuel injector begins spraying fuel See Test and Adjustment Specifications on page 7 7 for correct pressure readings Note Opening pressure of a new fuel injector will be approximately 72 5 psi 0 5 MPa 5 kgf c
110. ce the engine while it is operating remove all jewelry tie back long hair and keep your hands other body parts and clothing away from moving rotating parts Failure to comply could result in death or serious injury 0000010en e Series Service Manual ALTERNATOR SHOCK HAZARD Turn off the battery switch if equipped or disconnect the negative battery cable before servicing the electrical system Check the electrical harnesses for cracks abrasions and damaged or corroded connectors ALWAYS keep the connectors and terminals clean Failure to comply could result in death or serious injury 0000009en AM mh eee ai BURN HAZARD Keep your hands and other body parts away from hot engine surfaces such as the muffler exhaust pipe turbocharger if equipped and engine block during operation and shortly after you shut the engine down These surfaces are extremely hot while the engine is operating and could seriously burn you Failure to comply could result in death or serious injury 0000015en ALTERNATOR FUME BURN HAZARD Always read and follow safety related precautions found on containers of hazardous substances like parts cleaners primers sealants and sealant removers Failure to comply could result in death or serious injury 0000014en A CAUTION FLYING OBJECT HAZARD ALWAYS wear eye protection when servicing the engine and when
111. check the fuel system and engine coolant system hoses If they are cracked or degraded replace them Replace the hoses at least every two years See Check and Replace Fuel Hoses and Engine Coolant Hoses on page 5 37 Lap the Intake and Exhaust Valves Adjustment is necessary to maintain proper contact of the valves and seats See Inspection of Intake and Exhaust Valves on page 6 25 PERIODIC MAINTENANCE Periodic Maintenance Procedures This Page Intentionally Left Blank 5 38 TNM Series Service Manual Section 6 Before You Begin 6 3 IMTFOGUCHON epe EE 6 5 Cylinder Head Specifications 22 6 5 Adjustment Specifications 6 5 Cylinder eot vet adea ei Hi RIEN SUE RP tn QUE 6 5 Intake Exhaust Valve and 4 040012 6 6 PUSMMR OO METER 6 6 6 6 Rocker Arm and Shaft 6 7 Camshaft and Timing Gear Train Specifications 6 7 Camshaft 6 7 Idler Gear Shaft and Bushing 6 8 Timing Gear 6 8 Crankshaft and Pistons 6 8 ved
112. cifications Valve Clearance All 0 006 0 010 in 0 15 0 25 mm Cylinder Head Page Combustion Surface Distortion Flatness 00020 Osorno 9 0059 less 0 15 mm 0 0157 0 0236 in 0 0354 in ere ae Intake Recession on 0 4 0 6 mm 0 9 mm Valve Recession page 6 25 Valve Seat Seat Angle 25 Se Valve Face Seat Correction Angle 40 150 0 on page 6 26 Exhaust 0 0157 0 0236 in 0 0315 in 0 4 0 6 mm 0 8 mm Series Service Manual 6 5 Cylinder Head Specifications Intake Exhaust Valve and Guide Inspection Item 3TNM68 3TNM72 3TNM68 3TNM72 Page Guide Inside 0 2165 0 2172 in 0 2362 0 2367in 0 2197 in 0 2394 in Diameter 5 500 5 516 mm 6 000 6 012 mm 5 580 mm 6 080 mm Valve Stem 0 2152 0 2157 in 0 2346 0 2356 in 0 212 0 2323in Outside Diameter 5 465 5 480 mm 5 960 5 985 mm 5 400mm 5 900mm Oll Clearance 0 0008 0 0020 in 0 0006 0 0020 in 0 0063 in 0 0063 in 0 020 0 051 mm 0 015 0 052 mm 0 15 mm 0 15 mm 0 0004 in See 0 010 mm 2 alve Guide Inside 0 2165 0 2172 in 0 2362 0 2367in 0 2197 in 0 2394 in Springs on Diameter 5 500 5 516 mm 6 000 6 012 mm 5 580 mm 6 080 mm page 6 26 Valve Stem 0 2144 0 2150 in 0 2341 0 2350 in 0 2126 in 0 2323 in sss Outside Diameter 5 445 5 460 mm 5 945 5 970 mm 5 40 mm 5 90 mm
113. ck and adjust the V belt tension deflection as follows 1 Press the V belt down with your thumb with a force of approximately 22 ft lb 98 N m 10 kgf m to check the deflection There are three positions to check for V belt tension Figure 5 4 A B and C You can check the tension at whichever position is the most accessible The proper deflection of a used V belt at each position is 0006463 Figure 5 3 5 20 TNM Series Service Manual Periodic Maintenance Procedures 0006466 Figure 5 4 Used V Belt Tension A C 3 8 1 2 in 1 4 3 8 5 16 1 2 in 10 14 mm 7 10 mm 9 13mm 2 f necessary adjust the V belt tension Loosen the adjusting bolt Figure 5 5 1 and move the alternator Figure 5 5 2 with a pry bar Figure 5 5 3 to tighten the V belt to the desired tension Then tighten the adjusting bolt 0000653B Figure 5 5 e Series Service Manual PERIODIC MAINTENANCE 3 Tighten the V belt to the proper tension There must be clearance Figure 5 6 1 between the V belt and the bottom of the pulley groove If there is no clearance Figure 5 6 2 between the V belt and the bottom of the pulley groove replace the V belt 1 2 0000584 5 6 4 Check the V belt for cracks or wear If any of these conditions exist replac
114. cooling fan V belt Figure 7 7 1 e Series Service Manual FUEL SYSTEM 1 3 2 2 027017 00 7 7 Close any fuel valves in the fuel supply line Place a drain pan under the fuel injection pump to catch any spillage Clean the area to keep contaminants from entering the fuel system Remove the high pressure fuel injection lines as an assembly See Removal of High Pressure Fuel Injection Lines on page 7 11 The Pump Reset Method in the Market Preparation Prior to the Pump Removal Rotate the FW and read the FID angle 1 No 3 cyl eng Figure 7 8 Disconnect the fuel return lines from the fitting on the fuel injection pump Figure 7 9 1 Plug the open ends of the lines to minimize leakage and prevent contamination 7 13 FUEL SYSTEM Figure 7 9 9 Remove the fuel supply line Figure 7 9 2 from the fitting on the fuel injection pump 10 Plug or cap all openings to minimize leakage and prevent contamination 11 Remove the throttle cable from the fuel injection pump 12 Separate the stop solenoid wiring connector Figure 7 9 3 Fuel Injection Pump 13 Remove the fuel injection pump drive gear access cover Figure 7 10 1 from the gear case cover Figure 7 10 2 Note The cover is secured with an adhesive sealant Use a gasket scraper to separate the cover from the gear case Cover Figure 7 10 14 To aid in re
115. ctrical harnesses for cracks abrasions and damaged or corroded connectors ALWAYS keep the connectors and terminals clean Failure to comply could result in death or serious injury 0000009en FUME BURN HAZARD Always read and follow safety related precautions found on containers of hazardous substances like parts cleaners primers sealants and sealant removers Failure to comply could result in death or serious injury 0000014en STARTER MOTOR CAUTION FLYING OBJECT HAZARD ALWAYS wear eye protection when servicing the engine and when using compressed air or high pressure water Dust flying debris compressed air pressurized water or steam may injure your eyes Failure to comply may result in minor or moderate injury 0000003en CAUTION The starter motor can be damaged if operated continuously longer than 10 seconds while performing the no load test 0000034en CAUTION Make sure that the combined total resistance of the battery cable in both directions between the starter motor and the battery is within the value indicated on the wiring diagram The starter motor will malfunction or break down if the resistance is higher than the specified value 0000054en Before You STARTER MOTOR ppVefore You Begin Servicing Servicing CAUTION The starter motor is water proofed according to JIS D 0203 R2 which protects the motor from rain or general cleaning Do not use high pressure wash
116. d room manhole or ship s hold without proper ventilation NEVER block windows vents or other means of ventilation if the engine is operating in an enclosed area All internal combustion engines create carbon monoxide gas during operation Accumulation of this gas within an enclosure could cause illness or even death Make sure that all connections are tightened to specifications after repair is made to the exhaust system Failure to comply could result in death or serious injury 0000003en ALCOHOL AND DRUG HAZARD NEVER operate the engine while you are under the influence of alcohol or drugs NEVER operate the engine when you are feeling ill Failure to comply could result in death or serious injury 0000004en Safety Precautions EXPOSURE HAZARD Wear personal protective equipment such as gloves work shoes eye and hearing protection as required by the task at hand NEVER wear jewelry unbuttoned cuffs ties or loose fitting clothing when you are working near moving rotating parts such as the cooling fan flywheel or PTO shaft ALWAYS tie back long hair when you are working near moving rotating parts such as a cooling fan flywheel or PTO shaft NEVER operate the engine while wearing a headset to listen to music or radio because it will be difficult to hear the alert signals Failure to comply could result in death or serious injury 0000005 Series Ser
117. date the engine components Discard all used gaskets O rings and seals Use new gaskets O rings and seals for reassembly of engine CAUTION Identify all parts and their location using an appropriate method It is important that all parts are returned to the same position during the reassembly process 0000080en IMPORTANT Mark all valve train components so they can be installed in their original locations Note Record all measurements taken during disassembly If the engine will be completely disassembled the following preliminary steps should be performed 1 Disconnect the battery cables at the battery Always disconnect the negative cable first 2 Remove the throttle cable electrical connections intake and exhaust system connections and fuel supply lines from the engine 3 Remove the alternator See Hemoval of Alternator on page 11 12 4 Drain the engine coolant from the radiator and cylinder block See Drain Flush and Refill Cooling System with New Coolant on page 5 33 Remove the cooling system components from the engine CAUTION Be sure to secure the engine solidly to prevent injury or damage to parts due to the engine falling during work on the engine 0000009en 5 Remove the engine from the machine Mount the engine to a suitable engine repair stand having adequate weight capacity 6 Clean the engine by washing with solvent air or steam cleaning Carefully
118. e ALWAYS check the level of the engine coolant by observing the reserve tank Failure to comply will result in death or serious injury 0000002 DANGER EXPLOSION HAZARD Keep the area around the battery well ventilated While the engine is running or the battery is charging hydrogen gas is produced which can be easily ignited Keep sparks open flame and any other form of ignition away while the engine is running or battery is charging Failure to comply will result in death or serious injury 0000003en Safety Precautions DANGER UT FIRE AND EXPLOSION HAZARD Diesel fuel is flammable and explosive under certain conditions When you remove any fuel system component to perform maintenance such as changing the fuel filter place an approved container under the opening to catch the fuel NEVER use a shop rag to catch the fuel Vapors from the rag are flammable and explosive Wipe up any spills immediately Wear eye protection The fuel system is under pressure and fuel could spray out when you remove any fuel system component Failure to comply will result in death or serious injury 0000009 DANGER VAW FIRE AND EXPLOSION HAZARD Only use the key switch to start the engine NEVER jump start the engine Sparks caused by shorting the battery to the starter terminals may cause a fire or explosion Failure to comply will result in death or serious injury 0
119. e Manual Before You Begin Servicing BEFORE YOU BEGIN SERVICING DANGER SCALD HAZARD NEVER remove the radiator cap if the engine is hot Steam and hot engine coolant will spurt out and seriously burn you Allow the engine to cool down before you attempt to remove the radiator cap Tighten the radiator cap securely after you check the radiator Steam can spurt out during engine operation if the cap is loose ALWAYS check the level of the engine coolant by observing the reserve tank Failure to comply will result in death or serious injury 0000002en ARA BURN HAZARD Wait until the engine cools before you drain the engine coolant Hot engine coolant may splash and burn you e Failure to comply could result in death or serious injury 0000016en e Series Service Manual COOLING SYSTEM ENTANGLEMENT HAZARD Stop the engine before you begin to service it NEVER leave the key in the key switch when you are servicing the engine Someone may accidentally start the engine and not realize you are servicing it This could result in a serious injury If you must service the engine while it is operating remove all jewelry tie back long hair and keep your hands other body parts and clothing away from moving rotating parts Failure to comply could result in death or serious injury 0000010en FUME BURN HAZARD Always read and follo
120. e Sizes Voltage Drop ELECTRICAL WIRE SIZES VOLTAGE DROP Total Length of conductor from source of current to device and back to source in feet current on E d ee ld fd led ud i a al Hil bu el ed a amps 12 Volts 402 14 12 8 6 6 6 6 4 4 4 4 2 2 2 2 2 18 12110 10 8 8 61616 14 14 2 2 2 2 2 11111 1 22 10 ja jaja a t t t opo o 20 a 20 20 20 30 Eee 1 2 2 20 20 301 3 0 0 40140140 40 2 2020 vol vol 4 2 12 11 01 20 30 0140140144 2 211 130130144444 2 1 091 201304444 18 16 16 14 12 12 12 10 10 10 10 10 8 8 14 m2 vo to e s 6 6 12 12 10 10 8 8 6 8 6 68 68 6 4 4 4 0 19 8 6 6 6 4 4 4 4 2 2 2 2 ao 2e 26 p RT RT EC ES ES fan 26 56 30 i afe te a p eo 29 29 96 se 6 6 a afele o 29 29 99 6 6 afe e 3 eo 29 29 99 so ao 4 19 seae se se so so o Ea Ea 412 2H epepepw ps pepe
121. e and maintenance of the engine A DANGER EXPLOSION HAZARD NEVER check the remaining battery charge by shorting out the terminals This will result in a spark and may cause an explosion or fire Use a hydrometer to check the remaining battery charge If the electrolyte is frozen slowly warm the battery before you recharge it Failure to comply will result in death or serious injury 0000007en A DANGER UA FIRE AND EXPLOSION HAZARD Only use the key switch to start the engine NEVER jump start the engine Sparks caused by shorting the battery to the starter terminals may cause a fire or explosion Failure to comply will result in death or serious injury 0000004en e Series Service Manual PERIODIC MAINTENANCE DANGER VA SCALD HAZARD NEVER remove the radiator cap if the engine is hot Steam and hot engine coolant will spurt out and seriously burn you Allow the engine to cool down before you attempt to remove the radiator cap Tighten the radiator cap securely after you check the radiator Steam can spurt out during engine operation if the cap is loose ALWAYS check the level of the engine coolant by observing the reserve tank Failure to comply will result in death or serious injury 0000002en 5 3 PERIODIC MAINTENANCE 5 4 DANGER GL FIRE AND EXPLOSION HAZARD Diesel fuel is flammable and explosive under certain conditions O
122. e as a commercially available O ring the material is different 0000042en Reinstall the engine coolant pump bolts Tighten the bolts Inspect and reinstall the coolant hoses and the temperature switch lead wire Reinstall the engine coolant pump V pulley Figure 8 10 3 spacer Figure 8 10 2 engine coolant fan Figure 8 10 1 and engine coolant fan guard if equipped Figure 8 10 8 9 COOLING SYSTEM 8 Inspect the condition of the V belt There must be clearance Figure 8 11 1 between the V belt and the bottom of the pulley groove If there is no clearance Figure 8 11 2 between the V belt and the bottom of the pulley groove replace the V belt 2 1 0000584 Figure 8 11 Reinstall the V belt Tighten the V belt to the proper tension See Check and Adjust Cooling Fan V Belt on page 5 27 Reinstall and tighten the drain plug or close the drain cock in the radiator Reinstall and tighten the engine block drain plug or reconnect the coolant hose at the oil cooler Fill radiator and engine with engine coolant See Drain Flush and Refill Cooling System with New Coolant on page 5 33 CAUTION Only use the engine coolant specified Other engine coolants may affect warranty coverage cause an internal buildup of rust and scale and or shorten engine life Prevent dirt and debris from contaminating the engine coolant Carefully clean the radiator cap and the sur
123. e the V belt 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 5 Inspect the condition of the used V belt There must be clearance Figure 5 6 1 between the V belt and the bottom of the pulley groove If there is no clearance Figure 5 6 2 between the V belt and the bottom of the pulley groove replace the V belt 6 Install the new V belt Refer to the table for proper tension New V Belt Tension PAT C 5 16 7 16 in 8 12 mm 3 16 5 16 in 5 8 mm 1 4 7 16 in 7 11 mm 7 After adjusting run the engine for 5 minutes or more Check the tension again using the specifications for a used V belt Used V Belt Tension 1 4 3 8 in 5 16 1 2 in 7 10 mm 9 13 mm 3 8 1 2 in 10 14 mm PERIODIC MAINTENANCE Every 50 Hours of Operation After you complete the initial 50 hour maintenance procedures perform the following procedures every 50 hours thereafter Drain FuelFilter Water Separator Check Battery Drain Fuel Filter Water Separator DANGER FIRE AND EXPLOSION HAZARD Diesel fuel is flammable and explosive under certain conditions When you remove any fuel system component to perform maintenance such as changing the fuel filter place an approved container under the ope
124. e to tighten the air vent screw after the water has drained out 0000025en Safety Precautions CAUTION When the engine is operated in dusty conditions clean the air cleaner element more frequently NEVER operate the engine with the air cleaner element s removed This may allow foreign material to enter the engine and damage it 0000026en The maximum air intake restriction in terms of differential pressure measurement must not exceed 0 90 psi 6 23 kPa 635 mmAq Clean or replace the air cleaner element if the air intake restriction exceeds the above mentioned value 0000046 CAUTION Do not short circuit the charging system between alternator terminals IG and L Damage to the alternator will result 0000035 CAUTION Do not connect a load between alternator terminals L and E Damage to the alternator will result 0000036en CAUTION Do not remove the positive battery cable from alternator terminal B while the engine is operating Damage to the alternator will result 0000037en TNM Series Service Manual Safety Precautions CAUTION Do not turn the battery switch OFF while the engine is operating Damage to the alternator will result 0000038en CAUTION Do not operate the engine if the alternator is producing unusual sounds Damage to the alternator will result 0000039en CAUTION If the engine coolant pump must be replaced replace the en
125. ead Reinstall the fuel injector Figure 7 33 4 in the cylinder head and tighten to specification Reinstall new copper washers Figure 7 33 3 high pressure and return fuel lines Figure 7 33 2 See Installation of High Pressure Fuel Injection Lines on page 7 12 and Installation of Fuel Return Line on page 7 13 Tighten fuel line nuts Figure 7 33 1 to specifications Prime the fuel system See Priming the Fuel System on page 4 13 Operate the engine and check for fuel leaks 0002213 Figure 7 33 e Series Service Manual FUEL SYSTEM FUEL SYSTEM 7 28 This Page Intentionally Left Blank TNM Series Service Manual Fuel Injectors Section 8 COOLING SYSTEM Before You Begin 8 3 KANEKO EE 8 5 Cooling System Diagram eeeeeeseeeeeneeeeennnnnnnn 8 5 Engine Coolant Pump Components 40 8 6 Engine Coolant System Check eene 8 7 Engine Coolant PUMP e Qa DRM cU UE 8 7 Disassembly of Engine Coolant 8 7 Cleaning and Inspection 8 8 Reassembly of Engine Coolant 8 9 TNM Series Service Manual 8 1 COOLING SYSTEM 8 2 This Page Intentionally Left Blank TNM Series Servic
126. eck for proper operation of the thermostat Place the thermostat Figure 8 7 1 and an accurate thermometer Figure 8 7 2 in warm water 0000577A Figure 8 7 2 Slowly increase temperature of the water using an external heat source TNM Series Service Manual Engine Coolant Pump 3 The thermostat is normal if it starts to open at the temperature value stamped on the flange of the thermostat and fully opens as the temperature of the water is increased Radiator Cap 1 Check for proper operation of the radiator cap Install the radiator cap Figure 8 8 1 ona cooling system tester 0000577 8 8 2 Apply 10 8 14 8 psi 75 105 kPa 0 75 1 05 kgf cm to the radiator cap The radiator cap relief valve must open within the specified range Reassembly of Engine Coolant Pump 1 Reinstall the thermostat Figure 8 9 1 Figure 8 9 e Series Service Manual COOLING SYSTEM Reinstall the thermostat cover Figure 8 9 2 Tighten the thermostat cover bolts Reinstall the temperature switch Figure 8 9 3 and a new gasket Figure 8 9 4 Position the engine coolant pump on the engine and install a new gasket Figure 8 9 5 CAUTION Use a new special O ring between the engine coolant pump and the joint Be sure to use the special O ring for each engine model Although the O ring dimensions are the sam
127. ection port Rotate the crankshaft until the injection timing marks on the flywheel are visible for No 3 cylinder Typical flywheel markings are as shown in Figure 7 20 Note A typical flywheel will have multiple timing grids depending on the number of cylinders Any grid and its corresponding cylinder can be used to check the fuel injection timing i BS d 5 0002071A 1 15 BTDC Before Top Dead Center 2 20 BTDC 3 25 BTDC 4 Direction of Rotation 5 TDC Top Dead Center Figure 7 20 7 The flywheel shown in Figure 7 20 is fora Yanmar Standard Specification IDI engine Flywheels used on some OEM Specific IDI engines may be marked differently You should contact that specific OEM for information on the identification of the timing marks Note The TDC Top Dead Center mark can be identified by the cylinder numbers stamped near the TDC mark Figure 7 20 5 on the flywheel TNM Series Service Manual Checking and Adjusting Fuel Injection Timing 8 If you are uncertain as to the timing degree designation of the timing marks on the flywheel timing grid you can determine the timing degree designation by measuring the timing grid First measure the distance between two of the longer marks on the timing grid They are 5 apart Then measure the distance from the TDC mark to the first longer mark on the tim
128. ection Pump Drive Gear Nut 10 Fuel Injection Pump Drive Gear Assembly DO NOT remove or loosen the four bolts that fasten the injection pump drive gear to the injection pump drive gear hub 11 Mechanical Fuel Supply Pump Optional on some models 12 Low Pressure Fuel Inlet Fitting 13 Fuel Filter e Series Service Manual FUEL SYSTEM FUEL INJECTION LINES Removal of High Pressure Fuel Injection Lines CAUTION Remove or install the high pressure fuel injection lines as an assembly whenever possible Disassembling the high pressure fuel injection lines from the retainers or bending any of the fuel lines will make it difficult to reinstall the fuel lines 0000047en Note To prevent rounding the fuel line nuts always use a line or flare nut wrench 1 Close any fuel valves in the fuel supply line 2 Clean the area to keep contaminants from entering the fuel system 3 Place a drain pan under the fuel injection pump to catch any spillage 4 Loosen the fuel line nuts at the fuel injection pump 5 Next loosen the fuel line nuts at the fuel injectors Use one wrench to hold the fuel return line nut and fuel return line from rotating Use a second wrench to loosen the fuel line nut Figure 7 4 Repeat with the remaining fuel injectors a i Figure 7 4 7 11 FUEL SYSTEM 6 Finish loosening all the fuel line nuts and remove the high pressure fuel lines as an a
129. ed into the cylinder head with an extremely tight press fit Before installing the valve guides place the valve guides in a freezer for at least twenty minutes This will cause the valve guides to contract making it easier to install the valve guides in place 2 Immediately after removing the valve guides from the freezer insert the valve guides Figure 6 24 1 in their proper positions 2200 Il o d Vp o27134 00X Figure 6 24 3 Finish installing the valve guides Figure 6 25 1 to the proper height Figure 6 25 3 using the valve guide installation tool Figure 6 25 2 See valve guide projection specification on page 6 6 0001756A Figure 6 25 Reassembly of Intake and Exhaust Valves IMPORTANT Always install new valve stem seals For 72 engines the exhaust valve stem seals are different than the intake valve stem seals and can be identified by the color the seal spring Figure 6 26 4 For 3TNM68 engines all stem seals are the same Ensure they are installed in the correct locations Silver seal Spring Silver Seal Spring White Seal Spring 1 1 Oil the lip of the valve stem seal Figure 6 26 2 Using the valve stem seal installation tool Figure 6 26 1 install a new valve stem seal on each of the valve guides Figure 6 26 3 6 28 Cylinder Head 525797575 2595
