Yanmar 3TNV, 4TNV Industrial Diesel Engine Service Manual

Description

• Model List:
  • 3TNV, 4TNV Industrial Diesel Engine

• 1. PREFACE
• 2. SAFETY LABELS
• 3. Safety Precautions
• 4. Precautions for Service Work
• 5. CONTENTS
• 6. General
• 6.1. Engine Nomenclature
• 6.2. Specifications
• 6.3. Fuel Oil, Lubricating Oil and Coolant Water
• 6.3.1. Fuel oil
• 6.3.2. Lubricating oil
• 6.3.3. Coolant water
• 6.4. Engine External Views
• 6.5. Structural Description
• 6.6. Exhaust gas emission regulation
• 6.6.1. The Emission Standard in USA
• 6.6.2. Engine identification
• 6.6.3. Guarantee Conditions for the EPA Emission Standard
• 7. Inspection and Adjustment
• 7.1. Periodic Maintenance Schedule
• 7.2. Periodic Inspection and Maintenance Procedure
• 7.2.1. Check before Daily Operation
• 7.2.2. inspection after initial 50 hours operation
• 7.2.3. Inspection every 50 hours
• 7.2.4. Inspection every 250 hours or 3 months
• 7.2.5. Inspection every 500 hours or 6 months
• 7.2.6. Inspection every 1,000 hours or one year
• 7.2.7. Inspection every 2000 hours or 2 years
• 7.3. Adjusting the no-load maximum or minimum speed
• 7.4. Sensor Inspection
• 7.4.1. Oil pressure switch
• 7.4.2. Thermo switch
• 7.5. Water leak check in cooling water system
• 7.6. Radiator cap inspection
• 7.7. Thermostat Inspection
• 7.8. Adjusting Operation
• 7.9. Long storage
• 8. TROUBLESHOOTING
• 8.1. Preparation before troubleshooting
• 8.2. Quick Reference Table for Troubleshooting
• 8.3. Troubleshooting by measuring Compression Pressure
• 9. Disassembly, Inspection and Reassembly of Engines
• 9.1. Complete disassembly and reassembly
• 9.1.1. Introduction
• 9.1.2. Special service tools
• 9.1.3. Complete disassembly
• 9.1.4. Precautions before and during reassembly
• 9.1.5. Adjusting operation
• 9.2. Cylinder Head Disassembly, Inspection and Reassembly
• 9.2.1. Components (2-valve cylinder head)
• 9.2.2. Disassembly procedure
• 9.2.3. Reassembly procedure
• 9.2.4. Servicing points
• 9.2.5. Parts Inspection and measurement
• 9.2.6. Valve seat correction
• 9.2.7. Valve guide replacement
• 9.2.8. Valve stem seal replacement
• 9.3. Gear Train and Camshaft
• 9.3.1. Components
• 9.3.2. Disassembly procedure
• 9.3.3. Reassembly procedure
• 9.3.4. Servicing points
• 9.3.5. Parts inspection and measurement
• 9.3.6. Oil seal replacement (Gear case side)
• 9.3.7. Camshaft bushing replacement
• 9.4. Cylinder Block
• 9.4.1. Components
• 9.4.2. Disassembly procedure
• 9.4.3. Reassembly procedure
• 9.4.4. Servicing points
• 9.4.5. Parts inspection and measurement
• 9.4.6. Cylinder bore correction
• 9.4.7. Piston pin bushing replacement
• 9.4.8. Oil seal replacement (Flywheel housing side)
• 10. LUBRICATION SYSTEM
• 10.1. Lubrication System Diagram
• 10.2. Trochoid Pump Components
• 10.3. Disassembly(Reverse the procedure below for assembly)
• 10.4. Servicing Points
• 10.5. Parts Inspection and Measurement
• 10.5.1. Trochoid pump inspection and measurement
• 11. COOLING SYSTEM
• 11.1. Cooling Water System
• 11.2. Cooling Water Pump Components
• 11.3. Disassembly (Reverse the procedure below for assembly)
• 11.4. Servicing Points
• 12. FUEL INJECTION PUMP/GOVERNOR
• 12.1. Introduction
• 12.2. Fuel Injection Pump
• 12.2.1. Fuel system diagram
• 12.2.2. External view and components
• 12.2.3. Disassembly procedure
• 12.2.4. Assembly procedure
• 12.2.5. Servicing points
• 13. TURBOCHARGER Disassembly, inspection and reassembly
• 13.1. Structure and Functions
• 13.1.1. Main specifications
• 13.1.2. Construction
• 13.1.3. Structural and functional outline
• 13.1.4. Components
• 13.2. Service Standards and Tightening Torque
• 13.2.1. Service standards
• 13.2.2. Tightening torque
• 13.3. Periodic Inspection Procedure
• 13.3.1. Periodic inspection intervals
• 13.3.2. Inspection procedure
• 13.3.3. Waste gate valve adjustment procedure
• 13.4. Disassembly Procedure
• 13.4.1. Preparation for disassembly
• 13.4.2. Inspection before disassembly
• 13.4.3. Disassembly
• 13.5. Washing and Inspection procedure
• 13.5.1. Washing
• 13.5.2. Inspection procedure
• 13.6. Reassembly Procedure
• 13.6.1. Preparation for reassembly
• 13.6.2. Reassembly
• 13.7. Handling after Disassembly and Reassembly
• 13.7.1. Instructions for turbocharger installation
• 13.8. Troubleshooting
• 13.8.1. Excessively exhaust smoke
• 13.8.2. White smoke generation
• 13.8.3. Sudden oil decrease
• 13.8.4. Decrease in output
• 13.8.5. Poor (slow) response (starting) of turbocharger
• 13.8.6. Abnormal sound or vibration
• 14. STARTING MOTOR
• 14.1. For 4TNV94L/ 98
• 14.1.1. Specifications
• 14.1.2. Components
• 14.1.3. Troubleshooting
• 14.1.4. Names of parts and disassembly procedure
• 14.1.5. Inspection and Maintenance
• 14.1.6. Service standards
• 14.1.7. Assembly
• 14.1.8. Characteristic test
• 14.2. For 4TNV106(T)
• 14.2.1. Specifications
• 14.2.2. Congiguration drawing
• 14.2.3. Troubleshooting
• 14.2.4. Component names and disassembly procedure
• 14.2.5. Disassembly procedure
• 14.2.6. Inspection and maintenance
• 14.2.7. Assembly
• 14.2.8. Adjustment
• 14.2.9. Service standards
• 15. ALTERNATOR
• 15.1. The 40A Alternator for 3TNV84 and other models
• 15.1.1. Components
• 15.1.2. Specifications
• 15.1.3. Wiring diagram
• 15.1.4. Standard output characteristics
• 15.1.5. Inspection
• 15.1.6. Troubleshooting
• 16. ELECTRIC WIRING
• 16.1. Electric Wiring Diagram
• 16.2. PRECAUTION ON ELECTRIC WIRING
• 16.2.1. Alternator
• 16.2.2. Starting motor
• 16.2.3. Current limiter
• 16.2.4. Section area and resistance of electric wire
• 17. SERVICE STANDARDS
• 17.1. Engine Tuning
• 17.2. Engine Body
• 17.2.1. Cylinder head
• 17.2.2. Gear train and camshaft
• 17.2.3. Cylinder block
• 17.3. Lubricating Oil System (Trochoid Pump)
• 18. TIGHTENING TORQUE for BOLTS and NUTS
• 18.1. Tightening Torques for Main Bolts and Nuts
• 18.2. Tightening Torques for Standard Bolts and Nuts
• 19. BACKCOVER