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FUEL SYSTEM

7-14

TNV IDI Service Manual

Fuel Injection Pump

NOTICE

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.

Figure 7-11

NOTICE

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.

15. 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.

Figure 7-12

16. Hold the gear train stationary using a large

socket wrench on the crankshaft pulley bolt.
Loosen the fuel injection pump drive gear
retaining nut

(Figure 7-12, (1))

and turn it out to

the end of the fuel injection pump shaft.

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 from the gear case; however, it
is best to let it remain in the gear case.

(1)

0002096

(1)

(3)

(2)

0002209

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Summary of Contents for 2TNV70

Page 1: ...0BTNV G00202 PRINTED IN JAPAN 2TNV70 3TNV70 3TNV76 INDUSTRIAL ENGINES SERVICE MANUAL INDUSTRIAL ENGINES 2TNV70 3TNV70 3TNV76 SERVICE MANUAL ...

Page 2: ...ake any change at any time without notice YANMAR and 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 informa tion storage and retrieval systems without the written permission of YA...

Page 3: ...ar Warranties 2 1 Safety 3 1 General Service Information 4 1 Periodic Maintenance 5 1 Engine 6 1 Fuel System 7 1 Cooling System 8 1 Lubrication System 9 1 Starter Motor 10 1 Alternator 11 1 Electric Wiring 12 1 Troubleshooting 13 1 TNV_IDI_ServiceManual_A4 book i ページ２０１２年２月２４日金曜日午前１０時２４分 ...

Page 4: ...TABLE OF CONTENTS ii TNV DI Service Manual This Page Intentionally Left Blank TNV_IDI_ServiceManual_A4 book ii ページ２０１２年２月２４日金曜日午前１０時２４分 ...

Page 5: ...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 Yanma...

Page 6: ...INTRODUCTION 1 2 TNV IDI Service Manual This Page Intentionally Left Blank TNV_IDI_ServiceManual_A4 book 2 ページ２０１２年２月２４日金曜日午前１０時２４分 ...

Page 7: ... What Yanmar Will Do 2 4 What is Not Covered by this Warranty 2 4 Warranty Limitations 2 5 Warranty Modifications 2 5 Questions 2 5 Retail Purchaser Registration 2 5 Emission System Warranty 2 6 Yanmar Co Ltd Limited Emission Control System Warranty USA Only 2 6 Your Warranty Rights and Obligations 2 6 Manufacturer s Warranty Period 2 6 Warranty Coverage 2 7 Warranted Parts 2 7 Exclusions 2 8 Owne...

Page 8: ...YANMAR WARRANTIES 2 2 TNV IDI Service Manual This Page Intentionally Left Blank TNV_IDI_ServiceManual_A4 book 2 ページ２０１２年２月２４日金曜日午前１０時２４分 ...

Page 9: ...rovided for these specific parts only the cylinder block cylinder head crankshaft forging connecting rods flywheel flywheel housing camshaft timing gear and gear case The Warranty Period for both the standard limited warranty and the extended limited warranty by duration or operation hours begins on the date of delivery to the original retail purchaser and is valid only until the applicable warran...

Page 10: ... Yanmar product covered by this Warranty found to be defective in material and or workmanship Such repairs and or replacements will be made at a location designated by Yanmar at no cost to the purchaser for parts or labor What is Not Covered by this Warranty This Warranty does not cover parts affected by or damaged by any reason other than defective materials or workmanship including but not limit...

Page 11: ...d 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 al...

Page 12: ... warranted for the periods listed below If any emission related part on your engine is found to be defective during the applicable warranty period the part will be replaced by Yanmar Engine Type Warranty Period by Number of Years or Hours of Operation Constant speed engines rated at or above 50 hp SAE 37 kW The warranty period is five 5 years or 3 000 hours of use whichever occurs first In the abs...

Page 13: ... 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 disall...

Page 14: ...commends 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 imprope...

Page 15: ...TNV IDI Service Manual 3 1 TNV IDI Service Manual Section 3 SAFETY Page Safety Statements 3 3 Safety Precautions 3 4 TNV_IDI_ServiceManual_A4 book 1 ページ２０１２年２月２４日金曜日午前１０時２４分 ...

Page 16: ...SAFETY 3 2 TNV IDI Service Manual This Page Intentionally Left Blank TNV_IDI_ServiceManual_A4 book 2 ページ２０１２年２月２４日金曜日午前１０時２４分 ...

Page 17: ... an imminently hazardous situation which if not avoided will result in death or serious injury Danger is limited to the most extreme situations WARNING 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 CAUTION Caution the word CAUTION is in black letters with a yel...

Page 18: ...onditions 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...

Page 19: ... 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 DANGER CRUSH HAZARD...

Page 20: ...quired 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 b...

Page 21: ... Yanmar industrial engine dealer or distributor repair the damage Failure to comply could result in death or serious injury WARNING 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 F...

Page 22: ...ON Be sure to secure the engine solidly to prevent injury or damage to parts due to the engine falling during work on the engine 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 CAUTION If any oil pump component clearance exceeds its limit the oil pump must be replaced as an assembly N...

Page 23: ...gine wear The standard range of ambient temperatures for the normal operation of Yanmar engines is from 5 F 15 C to 113 F 45 C If the ambient temperature exceeds 113 F 45 C the engine may overheat and cause the engine oil to break down If the ambient temperature 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 engin...

Page 24: ... 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 environme...

Page 25: ...re not listed Apply 80 torque when tightened to aluminum alloy NOTICE 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 eng...

Page 26: ... OFF while the engine is operating Damage to the alternator will result NOTICE Do not operate the engine if the alternator is producing unusual sounds Damage to the alternator will result NOTICE 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 NOTICE Use a new special O ...

Page 27: ...normally high voltage and destroy electrical equipment NOTICE 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 ...

Page 28: ...en though the part currently meets the service standard limit NOTICE 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 adjustmen...

Page 29: ...ion 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 TNV_IDI_ServiceManual_A4 book 15 ページ２０１２年２月２４日金曜日午前１０時２４分 ...

Page 30: ...SAFETY 3 16 TNV IDI Service Manual Safety Precautions This Page Intentionally Left Blank TNV_IDI_ServiceManual_A4 book 16 ページ２０１２年２月２４日金曜日午前１０時２４分 ...

Page 31: ... Diesel Fuel 4 9 Diesel Fuel Specifications 4 9 Filling the Fuel Tank 4 13 Priming the Fuel System 4 14 Engine Oil 4 15 Engine Oil Specifications 4 15 Service Categories 4 15 Engine Oil Viscosity 4 15 Checking Engine Oil 4 15 Adding Engine Oil 4 16 Engine Oil Capacity Typical 4 16 Engine Coolant 4 17 Engine Coolant Specifications 4 18 Filling Radiator with Engine Coolant 4 18 Engine Coolant Capaci...

Page 32: ...orques for Standard Bolts and Nuts 4 26 Abbreviations and Symbols 4 28 Abbreviations 4 28 Symbols 4 28 Unit Conversions 4 29 Unit Prefixes 4 29 Units of Length 4 29 Units of Volume 4 29 Units of Mass 4 29 Units of Force 4 29 Units of Torque 4 29 Units of Pressure 4 29 Units of Power 4 29 Units of Temperature 4 29 TNV_IDI_ServiceManual_A4 book 2 ページ２０１２年２月２４日金曜日午前１０時２４分 ...

Page 33: ...et 10 Mechanical Fuel Pump If Equipped 11 Fuel Priming Lever 12 Dipstick Engine Oil 13 Engine Oil Filter 14 Governor Lever 15 Fuel Injection Pump 16 Intake Manifold 17 Air Intake Port From Air Cleaner 18 Fuel Filter 19 Fuel Return To Fuel Tank 20 Top Filler Port Engine Oil 21 Rocker Arm Cover 22 Flywheel 23 Starter Motor 24 Exhaust Manifold 25 Alternator Figure 4 1 Engine oil drain plug location m...

Page 34: ...ources Board ARB California regulations Only engines that conform to ARB regulations can be sold in the State of California Refer to the specific EPA ARB installation page 5 4 and maintenance page 5 4 in the Periodic Maintenance section of this manual Also refer to theYanmar Co Ltd Limited Emission Control System Warranty USA Only on page 2 6 EMISSION CONTROL LABELS Since emission control regulati...

Page 35: ...RMATION ULTRA LOW SULFUR FUEL ONLY THIS ENGINE COMPLIES WITH U S EPA REGULATIONS FOR M Y NONROAD AND STATIONARY DIESEL ENGINES ENGINE FAMILY DISPLACEMENT LITERS ENGINE MODEL E C S FUEL RATE MM3 STROKE kW RPM PM 0 30g kWh REFER TO OWNER S MANUAL FOR MAINTENANCE SPECIFICATIONS AND ADJUSTMENTS EMISSION CONTROL INFORMATION ENGINE FAMILY DISPLACEMENT LITERS ENGINE MODEL E C S FUEL RATE MM3 STROKE kW RP...

Page 36: ...conds to prime the fuel system Engine Oil Filter The engine oil filter removes contaminants and sediments from the engine oil Periodic replacement of the engine oil filter is necessary See the Periodic Maintenance Schedule on page 5 5 for the replacement frequency Fuel Filter The fuel filter removes contaminants and sediments from the diesel fuel Periodic replacement of the fuel filter is necessar...

Page 37: ...Fuel Pump 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 Side and Top Filler Port Engine Oil You can f...

Page 38: ...radiator As the engine cooling fan circulates air through the radiator the heat is transferred to the air Radiator Cap The radiator cap controls the cooling system pressure The cooling system is pressurized to raise the boiling point of the engine coolant As the engine coolant temperature rises the system pressure and the coolant volume increases When the pressure reaches a preset value the releas...

Page 39: ...ity 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 01 by volume Carbon residue content not to exceed 0 35 by volume Less than 0 1 is preferred Total aromatics content should not exceed 35 by volume Less than 30 i...

Page 40: ...han B5 can have an adverse affect on the engine s performance its integrity and or durability The risk of problems occurring in the engine increases as the level of biodiesel blend increases The following negative affects are exemplary and typical for the usage of high concentrated biodiesel blends Biodiesel can accelerate the oxidation of Aluminum Brass Bronze Copper and Zinc Biodiesel damages an...

Page 41: ...e fuel tank b It is required to inspect clean and adjust the fuel injector every 1000 operating hours c Replacement of the following parts before using the recommended biodiesel Fuel hose Fuel feed pump Diaphragm type If not already installed a water separator needs to be built in O ring of fuel filter O ring of water separator Please refer to the attached list of exchange parts for details d Plea...

