Yanmar TNV Series Industrial Diesel Engine Repair Service Manual
Yanmar TNV Series Industrial Diesel Engine Repair Service Manual
- This Workshop Service Repair manual PDF download for the TNV Series Yanmar Industrial Diesel Engine has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to fully at every opportunity.
Introduction Yanmar Warranties Safety General Service Information Engine Periodic Maintenance Fuel System Cooling System Lubrication System Turbocharger Starter Motor Alternator Electric Wiring Troubleshooting
MANUAL SPECIFICATION :
File Format : PDF Language : English Printable : Yes Searchable : Yes Bookmarked : Yes Part Number : OBTNV-U00100 Total Pages : 367
This Service / Repair / Workshop Manual PDF Download contains specs, diagrams, actual real photo illustrations, and schemes. In addition to space savings, nice thing about having completly searcheble PDF files instead of a hard-printed manual is that you can use the Search feature in your PDF reader software (Adobe Acrobat) to find just what your looking for and just print out the exact pages you need or all manual easily. This is the same manual your local dealer will use when doing a repair. This is a must for the Do-It-Yourselfer! Saving Yourself $$$$$$ In Service Repair And Maintenance Costs !!!!
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COVER Table of Contents Introduction Yanmar Warranties Yanmar Limited Warranty What is Covered by this Warranty? How Long is the Warranty Period? What the Engine Owner Must Do: To Locate an Authorized Yanmar Industrial Engine Dealer or Distributor: What Yanmar Will Do: What is Not Covered by this Warranty? Warranty Limitations: Warranty Modifications: Questions: Retail Purchaser Registration Emission System Warranty Yanmar Co., Ltd. Limited Emission Control System Warranty - USA Only Your Warranty Rights and Obligations: California Manufacturer’s Warranty Period: Warranty Coverage: Warranted Parts: Exclusions: Owner’s Warranty Responsibilities: Safety Safety Statements Safety Precautions General Service Information Component Identification Location of Labels Engine Nameplate (Typical) Emission Control Regulations EPA / ARB Regulations - USA Only Emission Control Labels The 97/68/EC Directive Certified Engines Engine Family Function of Major Engine Components Function of Cooling System Components Diesel Fuel Diesel Fuel Specifications Additional Technical Fuel Requirements Bio-Diesel Fuels Filling The Fuel Tank Priming the Fuel System Engine Oil Engine Oil Specifications Service Categories Definitions Additional Technical Engine Oil Requirements: Engine Oil Viscosity Checking Engine Oil Adding Engine Oil Engine Oil Capacity (Typical) Engine Coolant Engine Coolant Specifications Additional Technical Coolant Specifications: Alternative Engine Coolant Filling Radiator with Engine Coolant Engine Coolant Capacity (Typical) Specifications Description of Model Number Engine Speed Specifications Engine General Specifications Principal Engine Specifications 3TNV82A 3TNV84 3TNV84T 3TNV88 4TNV84 4TNV84T 4TNV88 4TNV94L 4TNV98 4TNV98T 4TNV106 4TNV106T Engine Service Standards Tightening Torques for Standard Bolts and Nuts Abbreviations and Symbols Abbreviations Symbols Unit Conversions Unit Prefixes Units of Length Units of Volume Units of Mass Units of Force Units of Torque Units of Pressure Units of Power Units of Temperature Periodic Maintenance Before You Begin Servicing Introduction The Importance of Periodic Maintenance Performing Periodic Maintenance Yanmar Replacement Parts Required EPA / ARB Maintenance - USA Only EPA / ARB Installation Requirements - USA Only Periodic Maintenance Schedule Periodic Maintenance Procedures After Initial 50 Hours of Operation Replace Engine Oil and Engine Oil Filter Check and Adjust Cooling Fan V-Belt Every 50 Hours of Operation Drain Fuel Filter / Water Separator Check Battery 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 Every 500 Hours of Operation Replace Air Cleaner Element Replace Fuel Filter Clean Fuel Filter / Water Separator Every 1000 Hours of Operation Drain, Flush and Refill Cooling System With New Coolant Adjust Intake / Exhaust Valve Clearance Every 1500 Hours of Operation Inspect, Clean and Test Fuel Injectors Inspect Turbocharger (Blower Wash as Necessary) - 3TNV84T, 4TNV98T, 4TNV84T, and 4TNV106T Inspect Crankcase Breather System Every 2000 Hours of Operation Check and Replace Fuel Hoses and Engine Coolant Hoses Lap the Intake and Exhaust Valves Engine Before You Begin Servicing Introduction Cylinder Head Specifications Adjustment Specifications Cylinder Head Intake / Exhaust Valve and Guide Push Rod Rocker Arm and Shaft Valve Spring Camshaft and Timing Gear Train Specifications Camshaft Idler Gear Shaft and Bushing Timing Gear Backlash Crankshaft and Piston Specifications Crankshaft Thrust Bearing Piston Piston Ring Connecting Rod Connecting Rod Small End Connecting Rod Big End Tappet Cylinder Block Specifications Cylinder Block Special Torque Chart Torque for Bolts and Nuts Special Service Tools Measuring Instruments 2-Valve Cylinder Head 2-Valve Cylinder Head Components Disassembly of 2-Valve Cylinder Head Removal of Valve Cover Removal of Rocker Arm Assembly Disassembly of Rocker Arm Assembly Removal of Cylinder Head Removal of Intake / Exhaust Valves Removal of Valve Guides Cleaning of Cylinder Head Components Inspection of Cylinder Head Components Inspection of Push Rods Inspection of Rocker Arm Assembly Inspection of Valve Guides Inspection of Cylinder Head Inspection of Intake and Exhaust Valves Inspection of Valve Springs Reassembly of Cylinder Head Reassembly of Valve Guides Reassembly of Intake and Exhaust Valves Reassembly of Cylinder Head Reassembly of Rocker Arm Reassembly Reassembly of the Valve Cover 4-Valve Cylinder Head 4-Valve Cylinder Head Components Disassembly of 4-Valve Cylinder Head Removal of Valve Cover Removal of Rocker Arm Assembly Disassembly of Rocker Arm Assembly Removal of Cylinder Head Removal of Intake and Exhaust Valves Removal of Valve Guides Cleaning of Cylinder Head Components Inspection of Cylinder Head Components Inspection of Push Rods Inspection of Rocker Arm Assembly Inspection of Valve Guides Inspection of Cylinder Head Inspection of Intake and Exhaust Valves Inspection of Valve Springs Inspection of Valve Bridges Reassembly of Cylinder Head Reassembly of Valve Guides Reassembly of Intake and Exhaust Valves Reassembly of Cylinder Head Reassembly of Rocker Arm Assembly Reassembly of the Valve Cover Measuring and Adjusting Valve Clearance 2-Valve Cylinder Heads 4-Valve Cylinder Heads Crankshaft and Camshaft Components Disassembly of Engine Disassembly of Camshaft and Timing Components Removal of Timing Gear Case Cover Checking Timing Gear Backlash Measuring Idler Gear-to-Crankshaft Gear Backlash Measuring Idler Gear-to-Camshaft Gear Backlash Removal of Timing Gears Removal of Oil Pan Removal of Camshaft Removal of Gear Case or Front Plate Disassembly of Crankshaft and Piston Components Removal of Pistons Removal of Crankshaft Inspection of Crankshaft and Camshaft Components Replacement of Crankshaft Oil Seals Measure Crankshaft Bearing Oil Clearance Inspection of Cylinder Block Inspection of Pistons, Piston Rings and Wrist Pin Inspection of Connecting Rod Inspection of Tappets Inspection of Crankshaft Inspection of Camshaft Inspection of Camshaft Bushing and Bores Inspection of Idler Gear and Shaft Honing and Boring Reassembly of Crankshaft and Piston Components Reassembly of Pistons Installation of Crankshaft Installation of Pistons Reassembly of Camshaft and Timing Components Installation of Gear Case or Front Plate Installation of Camshaft Installation of Timing Gears Installation of Gear Case Cover Installation of Oil Pan Final Reassembly of Engine Fuel System Before You Begin Servicing Introduction Fuel Injection Pump Stop Solenoid Cold Start Device Trochoid Fuel Pump Fuel System Specifications Special Torque Chart Test and Adjustment Specifications Special Service Tools Measuring Instruments Fuel System Diagram Fuel