Yanmar 2TNV70, 3TNV70, 3TNV76 Industrial Engine Service Manual 50940077

Description

• Model List:
  • 2TNV70, 3TNV70, 3TNV76 Industrial Engine

• 1. Table of Contents
• 2. Introduction
• 3. Yanmar Warranties
• 3.1. Yanmar Limited Warranty
• 3.1.1. What is Covered by this Warranty
• 3.1.2. How Long is the Warranty Period
• 3.1.3. What the Engine Owner Must Do
• 3.1.4. To Locate an Authorized Yanmar Industrial Engine Dealer or Distributor
• 3.1.5. What Yanmar Will Do
• 3.1.6. What is Not Covered by this Warranty
• 3.1.7. Warranty Limitations
• 3.1.8. Warranty Modifications
• 3.1.9. Questions
• 3.1.10. Retail Purchaser Registration
• 3.2. Emission System Warranty
• 3.3. Yanmar Co., Ltd. Limited Emission Control System Warranty – USA Only
• 3.3.1. Your Warranty Rights and Obligations
• 3.3.2. Manufacturers Warranty Period
• 3.3.3. Warranty Coverage
• 3.3.4. Warranted Parts
• 3.3.5. Exclusions
• 3.3.6. Owners Warranty Responsibilities
• 3.4. Safety Statements
• 3.5. Safety Precautions
• 4. General Service Information
• 4.1. Component Identification
• 4.2. Location of Labels
• 4.2.1. Engine Nameplate (Typical)
• 4.3. EPA / ARB Emission Control Regulations – USA Only
• 4.4. Emission Control Labels
• 4.4.1. EPA / CARB Labels (Typical)
• 4.5. The 97/68/EC Directive Certified Engines
• 4.6. Engine Family
• 4.7. Function of Major Engine Components
• 4.8. Function of Cooling System Components
• 4.9. Diesel Fuel
• 4.9.1. Diesel Fuel Specifications
• 4.9.2. Filling the Fuel Tank
• 4.9.3. Priming the Fuel System
• 4.10. Engine Oil
• 4.10.1. Engine Oil Specifications
• 4.10.2. Service Categories
• 4.10.3. Engine Oil Viscosity
• 4.10.4. Checking Engine Oil
• 4.10.5. Adding Engine Oil
• 4.10.6. Engine Oil Capacity (Typical)
• 4.11. Engine Coolant
• 4.11.1. Engine Coolant Specifications
• 4.11.2. Filling Radiator with Engine Coolant
• 4.11.3. Engine Coolant Capacity (Typical)
• 4.12. Specifications
• 4.12.1. Description of Model Number
• 4.12.2. Engine Speed Specifications
• 4.12.3. Engine General Specifications
• 4.13. Principal Engine Specifications
• 4.14. Engine Service Information
• 4.15. Tightening Torques for Standard Bolts and Nuts
• 4.16. Abbreviations and Symbols
• 4.16.1. Abbreviations
• 4.16.2. Symbols
• 4.17. Unit Conversions
• 4.17.1. Unit Prefixes
• 4.17.2. Units of Length
• 4.17.3. Units of Volume
• 4.17.4. Units of Mass
• 4.17.5. Units of Force
• 4.17.6. Units of Torque
• 4.17.7. Units of Pressure
• 4.17.8. Units of Power
• 4.17.9. Units of Temperature
• 5. Periodic Maintenance
• 5.1. Introduction
• 5.2. Precautions
• 5.2.1. The Importance of Periodic Maintenance
• 5.2.2. Performing Periodic Maintenance
• 5.2.3. Yanmar Replacement Parts
• 5.2.4. Required EPA / ARB Maintenance – USA Only
• 5.2.5. EPA / ARB Installation Requirements – USA Only
• 5.3. Periodic Maintenance Schedule
• 5.4. Periodic Maintenance Procedures
• 5.4.1. After Initial 50 Hours of Operation