130. ee Testing of Fuel Injectors on page 7 23 Check and Adjust See Testing of Fuel Injectors on page 7 23 Check and Adjust See Testing of Fuel Injectors on page 7 23 Foreign Matter Trapped ine See Fuel System Components Valve Inside the Priming Pump bn bage ZAG Disassemble and Clean pag Clean the Strainer See Drain Fuel Tank on page 5 25 See the appropriate procedure in Periodic Maintenance on page 5 1 Insufficient Fuel Supply to Fuel Injection Pump Uneven Injection Volume from Fuel Injection Pump Excessive Fuel Injection Volume BEER Poor Spray Pattern from Fuel Injection Nozzle Clogged Strainer at Feed Pump Inlet Fuel System BEARS o x 2 o o i cL il 2 o o o 91 4 21 E Fo pe 1 e tet de LI eR tet Tel NEN T Series Service Manual 13 15 TROUBLESHOOTING Troubleshooting Charts This Page Intentionally Left Blank 13 16 TNM Series Service Manual Troubleshooting Charts TROUBLESHOOTING Insufficient Exhaus Engine Engine Air Trouble Symptom Starting Problem Engine S gir Engine Oil a Intak Output urging oolant Intake Engine Starts but Stops Soon Corrective Action Reference Pages E a See
131. egative battery cable before servicing the electrical system Check the electrical harnesses for cracks abrasions and damaged or corroded connectors ALWAYS keep the connectors and terminals clean Failure to comply could result in death or serious injury 0000009en 3 9 SAFETY ENTANGLEMENT HAZARD Stop the engine before you begin to service it NEVER leave the key in the key switch when you are servicing the engine Someone may accidentally start the engine and not realize you are servicing it This could result in a serious injury If you must service the engine while it is operating remove all jewelry tie back long hair and keep your hands other body parts and clothing away from moving rotating parts Failure to comply could result in death or serious injury 0000010en Go 22 2 BURN HAZARD Wait until the engine cools before you drain the engine coolant Hot engine coolant may splash and burn you Failure to comply could result in death or serious injury 0000016en Safety Precautions To prevent possible eye injury always wear SAFETY GLASSES while servicing the engine 0000013en ARA 12 BURN HAZARD Keep your hands and other body parts away from hot engine surfaces such as the muffler exhaust pipe turbocharger if equipped and engine block during operation and shortly after you shut the engine down These surfaces are extremely hot while the engine is ope
132. ely to result valve Figure 7 30 1 for scoring or pitting 0000172en Use a magnifying glass to inspect 1 Clean carbon from used injectors using clean diesel fuel Hardened deposits or varnish can be cleaned using a brass wire brush 027025 00X Figure 7 30 1 Return Fuel Fitting Nut 2 Return Fuel Fitting 3 Seal PK 4 Injector Body 5 Pressure Adjusting Shims 6 Spring 7 Spring Seat 8 Valve Stop Spacer 9 Nozzle Valve 10 Nozzle Body 11 Nozzle Case Nut Figure 7 29 2 Place the fuel injector in a soft jawed vise with the nozzle pointing up 3 Remove the nozzle case nut 4 Carefully remove the injector from the vise e Series Service Manual 7 25 FUEL SYSTEM 7 Perform a nozzle valve slide test a Wash nozzle body and valve in clean diesel fuel b While holding the nozzle body vertical pull the nozzle valve about 2 3 of the way out Figure 7 31 c Release the valve It should fall smoothly to its seat by its own weight 0001332A Figure 7 31 Replace the fuel injector assembly if it fails any inspection Adjusting Fuel Injector Pressure The fuel injectors open when pressure reaches a predetermined pressure threshold They close when the pressure is reduced below that threshold The pressure threshold can be adjusted by adding or removing shims Figure 7 32 4 Fuel Injector Shim Kit Yanmar Part No 114250 53400 Includes one e
133. ent see your authorized Yanmar industrial engine dealer or distributor 0000017en 1 Checkthat the governor lever Figure 5 11 1 makes firm contact with the high idle stop Figure 5 11 2 and the low idle speed limit screw Figure 5 11 3 when the engine speed control is in the full speed or low idle speed positions PERIODIC MAINTENANCE Periodic Maintenance Procedures 2 If the governor lever does not make proper Clean Air Cleaner Element contact with the high idle stop or the low idle Note that a typical air cleaner is shown in speed limit screw adjust the throttle cable or Figure 5 12 and Figure 5 13 for illustrative linkage as necessary purposes only Note DO NOT FORCE the throttle cable or linkage to move This may damage the the governor lever the throttle cable or linkage and cause irregular operation of the engine speed control C ON IMPORTANT a The engine speed control throttle lever When the engines operated in dusty accelerator pedal etc should be equipped conditions clean the air cleaner with stops to prevent the application of element more frequently excessive pressure by the governor lever to NEVER operate the engine with the air either the high idle stop or low idle speed cleaner element s removed This may limit screw allow foreign material to enter the engine and damage it The engine performance is adversely affected when the air cleaner element is clogged with dust Be sure t
134. ent to perform maintenance such as changing the fuel filter place an approved container under the opening to catch the fuel NEVER use a shop rag to catch the fuel Vapors from the rag are flammable and explosive Wipe up any spills immediately Wear eye protection The fuel system is under pressure and fuel could spray out when you remove any fuel system component Failure to comply will result in death or serious injury 0000009 Introduction DANGER UT FIRE AND EXPLOSION HAZARD Diesel fuel is flammable and explosive under certain conditions Place an approved container under the air bleed port when you prime the fuel system Never use a shop rag to catch the fuel Wipe up any spills immediately ALWAYS close the air bleed port after you complete priming the system Wear eye protection The fuel system is under pressure and fuel could spray out when you open the air bleed port If the unit has an electric fuel pump turn the key switch to the ON position for 10 to 15 seconds or until the fuel coming out of the air bleed port is free of bubbles to allow the electric fuel pump to prime the system If the unit has a mechanical fuel pump operate the fuel priming pump several times until the fuel coming out of the air bleed port is free of bubbles Failure to comply will result in death or serious injury 0000006en TNM Series Service Manual Introduction EXHAUST HA
135. eplace both mating gears Do not allow the gear being checked to move axially as excess end play could cause a false reading See Timing Gear Backlash on page 6 8 for service limits 3 026975 00 1 Fuel Injection Pump Drive Gear 2 Camshaft Drive Gear 3 Crankshaft Drive Gear 4 Idler Gear Figure 6 40 TNM Series Service Manual Cylinder Block Measuring Idler Gear to Crankshaft Gear Backlash 1 Install a dial indicator as shown in Figure 6 41 0002192 6 41 2 Rotate the idler gear back and forth to check idler gear to crankshaft gear backlash Total indicator reading is backlash Record the measurement Measuring Idler Gear to Camshaft Gear Backlash 1 Drive a small wooden wedge between the crankshaft gear and idler gear to prevent the idler gear from rotating 2 Install a dial indicator to read camshaft gear backlash Rotate camshaft drive gear against idler gear to measure backlash Record the measurement 3 Check the idler gear to fuel injection pump drive gear backlash in the same manner as the camshaft drive gear Record the measurement e Series Service Manual ENGINE Removal of Timing Gears 1 Remove the bolts from the idler gear shaft Figure 6 42 1 Remove the idler gear shaft idler gear Figure 6 42 3 and bushing Figure 6 42 2 026976 00X Figure 6 42 2 Do not remove the crankshaft gear unles
136. er at the bottom of the solenoid switch Check for continuity between the B and M terminals using a multimeter Figure 10 25 The multimeter should indicate continuity If the multimeter does not indicate continuity replace the solenoid switch 10 25 0000126 Pinion Clutch Assembly Pinion Clutch Assembly Inspection Manually rotate the pinion clutch assembly in the drive direction It should rotate freely in the drive direction and is locked by turning it in the opposite direction Figure 10 26 Replace the pinion clutch assembly if the results are different 10 16 Starter Motor 0000127 10 26 Slide the pinion clutch assembly on the shaft Figure 10 27 It should slide smoothly on the shaft Rust too much grease or damage could prevent the pinion clutch from sliding smoothly If the pinion clutch assembly does not slide smoothly clean the shaft and pinion clutch assembly or replace the damaged component 0000128 Figure 10 27 TNM Series Service Manual Starter Motor Reassembly of Starter Motor 1 Apply a appropriate starter bendix grease obtain locally to the pinion shaft 2 Reassemble the reduction gear Figure 10 28 4 pinion shaft Figure 10 28 5 planetary gears Figure 10 28 6 and washers into the intermediate housing Figure 10 28 3 Reinstall snap ring Figure 10 28 1 4
137. er motor to overheat and damage the coils pinion and or ring gear GENERAL SERVICE INFORMATION To prime the fuel system if a mechanical fuel pump is installed 1 Operate the fuel priming lever Figure 4 4 1 several times until the fuel filter cup is filled with fuel 2 NEVER use the starter motor to prime the fuel system This may cause the starter motor to overheat and damage the coils pinion and or ring gear 0006462 Figure 4 4 Engine Oil ENGINE OIL CAUTION Only use the engine oil specified Other engine oils may affect warranty coverage cause internal engine components to seize and or shorten engine life Prevent dirt and debris from contaminating the engine oil Carefully clean the oil cap dipstick and the surrounding area before you remove the cap NEVER mix different types of engine oil This may adversely affect the lubricating properties of the engine oil NEVER overfill Overfilling may result in white exhaust smoke engine overspeed or internal damage 0000005en Engine Oil Specifications Use an engine oil that meets or exceeds the following guidelines and classifications Service Categories API Service Categories CD or higher ACEA Service Categories E 3 E 4 and E 5 JASO Service Category DH 1 Definitions API Classification American Petroleum Institute ACEA Classification Association des Constructeurs Europ ens d Automobilies JASO Jap
138. ering with or removing these devices may void the Yanmar Limited Warranty 0000146en Installation of Fuel Injection Pump 1 Ensure the fuel injection pump drive gear is aligned with the idler gear using the reference marks made earlier Figure 7 15 1 Fuel Injection Pump Figure 7 15 If installing the fuel injection pump on an engine with the front gear case cover removed the fuel injection pump drive gear can be aligned with the idler gear by aligning the stamped marks Figure 7 16 A B C on the fuel injection pump drive gear idler gear and crankshaft drive gear Ensure all three timing marks A B C are aligned 1 Fuel Injection Pump Drive Gear 2 Camshaft Drive Gear 3 Crankshaft Drive Gear 4 Idler Gear Figure 7 16 Install a new gasket on the fuel injection pump mounting flange Note Ensure the tapered surface of the fuel injection pump shaft is clean and dry Align the key on the fuel injection pump shaft with the keyway in the fuel injection pump drive gear hub Reinstall the fuel injection pump into the cylinder block Install the pump retaining bolts to specification TNM Series Service Manual Fuel Injection Pump 5 Reinstall the fuel injection pump drive gear lock washer Figure 7 17 1 and nut Figure 7 17 2 Do not lubricate threads of the nut or shaft Hold the crankshaft pulley bolt with a socket wrench and tighten the drive
139. erns above may affect the warranty coverage of your engine See Yanmar Limited Warranty on page 2 3 4 Series Service Manual GENERAL SERVICE INFORMATION Filling the Fuel Tank A DANGER VAY FIRE AND EXPLOSION HAZARD Diesel fuel is flammable and explosive under certain conditions Only fill the fuel tank with diesel fuel Filling the fuel tank with gasoline may result in a fire and will damage the engine NEVER refuel with the engine running Wipe up all spills immediately Keep sparks open flames or any other form of ignition match cigarette static electric source well away when refueling NEVER overfill the fuel tank Fill the fuel tank Store any containers containing fuel in a well ventilated area away from any combustibles or sources of ignition Failure to comply will result in death or serious injury 0000005en 4 11 GENERAL SERVICE INFORMATION DANGER UA FIRE AND EXPLOSION HAZARD Diesel fuel is flammable and explosive under certain conditions Be sure to place the diesel fuel container on the ground when transferring the diesel fuel from the pump to the container Hold the hose nozzle firmly against the side of the container while filling it This prevents static electricity buildup which could cause sparks and ignite fuel vapors NEVER place diesel fuel or other flammable material such as oil hay or dried grass close to the engine during en
140. facility The following describes the features of the MC fuel injection pump manufactured by Yanmar The fuel injection pump is a very important component of the engine It is capable of making very precise fuel delivery adjustments according to the varied loads applied to the engine All of the fuel injection pump components are very precisely machined It is extremely important to follow good service practices and maintain cleanliness when servicing the fuel injection pump e Series Service Manual The Yanmar MC Fuel Injection Pump is an in line type pump which consists of a fuel supply plunger Figure 7 1 1 for each cylinder a camshaft Figure 7 1 2 and a pump housing Figure 7 1 3 A delivery valve Figure 7 1 4 connects to a high pressure fuel line for each cylinder The fuel injection pump housing contains a governor Figure 7 1 5 Fuel from the fuel tank to the fuel injection pump is delivered by a low pressure electric fuel pump On a few special models a mechanical fuel pump is used instead of an electric pump The mechanical fuel pump is mounted to the fuel injection pump housing in place of the cover plate Figure 7 1 6 Fuel to be injected into the cylinders is pressurized by the up and down motion of each camshaft driven plunger and is then supplied by the high pressure fuel lines to the respective fuel injector 7 5 FUEL SYSTEM CAUTION NEVER remo
141. faintly during normal operation 0000051en CAUTION Using a non specified V belt will cause inadequate charging and shorten the belt life Use the specified belt 0000052en SAFETY CAUTION Agricultural or other chemicals especially those with a high sulfur content can adhere to the IC regulator This will corrode the conductor and result in battery over charging boiling and charging malfunctions Consult Yanmar before using the equipment in such an environment or the warranty is voided 0000053en Make sure that the combined total resistance of the battery cable in both directions between the starter motor and the battery is within the value indicated on the wiring diagram The starter motor will malfunction or break down if the resistance is higher than the specified value 0000054 CAUTION The starter motor is water proofed according to JIS D 0203 R2 which protects the motor from rain or general cleaning Do not use high pressure wash or submerse the starter motor in water 0000055en CAUTION Use a specialized battery charger to recharge a battery with a voltage of 8 volts or less Booster starting a battery with a voltage of 8 volts or less will generate an abnormally high voltage and destroy electrical equipment 0000056en Safety Precautions CAUTION Make sure that the combined total resistance of the battery cable in both directions between the starter motor and the battery is
142. first 2 Remove the electrical wires from the solenoid switch assembly 3 Remove the starter mounting bolts Figure 10 2 1 Remove the starter motor from the flywheel housing 0002126 Figure 10 2 Disassembly of Starter Motor 1 alignment marks across all mating joints 2 Disconnect the field wire from the solenoid switch Figure 10 3 0000138 Figure 10 3 10 10 Starter Motor 3 Remove the two bolts or nuts retaining the solenoid switch assembly Figure 10 4 1 to the pinion housing Remove the solenoid switch assembly and dust covers Figure 10 4 2 Remove the plunger Figure 10 4 4 and torsion spring Figure 10 4 3 from the pinion housing 2 0000140 10 4 4 Remove the two bolts Figure 10 5 1 securing the rear cover Figure 10 5 2 to the brush holder assembly Figure 10 5 3 2 1 0000142A Figure 10 5 5 Remove the two through bolts Remove the rear cover Figure 10 5 2 TNM Series Service Manual Starter Motor STARTER MOTOR 6 Pull the brush springs up using a brush spring 11 Remove the shift lever Figure 10 8 2 pin puller On the negative side bring the brush and spacer Figure 10 8 1 spring into contact with the side of the brushes to hold the brushes clear of the commutator 1 2 surface On the positive side remove the brushes from the brush holder assembly Fig
143. fluid contacts the eyes and or skin immediately flush the affected area with a large amount of clean water and obtain prompt medical treatment Failure to comply could result in death or serious injury 0000007en ad ALWAYS be environmentally responsible Follow the guidelines of the EPA or other governmental agencies for the proper disposal of hazardous materials such as engine oil diesel fuel and engine coolant Consult the local authorities or reclamation facility NEVER dispose of hazardous materials irresponsibly by dumping them into a sewer on the ground or into ground water or waterways Failure to follow these procedures may seriously harm the environment 0000013en 5 24 Periodic Maintenance Procedures When the amount of fluid nears the lower limit Figure 5 8 1 fill with distilled water Figure 5 8 2 so it is at the upper limit Figure 5 8 3 If operation continues with insufficient battery fluid the battery life is shortened and the battery may overheat and explode During the summer check the fluid level more often than specified 0000067A Figure 5 8 If the engine cranking speed is so slow that the engine does not start recharge the battery If the engine still will not start after charging have your authorized Yanmar industrial engine dealer or distributor check the battery and the engine s starting system If operating the machine where the ambient tem
144. g expander 13 Remove the oil ring Figure 6 51 4 from the piston using a piston ring expander 027272 00X Figure 6 51 14 Remove the circlips Figure 6 51 5 from the wrist pin 15 Remove the wrist pin Figure 6 51 6 and connecting rod Figure 6 51 8 from the piston Figure 6 51 9 16 Repeat steps until all pistons are removed and dissembled Removal of Crankshaft 1 Remove the flywheel Figure 6 52 1 from the crankshaft 2 Remove the bolts Figure 6 52 2 from the flywheel housing assembly Remove the flywheel housing from the engine 6 41 3 Before removing the main bearing measure the crankshaft end play Use either of the following Figure 6 52 two methods Method A Install a dial gauge 6 42 Figure 6 53 1 on the cylinder block Move the crankshaft Figure 6 53 2 in and out to measure the end play Record the measurement Figure 6 53 0001961 027074 00X Cylinder Block Method B Use a feeler gauge to measure the clearance Figure 6 54 3 between the thrust bearing Figure 6 54 1 and crankshaft Figure 6 54 2 Record the measurement See Thrust Bearing on page 6 9 for the service limit 3 0001962 Figure 6 54 4 Remove the ladder frame Do not remove the bearing inserts at this time 5 Wipe oil from the bearing insert and crankshaft journal surfaces 6 Place a piece of PLASTIGAGE
145. gine coolant 0000006en Only use the engine oil specified Other engine oils may affect warranty coverage cause internal engine CAUTION components to seize and or shorten NEVER attempt to modify the engine s engine life design or safety features such as defeating the engine speed limit control or the diesel fuel injection quantity control Prevent dirt and debris from contaminating the engine oil Carefully clean the oil cap dipstick and the surrounding area before you remove Modifications may impair the engine s the cap safety and performance characteristics and shorten the engine s life Any alterations to this engine may void its warranty Be sure sd to use Yanmar genuine replacement NEVER overfill Overfilling may result parts in white exhaust smoke engine overspeed or internal damage 0000005en NEVER mix different types of engine oil This may adversely affect the lubricating properties of the engine oil 0000079en e Series Service Manual 5 11 PERIODIC MAINTENANCE CAUTION Observe the following environmental operating conditions to maintain engine performance and avoid premature engine wear Avoid operating in extremely dusty conditions Avoid operating in the presence of chemical gases or fumes Avoid operating in a corrosive atmosphere such as salt water spray NEVER install the engine floodplain unless proper precautions are take
146. gine coolant pump as an assembly only Do not attempt to repair the engine coolant pump or replace individual components 0000041en CAUTION Use a new special O ring between the engine coolant pump and the joint Be sure to use the special O ring for each engine model Although the O ring dimensions are the same as a commercially available O ring the material is different 0000042en CAUTION Remove or install the high pressure fuel injection lines as an assembly whenever possible Disassembling the high pressure fuel injection lines from the retainers or bending any of the fuel lines will make it difficult to reinstall the fuel lines 0000047en e Series Service Manual SAFETY CAUTION After marking the position of the pump drive gear do not rotate the engine crankshaft Rotating the crankshaft will cause the fuel injection pump to become misaligned 0000048en Do not use a high pressure wash directly on the alternator Water will damage the alternator and result in inadequate charging 0000049en CAUTION Do not reverse the positive and negative ends of the battery cable The alternator diode and stator coil will be damaged 0000050en CAUTION When the battery indicator goes out it should not come on again The battery indicator only comes on during operation if the alternator fails However if an LED is used in the battery indicator the LED will shine
147. gine is operating Damage to the alternator will result 0000037en CAUTION Do not connect a load between alternator terminals L and E Damage to the alternator will result 0000036en 11 10 TNM Series Service Manual Alternator Standard Output ALTERNATOR ALTERNATOR STANDARD OUTPUT Output Current S a8 re EN ep Bx o9 T2 45 o we m Alternator RPM x10 min Figure 11 3 e Series Service Manual 11 11 ALTERNATOR ALTERNATOR SHOCK HAZARD Turn off the battery switch if equipped or disconnect the negative battery cable before servicing the electrical system Check the electrical harnesses for cracks abrasions and damaged or corroded connectors ALWAYS keep the connectors and terminals clean Failure to comply could result in death or serious injury 0000009 Removal of Alternator 1 Disconnect the electrical wires from the alternator 2 Loosen the V belt CAUTION PINCH HAZARD Carefully rotate the alternator toward the cylinder block while loosening the V belt Failure to comply may result in minor or moderate injury 0000014en 3 Remove the V belt adjuster from the alternator bolt Figure 11 4 1 4 Remove the nut Figure 11 4 2 from the gear case stud Remove the alternator 11 12 Alternator 0000264 11 4 Disas