Page 42: ...N PUMP FUEL OIL FILTER No 8 11 Length 320 450 Part No 119546 59210 119546 59220 Part Name FO T CMP FO T CMP Number 1 1 CAP FUEL INJECTION NOZZLE Part No NO NEED NO NEED Part Name Number FUEL INJECTION NOZZLE FUEL INJECTION NOZZLE No NO NEED NO NEED Length Part No Part Name Number FUEL INJECTION NOZZLE FUEL INJECTION PUMP No 16 16 Length 150 150 Part No 119546 59300 119546 59300 Part Name FO T CMP ...

Page 43: ...on or shortly after shutdown 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 o...

Page 44: ...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 star...

Page 45: ...il storage containers and engine oil filling equipment are free of sediments and water 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 Additio...

Page 46: ...sociated 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 4 5 1 0000587C 4 2 3 Engine Model Dipstick Upper Limit Lower Limit 2TNV70 VM 2TNV70 VH 1 9 1 ...

Page 47: ...engine coolant may splash and burn you Failure to comply could result in death or serious injury 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 NOTICE Only use the engine coola...

Page 48: ...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 Figure 4 7 1 Check to be sure the radiator drain plug is installed and tighten...

Page 49: ...hen 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 radiat...

Page 50: ...iable Medium Speed CH Constant High Speed CL Constant Low Speed 3 TNV 76 T 0 0000 Customer Code Rated rpm Turbocharged No symbol indicates naturally aspirated Cylinder Bore mm Engine Series No of Cylinders Notation Available Engine Speed Intended Uses VH 3200 3600 rpm min 1 Lawn Mower Construction Industrial Machine VM 2000 3000 rpm min 1 Agricultural Constructive Industrial Machines CH 3000 3600 ...

Page 51: ...c 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 PS 0 7355 kW 1 hp SAE Society of Automotive Engineers 0 7457 kW Type Vertical In line Water Cooled 4 Cycle Diesel Engine Combustion System Swirl Chamber Ball Type Starti...

Page 52: ...g System Liquid Cooled with Radiator Lubricating System Forced Lubrication with Trochoid Pump Normal Oil Pressure at Rated Engine Speed 42 64 psi 0 29 0 44 MPa 2 96 4 49 kgf cm2 Normal Oil Pressure at Low Idle Speed 8 5 psi 0 06 MPa 0 6 kgf cm2 or greater Starting System Electric Starting Starter Motor DC12V 1 3 hp 1 0 kW Dynamo DC12V 20A Recommended Battery Capacity 12V 36 Amp Hour 5h rating Dime...

Page 53: ...stem Liquid Cooled with Radiator Lubricating System Forced Lubrication with Trochoid Pump Normal Oil Pressure at Rated Engine Speed 35 51psi 0 24 0 35 MPa 2 44 3 57 kgf cm2 42 64 psi 0 29 0 44 MPa 2 96 4 49 kgf cm2 Normal Oil Pressure at Low Idle Speed 8 5 psi 0 06 MPa 0 6 kgf cm2 or greater Starting System Electric Starting Starter Motor DC12V 1 3 hp 1 0 kW Dynamo DC12V 20A Recommended Battery Ca...

Page 54: ...ling System Liquid Cooled with Radiator Lubricating System Forced Lubrication with Trochoid Pump Normal Oil Pressure at Rated Engine Speed 35 51psi 0 24 0 35 MPa 2 44 3 57 kgf cm2 42 64 psi 0 29 0 44 MPa 2 96 4 49 kgf cm2 Normal Oil Pressure at Low Idle Speed 8 5 psi 0 06 MPa 0 6 kgf cm2 or greater Starting System Electric Starting Starter Motor DC12V 1 5 hp 1 1 kW Alternator DC12V 40A Recommended...

Page 55: ...ion Pressure at 250 rpm 250 min 2TNV70 3TNV70 470 15 psi 3 24 0 1MPa 33 1 kgf cm 370 15 psi 2 55 0 1 MPa 26 1 kgf cm 3TNV76 498 15 psi 3 43 0 1MPa 35 1 kgf cm 399 15 psi 2 75 0 1 MPa 28 1 kgf cm Lubricating Oil Pressure At rated output 42 64 psi 0 29 0 44 MPa 2 96 4 49 kgf cm2 When idling 8 5 psi 0 06 MPa 0 6 kgf cm2 or greater Thermostat Valve Opening Temperature Full Opening Lift Temperature 157...

Page 56: ... 80 torque when tightened to aluminum alloy Item Nominal Thread Diameter x Pitch Tightening Torque Remarks Hexagon Bolt 7T and Nut M6 x 1 0 mm 87 104 in lb 9 8 11 8 N m 1 0 1 2 kgf m Use 80 of the value at left when the tightening part is aluminum Use 60 of the value at left for 4T bolts and lock nuts M8 x 1 25 mm 200 251 in lb 22 6 28 4 N m 2 3 2 9 kgf m M10 x 1 5 mm 33 40 ft lb 44 1 53 9 N m 4 5...

Page 57: ...ss otherwise specified Pipe Joint Bolt M8 112 148 in lb 12 7 16 7 N m 1 3 1 7 kgf m M10 173 225 in lb 19 6 18 734 N m 2 0 3 5 kgf m M12 18 25 ft lb 24 5 34 3 N m 2 5 3 5 kgf m M14 29 36 ft lb 39 2 49 0 N m 4 0 5 0 kgf m M16 36 43 ft lb 49 0 58 8 N m 5 0 6 0 kgf m Item Nominal Thread Diameter x Pitch Tightening Torque Remarks TNV_IDI_ServiceManual_A4 book 27 ページ２０１２年２月２４日金曜日午前１０時２４分 ...

Page 58: ...oot pound ft lbf min foot pound force per minute g gram gal hr gallon U S per hour gal gallon U S GL gear lubricant hp horsepower U S hrs hours I D inside diameter IDI indirect injection in inch in lb 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 L liter L hr lit...

Page 59: ...lb g x 0 03527 oz lbf x 4 4480 N lbf x 0 4536 kgf N x 0 2248 lbf N x 0 1020 kgf kgf x 2 2050 lbf kgf x 9 8070 N ft lb x 1 3558 N m ft lb x 0 1383 kgf m in lb x 0 1130 N m in lb x 0 0115 kgf m kgf m x 7 2330 ft lb kgf m x 86 8000 in lb kgf m x 9 8070 N m N m x 0 7376 ft lb N m x 8 8510 in lb N m x 0 1020 kgf m psi x 0 0689 bar psi x 6 8950 kPa psi x 0 0703 kg cm bar x 14 5030 psi bar x 100 0000 kPa...

Page 60: ...GENERAL SERVICE INFORMATION 4 30 TNV IDI Service Manual Unit Conversions This Page Intentionally Left Blank TNV_IDI_ServiceManual_A4 book 30 ページ２０１２年２月２４日金曜日午前１０時２４分 ...

Page 61: ...aintenance USA Only 5 4 EPA ARB Installation Requirements USA Only 5 4 Periodic Maintenance Schedule 5 5 Periodic Maintenance Procedures 5 7 After Initial 50 Hours of Operation 5 7 Every 50 Hours of Operation 5 10 Every 250 Hours of Operation 5 13 Every 500 Hours of Operation 5 18 Every 1000 Hours of Operation 5 21 Every 1500 Hours of Operation 5 23 Every 2000 Hours of Operation 5 25 TNV_IDI_Servi...

Page 62: ...PERIODIC MAINTENANCE 5 2 TNV IDI Service Manual This Page Intentionally Left Blank TNV_IDI_ServiceManual_A4 book 2 ページ２０１２年２月２４日金曜日午前１０時２４分 ...

Page 63: ...E TNV IDI Service Manual 5 3 Introduction INTRODUCTION This section of the Service Manual describes the procedures for proper care and maintenance of the engine TNV_IDI_ServiceManual_A4 book 3 ページ２０１２年２月２４日金曜日午前１０時２４分 ...

Page 64: ...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 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 p...

Page 65: ...ish definitively The following should be treated only as a general guideline NOTICE 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 covera...

Page 66: ... Adjust Intake Exhaust Valve Clearance z Lap Intake Exhaust Valve Seats if required z Electrical Equipment Check Indicators c Check Battery c Engine Oil Check Engine Oil Level c Drain and Fill Engine Oil 1st time 2nd and after Replace Engine Oil Filter Engine Speed Control Check and Adjust Governor Lever and Engine Speed Control c c Emission Control Warranty Inspect Clean and Test Fuel Injectors i...

Page 67: ...d 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 NOTICE ALWAYS be environmentally responsible Follow the guide...

Page 68: ...llow oil to drain 7 After all oil has been drained from the engine reinstall the oil drain plug Figure 5 2 1 and tighten to 39 8 47 0 ft lb 53 9 63 7 N m 5 5 6 5 kgf m 8 Dispose of used oil properly Remove the engine oil filter as follows 1 Turn the engine oil filter Figure 5 2 2 counterclockwise Figure 5 2 4 using a filter wrench Figure 5 2 2 Clean the engine oil filter mounting face 3 Lightly co...

Page 69: ...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 Figure 5 3 Figure 5 4 2 If necessary adjust the V belt tension Loosen the adjusting bolt Figure 5 5 1 and the other related bolts and or nuts then move the alternator Figure 5 5 2 with a pry bar Figure...

Page 70: ...e following procedures every 50 hours thereafter Drain Fuel Filter 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 opening to catch the fuel NEVER use ...

Page 71: ...ter 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 Figure 5 7 2 Close Fi...

Page 72: ...osion 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 WARNING 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 clothi...

Page 73: ...n a warm place until the next use This will help start the engine easily at low ambient temperatures 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 FIR...

Page 74: ...e drain plug firmly 5 Reinstall the fuel cap 6 Check for fuel leaks Replace Engine Oil and Engine Oil Filter NOTICE 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 rem...

Page 75: ... water NOTICE 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 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 9 Check and ...

Page 76: ...er the high idle stop or low idle speed limit screw Figure 5 11 Clean Air Cleaner Element Note that a typical air cleaner is shown in Figure 5 12 and Figure 5 13 for illustrative purposes only The engine performance is adversely affected when the air cleaner element is clogged with dust Be sure to clean the air filter element periodically NOTICE When the engine is operated in dusty conditions clea...

