Manual

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3. ENGINE

Summary of content (283 pages)

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3.
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TNV_IDI_ServiceManual_(3TNV72 for YN only).
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TNV_IDI_ServiceManual_(3TNV72 for YN only).book ii ページ２００７年１１月２９日木曜日午後２時５８分 This Service Manual has been developed for the exclusive use of service and repair professionals such as Yanmar authorized Distributors and Yanmar authorized Dealers. It is written with these professionals in mind and may not contain the necessary detail or safety statements that may be required for a non-professional to perform the service or repair properly and / or safely.
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TNV_IDI_ServiceManual_(3TNV72 for YN only).book iii ページ２００７年１１月２９日木曜日午後２時５８分 TABLE OF CONTENTS TNV IDI Service Manual Page Table of Contents ................................................................................... iii Introduction ......................................................................................... 1-1 Yanmar Warranties.............................................................................. 2-1 Safety............................................................
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TNV_IDI_ServiceManual_(3TNV72 for YN only).
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TNV_IDI_ServiceManual_(3TNV72 for YN only).book 1 ページ２００７年１１月２９日 TNV IDI Service Manual 木曜日午後２時５８分 Section 1 INTRODUCTION This Service Manual describes the service procedures for the TNV series indirect injection engines. These engines are certified by the U.S. EPA, California ARB and/or the 97/68/EC Directive for industrial use. Please use this manual for accurate, quick and safe servicing of the engine.
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TNV_IDI_ServiceManual_(3TNV72 for YN only).
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TNV_IDI_ServiceManual_(3TNV72 for YN only).book 1 ページ２００７年１１月２９日 TNV IDI Service Manual 木曜日午後２時５８分 Section 2 YANMAR WARRANTIES Page Yanmar Limited Warranty................................................................ What is Covered by this Warranty? .......................................... How Long is the Warranty Period? ........................................... What the Engine Owner Must Do: ............................................
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TNV_IDI_ServiceManual_(3TNV72 for YN only).
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TNV_IDI_ServiceManual_(3TNV72 for YN only).book 3 ページ２００７年１１月２９日 Yanmar Limited Warranty 木曜日午後２時５８分 YANMAR WARRANTIES YANMAR LIMITED WARRANTY What is Covered by this Warranty? Yanmar warrants to the original retail purchaser that a new Yanmar TNV Series Industrial Engine will be free from defects in material and / or workmanship for the duration of the warranty period.
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TNV_IDI_ServiceManual_(3TNV72 for YN only).book 4 ページ２００７年１１月２９日 YANMAR WARRANTIES 木曜日午後２時５８分 Yanmar Limited Warranty Yanmar Limited Warranty - Continued To Locate an Authorized Yanmar Industrial Engine Dealer or Distributor: You can locate your nearest authorized Yanmar industrial engine dealer or distributor by visiting the Yanmar Corp., LTD. website at: http://www.yanmar.co.jp (The Japanese language page will be displayed.) For English language “click” on “English Page.
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TNV_IDI_ServiceManual_(3TNV72 for YN only).book 5 ページ２００７年１１月２９日 Yanmar Limited Warranty 木曜日午後２時５８分 YANMAR WARRANTIES Yanmar Limited Warranty - Continued Warranty Limitations: The foregoing is Yanmar's only obligation to you and your exclusive remedy for breach of warranty. Failure to follow the requirements for submitting a claim under this Warranty may result in a waiver of all claims for damages and other relief.
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TNV_IDI_ServiceManual_(3TNV72 for YN only).book 6 ページ２００７年１１月２９日 YANMAR WARRANTIES 木曜日午後２時５８分 Emission System Warranty EMISSION SYSTEM WARRANTY YANMAR CO., LTD. LIMITED EMISSION CONTROL SYSTEM WARRANTY - USA ONLY Your Warranty Rights and Obligations: California The California Air Resources Board (CARB), the Environmental Protection Agency (EPA) and Yanmar Co., Ltd.
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TNV_IDI_ServiceManual_(3TNV72 for YN only).book 7 ページ２００７年１１月２９日木曜日午後２時５８分 Emission System Warranty YANMAR WARRANTIES Limited Emission Control System Warranty - USA Only - Continued Warranty Coverage: This warranty is transferable to each subsequent purchaser for the duration of the warranty period. Repair or replacement of any warranted part will be performed at an authorized Yanmar industrial engine dealer or distributor.
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TNV_IDI_ServiceManual_(3TNV72 for YN only).book 8 ページ２００７年１１月２９日木曜日午後２時５８分 YANMAR WARRANTIES Emission System Warranty Limited Emission Control System Warranty - USA Only - Continued Exclusions: Failures other than those arising from defects in material and / or workmanship are not covered by this warranty.
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TNV_IDI_ServiceManual_(3TNV72 for YN only).book 1 ページ２００７年１１月２９日木曜日午後２時５８分 Section 3 TNV IDI Service Manual SAFETY Page Safety Statements ........................................................................... 3-3 Safety Precautions ..........................................................................
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TNV_IDI_ServiceManual_(3TNV72 for YN only).
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TNV_IDI_ServiceManual_(3TNV72 for YN only).book 3 ページ２００７年１１月２９日木曜日午後２時５８分 Safety Statements SAFETY SAFETY STATEMENTS Yanmar is concerned for your safety and your machine’s condition. Safety statements are one of the primary ways to call your attention to the potential hazards associated with Yanmar TNV engine operation.
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TNV_IDI_ServiceManual_(3TNV72 for YN only).book 4 ページ２００７年１１月２９日 SAFETY 木曜日午後２時５８分 Safety Precautions SAFETY PRECAUTIONS A DANGER A DANGER EXPLOSION HAZARD! 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.
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TNV_IDI_ServiceManual_(3TNV72 for YN only).book 5 ページ２００７年１１月２９日木曜日午後２時５８分 Safety Precautions SAFETY A DANGER A DANGER FIRE AND EXPLOSION HAZARD! FIRE AND EXPLOSION HAZARD! • Diesel fuel is flammable and explosive under certain conditions. • 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.
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TNV_IDI_ServiceManual_(3TNV72 for YN only).book 6 ページ２００７年１１月２９日 SAFETY 木曜日午後２時５８分 Safety Precautions A DANGER A DANGER FIRE AND EXPLOSION HAZARD! FIRE AND EXPLOSION HAZARD! • Diesel fuel is flammable and explosive under certain conditions. • Diesel fuel is flammable and explosive under certain conditions. • Only fill the fuel tank with diesel fuel. Filling the fuel tank with gasoline may result in a fire and will damage the engine.
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TNV_IDI_ServiceManual_(3TNV72 for YN only).book 7 ページ２００７年１１月２９日木曜日午後２時５８分 Safety Precautions SAFETY A DANGER A DANGER FIRE AND EXPLOSION HAZARD! • Diesel fuel is flammable and explosive under certain conditions. • Be sure to place the diesel fuel container on the ground when transferring the diesel fuel from the pump to the container. Hold the hose nozzle firmly against the side of the container while filling it.
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TNV_IDI_ServiceManual_(3TNV72 for YN only).book 8 ページ２００７年１１月２９日 SAFETY 木曜日午後２時５８分 Safety Precautions A WARNING A WARNING SEVER HAZARD! EXHAUST HAZARD! • Keep hands and other body parts away from moving / rotating parts such as the cooling fan, flywheel or PTO shaft. • NEVER operate the engine in an enclosed area such as a garage, tunnel, underground room, manhole or ship’s hold without proper ventilation.
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TNV_IDI_ServiceManual_(3TNV72 for YN only).book 9 ページ２００７年１１月２９日木曜日午後２時５８分 Safety Precautions SAFETY A WARNING A WARNING BURN HAZARD! EXPOSURE HAZARD! • Wear personal protective equipment such as gloves, work shoes, eye and hearing protection as required 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.
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TNV_IDI_ServiceManual_(3TNV72 for YN only).book 10 ページ２００７年１１月２９日 SAFETY 木曜日午後２時５８分 Safety Precautions A WARNING A WARNING HIGH-PRESSURE HAZARD! ENTANGLEMENT HAZARD! • Avoid skin contact with the high-pressure diesel fuel spray caused by a fuel system leak such as a 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.
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TNV_IDI_ServiceManual_(3TNV72 for YN only).book 11 ページ２００７年１１月２９日木曜日午後２時５８分 Safety Precautions SAFETY A WARNING A WARNING To prevent possible eye injury, always wear SAFETY GLASSES while servicing the engine. 0000013en A WARNING FUME / BURN HAZARD! • Always read and follow safety related precautions found on containers of hazardous substances like parts cleaners, primers, sealants and sealant removers. • Failure to comply could result in death or serious injury.
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TNV_IDI_ServiceManual_(3TNV72 for YN only).book 12 ページ２００７年１１月２９日 SAFETY 木曜日午後２時５８分 Safety Precautions A CAUTION A CAUTION If any oil pump component clearance exceeds its limit, the oil pump must be replaced as an assembly. 0000015en FLYING OBJECT HAZARD! • ALWAYS wear eye protection when servicing the engine and when using compressed air or high-pressure water. Dust, flying debris, compressed air, pressurized water or steam may injure your eyes.
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TNV_IDI_ServiceManual_(3TNV72 for YN only).book 13 ページ２００７年１１月２９日木曜日午後２時５８分 Safety Precautions SAFETY CAUTION CAUTION Make sure the engine is installed on a level surface.
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TNV_IDI_ServiceManual_(3TNV72 for YN only).book 14 ページ２００７年１１月２９日 SAFETY 木曜日午後２時５８分 Safety Precautions CAUTION CAUTION If any indicator illuminates during engine operation, stop the engine immediately. Determine the cause and repair the problem before you continue to operate the engine. • NEVER overfill the engine with engine oil. • ALWAYS keep the oil level between the upper and lower lines on the oil cap / dipstick. 0000029en 0000015en CAUTION CAUTION • Only use the engine oil specified.
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TNV_IDI_ServiceManual_(3TNV72 for YN only).book 15 ページ２００７年１１月２９日木曜日午後２時５８分 Safety Precautions SAFETY CAUTION CAUTION New Engine Break-in: • ALWAYS be environmentally responsible. • Follow the 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.
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TNV_IDI_ServiceManual_(3TNV72 for YN only).book 16 ページ２００７年１１月２９日 SAFETY 木曜日午後２時５８分 Safety Precautions CAUTION CAUTION • NEVER attempt to modify the engine’s design or safety features such as defeating the engine speed limit control or the fuel injection quantity control. • Failure to comply may impair the engine’s safety and performance characteristics and shorten the engine’s life. Any alterations to this engine may affect the warranty coverage of your engine.
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TNV_IDI_ServiceManual_(3TNV72 for YN only).book 17 ページ２００７年１１月２９日木曜日午後２時５８分 Safety Precautions SAFETY CAUTION CAUTION • When the engine is operated in dusty conditions, clean the air cleaner element more frequently. • NEVER operate the engine with the air cleaner element(s) removed. This may allow foreign material to enter the engine and damage it. 0000026en Do not turn the battery switch OFF while the engine is operating. Damage to the alternator will result.
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TNV_IDI_ServiceManual_(3TNV72 for YN only).book 18 ページ２００７年１１月２９日 SAFETY 木曜日午後２時５８分 Safety Precautions CAUTION CAUTION 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. 0000048en CAUTION Do not use a high-pressure wash directly on the alternator. Water will damage the alternator and result in inadequate charging.
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TNV_IDI_ServiceManual_(3TNV72 for YN only).book 19 ページ２００７年１１月２９日木曜日午後２時５８分 Safety Precautions SAFETY CAUTION CAUTION 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.
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TNV_IDI_ServiceManual_(3TNV72 for YN only).book 20 ページ２００７年１１月２９日 SAFETY 木曜日午後２時５８分 Safety Precautions CAUTION CAUTION Do not allow the honing tool to operate in one position for any length of time. Damage to the cylinder wall will occur. Keep the tool in constant up-and-down motion. 0000090en CAUTION Any part which is found defective as a result of inspection or any part whose measured value does not satisfy the standard or limit must be replaced.
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TNV_IDI_ServiceManual_(3TNV72 for YN only).book 1 ページ２００７年１１月２９日 TNV IDI Service Manual 木曜日午後２時５８分 Section 4 GENERAL SERVICE INFORMATION Page Component Identification................................................................. 4-3 Location of Labels ........................................................................... 4-4 EPA / ARB Emission Control Regulations - USA Only.................... 4-4 Emission Control Labels..................................................................
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TNV_IDI_ServiceManual_(3TNV72 for YN only).book 2 ページ２００７年１１月２９日木曜日午後２時５８分 GENERAL SERVICE INFORMATION Principal Engine Specifications ..................................................... 4-20 3TNV72 ................................................................................... 4-20 Engine Service Information ........................................................... 4-21 Tightening Torques for Standard Bolts and Nuts .......................... 4-22 Abbreviations and Symbols..................
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TNV_IDI_ServiceManual_(3TNV72 for YN only).book 3 ページ２００７年１１月２９日木曜日 Component Identification 午後２時５８分 GENERAL SERVICE INFORMATION COMPONENT IDENTIFICATION Figure 4-1 shows where major engine components are located.
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TNV_IDI_ServiceManual_(3TNV72 for YN only).book 4 ページ２００７年１１月２９日 GENERAL SERVICE INFORMATION LOCATION OF LABELS Figure 4-2 shows the location of regulatory and safety labels on Yanmar TNV series engines. (2) (1) 木曜日午後２時５８分 Location of Labels EPA / ARB EMISSION CONTROL REGULATIONS - USA ONLY Yanmar TNV engines meet Environmental Protection Agency (EPA) (U. S. Federal) emission control standards as well as the California Air Resources Board (ARB, California) regulations.