148. gine oil NEVER overfill Overfilling may result in white exhaust smoke engine overspeed or internal damage 0000005en Periodic Maintenance Procedures s e ALWAYS be environmentally responsible Follow the guidelines of the EPA or other governmental agencies for the proper disposal of hazardous materials such as engine oil diesel fuel and engine coolant Consult the local authorities or reclamation facility NEVER dispose of hazardous materials irresponsibly by dumping them into a sewer on the ground or into ground water or waterways Failure to follow these procedures may seriously harm the environment 0000013en Change the engine oil every 250 hours of operation after the initial change at 50 hours Replace the engine oil filter at the same time See Replace Engine Oil and Engine Oil Filter on page 5 18 TNM Series Service Manual Periodic Maintenance Procedures Check and Clean Radiator Fins CAUTION FLYING OBJECT HAZARD ALWAYS wear eye protection when servicing the engine and when using compressed air or high pressure water Dust flying debris compressed air pressurized water or steam may injure your eyes Failure to comply may result in minor or moderate injury 0000003en Dirt and dust adhering to the radiator fins reduce the cooling performance causing overheating Make it a rule to check the radiator fins daily and clean as needed Note tha
149. gine operation or shortly after shutdown Failure to comply will result in death or serious injury 0000014en Diesel Fuel DANGER FIRE AND EXPLOSION HAZARD Diesel fuel is flammable and explosive under certain conditions Before you operate the engine check for fuel leaks Replace rubberized fuel hoses every two years or every 2000 hours of engine operation whichever comes first even if the engine has been out of service Rubberized fuel lines tend to dry out and become brittle after two years or 2000 hours of engine operation whichever comes first Failure to comply will result in death or serious injury 0000015en CAUTION Only use diesel fuels recommended by Yanmar for the best engine performance to prevent engine damage and to comply with EPA ARB warranty requirements Only use clean diesel fuel NEVER remove the primary strainer if equipped from the fuel tank filler port If removed dirt and debris could get into the fuel system causing it to clog 0000004 Series Service Manual Diesel Fuel Note that a typical fuel tank is shown The fuel tank on the equipment being serviced may be different 1 Clean the area around the fuel cap Figure 4 3 1 2 Remove the fuel cap Figure 4 3 1 from the fuel tank Figure 4 3 2 3 Observe the fuel level sight gauge Figure 4 3 3 and stop fueling when gauge shows fuel tank is ful
150. gplein11 1332 BS Almere de Vaart The Netherlands TEL 31 36 5493200 FAX 31 36 5493209 http www yanmar nl Yanmar Asia Singapore Corporation Pte Ltd 4 Tuas Lane Singapore 638613 TEL 65 68615077 FAX 65 68611509 http www yanmar co jp yasc Yanmar Engine Shanghai Corporation Ltd No 6 work shop EUREKA City Industrial Park Lane 333 Zhujian road Minhang district Shanghai China TEL 21 62210006 FAX 21 62211699 http www yanmar sha com YANMAR
151. gure 6 44 4 Remove the ladder frame Figure 6 44 1 if equipped Figure 6 44 4 Remove the oil pickup tube Figure 6 44 3 and O ring Figure 6 44 2 Note Torx bolts are used for oil sump mounting bolts and rudder frame mounting bolts Specialized tool Torx bolt wrench is required for Oil Sump Bolts TORX E8 for Ladder frame TORX E12 TNM Series Service Manual Cylinder Block Removal of Camshaft 1 Before removing the camshaft check the camshaft end play Method A Install a dial indicator Figure 6 45 1 on the cylinder block Move the camshaft and gear Figure 6 45 2 in and out to measure the end play Record the measurement See Camshaft on page 6 7 for the service limit 2 sc lt a 4 027137 00 6 45 Method B Use a feeler gauge to measure the clearance between the thrust plate Figure 6 46 1 and front camshaft bearing Figure 6 46 2 Record the measurement See Thrust Bearing on page 6 9 for the service limit e Series Service Manual ENGINE 2 0001710B Figure 6 46 2 Remove two bolts Figure 6 47 3 retaining the camshaft thrust plate Figure 6 47 1 5 Figure 6 47 Extract the tappets Figure 6 47 5 through the top of the cylinder block Mark the tappets so they can be reinstalled in the same location Slowly pull the camshaft Figure 6 4
152. he EPA or other governmental agencies for the proper disposal of hazardous materials such as engine oil diesel fuel and engine coolant Consult the local authorities or reclamation facility NEVER dispose of hazardous materials irresponsibly by dumping them into a sewer on the ground or into ground water or waterways Failure to follow these procedures may seriously harm the environment 0000013en CAUTION Protect the air cleaner turbocharger if equipped and electric components from damage when you use steam or high pressure water to clean the engine 0000014en CAUTION NEVER overfill the engine with engine oil ALWAYS keep the oil level between the upper and lower lines on the oil cap dipstick 0000015en PERIODIC MAINTENANCE CAUTION NEVER use high pressure water or compressed air at greater than 28 psi 193 kPa 19 686 mmAq or a wire brush to clean the radiator fins Radiator fins damage easily 0000016en CAU NEVER attempt to adjust the low or high idle speed limit screw This may impair the safety and performance of the machine and shorten its life If the idle speed limit screws require adjustment see your authorized Yanmar industrial engine dealer or distributor 0000017en CAUTION Establish a periodic maintenance plan according to the engine application and make sure you perform the required periodic maintenance at intervals indicated Failure to follow these guidelines
153. he dealer as expeditiously as possible If you have any questions regarding your warranty rights and responsibilities or would like information on the nearest Yanmar dealer or authorized service center you should contact Yanmar America Corporation at 1 800 872 2867 2 8 TNM Series Service Manual Section 3 SAFETY Page Safety Statements 21 2 21 12 4 4 44 444 1 141 nenne 3 3 E 3 4 Series Service Manual 3 1 SAFETY This Page Intentionally Left Blank 3 2 TNM Series Service Manual Safety Statements SAFETY SARER STATEMENTS Yanmar is concerned for your safety and your Caution the word CAUTION is in black machine s condition Safety statements are one of letters with a yellow rectangle behind it the primary ways to call your attention to the indicates a potentially hazardous potential hazards associated with Yanmar TNM situation which if not avoided may engine operation Follow the precautions listed result in minor or moderate injury throughout the manual before operation during operation and during periodic maintenance procedures for your safety the safety of others and 0000001en to protect the performance of your engine Keep the 11 CAUTION labels from becoming dirty or torn and replace Caution without the safety alert symbol them if the
154. he particulates Use the lowest possible air pressure to remove the dust without damaging the element If the air cleaner is equipped with a double element only remove and replace the inner element Figure 5 13 1 if the engine lacks power or the dust indicator actuates if equipped e Series Service Manual 5 29 PERIODIC MAINTENANCE Every 500 Hours of Operation Perform the following maintenance every 500 hours of operation Replace Air Cleaner Element Replace Fuel Filter Clean Fuel Filter Water Separator Replace Air Cleaner Element The maximum air intake restriction in terms of differential pressure measurement must not exceed 0 90 psi 6 23 kPa 635 mmAq Clean or replace the air cleaner element if the air intake restriction exceeds the above mentioned value 0000046 Replace the air cleaner element Figure 5 12 2 every 500 hours even if it is not damaged or dirty When replacing the element clean the inside of the air cleaner case Figure 5 12 4 If the air cleaner is equipped with a double element only remove and replace the inner element Figure 5 13 1 if the engine lacks power or the dust indicator actuates if equipped This is in addition to replacing the outer element 5 30 Periodic Maintenance Procedures Replace Fuel Filter DANGER VAW FIRE AND EXPLOSION HAZARD Diesel fuel is flammable and explosive under certain conditio
155. her Remove the bearing cap Do not remove the bearing inserts at this time Wipe oil from the bearing insert and crankshaft journal surfaces Place a piece of PLASTIGAGE Figure 6 49 1 along the full width of the bearing insert 1 0 0001898 6 49 TNM Series Service Manual Cylinder Block IMPORTANT Do not rotate crankshaft when using PLASTIGAGE A false reading may result 5 Reinstall the bearing cap and tighten to specification See Special Torque Chart on page 6 13 6 Remove the bearing cap 0001899 Figure 6 50 7 Compare the width of the flattened PLASTIGAGE Figure 6 50 1 to the graduation marks on the package The mark that most closely matches the width of the flattened PLASTIGAGE will indicate the bearing oil clearance Record the measurements See Crankshaft on page 6 8 8 Repeat with the remaining connecting rods IMPORTANT Do not allow the connecting rod to contact the crankshaft journal during piston removal Damage to the bearing journal may result 9 Use a wooden dowel against the connecting rod and tap the piston connecting rod assembly out of the cylinder 10 Mark the cylinder number on the piston and connecting rod e Series Service Manual ENGINE 11 Remove the bearing inserts Figure 6 51 2 12 Remove the compression rings Figure 6 51 3 from the piston using a piston rin
156. ice Manual Introduction BURN HAZARD Batteries contain sulfuric acid NEVER allow battery fluid to come in contact with clothing skin or eyes Severe burns could result ALWAYS wear safety goggles and protective clothing when servicing the battery If battery fluid contacts the eyes and or skin immediately flush the affected area with a large amount of clean water and obtain prompt medical treatment Failure to comply could result in death or serious injury 0000007en HIGH PRESSURE HAZARD Avoid skin contact with the high pressure diesel fuel spray caused by a fuel system leak such as a broken fuel injection line High pressure fuel can penetrate your skin and result in serious injury If you are exposed to high pressure fuel spray obtain prompt medical treatment NEVER check for a fuel leak with your hands ALWAYS use a piece of wood or cardboard Have your authorized Yanmar industrial engine dealer or distributor repair the damage Failure to comply could result in death or serious injury 0000008en e Series Service Manual PERIODIC MAINTENANCE SHOCK HAZARD Turn off the battery switch if equipped or disconnect the negative battery cable before servicing the electrical system Check the electrical harnesses for cracks abrasions and damaged or corroded connectors ALWAYS keep the connectors and terminals clean Failure to comply could result in dea
157. ightening Torque for Special Bolts Thread Diameter Lubricating Oil 31 34 16 3TNM68 M8 x 1 25 mm 51 Applied Seo Cylinder Head Bolts Cylinder Head on 40 43 ft lb page 6 29 3TNM72 M9 x 1 25 mm 53 9 57 9 N m Applied 5 5 5 9 kgf m 17 20 ft lb E M7 x 1 0 mm 22 6 27 5 Applied pin 2 3 2 8 kgf m pag 59 64 ft lb See Installation of Flywheel Bolts M10x 1 25 mm 80 4 86 4 N m Applied Crankshaft on 8 2 8 8 kgf m page 6 54 ns Cast 83 4 93 1 N m See Installation of 8 5 9 5 kgf Grankehait M12 x 1 25 mm Applied Crankshaft on Pulley Bolts 83 90 ft lb 6 54 Forged 113 123 N m 11 5 12 5 kgf m Connecting Rod 11 15 ft lb See Heassembly of M10 x 1 25 14 7 19 6 N m none Intake Manifold 1 5 2 0 kgf m Valve Cover on 14 1 4 ft lb page 6 31 M4 x 0 7 1 5 2 0 N m none 0 15 0 20 kgf m Glow Plug 35 38 ft lb Metal Cap Bolt M9 x 1 25 48 0 51 9 N m Applied 4 9 5 3 kgf m 33 x 1 5 ft lb Ladder Frame Bolt M9 x 1 25 45 2 Nm Applied 4 6 0 2 kgf m ae 36 39 ft lb Fuel Injection Nozzle M20 x 1 5 49 0 52 9 N m none Nut 5 0 5 4 kgf m Fuel High Pressure Me Pipe Nut M12 x 1 5 29 4 34 3 N m none 3 0 3 5 kgf m 24 27 ft lb FO Pump Gear Bolt M8 x 1 0 32 3 36 3 N m none 3 3 3 7 kgf m 43 51 ft lb FO Pump End Nut M12 x 1 25 58 8 68 6 N m Applied 6 0 7 0 kgf m 7 4 x 0 7 ft lb Oil Su
158. ing grid Divide that measurement by the distance between the two longer marks The resulting answer will tell you how many degrees there are between the TDC mark and the first longer mark EXAMPLE If the distance between the two longer marks is approximately 2 0 cm and the distance from the TDC mark is approximately 4 0 cm the answer is approximately 2 This indicates there is 10 2 x 5 between the TDC mark and the first longer mark on the timing grid That means the first CF onger mark on the timing grid indicates 10 BTDC the second longer mark indicates 15 BTDC andthe third timing mark indicates 20 If the answer is 3 that indicates there is 15 3 x 15 between the TDC mark and the first longer mark and that the first longer mark indicates 15 BTDC with the second and third longer marks indicating 20 BTDC and 25 BTDC respectively Highlight the timing reference mark on the flywheel housing Figure 7 21 2 or engine back plate Figure 7 22 2 Highlight the TDC Top Dead Center mark Figure 7 21 1 Figure 7 22 1 on the flywheel e Series Service Manual FUEL SYSTEM 0002065 7 21 1 7 22 10 Highlight the target timing mark Figure 7 22 1 Figure 7 23 1 on the flywheel timing grid as the injection timing measured before the fuel injection pump removal 0002066 Figure 7 23 FUEL
159. inst the side of the container while filling it This prevents static electricity buildup which could cause sparks and ignite fuel vapors NEVER place diesel fuel or other flammable material such as oil hay or dried grass close to the engine during engine operation or shortly after shutdown Failure to comply will result in death or serious injury DANGER UA FIRE AND EXPLOSION HAZARD Diesel fuel is flammable and explosive under certain conditions NEVER use diesel fuel as a cleaning agent Failure to comply will result in death or serious injury 0000012en e Series Service Manual PERIODIC MAINTENANCE A DANGER C FIRE AND EXPLOSION HAZARD Diesel fuel is flammable and explosive under certain conditions NEVER remove the fuel cap with the engine running Failure to comply will result in death or serious injury 000001 1en A DANGER CRUSH HAZARD When you need to transport an engine for repair have a helper assist you to attach it to a hoist and load it on a truck NEVER stand under a hoisted engine If the hoist mechanism fails the engine will fall on you causing death or serious injury Failure to comply will result in death or serious injury 0000008en 5 5 PERIODIC MAINTENANCE 5 6 DANGER 6 FIRE AND EXPLOSION HAZARD Diesel fuel is flammable and explosive under certain conditions When you remove any fuel system compon
160. ious injury 0000003en Perform periodic maintenance procedures in an open level area free from traffic If possible perform the procedures indoors to prevent environmental conditions such as rain wind or snow from damaging the machine PERIODIC MAINTENANCE Yanmar Replacement Parts Yanmar recommends that you use genuine Yanmar parts when replacement parts are needed Genuine replacement parts help ensure long engine life Required EPA ARB Maintenance USA Only To maintain optimum engine performance and compliance with the Environmental Protection Agency EPA Regulations Non road Engines and the California Air Resources Board ARB California it is essential that you follow the Periodic Maintenance Schedule on page 5 16 and Periodic Maintenance Procedures on page 5 18 EPA ARB Installation Requirements USA Only The following are the installation requirements for the EPA ARB Unless these requirements are met the exhaust gas emissions will not be within the limits specified by the EPA and ARB Maximum Exhaust Gas Restriction shall be 68 3TNM72 1 70 psi 11 76 kPa 1200 mm Aq or less Maximum air intake restriction shall be 0 90 psi 6 23kPa 635mm Aq or less Clean or replace the air cleaner element if the air intake restriction exceeds the above mentioned value PERIODIC MAINTENANCE SCHEDULE Daily and periodic maintenance is important to keep the engine in good operating co
161. ir location as designated by Yanmar e Series Service Manual 2 3 YANMAR WARRANTIES Yanmar Limited Warranty Yanmar Limited Warranty Continued To Locate an Authorized Yanmar Industrial Engine Dealer or Distributor You can locate your nearest authorized Yanmar industrial engine dealer or distributor by visiting the Yanmar Corp LTD website at http www yanmar co jp The Japanese language page will be displayed For English language click on English Click on Network in the website heading to view the Yanmar Worldwide Network Choose and Click on the desired product group Click on the Icon closest to your region Click on the desired country or Associate company to locate your nearest authorized Yanmar industrial engine dealer or distributor You may also contact Yanmar by clicking on Inquiry in the website heading and typing in your question or comment What Yanmar Will Do Yanmar warrants to the original retail purchaser of a new Yanmar engine that Yanmar will make such repairs and or replacements at Yanmar s option of any parts s of the Yanmar product covered by this Warranty found to be defective in material and or workmanship Such repairs and or replacements will be made at a location designated by Yanmar at no cost to the purchaser for parts or labor What is Not Covered by this Warranty This Warranty does not cover parts affec
162. ired Electrical Check Indicators Equipment Check Battery Check Engine Oil Level Engine Oil Drain and Fill Engine Oil Replace Engine Oil Filter Engine Speed Control Emission Inspect Clean and Test Fuel Injectors if necessary Check and Adjust Governor Lever and Engine Speed Control Control Warranty Inspect Crankcase Breather System Replace Fuel System and Cooling System Hoses eens Clean or Replace Air Cleaner Element Exhaust Complete overall Visual Check Daily Engine Note These procedures are considered normal maintenance and are performed at the owner s expense e Series Service Manual 5 17 PERIODIC MAINTENANCE PERIODIC MAINTENANCE PROCEDURES After Initial 50 Hours of Operation Perform the following maintenance after the initial 50 hours of operation Replace Engine Oil and Engine Oil Filter Check and Adjust Cooling Fan V Belt Replace Engine Oil and Engine Oil Filter ull 7 BURN HAZARD f you must drain the engine oil while it is still hot stay clear of the hot engine oil to avoid being burned ALWAYS wear eye protection Failure to comply could result in death or serious injury 0000011en Periodic Maintenance Procedures CAUTION Only use the engine oil specified Other engine oils may affect warranty coverage cause internal engine components to seize and or shorten engine life Prevent dirt and debris from
163. ispose of used oil properly Drain the engine oil as follows Remove the engine oil filter as follows Make sure the engine is level 2 Start the engine and bring it up to operating temperature 3 Stop the engine 4 Remove the oil filler cap Figure 5 1 1 to vent the engine crankcase and allow the engine oil to drain more easily 1 Turn the engine oil filter Figure 5 2 2 counterclockwise Figure 5 2 4 using a filter wrench 2 5 Position a container under the engine to collect waste oil 0006465 5 2 Clean the engine oil filter mounting face 3 Lightly coat the gasket on the new oil filter with clean engine oil Install the new engine oil filter manually by turning it clockwise Figure 5 2 3 until it contacts the mounting surface Tighten to 14 17 ft lb 19 6 23 5 N m 2 0 2 4 kgf m or one additional turn using the filter wrench Applicable Engine Oil Filter Part No 3TNM68 3TNM72 119305 35160 4 Add new engine oil to the engine as specified Adding Engine Oil on page 4 15 0006469 Figure 5 1 e Series Service Manual 5 19 PERIODIC MAINTENANCE Periodic Maintenance Procedures Check and Adjust Cooling Fan V Belt The V belt will slip if it does not have the proper tension This will prevent the alternator from generating sufficient power Also the engine will overheat due to the engine coolant pump pulley slipping Che
164. ive 5 years or 3 000 hours of use whichever occurs first In the absence of a device to measure the hours of use the engine has a warranty period of five 5 years The warranty period is five 5 years or 3 000 hours of use whichever occurs first In the absence of a device to measure the hours of use the engine has a warranty period of five 5 years Engines rated at or above 26 hp SAE 19 kW The warranty period is two 2 years or 1 500 hours of use whichever occurs first Engines rated under 26 hp SAE 19 kW In the absence of a device to measure the hours of use the engine has a warranty period of two 2 years 2 6 TNM Series Service Manual Emission System Warranty YANMAR WARRANTIES Limited Emission Control System Warranty USA Only Continued Warranty Coverage This warranty is transferable to each subsequent purchaser for the duration of the warranty period Repair or replacement of any warranted part will be performed at an authorized Yanmar industrial engine dealer or distributor Warranted parts not scheduled for replacement as required maintenance in the Operation Manual shall be warranted for the warranty period Warranted parts scheduled for replacement as required maintenance in the operation manual are warranted for the period of time prior to the first scheduled replacement Any part repaired or replaced under warranty shall be warranted for the remaining warranty period During the
165. ke manifold valve cover See Removal of Intake Manifold Valve Cover on page 6 20 Rotate the crankshaft clockwise as seen from the coolant pump end to bring No 1 piston to TDC of the compression stroke while watching the rocker arm motion and timing grid on the flywheel Position so both the intake and exhaust valves are closed Insert a feeler gauge Figure 6 35 1 between rocker arm and valve cap and record the measured valve clearance Use the data for estimating wear 6 32 TNM Series Service Manual Cylinder Head ENGINE 6 Insert a feeler gauge of the correct thickness Figure 6 37 1 between rocker arm and valve cap Turn the valve adjustment screw to adjust the valve clearance so there is a slight drag on the feeler gauge when sliding it between the rocker arm and valve cap Hold the adjusting screw while tightening the valve adjusting screw lock nut Figure 6 36 1 Recheck the clearance see Adjustment Specifications on page 6 5 Note There is a tendency for the clearance to decrease slightly when the lock nut is tightened It is suggested that the initial een clearance adjustment be made slightly Figure 6 35 on the loose side before tightening the lock nut 4 f adjustment is required proceed to the next step 5 Loosen the valve adjusting screw lock nut Figure 6 36 1 and valve adjusting screw Figure 6 36 2 on the rocker arm Check the valve for
166. l NEVER overfill the fuel tank 4 Replace the fuel cap and hand tighten Over tightening the fuel cap will damage it 1 gt 0000002 4 3 e Series Service Manual GENERAL SERVICE INFORMATION Priming the Fuel System A DANGER fj FIRE AND EXPLOSION HAZARD Diesel fuel is flammable and explosive under certain conditions If the unit has an electric fuel pump when you prime the fuel system turn the key switch to the ON position for 10 to 15 seconds to allow the electric fuel pump to prime the system If the unit has a mechanical fuel pump when you prime the fuel system operate the fuel priming lever of the mechanical fuel pump several times until the fuel filter cup is filled with fuel Failure to comply will result in death or serious injury 0000010en The fuel system needs to be primed under certain conditions Before starting the engine for the first time After running out of fuel and fuel has been added to the fuel tank After fuel system maintenance such as changing the fuel filter and draining the fuel filter water separator or replacing a fuel System component To prime the fuel system if an electric fuel pump is installed 1 Turn the key to the ON position for 10 to 15 seconds This will allow the electric fuel pump to prime the fuel system 2 NEVER use the starter motor to prime the fuel system This may cause the start