• 5.4.2. Every 50 Hours of Operation
• 5.4.3. Every 250 Hours of Operation
• 5.4.4. Every 500 Hours of Operation
• 5.4.5. Every 1000 Hours of Operation
• 5.4.6. Every 1500 Hours of Operation
• 5.4.7. Every 2000 Hours of Operation
• 5.5. Before You Begin Servicing
• 5.6. Introduction
• 5.7. Cylinder Head Specifications
• 5.7.1. Adjustment Specifications
• 5.7.2. Cylinder Head
• 5.7.3. Intake / Exhaust Valve and Guide
• 5.7.4. Push Rod
• 5.7.5. Valve Spring
• 5.7.6. Rocker Arm and Shaft
• 5.8. Camshaft and Timing Gear Train Specifications
• 5.8.1. Camshaft
• 5.8.2. Idler Gear Shaft and Bushing
• 5.8.3. Timing Gear Backlash
• 5.9. Crankshaft and Pistons Specifications
• 5.9.1. Crankshaft
• 5.9.2. Crankshaft Reconditioning
• 5.9.3. Thrust Bearing
• 5.9.4. Piston Ring
• 5.9.5. Connecting Rod
• 5.10. Cylinder Block Specifications
• 5.10.1. Cylinder Block
• 5.11. Special Torque Chart
• 5.11.1. Torque for Bolts and Nuts
• 5.12. Special Service Tools
• 5.13. Measuring Instruments
• 5.14. Cylinder Head
• 5.14.1. Cylinder Head Components
• 5.14.2. Disassembly of Cylinder Head
• 5.14.3. Cleaning of Cylinder Head Components
• 5.14.4. Inspection of Cylinder Head Components
• 5.14.5. Reassembly of Cylinder Head
• 5.14.6. Measuring and Adjusting Valve Clearance
• 5.15. Cylinder Block
• 5.15.1. Crankshaft and Camshaft Components
• 5.15.2. Disassembly of Cylinder Block Components
• 5.15.3. Disassembly of Camshaft and Timing Components
• 5.15.4. Disassembly of Crankshaft and Piston Components
• 5.15.5. Inspection of Crankshaft and Camshaft Components
• 5.15.6. Reconditioning the Crankshaft
• 5.15.7. Honing and Boring
• 5.15.8. Reassembly of Crankshaft and Piston Components
• 5.15.9. Reassembly of Camshaft and Timing Components
• 6. Fuel System
• 6.1. Before You Begin Servicing
• 6.2. Introduction
• 6.2.1. Fuel Injection Pump
• 6.2.2. Stop Solenoid
• 6.3. Fuel System Specifications
• 6.3.1. Special Torque Chart
• 6.3.2. Test and Adjustment Specifications
• 6.4. Special Service Tools
• 6.5. Measuring Instruments
• 6.6. Fuel System Diagram
• 6.7. Fuel System Components
• 6.8. Fuel Injection Lines
• 6.8.1. Removal of High-Pressure Fuel Injection Lines
• 6.8.2. Installation of High-Pressure Fuel Injection Lines
• 6.8.3. Removal of Fuel Return Line
• 6.8.4. Installation of Fuel Return Line
• 6.9. Fuel Injection Pump
• 6.9.1. Removal of Fuel Injection Pump
• 6.9.2. Installation of Fuel Injection Pump
• 6.10. Checking and Adjusting Fuel Injection Timing
• 6.10.1. Checking Fuel Injection Timing
• 6.10.2. Adjusting Fuel Injection Timing
• 6.11. Fuel Injectors
• 6.11.1. Removal of Fuel Injectors
• 6.11.2. Testing of Fuel Injectors
• 6.11.3. Disassembly and Inspection of Fuel Injectors
• 6.11.4. Adjusting Fuel Injector Pressure
• 6.11.5. Reassembly of Fuel Injectors
• 6.11.6. Installation of the Fuel Injectors
• 7. Cooling System
• 7.1. Before You Begin Servicing