Page 77: ... inner element Figure 5 13 1 if the engine lacks power or the dust indicator actuates if equipped The inner element should not be removed when cleaning or replacing the outer element The inner element is used to prevent dust from entering the engine while servicing the outer element 4 Replace the element with a new one if the element is damaged excessively dirty or oily 5 Clean inside of the air c...

Page 78: ...ped This is in addition to replacing the outer element Replace Fuel Filter 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 opening to catch the fuel NEVER use a shop rag to catch the fuel Vapors from the rag are fla...

Page 79: ...parator 3 Turn the retaining ring Figure 5 14 1 to the left Figure 5 14 2 Figure 5 14 4 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 5 Remove the element Figure 5 14 4 by pulling it down 6 Replace the element with a new o...

Page 80: ... 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 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 Figure 5 15 2...

Page 81: ...Flush and Refill Cooling System with New 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 spurt out during engine operation if the cap is loose ALWAYS che...

Page 82: ...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 Allow engine and coolant to cool 2 Remove the radiator cap Figure 5 16 1 3 Remove the drain plug or open the drain cock Figu...

Page 83: ...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 i...

Page 84: ...uted 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 4 Reinstall the diaphragm diaphragm plate spring and diaphragm cove...

Page 85: ...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 Regularly check the fuel system and engine coolant system hoses If they are cracked or degraded replace them Replace the hoses at least every two years See Check and ...

Page 86: ...PERIODIC MAINTENANCE 5 26 TNV IDI Service Manual Periodic Maintenance Procedures This Page Intentionally Left Blank TNV_IDI_ServiceManual_A4 book 26 ページ２０１２年２月２４日金曜日午前１０時２４分 ...

Page 87: ...nd Timing Gear Train Specifications 6 6 Camshaft 6 6 Idler Gear Shaft and Bushing 6 7 Timing Gear Backlash 6 7 Crankshaft and Pistons Specifications 6 7 Crankshaft 6 7 Crankshaft Reconditioning 6 8 Thrust Bearing 6 8 Piston 6 9 Piston Ring 6 10 Connecting Rod 6 11 Tappet 6 12 Cylinder Block Specifications 6 12 Cylinder Block 6 12 Special Torque Chart 6 13 Torque for Bolts and Nuts 6 13 Special Ser...

Page 88: ...Cylinder Block 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 Components 6 40 Inspection of Crankshaft and Camshaft Components 6 44 Reconditioning the Crankshaft 6 49 Honing and Boring 6 51 Reassembly of Crankshaft and Piston Components 6 52 Reassembly of Camshaft and...

Page 89: ...u Begin Servicing BEFORE YOU BEGIN SERVICING Before performing any service procedures within this section read the following safety information and review the Safety section on page 3 1 TNV_IDI_ServiceManual_A4 book 3 ページ２０１２年２月２４日金曜日午前１０時２４分 ...

Page 90: ...spection Item Standard Limit Reference Page Combustion Surface Distortion Flatness 0 0020 in 0 05 mm or less 0 0059 in 0 15 mm See Valve Recession on page 6 25 Valve Recession Intake 0 0157 0 0236 in 0 4 0 6 mm 0 0354 in 0 9 mm Exhaust 0 0157 0 0236 in 0 4 0 6 mm 0 0315 in 0 8 mm Valve Seat Seat Angle Intake 120 See Valve Face and Valve Seat on page 6 26 Exhaust 90 Seat Correction Angle 40 150 TNV...

Page 91: ... Stem Outside Diameter 0 2341 0 2346 in 5 945 5 960 mm 0 2323 in 5 90 mm Oil Clearance 0 0016 0 0026 in 0 040 0 067 mm 0 0067 in 0 17 mm Valve Stem Bend 0 0004 in 0 010 mm Valve Guide Projection From Cylinder Head 0 3858 0 3937 in 9 8 10 0 mm See Reassembly of Valve Guides on page 6 27 Valve Stem Seal Projection From Cylinder Head 0 429 0 441 in 10 9 11 2 mm Valve Guide Installation Method Cold fi...

Page 92: ...Camshaft on page 6 50 Cam Lobe Height 1 3439 1 3490 in 34 135 34 265 mm 1 3343 in 33 89 mm Shaft Outside Diameter Bearing Inside Diameter Gear End Bushing Inside Diameter 1 5748 1 5778 in 40 000 40 075 mm 1 5807 in 40 150 mm Camshaft Outside Diameter 1 5724 1 5732 in 39 940 39 960 mm 1 5711 in 39 905 mm Oil Clearance 0 0016 0 0053 in 0 040 0 135 mm 0 0096 in 0 245 mm Intermediate Bushing Inside Di...

Page 93: ... Gear and PTO Gear 0 0024 0 0047 in 0 06 0 12 mm 0 0055 in 0 14 mm See Checking Timing Gear Backlash on page 6 36 Inspection Item Standard Limit Reference Page Bend 1 2 the dial gauge reading 0 0008 in 0 02 mm See Inspection of Crankshaft on page 6 49 Roundness 0 0004 in 0 01 mm or less 0 0008 in 0 02 mm Connecting Rod Journals Journal Outside Diameter 2TNV70 3TNV70 1 4942 1 4946 in 37 952 37 962 ...

Page 94: ...0 050 mm 0 0047 in 0 120 mm Item Finishing Precision Reference Page Connecting Rod Journal Undersize Finished Size 1 6418 1 6422 in 41 702 41 712 mm See Reconditioning the Crankshaft on page 6 49 Main Bearing Journal Undersize Finished Size 1 8387 1 8391 in 46 702 46 712 mm Journal Radius 0 138 0 150 in 3 5 3 8 mm Journal Face Finish 0 8S Super Polish Thrust Face Finish 1 6 Inspection Item Standar...

Page 95: ...75 955 75 985 mm 2 9886 in 75 910 mm Piston Diameter Measurement Location Upward From the Bottom of the Piston 0 8661 0 9843 in 22 0 25 0 mm Piston to Cylinder Clearance 2 3TNV70 0 0012 0 0020 in 0 030 0 050 mm 3TNV76 0 0014 0 0022 in 0 035 0 055 mm Wrist Pin Hole Inside Diameter 0 8661 0 8665 in 22 000 22 009 mm 0 8677 in 220 039 mm Pin Outside Diameter 0 8659 0 8661 in 21 995 22 000 mm 0 8648 in...

Page 96: ...0 mm 0 0154 in 0 390 mm Second Ring Ring Groove Width 0 0606 0 0614 in 1 540 1 560 mm 0 0654 in 1 660 mm Ring Width 0 0579 0 0587 in 1 470 1 490 mm 0 0571 in 1 950 mm Side Clearance 0 0020 0 0035 in 0 050 0 090 mm 0 0083 in 0 210 mm End Clearance 0 0071 0 0130 in 0 180 0 33 mm 0 0165 in 0 42 mm Oil Ring Ring Groove Width 0 1185 0 1193 in 3 010 3 030 mm 0 1232 in 3 130 mm Ring Width 0 1170 0 1177 i...

Page 97: ... mm 0 0555 in 1 410 mm Side Clearance 0 0005 0 0065 in 0 013 0 165 mm 0 0112 in 0 285 mm End Clearance 0 0071 0 0130 in 0 180 0 33 mm 0 0165 in 0 42 mm Oil Ring Ring Groove Width 0 1185 0 1193 in 3 010 3 030 mm 0 1232 in 3 130 mm Ring Width 0 1169 0 1177 in 2 970 2 990 mm 0 1161 in 2 950 mm Side Clearance 0 0008 0 0024 in 0 020 0 060 mm 0 0071 in 0 180 mm End Clearance 0 0079 0 0177 in 0 200 0 450...

Page 98: ...onnecting Rod on page 6 47 Inspection Item Standard Limit Reference Page Tappet Bore Block Inside Diameter 0 8268 0 8276 in 21 000 21 021 mm 0 8284 in 21 041 mm See Inspection of Tappets on page 6 48 Tappet Stem Outside Diameter 0 8239 0 8252 in 20 927 20 960 mm 0 8231 in 20 907 mm Oil Clearance 0 0016 0 0037 in 0 040 0 094 mm 0 0053 in 0 134 mm Inspection Item Model Standard Limit Reference Page ...

Page 99: ... 27 5 N m 2 3 2 8 kgf m Applied See Installation of Pistons on page 6 56 Flywheel Bolts M10 x 1 25 mm 59 64 ft lb 80 4 86 4 N m 8 2 8 8 kgf m Applied See Installation of Crankshaft on page 6 55 Main Bearing Cap Bolts M10 x 1 25 mm 56 60 ft lb 75 5 81 5 N m 7 7 8 3 kgf m Applied See Installation of Crankshaft on page 6 55 Crankshaft Pulley Bolts Cast FC250 M12 x 1 25 mm 61 69 ft lb 83 4 93 1 N m 8 ...

Page 100: ... Guides L1 L2 d1 d2 0 394 in 10 mm 2 362 in 60 mm 0 433 in 11 mm 0 669 in 17 mm Locally Manufactured Allowance L1 0 to 0 0118 in 0 to 0 3 mm 3 Wrist Pin Bushing Tool For Removing Installing of Wrist Pin Bushings L1 L2 d1 d2 0 984 in 25 mm 3 346 in 85 mm 0 866 in 22 mm 0 984 in 25 mm Locally Manufactured Allowance d1 0 0118 to 0 0236 in 0 3 to 0 6 mm Allowance d2 0 0118 to 0 0236 in 0 3 to 0 6 mm 4...

Page 101: ...ocally Manufactured Allowance d1 0 0118 to 0 0236 in 0 3 to 0 6 mm Allowance d2 0 0118 to 0 0236 in 0 3 to 0 6 mm 7 Flex Hone For Preparing Cylinder Walls Yanmar Part No Cylinder Bore 129400 92410 2 756 2 992 in 70 76 mm 8 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 9 Piston Ring Too...

Page 102: ...crometer Available Locally For measuring the outside diameters of crankshaft pistons piston pins etc 5 Cylinder Bore Gauge Available Locally For measuring the inside diameters of cylinder liners bearing bores etc 6 Calipers Available Locally For measuring outside diameters depth thickness and width 7 Depth Micrometer Available Locally For measuring of valve recession 8 Square Available Locally For...

Page 103: ...ck Available Locally For measuring shaft bend 10 Torque Wrench Available Locally For tightening nuts and bolts to the specified torque 11 Feeler Gauge Available Locally For measuring piston ring gaps piston ring clearance and valve adjustment clearance 0000839 0000840 0000841 TNV_IDI_ServiceManual_A4 book 17 ページ２０１２年２月２４日金曜日午前１０時２４分 ...