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TNV_IDI_ServiceManual_(3TNV72 for YN only).book 5 ページ２００７年１１月２９日木曜日 The 97/68/EC Directive Certified Engines EPA / ARB Labels (Typical) EMISSION CONTROL INFORMATION THIS ENGINE COMPLIES WITH U.S. EPA REGULATIONS FOR NONROAD DIESEL ENGINES. LOW SULFUR FUEL OR ULTRA LOW SULFUR FUEL ONLY M. Y.
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TNV_IDI_ServiceManual_(3TNV72 for YN only).book 6 ページ２００７年１１月２９日 GENERAL SERVICE INFORMATION 木曜日午後２時５８分 Function of Major Engine Components FUNCTION OF MAJOR ENGINE COMPONENTS 4-6 Component Function Air Cleaner The air cleaner prevents airborne contaminants from entering the engine. Since the air cleaner is application specific, it must be carefully selected by an application engineer. It is not part of the basic engine package as shipped from the Yanmar factory.
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TNV_IDI_ServiceManual_(3TNV72 for YN only).book 7 ページ２００７年１１月２９日 Function of Major Engine Components 木曜日午後２時５８分 GENERAL SERVICE INFORMATION Component Function Fuel Tank The fuel tank is a reservoir that holds diesel fuel. When fuel leaves the fuel tank it goes to the fuel filter / water separator. Next, fuel is pumped to the fuel filter by the fuel pump. Next the fuel goes to the fuel injection pump.
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TNV_IDI_ServiceManual_(3TNV72 for YN only).book 8 ページ２００７年１１月２９日 GENERAL SERVICE INFORMATION 木曜日午後２時５８分 Function of Cooling System Components FUNCTION OF COOLING SYSTEM COMPONENTS 4-8 Component Function Cooling System The TNV engine is liquid-cooled by means of a cooling system. The cooling system consists of a radiator, radiator cap, engine cooling fan, engine coolant pump, thermostat, and reserve tank. Note that all cooling system components are required for proper engine operation.
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TNV_IDI_ServiceManual_(3TNV72 for YN only).book 9 ページ２００７年１１月２９日 Diesel Fuel 木曜日午後２時５８分 GENERAL SERVICE INFORMATION DIESEL FUEL • Carbon residue content not to exceed 0.35% by volume. Less than 0.1% is preferred. Diesel Fuel Specifications • Total aromatics content should not exceed 35% by volume. Less than 30% is preferred. Diesel fuel should comply with the following specifications. The table lists several worldwide specifications for diesel fuels. Diesel Fuel Specification Location No.
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TNV_IDI_ServiceManual_(3TNV72 for YN only).book 10 ページ２００７年１１月２９日木曜日午後２時５８分 GENERAL SERVICE INFORMATION Precautions and concerns regarding the use of bio-fuels: 1. Free methanol in FAME may result in corrosion of aluminum and zinc FIE components. Diesel Fuel Filling the Fuel Tank A DANGER 2. Free water in FAME may result in plugging of fuel filters and increased bacterial growth. 3.
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TNV_IDI_ServiceManual_(3TNV72 for YN only).book 11 ページ２００７年１１月２９日 Diesel Fuel 木曜日午後２時５８分 GENERAL SERVICE INFORMATION A DANGER A DANGER FIRE AND EXPLOSION HAZARD! FIRE AND EXPLOSION HAZARD! • Diesel fuel is flammable and explosive under certain conditions. • Diesel fuel is flammable and explosive under certain conditions. • Be sure to place the diesel fuel container on the ground when transferring the diesel fuel from the pump to the container.
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TNV_IDI_ServiceManual_(3TNV72 for YN only).book 12 ページ２００７年１１月２９日木曜日午後２時５８分 GENERAL SERVICE INFORMATION Note that a typical fuel tank is shown. The fuel tank on the equipment being serviced may be different. 1. Clean the area around the fuel cap (Figure 4-3, (1)). Diesel Fuel Priming the Fuel System A DANGER 2. Remove the fuel cap (Figure 4-3, (1)) from the fuel tank (Figure 4-3, (2)). 3. Observe the fuel level sight gauge (Figure 4-3, (3)) and stop fueling when gauge shows fuel tank is full.
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TNV_IDI_ServiceManual_(3TNV72 for YN only).book 13 ページ２００７年１１月２９日 Engine Oil 木曜日午後２時５８分 GENERAL SERVICE INFORMATION To prime the fuel system if a mechanical fuel pump is installed: 1. Operate the fuel priming lever (Figure 4-4, (1)) several times until the fuel filter cup (Figure 4-4, (2)) is filled with fuel. 2. NEVER use the starter motor to prime the fuel system. This may cause the starter motor to overheat and damage the coils, pinion and / or ring gear.
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TNV_IDI_ServiceManual_(3TNV72 for YN only).book 14 ページ２００７年１１月２９日木曜日午後２時５８分 GENERAL SERVICE INFORMATION 2. Change the engine oil after the first 50 hours of operation and then every 250 hours thereafter. Engine Oil (4) 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) 4. Yanmar does not recommend the use of engine oil “additives.
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TNV_IDI_ServiceManual_(3TNV72 for YN only).book 15 ページ２００７年１１月２９日 Engine Coolant 木曜日午後２時５８分 GENERAL SERVICE INFORMATION Engine Oil Capacity (Typical) Note: These are the engine oil capacities associated 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.
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TNV_IDI_ServiceManual_(3TNV72 for YN only).book 16 ページ２００７年１１月２９日木曜日午後２時５８分 GENERAL SERVICE INFORMATION Engine Coolant Engine Coolant Specifications A CAUTION Use a Long Life Coolant (LLC) or an Extended Life Coolant (ELC) that meets or exceeds the following guidelines and specifications: Additional Technical Coolant Specifications: COOLANT HAZARD! • ASTM D6210, D4985 (US) • Wear eye protection and rubber gloves when you handle long life or extended life engine coolant.
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TNV_IDI_ServiceManual_(3TNV72 for YN only).book 17 ページ２００７年１１月２９日 Engine Coolant 午後２時５８分 GENERAL SERVICE INFORMATION 5. Remove the cap of the reserve tank (Figure 4-7, (3)), and fill it to the LOW (COLD) mark (Figure 4-7, (4)) with engine coolant. Reinstall the cap. (2) (5) 6. Check the hose (Figure 4-7, (5)) that connects the reserve tank (Figure 4-7, (3)) to the radiator. Be sure it is securely connected and there are no cracks or damage.
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TNV_IDI_ServiceManual_(3TNV72 for YN only).book 18 ページ２００７年１１月２９日木曜日午後２時５８分 GENERAL SERVICE INFORMATION Specifications SPECIFICATIONS Description of Model Number 3 TNV 72 - 0 0000 Customer Code Rated rpm Cylinder Bore (mm) Engine Series No. of Cylinders When ordering parts or making an inquiry about the engine you are working on, be sure to include the complete model and serial numbers as shown on the engine nameplate. See Location of Labels on page 4-4.
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TNV_IDI_ServiceManual_(3TNV72 for YN only).
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TNV_IDI_ServiceManual_(3TNV72 for YN only).book 20 ページ２００７年１１月２９日木曜日午後２時５８分 GENERAL SERVICE INFORMATION Principal Engine Specifications PRINCIPAL ENGINE SPECIFICATIONS 3TNV72 Engine Model 3TNV72 Version VH Type Vertical In-line Diesel Engine Combustion System Ball-Type Swirl Chamber Aspiration Natural No. of Cylinders 3 Bore × Stroke 2.835 x 2.913in. (72 x 74mm) Displacement Max. Rated Output (Net) High Idling 55.104 cu in. (0.903L) RPM (min-1) hp SAE 3300 20.1 kW 15.
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TNV_IDI_ServiceManual_(3TNV72 for YN only).book 21 ページ２００７年１１月２９日 Engine Service Information 木曜日午後２時５８分 GENERAL SERVICE INFORMATION ENGINE SERVICE INFORMATION Inspection Item Intake / Exhaust Valve Gap Fuel Injection Timing Standard Limit 0.006 - 0.010 in (0.15 - 0.25 mm) - See Checking and Adjusting Fuel Injection Timing on page 7-19 1711 - 1842 psi (11.8 - 12.8 MPa; 120 - 130 kgf / cm²) - 3TNV72 470 ± 15 psi (3.24 ± 0.1MPa; 33 ± 1 kgf / cm²) 370 ± 15 psi (2.55 ± 0.
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TNV_IDI_ServiceManual_(3TNV72 for YN only).book 22 ページ２００７年１１月２９日木曜日午後２時５８分 GENERAL SERVICE INFORMATION Tightening Torques for Standard Bolts and Nuts TIGHTENING TORQUES FOR STANDARD BOLTS AND NUTS Use the correct amount of torque when you tighten fasteners on the machine. Applying excessive torque may damage the fastener or component and not enough torque may cause a leak or component failure.
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TNV_IDI_ServiceManual_(3TNV72 for YN only).book 23 ページ２００７年１１月２９日木曜日午後２時５８分 Tightening Torques for Standard Bolts and Nuts GENERAL SERVICE INFORMATION Item Pipe Joint Bolt Nominal Thread Diameter x Pitch Tightening Torque 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.
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TNV_IDI_ServiceManual_(3TNV72 for YN only).book 24 ページ２００７年１１月２９日木曜日午後２時５８分 GENERAL SERVICE INFORMATION Abbreviations and Symbols ABBREVIATIONS AND SYMBOLS Abbreviations A AC ACEA Ah approx. API ARB ATDC BTDC °C CARB CCA cm cm³ cm³/min cu in DC DI DVA EPA ESG °F fl oz fl oz/min ft ft·lb ft·lbf/min g gal/hr gal GL hp hrs I.D.
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TNV_IDI_ServiceManual_(3TNV72 for YN only).book 25 ページ２００７年１１月２９日 Unit Conversions 木曜日午後２時５８分 GENERAL SERVICE INFORMATION UNIT CONVERSIONS Units of Torque Unit Prefixes ft·lb ft·lb in·lb in·lb kgf·m kgf·m kgf·m N·m N·m N·m Prefix mega kilo centi milli micro Symbol M k c m μ Power x 1,000,000 x 1,000 x 0.01 x 0.001 x 0.000001 Units of Length mile ft in in km m cm mm x x x x x x x x 1.6090 0.3050 2.5400 25.4000 0.6210 3.2810 0.3940 0.
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TNV_IDI_ServiceManual_(3TNV72 for YN only).book 1 ページ２００７年１１月２９日 TNV IDI Service Manual 木曜日午後２時５８分 Section 5 PERIODIC MAINTENANCE Page Introduction...................................................................................... 5-3 Precautions ................................................................................... The Importance of Periodic Maintenance................................ Performing Periodic Maintenance ...........................................
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TNV_IDI_ServiceManual_(3TNV72 for YN only).
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TNV_IDI_ServiceManual_(3TNV72 for YN only).book 3 ページ２００７年１１月２９日 Introduction 木曜日午後２時５８分 PERIODIC MAINTENANCE INTRODUCTION This section of the Service Manual describes the procedures for proper care and maintenance of the engine. A DANGER A DANGER SCALD HAZARD! EXPLOSION HAZARD! • NEVER check the remaining battery charge by shorting out the terminals. This will result in a spark and may cause an explosion or fire. Use a hydrometer to check the remaining battery charge.
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TNV_IDI_ServiceManual_(3TNV72 for YN only).book 4 ページ２００７年１１月２９日木曜日午後２時５８分 PERIODIC MAINTENANCE Introduction A DANGER A DANGER FIRE AND EXPLOSION HAZARD! FIRE AND EXPLOSION HAZARD! • Diesel fuel is flammable and explosive under certain conditions. • Diesel fuel is flammable and explosive under certain conditions. • Only fill the fuel tank with diesel fuel. Filling the fuel tank with gasoline may result in a fire and will damage the engine.
PAGE 66
TNV_IDI_ServiceManual_(3TNV72 for YN only).book 5 ページ２００７年１１月２９日 Introduction 木曜日午後２時５８分 PERIODIC MAINTENANCE A DANGER A DANGER FIRE AND EXPLOSION HAZARD! FIRE AND EXPLOSION HAZARD! • Diesel fuel is flammable and explosive under certain conditions. • Diesel fuel is flammable and explosive under certain conditions. • Be sure to place the diesel fuel container on the ground when transferring the diesel fuel from the pump to the container.
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TNV_IDI_ServiceManual_(3TNV72 for YN only).book 6 ページ２００７年１１月２９日木曜日午後２時５８分 PERIODIC MAINTENANCE Introduction A DANGER A DANGER FIRE AND EXPLOSION HAZARD! FIRE AND EXPLOSION HAZARD! • Diesel fuel is flammable and explosive under certain conditions. • 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.
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TNV_IDI_ServiceManual_(3TNV72 for YN only).book 7 ページ２００７年１１月２９日 Introduction 木曜日午後２時５８分 PERIODIC MAINTENANCE A WARNING A WARNING EXHAUST HAZARD! SEVER HAZARD! • NEVER operate the engine in an enclosed area such as a garage, tunnel, underground room, manhole or ship’s hold without proper ventilation. • Keep hands and other body parts away from moving / rotating parts such as the cooling fan, flywheel or PTO shaft.
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TNV_IDI_ServiceManual_(3TNV72 for YN only).book 8 ページ２００７年１１月２９日木曜日午後２時５８分 PERIODIC MAINTENANCE Introduction A WARNING A WARNING BURN HAZARD! • Keep your hands and other body parts away from hot engine surfaces such as the muffler, exhaust pipe, turbocharger (if equipped) and engine block during operation and shortly after you shut the engine down. These surfaces are extremely hot while the engine is operating and could seriously burn you.
