Yanmar 3TNV88F Service Manual

Description

• Model List:
  • 3TNV88F

• 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
• 3.2. 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. Location of labels/nameplates on direct injection model engines
• 4.2.2. Engine Nameplate (Typical)
• 4.3. Emission Control Regulations
• 4.3.1. EPA/ARB Regulations – USA Only
• 4.4. Emission Control Labels
• 4.4.1. EPA/CARB Labels (Typical)
• 4.5. Engine Family
• 4.6. Function of Major Engine Components
• 4.7. Main Electronic Control Components and Features
• 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. Engine Oil Viscosity
• 4.10.3. Checking Engine Oil
• 4.10.4. Adding Engine Oil
• 4.10.5. 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 General Specifications
• 4.13. Principal Engine Specifications
• 4.14. Engine Service Standards
• 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. Before You Begin Servicing
• 5.2. Introduction
• 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
• 5.4.8. Every 3000 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. Rocker Arm and Shaft
• 5.7.5. Valve Spring
• 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 Piston Specifications
• 5.9.1. Crankshaft
• 5.9.2. Thrust Bearing
• 5.9.3. 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. Components of a Cylinder Head
• 5.14.3. Disassembly of Cylinder Head
• 5.14.4. Cleaning of Cylinder Head Components
• 5.14.5. Inspection of Cylinder Head Components
• 5.14.6. Reassembly of Cylinder Head
• 5.15. Measuring and Adjusting Valve Clearance
• 5.15.1. cylinder engines
• 5.16. Crankshaft and Camshaft Components
• 5.16.1. Disassembly of Engine
• 5.16.2. Disassembly of Camshaft and Timing Components
• 5.16.3. Disassembly of Crankshaft and Piston Components
• 5.16.4. Inspection of Crankshaft and Camshaft Components
• 5.16.5. Honing and Boring
• 5.16.6. Reassembly of Crankshaft and Piston Components
• 5.16.7. Reassembly of Camshaft and Timing Components
• 5.16.8. Final Reassembly of Engine
• 5.17. EGR system
• 5.17.1. EGR System
• 5.17.2. Inspecting/Cleaning EGR Related Components
• 6. Fuel System
• 6.1. Before You Begin Servicing
• 6.1.1. Trochoid Fuel Pump
• 6.1.2. Electronically Controlled Governor
• 6.2. Fuel System Specifications
• 6.2.1. Special Torque Chart
• 6.3. Special Service Tools
• 6.4. Measuring Instruments
• 6.5. Fuel System Diagram
• 6.6. Fuel System Components
• 6.7. Fuel Injection Pump
• 6.7.1. Removal of Fuel Injection Pump
• 6.7.2. Installation of Fuel Injection Pump
• 6.8. Checking and Adjusting Fuel Injection Timing
• 6.8.1. Determining the Fuel Injection Timing Specification
• 6.8.2. Checking Fuel Injection Timing
• 6.8.3. Adjusting Fuel Injection Timing
• 6.9. Fuel Injectors
• 6.9.1. Removal of Fuel Injectors
• 6.9.2. Testing of Fuel Injectors
• 6.9.3. Disassembly and Inspection of Fuel Injectors
• 6.9.4. Adjusting Fuel Injector Pressure
• 6.9.5. Reassembly of Fuel Injectors
• 6.9.6. 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. Removal of Engine Coolant Pump
• 7.6.2. Disassembly of Engine Coolant Pump
• 7.6.3. Cleaning and Inspection
• 7.6.4. Reassembly of Engine Coolant Pump
• 7.6.5. Installation 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. Rotor shaft 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
• 9.3.1. Standard and Optional
• 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. Inspection and Maintenance
• 9.7.4. No-load Test
• 9.7.5. Installation of Starter Motor
• 10. Alternator
• 10.1. Before You Begin Servicing
• 10.2. Introduction
• 10.3. Dynamo and Alternator Information
• 10.3.1. Standard and Optional Dynamos
• 10.3.2. Standard and Optional Alternators
• 10.4. Alternator Specifications
• 10.5. Dynamo Specifications
• 10.6. Alternator Troubleshooting
• 10.7. Alternator Components
• 10.8. Alternator Wiring Diagram
• 10.9. Alternator Standard Output
• 10.10. Alternator
• 10.10.1. Removal of Alternator
• 10.10.2. Disassembly of Alternator
• 10.10.3. Reassembly of Alternator
• 10.10.4. Installation of Alternator
• 10.11. Dynamo Component Location
• 10.12. Dynamo Wiring Diagram
• 10.13. Operation of Dynamo
• 10.14. Dynamo Standard Output
• 10.15. Testing of Dynamo
• 10.15.1. Testing Stator Coil Continuity
• 10.15.2. Testing Stator Coil Short-to-Ground
• 10.15.3. Testing Dynamo Regulated Output
• 10.15.4. Removal of Dynamo
• 10.15.5. Disassembly of Dynamo
• 10.15.6. Reassembly of Dynamo
• 10.15.7. Installation of Dynamo
• 11. ELECTRONIC CONTROL SYSTEM
• 11.1. Before You Begin Servicing
• 11.2. Introduction
• 11.3. Electronic Control System
• 11.4. Electronic control harness connections
• 12. Electric Wiring
• 12.1. Electric Wiring Precautions
• 12.2. Electrical Wire Resistance
• 12.3. Battery Cable Resistance
• 12.4. Electrical Wire Sizes – Voltage Drop
• 12.5. Conversion of AWG to European Standards
• 13. Failure Diagnosis
• 13.1. Special Service Tools
• 13.2. Troubleshooting By Measuring Compression Pressure
• 13.2.1. Compression Pressure Measurement Method
• 13.3. Quick Reference Table For Troubleshooting
• 13.3.1. Failure Diagnostic List