Page 104: ...vice Manual Cylinder Head CYLINDER HEAD Cylinder Head Components Figure 6 1 0002130 1 2 3 4 5 6 7 8 9 10 11 12 23 24 25 26 13 14 15 16 30 29 28 27 17 18 19 20 21 22 TNV_IDI_ServiceManual_A4 book 18 ページ２０１２年２月２４日金曜日午前１０時２４分 ...

Page 105: ...ad 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 Refill Cooling System with New Coolant on page 5 21 NOTICE Ide...

Page 106: ...gure 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 Figure 6 3 Removal of Rocker Arm Assembly 1 Remove the bolts Figure 6 4 1 and nuts Figure 6 4 2 that retain the rocker arm shaft supports 2 Remove the rocker arm shaft assembly from the cylinder head Note Identify the push rods so they can...

Page 107: ...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 so they can be reinstalled on the same rocker arm Removal of Cylinder Head 1 Loosen the cylinder head bolts following the sequence sh...

Page 108: ...with all remaining valves Note If the valves are to be reused identify them so they can be reinstalled in their original location 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 postponed until inspection and...

Page 109: ...n or any part whose measured value does not satisfy the standard or limit must be replaced NOTICE 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 IMPORTANT Mark all valve train components so they can be installed in their orig...

Page 110: ...n 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 5 for the service limit Replace v...

Page 111: ...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 5 for the service limit Figure 6 17 Valve Recession Note The valve guides must be installed to...

Page 112: ...ed by the use of a hand operated cutter Figure 6 21 3 Figure 6 21 Valve seat diameter can be adjusted by top grinding with a 150 stone to make the seat diameter smaller and bottom grinding using a 40 stone to make the seat diameter larger Once the seat location has been corrected grind and lap the seat angle Figure 6 21 1 to specification See Cylinder Head on page 6 4 for the service limit Grind t...

Page 113: ...T Liberally oil all components during assembly to prevent premature wear or damage Reassembly of Valve Guides 1 The valve guides are installed into the cylinder head with an extremely tight press fit Before installing the valve guides place the valve guides in a freezer for at least twenty minutes This will cause the valve guides to contract making it easier to install the valve guides in place 2 ...

Page 114: ...ip 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 Figure 6 26 2 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 5 Figure 6...

Page 115: ...oth 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 2 Position the cylinder head on the cylinder head gasket 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 below Tighten in the sequence shown in Fig...

Page 116: ... models the set screw is located in the center support On 2 cylinder models the set screw is located in the front cooling fan end support 2 Align the hole in the rocker arm shaft Figure 6 32 7 and the hole in the rocker arm support Figure 6 32 5 Reinstall the alignment set screw Figure 6 32 6 3 Place the rocker arm shaft assembly onto the cylinder head 4 If removed reinstall the valve adjusting sc...

Page 117: ...l and tighten bolts Figure 6 34 1 and 2 securely Figure 6 34 5 Reinstall the exhaust manifold using a new gasket Tighten the bolts and nuts Figure 6 34 5 and 6 securely 6 Reinstall the fuel injectors See Installation of the Fuel Injectors on page 7 28 7 Reinstall the high pressure and return fuel injection lines See Installation of the Fuel Injectors on page 7 28 8 Reinstall the coolant pump See R...

Page 118: ...d center after turning Adjust the remaining cylinders in the order of firing by turning the crankshaft each time To decrease the number of rotations required to check all cylinders of a 3 cylinder engine other cylinders can also be checked as indicated in the chart below 2 cylinder engines must have each cylinder adjusted when the piston is at TDC Example On a 3 cylinder engine with the No 1 pisto...

Page 119: ...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 4 Note There is a tendency for the clearance to decrease slightly when the lock nut is tightened It is suggested that the initial clearance adjustment be made slightly on the loose ...

Page 120: ...ck CYLINDER BLOCK Crankshaft and Camshaft Components Figure 6 38 0002180 1 4 3 5 6 5 2 8 7 9 10 11 12 13 17 18 19 23 24 25 20 21 22 26 28 27 29 30 32 31 33 34 36 37 38 35 14 15 16 39 41 40 TNV_IDI_ServiceManual_A4 book 34 ページ２０１２年２月２４日金曜日午前１０時２４分 ...

Page 121: ...sed gaskets O rings and seals Use new gaskets O rings and seals for reassembly of engine NOTICE 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 IMPORTANT Mark all valve train components so they can be installed in their original locations Note Record all measurements taken during disass...

Page 122: ...y 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 c...

Page 123: ...mshaft drive gear Record the measurement 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 Figure 6 42 2 Do not remove the crankshaft gear unless 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 ca...

Page 124: ... 6 43 NOTICE 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 Removal of Oil Pan 1 Invert the engine oil pan up on the engine stand 2 Remove the oil pan Figure 6 44 2 3 Remove the crankcase...

Page 125: ...n page 6 8 for the service limit Figure 6 47 2 Remove two bolts Figure 6 48 3 retaining the camshaft thrust plate Figure 6 48 1 Figure 6 48 3 Extract the tappets Figure 6 48 5 through the top of the cylinder block Mark the tappets so they can be reinstalled in the same location 4 Slowly pull the camshaft Figure 6 48 2 assembly out of the engine being careful not to damage the front camshaft bushin...

Page 126: ...ts remove the camshaft bushing Figure 6 49 3 4 Remove O rings Figure 6 49 2 Figure 6 49 Disassembly of Crankshaft and Piston Components Removal of Pistons NOTICE 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 IMPORTANT Engines with high operating hours m...

Page 127: ...ASTIGAGE 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 Figure 6 52 7 Compare the width of the flattened PLASTIGAGE Figure 6 52 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 measure...

Page 128: ...eps until all pistons are removed and dissembled Removal of Crankshaft 1 Remove the flywheel Figure 6 54 1 from the crankshaft 2 Remove the bolts Figure 6 54 2 from the flywheel housing assembly Remove the flywheel housing from the engine Figure 6 54 3 Before removing the main bearing caps measure the crankshaft end play Use either of the following two methods Method A Install a dial gauge Figure ...

Page 129: ...may result 7 Reinstall the bearing cap and tighten to specification See Special Torque Chart on page 6 13 8 Remove the bearing cap Figure 6 58 9 Compare the width of the flattened PLASTIGAGE Figure 6 58 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 pa...

Page 130: ...ances like parts cleaners primers sealants and sealant removers Failure to comply could result in death or serious injury 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 61 2 from th...

Page 131: ...loration or evidence of cracks If a fracture is suspected use the color check method or the MAGNAFLUX method to determine if the cylinder block is fractured 3 Measure cylinders for roundness taper and inspect for evidence of scoring Consider honing re boring or replacing the cylinder block if the measurements are not within specification Take measurements at three places Figure 6 63 a b and c and ...

Page 132: ...ements must be taken at a specified distance Figure 6 64 1 from the bottom of the piston based on engine model Record the measurements See Piston on page 6 9 for specifications Figure 6 64 5 Subtract the piston measurement from the greatest measurement acquired during cylinder inspection see Inspection of Cylinder Block on page 6 45 to obtain piston to cylinder clearance Record the measurements Se...

Page 133: ...ntil it is approximately 1 18 in 30 mm Figure 6 68 2 from the bottom of the bore Remove the piston Measure the end gap Figure 6 68 3 of each piston ring Record the measurements See Piston Ring on page 6 10 for specifications Figure 6 68 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...

Page 134: ...eter Record the measurements See Crankshaft on page 6 7 for specifications Inspection of Tappets 1 Inspect the tappet contact surfaces for abnormal wear Figure 6 72 1 Normal wear will be even as shown in Figure 6 72 2 Slight surface defects can be corrected using an oilstone Figure 6 72 2 Measure the outside diameter of the tappet stem Figure 6 73 1 Record the measurements See Tappet on page 6 12 ...

Page 135: ...ing journal Figure 6 75 1 See Crankshaft on page 6 7 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 Figure 6 75 Reconditioning the Crankshaft If any of the crankshaft journals do not meet the specifications it may be possible to grind a...

Page 136: ...ications Figure 6 78 4 Measure the diameter of the gear end Figure 6 79 1 intermediate Figure 6 79 2 and flywheel end Figure 6 79 3 bearing journals Record the measurements See Camshaft on page 6 6 for specifications Figure 6 79 Item Finishing Precision Connecting Rod Journal Undersize Finished Size 1 6418 1 6422 in 41 702 41 712 mm Main Bearing Journal Undersize Finished Size 1 8387 1 8391 in 46 ...

Page 137: ...ondition 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 prepa...

Page 138: ...ped 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 ...

Page 139: ... into the top of the piston will be on the opposite side of the connecting rod as the match marks Figure 6 84 3 stamped into the connecting rod and connecting rod cap When reinstalled in the cylinder the embossed mark Figure 6 84 2 cast into the beam of connecting rod will face the flywheel end of the engine Note The actual appearance of the match marks will vary but they will always be in the sam...

Page 140: ...tion of Pistons Piston Rings and Wrist Pin on page 6 46 Use a piston ring end gap filing tool to adjust the piston ring end gap on new piston rings Figure 6 86 Note Reinstall the top and second piston rings with the stamped makers mark Figure 6 87 1 facing the top of the piston The makers mark may vary in appearance but will always be located on the top surface of the piston ring adjacent to the p...

Page 141: ... 3 end gap Figure 6 88 10 Stagger the piston ring end gaps at 120 intervals Figure 6 89 1 2 and 3 Do not position the top piston ring end gap in line with the wrist pin 1 Top Compression Ring End Gap 2 Second Compression Ring End Gap 3 Oil Ring End Gap Figure 6 89 Installation of Crankshaft 1 If removed reinstall the key and timing gear on crankshaft 2 Install new bearing inserts Figure 6 90 1 and...

Page 142: ...mar Part No 977770 01212 to the mounting flange of the flywheel housing Figure 6 91 2 8 Align the flywheel housing with the two dowel pins Figure 6 91 3 9 Reinstall flywheel housing and seal assembly 10 Reinstall the flywheel Figure 6 91 1 and tighten the bolts to the specified torque See Special Torque Chart on page 6 13 Figure 6 91 Installation of Pistons IMPORTANT Do not allow the connecting ro...

Page 143: ...ly reinstall the piston and rod assembly Be sure the match marks Figure 6 93 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 93 2 stamped into the piston top is facing the camshaft side Figure 6 93 6 The embossed mark cast into the connecting rod beam Figure 6 93 3 will be facing the flywheel end of...