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TNV_IDI_ServiceManual_(3TNV72 for YN only).book 9 ページ２００７年１１月２９日 Introduction 木曜日午後２時５８分 PERIODIC MAINTENANCE A WARNING A 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 clothing when servicing the battery.
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TNV_IDI_ServiceManual_(3TNV72 for YN only).book 10 ページ２００７年１１月２９日木曜日午後２時５８分 PERIODIC MAINTENANCE Introduction A WARNING A CAUTION BURN HAZARD! • If you must drain the engine oil while it is still hot, stay clear of the hot engine oil to avoid being burned. • ALWAYS wear eye protection. • Failure to comply could result in death or serious injury. 0000011en COOLANT HAZARD! • Wear eye protection and rubber gloves when you handle long life or extended life engine coolant.
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TNV_IDI_ServiceManual_(3TNV72 for YN only).book 11 ページ２００７年１１月２９日 Introduction 木曜日午後２時５８分 PERIODIC MAINTENANCE CAUTION CAUTION • Only use diesel fuels recommended by Yanmar for the best engine performance, to prevent engine damage and to comply with EPA / ARB warranty requirements. • 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. • Only use clean diesel fuel.
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TNV_IDI_ServiceManual_(3TNV72 for YN only).book 12 ページ２００７年１１月２９日木曜日午後２時５８分 PERIODIC MAINTENANCE Introduction CAUTION CAUTION Observe the following environmental operating conditions to maintain engine performance and avoid premature engine wear: • Avoid operating in extremely dusty conditions. • Avoid operating in the presence of chemical gases or fumes. • Avoid operating in a corrosive atmosphere such as salt water spray.
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TNV_IDI_ServiceManual_(3TNV72 for YN only).book 13 ページ２００７年１１月２９日 Introduction 木曜日午後２時５８分 PERIODIC MAINTENANCE CAUTION CAUTION New Engine Break-in: • On the initial engine start-up, allow the engine to idle for approximately 15 minutes while you check for proper engine oil pressure, diesel fuel leaks, engine oil leaks, coolant leaks, and for proper operation of the indicators and / or gauges. • During the first hour of operation, vary the engine speed and the load on the engine.
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TNV_IDI_ServiceManual_(3TNV72 for YN only).book 14 ページ２００７年１１月２９日木曜日午後２時５８分 PERIODIC MAINTENANCE Introduction CAUTION CAUTION 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. If the fuel filter / water separator is positioned higher than the fuel level in the fuel tank, water may not drip out when the fuel filter / water separator drain cock is opened.
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TNV_IDI_ServiceManual_(3TNV72 for YN only).book 15 ページ２００７年１１月２９日 Precautions 木曜日午後２時５８分 PERIODIC MAINTENANCE PRECAUTIONS CAUTION The tightening torque in the Standard Torque Chart in General Service Information should be applied only to the bolts with a “7” head. (JIS strength classification: 7T) • Apply 60% torque to bolts that are not listed. • Apply 80% torque when tightened to aluminum alloy.
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TNV_IDI_ServiceManual_(3TNV72 for YN only).book 16 ページ２００７年１１月２９日 PERIODIC MAINTENANCE Perform periodic maintenance procedures in 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.
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TNV_IDI_ServiceManual_(3TNV72 for YN only).book 17 ページ２００７年１１月２９日木曜日午後２時５８分 Periodic Maintenance Schedule PERIODIC MAINTENANCE c:Check :Replace z: Contact your authorized Yanmar industrial engine dealer or distributor Periodic Maintenance Interval System Check Item Check and Refill Engine Coolant Daily Every 50 hours Every 250 hours c1st time c 2nd and after Every 500 hours Cooling System Drain, Flush and Refill Cooling System with New Coolant or every 1 yr.
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TNV_IDI_ServiceManual_(3TNV72 for YN only).book 18 ページ２００７年１１月２９日 PERIODIC MAINTENANCE 木曜日午後２時５８分 Periodic Maintenance Procedures PERIODIC MAINTENANCE PROCEDURES CAUTION After Initial 50 Hours of Operation Perform the following maintenance after the initial 50 hours of operation. • Replace Engine Oil and Engine Oil Filter • Check and Adjust Cooling Fan V-Belt Replace Engine Oil and Engine Oil Filter • Only use the engine oil specified.
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TNV_IDI_ServiceManual_(3TNV72 for YN only).book 19 ページ２００７年１１月２９日 Periodic Maintenance Procedures 木曜日午後２時５８分 PERIODIC MAINTENANCE The engine oil on a new engine becomes contaminated from the initial break-in of internal parts. It is very important that the initial oil and filter change is performed as scheduled. 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.
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TNV_IDI_ServiceManual_(3TNV72 for YN only).book 20 ページ２００７年１１月２９日木曜日午後２時５８分 PERIODIC MAINTENANCE Periodic Maintenance Procedures Check and adjust the V-belt tension (deflection) as follows: B 1. Press the V-belt down with your thumb with a force of approximately 22 ft·lb (98 N·m, 10 kgf·m) to check the deflection. There 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.
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TNV_IDI_ServiceManual_(3TNV72 for YN only).book 21 ページ２００７年１１月２９日 Periodic Maintenance Procedures 木曜日午後２時５８分 PERIODIC MAINTENANCE 3. Tighten the V-belt to the proper tension. There must be clearance (Figure 5-6, (1)) between the V-belt and the bottom of the pulley groove. If there is no clearance (Figure 5-6, (2)) between the V-belt and the bottom of the pulley groove, replace the V-belt.
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TNV_IDI_ServiceManual_(3TNV72 for YN only).book 22 ページ２００７年１１月２９日木曜日午後２時５８分 PERIODIC MAINTENANCE Periodic Maintenance Procedures CAUTION If the fuel filter / water separator is positioned higher than the fuel level in the fuel tank, water may not drip out when the fuel filter / water separator drain cock is opened. If this happens, turn the air vent screw on the top of the fuel filter / water separator 2-3 turns counterclockwise.
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TNV_IDI_ServiceManual_(3TNV72 for YN only).book 23 ページ２００７年１１月２９日 Periodic Maintenance Procedures 木曜日午後２時５８分 PERIODIC MAINTENANCE 8. Put the float (Figure 5-7, (7)) and retaining spring (Figure 5-7, (6)) inside the cup. 9. Reinstall the cup to the mounting flange (Figure 5-7, (8)) and turn the retaining ring (Figure 5-7, (4)) to the right (Figure 5-7, (5)). Hand-tighten only. Check Battery A DANGER 10. Open the fuel cock (Figure 5-7, (3)). 11. Be sure to prime the fuel system.
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TNV_IDI_ServiceManual_(3TNV72 for YN only).book 24 ページ２００７年１１月２９日 PERIODIC MAINTENANCE 木曜日午後２時５８分 Periodic Maintenance Procedures • If the engine cranking speed is so slow that the engine does not start, recharge the battery. CAUTION • If the engine still will not start after charging, have your authorized Yanmar industrial engine dealer or distributor check the battery and the engine’s starting system. • ALWAYS be environmentally responsible.
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TNV_IDI_ServiceManual_(3TNV72 for YN only).book 25 ページ２００７年１１月２９日木曜日午後２時５８分 Periodic Maintenance Procedures PERIODIC MAINTENANCE Every 250 Hours of Operation CAUTION Perform the following maintenance every 250 hours of operation.
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TNV_IDI_ServiceManual_(3TNV72 for YN only).book 26 ページ２００７年１１月２９日 PERIODIC MAINTENANCE 木曜日午後２時５８分 Periodic Maintenance Procedures 4. Drain the tank until clean diesel fuel with no water or dirt flows out. Reinstall and tighten the drain plug firmly. CAUTION 5. Reinstall the fuel cap. 6. Check for fuel leaks. Replace Engine Oil and Engine Oil Filter • ALWAYS be environmentally responsible. CAUTION • Only use the engine oil specified.
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TNV_IDI_ServiceManual_(3TNV72 for YN only).book 27 ページ２００７年１１月２９日 Periodic Maintenance Procedures 木曜日午後２時５８分 PERIODIC MAINTENANCE Check and Clean Radiator Fins A CAUTION (1) FULL LOW FLYING OBJECT HAZARD! • ALWAYS wear eye protection when servicing the engine and when using compressed air or high-pressure water. Dust, flying debris, compressed air, pressurized water or steam may injure your eyes. • Failure to comply may result in minor or moderate injury.
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TNV_IDI_ServiceManual_(3TNV72 for YN only).book 28 ページ２００７年１１月２９日木曜日午後２時５８分 PERIODIC MAINTENANCE 2. If the governor lever does not make proper contact with the high idle stop or the low idle speed limit screw, adjust the throttle cable or linkage as necessary. Note: DO NOT FORCE the throttle cable or linkage to move. This may damage the the governor lever, the throttle cable or linkage and cause irregular operation of the engine speed control.
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TNV_IDI_ServiceManual_(3TNV72 for YN only).book 29 ページ２００７年１１月２９日 Periodic Maintenance Procedures 木曜日午後２時５８分 PERIODIC MAINTENANCE 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. (1) 5. Clean inside of the air cleaner cover. 0000071A 6.
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TNV_IDI_ServiceManual_(3TNV72 for YN only).book 30 ページ２００７年１１月２９日 PERIODIC MAINTENANCE 木曜日午後２時５８分 Periodic Maintenance Procedures Every 500 Hours of Operation Perform the following maintenance every 500 hours of operation. Replace Fuel Filter A DANGER • Replace Air Cleaner Element • Replace Fuel Filter • Clean Fuel Filter / Water Separator FIRE AND EXPLOSION HAZARD! • Diesel fuel is flammable and explosive under certain conditions.
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TNV_IDI_ServiceManual_(3TNV72 for YN only).book 31 ページ２００７年１１月２９日木曜日午後２時５８分 Periodic Maintenance Procedures PERIODIC MAINTENANCE CAUTION (6) (2) (5) • ALWAYS be environmentally responsible. (1) (4) (3) • Follow the 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.
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TNV_IDI_ServiceManual_(3TNV72 for YN only).book 32 ページ２００７年１１月２９日木曜日午後２時５８分 PERIODIC MAINTENANCE Periodic Maintenance Procedures Clean Fuel Filter / Water Separator CAUTION A DANGER FIRE AND EXPLOSION HAZARD! • Diesel fuel is flammable and explosive under certain conditions. • NEVER use diesel fuel as a cleaning agent. • Failure to comply will result in death or serious injury. 0000012en A DANGER • ALWAYS be environmentally responsible.
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TNV_IDI_ServiceManual_(3TNV72 for YN only).book 33 ページ２００７年１１月２９日 Periodic Maintenance Procedures 3. Turn the retaining ring (Figure 5-15, (4)) to the left (Figure 5-15, (10)). 4. Carefully remove the cup (Figure 5-15, (1)) and pour the fuel into an approved container and dispose of properly. Hold the bottom of the cup with a shop towel to prevent the fuel from dripping. Wipe up any spills immediately. 5. Keep the retaining spring (Figure 5-15, (6)) and float (Figure 5-15, (7)) handy for reassembly. 6.
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TNV_IDI_ServiceManual_(3TNV72 for YN only).book 34 ページ２００７年１１月２９日 PERIODIC MAINTENANCE 木曜日午後２時５８分 Periodic Maintenance Procedures A WARNING CAUTION BURN HAZARD! • Wait until the engine cools before you drain the engine coolant. Hot engine coolant may splash and burn you. • Failure to comply could result in death or serious injury. 0000016en A CAUTION • ALWAYS be environmentally responsible.
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TNV_IDI_ServiceManual_(3TNV72 for YN only).book 35 ページ２００７年１１月２９日 Periodic Maintenance Procedures 木曜日午後２時５８分 PERIODIC MAINTENANCE Adjust Intake / Exhaust Valve Clearance Proper adjustment is necessary to maintain the correct timing for opening and closing the valves. Improper adjustment will cause the engine to run noisily, resulting in poor engine performance and engine damage. See Measuring and Adjusting Valve Clearance on page 6-34. (1) FULL LOW (2) 0000074A Figure 5-16 4.
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TNV_IDI_ServiceManual_(3TNV72 for YN only).book 36 ページ２００７年１１月２９日 PERIODIC MAINTENANCE 木曜日午後２時５８分 Periodic Maintenance Procedures Every 1500 Hours of Operation Perform the following maintenance every 1500 hours of operation.
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TNV_IDI_ServiceManual_(3TNV72 for YN only).book 37 ページ２００７年１１月２９日 Periodic Maintenance Procedures 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 cover. Tighten the diaphragm bolts to the specified torque. See Tightening Torques for Standard Bolts and Nuts on page 4-22.
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TNV_IDI_ServiceManual_(3TNV72 for YN only).
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TNV_IDI_ServiceManual_(3TNV72 for YN only).book 1 ページ２００７年１１月２９日木曜日午後２時５８分 Section 6 TNV IDI Service Manual ENGINE Page Before You Begin Servicing ............................................................ 6-3 Introduction...................................................................................... 6-5 Cylinder Head Specifications .......................................................... Adjustment Specifications ......................................................... Cylinder Head..
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TNV_IDI_ServiceManual_(3TNV72 for YN only).book 2 ページ２００７年１１月２９日木曜日午後２時５８分 ENGINE 6-2 Cylinder Head................................................................................ Cylinder Head Components .................................................... Disassembly of Cylinder Head ................................................ Cleaning of Cylinder Head Components ................................. Inspection of Cylinder Head Components...............................
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TNV_IDI_ServiceManual_(3TNV72 for YN only).book 3 ページ２００７年１１月２９日木曜日午後２時５８分 Before You Begin Servicing ENGINE BEFORE YOU BEGIN SERVICING A WARNING A WARNING FUME / BURN HAZARD! To prevent possible eye injury, always wear SAFETY GLASSES while servicing the engine. 0000013en • Always read and follow safety related precautions found on containers of hazardous substances like parts cleaners, primers, sealants and sealant removers. • Failure to comply could result in death or serious injury.