167. l filter at specified intervals to prevent contaminants from adversely affecting the diesel fuel flow Stop the engine and allow it to cool 2 Close the fuel cock of the fuel filter water separator 3 Turn the retaining ring Figure 5 14 1 to the left Figure 5 14 2 0000589 5 14 e Series Service Manual PERIODIC MAINTENANCE Carefully remove the cup Figure 5 14 3 and pour the fuel into an approved container and dispose of waste properly Hold the bottom of the cup with a shop towel to prevent the fuel from dripping Wipe up any spills immediately Remove the element Figure 5 14 4 by pulling it down Replace the element with a new one Applicable Fuel Filter Part No 10 11 12 3TNM68 3TNM72 129053 55620 Wash the inside of the cup with clean fuel Check the condition of the cup O ring Figure 5 14 6 Replace if necessary Reinstall the cup to the mounting flange and turn the retaining ring Figure 5 14 1 to the right Figure 5 14 2 Hand tighten only Open the fuel cock of the fuel filter water separator Prime the fuel system See Priming the Fuel System on page 4 13 Check for fuel leaks Periodic Maintenance Procedures CAUTION PERIODIC MAINTENANCE Clean Fuel Filter Water Separator DANGER UA FIRE AND EXPLOSION HAZARD Diesel fuel is flammable and explosive under certain conditions NEVER
168. l hr gallon U S per hour gal gallon U S GL gear lubricant hp horsepower U S hrs hours inside diameter IDI indirect injection in inch in Ib inch pound JASO Japanese Automobile Standards Organization kg kilogram kgf cm kilogram force per square centimeter kgf m kilogram force meter km kilometers kPa kilopascal kW kilowatt 4 26 Abbreviations and Symbols L liter L hr liter per hour Ib pound Ibf pond force mL milliliter mm millimeter MPa megapascal mV millivolt N newton newton meter No number O D outside diameter oz ounce PS horsepower metric psi pound per square inch qt quart U S RPM revolutions per minute SAE Society of Automotive Engineers sec second t short ton 2000lb TBN Total Base Number TDC top dead center V volt VAC volt alternating current VDC volt direct current W watt Symbols angular degree plus minus plus or minus Q ohm micro percent i approximate TNM Series Service Manual Unit Conversions UNIT CONVERSIONS Unit Prefixes Prefix Symbol Power mega M 1 000 000 kilo k 1 000 centi x 0 01 milli m x 0 001 micro 0 000001 Units of Length mile x 1 6090 km ft x 0 3050 m in X 2 5400 cm in X 25 4000 mm km 0 6210 mile X 3 2810 ft X 0 3940 X 0 0394 jin Units of Volume gal U S X 3 78540 L qt U S X 0 94635 L cu X 0 01639
169. lable in 0 020 in 0 5 mm and 0 031 in 0 8 mm thicknesses 9 CL 0000133 10 36 TNM Series Service Manual a STARTER MOTOR No Load Test Test the characteristics of the starter motor by performing a no load test CAUTION The starter motor can be damaged if operated continuously longer than 10 seconds while performing the no load test 0000034en 1 Secure the starting motor in a vise or other suitable fixture 2 Connect an ammeter Figure 10 37 1 in series between the battery positive terminal Figure 10 37 2 and the main positive terminal Figure 10 37 3 on the starter motor Note The ammeter and all wire leads used in this test must have a capacity equal to or greater than the amperage draw specification for the starter motor being tested 0002127 10 37 3 Connect wire lead between the mounting base of the starter motor Figure 10 37 4 and the battery negative terminal Figure 10 37 5 4 Connect a voltmeter Figure 10 37 7 to the battery negative terminal Figure 10 37 5 and the main positive battery terminal Figure 10 37 3 on the starter motor 10 19 STARTER MOTOR 5 Install a switch Figure 10 37 6 in a circuit between the battery positive terminal Figure 10 37 2 and the starter solenoid switch terminal Figure 10 37 8 on the starter m
170. lick the nozzle of the timing tool with a finger to remove bubbles and establish a fuel level of approximately 1 2 the height of the nozzle Very slowly rotate the crankshaft clockwise until the fuel level in the nozzle of the spill timing tool or in the delivery valve just begins to move Immediately stop rotating the crankshaft Check the position of the flywheel target timing mark Figure 7 23 1 on the flywheel grid in relation to the timing reference mark Figure 7 23 2 on the flywheel housing or back plate If the two marks are aligned the fuel injection timing is correct If the marks do not align the fuel injection timing must be adjusted See Adjusting Fuel Injection Timing on page 7 21 Repeat Steps 13 17 two or three times to verify timing Remove the spill timing tool Reinstall the shut off solenoid Reinstall the high pressure fuel injection lines See Installation of High Pressure Fuel Injection Lines on page 7 12 Replace the flywheel inspection port cover Prime the fuel system Operate the engine and check for leaks TNM Series Service Manual Checking and Adjusting Fuel Injection Timing Adjusting Fuel Injection Timing If the timing marks did not align when performing the Checking Fuel Injection Timing on page 7 18 the following steps must be performed to properly time the engine The fuel injection pump of TNM is fixed with four bolts Adjust the injection timing
171. limited to loss of revenue loan payments cost of rental of substitute equipment insurance coverage storage lodging transportation fuel mileage and telephone costs The limitations in this Warranty apply regardless of whether your claims are based on breach of contract tort including negligence and strict liability or any other theory Any action arising hereunder must be brought within one 1 year after the cause of action accrues or it shall be barred Some states and countries do not allow certain limitations on warranties or for breach of warranties This Warranty gives you specific legal rights and you may also have other rights which vary from state to state and country to country Limitations set forth in this paragraph shall not apply to the extent that they are prohibited by law Warranty Modifications Except as modified in writing and signed by the parties this Warranty is and shall remain the complete and exclusive agreement between the parties with respect to warranties superseding all prior agreements written and oral and all other communications between the parties relating to warranties No person or entity is authorized to give any other warranty or to assume any other obligation on behalf of Yanmar either orally or in writing Questions If you have any questions or concerns regarding this Warranty please call or write to the nearest authorized Yanmar industrial engine dealer distributor or other authorized facili
172. lternator toward the cylinder block while loosening the V belt Failure to comply may result in minor or moderate injury 0000014en Remove the engine coolant fan guard if equipped engine coolant fan Figure 8 4 1 spacer Figure 8 4 2 and engine coolant pump V pulley Figure 8 4 3 Figure 8 4 8 7 COOLING SYSTEM 5 Disconnect the coolant hoses and the temperature switch lead wire from the engine coolant pump Remove the engine coolant pump Figure 8 4 4 Discard the gasket Remove the thermostat cover Figure 8 5 1 Figure 8 5 8 Remove the thermostat Figure 8 5 2 Remove the temperature switch Figure 8 5 3 and gasket Figure 8 5 4 Discard the gasket Cleaning and Inspection Temperature Switch 1 8 8 Check for proper operation of the temperature switch Connect a continuity light or onmmeter to the temperature switch Connect one lead to the terminal of the switch Figure 8 6 1 and the other lead to the metal portion of the switch Figure 8 6 2 Engine Coolant Pump 0000577A Figure 8 6 Place the temperature switch and an accurate thermometer Figure 8 6 3 in engine coolant Slowly increase temperature of the fluid using an external heat source The temperature switch is normal if the continuity light or ohmmeter indicates continuity when the fluid temperature reaches 225 F 235 F 107 C 113 C Thermostat Ch
173. m higher than one that has been operated for five hours or longer e Series Service Manual FUEL SYSTEM Pump the operating lever slowly to hold the pressure steady at a point just below the opening pressure and hold that pressure for five seconds Observe the injector to see that it is sealing properly and is not dripping If fuel leaks from the return line fitting check that the nozzle case nut is tight Service or replace the injector if fuel continues to leak from either the return line fitting or nozzle Pump the operating lever more rapidly to repeatedly pop the injector and observe the spray pattern The pattern should be a very fine uniform spray If dripping or an uneven pattern is seen service or replace the injector See Fuel Injector Test Results on page 7 24 7 23 FUEL SYSTEM Fuel Injector Test Results Injection Pattern 0001742 Pressure Gauge 0001747 Reading Gauge needle fluctuates around the valve opening pressure Atomization Pattern 5 10 cone and roughly uniform Normal injector is Possible Cause good 0001748 Gauge needle fluctuates around the valve opening pressure Atomization is excessively one sided Normally caused by carbon contamination of the nozzle tip Sometimes caused by flaws in or damage to the needle tip 0001744 0001749 Gauge needle stays at a position near the valve opening pressure
174. m Inspection of Connecting Rod Diameter 37 982 38 010 mm on page 6 48 Journals Bearing Insert 0 0592 0 0594 in Thickness 1 503 1 509 mm Oil Clearance 0 0008 0 0023 in 0 0043 in 0 020 0 058 mm 0 110 mm 6 8 TNM Series Service Manual Crankshaft and Pistons Specifications ENGINE Crankshaft Cont Inspection Item 3TNM68 3TNM72 3TNM68 3TNM72 Page Journal Outside 1 7311 1 7315 in 1 7293 in Diameter 43 970 43 980 mm 43 924 mm Bearing Inside 1 7328 1 7338 in See Main Bearing Diameter 44 014 44 038 mm Inspection of Journal Bearing Insert 0 0786 0 0791 in Crankshaft Thickness 1 996 2 008 mm on page 6 48 Clearance 0 0013 0 0027 in 0 0047 in 0 034 0 068 mm 0 120 mm Crankshaft Reconditioning Page 5 s er 1 4853 1 4857 in Connecting Rod Journal Undersize Finished Size 37 726 37 736 mm 1 7219 1 7223 See Main Bearing Journal Undersize Finished Size 43 736 43 746 mm Reconditioni ng the Journal Radius Crankshaft 3 5 3 8 mm on page 6 49 Journal Face Finish 0 8S Super Polish Thrust Bearing Inspection Item 3TNM68 3TNM72 3TNM68 3TNM72 Page 0 0044 0 0098 in 0 0110 in Crankshaft End Play All Models 0 111 0 250 mm 0 28 mm See Removal 0 0760 0 0780 i 0 0728 i d 0 6 41 Thickness 1 930 1 980 1 850 Bem e
175. m entering the engine Since the air cleaner is application specific it must be carefully selected by an application engineer It is not part of the basic engine package as shipped from the Yanmar factory Periodic replacement of the air cleaner filter element is necessary See the Periodic Maintenance Schedule on page 5 16 for the replacement frequency The dynamo is driven by a V belt which is powered by the crankshaft V pulley The dynamo supplies electricity to the engine systems and charges the battery while the engine is running The engine oil dipstick is used to determine the amount of engine oil in the crankcase The electric fuel pump makes sure there is a constant supply of diesel fuel to the fuel injection pump The electric fuel pump is electro magnetic and runs on 12 VDC An electric fuel pump may be installed as standard equipment based on engine model and specification If an electric fuel pump is installed turn the key switch to the ON position for 10 to 15 seconds to prime the fuel system The engine oil filter removes contaminants and sediments from the engine oil Periodic replacement of the engine oil filter is necessary See the Periodic Maintenance Schedule on page 5 16 for the replacement frequency The fuel filter removes contaminants and sediments from the diesel fuel Periodic replacement of the fuel filter is necessary See the Periodic Maintenance Schedule on page 5 16 for the replacement frequency Please note
176. mbling the high pressure fuel injection lines from the retainers or bending any of the fuel lines will make it difficult to reinstall the fuel lines 0000047en Troubleshooting By Measuring Compression Pressure 3 Turn off the fuel supply valve in the fuel supply line Disconnect the fuel injection stop solenoid at the connector Crank the engine for a few seconds with the stop solenoid disconnected no injection state before installing the compression gauge adapter Figure 13 1 1 this will expel any residual fuel from the cylinder Install one injector gasket at the tip end of the compression gauge adapter Install the compression gauge and the compression gauge adapter at the cylinder to be measured 5 Crank the engine until the compression gauge reading is stabilized Figure 13 1 6 After performing the compression check remove the compression gauge and compression gauge adapter from the cylinder Reinstall the fuel injector high pressure fuel injection lines and reconnect the stop solenoid See Installation of the Fuel Injectors on page 7 27 and Installation of High Pressure Fuel Injection Lines on page 7 12 7 Turn on the fuel supply valve and reconnect the injection pump stop solenoid 8 Prime the fuel system Check for leaks Test the engine TNM Series Service Manual Quick Reference Table For Troubleshooting TROUBLESHOOTING Standard Compression Pressure Engine compressi
177. meets or exceeds the following guidelines and specifications Additional Technical Coolant Specifications ASTM D6210 D4985 US JIS K 2234 Japan SAE J814C J1941 J1034 or J2036 International Alternative Engine Coolant If an Extended or Long Life Coolant is not available you may use an ethylene glycol or propylene glycol based conventional coolant green Notes 1 ALWAYS use a mix of coolant and water NEVER use water only 2 Mix coolant and water per the mixing instructions on the coolant container 3 Water quality is important to coolant performance Yanmar recommends that soft distilled or demineralized water be used to mix with coolants 4 NEVER mix extended or long life coolants and conventional green coolants 5 NEVER mix different types and or colors of extended life coolants 6 Replace the coolant every 1000 engine hours or once a year Filling Radiator with Engine Coolant Fill the radiator and reserve tank as follows This procedure is for filling the radiator for the first time or refilling it after it is flushed Note that a typical radiator is illustrated 4 17 GENERAL SERVICE INFORMATION Figure 4 7 Check to be sure the radiator drain plug is installed and tightened or the drain cock Figure 4 7 1 is closed Also make sure the coolant drain plug Figure 4 8 1 in the cylinder block is closed 0006464 i Figure 4 8 Remove the radiator
178. mmodate the cylinder head assembly Discard all gaskets O rings and seals Use new gaskets O rings and seals on reassembly of cylinder head IMPORTANT Mark all valve train components so they can be installed in their original locations Note Record all measurements taken during disassembly 1 Drain coolant from engine into a suitable container See Drain Flush and Hefill Cooling System with New Coolant on page 5 33 CAUTION Identify all parts and their location using an appropriate method It is important that all parts are returned to the same position during the reassembly process 0000080en 2 Remove the coolant pump See Disassembly of Engine Coolant Pump on page 8 7 3 Remove the high pressure fuel lines and fuel injectors from the cylinder head See Removal of Fuel Injectors on page 7 22 Cylinder Head Removal of Intake Manifold Valve Cover 1 Remove the intake manifold bolts Figure 6 2 1 and valve cover bolts Figure 6 2 2 2 Remove the valve cover intake manifold Figure 6 2 3 Discard gasket Figure 6 2 4 Figure 6 3 Removal of Rocker Arm Assembly 1 Remove the bolts Figure 6 4 1 that retain the rocker arm shaft supports 2 Remove the rocker arm shaft assembly from the cylinder head Note Identify the push rods so they can be reinstalled in their original locations 3 Remove the push rods and identify for reinstallation 026967
179. moderate injury 0000014en SAFETY CAUTION If any oil pump component clearance exceeds its limit the oil pump must be replaced as an assembly 0000015en CAUTION Only use diesel fuels recommended by Yanmar for the best engine performance to prevent engine damage and to comply with EPA ARB warranty requirements Only use clean diesel fuel NEVER remove the primary strainer if equipped from the fuel tank filler port If removed dirt and debris could get into the fuel system causing it to clog 0000004 CAUTION If any problem is noted during the visual check the necessary corrective action should be taken before you operate the engine 0000021en CAUTION NEVER hold the key in the START position for longer than 15 seconds or the starter motor will overheat 0000007 Safety Precautions CAUTION Make sure the engine is installed on a level surface If a continuously running engine is installed at an angle greater than 25 in any direction or if an engine runs for short periods of time less than three minutes at an angle greater than 30 in any direction engine oil may enter the combustion chamber causing excessive engine speed and white exhaust smoke This may cause serious engine damage 0000010enTNM CAUTION Protect the air cleaner turbocharger if equipped and electric components from damage when you use steam or high pressure water to clean the engi
180. mp Bolts M6 x 1 0mm 10 x 1 N m Applied 1 0 0 1 kgf m See Tightening Torques for Standard Bolts and Nuts on page 4 24 for standard hardware torque values Note Torx bolts are used for oil sump mounting bolts and rudder frame mounting bolts Specialized tool Torx bolt wrench is required for Sump Bolts TORX E8 for Ladder frame TORX E12 e Series Service Manual 6 13 SPECIAL SERVICE TOOLS Note Tools not having Yanmar part numbers must be acquired locally Ne TesiName Valve Guide Tool For Removing Valve Guides Valve Guide Tool For Installing Valve Guides Wrist Pin Bushing Tool For Removing Installing of Wrist Pin Bushings Valve Spring Compressor For Removing Installing Valve Springs Special Service Tools Applicable Model and Tool Size 0000827 0000828 Allowance L1 O to 0 0118 in 0 to 0 3 mm 0 984 in 3 346 in 0 984 in 25 mm 85 mm 4 25 0000829 Allowance 41 Allowance d2 0 0118 to 0 0118 to Locally Manufactured 0 0236 in 0 0236 in 0 3 to 0 6 0 3 to 0 6 mm mm Yanmar Part No 129100 92630 TNM Series Service Manual Special Service Tools ENGINE No Applicable Model and Tool Size 0 591 in 0 827 in 0 472 0 433 in 2 559 in 15 mm 21 mm 12 mm 11 65 mm Allowance 01 0 00787 in 40 2 mm L1 0 0039
181. n 0 0051 in page 6 24 0 010 0 050 mm 0 016 0 054 mm 0 13 mm 0 13 mm CAMSHAFT AND TIMING GEAR TRAIN SPECIFICATIONS Camshaft Inspection Item 3TNM68 3TNM72 3TNM68 3TNM72 Page See End Pla 0 0020 0 0059 in 0 0098 in Removal of y 0 05 0 15 mm 0 25 mm Camshafton page 6 39 Bend 0 0 0008 in 0 0020 in 0 0 02 mm 0 05 mm Cam Lobe Height 1 2100 1 2152 in 1 3596 1 3648 in 1 2287 in 1 3499 in 9 30 735 30 865 mm 34 535 34 665 mm 31 21 mm 34 287 mm Inside Diameter 1 4173 1 4183 in 1 5748 1 5758 in 1 5807 in 1 5787 in 36 000 36 025 mm 40 000 40 025 mm 40 150 mm 40 100 mm Gear End Camshaft 1 4150 1 4157 in 1 5724 1 5732 in 1 4138 in 1 5711 in Outside Diameter 35 940 35 960 mm 39 940 39 960 mm 35 911 mm 39 906 mm Oil Clearance 0 0016 0 0033 in 0 0061 in 0 04 0 085 mm 0 154 mm See Diameter Bearing Inside Diameter Camshaft 1 4138 1 4148 in 1 5713 1 5722 in 1 4126 in 1 5699 in Page 6 49 Outside Diameter 35 910 35 935 mm 39 910 39 935 mm 35 881mm 39 875 mm pamm 0 0026 0 0045 in 0 0089 in 0 065 0 115 mm 0 225 mm Inside Diameter 1 4173 1 4183 in 1 5748 1 5758 in 1 4209 in 1 5787 in 86 000 36 025 mm 40 000 40 025 mm 36 092 mm 40 100 mm Flywheel Shaf i 1 4173 1 4183 in 1 5748 1 5758 in 1 4210 in 1 5787 in Ins
182. n pump and to the engine When the starter switch is turned to the start position the pull coil 86 5 Amp draw white wire inside the solenoid is activated and pulls the solenoid plunger into the solenoid This releases the fuel injection pump fuel rack allowing fuel to flow through the injection pump and allowing the engine to start and run When the starter switch is returned to the ON or RUN position the pull coil no longer receives current and the hold coil 0 5 Amp draw red wire inside the solenoid is activated The hold coil holds the solenoid plunger in the RUN position allowing fuel to continue flowing and the engine to continue running To stop the engine the key switch is turned to the OFF position Current no longer flows to the stop solenoid hold and the solenoid plunger extends and moves the injection pump fuel rack to the closed position and shutting off the fuel flow and stopping the engine Failure of the stop solenoid could result in the engine not starting the engine stopping suddenly or the engine continuing to run with the key switch returned to the ON or RUN position or the engine failing to stop when the key switch is turned to the OFF position Use a VOA multimeter or continuity light to check for a good ground and 12V at the stop solenoid in the correct sequence TNM Series Service Manual Fuel System Specifications FUEL SYSTEM SPE
183. n to avoid being subject to a flood NEVER expose the engine to the rain 0000003en CAUTION Observe the following environmental operating conditions to maintain engine performance and avoid premature engine wear The standard range of ambient temperatures for the normal operation of Yanmar engines is from 5 F 15 C to 113 F 45 If the ambient temperature exceeds 113 F 45 C the engine may overheat and cause the engine oil to break down If the ambient temperature is below 5 F 15 C the engine will be hard to start and the engine oil may not flow easily Contact your authorized Yanmar industrial engine dealer or distributor if the engine will be operated outside of this standard temperature range 0000065en Introduction CAUTION NEVER hold the key in the START position for longer than 15 seconds or the starter motor will overheat 0000007en CAUTION For maximum engine life Yanmar recommends that when shutting the engine down you allow the engine to idle without load for five minutes This will allow the engine components that operate at high temperatures such as the turbocharger if equipped and exhaust system to cool slightly before the engine itself is shut down 0000008en CAUTION NEVER use an engine starting aid such as ether Engine damage will result 0000009 CAUTION Make sure the engine is installed on a level surface If a continuously runni
184. ndard or limit before the next service as determined from the state of current rate of wear should be replaced even though the part currently meets the service standard limit 0000120en IMPORTANT Mark all valve train components so they can be installed in their original locations Note Record all measurements taken during inspection Inspection of Push Rods Push Rod Bend Determine if the bend of the push rods is within the specified limit 1 Place the push rods on a flat inspection block or layout bed 2 Roll the push rods until a gap can be observed between a portion of the push rod and the surface of the block or layout bed 3 Use feeler gauge to measure the gap Figure 6 11 See Push Rod on page 6 6 for the service limit 6 11 0000204 Inspection of Rocker Arm Assembly Rocker Arm Shaft Hole Diameter Use a telescoping gauge and micrometer to measure the inside diameter of all the rocker arm support brackets and the rocker arms Figure 6 12 Record the measurements See Rocker Arm and Shaft on page 6 7 for the service limit Inspect contact areas Figure 6 12 1 for excessive wear or damage 0001916 Figure 6 12 Rocker Arm Shaft Outside Diameter Use a micrometer to measure rocker arm shaft diameter Measure at each rocker arm location in two directions 90 apart Figure 6 13 Record the measurements See Rocker Arm and Shaft on page 6 7
185. ndition The following is a summary of maintenance items by periodic maintenance intervals Periodic maintenance intervals vary depending on engine application loads diesel fuel and engine oil used and are hard to establish definitively The following should be treated only as a general guideline Periodic Maintenance Schedule CAUTION Establish a periodic maintenance plan according to the engine application and make sure you perform the required periodic maintenance at intervals indicated Failure to follow these guidelines will impair the engine s safety and performance characteristics shorten the engine s life and may affect the warranty coverage on your engine See Yanmar Warranties section Consult your authorized Yanmar dealer or distributor for assistance when checking items marked with a e 0000024enTNVIDISM TNM Series Service Manual Periodic Maintenance Schedule PERIODIC MAINTENANCE O Check O Replace Contact your authorized Yanmar industrial engine dealer or distributor Periodic Maintenance Interval System Check Item Daily Every Every Every Every Every Every 50 250 500 hours hours hours Check and Refill Engine Coolant Check and Clean Radiator Fins Check and Adjust Cooling Fan V Belt Cooling System Drain Flush and Refill Cooling System with New Coolant Cylinder Adjust Intake Exhaust Valve Clearance Head Lap Intake Exhaust Valve Seats if requ