Page 144: ...r case Be sure to circle each bolt hole 3 Reinstall dowels and new O rings Figure 6 95 2 Figure 6 95 4 Reinstall the gear case Figure 6 95 1 Tighten the bolts Figure 6 95 4 to the specified torque Installation of Camshaft Note The gear housing must be installed prior to reinstalling the camshaft See Installation of Gear Case on page 6 58 1 If removed reinstall the camshaft end plate Figure 6 96 1 ...

Page 145: ...lube Figure 6 97 4 Align the timing gears as shown in Figure 6 98 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 98 A B and C are aligned 1 Fuel Injection Pump Gear 2 Camshaft Gear 3 Optional Accessory Drive Gear 4 Crankshaft Gear 5 Idler Gear Figure 6 98 7 When all gears are proper...

Page 146: ...t No 977770 01212 to the mounting surface of the oil pan Figure 6 101 2 and crankcase extension if equipped Figure 6 101 1 Be sure to circle each bolt hole 3 If equipped reinstall the crankcase extension Figure 6 101 1 Reinstall the oil pan and tighten the bolts securely Figure 6 101 Final Assembly of Engine 1 Reinstall the starter motor 2 Reinstall the cylinder head See Reassembly of Cylinder Hea...

Page 147: ...el Injection Lines 7 10 Removal of High Pressure Fuel Injection Lines 7 10 Installation of High Pressure Fuel Injection Lines 7 11 Removal of Fuel Return Line 7 11 Installation of Fuel Return Line 7 12 Fuel Injection Pump 7 12 Removal of Fuel Injection Pump 7 12 Installation of Fuel Injection Pump 7 15 Checking and Adjusting Fuel Injection Timing 7 18 Checking Fuel Injection Timing 7 18 Adjusting ...

Page 148: ...ce Manual Disassembly and Inspection of Fuel Injectors 7 26 Adjusting Fuel Injector Pressure 7 27 Reassembly of Fuel Injectors 7 28 Installation of the Fuel Injectors 7 28 TNV_IDI_ServiceManual_A4 book 2 ページ２０１２年２月２４日金曜日午前１０時２４分 ...

Page 149: ...You Begin Servicing BEFORE YOU BEGIN SERVICING Before performing any service procedures within this section read the following safety information and review the Safety section on page 3 1 TNV_IDI_ServiceManual_A4 book 3 ページ２０１２年２月２４日金曜日午前１０時２４分 ...

Page 150: ...ly machined It is extremely important to follow good service practices and maintain cleanliness when servicing the fuel injection pump The Yanmar ML Fuel Injection Pump is an in line type pump which consists of a fuel supply plunger Figure 7 1 1 for each cylinder a 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 cyl...

Page 151: ...he solenoid plunger is extended holding the fuel injection pump fuel rack in the closed position and not allowing fuel to flow through the injection pump and to the engine When the starter switch is turned to the start position the pull coil 36 5 Amp draw white wire inside the solenoid is activated and pulls the solenoid plunger into the solenoid This releases the fuel injection pump fuel rack all...

Page 152: ... m 5 0 60 kgf m Not Applied Fuel Pump Drive Gear Nut 44 51 ft lb 59 69 N m 6 7 kgf m Not Applied High Pressure Fuel Injection Line Nuts 22 25 ft lb 29 34 N m 3 0 3 5 kgf m Not Applied Fuel Return Line Nuts 18 24 ft lb 24 33 N m 2 5 3 3 kgf m Not Applied Fuel Injection Pump Mounting Nuts 17 21 ft lb 23 28 N m 2 3 2 9 kgf m Not Applied Fuel Injector Nozzle Case Nut 21 4 36 1 ft lb 29 49 N m 3 0 5 0 ...

Page 153: ...lly Available For observing injection spray pattern of fuel injection nozzle and measuring injection pressure 2 Spill Timing Tool Shop Fabricated Used to set fuel injection timing Make from a short piece of the end of a high pressure fuel line a high pressure fuel line nut and a short piece of clear plastic tubing a thin nozzle from an aerosol spray can works well Drill out the end of the fuel lin...

Page 154: ...mp on some models 4 Electric Fuel Pump Used on models without mechanical fuel pump 5 Low Pressure Fuel Supply Lines 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 Figure 7 2 1 9 7 12 6 11 5 4 2 3 8 10 0001058A TNV_IDI_ServiceManual_A4 book 8 ページ２０１２年２月２４日金曜日午前１０時２４分 ...

Page 155: ...YSTEM TNV IDI Service Manual 7 9 Fuel System Components FUEL SYSTEM COMPONENTS Figure 7 3 0002208 1 2 3 17 18 19 4 6 7 5 9 10 11 12 13 15 7 14 16 8 TNV_IDI_ServiceManual_A4 book 9 ページ２０１２年２月２４日金曜日午前１０時２４分 ...

Page 156: ...ction Lines NOTICE 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 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 Cle...

Page 157: ...n pump to the specified torque See Special Torque Chart on page 7 6 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 6 Figure 7 5 Removal of Fuel Return Line 1 Clean the area to keep contaminants from entering t...

Page 158: ...JECTION 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 cooling fan V belt Figure 7 7 1 Figure 7 7 3 Close any fuel valves in the fuel supply line 4 Place a drain pan under the fuel injection pump to catch any spillage 5 Clean the area to k...

Page 159: ...il line Figure 7 9 1 from the fuel injection pump and cylinder block IMPORTANT Take care to not damage or bend the lube oil line Figure 7 9 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 reass...

Page 160: ...re 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 Figure 7 12 16 Hold the gear train stationary using a large socket wrench on the crankshaft pulley bolt Loosen the fuel injection pump drive gear retaining nut Figure 7 12 1 and turn it out to the end of the fuel injection pump shaft 17 ...

Page 161: ...rized Yanmar FIE repair facility for repair and calibration or replaced with a new fuel injection pump NOTICE 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 s...

Page 162: ...mp shaft is clean and dry 4 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 fuel injection pump drive gear and gear housing Install the pump retaining nuts finger tight 5 Reinstall the fuel injection pump drive gear lock washer Figure 7 18 2 and nut Figure 7 18 1 Do not lubricate threads of the nut ...

Page 163: ...ed that it be done 11 Reinstall the lube oil line Figure 7 20 1 Figure 7 20 12 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 13 Reinstall the fuel injection high pressure lines See Installation of High Pressure F...

Page 164: ... 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 14 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 2...

Page 165: ...ific 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 24 5 on the flywheel 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...

Page 166: ... and 25 BTDC respectively 9 Highlight the timing reference mark on the flywheel housing Figure 7 25 2 or engine back plate Figure 7 26 2 Highlight the TDC Top Dead Center mark Figure 7 25 1 Figure 7 26 1 on the flywheel Figure 7 25 Figure 7 26 10 Highlight the target timing mark Figure 7 26 1 Figure 7 27 1 on the flywheel timing grid as determined in the Fuel Injection Timing Chart below Figure 7 ...

Page 167: ...ing checked is at approximately 30 BTDC Note The fuel injection pump injects fuel to a cylinder only once every two engine revolutions 16 Flick the nozzle of the timing tool with a finger to remove bubbles and establish a fuel level of approximately 1 2 the height of the nozzle 17 Very slowly rotate the crankshaft clockwise until the fuel level in the nozzle of the spill timing tool or in the deli...

Page 168: ... the fuel injection pump and tighten the fuel injection pump mounting nuts 6 Recheck the fuel injection timing Repeat the fuel injection timing and adjustment procedures until the timing is correct See Checking Fuel Injection Timing on page 7 18 and repeat steps 3 6 7 Remove the spill timing tool 8 Reinstall the shut off solenoid 9 Reinstall the high pressure fuel injection lines See Installation ...

Page 169: ...ire brush 2 Visually inspect the fuel injectors and nozzle protectors for deposits or damage Clean repair or replace as necessary Note Test the fuel injector using an injection nozzle tester Operate the tester 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 te...

Page 170: ...or begins spraying fuel See Test and Adjustment Specifications on page 7 6 for correct pressure readings Note Opening pressure of a new fuel injector will be approximately 72 5 psi 0 5 MPa 5 kgf cm2 higher than one that has been operated for five hours or longer 5 Pump the operating lever slowly to hold the pressure steady at a point just below the opening pressure and hold that pressure for five ...

Page 171: ...ot increase even when the tester lever is operated Atomization Pattern 5 10 cone and roughly uniform Atomization is excessively one sided Although atomized burner like shape the needle does not pulsate Bar shape with excessive after drops Drops Possible Cause Normal injector is good Normally caused by carbon contamination of the nozzle tip Sometimescaused by flaws in or damage to the needle tip Ca...

Page 172: ...e 9 Nozzle Body 10 Nozzle Case Nut Figure 7 32 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 5 Turn the injector over and remove the nozzle body nozzle valve valve stop spacer nozzle spring seat nozzle spring and shims 6 Inspect the sealing surfaces Figure 7 33 2 between the valve stop spacer an...

Page 173: ...er 8 Nozzle Valve 9 Nozzle Body 10 Nozzle Case Nut Figure 7 35 The injection pressure will change by approximately 100 142 psi 0 69 0 98 MPa 7 10 kgf cm2 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 26 2 Remove or add adjusting shims as needed 3 Reassemble the f...

Page 174: ...of the Fuel Injectors 1 Insert the nozzle gaskets Figure 7 36 5 and nozzle protector Figure 7 36 6 in the cylinder head 2 Reinstall the fuel injector Figure 7 36 4 in the cylinder head and tighten to specification 3 Reinstall new copper washers Figure 7 36 3 high pressure and return fuel lines Figure 7 36 2 See Installation of High Pressure Fuel Injection Lines on page 7 11 and Installation of Fue...

Page 175: ...ng 8 3 Introduction 8 4 Cooling System Diagram 8 4 Engine Coolant Pump Components 8 5 Engine Coolant System Check 8 6 Engine Coolant Pump 8 6 Disassembly of Engine Coolant Pump 8 6 Cleaning and Inspection 8 7 Reassembly of Engine Coolant Pump 8 8 TNV_IDI_ServiceManual_A4 book 1 ページ２０１２年２月２４日金曜日午前１０時２４分 ...

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Page 177: ...e You Begin Servicing BEFORE YOU BEGIN SERVICING Before performing any service procedures within this section read the following safety information and review the Safety section on page 3 1 TNV_IDI_ServiceManual_A4 book 3 ページ２０１２年２月２４日金曜日午前１０時２４分 ...