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TNV_IDI_ServiceManual_(3TNV72 for YN only).book 4 ページ２００７年１１月２９日 ENGINE 木曜日午後２時５８分 Before You Begin Servicing CAUTION CAUTION • Only use the engine oil specified. Other engine oils may affect warranty coverage, cause internal engine components to seize and / or shorten engine life. 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.
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TNV_IDI_ServiceManual_(3TNV72 for YN only).book 5 ページ２００７年１１月２９日木曜日午後２時５８分 Introduction ENGINE INTRODUCTION This section of the Service Manual describes servicing of the engine. CYLINDER HEAD SPECIFICATIONS Adjustment Specifications Model Valve Clearance All 0.006 - 0.010 in. (0.15 - 0.25 mm) Cylinder Head Inspection Item Standard Limit 0.0020 in. (0.05 mm) or less 0.0059 in. (0.15 mm) 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.
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TNV_IDI_ServiceManual_(3TNV72 for YN only).book 6 ページ２００７年１１月２９日木曜日午後２時５８分 ENGINE Cylinder Head Specifications Intake / Exhaust Valve and Guide Inspection Item Intake Exhaust Standard Limit Guide Inside Diameter 0.2362 - 0.2367 in. (6.000 - 6.012 mm) 0.2394 in. (6.08 mm) Valve Stem Outside Diameter 0.2346 - 0.2352 in. (5.960 - 5.975 mm) 0.2323 in. (5.90 mm) Oil Clearance 0.0010 - 0.0020 in. (0.025 - 0.052 mm) 0.0063 in. (0.15 mm) Valve Stem Bend - 0.0004 in. (0.
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TNV_IDI_ServiceManual_(3TNV72 for YN only).book 7 ページ２００７年１１月２９日木曜日午後２時５８分 Camshaft and Timing Gear Train Specifications ENGINE Rocker Arm and Shaft Inspection Item Standard Limit Arm Shaft Hole Diameter 0.4724 - 0.4732 in. (12.000 - 12.020 mm) 0.4752 in. (12.07 mm) Shaft Outside Diameter 0.4711 - 0.4718 in. (11.966 - 11.984 mm) 0.4701 in. (11.94 mm) 0.0006 - 0.0021 in. (0.016 - 0.054 mm) 0.0051 in. (0.
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TNV_IDI_ServiceManual_(3TNV72 for YN only).book 8 ページ２００７年１１月２９日 ENGINE 木曜日午後２時５８分 Crankshaft and Pistons Specifications Idler Gear Shaft and Bushing Inspection Item Reference Page Standard Limit Shaft Outside Diameter 1.4547 - 1.4557 in. (36.950 - 36.975 mm) 1.4528 in. (36.900 mm) Bushing Inside Diameter 1.4567 - 1.4577 in. (37.000 - 37.025 mm) 1.4596 in. (37.075 mm) 0.0010 - 0.0030 in. (0.025 - 0.075 mm) 0.0069 in. (0.175 mm) Standard Limit Reference Page 0.0055 in. (0.
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TNV_IDI_ServiceManual_(3TNV72 for YN only).book 9 ページ２００７年１１月２９日木曜日午後２時５８分 Crankshaft and Pistons Specifications ENGINE (Crankshaft Cont.) Inspection Item Main Bearing Journal Standard Limit Journal Outside Diameter 1.8485 - 1.8489 in. (46.952 - 46.962 mm) 1.8465 in. (46.902 mm) Bearing Inside Diameter 1.8497 - 1.8505 in. (46.982 - 47.002 mm) - Bearing Insert Thickness 0.0791 - 0.0793 in. (2.009 - 2.014 mm) - Oil Clearance 0.0008 - 0.0020 in. (0.020 - 0.050 mm) 0.0047 in. (0.
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TNV_IDI_ServiceManual_(3TNV72 for YN only).book 10 ページ２００７年１１月２９日 ENGINE 木曜日午後２時５８分 Crankshaft and Pistons Specifications Piston Inspection Item Standard Limit 2.8331 - 2.8343 in. (71.960 - 71.990 mm) 2.8313 in. (71.915 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 3TNV72 0.0012 - 0.0020 in. (0.030 - 0.050 mm) - Hole Inside Diameter 0.8661 - 0.8665 in. (22.000 - 22.009 mm) 0.8677 in.
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TNV_IDI_ServiceManual_(3TNV72 for YN only).book 11 ページ２００７年１１月２９日木曜日午後２時５８分 Crankshaft and Pistons Specifications ENGINE Piston Ring Model Inspection Item Standard Limit Ring Groove Width 0.0610 - 0.0618 in. (1.550 - 1.570 mm) - Ring Width 0.0579 - 0.0587 in. (1.470 - 1.490 mm) 0.0571 in. (1.450 mm) Side Clearance 0.0024 - 0.0039 in. (0.060 - 0.100 mm) - End Clearance 0.0059 - 0.0118 in. (0.150 - 0.300 mm) 0.0154 in. (0.390 mm) Ring Groove Width 0.0606 - 0.0614 in. (1.540 - 1.
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TNV_IDI_ServiceManual_(3TNV72 for YN only).book 12 ページ２００７年１１月２９日 ENGINE 木曜日午後２時５８分 Crankshaft and Pistons Specifications Connecting Rod Connecting Rod Small End Inspection Item Standard Limit Wrist Pin Bushing Inside Diameter 0.8671 - 0.8676 in. (22.025 - 22.038 mm) 0.8688 in. (22.068 mm) Wrist Pin Outside Diameter 0.8658 - 0.8661 in. (21.991 - 22.000 mm) 0.8647 in. (21.963 mm) 0.0010 - 0.0019 in. (0.025 - 0.047 mm) 0.0041 in. (0.105 mm) Standard Limit 0.0079 - 0.0157 in. (0.20 - 0.
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TNV_IDI_ServiceManual_(3TNV72 for YN only).book 13 ページ２００７年１１月２９日木曜日午後２時５８分 Cylinder Block Specifications ENGINE CYLINDER BLOCK SPECIFICATIONS Cylinder Block Inspection Item Cylinder Inside Diameter Model Standard Limit 3TNV72 2.8346 - 2.8358 in. (72.000 - 72.030 mm) 2.7638 in. (70.200 mm) 0.0004 in. (0.01 mm) or less 0.0012 in. (0.
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TNV_IDI_ServiceManual_(3TNV72 for YN only).book 14 ページ２００７年１１月２９日木曜日午後２時５８分 ENGINE SPECIAL TORQUE CHART Torque for Bolts and Nuts Tightening Torque Lubricating Oil Application (Thread Portion and Seat Surface) Reference Page M9 x 1.25 mm 40 - 43 ft·lb (53.9 - 57.9 N·m; 5.5 - 5.9 kgf·m) Applied See Reassembly of Cylinder Head on page 6-31 M7 x 1.0 mm 17 - 20 ft·lb (22.6 - 27.5 N·m; 2.3 - 2.8 kgf·m) Applied See Installation of Pistons on page 6-58 Flywheel Bolts M10 x 1.
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TNV_IDI_ServiceManual_(3TNV72 for YN only).book 15 ページ２００７年１１月２９日木曜日午後２時５８分 Special Service Tools ENGINE SPECIAL SERVICE TOOLS Note: Tools not having Yanmar part numbers must be acquired locally. No Tool Name Applicable Model and Tool Size 1 Valve Guide Tool (For Removing Valve Guides) Illustration L1 L2 d1 d2 0.787 in. (20 mm) 2.953 in. (75 mm) 0.217 in. (5.5 mm) 0.374 in. (9.5 mm) Locally Manufactured 2 Valve Guide Tool (For Installing Valve Guides) L1 L2 d1 d2 0.394 in.
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TNV_IDI_ServiceManual_(3TNV72 for YN only).book 16 ページ２００７年１１月２９日木曜日午後２時５８分 ENGINE No Special Service Tools Tool Name Applicable Model and Tool Size d1 d2 0.591 in. (15 mm) 5 d3 0.827 in. (21 mm) Stem Seal Tool (for Installing Stem Seals) 0.472 in. (12 mm) L1 0.433 in. (11 mm) Illustration L2 L3 2.559 in. (65 mm) 0.157 in. (4 mm) or more Allowance: d1: ±0.00787 in. (±0.2 mm) L1: ±0.00393 in. (±0.
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TNV_IDI_ServiceManual_(3TNV72 for YN only).book 17 ページ２００７年１１月２９日木曜日午後２時５８分 Measuring Instruments ENGINE MEASURING INSTRUMENTS No. Instrument Name Application 1 Dial Indicator (Available Locally) Measure shaft bend and end play Illustration 0000831 2 Test Indicator (Available Locally) Measurements of narrow or deep portions that cannot be measured by dial gauge 0000832 3 Magnetic Stand (Available Locally) For holding the dial gauge when measuring.
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TNV_IDI_ServiceManual_(3TNV72 for YN only).book 18 ページ２００７年１１月２９日木曜日午後２時５８分 ENGINE Measuring Instruments (Measuring instruments Cont.) No.
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TNV_IDI_ServiceManual_(3TNV72 for YN only).book 22 ページ２００７年１１月２９日木曜日午後２時５８分 ENGINE Cylinder Head Removal of Intake Manifold / Valve Cover 1. Remove the intake manifold bolts (Figure 6-2, (1)) and valve cover bolts (Figure 6-2, (2)). (2) 2. Remove the valve cover / intake manifold (Figure 6-2, (3)). Discard gasket (Figure 6-2, (4)). (1) (1) (2) Figure 6-3 (3) Removal of Rocker Arm Assembly (4) 1.
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TNV_IDI_ServiceManual_(3TNV72 for YN only).book 23 ページ２００７年１１月２９日木曜日午後２時５８分 Cylinder Head ENGINE Disassembly of Rocker Arm Assembly Removal of Cylinder Head 1. Remove the rocker arm shaft alignment set screw (Figure 6-5, (6)) from support (Figure 6-5, (5)). 1. Loosen the cylinder head bolts following the sequence shown in Figure 6-6.
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TNV_IDI_ServiceManual_(3TNV72 for YN only).book 24 ページ２００７年１１月２９日木曜日午後２時５８分 ENGINE Cylinder Head Removal of Intake / Exhaust Valves 1. Put the cylinder head on the work bench with the combustion side down (Figure 6-8). 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)).
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TNV_IDI_ServiceManual_(3TNV72 for YN only).book 25 ページ２００７年１１月２９日木曜日午後２時５８分 Cylinder Head ENGINE Cleaning of Cylinder Head Components CAUTION 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.
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TNV_IDI_ServiceManual_(3TNV72 for YN only).book 26 ページ２００７年１１月２９日木曜日午後２時５８分 ENGINE Cylinder Head Inspection of Rocker Arm Assembly Inspection of Valve Guides Rocker Arm Shaft Hole Diameter Use a telescoping gauge and micrometer to measure the inside diameter of all the rocker arm support brackets and the rocker arms (Figure 6-12). Record the measurements. See Rocker Arm and Shaft on page 6-7 for the service limit. Visually inspect the valve guides for distortions, scoring or other damage.
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TNV_IDI_ServiceManual_(3TNV72 for YN only).book 27 ページ２００７年１１月２９日木曜日午後２時５８分 Cylinder Head ENGINE If distortion exceeds the service limit, resurface or replace the cylinder head. Remove only enough material to make the cylinder head flat, but do not remove more than 0.008 in. (0.20 mm). Inspection of Intake and Exhaust Valves Visually inspect the intake and exhaust valves. Replace any valves that are obviously discolored, heavily pitted or otherwise damaged.
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TNV_IDI_ServiceManual_(3TNV72 for YN only).book 28 ページ２００７年１１月２９日木曜日午後２時５８分 ENGINE Cylinder Head Valve Face and Valve Seat Always check the clearance between the valve and valve guide before grinding or lapping the valve seats. See Intake / Exhaust Valve and Guide on page 6-6 for the service limit. If the clearance exceeds the limit, replace the valve and / or valve guide to bring the clearance within the limit. Roughness or burrs will cause poor seating of a valve.
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TNV_IDI_ServiceManual_(3TNV72 for YN only).book 29 ページ２００７年１１月２９日木曜日午後２時５８分 Cylinder Head ENGINE Squareness Use a flat surface and a square to check each spring for squareness (Figure 6-22). See Valve Spring on page 6-6 for the service limit. Reassembly of Cylinder Head Use new gaskets, O-rings and seals on reassembly of cylinder head. IMPORTANT Liberally oil all components during assembly to prevent premature wear or damage.
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TNV_IDI_ServiceManual_(3TNV72 for YN only).book 30 ページ２００７年１１月２９日木曜日午後２時５８分 ENGINE Cylinder Head 3. Finish installing the valve guides (Figure 6-25, (1)) to the proper height (Figure 6-25, (3)) using the valve guide installation tool (Figure 6-25, (2)). See valve guide projection specification on page 6-6. (1) (4) (2) (2) (3) (3) (1) 0001873B Figure 6-26 0001756A Figure 6-25 Reassembly of Intake and Exhaust Valves IMPORTANT Always install new valve stem seals.
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TNV_IDI_ServiceManual_(3TNV72 for YN only).book 31 ページ２００７年１１月２９日木曜日午後２時５８分 Cylinder Head ENGINE (1) (1) (2) (3) (4) (5) (2) (6) 0002151 Figure 6-28 5. Put the cylinder head on the workbench with the combustion side down to install the valve springs. Reinstall the valve spring (Figure 6-28, (4)) and spring retainer (Figure 6-28, (5)). 6. Using a valve spring compressor tool, compress the valve spring. 7.