System Components 2-Valve Cylinder Head 4-Valve Cylinder Head Fuel Injection Pump Removal of Fuel Injection Pump Installation of Fuel Injection Pump Checking and Adjusting Fuel Injection Timing Determining the Fuel Injection Timing Specification (6.8 X 2) = 13.6 + 4 = 17.6˚ Fuel injection Timing Checking Fuel Injection Timing Adjusting Fuel Injection Timing Fuel Injectors Removal of Fuel Injectors 2-Valve Cylinder Head 4-Valve Cylinder Head Testing of Fuel Injectors Disassembly and Inspection of Fuel Injectors Adjusting Fuel Injector Pressure Reassembly of Fuel Injectors Installation of the Fuel Injectors 2-Valve Cylinder Head 4-Valve Cylinder Head Cooling System Before You Begin Servicing Introduction Cooling System Diagram Engine Coolant Pump Components Engine Coolant System Check Engine Coolant Pump Removal of Engine Coolant Pump Disassembly of Engine Coolant Pump Cleaning and Inspection Temperature Switch Thermostat Radiator Cap Reassembly of Engine Coolant Pump Installation of Engine Coolant Pump Lubrication System Before You Begin Servicing Introduction Oil Pump Service Information Lubrication System Diagram Checking Engine Oil Pressure Trochoid Oil Pump 3TNV82A to 4TNV88 Oil Pump Components Disassembly of Oil Pump Cleaning and Inspection Check Outer Rotor Outside Clearance Outer Rotor to Inner Rotor Tip Clearance Check Outer Rotor Side Clearance Check Inner Rotor and Gear Boss Clearance Reassembly of Oil Pump Trochoid Oil Pump 4TNV94L/98/106 Oil Pump Components Disassembly of Oil Pump Cleaning and Inspection Check Outer Rotor Outside Clearance Outer Rotor to Inner Rotor Tip Clearance Check Outer Rotor Side Clearance Check Rotor Shaft Clearance Reassembly of Oil Pump Turbocharger Before You Begin Servicing Introduction Specifications Turbocharger Service Information Troubleshooting Excessive Exhaust Smoke Generates White Smoke Sudden Oil Decrease Decrease in Output Poor (Slow) Response (Starting) of Turbocharger Abnormal Sound or Vibration Turbocharger Components Turbocharger Component Functions Theory of Operation Turbine Compressor Bearings Compressor Side Sealing Mechanism Waste Gate Modulation Waste Gate Control Washing Procedure Periodic Inspection Visual Inspection Inspection of Rotor Rotation Inspection of Rotor Play Removal of Turbocharger Checking Rotor Play To Check Rotor End Play: To Check Rotor Run-out: Waste Gate Valve Test Waste Gate Actuator Leak Test Installation of Turbocharger Starter Motor Before You Begin Servicing Introduction Starter Motor Information 3TNV82A to 4TNV88 - Standard and Optional Starter Motor Specifications Starter Motor Troubleshooting Starter Motor Components Starter Motor Removal of Starter Motor Disassembly of Starter Motor Cleaning and Inspection Armature Field Coil Magnetic Switch Pinion Clutch Assembly Reassembly of Starter Motor Check Pinion Projection Length No-Load Test Installation of Starter Motor Alternator Before You Begin Servicing Introduction Dynamo and Alternator Information 3TNV82A to 4TNV106T - Standard and Optional Dynamos 3TNV82A to 4TNV106T - Standard and Optional Alternators Alternator Specifications Dynamo Specifications Alternator Troubleshooting Alternator Components Alternator Wiring Diagram Alternator Standard Output Alternator Removal of Alternator Disassembly of Alternator Reassembly of Alternator Installation of Alternator Dynamo Component Location Dynamo Wiring Diagram Operation of Dynamo Dynamo Standard Output Testing of Dynamo Testing Stator Coil Continuity Testing Stator Coil Short-to-Ground Testing Dynamo Regulated Output Dynamo Removal of Dynamo Disassembly of Dynamo Reassembly of Dynamo Installation of Dynamo Electric Wiring Electric Wiring Precautions Electrical Wire Resistance Battery Cable Resistance Electrical Wire Sizes - Voltage Drop Conversion of AWG to European Standards Troubleshooting Special Service Tools Troubleshooting By Measuring Compression Pressure Compression Pressure Measurement Method Measured Value and Troubleshooting Quick Reference Table For Troubleshooting BACK COVER