Page 178: ...cribes the procedures necessary to service the 2TNV70 3TNV70 and 3TNV76 engine coolant pump COOLING SYSTEM DIAGRAM 1 Cylinder Head 2 Thermostat 3 Engine Coolant Pump 4 Radiator 5 Coolant Recovery Tank 6 Cylinder Block Figure 8 1 1 4 3 2 6 5 0002046 TNV_IDI_ServiceManual_A4 book 4 ページ２０１２年２月２４日金曜日午前１０時２４分 ...

Page 179: ... 1 Thermostat Cover 2 Thermostat 3 Special O Ring 4 Engine Coolant Pump 5 Temperature Switch 6 Gasket 7 Engine Coolant Pump Gasket 8 V Belt 9 Engine Coolant Pump V Pulley 10 Spacer 11 Engine Coolant Fan Figure 8 2 0001959 1 8 6 5 7 4 2 10 9 11 3 TNV_IDI_ServiceManual_A4 book 5 ページ２０１２年２月２４日金曜日午前１０時２４分 ...

Page 180: ...e engine and engine coolant are not hot 2 Before removing the engine coolant pump or thermostat it will be necessary to drain the engine coolant Drain the coolant into a clean container if the coolant is to be reused Otherwise properly dispose of the coolant Drain the coolant from the radiator See steps 1 4 in Drain Flush and Refill Cooling System with New Coolant on page 5 21 3 Loosen the alterna...

Page 181: ... fluid using an external heat source 4 The temperature switch is normal if the continuity light or ohmmeter indicates continuity when the fluid temperature reaches 225 F 235 F 107 C 113 C Thermostat 1 Check for proper operation of the thermostat Place the thermostat Figure 8 7 1 and an accurate thermometer Figure 8 7 2 in warm water Figure 8 7 2 Slowly increase temperature of the water using an ex...

Page 182: ...ng 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 5 Reinstall the engine coolant pump bolts Tighten the bolts 6 Inspect and reinstall the coolant hoses and the temperature switch lead wire 7 Reinstall the engine coolant pump V pulley Figure...

Page 183: ...engine with engine coolant See Drain Flush and Refill Cooling System with New Coolant on page 5 21 NOTICE 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 rem...

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Page 185: ...Rotor Outside Clearance 9 4 Outer Rotor Side Clearance 9 4 Outer Rotor to Inner Rotor Tip Clearance 9 4 Inner Rotor and Gear Boss Clearance 9 5 Lubrication System Diagram 9 6 Checking Engine Oil Pressure 9 7 Trochoid Oil Pump 9 7 Oil Pump Components 9 7 Disassembly of Oil Pump 9 8 Cleaning and Inspection 9 9 Reassembly of Oil Pump 9 10 TNV_IDI_ServiceManual_A4 book 1 ページ２０１２年２月２４日金曜日午前１０時２４分 ...

Page 186: ...LUBRICATION SYSTEM 9 2 TNV IDI Service Manual This Page Intentionally Left Blank TNV_IDI_ServiceManual_A4 book 2 ページ２０１２年２月２４日金曜日午前１０時２４分 ...

Page 187: ...ore You Begin Servicing BEFORE YOU BEGIN SERVICING Before performing any service procedures within this section read the following safety information and review the Safety section on page 3 1 TNV_IDI_ServiceManual_A4 book 3 ページ２０１２年２月２４日金曜日午前１０時２４分 ...

Page 188: ...ine rpm at Low Idle Speed 2TNV70 VM 42 64 psi 0 29 0 44 MPa 2 96 4 49 kgf cm2 8 8 psi 0 06 MPa 0 6 kfg cm2 or greater 3TNV70 VH 3TNV76 CH 3TNV70 CL 35 51 psi 0 24 0 35 MPa 2 44 3 57 kgf cm2 3TNV76 CL Model Standard Limit Reference Page 2TNV70 3TNV70 3TNV76 0 0047 0 0083 in 0 12 0 21 mm 0 0118 in 0 30 mm Check Outer Rotor Outside Clearance on page 9 9 Model Standard Limit Reference Page 2TNV70 3TNV...

Page 189: ...ameter 2 0886 2 0925 in 53 05 53 15 mm 0 012 0 020 in 0 3 0 5 mm 0 024 in 0 6 mm Check Inner Rotor and Gear Boss Clearance on page 9 10 Rotor Diameter 2 1043 2 1083 in 53 45 53 55 mm Inner Rotor Width Across Flat Clearance Width Across Flat of Gear Boss 1 9468 1 9587 in 49 45 49 75 mm 0 008 0 024 in 0 2 0 6 mm 0 028 in 0 7 mm Width Across Flat of Rotor 1 9665 1 9705 in 49 95 50 05 mm TNV_IDI_Servi...

Page 190: ...EM DIAGRAM Figure 9 1 Idle Gear Shaft Pressure Regulator Valve Oil Pump Oil Suction Pipe Strainer Cylinder Body Main Gallery Camshaft Bearing Rocker Arm Bearing Rocker Arm Tappet Cam Face Oil Pressure Switch Bypass Valve Oil Filter Crank Pin Crank Journal Fuel Injection Pump Oil Pan 0001624 ...

Page 191: ...nical oil pressure gauge in the oil pressure switch port 4 Start the engine If the mechanical oil pressure test gauge indicates good oil pressure replace the faulty oil pressure switch or sending unit or faulty machine oil pressure gauge in instrument panel If the mechanical oil pressure test gauge indicates low oil pressure troubleshoot the lubrication system to locate the cause of the low oil pr...

Page 192: ...ear Case Cover on page 6 36 3 Remove the seven oil pump cover screws Figure 9 5 2 Note The oil pump cover screws are installed using a liquid thread lock It may be necessary to used localized heat small propane torch and an impact type screwdriver to remove these screws Figure 9 5 4 Remove the oil pump cover Figure 9 5 1 from the gear case 5 Remove the outer rotor Figure 9 5 3 and inner rotor Figu...

Page 193: ... of the outer rotor Insert a feeler gauge between the outer rotor Figure 9 7 1 and the gear case oil pump cavity Figure 9 7 2 Figure 9 7 Record the measurement See Outer Rotor Outside Clearance on page 9 4 for the service limit Outer Rotor to Inner Rotor Tip Clearance Determine the outer rotor to inner rotor tip clearance Insert a feeler gauge between the top of an inner rotor tooth Figure 9 8 1 a...

Page 194: ...he back side of the inner rotor fits into the bore in the gear case cover and the top surface of the inner rotor is flush with the top surface of the outer rotor 4 Reinstall the oil pressure regulator valve Figure 9 11 4 into the oil pump cover Figure 9 11 5 Apply LOCTITE 242 red to the valve plug following the manufacturer s instructions 5 Reinstall the oil pump cover Figure 9 11 5 Apply LOCTITE ...

Page 195: ...cifications 10 5 Starter Motor Troubleshooting 10 6 Starter Motor Components 10 7 Starter Motor 10 8 Removal of Starter Motor 10 9 Disassembly of Starter Motor 10 9 Cleaning and Inspection 10 11 Reassembly of Starter Motor 10 16 Check Pinion Projection Length 10 18 No Load Test 10 18 Installation of Starter Motor 10 19 TNV_IDI_ServiceManual_A4 book 1 ページ２０１２年２月２４日金曜日午前１０時２４分 ...

Page 196: ...STARTER MOTOR 10 2 TNV IDI Service Manual This Page Intentionally Left Blank TNV_IDI_ServiceManual_A4 book 2 ページ２０１２年２月２４日金曜日午前１０時２４分 ...

Page 197: ...e You Begin Servicing BEFORE YOU BEGIN SERVICING Before performing any service procedures within this section read the following safety information and review the Safety section on page 3 1 TNV_IDI_ServiceManual_A4 book 3 ページ２０１２年２月２４日金曜日午前１０時２４分 ...

Page 198: ...ARTER MOTOR INFORMATION YANMAR Part Number Mfg Mfg Model Number Specification No Load Loaded Terminal Voltage Amperage Draw RPM Terminal Voltage Amperage Draw Torque RPM 119515 77010 Denso 428000 2190 DC12V 1 3 hp 1 0 kW 11 5 90A Max 3000 Min 8 0 200 Max 42 in lb 4 7 N m 0 48 kgf m 1240 Min 119717 77010 Denso 428000 1590 DC12V 1 5 hp 1 1 kW 11 5 90A Max 3000 Min 8 7 230 Max 61 in lb 6 9 N m 0 70 k...

Page 199: ...b 4 9 N m 0 5 kgf m minimum Clutch System Overrunning Overrunning Pinion Projection Voltage at 212 F 100 C 8 0 V max 8 0 V max Pinion DP or Module Number of Teeth M2 54 9 M2 54 9 Application Standard Standard Brush Spring Force 3 1 4 0 lbf 13 7 17 6 N 1 4 1 8 kgf 3 1 4 0 lbf 13 7 17 6 N 1 4 1 8 kgf Length Standard 0 55 in 14 mm 0 55 in 14 mm Service Limit 0 44 in 11 1 mm 0 44 in 11 1 mm Solenoid S...

Page 200: ...ion projection length Inspect shift lever for deformation return spring for fatigue and pinion for sliding Repair meshing between pinion and ring gear or replace as needed Replace engine oil Repair or replace starter motor Solenoid switch assembly contact defective Repair or replace Repair or replace key switch starting motor relay or magnetic switch assembly If a problem occurs Immediately discon...

Page 201: ...V IDI Service Manual 10 7 Starter Motor Components STARTER MOTOR COMPONENTS Figure 10 1 0002486 1 2 3 4 5 6 7 9 10 11 12 13 14 15 8 16 17 18 19 20 21 22 23 24 TNV_IDI_ServiceManual_A4 book 7 ページ２０１２年２月２４日金曜日午前１０時２４分 ...

Page 202: ...r 3 used 24 Pinion Shaft STARTER MOTOR WARNING 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 Note While starter motor des...

Page 203: ...e from the solenoid switch Figure 10 3 Figure 10 3 3 Remove the two bolts or nuts retaining the solenoid switch assembly Figure 10 4 1 to the pinion housing Remove the solenoid switch assembly and dust covers Figure 10 4 2 Remove the plunger Figure 10 4 4 and torsion spring Figure 10 4 3 from the pinion housing Figure 10 4 4 Remove the two bolts Figure 10 5 1 securing the rear cover Figure 10 5 2 ...