• 7.2. Introduction
• 7.3. Cooling System Diagram
• 7.4. Engine Coolant Pump Components
• 7.5. Engine Coolant System Check
• 7.6. Engine Coolant Pump
• 7.6.1. Disassembly of Engine Coolant Pump
• 7.6.2. Cleaning and Inspection
• 7.6.3. Reassembly of Engine Coolant Pump
• 8. Lubrication System
• 8.1. Before You Begin Servicing
• 8.2. Introduction
• 8.3. Oil Pump Service Information
• 8.3.1. Engine Oil Pressure
• 8.3.2. Outer Rotor Outside Clearance
• 8.3.3. Outer Rotor Side Clearance
• 8.3.4. Outer Rotor to Inner Rotor Tip Clearance
• 8.3.5. Inner Rotor and Gear Boss Clearance
• 8.4. Lubrication System Diagram
• 8.5. Checking Engine Oil Pressure
• 8.6. Trochoid Oil Pump
• 8.6.1. Oil Pump Components
• 8.6.2. Disassembly of Oil Pump
• 8.6.3. Cleaning and Inspection
• 8.6.4. Reassembly of Oil Pump
• 9. Starter Motor
• 9.1. Before You Begin Servicing
• 9.2. Introduction
• 9.3. Starter Motor Information
• 9.4. Starter Motor Specifications
• 9.5. Starter Motor Troubleshooting
• 9.6. Starter Motor Components
• 9.7. Starter Motor
• 9.7.1. Removal of Starter Motor
• 9.7.2. Disassembly of Starter Motor
• 9.7.3. Cleaning and Inspection
• 9.7.4. Reassembly of Starter Motor
• 9.7.5. Check Pinion Projection Length
• 9.7.6. No-Load Test
• 9.7.7. Installation of Starter Motor
• 10. Alternator
• 10.1. Before You Begin Servicing
• 10.2. Introduction
• 10.3. Standard and Optional Dynamo Information
• 10.4. Standard and Optional Alternator Information
• 10.5. Alternator Specifications
• 10.6. Dynamo Specifications
• 10.7. Alternator Troubleshooting
• 10.8. Alternator Components
• 10.9. Alternator Wiring Diagram
• 10.10. Alternator Standard Output
• 10.11. Alternator
• 10.11.1. Removal of Alternator
• 10.11.2. Disassembly of Alternator
• 10.11.3. Reassembly of Alternator
• 10.11.4. Installation of Alternator
• 10.12. Dynamo Component Location
• 10.13. Dynamo Wiring Diagram
• 10.14. Operation of Dynamo
• 10.15. Dynamo Standard Output
• 10.16. Testing of Dynamo
• 10.16.1. Testing Stator Coil Continuity
• 10.16.2. Testing Stator Coil Short-to-Ground
• 10.16.3. Testing Dynamo Regulated Output
• 10.16.4. Removal of Dynamo
• 10.16.5. Disassembly of Dynamo
• 10.16.6. Reassembly of Dynamo
• 10.16.7. Installation of Dynamo
• 11. Electric Wiring
• 11.1. Electric Wiring Precautions
• 11.2. Electric Wire Resistance
• 11.3. Battery Cable Resistance
• 11.4. Electrical Wire Sizes – Voltage Drop
• 11.5. Conversion of AWG to European Standards
• 12. Troubleshooting
• 12.1. Special Service Tools
• 12.2. Troubleshooting By Measuring Compression Pressure
• 12.2.1. Compression Pressure Measurement Method
• 12.2.2. Standard Compression Pressure
• 12.2.3. Engine Speed and Compression Pressure (Use for Reference)
• 12.2.4. Measured Value and Troubleshooting
• 12.3. Quick Reference Table For Troubleshooting
• 12.3.1. Troubleshooting Charts
• 12.4. Electric Wiring
• 13. Back Cover