186. ne 0000014en CAUTION Observe the following environmental operating conditions to maintain engine performance and avoid premature engine wear Avoid operating in extremely dusty conditions Avoid operating in the presence of chemical gases or fumes Avoid operating a corrosive atmosphere such as salt water spray NEVER install the engine in floodplain unless proper precautions are taken to avoid being subject to a flood NEVER expose the engine to the rain 0000003en TNM Series Service Manual Safety Precautions CAUTION Do not loosen or remove the four bolts retaining the fuel injection pump drive gear to the fuel injection pump hub Do not disassemble the fuel injection pump drive gear from the hub Correct fuel injection timing will be very difficult or impossible to achieve 0000031en If the oil pump must be replaced replace it as an assembly only Do not replace individual components 0000030en CAUTION Observe the following environmental operating conditions to maintain engine performance and avoid premature engine wear The standard range of ambient temperatures for the normal operation of Yanmar engines is from 5 F 15 C to 113 F 45 If the ambient temperature exceeds 113 F 45 C the engine may overheat and cause the engine oil to break down If the ambient temperature is below 5 F 15 C the engine will be hard to
187. ne coolants This may adversely affect the properties of the engine coolant 0000006en 6 4 Before You Begin Servicing CAUTION Do not loosen or remove the four bolts retaining the fuel injection pump drive gear to the fuel injection pump hub Do not disassemble the fuel injection pump drive gear from the hub Correct fuel injection timing will be very difficult or impossible to achieve 0000031en Identify all parts and their location using an appropriate method It is important that all parts are returned to the same position during the reassembly process 0000080en CAUTION Keep the piston pin parts piston assemblies and connecting rod assemblies together to be returned to the same position during the reassembly process Label the parts using an appropriate method 0000088en CAUTION Do not allow the honing tool to operate in one position for any length of time Damage to the cylinder wall will occur Keep the tool in constant up and down motion 0000090en CAUTION Any part determined to not meet the service standard or limit before the next service as determined from the state of current rate of wear should be replaced even though the part currently meets the service standard limit 0000120en TNM Series Service Manual Introduction ENGINE INTRODUCTION This section of the Service Manual describes servicing of the engine CYLINDER HEAD SPECIFICATIONS Adjustment Spe
188. ne may void its warranty Be sure to use Yanmar genuine replacement parts 0000079en CAUTION Identify all parts and their location using an appropriate method It is important that all parts are returned to the same position during the reassembly process 0000080en CAUTION Do not rotate the crankshaft with the injection pump removed 0000083en CAUTION Keep the piston pin parts piston assemblies and connecting rod assemblies together to be returned to the same position during the reassembly process Label the parts using an appropriate method 0000088en e Series Service Manual SAFETY CAUTION Do not allow the honing tool to operate in one position for any length of time Damage to the cylinder wall will occur Keep the tool in constant up and down motion 0000090en CAUTION Any part which is found defective as a result of inspection or any part whose measured value does not satisfy the standard or limit must be replaced 0000119en CAUTION Any part determined to not meet the service standard or limit before the next service as determined from the state of current rate of wear should be replaced even though the part currently meets the service standard limit 0000120en CAUTION Never use a steel wire brush to clean fuel injectors Damage to the nozzle and other components is likely to result 0000172en SAFETY Safety Precautions CAUTION
189. ne oil to the rod cap bolts Reinstall the connecting rod cap Figure 6 97 2 Tighten the connecting rod bolts to the specified torque in two stages 1 2 then full torque See Special Torque Chart on page 6 13 1 0001965 Figure 6 97 6 8 Reinstall the remaining pistons in their respective cylinders Reassembly of Camshaft and Timing 2 isi Components Installation of Camshaft Note The gear housing must be installed prior to reinstalling the camshaft 1 If removed reinstall the camshaft end plate Figure 6 98 1 key and camshaft gear 4 Figure 6 98 4 onto the camshaft using a press Heat the gear to 356 392 F 180 200 C and press onto the end of the camshaft 2 Lubricate the camshaft Figure 6 98 2 with clean engine oil or assembly lube Slowly insert 0000227A 1 Fuel Injection Pump Side of Engine 2 Piston Identification Mark 3 Embossed Mark on Connecting Rod 4 Rod and Cap Match Marks the camshaft through the front of the engine 5 Flywheel End of Engine 3 Reinstall and tighten the cap screws 6 Camshaft Side of Engine Figure 6 98 3 Figure 6 96 e Series Service Manual 6 57 Cylinder Block Installation of Timing Gears 1 Set No 1 piston to top dead center 2 Rotate the camshaft until mark Figure 6 100 C is approximately at the 9 o clock position 3 Lubricate the idler gear Figure 6 99 3
190. nets that rotate around a stationary stator coil The magnets are attached to the flywheel which is rotated via the engine cooling fan drive belt The resultant output is an AC alternating current signal The AC is converted to DC direct current by the current limiter The current limiter outputs charging DC current to the battery 11 18 TNM Series Service Manual ALTERNATOR DYNAMO STANDARD OUTPUT Dynamo Standard Output STANDARD CHARACTERISTICS 12V D D 0 t e Sei t t T D D D PEE D t B i 4 D 4 D idc i 7x103 D T i t PT eec eges Loads r eu 1 1 285 1 ud 1 T 1 pus i 1 mid mm 6 t t 1 v LNANYNO Lndino ALTERNATOR SPEED min 0002138 Figure 11 22 11 19 TNM Series Service Manual a ALTERNATOR TESTING OF DYNAMO Use a circuit tester or multimeter to perform the following tests Testing Stator Coil Continuity 1 Disconnect the dynamo output wire connector 2 Connect one meter lead to each of the stator wire terminals and read the meter Results The meter reading should indicate continuity If continuity is not indicated the windings are open and the stator must be replaced Testing Stator Coil Short to Ground 1 Di
191. ng engine is installed at an angle greater than 25 in any direction or if an engine runs for short periods of time less than three minutes at an angle greater than 30 in any direction engine oil may enter the combustion chamber causing excessive engine speed and white exhaust smoke This may cause serious engine damage 0000010enTNM TNM Series Service Manual Introduction CAUTION New Engine Break in On the initial engine start up allow the engine to idle for approximately 15 minutes while you check for proper engine oil pressure diesel fuel leaks engine oil leaks coolant leaks and for proper operation of the indicators and or gauges During the first hour of operation vary the engine speed and the load on the engine Short periods of maximum engine speed and load are desirable Avoid prolonged operation at minimum or maximum engine speeds and loads for the next four to five hours During the break in period carefully observe the engine oil pressure and engine temperature During the break in period check the engine oil and coolant levels frequently 000001 ten CAUTION NEVER engage the starter motor while the engine is running This may damage the starter motor pinion and or ring gear 0000012en e Series Service Manual PERIODIC MAINTENANCE CAUTION ALWAYS be environmentally responsible Follow the guidelines of t
192. ng hair and keep your hands or moderate injury other body parts and clothing away 0000003en from moving rotating parts Failure to comply could result in death CAUTION Pe Se ee TOR EY NEVER use an engine starting aid such as ether Engine damage will result 0000009en 0000010en e Series Service Manual 6 3 CAUTION Only use the engine oil specified Other engine oils may affect warranty coverage cause internal engine components to seize and or shorten engine life Prevent dirt and debris from contaminating the engine oil Carefully clean the oil cap dipstick and the surrounding area before you remove the cap NEVER mix different types of engine oil This may adversely affect the lubricating properties of the engine oil NEVER overfill Overfilling may result in white exhaust smoke engine overspeed or internal damage 0000005en CAUTION Any part which is found defective as a result of inspection or any part whose measured value does not satisfy the standard or limit must be replaced 0000119en CAUTION Only use the engine coolant specified Other engine coolants may affect warranty coverage cause an internal buildup of rust and scale and or shorten engine life Prevent dirt and debris from contaminating the engine coolant Carefully clean the radiator cap and the surrounding area before you remove the cap NEVER mix different types of engi
193. ngine coolant 0000006en SAFETY Safety Precautions CAUTION CAUTION NEVER overfill the engine with engine oil ALWAYS keep the oil level between the upper and lower lines on the oil cap dipstick ALWAYS be environmentally responsible 0000015en Follow the guidelines of the EPA or other governmental agencies for the For maximum engine life Yanmar proper disposal of hazardous recommends that when shutting the materials such as engine oil diesel engine down you allow the engine to fuel and engine coolant Consult the idle without load for five minutes This local authorities or reclamation facility will allow the engine components that d operate at high temperatures such as NEVER dispose of hazardous the turbocharger if equipped and materials irresponsibly by dumping exhaust system to cool slightly before them into a sewer on the ground or the engine itself is shut down into ground water or waterways 0000008en Failure to follow these procedures may seriously harm the environment CAUTION 0000013en NEVER use an engine starting aid such as ether Engine damage will result 0000009 3 14 Series Service Manual Safety Precautions CAUTION New Engine Break in On the initial engine start up allow the engine to idle for approximately 15 minutes while you check for proper engine oil pressure diesel fuel leaks engine oil leaks coolant leaks
194. ngth Inspect shift lever for deformation Pinion and ring gear NO gt return spring for fatigue and pinion meshing normal for sliding YES Repair meshing between pinion and Y ring gear or replace as needed Connect M terminal of starter wo Inspect brush and replace if worn Pinion roller clutch or motor directly to battery If brushes are not worn replace armature reduction gear damaged Does starter motor operate assembly inspect and replace ves Solenoid switch assembl If starter motor becomes wet replace solenoid switch contact defective Repair assembly even if function is normal Y NO or replace is revol ti n h miat slowirevolutio Is battery fully charged Charge or replace battery problem occurs i and terminals clean Clean terminals immediately disconnect battery negative terminal Y YES Inspect fuel system 2010000 ves Is the engine viscosity correct Replace engine ves Engine does not stop even when key switch is turned OFF Repair or replace Does engine turn when YES starter motor starter motor is replaced Repair or replace key switch starting motor relay or magnetic switch assembly siow Revolution Inspect condition of engine ONILOOHSATENOUL HOLON
195. ning to catch the fuel NEVER use a shop rag to catch the fuel Vapors from the rag are flammable and explosive Wipe up any spills immediately Wear eye protection The fuel system is under pressure and fuel could spray out when you remove any fuel system component Failure to comply will result in death or serious injury 0000009en 5 22 Periodic Maintenance Procedures CAUTION If the fuel filter water separator is positioned higher than the fuel level in the fuel tank water may not drip out when the fuel filter water separator drain cock is opened If this happens turn the air vent screw on the top of the fuel filter water separator 2 3 turns counterclockwise Be sure to tighten the air vent screw after the water has drained out 0000025en CAUTION ALWAYS be environmentally responsible Follow the guidelines of the EPA or other governmental agencies for the proper disposal of hazardous materials such as engine oil diesel fuel and engine coolant Consult the local authorities or reclamation facility NEVER dispose of hazardous materials irresponsibly by dumping them into a sewer on the ground or into ground water or waterways Failure to follow these procedures may seriously harm the environment 0000013en Drain the fuel filter water separator whenever there are contaminants such as water collected in the bottom of the cup NEVER wait until the scheduled periodic maintenance
196. njury 0000005en CAUTION Only use the engine oil specified Other engine oils may affect warranty coverage cause internal engine components to seize and or shorten engine life Prevent dirt and debris from contaminating the engine oil Carefully clean the oil cap dipstick and the surrounding area before you remove the cap NEVER mix different types of engine oil This may adversely affect the lubricating properties of the engine oil NEVER overfill Overfilling may result in white exhaust smoke engine overspeed or internal damage 0000005en TNM Series Service Manual Introduction PERIODIC MAINTENANCE CAUTION CAUTION Only use diesel fuels recommended by Only use the engine coolant specified Yanmar for the best engine Other engine coolants may affect performance to prevent engine warranty coverage cause an internal damage and to comply with EPA ARB buildup of rust and scale and or warranty requirements shorten engine life Only use clean diesel fuel Prevent dirt and debris from contaminating the engine coolant Carefully clean the radiator cap and the surrounding area before you remove the cap NEVER remove the primary strainer if equipped from the fuel tank filler port If removed dirt and debris could get into the fuel system causing it to clog NEVER mix different types of engine coolants This may adversely affect the CAUTION properties of the en
197. nly fill the fuel tank with diesel fuel Filling the fuel tank with gasoline may result in a fire and will damage the engine NEVER refuel with the engine running Wipe up all spills immediately Keep sparks open flames or any other form of ignition match cigarette static electric source well away when refueling NEVER overfill the fuel tank Fill the fuel tank Store any containers containing fuel in a well ventilated area away from any combustibles or sources of ignition Failure to comply will result in death or serious injury 0000005 Introduction DANGER GL FIRE AND EXPLOSION HAZARD Diesel fuel is flammable and explosive under certain conditions Before you operate the engine check for fuel leaks Replace rubberized fuel hoses every two years or every 2000 hours of engine operation whichever comes first even if the engine has been out of service Rubberized fuel lines tend to dry out and become brittle after two years or 2000 hours of engine operation whichever comes first Failure to comply will result in death or serious injury 0000015en TNM Series Service Manual Introduction DANGER GL 7 FIRE AND EXPLOSION HAZARD Diesel fuel is flammable and explosive under certain conditions Be sure to place the diesel fuel container on the ground when transferring the diesel fuel from the pump to the container Hold the hose nozzle firmly aga
198. nnecting rods flywheel flywheel housing camshaft timing gear and gear case The Warranty Period for both the standard limited warranty and the extended limited warranty by duration or operation hours begins on the date of delivery to the original retail purchaser and is valid only until the applicable warranted duration has passed or the operation hours are exceeded whichever comes first What the Engine Owner Must Do If you believe your Yanmar engine has experienced a failure due to a defect in material and or workmanship you must contact an authorized Yanmar industrial engine dealer or distributor within thirty 30 days of discovering the failure You must provide proof of ownership of the engine proof of the date of the engine purchase and delivery and documentation of the engine operation hours Acceptable forms of proof of delivery date include but are not limited to the original warranty registration or sales receipts or other documents maintained in the ordinary course of business by Yanmar dealers and or distributors indicating the date of delivery of the Yanmar product to the original retail purchaser This information is necessary to establish whether the Yanmar product is still within the warranty period Thus Yanmar strongly recommends you register your engine as soon as possible after purchase in order to facilitate any future warranty matters You are responsible for the transportation of the engine to and from the repa
199. ns When you remove any fuel system component to perform maintenance such as changing the fuel filter place an approved container under the opening to catch the fuel NEVER use a shop rag to catch the fuel Vapors from the rag are flammable and explosive Wipe up any spills immediately Wear eye protection The fuel system is under pressure and fuel could spray out when you remove any fuel system component Failure to comply will result in death or serious injury 0000009 CAUTION For maximum engine life Yanmar recommends that when shutting the engine down you allow the engine to idle without load for five minutes This will allow the engine components that operate at high temperatures such as the turbocharger if equipped and exhaust system to cool slightly before the engine itself is shut down 0000008en TNM Series Service Manual Periodic Maintenance Procedures CAUTION ALWAYS be environmentally responsible Follow the guidelines of the EPA or other governmental agencies for the proper disposal of hazardous materials such as engine oil diesel fuel and engine coolant Consult the local authorities or reclamation facility NEVER dispose of hazardous materials irresponsibly by dumping them into a sewer on the ground or into ground water or waterways Failure to follow these procedures may seriously harm the environment 0000013en Replace the fue
200. o clean the air filter element periodically 0000026en 1 Unlatch and remove the air cleaner cover Figure 5 12 1 2 Remove the element Figure 5 12 2 outer element if equipped with two elements 0006460 Figure 5 11 0000070A Figure 5 12 5 28 TNM Series Service Manual Periodic Maintenance Procedures PERIODIC MAINTENANCE The inner element should not be removed when cleaning or replacing the outer element The inner element is used to prevent dust from entering the engine while servicing the outer element 4 Replace the element with a new one if the element is damaged excessively dirty or oily 5 Clean inside of the air cleaner cover G 6 Install the element into the air cleaner case 0000071 Figure 5 12 4 Figure 5 13 7 Install the air cleaner cover making sure you match the arrow Figure 5 12 5 on the cover A CAUTION with the arrow on the case Figure 5 12 6 8 Latch the air cleaner cover to the case FLYING OBJECT HAZARD ALWAYS wear eye protection when servicing the engine and when using compressed air or high pressure water Dust flying debris compressed air pressurized water or steam may injure your eyes Failure to comply may result in minor or moderate injury 0000003en 3 Blow air Figure 5 12 3 through the element from the inside out using 42 71 psi 0 29 0 49 MPa 3 0 5 0 kgf cm2 compressed air to remove t
201. o the oil pump 2 027029 00X Figure 9 2 1 Body 2 Shaft 3 Inner rotor 4 Outer rotor 5 Cover 6 Drive gear 7 regulator valve e Series Service Manual LUBRICATION SYSTEM Disassembly of Oil Pump CAUTION If the oil pump must be replaced replace it as an assembly only Do not replace individual components 0000030en Remove the cooling water fan guard if equipped cooling fan Figure 9 3 3 spacer Figure 9 3 2 cooling water pump V pulley Figure 9 3 1 and V belt Figure 9 3 1 Remove the crank shaft pulley and gear case cover See Removal of Timing Gear Case Cover on page 6 36 2 Remove the lubricating oil pump assembly mounting bolts Remove the lubricating oil pump assembly Figure 9 4 1 from the gear case flange Figure 9 4 2 3 You can remove by hand the lubricating oil pump cover Figure 9 2 5 and outer rotor Figure 9 2 4 9 7 LUBRICATION SYSTEM Trochoid Oil Pump Figure 9 4 Cleaning and inspection Figure 9 5 Clean the lubricating oil pump pressure regulator Record the measurement s and see Outer Rotor valve Figure 9 2 7 and rotor inserting portion Outside Clearance on page 9 5 for the service Check the parts for wear or flaw Replace the parts limits with new ones as needed Outer Rotor to Inner Rotor Tip Clearance CAUTION Inspect the tip clearance between the outer and
202. older Brush Holder Insulation Test Check for continuity between each brush holder and the base using a multimeter Figure 10 21 The multimeter should not indicate continuity If the multimeter indicates continuity replace the brush holder 0000122 Figure 10 21 Brush Spring Test Test the spring force for each brush spring Figure 10 22 Replace the brush spring if the force is not within the range See Starter Motor Specifications on page 10 6 for the service limit ja 0000123 10 22 e Series Service Manual STARTER MOTOR Solenoid Switch If the starter motor becomes wet replace the solenoid switch even if the solenoid switch assembly function is normal Shunt Coil Continuity Test Check for continuity between the S terminal and the switch body using a multimeter Figure 10 23 The multimeter should indicate continuity If the multimeter does not indicate continuity replace the solenoid switch 0000124 Figure 10 23 Series Coil Continuity Test Check for continuity between the S and M terminals using a multimeter Figure 10 24 The multimeter should indicate continuity If the multimeter does not indicate continuity replace the solenoid switch 0000125 Figure 10 24 10 15 STARTER MOTOR Coil Resistance Test See Starter Motor Specifications on page 10 6 for service limit Contact Continuity Test Depress the plung
203. om See Engine Coolant System Engine Coolant System Check on page 8 7 See Disassembly of Engine Repair or Replace Coolant Pump on page 8 7 1 See Check and Adjust Cooling Adjust the Belt Tension Fan V Belt on page 5 20 See Disassembly of Engine Checker epics Coolant Pump on page 8 7 Use Correct Engine Oil See Engine Oil Specifications on page 4 14 See Disassembly of Oil Pump on Repair page 9 7 Check and Repair See Disassembly of Oil Pump on page 9 7 See Replace Engine Oil and Pleainonieplace Engine Oil Filter on page 5 26 Clean Adjust or Replace See Disassembly of Oil Pump on page 9 7 Add Correct Engine Oil eu ISO SON 4 15 Check Engine See Checking Engine Oil on page 4 15 2 oc 5 5 olol 3 353 83 i Ja LL 13 11 TROUBLESHOOTING Troubleshooting Charts This Page Intentionally Left Blank 13 12 TNM Series Service Manual Troubleshooting Charts Trouble Symptom S 9 2 c Too Early Timing of Fuel Injection Pump Too Late Timing of Fuel Injection Pump Incorrect Diesel Fuel Water Fuel System Clogged Fuel Filter Fuel System Series Service Manual Starting Problem Engine Insufficient
204. on manual provided by the driven machine manufacturer for actual engine coolant capacity on your machine The following are the engine coolant capacities for various Yanmar TNV engines Engine Model Engine Coolant Capacity 3TNM68 72 1 1 qt 1 0L TNM Series Service Manual Specifications GENERAL SERVICE INFORMATION SPECIFICATIONS Description of Model Number 3 TNM 68 O 0000 L Customer Code Rated rpm Oylinder Bore mm Engine Series No of Cylinders When ordering parts or making an inquiry about the engine you are working on be sure to include the complete model and serial numbers as shown on the engine nameplate See Location of Labels on page 4 4 Engine Speed Specifications Notation Available Engine Speed Intended Uses 3200 3600 rpm min Lawn Mower Construction Industrial Machine 2000 3000 rpm Agricultural Constructive Industrial Machines 3000 3600 rpm 2 pole Generator Sets Irrigation Pumps 1500 or 1800 rpm min 4 pole Generator Sets Irrigation Pumps VH Variable High Speed VM Variable Medium Speed CH Constant High Speed CL Constant Low Speed e Series Service Manual 4 19 GENERAL SERVICE INFORMATION Specifications Engine General Specifications Lubricating System Forced Lubrication with Trochoid Pump PTO Position Flywheel End Direction of Rotation Counterclockwise Viewed from Flywheel End