Page 204: ... 10 7 3 off from the armature assembly Figure 10 7 2 9 Remove the armature from the intermediate housing 10 Remove the intermediate housing gear and pinion shaft assembly Figure 10 8 4 from the pinion housing Figure 10 8 3 Disengage from the shift lever as it is removed 11 Remove the shift lever Figure 10 8 2 pin and spacer Figure 10 8 1 Figure 10 8 12 Pull the pinion stop Figure 10 9 1 down to ex...

Page 205: ...5 Inspect the intermediate bushing Figure 10 11 2 and replace if worn or damaged 16 Inspect armature bushing Figure 10 11 7 and replace if worn or damaged Cleaning and Inspection Armature Commutator Surface Inspection If the commutator surface is rough polish the surface with a 500 to 600 emery cloth Figure 10 12 Measure Commutator Outside Diameter Measure the commutator outside diameter Replace t...

Page 206: ...4 An abnormal commutator condition is indicated in Figure 10 14 5 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 Figure 10 15 Armature Coil Insulation Test Check for continuity between a commutator segment and...

Page 207: ... multimeter should indicate continuity If the multimeter does not indicate continuity replace the field coil assembly Figure 10 18 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 Figure 10 19 Measure Bru...

Page 208: ... 10 22 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 Figure 10 23 Series ...

Page 209: ...ly 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 Figure 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 c...

Page 210: ...e 10 29 4 in the groove in the pinion shaft Slide the pinion stop over the retaining ring Figure 10 29 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...

Page 211: ...rds 11 Carefully reinstall the brush holder Figure 10 32 3 assembly 12 Reinstall the rear cover Figure 10 32 2 and secure with two bolts Figure 10 32 1 Figure 10 32 13 Reinstall the two through bolts and tighten securely 14 Reinstall the return spring if equipped Figure 10 33 3 on the solenoid plunger Figure 10 33 4 Reinstall the solenoid switch coil Figure 10 33 1 and dust covers Figure 10 33 2 S...

Page 212: ...ng a no load test NOTICE The starter motor can be damaged if operated continuously longer than 10 seconds while performing the no load test 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 ...

Page 213: ... and voltage For test specifications see Starter Motor Information on page 10 4 for the appropriate starter motor Installation of Starter Motor 1 Reinstall the starter motor to the flywheel housing 2 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 26 Figure 10 38 3 Reconnect the electrical wires to ...

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Page 215: ...onents 11 7 Alternator Wiring Diagram 11 8 Alternator Standard Output 11 9 Alternator 11 10 Removal of Alternator 11 10 Disassembly of Alternator 11 10 Reassembly of Alternator 11 12 Installation of Alternator 11 14 Dynamo Component Location 11 15 Dynamo Wiring Diagram 11 16 Operation of Dynamo 11 16 Dynamo Standard Output 11 17 Testing of Dynamo 11 18 Testing Stator Coil Continuity 11 18 Testing ...

Page 216: ...R 11 2 TNV IDI Service Manual Dynamo 11 18 Removal of Dynamo 11 18 Disassembly of Dynamo 11 19 Reassembly of Dynamo 11 19 Installation of Dynamo 11 20 TNV_IDI_ServiceManual_A4 book 2 ページ２０１２年２月２４日金曜日午前１０時２４分 ...

Page 217: ...You Begin Servicing BEFORE YOU BEGIN SERVICING Before performing any service procedures within this section read the following safety information and review the Safety section on page 3 1 TNV_IDI_ServiceManual_A4 book 3 ページ２０１２年２月２４日金曜日午前１０時２４分 ...

Page 218: ...r Mfg Mfg Part Number Specification 171301 77201 Kokusan GP8138 DC12V 15A 119910 77200 Kokusan GP9191 DC12V 20A YANMAR Part Number Mfg Mfg Part Number Specification 119620 77201 Denso 100211 4531 DC12V 40A 129423 77200 Denso 101211 1170 DC12V 40A with Pulse 129961 77200 Denso 101211 2591 DC12V 55A 119626 77210 Denso 101211 2951 DC12V 55A with Pulse Yanmar Part Number 129423 77200 Nominal Output 13...

Page 219: ... From Pulley Clockwise Rating Continuous Battery Voltage 12 Volts Rated Revolution 3500 rpm Operating Range 1400 6600 rpm Grounding Characteristics Negative Side of Circuit Regulator Current Limiter Part No 119653 77710 Outside Diameter of Pulley A Belt 2 56 in 65 mm Special M Belt 2 28 in 58 mm Belt Shape Type A or Type Special M TNV_IDI_ServiceManual_A4 book 5 ページ２０１２年２月２４日金曜日午前１０時２４分 ...

Page 220: ...plicable to the bench test With engine idling measure voltage at L terminal and at battery With engine idling turn light switch ON Replace the battery indicator Battery indicator is available from driven machine manufacturer Battery indicator flashes Battery voltage is between 13 and 15 volts Battery voltage greater than 15 5 volts Battery voltage minus L terminal voltage is greater than 0 5 volt ...

Page 221: ...d 2 used 7 Front Frame Housing Bearing 8 Bearing Cover 9 Bearing Cover Bolt 4 used 10 Rotor Assembly 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 20 Rear Frame Housing 21 Bolt 2 used 22 Holder 23 IC Regulator Assembly 24 Bolt 2 used 25 Bolt 26 Brush 2 used 27 Bolt 28 Rear Cover 29 Bolt 3...

Page 222: ...ing system between alternator terminals IG and L Damage to the alternator will result NOTICE Do not connect a load between alternator terminals L and E Damage to the alternator will result NOTICE Do not remove the positive battery cable from alternator terminal B while the engine is operating Damage to the alternator will result L IG B P L IG IC B F E 0 5µF E PI P 1 5 6 2 4 3 3 B A T TNV_IDI_Servi...

Page 223: ... Standard Output ALTERNATOR STANDARD OUTPUT Figure 11 3 Alternator RPM x10 min 13 5 Volts Constant Ambient Temperature at 77 F 25 C Output Current Cold Hot 60 50 40 30 20 10 0 1 2 3 4 5 6 7 8 TNV_IDI_ServiceManual_A4 book 9 ページ２０１２年２月２４日金曜日午前１０時２４分 ...

Page 224: ... 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 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 Figure 11 4 Disas...

Page 225: ...s retaining the holder Figure 11 7 2 to the rear frame housing 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 Figure 11 8 8 Using a press remove the rotor assembly Figure 11 9 1 from the front frame...

Page 226: ...ve the bearing cover Figure 11 11 2 and two thrust washers Figure 11 11 3 Figure 11 11 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 Figure 11 12 2 If removed lubricate the outside diameter of...

Page 227: ...and two nuts Figure 11 15 2 Figure 11 15 6 Reinstall the insulation bushing Figure 11 16 4 and nut Figure 11 16 3 Figure 11 16 7 Reassemble the regulator assembly Figure 11 16 1 to the holder Figure 11 16 2 8 Reinstall the brush holder Figure 11 17 3 springs Figure 11 17 4 and brushes Figure 11 17 5 9 Reattach the regulator assembly and holder to the rear frame housing Figure 11 17 10 Reinstall th...

Page 228: ...e alternator Tighten the nuts to 15 20 in lb 1 7 2 3 N m 17 23 kgf m 3 Reinstall the V belt Tighten the V belt to the proper tension See Check and Adjust Cooling Fan V Belt on page 5 15 4 Start the engine Listen for any unusual sounds from the alternator NOTICE Do not operate the engine if the alternator is producing unusual sounds Damage to the alternator will result 5 Verify that the charge indi...

Page 229: ... 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 8 Spacer 9 Stator Assembly 10 Front Bearing 2 used 11 Flat Washer 12 Flywheel Assembly 13 Pulley Half 14 Through Bolt Figure 11 20 0002140 0002140 1 2 3 6 4 5 7 8 9 10 11 12 13 14 TNV_IDI_ServiceManual_A4 book 15 ページ２０１２年２月...

Page 230: ... a series of permanent magnets that rotate around a stationary stator coil The magnets are attached to the flywheel which is rotated via the engine cooling fan drive belt The resultant output is an AC alternating current signal The AC is converted to DC direct current by the current limiter The current limiter outputs charging DC current to the battery 0002137 1 2 3 4 5 6 TNV_IDI_ServiceManual_A4 ...

Page 231: ...ALTERNATOR TNV IDI Service Manual 11 17 Dynamo Standard Output DYNAMO STANDARD OUTPUT Figure 11 22 0002138 TNV_IDI_ServiceManual_A4 book 17 ページ２０１２年２月２４日金曜日午前１０時２４分 ...

Page 232: ...ynamo 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 If results are not correct test the stator for continuity and shorts to the ground Check the charging system wi...

Page 233: ...ve the screws Figure 11 26 1 and the stator assembly Figure 11 26 2 5 Remove the rear bearing Figure 11 26 3 Figure 11 26 Reassembly of Dynamo 1 Reinstall the rear bearing Figure 11 26 3 2 Reinstall the stator Figure 11 26 1 3 Reinstall screws Figure 11 26 1 4 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 pu...

Page 234: ...1 Figure 11 29 2 Reconnect the dynamo output wire connector 3 Reinstall the V belt Tighten the V belt to the proper tension See Check and Adjust Cooling Fan V Belt on page 5 15 4 Start the engine Listen for any unusual sounds from the alternator NOTICE Do not operate the engine if the alternator is producing unusual sounds Damage to the alternator will result 5 Verify that the charge indicator is ...

Page 235: ...12 ELECTRIC WIRING Page Electric Wiring Precautions 12 3 Electric Wire Resistance 12 4 Battery Cable Resistance 12 5 Electrical Wire Sizes Voltage Drop 12 6 Conversion of AWG to European Standards 12 7 TNV_IDI_ServiceManual_A4 book 1 ページ２０１２年２月２４日金曜日午前１０時２４分 ...

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Page 237: ...sistance 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 NOTICE Removing the battery cables or the battery while the engine is operating may cause damage t...

Page 238: ...xample 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 AWG Metric Nominal mm Ohms Foot 20 0 5 0 009967 18 0 8 0 006340 16 1 25 0 004359 14 2 0 002685 12 3 0 001704 10 5 0 001073 8 8 0 000707 6 15 0 000421 4 20 0 000270 2 30 0 000158 1 40 0 000130 0 1 0 50 0 000103 00 2 0 60 0 000087 000 3 0 85 0 000066 0000 4 0 100 0 000051 TNV_IDI_ServiceManual...