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TNV_IDI_ServiceManual_(3TNV72 for YN only).book 32 ページ２００７年１１月２９日木曜日午後２時５８分 ENGINE Cylinder Head Reassembly of Rocker Arm Assembly (2) (1) Note: On 3-cylinder 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)). (1) 0001914 4.
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TNV_IDI_ServiceManual_(3TNV72 for YN only).book 33 ページ２００７年１１月２９日木曜日午後２時５８分 Cylinder Head ENGINE Reassembly of Intake Manifold / Valve Cover 1. Reinstall the glow plugs (Figure 6-33, (1)) and tighten to specification. Reinstall the electrical harness (Figure 6-33, (2)). (1) (2) (3) (2) (4) (1) (5) (6) (7) (8) 0002131 Figure 6-34 0002146 Figure 6-33 2. Lightly grease a new valve cover gasket (Figure 6-34, (4)).
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TNV_IDI_ServiceManual_(3TNV72 for YN only).book 34 ページ２００７年１１月２９日木曜日午後２時５８分 ENGINE Cylinder Head Measuring and Adjusting Valve Clearance • If there is no valve clearance, and the piston is at TDC of the compression stroke, extreme wear or damage to the cylinder head or valves may be possible. Measure and adjust while the engine is cold. Notes: • The No. 1 piston position is on the flywheel end of the engine, opposite end of the radiator.
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TNV_IDI_ServiceManual_(3TNV72 for YN only).book 35 ページ２００７年１１月２９日木曜日午後２時５８分 Cylinder Head ENGINE 6. Insert a feeler gauge of the correct thickness (Figure 6-37, (1)) between rocker arm and valve cap. Turn the valve adjustment screw to adjust the valve clearance so there is a slight “drag” on the 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)).
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TNV_IDI_ServiceManual_(3TNV72 for YN only).book 38 ページ２００７年１１月２９日木曜日午後２時５８分 ENGINE Cylinder Block 5. Remove the engine from the machine. Mount the engine to a suitable engine repair stand having adequate weight capacity. 6. Clean the engine by washing with solvent, air or steam cleaning. Carefully operate to prevent any foreign matter or fluids from entering the engine, fuel system, or electrical components remaining on the engine. (3) (1) (2) 7. Drain the engine oil into a suitable container.
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TNV_IDI_ServiceManual_(3TNV72 for YN only).book 39 ページ２００７年１１月２９日木曜日午後２時５８分 Cylinder Block ENGINE Measuring Idler Gear-to-Crankshaft Gear Backlash 1. Install a dial indicator as shown in Figure 6-41. 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)). (3) (2) (1) 00021 0002192 Figure 6-41 2.
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TNV_IDI_ServiceManual_(3TNV72 for YN only).book 40 ページ２００７年１１月２９日木曜日午後２時５８分 ENGINE Cylinder Block 4. Do not remove the fuel injection pump drive gear unless absolutely necessary due to damage to the gear or pump. Do not loosen or remove the four bolts (Figure 6-43, (3)) retaining pump drive gear to the hub. Only remove the nut (Figure 6-43, (1)) and washer (Figure 6-43, (2)), leaving the hub attached to the gear. Remove the pump drive gear and hub as an assembly using a gear puller.
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TNV_IDI_ServiceManual_(3TNV72 for YN only).book 41 ページ２００７年１１月２９日木曜日午後２時５８分 Cylinder Block ENGINE Removal of Camshaft 1. Before removing the camshaft, check the camshaft end play. • Method A: Install a dial indicator (Figure 6-46, (1)) on the cylinder block. Move the camshaft and gear (Figure 6-46, (2)) in and out to measure the end play. Record the measurement. See Camshaft on page 6-7 for the service limit. 2.
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TNV_IDI_ServiceManual_(3TNV72 for YN only).book 42 ページ２００７年１１月２９日木曜日午後２時５８分 ENGINE Cylinder Block Removal of Gear Case Note: The camshaft must be removed before the gear case can be removed. See Removal of Camshaft on page 6-41. 1. Remove bolts (Figure 6-49, (4)). Note: It is not necessary to remove the fuel injection pump from the gear case to remove the gear case. If the fuel injection pump does not need to be repaired, leave it mounted to the timing gear case.
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TNV_IDI_ServiceManual_(3TNV72 for YN only).book 43 ページ２００７年１１月２９日木曜日午後２時５８分 Cylinder Block ENGINE 1. Using a feeler gauge, measure the connecting rod side clearance (Figure 6-50). See Connecting Rod on page 6-12 for the standard limit. If the measurement is out of specification, replace the crankshaft, connecting rod, or both. IMPORTANT Do not rotate crankshaft when using PLASTIGAGE. A false reading may result. 5. Reinstall the bearing cap and tighten to specification.
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TNV_IDI_ServiceManual_(3TNV72 for YN only).book 44 ページ２００７年１１月２９日木曜日午後２時５８分 ENGINE Cylinder Block 11. Remove the bearing inserts (Figure 6-53, (2)). (2) 12. Remove the compression rings (Figure 6-53, (3)) from the piston using a piston ring expander. 13. Remove the oil ring (Figure 6-53, (4)) from the piston using a piston ring expander. (3) (1) (3) (4) (4) (5) (6) (9) (5) 0002188 Figure 6-54 (8) (7) (2) (1) 3. Before removing the main bearing caps, measure the crankshaft end play.
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TNV_IDI_ServiceManual_(3TNV72 for YN only).book 45 ページ２００７年１１月２９日木曜日午後２時５８分 Cylinder Block ENGINE • Method B: Use a feeler gauge to measure the clearance (Figure 6-56, (3)) between the thrust bearing (Figure 6-56, (1)) and crankshaft (Figure 6-56, (2)). Record the measurement. See Thrust Bearing on page 6-9 for the service limit. (1) 0001899 Figure 6-58 (1) (2) (3) 0001962 Figure 6-56 4. Remove the bearing cap. Do not remove the bearing inserts at this time. 5.
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TNV_IDI_ServiceManual_(3TNV72 for YN only).book 46 ページ２００７年１１月２９日木曜日午後２時５８分 ENGINE Cylinder Block 11. Remove the crankshaft from the engine. 12. Remove the bearing inserts (Figure 6-59, (1)) and thrust bearings (Figure 6-59, (2)). Inspection of Crankshaft and Camshaft Components A WARNING Note: Do not remove the crankshaft gear unless the gear or crankshaft are damaged and require replacement.
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TNV_IDI_ServiceManual_(3TNV72 for YN only).book 47 ページ２００７年１１月２９日木曜日午後２時５８分 Cylinder Block ENGINE (1) Inspection of Cylinder Block 1. Ensure that oil passages are clear and unobstructed. (2) 0002181A Figure 6-61 4. Remove the rear oil seal (Figure 6-62, (1)) from the flywheel housing (Figure 6-62, (2)). (2) 2. Check for discoloration 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.
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TNV_IDI_ServiceManual_(3TNV72 for YN only).book 48 ページ２００７年１１月２９日木曜日午後２時５８分 ENGINE Cylinder Block Inspection of Pistons, Piston Rings and Wrist Pin Notes: • On an engine with low hours, the pistons, piston rings may be reused if they are found to be within specifications. The pistons and piston rings must be reinstalled in the same cylinders from which they were originally removed.
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TNV_IDI_ServiceManual_(3TNV72 for YN only).book 49 ページ２００７年１１月２９日木曜日午後２時５８分 Cylinder Block ENGINE • On an engine with high hours, the pistons rings should be replaced and the cylinder honed (See Honing and Boring on page 6-53) or replaced. The piston should be replaced as necessary. 9. Place each compression piston ring in the groove as shown (Figure 6-67). Use a feeler gauge to measure the clearance between the piston ring and the piston ring land. Record the measurements.
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TNV_IDI_ServiceManual_(3TNV72 for YN only).book 50 ページ２００７年１１月２９日木曜日午後２時５８分 ENGINE Cylinder Block 3. Place the connecting rod bearing inserts into the connecting rod and connecting rod cap. Install the rod cap and tighten the bolts to the specified torque. 4. Measure the inside diameter. Record the measurements. See Crankshaft on page 6-8 for specifications. Inspection of Tappets (1) (2) 0001724A 1. Inspect the tappet contact surfaces for abnormal wear (Figure 6-72, (1)).
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TNV_IDI_ServiceManual_(3TNV72 for YN only).book 51 ページ２００７年１１月２９日木曜日午後２時５８分 Cylinder Block ENGINE Inspection of Crankshaft 1. Put the crankshaft end journals (Figure 6-74, (4)) on V-blocks. 2. Place a dial indicator (Figure 6-74, (3)) on a center main bearing surface. (2) (1) R R (3) (1) (2) 0001733A Figure 6-75 Reconditioning the Crankshaft (4) (4) 0000232A Figure 6-74 3. Rotate the crankshaft and observe runout. Record the measurements. See Crankshaft on page 6-8 for specifications. 4.
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TNV_IDI_ServiceManual_(3TNV72 for YN only).book 52 ページ２００７年１１月２９日木曜日午後２時５８分 ENGINE Cylinder Block (1) Ry (1) Ry R R R 0001712A Figure 6-78 0000234A Figure 6-76 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. (46.702 - 46.712 mm) 0.138 - 0.150 in. (3.5 - 3.8 mm) Journal Radius (R) Journal Face Finish (Ry) 0.8S (Super Polish) Thrust Face Finish (1) 4.
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TNV_IDI_ServiceManual_(3TNV72 for YN only).book 53 ページ２００７年１１月２９日木曜日午後２時５８分 Cylinder Block ENGINE Inspection of Camshaft Bushing and Bores Honing and Boring 1. Measure the I.D. of the front bushing and the remaining bores in the cylinder block. Record the measurements. See Camshaft on page 6-7 for specifications. Pistons must move freely in the cylinders while maintaining adequate compression and oil sealing.
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TNV_IDI_ServiceManual_(3TNV72 for YN only).book 54 ページ２００７年１１月２９日木曜日午後２時５８分 ENGINE Cylinder Block CAUTION Do not allow the honing tool to operate in one position for any length of time. Damage to the cylinder wall will occur. Keep the tool in constant up-and-down motion. 0000090en • When honing is completed, wash the cylinder block with hot water and soap. The cylinder wall is adequately cleaned when a white rag wiped in cylinder comes out clean. Use brushes to clean all passages and crevices.
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TNV_IDI_ServiceManual_(3TNV72 for YN only).book 55 ページ２００７年１１月２９日木曜日午後２時５８分 Cylinder Block ENGINE Reassembly of Pistons 1. Select the parts needed to assemble the piston and connecting rod for one cylinder. Note: The actual appearance of the match marks will vary but they will always be in the same locations. 2. If removed, install a new wrist pin bushing (Figure 6-83, (7)) using a press and the appropriate service tool. Be sure to align the oil holes.
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TNV_IDI_ServiceManual_(3TNV72 for YN only).book 56 ページ２００７年１１月２９日木曜日午後２時５８分 ENGINE Cylinder Block (3) (1) (6) (4) (5) (6) (9) (5) (2) (5) (8) (7) (2) (3) (1) (4) 0001705A 0000227A 1 2 3 4 5 6 – Fuel Injection Pump Side of Engine – Piston Identification Mark – Embossed Mark on Connecting Rod – Connecting Rod and Cap Match Marks – Flywheel End of Engine – Camshaft Side of Engine Figure 6-85 5. Lubricate and install the wrist pin (Figure 6-86, (6)) through the piston and connecting rod. 6.
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TNV_IDI_ServiceManual_(3TNV72 for YN only).book 57 ページ２００７年１１月２９日木曜日午後２時５８分 Cylinder Block ENGINE 7. Reinstall the oil ring expander (Figure 6-88, (4)). Install the oil ring (Figure 6-88, (3)) with the end gap at 180° from the expander end gap. 8. Reinstall the second compression ring (Figure 6-88, (2)). This ring is identified by its dark color and tapered face profile. (1) (2) (3) 9. Reinstall the top compression ring (Figure 6-88, (1)).
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TNV_IDI_ServiceManual_(3TNV72 for YN only).book 58 ページ２００７年１１月２９日木曜日午後２時５８分 ENGINE Cylinder Block (2) (3) (1) (1) (4) (2) 0002188 0002189 Figure 6-90 3. Install the crankshaft in the engine. IMPORTANT The main bearing caps are numbered and have arrows for proper positioning. The No. 1 cap is at the flywheel end. The arrows point toward the flywheel end of the engine. 4. Reinstall the main bearing caps. 5.
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TNV_IDI_ServiceManual_(3TNV72 for YN only).book 59 ページ２００７年１１月２９日木曜日午後２時５８分 Cylinder Block ENGINE 4. Carefully 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)).
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TNV_IDI_ServiceManual_(3TNV72 for YN only).book 60 ページ２００７年１１月２９日木曜日午後２時５８分 ENGINE Cylinder Block 7. Apply a light coat of clean engine oil to the rod cap bolts. Reinstall the connecting rod cap (Figure 6-94, (2)). Tighten the connecting rod bolts to the specified torque in two stages (1/2 then full torque). See Special Torque Chart on page 6-14. (3) (1) (4) (2) 0002187 (1) Figure 6-95 4. Reinstall the gear case (Figure 6-95, (1)). Tighten the bolts (Figure 6-95, (4)) to the specified torque.
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TNV_IDI_ServiceManual_(3TNV72 for YN only).book 61 ページ２００７年１１月２９日木曜日午後２時５８分 Cylinder Block ENGINE 4. Lubricate the camshaft lobes and tappets with clean oil or assembly lube. Reinstall the tappets in their respective locations in the cylinder block. Push the tappets fully into the tappet bores until they make solid contact with the camshaft. (1) (2) (3) B B C C A 5. If removed, reinstall the fuel injection pump. Adjust the fuel injection timing after installation.