205. on page 6 13 0000226A 1 Top Compression Ring End Gap 2 Second Compression Ring End Gap 3 Oil Ring End Gap Figure 6 95 IMPORTANT Ensure piston ring gaps are located correctly Figure 6 95 3 Using a piston ring compressor compress the piston rings Figure 6 94 6 56 TNM Series Service Manual Cylinder Block ENGINE IMPORTANT 5 Reinstall the bearing inserts Figure 6 97 1 The piston and connecting rod must be in the connecting rod and cap reinstalled with the correct orientation 6 Apply a liberal coat of clean engine oil to the When installed correctly the identification bearing inserts and crankshaft journal mark Figure 6 96 2 stamped into the top of the piston will be on the same side of the engine as the fuel injection pump Figure 6 96 1 and the embossed mark Figure 6 96 3 cast into the connecting rod beam will face the flywheel end of the engine Figure 6 96 5 4 Carefully reinstall the piston and rod assembly Be sure the match marks Figure 6 96 4 stamped into the connecting rod and cap are facing the fuel injection pump side of the cylinder block and the piston identification mark Figure 6 96 2 stamped into the piston top is facing the camshaft side Figure 6 96 6 The embossed mark cast into the connecting rod beam Figure 6 96 3 will be facing the flywheel end of the engine Figure 6 96 5 7 Apply a light coat of clean engi
206. on page 6 8 for specifications Put the crankshaft end journals Figure 6 73 4 on V blocks 2 Place a dial indicator Figure 6 73 3 ona center main bearing surface Inspection of Tappets 1 Inspect the tappet contact surfaces for abnormal wear Figure 6 71 1 Normal wear will be even as shown in Figure 6 71 2 Slight surface defects can be corrected using an oilstone 4 4 00002324 4 2 0002194 6 73 Figure 6 71 3 Rotate the crankshaft and observe runout 2 Measure the outside diameter of the tappet Record the measurements See Crankshaft on stem Figure 6 72 1 Record the measurements See Tappet on page 6 11 for the service limit page 6 8 for specifications Use the color check method or MAGNAFLUX to inspect the crankshaft for cracks Replace the crankshaft if evidence of fractures is found 5 Measure the outside diameter of each crankpin Figure 6 74 2 and main bearing journal Figure 6 74 1 See Crankshaft on page 6 8 for specifications Take measurements at several places around each bearing surface If not within specification grind the journals and install undersize bearings or replace the crankshaft Record the measurements 0002195 Figure 6 72 3 Measure the tappet bores in the cylinder block Record the measurements See Tappet on page 6 11 for the service limit 6 48 TNM Series Service Manual Cylinder Block ENGINE
207. on pressure list reference value Compression Pressure at 250 rpm 250 min Hn Engine Model Deviation Between Cylinders 3TNM68 470 x 15 psi 370 15 psi 29 to 43 psi 3TNM72 3 24 0 1 MPa 33 1 kgf cm 2 55 0 1 MPa 26 1 kgf cm 0 2 to 0 3 MPa 2 to 3 kgf cm Measured Value and Troubleshooting When the measured compression pressure is below the limit value inspect each part by referring to the table below Clogged element Clean the element Air Cleaner Element Broken element Replace the element Defect at element seal portion Valve Clearance Adjust the valve clearance Valve Timing Incorrect valve clearance Adjust the valve clearance Replace the gasket Cylinder Head Gasket Gas leak from gasket Retighten the cylinder head bolts to the specified torque Intake Exhaust Valve Sticking valve Replace the intake exhaust valve 5 Gas leak due to worn valve seat Valve Seat or foreign matter trapped in Lap the valve seat valve Gas leak due to scratching or HEAT Perform honing and use an oversized part Cylinder QUICK REFERENCE TABLE FOR TROUBLESHOOTING The following table summarizes the general trouble symptoms and their causes If any trouble symptom occurs take corrective action before it becomes a serious problem so as not to shorten the engine service life TNM Series Service Manual 13 5 a TROUBLESHOOTING Quick Reference Table For Troubleshooting This Page
208. ooling System with New Coolant Adjust Intake Exhaust Valve Clearance Drain Flush and Refill Cooling System with New Coolant SCALD HAZARD NEVER remove the radiator cap if the engine is hot Steam and hot engine coolant will spurt out and seriously burn you Allow the engine to cool down before you attempt to remove the radiator cap Tighten the radiator cap securely after you check the radiator Steam can spurt out during engine operation if the cap is loose ALWAYS check the level of the engine coolant by observing the reserve tank Failure to comply will result in death or serious injury 0000002en PERIODIC MAINTENANCE Guill Go o BURN HAZARD Wait until the engine cools before you drain the engine coolant Hot engine coolant may splash and burn you Failure to comply could result in death or serious injury 0000016en CAUTION COOLANT HAZARD Wear eye protection and rubber gloves when you handle long life or extended life engine coolant If contact with the e
209. or distributor repair the damage Failure to comply could result in death or serious injury 0000008en Proper operation of the fuel injectors is required to obtain the optimum injection pattern for full engine performance The EPA ARB requires that the fuel injectors are inspected cleaned and tested every 1500 hours See Testing of Fuel Injectors on page 7 22 This procedure is considered normal maintenance and is performed at the owner s expense This procedure is not covered by the Yanmar Limited Warranty 5 36 Periodic Maintenance Procedures Inspect Crankcase Breather System Proper operation of the crankcase breather system is required to maintain the emission requirements of the engine The EPA ARB requires that the crankcase breather system is inspected every 1500 hours The TNM engines use a crankcase breather system that has a spring backed diaphragm Figure 5 18 1 in the valve cover Figure 5 18 2 When the crankcase pressure reaches a predetermined value the diaphragm opens a passage that allows crankcase fumes to be routed to the intake manifold Figure 5 18 To inspect the diaphragm and spring Figure 5 18 3 1 Remove the bolts retaining the diaphragm cover Figure 5 18 4 2 Remove the diaphragm cover spring diaphragm plate Figure 5 18 5 and diaphragm 3 Inspect the diaphragm for tears Inspect the spring for distortion Replace components if necessary
210. otor Use a suitable tachometer to monitor the rpm of the starter Turn the switch to the ON position to energize the solenoid and operate the starter Monitor the rpm amperage draw and voltage For test specifications see Starter Motor Information on page 10 5 for the appropriate starter motor 10 20 Starter Motor Installation of Starter Motor 1 Reinstall the starter motor to the flywheel housing Reinstall the starter mounting bolts Figure 10 38 1 Tighten the bolts to specification See Tightening Torques for Standard Bolts and Nuts on page 4 24 0002126 Figure 10 38 Reconnect the electrical wires to the solenoid switch assembly Be sure to place the cover over the battery positive cable connection Reconnect the battery negative cable last TNM Series Service Manual Section 11 ALTERNATOR Page Before You Begin 11 3 INTO GU CH OM EE 11 6 Standard and Optional Dynamo Information 11 6 Standard and Optional Alternator Information 11 6 Alternator Specifications 11 6 Dynamo Specifications 11 7 Alternator 11 8 Alternator Components 11 9 Alternator Wiring 11 10 Alternator Standard Output 2
211. p on new piston rings e Series Service Manual ENGINE 027272 00X Figure 6 85 Note Reinstall the top and second piston rings with the stamped makers mark Figure 6 86 1 facing the top of the piston The makers mark may vary in appearance but will always be located on the top surface of the piston ring adjacent to the piston ring gap The oil ring and oil ring expander can be installed either side up 2 0000225 6 86 IMPORTANT Always use a piston ring expander when installing piston rings Never attempt to install piston rings by hand 7 Reinstall the oil ring expander Figure 6 87 4 Install the oil ring Figure 6 87 3 with the end gap at 180 from the expander end gap 8 Reinstall the second compression ring Figure 6 87 2 This ring is identified by its dark color and tapered face profile 9 Reinstall the top compression ring Figure 6 87 1 This ring is identified by its silver color and barrel shaped face profile IMPORTANT The oil ring expander Figure 6 87 4 end gap must be located 180 from the oil ring Figure 6 87 3 end gap 00017228 Figure 6 87 10 Stagger the piston ring end gaps at 120 intervals Figure 6 88 1 2 and 3 Do not position the top piston ring end gap in line with the wrist pin 6 54 Cylinder Block 1 Top Compression Ring End Gap 2 Second Compression Ring
212. pe e pepe e e e pe 8 ES E 6 4 ES Ea 4 2 2 2 211 40 EJ ie 12 6 TNM Series Service Manual Conversion of AWG to European Standards ELECTRIC WIRING CONVERSION OF AWG TO EUROPEAN STANDARDS Conductor Size Conductor Diameter Conductor Cross sectional Area AWG mm mm 24 2 2 2 a 8 7 i E i E 2 n TUS 000 00 0000050 ll 000000 6 0 14 73 170 3 1 1 circular mil CM 0 0005067 mm e Series Service Manual 12 7 ELECTRIC WIRING 12 8 Conversion of AWG to European Standards This Page Intentionally Left Blank TNM Series Service Manual Section 13 TROUBLESHOOTING Page Special Service 5 2121 2 41 4 4441142 44 13 3 Troubleshooting By Measuring Compression Pressure 13 4 Compression Pressure Measurement Method 13 4 Standard Compression Pressure 13 5 Measured Value and 0 13 5 Quick Reference Table For Troubleshooting 13 5 Series Service Manual 13 1 TROUBLESHOOTING This Page Intentionally Left Blank 13 2 TNM Series Service Manual Special Service Tools
213. pecific information Inspection of Cylinder Block 1 Ensure that oil passages are clear and unobstructed 2 Check for discoloration or evidence of cracks If a fracture is suspected use the color check method or the MAGNAFLUX method to determine if the cylinder block is fractured 3 Measure cylinders for roundness taper and inspect for evidence of scoring Consider honing re boring or replacing the cylinder block if the measurements are not within specification TNM Series Service Manual Cylinder Block Take measurements at three places Figure 6 62 a b and c and in two directions d and e in each cylinder Collect and record the measurements See Cylinder Block on page 6 12 for specifications 20 mm f A 3 3 0 75 in 00002308 Figure 6 62 Roundness Roundness be calculated by subtracting the smaller measured value from the larger measured value of d or e at each measuring location a b and c Taper Taper can be calculated by subtracting the minimum measured value from the maximum measured value of locations a b and c Calculate along both the d axis and e axis and use the larger of the two calculations as the value to compare to the specifications e Series Service Manual ENGINE Inspection of Pistons Piston Rings and Wrist Pin Notes an engine with low hours the pis
214. pection of aft Inside Diameter Outside 36 000 36 025 mm 40 000 40 025 mm 36 093 mm 40 100 mm Camshafton Interme diate Camshaft 1 4150 1 4157 in 1 5724 1 5732 in 1 4138 in 1 5711 in Outside Diameter 35 940 35 960 mm 39 940 39 960 mm 35 911 mm 39 906 mm Oil Clearance 0 0016 0 0033 in 0 0061 in 0 040 0 085 mm 0 154 mm Series Service Manual 6 7 Crankshaft and Pistons Specifications Idler Gear Shaft and Bushing Inspection Item 3TNM68 3TNM72 3TNM68 3TNM72 Page 1 1795 1 1803 in 1 1779 in Shaft Outside Diameter 29 959 29 980 mm 29 919 mm See 2 s Inspection of 1 1811 1 1821 in 1 1837 in Bushing Inside Diameter 1 Idler Gear 0 0008 0 0026 in 0 0058 in page 6 50 Oil Clearance 0 020 0 066 mm 0 147 mm Timing Gear Backlash Standard Reference Inspection Item 3TNM68 3TNM72 3TNM68 3TNM72 Page See Checking Timing Gear Backlash on page 6 36 Crank Gear Cam Gear Idle Gear Fuel 0 0024 0 0047 in 0 0055 in Injection Pump Gear 0 06 0 12 mm 0 14 mm CRANKSHAFT AND PISTONS SPECIFICATIONS Crankshaft Note Check appropriate parts catalog for undersized replacement main bearing inserts Inspection 3TNM68 3TNM72 3TNM68 3TNM72 Page 0 0008 in Be 000 0 0004 in 0 01 mm 0 0008 in Roundness or less 0 02 mm Diameter 37 952 37 962 mm 37 402 m
215. perature Thermostat i 157 163 F 0 32 in 8 mm or Above uem 185 F 85 C 225 235 F Temperature Coolant Switch 107 113 C e Series Service Manual 4 23 GENERAL SERVICE INFORMATION Tightening Torques for Standard Bolts and Nuts TIGHTENING TORQUES FOR STANDARD BOLTS AND NUTS Use the correct amount of torque when you tighten fasteners on the machine Applying 5 2 torque may damage the fastener or component The tightening torque in the Standard not enough torque may cause a leak or component Torque Chart in General Service failure Information should be applied only to the bolts with a 7 head JIS strength classification 7T Apply 60 torque to bolts that are not listed Apply 80 torque when tightened to aluminum alloy 0000023enTNVIDISM Nominal Thread i 87 104 in Ib M6 x 1 0mm 9 8 11 8 1 0 1 2 kgf m 200 251 in lb M8 x 1 25 mm 22 6 28 4 N m 2 3 2 9 kgf m 33 40 ft lb M10x 1 5 mm 44 1 53 9 Nm i at x valusat eit Hexagon Bolt 7T 4 5 5 5 kgf m YR MAL partig 58 72 ft lb Use 60 of the value at left M12 x 1 75 mm 78 4 98 0 N m for 4T bolts and lock nuts 8 0 10 kgf m 94 108 ft lb M14 x 1 5 mm 127 5 147 1 N m 13 15 kgf m 159 174 ft lb M16 x 1 5 mm 215 7 235 4 N m 22 24 kgf m 87 in Ib 9 8 N m 1 0 kgf m 173 in Ib PT Plug ape 22 ft lb
216. perature could drop to 5 F 15 C orless remove the battery from the machine atthe end of the day Store the battery in a warm place until the next use This will help start the engine easily at low ambient temperatures TNM Series Service Manual Periodic Maintenance Procedures Every 250 Hours Operation Perform the following maintenance every 250 hours of operation Drain Fuel Tank Replace Engine Oil and Engine Oil Filter Check and Clean Radiator Fins Check and Adjust Cooling Fan V Belt Check and Adjust the Governor Lever and Engine Speed Control Clean Air Cleaner Element Drain Fuel Tank DANGER YAY FIRE AND EXPLOSION HAZARD Diesel fuel is flammable and explosive under certain conditions When you remove fuel system component to perform maintenance such as changing the fuel filter place an approved container under the opening to catch the fuel NEVER use a shop rag to catch the fuel Vapors from the rag are flammable and explosive e Wipe up any spills immediately Wear eye protection The fuel system is under pressure and fuel could spray out when you remove any fuel system component Failure to comply will result in death or serious injury 0000009en e Series Service Manual PERIODIC MAINTENANCE ad ALWAYS be environmentally responsible Follow the guidelines of the EPA or other go
217. pport in a padded vise Twist and push on the rocker arm shaft to reinstall Note The set screw is located in the center support 6 30 TNM Series Service Manual Cylinder Head Reassembly of Intake Manifold Valve Cover 1 Reinstall the glow plugs Figure 6 33 1 and tighten to specification Reinstall the electrical harness Figure 6 33 2 Figure 6 33 2 Lightly grease a new valve cover gasket Figure 6 34 4 Place the gasket in the groove of the intake manifold valve cover Figure 6 34 3 3 Place the valve cover on the cylinder head 4 Reinstall and tighten bolts Figure 6 34 1 and 2 securely 4 Series Service Manual ENGINE Figure 6 34 Reinstall the exhaust manifold using a new gasket Tighten the bolts and nuts Figure 6 34 5 and 6 securely Reinstall the fuel injectors See Installation of the Fuel Injectors on page 7 27 Reinstall the high pressure and return fuel injection lines See Installation of the Fuel Injectors on page 7 27 Reinstall the coolant pump See Reassembly of Engine Coolant Pump on page 8 9 Reinstall the alternator See Installation of Alternator on page 11 16 Measuring and Adjusting Valve Clearance Measure and adjust while the engine is cold Notes The No 1 piston position is on the flywheel end of the engine opposite end of the radiator The firing order is 1 3 2
218. purt out during engine operation if the cap is loose ALWAYS check the level of the engine coolant by observing the reserve tank Failure to comply will result in death or serious injury 0000002en full C 2200001 BURN HAZARD Wait until the engine cools before you drain the engine coolant Hot engine coolant may splash and burn you Failure to comply could result in death or serious injury 0000016en TNM Series Service Manual Engine Coolant CAUTION COOLANT HAZARD Wear eye protection and rubber gloves when you handle long life or extended life engine coolant If contact with the eyes or skin should occur flush eyes and wash immediately with clean water Failure to comply may result in minor or moderate injury 0000005en CAUTION Only use the engine coolant specified Other engine coolants may affect warranty coverage cause an internal buildup of rust and scale and or shorten engine life Prevent dirt and debris from contaminating the engine coolant Carefully clean the radiator cap and the surrounding area before you remove the cap NEVER mix different types of engine coolants This may adversely affect the properties of the engine coolant 0000006en e Series Service Manual GENERAL SERVICE INFORMATION Engine Coolant Specifications Use a Long Life Coolant LLC or an Extended Life Coolant ELC that
219. r valve guide to bring the clearance within the limit Roughness or burrs will cause poor seating of a valve Visually inspect the seating surfaces of each valve and valve seat to determine if lapping or grinding is needed Visually inspect all valve faces and valve seats for pitting distortion cracking or evidence of overheating Usually the valves and valve seats can be lapped or ground to return them to serviceable condition Severely worn or damaged components will require replacement Coat the valve seat with a thin coat of bluing compound Install valve and rotate to distribute bluing onto the valve face The contact pattern should be approximately centered on the valve face Figure 6 20 1 and even in width 0001691B Figure 6 20 Also visually inspect the valve seat for even contact Light cutting can be performed by the use of a hand operated cutter Figure 6 21 3 6 26 Cylinder Head ae 4097 0001862 6 21 Valve seat diameter be adjusted by top grinding with a 150 stone to make the seat diameter smaller and bottom grinding using a 40 stone to make the seat diameter larger Once the seat location has been corrected grind and lap the seat angle Figure 6 21 1 to specification See Cylinder Head on page 6 5 for the service limit Grind the valve face and or valve seat only enough to return them to serviceable condition Grinding is needed if the valve and
220. rating and could seriously burn you Failure to comply could result in death or serious injury 0000015en TNM Series Service Manual Safety Precautions FUME BURN HAZARD Always read and follow safety related precautions found on containers of hazardous substances like parts cleaners primers sealants and sealant removers Failure to comply could result in death or serious injury 0000014en A CAUTION COOLANT HAZARD Wear eye protection and rubber gloves when you handle long life or extended life engine coolant If contact with the eyes or skin should occur flush eyes and wash immediately with clean water Failure to comply may result in minor or moderate injury 0000005en e Series Service Manual SAFETY A CAUTION FLYING OBJECT HAZARD ALWAYS wear eye protection when servicing the engine and when using compressed air or high pressure water Dust flying debris compressed air pressurized water or steam may injure your eyes Failure to comply may result in minor or moderate injury 0000003en A CAUTION Be sure to secure the engine solidly to prevent injury or damage to parts due to the engine falling during work on the engine 0000009 CAUTION E PINCH HAZARD Carefully rotate the alternator toward the cylinder block while loosening the V belt Failure to comply may result in minor or
221. red to replace the cylinder block Inspection of Idler Gear and Shaft 1 Measure the outside diameter Figure 6 79 1 of the idler gear shaft Figure 6 79 2 Record the measurements See Idler Gear Shaft and Bushing page 6 8 for specifications 2 Measure the inside diameter Figure 6 79 3 of the idler gear bushing Figure 6 79 4 Record the measurements See dler Gear Shaft and Bushing on page 6 8 for specifications 4 0 3 2 Figure 6 79 6 50 Cylinder Block Honing and Boring Pistons must move freely in the cylinders while maintaining adequate compression and oil sealing If the cylinder walls are scuffed scored out of round or tapered beyond specifications rebore and hone to restore cylinders to usable condition Slight imperfections can be corrected by honing alone 1 Boring Significant cylinder damage may be corrected by boring the cylinder to an oversize dimension Refer to the appropriate parts catalog for available oversize pistons and piston rings Boring a cylinder should always be done in a properly equipped machine shop A bored cylinder should always be finished with a hone to properly prepare the cylinder surface so the new piston rings will seat properly After the cylinder has been bored and honed install the appropriate oversize pistons and piston rings 2 Honing Minor cylinder imperfections may be corrected by using a rigid cylinder hone Figure 6 81
222. rength classification 7T Apply 60 torque to bolts that are not listed Apply 80 torque when tightened to aluminum alloy 0000023enTNVIDISM CAUTION It is important to perform daily checks Periodic maintenance prevents unexpected downtime reduces the number of accidents due to poor machine performance and helps extend the life of the engine 0000060en e Series Service Manual PERIODIC MAINTENANCE PRECAUTIONS The Importance of Periodic Maintenance Engine deterioration and wear occurs in proportion to length of time the engine has been in service and the conditions the engine is subject to during operation Periodic maintenance prevents unexpected downtime reduces the number of accidents due to poor machine performance and helps extend the life of the engine Performing Periodic Maintenance EXHAUST HAZARD NEVER operate the engine in an enclosed area such as a garage tunnel underground room manhole or ship s hold without proper ventilation NEVER block windows vents or other means of ventilation if the engine is operating in an enclosed area All internal combustion engines create carbon monoxide gas during operation Accumulation of this gas within an enclosure could cause illness or even death Make sure that all connections are tightened to specifications after repair is made to the exhaust system Failure to comply could result in death or ser
223. result in death or serious injury 0000002en 5 7 PERIODIC MAINTENANCE 5 8 BURN HAZARD Keep your hands and other body parts away from hot engine surfaces such as the muffler exhaust pipe turbocharger if equipped and engine block during operation and shortly after you shut the engine down These surfaces are extremely hot while the engine is operating and could seriously burn you Failure to comply could result in death or serious injury 0000015en ALCOHOL AND DRUG HAZARD NEVER operate the engine while you are under the influence of alcohol or drugs NEVER operate the engine when you are feeling ill Failure to comply could result in death or serious injury 0000004en Introduction EXPOSURE HAZARD Wear personal protective equipment such as gloves work shoes eye and hearing protection as required by the task at hand NEVER wear jewelry unbuttoned cuffs ties or loose fitting clothing when you are working near moving rotating parts such as the cooling fan flywheel or PTO shaft ALWAYS tie back long hair when you are working near moving rotating parts such as a cooling fan flywheel or PTO shaft NEVER operate the engine while wearing a headset to listen to music or radio because it will be difficult to hear the alert signals Failure to comply could result in death or serious injury 0000005 Series Serv