Page 239: ...For starter motors of greater than 2 68 HP 2 kW the total resistance must be less than 0 0012 Ω AWG mm Maximum Total Battery Cable Length Positive Cable Negative Cable a 12V Starter Motor Output Less Than 2 68 hp 2 kW Greater Than 2 68 hp 2 kW m ft m ft 6 15 1 5 4 75 N A N A 4 20 2 3 7 4 N A N A 2 30 3 8 12 6 2 3 7 5 1 40 4 6 15 3 2 8 9 2 0 1 0 50 5 9 19 5 3 5 11 6 00 2 0 60 7 0 22 8 4 2 13 7 000 ...

Page 240: ...4 0 4 0 4 0 60 6 4 4 2 2 1 0 2 0 3 0 3 0 4 0 4 0 4 0 70 6 4 2 2 1 0 2 0 3 0 3 0 4 0 4 0 80 6 4 2 2 1 0 3 0 3 0 4 0 4 0 90 4 2 2 1 0 2 0 3 0 4 0 4 0 100 4 2 2 1 0 2 0 3 0 4 0 24 Volts 5 18 18 18 16 16 14 12 12 12 10 10 10 10 10 8 8 8 8 8 10 18 16 14 12 12 10 10 10 8 8 8 6 6 6 6 6 6 6 6 15 16 14 12 12 10 10 8 8 6 6 6 6 6 4 4 4 4 4 2 20 14 12 10 10 10 8 6 6 6 6 4 4 4 4 2 2 2 2 2 25 12 12 10 10 8 6 6 ...

Page 241: ...412 20 0 812 0 519 19 0 992 0 653 18 1 024 0 823 17 1 15 1 04 16 1 29 1 31 15 1 45 1 65 14 1 63 2 08 13 1 83 2 63 12 2 05 3 31 11 2 30 4 15 10 2 59 5 27 9 2 91 6 62 8 3 26 8 35 7 3 67 10 6 6 4 11 13 3 5 4 62 16 8 4 5 19 21 2 3 5 83 26 7 2 6 54 33 6 1 7 35 42 4 0 1 0 8 25 53 4 00 2 0 9 27 67 5 000 3 0 10 40 85 0 0000 4 0 11 68 107 2 00000 5 0 13 12 135 1 000000 6 0 14 73 170 3 1 1 circular mil CM 0...

Page 242: ...ELECTRIC WIRING 12 8 TNV IDI Service Manual Conversion of AWG to European Standards This Page Intentionally Left Blank TNV_IDI_ServiceManual_A4 book 8 ページ２０１２年２月２４日金曜日午前１０時２４分 ...

Page 243: ...n 13 TROUBLESHOOTING Page Special Service Tools 13 3 Troubleshooting By Measuring Compression Pressure 13 4 Compression Pressure Measurement Method 13 4 Quick Reference Table For Troubleshooting 13 6 TNV_IDI_ServiceManual_A4 book 1 ページ２０１２年２月２４日金曜日午前１０時２４分 ...

Page 244: ...TROUBLESHOOTING 13 2 TNV IDI Service Manual This Page Intentionally Left Blank TNV_IDI_ServiceManual_A4 book 2 ページ２０１２年２月２４日金曜日午前１０時２４分 ...

Page 245: ... IDI Service Manual 13 3 Special Service Tools SPECIAL SERVICE TOOLS Compression Gauge Kit For measuring compression pressure Yanmar Part No TOL 97190080 0000849 TNV_IDI_ServiceManual_A4 book 3 ページ２０１２年２月２４日金曜日午前１０時２４分 ...

Page 246: ...rs on page 7 22 NOTICE 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 3 Turn off the fuel supply valve in the fuel supply line Disconnect the fuel injection stop solenoid at the connector Crank the eng...

Page 247: ...Between Cylinders Standard Limit 2TNV70 3TNV70 470 15 psi 3 24 0 1 MPa 33 1 kgf cm 370 15 psi 2 55 0 1 MPa 26 1 kgf cm 29 to 43 psi 0 2 to 0 3 MPa 2 to 3 kgf cm 3TNV76 498 15 psi 3 43 0 1 MPa 35 1 kgf cm 399 15 psi 2 75 0 1 MPa 28 1 kgf cm 569 psi 40 kgf cm2 498 psi 35 kgf cm2 427 psi 30 kgf cm2 356 psi 25 kgf cm2 285 psi 20 kgf cm2 200 250 300 350 400 Engine Speed min 1 Compression Pressure 3 92 ...

Page 248: ...on 1 Air Cleaner Element Clogged element Clean the element Broken element Replace the element Defect at element seal portion 2 Valve Clearance Excessive or no clearance Adjust the valve clearance 3 Valve Timing Incorrect valve clearance Adjust the valve clearance 4 Cylinder Head Gasket Gas leak from gasket Replace the gasket Retighten the cylinder head bolts to the specified torque 5 Intake Exhaus...

Page 249: ...r Intake Exhaust Valve Clearance O O O O O O Adjust the Valve Clearance See Measuring and Adjusting Valve Clearance on page 6 32 Compression Leakage from Valve Seat O O O O O O O O Lap the Valve Seat See Valve Face and Valve Seat on page 6 26 Intake Exhaust Valve Seizure O O O O O O O O O O O Correct or Replace Intake Exhaust Valve See Inspection of Intake and Exhaust Valves on page 6 25 Cylinder ...

Page 250: ...TROUBLESHOOTING 13 8 TNV IDI Service Manual Troubleshooting Charts This Page Intentionally Left Blank TNV_IDI_ServiceManual_A4 book 8 ページ２０１２年２月２４日金曜日午前１０時２４分 ...

Page 251: ...erse Assembly of Piston Rings O O O O Reassemble Correctly See Reassembly of Pistons on page 6 53 Worn Crankpin and Journal Bearing O O O O O O Measure and Replace See Inspection of Crankshaft and Camshaft Components on page 6 44 Loose Connecting Rod Bolt O O O Tighten to the Specified Torque See Torque for Bolts and Nuts on page 6 13 Foreign Matter Trapped in Combustion Chamber O O O O Disassembl...

Page 252: ...TROUBLESHOOTING 13 10 TNV IDI Service Manual Troubleshooting Charts This Page Intentionally Left Blank TNV_IDI_ServiceManual_A4 book 10 ページ２０１２年２月２４日金曜日午前１０時２４分 ...

Page 253: ...page 8 6 or Check and Adjust Cooling Fan V Belt on page 5 15 Insufficient Engine Coolant Level O O O Check Water Leakage from Engine Coolant System See Engine Coolant System Check on page 8 6 Cracked Water Jacket O O O Repair or Replace See Disassembly of Engine Coolant Pump on page 8 6 Stretched Fan Belt O O O Adjust the Belt Tension See Check and Adjust Cooling Fan V Belt on page 5 9 Defective T...

Page 254: ...TROUBLESHOOTING 13 12 TNV IDI Service Manual Troubleshooting Charts This Page Intentionally Left Blank TNV_IDI_ServiceManual_A4 book 12 ページ２０１２年２月２４日金曜日午前１０時２４分 ...

Page 255: ... by Diesel Fuel Oil with Water Low Oil Pressure Overheat Low Water Temperature Pressure Drop Pressure Rise Exhaust Smoke Ordinary White Black White Black Cause None Little Much Fuel System Too Early Timing of Fuel Injection Pump O O O Check and Adjust See Checking and Adjusting Fuel Injection Timing on page 7 18 Too Late Timing of Fuel Injection Pump O O O O Check and Adjust See Checking and Adjus...

Page 256: ...TROUBLESHOOTING 13 14 TNV IDI Service Manual Troubleshooting Charts This Page Intentionally Left Blank TNV_IDI_ServiceManual_A4 book 14 ページ２０１２年２月２４日金曜日午前１０時２４分 ...

Page 257: ...O O Bleed the Air See Priming the Fuel System on page 4 14 Clogged or Cracked Fuel Line O O O Clean or Replace See Check and Replace Fuel Hoses and Engine Coolant Hoses on page 5 25 Insufficient Fuel Supply to Fuel Injection Pump O O O Check the Fuel Tank Cock Fuel Filter Fuel Line and Fuel Feed Pump See the appropriate procedure in Periodic Maintenance on page 5 1 Uneven Injection Volume from Fue...

Page 258: ...TROUBLESHOOTING 13 16 TNV IDI Service Manual Troubleshooting Charts This Page Intentionally Left Blank TNV_IDI_ServiceManual_A4 book 16 ページ２０１２年２月２４日金曜日午前１０時２４分 ...

Page 259: ...Water Low Oil Pressure Overheat Low Water Temperature Pressure Drop Pressure Rise Exhaust Smoke Ordinary White Black White Black Cause None Little Much Air Exhaust Gas System Clogged Air Filter O O O O O Clean Air Filter See Clean Air Cleaner Element on page 5 16 Engine Used at High Temperatures or at High Altitude O O O O O Study Output Drop and Load Matching Clogged Exhaust Pipe O O O O Clean Ex...

Page 260: ...TROUBLESHOOTING 13 18 TNV IDI Service Manual Troubleshooting Charts This Page Intentionally Left Blank TNV_IDI_ServiceManual_A4 book 18 ページ２０１２年２月２４日金曜日午前１０時２４分 ...

Page 261: ...nstallation may be equipped with a variety of electrical components and wiring harnesses Contact the machine manufacturer for specific information 0002427A LA206 11V 9 1 0 A PER ONE GLOW PLUG 119717 77800 PRE HEAT TIME 3 sec YAZAKI NO YAZAKI NO 7122 3016 7123 3010 Items marked with are not provided by Yanmar KEY SWITCH 30A FUSE EMERGENCY STOP SWITCH TNV_IDI_ServiceManual_A4 book 19 ページ２０１２年２月２４日 ...

Page 262: ...WIRING DIAGRAM 13 20 TNV IDI Service Manual Electric Wiring This Page Intentionally Left Blank TNV_IDI_ServiceManual_A4 book 20 ページ２０１２年２月２４日金曜日午前１０時２４分 ...

Page 263: ...ake any change at any time without notice YANMAR and 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 informa tion storage and retrieval systems without the written permission of YA...

Page 264: ...0BTNV G00202 PRINTED IN JAPAN 2TNV70 3TNV70 3TNV76 INDUSTRIAL ENGINES SERVICE MANUAL INDUSTRIAL ENGINES 2TNV70 3TNV70 3TNV76 SERVICE MANUAL ...

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