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TNV_IDI_ServiceManual_(3TNV72 for YN only).book 62 ページ２００７年１１月２９日木曜日午後２時５８分 ENGINE Cylinder Block IMPORTANT Be sure to align the flats on the oil pump with the flats on the crankshaft gear. 3. Reinstall the timing gear case cover. (1) 4. Reinstall and tighten the gear case cover bolts. 5. Reinstall the crankshaft pulley. 6. Reinstall the washer and bolt. Tighten to the specified torque. See Special Torque Chart on page 6-14 for specifications. (2) Installation of Oil Pan 1.
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TNV_IDI_ServiceManual_(3TNV72 for YN only).book 1 ページ２００７年１１月２９日 TNV IDI Service Manual 木曜日午後２時５８分 Section 7 FUEL SYSTEM Page Before You Begin Servicing ............................................................ 7-3 Introduction...................................................................................... 7-5 Fuel Injection Pump................................................................... 7-5 Stop Solenoid ............................................................................
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TNV_IDI_ServiceManual_(3TNV72 for YN only).book 2 ページ２００７年１１月２９日木曜日午後２時５８分 FUEL SYSTEM Disassembly and Inspection of Fuel Injectors ......................... Adjusting Fuel Injector Pressure ............................................. Reassembly of Fuel Injectors .................................................. Installation of the Fuel Injectors...............................................
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TNV_IDI_ServiceManual_(3TNV72 for YN only).book 3 ページ２００７年１１月２９日 Before You Begin Servicing 木曜日午後２時５８分 FUEL SYSTEM BEFORE YOU BEGIN SERVICING A WARNING A WARNING ENTANGLEMENT HAZARD! • Stop the engine before you begin to service it. • NEVER leave the key in the key switch when you are servicing the engine. Someone may accidentally start the engine and not realize you are servicing it. This could result in a serious injury.
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TNV_IDI_ServiceManual_(3TNV72 for YN only).book 4 ページ２００７年１１月２９日 FUEL SYSTEM 木曜日午後２時５８分 Before You Begin Servicing CAUTION CAUTION • 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.
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TNV_IDI_ServiceManual_(3TNV72 for YN only).book 5 ページ２００７年１１月２９日木曜日午後２時５８分 Introduction FUEL SYSTEM INTRODUCTION (4) (3) (1) (2) (5) 0002238 (6) Figure 7-1 This section of the Service Manual describes the procedures necessary to remove, install, and time the ML fuel injection pump and its associated system components. This fuel injection pump is representative of the fuel injection pumps used on other TNV IDI model engines.
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TNV_IDI_ServiceManual_(3TNV72 for YN only).book 6 ページ２００７年１１月２９日木曜日午後２時５８分 FUEL SYSTEM Introduction Stop Solenoid CAUTION • 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 adjustments to these sealed adjustment screws.
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TNV_IDI_ServiceManual_(3TNV72 for YN only).book 7 ページ２００７年１１月２９日木曜日午後２時５８分 Fuel System Specifications FUEL SYSTEM FUEL SYSTEM SPECIFICATIONS Special Torque Chart Tightening Torque Lubricating Oil Application (Thread Portion and Seat Surface) 36.1 - 43.5 ft·lb (49 - 59 N·m, 5.0 - 60 kgf·m) Not Applied 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.
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TNV_IDI_ServiceManual_(3TNV72 for YN only).book 8 ページ２００７年１１月２９日木曜日午後２時５８分 FUEL SYSTEM Special Service Tools SPECIAL SERVICE TOOLS Note: Tools not having Yanmar part numbers must be acquired locally. No. Tool Name Application Illustration 1 Torque Wrench (Locally Available) For tightening nuts and bolts to the specified torque 0000840 MEASURING INSTRUMENTS No.
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TNV_IDI_ServiceManual_(3TNV72 for YN only).book 12 ページ２００７年１１月２９日木曜日午後２時５８分 FUEL SYSTEM Fuel Injection Lines 6. Finish loosening all the fuel line nuts and remove the high-pressure fuel lines as an assembly being careful not to bend any of the fuel lines. Be sure to protect the fuel system from contamination by plugging or covering all open connections. 7. Plug or cap all openings to minimize leakage and prevent contamination.
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TNV_IDI_ServiceManual_(3TNV72 for YN only).book 13 ページ２００７年１１月２９日木曜日午後２時５８分 Fuel Injection Pump FUEL SYSTEM 4. Remove the fuel return hose from the fuel return fitting on the fuel injection pump. 5. Carefully remove the fuel return line assembly (Figure 7-6, (3)). 6. Remove and discard the copper gasket (Figure 7-6, (1)) from each fuel injector. (3) (2) 7. Plug or cap all openings to minimize leakage and prevent contamination. Installation of Fuel Return Line (1) 1.
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TNV_IDI_ServiceManual_(3TNV72 for YN only).book 14 ページ２００７年１１月２９日木曜日午後２時５８分 FUEL SYSTEM Fuel Injection Pump 12. Remove the lube oil 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. (2) (1) (1) (3) 0002239 Figure 7-9 0002210 Figure 7-8 8. Remove the fuel supply line (Figure 7-8, (2)) from the fitting on the fuel injection pump. 9. Plug or cap all openings to minimize leakage and prevent contamination. 10.
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TNV_IDI_ServiceManual_(3TNV72 for YN only).book 15 ページ２００７年１１月２９日 Fuel Injection Pump 木曜日午後２時５８分 FUEL SYSTEM CAUTION 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. (3) 0000048en (1) (2) Figure 7-12 (1) 16. Hold the gear train stationary using a large socket wrench on the crankshaft pulley bolt.
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TNV_IDI_ServiceManual_(3TNV72 for YN only).book 16 ページ２００７年１１月２９日 FUEL SYSTEM 木曜日午後２時５８分 Fuel Injection Pump 18. Once the fuel injection pump drive gear and hub assembly have “popped” loose from the tapered fuel injection pump drive shaft, carefully remove the drive gear nut (Figure 7-14, (1)) and lock washer (Figure 7-14, (2)). 20. Remove the three nuts fastening the fuel injection pump to the gear case. Remove the fuel injection pump.
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TNV_IDI_ServiceManual_(3TNV72 for YN only).book 17 ページ２００７年１１月２９日 Fuel Injection Pump 木曜日午後２時５８分 FUEL SYSTEM 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. (1) 5. Reinstall the fuel injection pump drive gear lock washer (Figure 7-18, (2)) and nut (Figure 7-18, (1)).
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TNV_IDI_ServiceManual_(3TNV72 for YN only).book 18 ページ２００７年１１月２９日木曜日午後２時５８分 FUEL SYSTEM Fuel Injection Pump 11. Reinstall the lube oil line (Figure 7-20, (1)). (1) (1) 0002416 Figure 7-19 7. Tighten the fuel injection pump retaining nuts to specification. See Special Torque Chart on page 7-7. 8. Reconnect the fuel supply and return lines to the fuel injection pump. 9. Reconnect the throttle linkage and stop solenoid connector. 10.
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TNV_IDI_ServiceManual_(3TNV72 for YN only).book 19 ページ２００７年１１月２９日木曜日午後２時５８分 Checking and Adjusting Fuel Injection Timing FUEL SYSTEM 2. Clean the area around the fuel injection pump. (3) (2) Note: The stop solenoid must be removed to allow fuel to flow through the fuel injection pump. 3. Remove two screws (Figure 7-22, (1)). Remove the stop solenoid (Figure 7-22, (2)) and O-ring (Figure 7-22, (3)). (1) (4) (2) 0000163A Figure 7-21 15. Reinstall the cooling fan V-belt (Figure 7-21, (1)).
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TNV_IDI_ServiceManual_(3TNV72 for YN only).book 20 ページ２００７年１１月２９日 FUEL SYSTEM 木曜日午後２時５８分 Checking and Adjusting Fuel Injection Timing (3) (2) (4) (1) 1 (5) (1) 00020 0002071A Figure 7-23 6. Typical flywheel markings are as shown in (Figure 7-24). Note: A typical flywheel will have multiple timing grids depending on the number of cylinders. Any grid and its corresponding cylinder can be used to check the fuel injection timing.
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TNV_IDI_ServiceManual_(3TNV72 for YN only).book 21 ページ２００７年１１月２９日木曜日午後２時５８分 Checking and Adjusting Fuel Injection Timing • EXAMPLE: If the distance between the two “longer” marks is approximately 2.0 cm and the distance from the TDC mark is approximately 4.0 cm, the answer is approximately 2. This indicates there is 10° (2 x 5°) between the TDC mark and the first “longer” mark on the timing grid.
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TNV_IDI_ServiceManual_(3TNV72 for YN only).book 22 ページ２００７年１１月２９日 FUEL SYSTEM 木曜日午後２時５８分 Checking and Adjusting Fuel Injection Timing Note: As the injection pump injects fuel to a cylinder only once every two engine revolutions, it may be necessary to rotate the crankshaft twice to see fuel being pumped from the timing tool or delivery valve of the cylinder you are using to check injection timing. 13.
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TNV_IDI_ServiceManual_(3TNV72 for YN only).book 23 ページ２００７年１１月２９日木曜日午後２時５８分 Fuel Injectors FUEL SYSTEM Adjusting Fuel Injection Timing If the timing marks did not align when performing the Checking Fuel Injection Timing on page 7-19, the following steps must be performed to properly time the engine. 1. Leave the “spill-timing” tool installed in the fuel injection pump. 2.
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TNV_IDI_ServiceManual_(3TNV72 for YN only).book 24 ページ２００７年１１月２９日木曜日午後２時５８分 FUEL SYSTEM Fuel Injectors Testing of Fuel Injectors (1) CAUTION (2) Never use a steel wire brush to clean fuel injectors. Damage to the nozzle and other components is likely to result. (3) (4) 0000172en 1. Thoroughly clean the fuel injector nozzle using clean diesel fuel and a brass wire brush. (6) 2. Visually inspect the fuel injectors and nozzle protectors for deposits or damage.
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TNV_IDI_ServiceManual_(3TNV72 for YN only).book 25 ページ２００７年１１月２９日 Fuel Injectors 木曜日午後２時５８分 FUEL SYSTEM A WARNING HIGH-PRESSURE HAZARD! • Avoid skin contact with the high-pressure diesel fuel spray caused by a fuel system leak such as a 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. 5.
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TNV_IDI_ServiceManual_(3TNV72 for YN only).book 26 ページ２００７年１１月２９日木曜日午後２時５８分 FUEL SYSTEM Fuel Injectors Fuel Injector Test Results A B C D E Injection Pattern 0001742 0001744 0001743 Pressure Gauge Reading Atomization Pattern Possible Cause 120 120 120 120 120 0 0 0 0 0 0001747 0001748 0001750 0001749 Gauge needle fluctuates around the valve opening pressure. Gauge needle fluctuates around the valve opening pressure.
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TNV_IDI_ServiceManual_(3TNV72 for YN only).book 27 ページ２００７年１１月２９日木曜日午後２時５８分 Fuel Injectors FUEL SYSTEM Disassembly and Inspection of Fuel Injectors CAUTION Never use a steel wire brush to clean fuel injectors. Damage to the nozzle and other components is likely to result. 0000172en 1. Clean carbon from used injectors using clean diesel fuel. Hardened deposits or varnish can be cleaned using a brass wire brush. 3. Remove the nozzle case nut. 4. Carefully remove the injector from the vise. 5.
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TNV_IDI_ServiceManual_(3TNV72 for YN only).book 28 ページ２００７年１１月２９日木曜日午後２時５８分 FUEL SYSTEM Fuel Injectors 7. Perform a nozzle valve slide test: (a) Wash nozzle body and valve in clean diesel fuel. (b) While holding the nozzle body vertical, pull the nozzle valve about 2/3 of the way out (Figure 7-34). (c) Release the valve. It should fall smoothly to its seat by its own weight.
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TNV_IDI_ServiceManual_(3TNV72 for YN only).book 29 ページ２００７年１１月２９日木曜日午後２時５８分 Fuel Injectors FUEL SYSTEM 4. Retest the fuel injector. See Testing of Fuel Injectors on page 7-24. If the injector cannot be adjusted to the appropriate pressure, discard the fuel injector. Reassembly of Fuel Injectors (1) (2) (3) (4) 1. Secure the injector in a soft-jawed vise with the nozzle end up. 2. Reinstall the shims, nozzle spring, nozzle spring seat, valve stop spacer, nozzle valve, and nozzle body.
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TNV_IDI_ServiceManual_(3TNV72 for YN only).book 1 ページ２００７年１１月２９日 TNV IDI Service Manual 木曜日午後２時５８分 Section 8 COOLING SYSTEM Page Before You Begin Servicing ............................................................ 8-3 Introduction...................................................................................... 8-5 Cooling System Diagram................................................................. 8-5 Engine Coolant Pump Components ................................................
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TNV_IDI_ServiceManual_(3TNV72 for YN only).book 3 ページ２００７年１１月２９日 Before You Begin Servicing 木曜日午後２時５８分 COOLING SYSTEM BEFORE YOU BEGIN SERVICING A WARNING A DANGER ENTANGLEMENT HAZARD! • Stop the engine before you begin to service it. 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.
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TNV_IDI_ServiceManual_(3TNV72 for YN only).book 4 ページ２００７年１１月２９日 COOLING SYSTEM 木曜日午後２時５８分 Before You Begin Servicing A WARNING A CAUTION BURN HAZARD! • If you must drain the engine oil while it is still hot, stay clear of the hot engine oil to avoid being burned. • ALWAYS wear eye protection. 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.