224. riodic Maintenance section of this manual Also refer to the Yanmar Co Ltd Limited Emission Control System Warranty USA Only on page 2 6 TNM Series Service Manual Emission Control Labels EMISSION CONTROL LABELS Since emission control regulations are being issued on a global basis it is necessary to identify with which regulations a particular engine complies We have listed several different types of labels you might find on your engine EPA ARB Labels Typical EMISSION CONTROL INFORMATION THIS ENGINE COMPLIES WITH U S EPA REGULATIONS FOR M Y NONROAD DIESEL ENGINES LOW SULFUR FUEL OR ULTRA LOW SULFUR FUEL ONLY ENGINE FAMILY DISPLACEMENT L LITERS ENGINE MODEL EMISSION CONTROL SYSTEM 7 FUEL RATE L JWMSTROKE e Jaw iL RPM REFER TO OWNER S MANUAL FOR MAINTENANCE SPECIFICATIONS AND ADJUSTMENTS YAN MAR CO LTO 021751 00X EPA EMISSION CONTROL INFORMATION THIS ENGINE COMPLIES WITH U S EPA AND CALIFORNIA REGULATIONS FOR 7 M Y NONROAD OFF ROAD DIESEL ENGINES LOW SULFUR FUEL OR ULTRA LOW SULFUR FUEL ONLY ENGINE FAMILY DISPLACEMENT C LITERS ENGINE MODEL EMISSION CONTROL SYSTEM FUEL RATE L JW STROKE L 1 1 REFER TO OWNER S MANUAL FOR MAINTENANCE SPECIFICATIONS AND ADJUSTM
225. rounding area before you remove the cap NEVER mix different types of engine coolants This may adversely affect the properties of the engine coolant 0000006en Engine Coolant Pump TNM Series Service Manual Section 9 LUBRICATION SYSTEM Page Before You Begin 9 3 INTOGUCHOM ep 9 5 Oil Pump Service 000 2 2 1 1 9 5 Engine Oil 44 44 9 5 Outer Rotor Outside 9 5 Outer Rotor Side 9 5 Outer Rotor to Inner Rotor Tip Clearance 9 5 Lubrication System 9 6 OIl deno 9 7 amp 9 7 Disassembly of Oil 9 7 Cleaning and 404000 9 8 Reassembly of Oil 0 2 9 9 TNM Series Service Manual 9 1 LUBRICATION SYSTEM This Page Intentionally Left Blank 9 2 TNM Series Service Manual Before You Begin Servicing BEFORE YOU BEGIN SERVICING CAUTION ia NEVER permit anyone to operate the engine or driven machine without proper training Read and understand this Operation Manual before you operate or service the machine to ensure
226. s it is damaged and requires replacement If the gear must be removed remove it with a gear puller 3 Removal of the camshaft gear requires the camshaft be removed with a press Do not remove the camshaft gear unless it or the camshaft is damaged and requires replacement See Removal of Camshaft on page 6 39 CAUTION Do not loosen or remove the four bolts retaining the fuel injection pump drive gear to the fuel injection pump hub Do not disassemble the fuel injection pump drive gear from the hub Correct fuel injection timing will be very difficult or impossible to achieve 0000031en 4 Do not remove the fuel injection pump drive gear unless absolutely necessary due to damage to the gear or pump Do not loosen or remove the four bolts Figure 6 43 3 retaining pump drive gear to the hub Only remove the nut Figure 6 43 1 and washer Figure 6 43 2 leaving the hub attached to the gear Remove the pump drive gear and hub as an assembly using a gear puller Figure 6 43 CAUTION Do not loosen or remove the four bolts retaining the fuel injection pump drive gear to the fuel injection pump hub Do not disassemble the fuel injection pump drive gear from the hub Correct fuel injection timing will be very difficult or impossible to achieve 0000031en 6 38 Cylinder Block Removal of Oil Pan 1 Invert the engine oil pan up on the engine stand Remove the oil pan Fi
227. s the servicing of the dynamos and alternators Yanmar Part No 129423 77200 alternator is used in this section to show the service procedures for the representative alternator Yanmar Part No 171301 77201 dynamo is used in this section to show the service procedures for the representative dynamo For specific part detail see the Parts Catalog for the engine you are working on STANDARD AND OPTIONAL DYNAMO INFORMATION YANMAR Par Number Mig Wig Pan Number Specification 171301 77201 GP8138 DC12V 15A 119910 77200 GP9191 DC12V 20A STANDARD AND OPTIONAL ALTERNATOR INFORMATION LYANWATPanNumber Wwa Wa PetNumber Specification ALTERNATOR SPECIFICATIONS 11 6 TNM Series Service Manual Dynamo Specifications ALTERNATOR DYNAMO SPECIFICATIONS Operating Range 1400 6600 rom Grounding Characteristics Negative Side of Circuit Outside Diameter of Pulley Belt Shape Type Type Special e Series Service Manual 11 7 8 LL enuey eot ues sanes WNL Turn key switch ON OFF Does battery indicator turn ON y 9N C Start Engine Y At idle does battery indicator turn OFF Increase engine speed to 1500 rpm Turn light switch ON Does battery indicator come ON With engine running at 1500 Disconnect harness L terminal and IG terminal at alterna
228. sconnect the dynamo output wire connector 2 Test continuity between each stator wire terminal and engine ground Results The meter reading should indicate infinity If the meter reading indicates continuity the windings are shorted to ground and the stator must be replaced Testing Dynamo Regulated Output 1 Test and record the battery voltage with the engine OFF 2 Start the engine and operate it at normal operating rpm 3 Check the battery voltage with the engine running Results The meter reading with the engine running must be higher than with the engine not running f results are not correct test the stator for continuity and shorts to the ground Check the charging system wiring f no problems are found in previous checks replace the IC regulator 11 20 Testing of Dynamo DYNAMO Removal of Dynamo 1 Disconnect the output wire connector from the dynamo 2 Loosen the V belt CAUTION PINCH HAZARD Carefully rotate the alternator toward the cylinder block while loosening the V belt Failure to comply may result in minor or moderate injury 0000014en 3 Remove the V belt adjuster from the dynamo bolt Figure 11 23 1 4 Remove the nut Figure 11 23 2 from the gear case stud Remove the dynamo 0002141 Figure 11 23 TNM Series Service Manual Dynamo Disassembly of Dynamo 1 Remove the rear cover Figure
229. sed to set fuel injection timing Make from a short piece of the end of a high pressure fuel line a high pressure fuel line nut and a short piece of clear plastic tubing a thin nozzle from an aerosol spray can works well Drill out the end of the fuel line to accept the nozzle Use a small amount of silicone sealant to seal the nozzle into the fuel line 7 8 TNM Series Service Manual Fuel System Diagram FUEL SYSTEM DIAGRAM 12 11 6 5 7 2 1 Diesel Fuel Supply 2 FuelFilter Water Separator 3 Mechanical Fuel Pump Used in place of the electric fuel pump on some models 4 Electric Fuel Pump Used on models without mechanical fuel pump 5 Low Pressure Fuel Supply Lines e Series Service Manual FUEL SYSTEM 8 10 7 i 1 3 2 0001058 6 Fuel Filter 7 Fuel Injection Pump 8 High Pressure Fuel Injection Lines 9 Fuel Injectors 10 Fuel Return from Fuel Injectors 11 Air Bleed Orifice 12 Fuel Return to Tank 7 9 FUEL SYSTEM FUEL SYSTEM COMPONENTS Fuel System Components 7 10 Figure 7 3 TNM Series Service Manual Fuel Injection Lines 1 Fuel Return Line Nut 2 Fuel Return Line 3 High Pressure Fuel Injection Lines 4 Fuel Return Hose 5 Fuel Return Fitting 6 Fuel Injector 7 Fuel Injection Pump 8 Lock Washer 9 Fuel Inj
230. sembly of Alternator Remove the nut Figure 11 5 1 from the shaft of the rotor assembly Remove the pulley Figure 11 5 2 mal 0000256 Figure 11 5 TNM Series Service Manual Alternator ALTERNATOR 2 Remove the three bolts Figure 11 6 1 5 Remove the bolts retaining the holder retaining the rear cover Figure 11 6 2 to the Figure 11 7 2 to the rear frame housing rear frame assembly Remove the holder 6 Remove the nut Figure 11 7 3 retaining the insulation bushing Figure 11 7 4 Remove the insulation bushing 7 Remove the two bolts Figure 11 8 1 and two nuts Figure 11 8 2 securing the rear frame housing to the front frame housing 0000257A Figure 11 6 3 Remove the brush holder Figure 11 6 3 Remove the brush springs Figure 11 6 4 0000265 brushes Figure 11 6 5 Figure 11 8 4 Remove the bolt retaining the regulator 8 Using a press remove the rotor assembly assembly Figure 11 7 1 to the holder Figure 11 9 1 from the front frame housing Figure 11 7 2 Figure 11 9 2 and rear frame housing Figure 11 10 1 3 100266 11 9 0000258 11 7 e Series Service Manual 11 13 ALTERNATOR 9 Remove the stator assembly Figure 11 10 1 from the front frame housing 00002594 Figure 11 10 10 If itis necessary to repl
231. ssembly being careful not to bend any of the fuel lines Be sure to protect the fuel system from contamination by plugging or covering all open connections 7 Plug or cap all openings to minimize leakage and prevent contamination Installation of High Pressure Fuel Injection Lines Remove or install the high pressure fuel injection lines as an assembly whenever possible Disassembling the high pressure fuel injection lines from the retainers or bending any of the fuel lines will make it difficult to reinstall the fuel lines 0000047en Note To prevent rounding the fuel line nuts always use a line or flare nut wrench 1 Start all the fuel line nuts by hand Then use a wrench to just snug all the fuel line nuts 2 Tighten the fuel line nuts on the fuel injection pump to the specified torque See Special Torque Chart on page 7 7 3 When tightening the fuel line nuts on the fuel injectors use one wrench to hold the fuel return line nut and fuel return line from rotating Use a second wrench to tighten the fuel line nuts Figure 7 5 See Special Torque Chart on page 7 7 Fuel Injection Lines gt 0002237 7 5 Removal of Fuel Return Line 1 Clean the area to keep contaminants from entering the fuel system 2 Remove the high pressure fuel injection lines as an assembly See Removal of High Pressure Fuel Injection Lines on page 7 11 CAUTION The fuel ret
232. stem diameter Measure the valve stem near the combustion end and near the opposite end Figure 6 16 1 Record the measurements See Intake Exhaust Valve and Guide on page 6 6 for the service limit 1 0000197 Figure 6 16 Valve Stem Bend Place the valve stem on a flat inspection block or layout bed Roll the valve until a gap can be observed between a portion of the valve stem and the surface of the block or bed Use a feeler gauge to measure the gap Figure 6 17 Record the measurements See Intake Exhaust Valve and Guide on page 6 6 for the service limit Figure 6 17 e Series Service Manual ENGINE Valve Recession Note The valve guides must be installed to perform this check Insert the valves into their original locations and press them down until they are fully seated Use a depth micrometer Figure 6 18 to measure the difference between the cylinder head gasket surface and the combustion surface of each exhaust and intake valve Figure 6 19 Record the measurements See Cylinder Head on page 6 5 for the service limit QLC sl gomme T Figure 6 18 0001755 Figure 6 19 Valve Face and Valve Seat Always check the clearance between the valve and valve guide before grinding or lapping the valve seats See Intake Exhaust Valve and Guide on page 6 6 for the service limit f the clearance exceeds the limit replace the valve and o
233. sure fuel injection lines See Installation of High Pressure Fuel Injection Lines on page 7 12 Replace the flywheel inspection port cover Prime the fuel system Operate the engine and check for leaks 7 21 FUEL SYSTEM FUEL INJECTORS Removal of Fuel Injectors 1 2 Close any fuel valves in the fuel supply line Clean the area around the fuel injection pump and fuel injectors to keep contaminants from entering the engine or fuel system Remove the high pressure fuel injection lines as an assembly See Removal of High Pressure Fuel Injection Lines on page 7 11 Remove nut Figure 7 27 1 Remove the fuel return line Figure 7 27 2 and copper washer Figure 7 27 3 from the fuel injectors See Removal of Fuel Return Line on page 7 12 Note The fuel injectors used on IDI engines 5 6 7 22 screw into the cylinder head Remove the fuel injectors Figure 7 27 4 0002213 Figure 7 27 Remove the injector nozzle gaskets Figure 7 27 5 and protector Figure 7 27 6 from the cylinder head Fuel Injectors Testing of Fuel Injectors CAUTION Never use a steel wire brush to clean fuel injectors Damage to the nozzle and other components is likely to result 0000172en Thoroughly clean the fuel injector nozzle using clean diesel fuel and a brass wire brush Visually inspect the fuel injectors and nozzle protectors for deposits or damage Clean repair or repla
234. t a typical radiator is shown in Figure 5 10 for illustrative purposes only Blow off dirt and dust from fins and radiator with 28 psi 0 19 MPa 2 kgf cm or less of compressed air Figure 5 10 1 Be careful notto damage the fins with the compressed air If there is a large amount of contamination on the fins apply detergent thoroughly clean and rinse with tap water CAUTION NEVER use high pressure water or compressed air at greater than 28 psi 193 kPa 19 686 mmAq or a wire brush to clean the radiator fins Radiator fins damage easily 0000016en e Series Service Manual PERIODIC MAINTENANCE 0000085A Figure 5 10 Check and Adjust Cooling Fan V Belt Check and adjust the cooling fan V belt every 250 hours of operation after the initial 50 hour V belt maintenance See Check and Adjust Cooling Fan V Belt on page 5 20 Check and Adjust the Governor Lever and Engine Speed Control The governor lever and engine speed control throttle lever accelerator pedal etc are connected together by a cable or linkage If the cable becomes stretched or the linkage wears or loosens the governor lever may not respond to a change in the position of the engine speed control CAUTION NEVER attempt to adjust the low or high idle speed limit screw This may impair the safety and performance of the machine and shorten its life If the idle speed limit screws require adjustm
235. t extend to the following malfunctions caused by abuse misuse improper adjustment modification alteration tampering disconnection improper or inadequate maintenance or use of non recommended fuels and lubricating oils accident caused damage and replacement of expendable items made in connection with scheduled maintenance Yanmar disclaims any responsibility for incidental or consequential damages such as loss of time inconvenience loss of use of equipment engine commercial loss Owner s Warranty Responsibilities As the engine owner you are responsible for the performance of the required maintenance listed in your owner s manual Yanmar recommends that you retain all documentation including receipts covering maintenance on your non road compression ignition engine but Yanmar cannot deny warranty solely for the lack of receipts or for your failure to ensure the performance of all scheduled maintenance Yanmar may deny your warranty coverage of your non road compression ignition engine if a part has failed due to abuse neglect improper maintenance or unapproved modifications Your engine is designed to operate on diesel fuel only Use of any other fuel may result in your engine no longer operating in compliance with applicable emissions requirements You are responsible for initiating the warranty process You must present your engine to a Yanmar dealer as soon as a problem exists The warranty repairs should be completed by t
236. t the time of publishing The illustrations used in this manual are intended as representative reference views only Moreover because of our continuous product improvement policy we may modify information illustrations and or specifications to explain and or exemplify a product service or maintenance improvement We reserve the right to make any change at any time Yanmar and YANMAR are registered trademarks of Yanmar Co Ltd in Japan the United States and or other countries All Rights Reserved No part of this publication may be reproduced or used in any form by any means graphic electronic or mechanical including photocopying recording taping or information storage and retrieval systems without the written permission of Yanmar Co Ltd 2008 Yanmar Co Ltd ii TNM Series Service Manual TABLE CONTENTS Page Table of 2 2 02 iii Introduction oe isch EN CE 1 1 Yanmar eo ei ctor Oen EORR RE ME es 2 1 ec caine ied 3 1 General Service Information 2 4 1 Periodic Maintenance 5 1 LX 6 1 F el Syste 7 1 Cooling SyStel 8 1 Lubrication System ee
237. tat is placed in the cooling system to prevent engine coolant from circulating into the radiator until the engine coolant temperature reaches a preset temperature When the engine is Thermostat cold no engine coolant flows through the radiator Once the engine reaches its operating temperature the thermostat opens By letting the engine warm up as quickly as possible the thermostat reduces engine wear deposits and emissions e Series Service Manual 4 9 GENERAL SERVICE INFORMATION DIESEL FUEL Diesel Fuel Specifications Diesel fuel should comply with the following specifications The table lists several worldwide specifications for diesel fuels Diesel Fuel Specification ASTM D975 No 1D 15 S500 USA No 2D S15 S500 EN590 96 ISO 8217 DMX United BS 2869 A1 or A2 JIS K2204 Grade No 2 KSM 2600 7 Koea GB252 European Union Additional Technical Fuel Requirements The fuel cetane number should be equal to 45 or higher The sulfur content must not exceed 0 596 by volume Less than 0 05 is preferred Especially in U S A and Canada Low Sulfur 800 500mg kg sulfur content or Ultra Low Sulfur fuel should be used Bio Diesel fuels See Bio Diesel Fuels on page 4 10 NEVER mix kerosene used engine oil or residual fuels with the diesel fuel Water and sediment in the fuel should not exceed 0 0596 by volume Keep the fuel tank and fuel handling equipment clean
238. ted by or damaged by any reason other than defective materials or workmanship including but not limited to accident misuse abuse Acts of God neglect improper installation improper maintenance improper storage the use of unsuitable attachments or parts the use of contaminated fuels the use of fuels oils lubricants or fluids other than those recommended in your Yanmar Operation Manual unauthorized alterations or modifications ordinary wear and tear and rust or corrosion This Warranty does not cover the cost of parts and or labor required to perform normal scheduled maintenance on your Yanmar engine This Warranty does not cover consumable parts such as but not limited to filters belts hoses fuel injector nozzles lubricants and cleaning fluids This warranty does not cover the cost of shipping the product to or from the warranty repair facility 2 4 TNM Series Service Manual Yanmar Limited Warranty YANMAR WARRANTIES Yanmar Limited Warranty Continued Warranty Limitations The foregoing is Yanmar s only obligation to you and your exclusive remedy for breach of warranty Failure to follow the requirements for submitting a claim under this Warranty may result in a waiver of all claims for damages and other relief In no event shall Yanmar or any authorized industrial engine dealer or distributor be liable for incidental special or consequential damages Such consequential damages may include but not be
239. th or serious injury 0000009en ENTANGLEMENT HAZARD Stop the engine before you begin to service it NEVER leave the key in the key switch when you are servicing the engine Someone may accidentally start the engine and not realize you are servicing it This could result in a serious injury If you must service the engine while it is operating remove all jewelry tie back long hair and keep your hands other body parts and clothing away from moving rotating parts Failure to comply could result in death or serious injury 0000010en 5 9 PERIODIC MAINTENANCE BURN HAZARD If you must drain the engine oil while it is still hot stay clear of the hot engine oil to avoid being burned ALWAYS wear eye protection Failure to comply could result in death or serious injury 0000011en A CAUTION FLYING OBJECT HAZARD ALWAYS wear eye protection when servicing the engine and when using compressed air or high pressure water Dust flying debris compressed air pressurized water or steam may injure your eyes Failure to comply may result in minor or moderate injury 0000003en Introduction CAUTION COOLANT HAZARD Wear eye protection and rubber gloves when you handle long life or extended life engine coolant If contact with the eyes or skin should occur flush eyes and wash immediately with clean water Failure to comply may result in minor or moderate i
240. that you follow safe operating practices and maintenance procedures Machine safety signs and labels are additional reminders for safe operating and maintenance techniques See your authorized Yanmar industrial engine dealer or distributor for additional training 0000002 e Series Service Manual LUBRICATION SYSTEM ENTANGLEMENT HAZARD Stop the engine before you begin to service it NEVER leave the key in the key switch when you are servicing the engine Someone may accidentally start the engine and not realize you are servicing it This could result in a serious injury If you must service the engine while it is operating remove all jewelry tie back long hair and keep your hands other body parts and clothing away from moving rotating parts Failure to comply could result in death or serious injury 0000010en m iih BEBES p BURN HAZARD Keep your hands and other body parts away from hot engine surfaces such as the muffler exhaust pipe turbocharger if equipped and engine block during operation and shortly after you shut the engine down These surfaces are extremely hot while the engine is operating and could seriously burn you Failure to comply could result in death or serious injury 0000015en 9 3 LUBRICATION SYSTEM FUME BURN HAZARD Always read and follow safety related precautions found on containers of hazardous substances like par
241. the connecting rod as the match marks Figure 6 83 3 stamped into the connecting rod and connecting rod cap When reinstalled in the cylinder the embossed mark Figure 6 83 2 cast into the beam of connecting rod will face the flywheel end of the engine Cylinder Block Note The actual appearance of the match gt A marks will vary but they will always be in the same locations 1 027026 00X 026984 00 0002089 6 83 Place the connecting rod into the piston The match marks Figure 6 84 4 on the connecting rod and cap must be on the opposite side as the piston identification mark Figure 6 84 2 on the top of the piston TNM Series Service Manual Cylinder Block 1 6 2 5 4 0000227A 1 Fuel Injection Pump Side of Engine 2 Piston Identification Mark 3 Embossed Mark on Connecting Rod 4 Connecting Rod and Cap Match Marks 5 Flywheel End of Engine 6 Camshaft Side of Engine Figure 6 84 5 Lubricate and install the wrist pin Figure 6 85 6 through the piston and connecting rod 6 Reinstall the second circlip Figure 6 85 5 and ensure it is securely seated in the groove Note If installing new piston rings the end gap must be checked and adjusted as necessary See Inspection of Pistons Piston Rings and Wrist Pin on page 6 45 Use a piston ring end gap filing tool to adjust the piston ring end ga
242. the gear case stud and the V belt adjuster bolt Figure 11 29 1 2 1 14 11 29 Reconnect the dynamo output wire connector Reinstall the V belt Tighten the V belt to the proper tension See Check and Adjust Cooling Fan V Belt on page 5 27 Start the engine Listen for any unusual sounds from the alternator CAUTION Do not operate the engine if the alternator is producing unusual sounds Damage to the alternator will result 0000039en Verify that the charge indicator is ON while the engine is operating If the charge indicator is not ON repair the problem before operating the engine TNM Series Service Manual Section 12 ELECTRIC WIRING Page Electric Wiring Precautions cost scectennivnettvenetindenvertengeeinurteeayerenntees 12 3 Electric Wire 12 4 Battery Cable 12 5 Electrical Wire Sizes Voltage 12 6 Conversion of AWG to European Standards 12 7 TNM Series Service Manual 12 1 ELECTRIC WIRING 12 2 This Page Intentionally Left Blank TNM Series Service Manual Electric Wiring Precautions ELECTRIC WIRING PRECAUTIONS Failure to follow these precautions may result in the f