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TNV_IDI_ServiceManual_(3TNV72 for YN only).book 5 ページ２００７年１１月２９日木曜日午後２時５８分 Introduction COOLING SYSTEM INTRODUCTION This section of the Service Manual describes the procedures necessary to service the 3TNV72 engine coolant pump.
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TNV_IDI_ServiceManual_(3TNV72 for YN only).book 7 ページ２００７年１１月２９日木曜日午後２時５８分 Engine Coolant System Check COOLING SYSTEM ENGINE COOLANT SYSTEM CHECK Check the engine coolant system for leakage. 1. With the radiator properly filled, install a cooling system tester (Figure 8-3, (1)). 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.
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TNV_IDI_ServiceManual_(3TNV72 for YN only).book 8 ページ２００７年１１月２９日木曜日午後２時５８分 COOLING SYSTEM Engine Coolant Pump 6. Remove the engine coolant pump (Figure 8-4, (4)). Discard the gasket. 7. Remove the thermostat cover (Figure 8-5, (1)). 2. Place the temperature switch and an accurate thermometer (Figure 8-6, (3)) in engine coolant. 3. Slowly increase temperature of the fluid using an external heat source. (1) (2) 4.
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TNV_IDI_ServiceManual_(3TNV72 for YN only).book 9 ページ２００７年１１月２９日木曜日午後２時５８分 Engine Coolant Pump COOLING SYSTEM CAUTION (1) 0000577A Use a new special O-ring 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. Figure 8-8 0000042en 2. Apply 10.8 - 14.8 psi (75 - 105 kPa; 0.75 - 1.05 kgf/cm²) to the radiator cap.
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TNV_IDI_ServiceManual_(3TNV72 for YN only).book 10 ページ２００７年１１月２９日 COOLING SYSTEM 木曜日午後２時５８分 Engine Coolant Pump (2) (1) 0000584 Figure 8-11 9. Reinstall the V-belt. Tighten the V-belt to the proper tension. See Check and Adjust Cooling Fan V-Belt on page 5-27. 10. Reinstall and tighten the drain plug or close the drain cock in the radiator. Reinstall and tighten the engine block drain plug or reconnect the coolant hose at the oil cooler. 11. Fill radiator and engine with engine coolant.
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TNV_IDI_ServiceManual_(3TNV72 for YN only).book 1 ページ２００７年１１月２９日 TNV IDI Service Manual 木曜日午後２時５８分 Section 9 LUBRICATION SYSTEM Page Before You Begin Servicing ............................................................ 9-3 Introduction...................................................................................... 9-5 Oil Pump Service Information.......................................................... Engine Oil Pressure...................................................................
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TNV_IDI_ServiceManual_(3TNV72 for YN only).book 3 ページ２００７年１１月２９日 Before You Begin Servicing 木曜日午後２時５８分 LUBRICATION SYSTEM BEFORE YOU BEGIN SERVICING A WARNING CAUTION ENTANGLEMENT HAZARD! • Stop the engine before you begin to service it. NEVER permit anyone to operate the engine or driven machine without proper training. • Read and understand this Operation Manual before you operate or service the machine to ensure that you follow safe operating practices and maintenance procedures.
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TNV_IDI_ServiceManual_(3TNV72 for YN only).book 4 ページ２００７年１１月２９日 LUBRICATION SYSTEM 木曜日午後２時５８分 Before You Begin Servicing A WARNING CAUTION • Only use the engine oil specified. Other engine oils may affect warranty coverage, cause internal engine components to seize and / or shorten engine life. FUME / BURN HAZARD! • Always read and follow safety related precautions found on containers of hazardous substances like parts cleaners, primers, sealants and sealant removers.
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TNV_IDI_ServiceManual_(3TNV72 for YN only).book 5 ページ２００７年１１月２９日木曜日午後２時５８分 Introduction LUBRICATION SYSTEM INTRODUCTION This section of the Service Manual describes the procedures necessary to service the 2TNV70, 3TNV70 and 3TNV76 trochoid oil pumps. Note: See Replace Engine Oil and Engine Oil Filter on page 5-26 for engine oil and engine oil filter replacement procedures. OIL PUMP SERVICE INFORMATION Engine Oil Pressure Model 3TNV72 at Rated Engine rpm at Low Idle Speed 42 - 64 psi (0.29 - 0.
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TNV_IDI_ServiceManual_(3TNV72 for YN only).book 6 ページ２００７年１１月２９日木曜日 LUBRICATION SYSTEM 午後２時５８分 Oil Pump Service Information Inner Rotor and Gear Boss Clearance Item Inside Clearance of Inner Rotor Inner Rotor Width Across Flat Clearance 9-6 Parts Standard Dimension Gear Boss Diameter 2.0886 - 2.0925 in. (53.05 - 53.15 mm) Rotor Diameter 2.1043 - 2.1083 in. (53.45 - 53.55 mm) Width Across Flat of Gear Boss 1.9468 - 1.9587 in. (49.45 - 49.75 mm) Width Across Flat of Rotor 1.9665 - 1.
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TNV_IDI_ServiceManual_(3TNV72 for YN only).book 8 ページ２００７年１１月２９日木曜日午後２時５８分 LUBRICATION SYSTEM Checking Engine Oil Pressure CHECKING ENGINE OIL PRESSURE TROCHOID OIL PUMP Oil Pump Components Perform an engine oil pressure check if there is any indication of low oil pressure such as the oil pressure indicator is on or the oil pressure gauge indicates low oil pressure. See Engine Oil Pressure on page 9-5 for the engine oil pressure specification. (1) (2) (5) (6) 1.
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TNV_IDI_ServiceManual_(3TNV72 for YN only).book 9 ページ２００７年１１月２９日木曜日午後２時５８分 Trochoid Oil Pump LUBRICATION SYSTEM Disassembly of Oil Pump (2) CAUTION (1) (3) (4) If the oil pump must be replaced, replace it as an assembly only. Do not replace individual components. 0000030en 1. Remove the engine cooling fan guard (if equipped), engine cooling fan (Figure 9-4, (1)), spacer (Figure 9-4, (2)), engine coolant pump V-pulley (Figure 9-4, (3)) and V-belt. (4) 0001955B Figure 9-5 (3) (2) 4.
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TNV_IDI_ServiceManual_(3TNV72 for YN only).book 10 ページ２００７年１１月２９日木曜日午後２時５８分 LUBRICATION SYSTEM Trochoid Oil Pump Cleaning and Inspection Outer Rotor to Inner Rotor Tip Clearance Wash the oil pump cover, the oil pressure regulator valve, the oil pump cavity and the inner and outer rotors. Inspect the parts for wear or damage. Replace as necessary. Determine the outer rotor to inner rotor tip clearance.
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TNV_IDI_ServiceManual_(3TNV72 for YN only).book 11 ページ２００７年１１月２９日 Trochoid Oil Pump 2. Reinstall the outer rotor in the gear case. The dot mark on the face of the outer rotor must face up toward the oil pump cover. (5) 3. Reinstall the inner rotor into the gear case cover with the dot mark also facing up. Make sure that the pilot on the 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.
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TNV_IDI_ServiceManual_(3TNV72 for YN only).book 1 ページ２００７年１１月２９日 TNV IDI Service Manual 木曜日午後２時５８分 Section 10 STARTER MOTOR Page Before You Begin Servicing .......................................................... 10-3 Introduction.................................................................................... 10-5 Starter Motor Information .............................................................. 10-5 Starter Motor Specifications ..........................................................
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TNV_IDI_ServiceManual_(3TNV72 for YN only).book 3 ページ２００７年１１月２９日 Before You Begin Servicing 木曜日午後２時５８分 STARTER MOTOR BEFORE YOU BEGIN SERVICING A WARNING A WARNING SHOCK HAZARD! ENTANGLEMENT HAZARD! • Stop the engine before you begin to service it. • NEVER leave the key in the key switch when you are servicing the engine. Someone may accidentally start the engine and not realize you are servicing it. This could result in a serious injury.
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TNV_IDI_ServiceManual_(3TNV72 for YN only).book 4 ページ２００７年１１月２９日 STARTER MOTOR 木曜日午後２時５８分 Before You Begin Servicing A CAUTION CAUTION The starter motor is water-proofed according to JIS D 0203, R2 which protects the motor from rain or general cleaning. Do not use high-pressure wash or submerse the starter motor in water. FLYING OBJECT HAZARD! • ALWAYS wear eye protection when servicing the engine and when using compressed air or high-pressure water.
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TNV_IDI_ServiceManual_(3TNV72 for YN only).book 5 ページ２００７年１１月２９日木曜日午後２時５８分 Introduction STARTER MOTOR INTRODUCTION This section of the Service Manual covers the servicing of starter motor. Yanmar Part No. 119717-77010 is used in this section to show the service procedures for a representative starter motor. For specific part detail, see the Yanmar Parts Catalog for the engine being serviced. STARTER MOTOR INFORMATION No Load YANMAR Part Number Mfg. Mfg.
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TNV_IDI_ServiceManual_(3TNV72 for YN only).book 6 ページ２００７年１１月２９日木曜日午後２時５８分 STARTER MOTOR Starter Motor Specifications STARTER MOTOR SPECIFICATIONS Yanmar Part Number 119717-77010 119515-77010 Nominal Output 1.5 hp (1.1 kW) 1.34 hp (1.0 kW) 6.6 lb (3.0 kg) 6.3 lb (2.85 kg) Clockwise Clockwise Weight Revolution Direction (As Viewed From Pinion) Engagement System No-load Magnetic Shift Magnetic Shift Terminal Voltage/Current 11.5 V / 90 A max 11.
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TNV IDI Service Manual Inspect fuel system. YES Inspect condition of engine. Slow Revolution YES NO NO Repair or replace starter motor. Replace engine oil. • Inspect brush and replace if worn. • If brushes are not worn, replace armature assembly. • Adjust / pinion 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.
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TNV_IDI_ServiceManual_(3TNV72 for YN only).book 10 ページ２００７年１１月２９日木曜日午後２時５８分 STARTER MOTOR Starter Motor Removal of Starter Motor 1. Disconnect the battery cables at the battery, negative (-) cable first. 2. Remove the electrical wires from the solenoid switch assembly. 3. Remove the starter mounting bolts (Figure 10-2, (1)). Remove the starter motor from the flywheel housing. 3. Remove the two bolts or nuts retaining the solenoid switch assembly (Figure 10-4, (1)) to the pinion housing.
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TNV_IDI_ServiceManual_(3TNV72 for YN only).book 11 ページ２００７年１１月２９日木曜日午後２時５８分 Starter Motor STARTER MOTOR 6. Pull the brush springs up using a brush spring puller. On the negative (-) side, bring the brush spring into contact with the side of the brushes to hold the brushes clear of the commutator surface. On the positive (+) side, remove the brushes from the brush holder assembly (Figure 10-6). 11. Remove the shift lever (Figure 10-8, (2)), pin, and spacer (Figure 10-8, (1)).
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TNV_IDI_ServiceManual_(3TNV72 for YN only).book 12 ページ２００７年１１月２９日木曜日午後２時５８分 STARTER MOTOR Starter Motor 13. Remove the pinion stop (Figure 10-10, (3)), return spring (if equipped), and pinion clutch assembly (Figure 10-10, (2)), from the pinion shaft (Figure 10-10, (1)). (2) 15. 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.
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TNV_IDI_ServiceManual_(3TNV72 for YN only).book 13 ページ２００７年１１月２９日 Starter Motor 木曜日午後２時５８分 STARTER MOTOR Measure Commutator Insulation Depth Measure the depth of the insulating material (Figure 10-14, (1)) between commutator segments (Figure 10-14, (2)). If the depth measures less than the limit, use a hacksaw blade (Figure 10-14, (3)) to remove the insulating material until the depth is within the limit. See Starter Motor Specifications on page 10-6 for service limit.
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TNV_IDI_ServiceManual_(3TNV72 for YN only).book 14 ページ２００７年１１月２９日木曜日午後２時５８分 STARTER MOTOR Starter Motor Measure Armature and Commutator Run-Out Measure the armature core run-out and the commutator run-out using a dial indicator (Figure 10-17). Replace the armature if either of the measurements is not within specifications. See Starter Motor Specifications on page 10-6 for service limit.
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TNV_IDI_ServiceManual_(3TNV72 for YN only).book 15 ページ２００７年１１月２９日木曜日午後２時５８分 Starter Motor STARTER MOTOR Brush Holder Solenoid Switch Brush Holder Insulation Test Check for continuity between each brush holder and the base using a multimeter (Figure 10-21). The multimeter should not indicate continuity. If the starter motor becomes wet, replace the solenoid switch even if the solenoid switch assembly function is normal. If the multimeter indicates continuity, replace the brush holder.
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TNV_IDI_ServiceManual_(3TNV72 for YN only).book 16 ページ２００７年１１月２９日木曜日午後２時５８分 STARTER MOTOR Starter Motor Coil Resistance Test See Starter Motor Specifications on page 10-6 for service limit. Contact Continuity Test Depress the plunger at the bottom of the solenoid switch. Check for continuity between the “B” and “M” terminals using a multimeter (Figure 10-25). The multimeter should indicate continuity. If the multimeter does not indicate continuity, replace the solenoid switch.
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TNV_IDI_ServiceManual_(3TNV72 for YN only).book 17 ページ２００７年１１月２９日木曜日午後２時５８分 Starter Motor STARTER MOTOR Reassembly of Starter Motor (2) 1. Apply a appropriate starter bendix grease (obtain locally) to the pinion shaft. 2. Reassemble the reduction gear (Figure 10-28, (4)), pinion shaft (Figure 10-28, (5)), planetary gears (Figure 10-28, (6)), and washers into the intermediate housing (Figure 10-28, (3)). Reinstall snap ring (Figure 10-28, (1)). (1) (4) (3) (4) 0000152B Figure 10-29 (3) 4.