243. they are used n Europe bio diesel fuels must comply with the European Standard 14214 Inthe United States bio diesel fuels must comply with the American Standard ASTM D 6751 2 Bio fuels should be purchased only from recognized and authorized diesel fuel suppliers TNM Series Service Manual Diesel Fuel Precautions and concerns regarding the use of bio fuels 1 Free methanol in FAME may result in corrosion of aluminum and zinc FIE components Free water in FAME may result in plugging of fuel filters and increased bacterial growth High viscosity at low temperatures may result in fuel delivery problems injection pump seizures and poor injection nozzle spray atomization FAME may have adverse effects on some elastomers seal materials and may result in fuel leakage and dilution of the engine lubricating oil Even bio diesel fuels that comply with a suitable standard as delivered will require additional care and attention to maintain the quality of the fuel in the equipment or other fuel tanks It is important to maintain a supply of clean fresh fuel Regular flushing of the fuel system and or fuel storage containers may be necessary The use of bio diesel fuels that do not comply with the standards as agreed to by the diesel engine manufacturers and the diesel fuel injection equipment manufacturers or bio diesel fuels that have degraded as per the precautions and conc
244. tons piston rings may be reused if they are found to be within specifications The pistons and piston rings must be reinstalled in the same cylinders from which they were originally removed Onanengine with high hours the pistons rings should be replaced and the cylinder honed See Honing and Boring on page 6 50 or replaced The piston should be replaced as necessary Clean piston ring grooves using a piston ring groove cleaning tool Follow manufacturer s instructions for correct operation Wash the pistons in an appropriate solvent using a soft brush Visually inspect each piston for cracks Pay particular attention to the ring lands between the piston ring grooves Measure the diameter of the piston skirt at 90 to the wrist pin bore as shown Figure 6 63 Measurements must be taken at a specified distance Figure 6 63 1 from the bottom of the piston based on engine model Record the measurements See Piston on page 6 10 for specifications 0000235 Figure 6 63 6 45 5 6 46 Subtract the piston measurement from the greatest measurement acquired during cylinder inspection see Inspection of Cylinder Block on page 6 44 to obtain piston to cylinder clearance Record the measurements See Piston on page 6 10 for specifications Measure the diameter of the wrist pin bore on both sides of the piston Figure 6 64 See Piston on page 6 10 for specifications Record the measurements
245. tor Replace the baitery indicator Battery indicator is available from driven machine manufacturer Inspect rotor assembly and brushes Battery indicator L Battery indicator flashes Ground drive machine side OFF L terminal Does battery indicator turn on ON gt Inspect or replace V belt Inspect alternator __ Battery indicator is dim Inspect diode positive side Battery voltage minus L terminal voltage is Battery indicator is dim With engine idling measure voltage at L terminal and at battery greater than 0 5 volt a Excessive voltage drop between BAT and batt side terminal Battery voltage minus rpm measure voltage at battery Notes 1 Use a fully charged battery Battery voltage greater L terminal voltage is less than 0 5 volt Check condition of L terminal Inspect diode negative side than 15 5 volts Replace regulator Baitery voltage is between 13 and 15 volts With engine idling turn light switch ON Does battery indicator come ON 2 DC voltmeter 0 to 30 V 0 5 class 3 The check method is also applicable to the bench test Inspect auxiliary diode OFF
246. ts 6 40 Inspection of Crankshaft and Camshaft Components 6 44 Reconditioning the Crankshaft sse 6 49 Honing e RE ERE ER da gos 6 50 Reassembly of Crankshaft and Piston Components 6 51 Reassembly of Camshaft and Timing Components 6 57 6 2 TNM Series Service Manual Before You Begin Servicing ENGINE BEFORE YOU BEGIN SERVICING FUME BURN HAZARD Always read and follow safety related precautions found on containers of hazardous substances like parts cleaners primers sealants and sealant removers To prevent possible eye injury always wear SAFETY GLASSES while servicing the engine f Failure to comply could result in death or serious injury 0000013en 0000014en A CAUTION ENTANGLEMENT HAZARD Stop the engine before you begin to service it NEVER leave the key in the key switch FLYING OBJECT HAZARD when you are servicing the engine ALWAYS wear eye protection when Someone may accidentally start the servicing the engine and when using engine and not realize you are compressed air or high pressure servicing it This could result in a water Dust flying debris compressed serious injury air pressurized water or steam may If you must service the engine while it injure your eyes is operating remove all jewelry tie Failure to comply may result in minor back lo
247. ts cleaners primers sealants and sealant removers Failure to comply could result in death or serious injury 0000014en A CAUTION FLYING OBJECT HAZARD ALWAYS wear eye protection when servicing the engine and when using compressed air or high pressure water Dust flying debris compressed air pressurized water or steam may injure your eyes Failure to comply may result in minor or moderate injury 0000003en 9 4 Before You Begin Servicing CAUTION Only use the engine oil specified Other engine oils may affect warranty coverage cause internal engine components to seize and or shorten engine life Prevent dirt and debris from contaminating the engine oil Carefully clean the oil cap dipstick and the surrounding area before you remove the cap NEVER mix different types of engine oil This may adversely affect the lubricating properties of the engine oil NEVER overfill Overfilling may result in white exhaust smoke engine overspeed or internal damage 0000005en CAUTION If the oil pump must be replaced replace it as an assembly only Do not replace individual components 0000030en TNM Series Service Manual Introduction LUBRICATION SYSTEM INTRODUCTION This section of the Service Manual describes the procedures necessary to service the 3TNM68 and 2 trochoid oil pumps Note See Replace Engine and Engine Oil Filter on page 5 26 for engine
248. ty Retail Purchaser Registration It is very important for the original retail purchaser to register the Yanmar product Registration enables Yanmar to provide the best support for your Yanmar product As soon as possible after the purchase of your engine Yanmar highly recommends that you use the following website to register your purchase http www yanmar co jp If it is not possible to access the web site please contact the nearest Yanmar dealer or distributor e Series Service Manual 2 5 YANMAR WARRANTIES Emission System Warranty EMISSION SYSTEM WARRANTY YANMAR LTD LIMITED EMISSION CONTROL SYSTEM WARRANTY USA ONLY Your Warranty Rights and Obligations California The California Air Resources Board CARB the Environmental Protection Agency EPA and Yanmar Co Ltd hereafter referred to as Yanmar are pleased to explain the emission control system warranty on your industrial compression ignition engine In California model year 2000 or later off road compression ignition engines must be designed built and equipped to meet the State s stringent anti smog standards In all states 1998 and later non road compression ignition engines must be designed built and equipped to meet the United States EPA emissions standards Yanmar warrants the emission control system on your engine for the periods of time listed below provided there has been no abuse neglect or improper maintenance of your
249. ure 10 6 ae 4 Figure 10 8 00001484 12 Pull the pinion stop Figure 10 9 1 down to expose the retaining ring Using a flat blade screwdriver remove the retaining ring Figure 10 9 2 from the pinion shaft 0000143 Figure 10 6 7 Remove the brush plate and holder Figure 10 7 1 0000151 10 9 0000144A Figure 10 7 8 Pull the field assembly Figure 10 7 3 off from the armature assembly Figure 10 7 2 9 Remove the armature from the intermediate housing 10 Remove the intermediate housing gear and pinion shaft assembly Figure 10 8 4 from the pinion housing Figure 10 8 3 Disengage from the shift lever as it is removed e Series Service Manual 10 11 STARTER MOTOR 13 Remove the pinion stop Figure 10 10 3 return spring if equipped and pinion clutch assembly Figure 10 10 2 from the pinion shaft Figure 10 10 1 2 4 3 Figure 10 10 0000152B 14 Remove the snap ring Figure 10 11 1 Remove the pinion shaft Figure 10 11 5 planetary gears Figure 10 11 6 washers and reduction gear Figure 10 11 4 from the intermediate housing Figure 10 11 3 4 0002487 10 11 10 12 Starter Motor 15 Inspect the intermediate bushing Figure 10 11 2 and replace if worn or damaged 16 Inspect armature bushing Figure 10 11 7 and replace
250. urn line is a one piece assembly Use care not to bend or twist the fuel return line 0000171en Figure 7 6 3 Remove all fuel return line nuts Figure 7 6 2 from the injectors Figure 7 6 4 TNM Series Service Manual Fuel Injection Pump 4 Remove the fuel return hose from the fuel return fitting on the fuel injection pump 5 Carefully remove the fuel return line assembly Figure 7 6 3 6 Remove and discard the copper gasket Figure 7 6 1 from each fuel injector 7 Plug or cap all openings to minimize leakage and prevent contamination Installation of Fuel Return Line 1 Install a new copper gasket on each fuel injector CAUTION The fuel return line is a one piece assembly Use care not to bend or twist the fuel return line 0000171 2 Carefully reinstall the fuel return line assembly 3 Reinstall and hand tighten the fuel return line nuts 4 Tighten the fuel return line nuts to the specified torque See Special Torque Chart on page 7 7 5 Reinstall the fuel return hose 6 Reinstall the high pressure fuel injection line assembly See Installation of High Pressure Fuel Injection Lines on page 7 12 FUEL INJECTION PUMP Removal of Fuel Injection Pump 1 Loosen the cooling fan V belt 2 Remove the engine cooling fan guard if equipped engine cooling fan Figure 7 7 2 spacer Figure 7 7 3 if equipped V pulley Figure 7 7 4 and
251. ut the float Figure 5 7 7 and retaining spring Figure 5 7 6 inside the cup 9 Reinstall the cup to the mounting flange Figure 5 7 8 and turn the retaining ring Figure 5 7 4 to the right Figure 5 7 5 Hand tighten only 10 Open the fuel cock Figure 5 7 3 11 Be sure to prime the fuel system See Priming the Fuel System on page 4 13 12 Check for fuel leaks If the fuel filter water separator is positioned higher than the fuel level in the fuel tank water may not drip out when the fuel filter water separator drain cock is opened If this happens turn the air vent screw on the top of the fuel filter water separator 2 3 turns counterclockwise Be sure to tighten the air vent screw after the water has drained out 0000025en Check Battery DANGER EXPLOSION HAZARD NEVER check the remaining battery charge by shorting out the terminals This will result in a spark and may cause an explosion or fire Use a hydrometer to check the remaining battery charge If the electrolyte is frozen slowly warm the battery before you recharge it Failure to comply will result in death or serious injury 0000007en PERIODIC MAINTENANCE BURN HAZARD Batteries contain sulfuric acid NEVER allow battery fluid to come in contact with clothing skin or eyes Severe burns could result ALWAYS wear safety goggles and protective clothing when servicing the battery If battery
252. valve allows excess fuel to be returned back to the fuel tank The fuel tank is a required engine component The mechanical fuel pump is a diaphragm type of pump and is installed on the fuel injection pump body The mechanical fuel pump is standard equipment on some engine models and is driven by a cam on the camshaft of the fuel injection pump The mechanical fuel pump is not installed on the fuel injection pump if the electric fuel pump is installed You can fill the crankcase with engine oil from either the side or top filler port depending upon which one is most convenient The starter motor is powered by the battery When you turn the key switch in the operator s console to the START position the starter motor engages with the ring gear installed on the flywheel and starts the flywheel in motion TNM Series Service Manual Function of Cooling System Components GENERAL SERVICE INFORMATION FUNCTION OF COOLING SYSTEM COMPONENTS The TNM engine is liquid cooled by means of a cooling system The cooling system consists of a radiator radiator cap engine cooling fan engine coolant pump thermostat and reserve tank Note that all cooling system components are required for proper engine operation Since some of the components are application specific they must be carefully selected by an application engineer The application specific items are not part of the basic engine package as shipped from the Yanmar factory
253. ve or attempt to remove the tamper proof devices from the full load fuel adjusting screw or the high speed throttle limit screw on the fuel injection pump and governor assembly These adjustments have been made at the factory to meet all applicable emissions regulations and then sealed NEVER attempt to make any adjustments to these sealed adjustment screws If adjustments are required they can be made only by a qualified fuel injection shop that will ensure the injection pump continues to meet all applicable emissions regulations and then replace the tamper proof seals Tampering with or removing these devices may void the Yanmar Limited Warranty 0000146en The fuel injector is essentially a spring loaded valve When fuel pressure from the fuel injection pump reaches a pre determined level the pintle valve is forced off its seat and fuel is atomized as it passes between the pintle and seat The timing and quantity of the fuel injected into the cylinder is controlled by the fuel injection pump and governor assembly 7 6 Introduction Stop Solenoid The ML fuel injection pumps are equipped with a stop solenoid that controls the fuel flow inside the fuel injection pump With the starter switch in the OFF position no current flows to the stop solenoid and the solenoid plunger is extended holding the fuel injection pump fuel rack in the closed position and not allowing fuel to flow through the injectio
254. vernmental agencies for the proper disposal of hazardous materials such as engine oil diesel fuel and engine coolant Consult the local authorities or reclamation facility NEVER dispose of hazardous materials irresponsibly by dumping them into a sewer on the ground or into ground water or waterways Failure to follow these procedures may seriously harm the environment 0000013en Note that a typical fuel tank is illustrated 1 Position an approved container under the diesel fuel tank Figure 5 9 1 to collect the contaminates 0000065 5 9 Remove the fuel Figure 5 9 3 3 Remove the drain plug Figure 5 9 2 of the fuel tank to drain the contaminates water dirt etc from the bottom of the tank PERIODIC MAINTENANCE 4 Drain the tank until clean diesel fuel with no water or dirt flows out Reinstall and tighten the drain plug firmly 5 6 Reinstall the fuel cap Check for fuel leaks Replace Engine Oil and Engine Oil Filter CAUTION 5 26 Only use the engine oil specified Other engine oils may affect warranty coverage cause internal engine components to seize and or shorten engine life Prevent dirt and debris from contaminating the engine oil Carefully clean the oil cap dipstick and the surrounding area before you remove the cap NEVER mix different types of engine oil This may adversely affect the lubricating properties of the en
255. vice Manual Safety Precautions Ail Gi 5 BURN HAZARD If you must drain the engine oil while it is still hot stay clear of the hot engine oil to avoid being burned ALWAYS wear eye protection Failure to comply could result in death or serious injury 000001 1en BURN HAZARD Batteries contain sulfuric acid NEVER allow battery fluid to come in contact with clothing skin or eyes Severe burns could result ALWAYS wear safety goggles and protective clothing when servicing the battery If battery fluid contacts the eyes and or skin immediately flush the affected area with a large amount of clean water and obtain prompt medical treatment Failure to comply could result in death or serious injury 0000007en e Series Service Manual SAFETY HIGH PRESSURE HAZARD Avoid skin contact with the high pressure diesel fuel spray caused by a fuel system leak such as a broken fuel injection line High pressure fuel can penetrate your skin and result in serious injury If you are exposed to high pressure fuel spray obtain prompt medical treatment NEVER check for a fuel leak with your hands ALWAYS use a piece of wood or cardboard Have your authorized Yanmar industrial engine dealer or distributor repair the damage Failure to comply could result in death or serious injury 0000008en SHOCK HAZARD Turn off the battery switch if equipped or disconnect the n
256. vice Manual LUBRICATION SYSTEM 1 2 Figure 9 8 Reassembly of Oil Pump 1 Apply clean lubricating to the lubricating pump body and inner rotor assembly as well as to the outer rotor Insert the outer rotor into the lubricating oil pump body and inner rotor assembly and install the cover Replace the packing with new one Install the lubricating oil pump assembly to the gear case flange by tightening the bolts with the specified torque Install the gear case cover For more information See Installation of Gear Case Cover on page 6 59 Install the crank shaft pulley Install the cooling water pump V pulley Figure 9 9 1 spacer Figure 9 9 2 cooling water fan Figure 9 9 3 and fan guard if equipped 9 9 LUBRICATION SYSTEM 027030 00X Figure 9 9 8 Install the V belt Adjust the belt to uniform tensile strength in accordance with the instructions given in Check and Adjust Cooling Fan V Belt on page 5 20 Trochoid Oil Pump TNM Series Service Manual Section 10 STARTER MOTOR Before You Begin 10 3 IMTFOGUCI OM cp EET 10 5 Starter Motor Information 10 5 Starter Motor Specifications 222 10 6 Starter Motor 1 10 7 Starter Motor 10 8 Starter nica tote ori
257. w safety related precautions found on containers of hazardous substances like parts cleaners primers sealants and sealant removers Failure to comply could result in death or serious injury 0000014en 8 3 COOLING SYSTEM Before You Begin Servicing CAUTION E PINCH HAZARD Carefully rotate the alternator toward the cylinder block while loosening the V belt Failure to comply may result ALWAYS wear eye protection minor or moderate injury Failure to comply could result in death 0000014 or serious injury 000001 1en CAUTION A Only use the engine coolant specified CAUTION Other engine coolants may affect warranty coverage cause an internal buildup of rust and scale and or shorten engine life BURN HAZARD If you must drain the engine oil while it is still hot stay clear of the hot engine oil to avoid being burned Prevent dirt and debris from contaminating the engine coolant Carefully clean the radiator cap and FLYING OBJECT HAZARD the surrounding area before you ALWAYS wear eye protection when remove the cap servicing the engine and when using NEVER mix different types of engine compressed air or high pressure coolants This may adversely affect the water Dust flying debris compressed properties of the engine coolant air pressurized water or steam may injure your eyes Failure to comply may result in minor
258. will impair the engine s safety and performance characteristics shorten the engine s life and may affect the warranty coverage on your engine See Yanmar Warranties section Consult your authorized Yanmar dealer or distributor for assistance when checking items marked with a e 0000024enTNVIDISM Introduction CAUTION If the fuel filter water separator is positioned higher than the fuel level in the fuel tank water may not drip out when the fuel filter water separator drain cock is opened If this happens turn the air vent screw on the top of the fuel filter water separator 2 3 turns counterclockwise Be sure to tighten the air vent screw after the water has drained out 0000025en CAUTION When the engine is operated in dusty conditions clean the air cleaner element more frequently NEVER operate the engine with the air cleaner element s removed This may allow foreign material to enter the engine and damage it 0000026en CAUTION The maximum air intake restriction in terms of differential pressure measurement must not exceed 0 90 psi 6 23 kPa 635 mmAq Clean or replace the air cleaner element if the air intake restriction exceeds the above mentioned value 0000046en TNM Series Service Manual Precautions CAUTION The tightening torque in the Standard Torque Chart in General Service Information should be applied only to the bolts with a 7 head JIS st
259. within the value indicated in the Battery Cable Resistance chart in the Electric Wiring Section of this manual The starter motor will malfunction and fail if the resistance is higher than the specified value 0000057en CAUTION Removing the battery cables or the battery while the engine is operating may cause damage to the current limiter depending on the electrical equipment being used This situation could cause loss of control of output voltage The continuous high voltage of 23 24 volts for 5000 rpm dynamo will damage the current limiter and other electrical equipment 0000058en CAUTION Reversing the battery cable connections at the battery or on the engine will destroy the SCR diode in the current limiter This will cause the charging system to malfunction and may cause damage to the electrical harnesses 0000059en CAUTION It is important to perform daily checks Periodic maintenance prevents unexpected downtime reduces the number of accidents due to poor machine performance and helps extend the life of the engine 0000060en TNM Series Service Manual Safety Precautions CAUTION NEVER attempt to modify the engine s design or safety features such as defeating the engine speed limit control or the diesel fuel injection quantity control Modifications may impair the engine s safety and performance characteristics and shorten the engine s life Any alterations to this engi
260. y are lost or damaged Also if you need indicates a potentially hazardous to replace a part that has a label attached to it situation that can cause damage to the make sure you order the new part and label at the machine personal property and or the same time environment or cause the machine to operate improperly This safety alert symbol appears nooacoten with most safety statements It means attention become alert your safety is involved Please read and abide by the message that follows the safety alert symbol A DANGER Danger the word DANGER is in white letters with a red rectangle behind it indicates an imminently hazardous situation which if not avoided will result in death or serious injury Danger is limited to the most extreme situations 0000001en Warning the word WARNING is in black letters with an orange rectangle behind it indicates a potentially hazardous situation which if not avoided could result in death or serious injury 0000001en e Series Service Manual 3 3 SAFETY SAFETY PRECAUTIONS A DANGER SCALD HAZARD NEVER remove the radiator cap if the engine is hot Steam and hot engine coolant will spurt out and seriously burn you Allow the engine to cool down before you attempt to remove the radiator cap Tighten the radiator cap securely after you check the radiator Steam can spurt out during engine operation if the cap is loos
261. yes or skin should occur flush eyes and wash immediately with clean water Failure to comply may result in minor or moderate injury 0000005en 5 34 Periodic Maintenance Procedures CAUTION ALWAYS be environmentally responsible Follow the guidelines of the EPA or other governmental agencies for the proper disposal of hazardous materials such as engine oil diesel fuel and engine coolant Consult the local authorities or reclamation facility NEVER dispose of hazardous materials irresponsibly by dumping them into a sewer on the ground or into ground water or waterways Failure to follow these procedures may seriously harm the environment 0000013en Engine coolant contaminated with rust or scale reduces the cooling effect Even when extended life engine coolant is properly mixed the engine coolant gets contaminated as its ingredients deteriorate Drain flush and refill the cooling system with new coolant every 1000 hours or once a year whichever comes first 1 2 Allow engine and coolant to cool Remove the radiator cap Figure 5 16 1 Remove the drain plug or open the drain cock Figure 5 16 2 at the lower position of the radiator and drain the engine coolant TNM Series Service Manual Periodic Maintenance Procedures 0000074A Figure 5 16 4 Drain the coolant from the engine block Remove the coolant drain plug Figure 5 17 0006464 Figure 5 17

SERVICE MANUAL - Martin Diesel Inc

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