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TNV_IDI_ServiceManual_(3TNV72 for YN only).book 18 ページ２００７年１１月２９日木曜日午後２時５８分 STARTER MOTOR Starter Motor 8. Reinstall the plate onto the intermediate housing and carefully reinstall the armature assembly (Figure 10-31, (2)) into the pinion shaft assembly. (2) (1) 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)).
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TNV_IDI_ServiceManual_(3TNV72 for YN only).book 19 ページ２００７年１１月２９日木曜日午後２時５８分 Starter Motor STARTER MOTOR Check Pinion Projection Length No-Load Test 1. Connect the positive (+) lead from a battery to the “S” terminal. Test the characteristics of the starter motor by performing a no load test. 2. Connect the negative (-) lead to the “M” terminal. 3. Lightly pull the pinion away from the gear housing. 4.
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TNV_IDI_ServiceManual_(3TNV72 for YN only).book 20 ページ２００７年１１月２９日木曜日午後２時５８分 STARTER MOTOR 5. Install a switch (Figure 10-37, (6)) in a circuit between the battery positive (+) terminal (Figure 10-37, (2)) and the starter solenoid switch terminal (Figure 10-37, (8)) on the starter motor. 6. Use a suitable tachometer to monitor the rpm of the starter. 7. Turn the switch to the ON position to energize the solenoid and operate the starter. Monitor the rpm, amperage draw and voltage.
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TNV_IDI_ServiceManual_(3TNV72 for YN only).book 1 ページ２００７年１１月２９日 TNV IDI Service Manual 木曜日午後２時５８分 Section 11 ALTERNATOR Page Before You Begin Servicing .......................................................... 11-3 Introduction.................................................................................... 11-6 Standard and Optional Dynamo Information ................................. 11-6 Standard and Optional Alternator Information...............................
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TNV_IDI_ServiceManual_(3TNV72 for YN only).book 2 ページ２００７年１１月２９日木曜日午後２時５８分 ALTERNATOR Dynamo ....................................................................................... Removal of Dynamo.............................................................. Disassembly of Dynamo........................................................ Reassembly of Dynamo ........................................................ Installation of Dynamo...........................................................
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TNV_IDI_ServiceManual_(3TNV72 for YN only).book 3 ページ２００７年１１月２９日 Before You Begin Servicing 木曜日午後２時５８分 ALTERNATOR BEFORE YOU BEGIN SERVICING A WARNING A WARNING SHOCK HAZARD! ENTANGLEMENT HAZARD! • Stop the engine before you begin to service it. • NEVER leave the key in the key switch when you are servicing the engine. Someone may accidentally start the engine and not realize you are servicing it. This could result in a serious injury.
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TNV_IDI_ServiceManual_(3TNV72 for YN only).book 4 ページ２００７年１１月２９日 ALTERNATOR 木曜日午後２時５８分 Before You Begin Servicing A WARNING A CAUTION FUME / BURN HAZARD! • Always read and follow safety related precautions found on containers of hazardous substances like parts cleaners, primers, sealants and sealant removers. • Failure to comply could result in death or serious injury. 0000014en PINCH HAZARD! Carefully rotate the alternator toward the cylinder block while loosening the V-belt.
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TNV_IDI_ServiceManual_(3TNV72 for YN only).book 5 ページ２００７年１１月２９日 Before You Begin Servicing 木曜日午後２時５８分 ALTERNATOR CAUTION CAUTION Do not connect a load between alternator terminals L and E. Damage to the alternator will result. Using a non-specified V-belt will cause inadequate charging and shorten the belt life. Use the specified belt. 0000036en CAUTION 0000052en CAUTION Do not operate the engine if the alternator is producing unusual sounds. Damage to the alternator will result.
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TNV_IDI_ServiceManual_(3TNV72 for YN only).book 6 ページ２００７年１１月２９日木曜日午後２時５８分 ALTERNATOR Introduction INTRODUCTION This section of the Service Manual describes the servicing of the dynamos and alternators. Yanmar Part No. 129423-77200 alternator is used in this section to show the service procedures for the representative alternator. Yanmar Part No. 171301-77201 dynamo is used in this section to show the service procedures for the representative dynamo.
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TNV_IDI_ServiceManual_(3TNV72 for YN only).book 7 ページ２００７年１１月２９日木曜日午後２時５８分 Dynamo Specifications ALTERNATOR DYNAMO SPECIFICATIONS Yanmar Part Number 119910-77200 Nominal Output 20 Amps Weight 3.97 lb (1.8 kg) Revolution Direction (As Viewed 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.
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11-8 1) Use a fully charged battery 2) DC voltmeter: 0 to 30 V, 0.5 class 3) The check method is also applicable to the bench test OFF Not abnormal. Inspect auxiliary diode. ON Battery voltage is between 13 and 15 volts. Does battery indicator come ON? Replace regulator. Check condition of L terminal. Inspect diode negative (-) side. Excessive voltage drop between BAT and batt ( + side) terminal. Inspect diode positive (+) side. Inspect or replace V-belt. Inspect alternator.
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TNV_IDI_ServiceManual_(3TNV72 for YN only).book 9 ページ２００７年１１月２９日木曜日午後２時５８分 Alternator Components ALTERNATOR ALTERNATOR COMPONENTS Yanmar Part No. 129423-77200 alternator is used in this section to show the service procedures for the representative alternator. For specific part detail, see the Parts Catalog for the engine you are working on.
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TNV_IDI_ServiceManual_(3TNV72 for YN only).book 10 ページ２００７年１１月２９日木曜日午後２時５８分 ALTERNATOR Alternator Wiring Diagram ALTERNATOR WIRING DIAGRAM B IG B PI P F 0.5μF IC E 1 IG P L 2 L 3 3 B 4A T E 5 6 1 – Key Switch 2 – Charge Lamp (3.4 Watts Max.) 3 – Load 4 – Battery 5 – Alternator Assembly 6 – IC Regulator Assembly Figure 11-2 CAUTION CAUTION Do not short-circuit the charging system between alternator terminals IG and L. Damage to the alternator will result.
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TNV_IDI_ServiceManual_(3TNV72 for YN only).book 11 ページ２００７年１１月２９日木曜日午後２時５８分 Alternator Standard Output ALTERNATOR ALTERNATOR STANDARD OUTPUT Output Current 60 Cold 13.
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TNV_IDI_ServiceManual_(3TNV72 for YN only).book 12 ページ２００７年１１月２９日木曜日午後２時５８分 ALTERNATOR Alternator ALTERNATOR A WARNING SHOCK HAZARD! 2 • 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. 1 0000264 Figure 11-4 Disassembly of Alternator 1.
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TNV_IDI_ServiceManual_(3TNV72 for YN only).book 13 ページ２００７年１１月２９日木曜日午後２時５８分 Alternator ALTERNATOR 2. Remove the three bolts (Figure 11-6, (1)) retaining the rear cover (Figure 11-6, (2)) to the rear frame assembly. 5. Remove the bolts 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. 1 3 7.
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TNV_IDI_ServiceManual_(3TNV72 for YN only).book 14 ページ２００７年１１月２９日木曜日午後２時５８分 ALTERNATOR Alternator Reassembly of Alternator 9. Remove the stator assembly (Figure 11-10, (1)) from the front frame housing. 4 3 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. 2 3 1 2 1 0000259A Figure 11-10 10.
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TNV_IDI_ServiceManual_(3TNV72 for YN only).book 15 ページ２００７年１１月２９日木曜日午後２時５８分 Alternator ALTERNATOR 3. Position the stator assembly (Figure 11-13, (1)) on the front frame housing studs. 4. Lubricate the shaft of the rotor assembly (Figure 11-14, (1)). Press the rotor assembly into the front frame housing (Figure 11-14, (2)) and rear frame housing (Figure 11-14, (3)). 3 1 4 3 1 2 2 0000258A 100266A Figure 11-14 5. Align the front frame housing with the rear frame housing.
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TNV_IDI_ServiceManual_(3TNV72 for YN only).book 16 ページ２００７年１１月２９日木曜日午後２時５８分 ALTERNATOR Alternator 4. Start the engine. Listen for any unusual sounds from the alternator. CAUTION Do not operate the engine if the alternator is producing unusual sounds. Damage to the alternator will result. 0000039en 5. Verify that the charge indicator is ON while the engine is operating. If the charge indicator is not ON, repair the problem before operating the engine. 1 2 0000256 Figure 11-18 11.
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TNV_IDI_ServiceManual_(3TNV72 for YN only).book 17 ページ２００７年１１月２９日木曜日午後２時５８分 Dynamo Component Location ALTERNATOR DYNAMO COMPONENT LOCATION Yanmar Part No. 171301-77201 dynamo is used in this section to show the service procedures for the representative dynamo. For specific part detail, see the Parts Catalog for the engine you are working on.
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TNV_IDI_ServiceManual_(3TNV72 for YN only).book 18 ページ２００７年１１月２９日木曜日午後２時５８分 ALTERNATOR Dynamo Wiring Diagram DYNAMO WIRING DIAGRAM (3) (5) (2) (6) (4) (1) 0002137 Figure 11-21 1 – Dynamo 2 – Current Limiter Assembly 3 – Key Switch 4 – Charge Lamp (3.4 Watts Max.) 5 – Battery 6 – Load OPERATION OF DYNAMO The dynamo consists of a series of permanent magnets that rotate around a stationary stator coil.
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TNV_IDI_ServiceManual_(3TNV72 for YN only).
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TNV_IDI_ServiceManual_(3TNV72 for YN only).book 20 ページ２００７年１１月２９日木曜日午後２時５８分 ALTERNATOR Testing of Dynamo TESTING OF DYNAMO DYNAMO Use a circuit tester or multimeter to perform the following tests. Removal of Dynamo Testing Stator Coil Continuity 1. Disconnect the output wire connector from the dynamo. 1. Disconnect the dynamo output wire connector. 2. Loosen the V-belt. 2. Connect one meter lead to each of the stator wire terminals and read the meter.
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TNV_IDI_ServiceManual_(3TNV72 for YN only).book 21 ページ２００７年１１月２９日木曜日午後２時５８分 Dynamo ALTERNATOR Disassembly of Dynamo 1. Remove the rear cover (Figure 11-24, (1)). (3) 2. Remove the nut (Figure 11-23, (2)), lock washer (Figure 11-24, (3)), and flat washer (Figure 11-24, (4)). (2) (1) (2) (3) (1) (4) 0002145 Figure 11-26 Reassembly of Dynamo 1. Reinstall the rear bearing (Figure 11-26, (3)). 2. Reinstall the stator (Figure 11-26, (1)). 0002143 Figure 11-24 3.
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TNV_IDI_ServiceManual_(3TNV72 for YN only).book 22 ページ２００７年１１月２９日木曜日午後２時５８分 ALTERNATOR Dynamo 6. Reinstall the flat washer (Figure 11-28, (4)), lock washer (Figure 11-28, (3)), and nut (Figure 11-28, (2)). Tighten the nut to the specified torque. 7. Reinstall the rear cap (Figure 11-28, (1)). Installation of Dynamo 1. Position the dynamo on the gear case. Loosely reinstall the nut (Figure 11-29, (2)) on the gear case stud and the V-belt adjuster bolt (Figure 11-29, (1)).
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TNV_IDI_ServiceManual_(3TNV72 for YN only).book 1 ページ２００７年１１月２９日 TNV IDI Service Manual 木曜日午後２時５８分 Section 12 ELECTRIC WIRING Page Electric Wiring Precautions .......................................................... 12-3 Electric Wire Resistance ............................................................... 12-4 Battery Cable Resistance.............................................................. 12-5 Electrical Wire Sizes - Voltage Drop .............................................
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TNV_IDI_ServiceManual_(3TNV72 for YN only).
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TNV_IDI_ServiceManual_(3TNV72 for YN only).book 3 ページ２００７年１１月２９日 Electric Wiring Precautions 木曜日午後２時５８分 ELECTRIC WIRING ELECTRIC WIRING PRECAUTIONS CAUTION Failure to follow these precautions may result in the failure of an electrical component and the loss of warranty coverage on that item as well as related items. Make sure that all users read and understand these precautions. CAUTION Do not reverse the positive (+) and negative (-) ends of the battery cable.
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TNV_IDI_ServiceManual_(3TNV72 for YN only).book 4 ページ２００７年１１月２９日木曜日午後２時５８分 ELECTRIC WIRING Electric Wire Resistance ELECTRIC WIRE RESISTANCE AWG Metric Nominal mm² 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.
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TNV_IDI_ServiceManual_(3TNV72 for YN only).book 5 ページ２００７年１１月２９日木曜日午後２時５８分 Battery Cable Resistance ELECTRIC WIRING BATTERY CABLE RESISTANCE AWG Maximum Total Battery Cable Length (Positive Cable + Negative Cable + a*) 12V Starter Motor Output mm² 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.
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TNV_IDI_ServiceManual_(3TNV72 for YN only).book 6 ページ２００７年１１月２９日木曜日午後２時５８分 ELECTRIC WIRING Electrical Wire Sizes - Voltage Drop ELECTRICAL WIRE SIZES - VOLTAGE DROP Total current on circuit in amps.
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TNV_IDI_ServiceManual_(3TNV72 for YN only).book 7 ページ２００７年１１月２９日木曜日午後２時５８分 Conversion of AWG to European Standards ELECTRIC WIRING CONVERSION OF AWG TO EUROPEAN STANDARDS Conductor Size (AWG) Conductor Diameter (mm) Conductor Cross-sectional Area (mm2) 25 0.455 0.163 24 0.511 0.205 23 0.573 0.259 22 0.644 0.325 21 0.723 0.412 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.
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TNV_IDI_ServiceManual_(3TNV72 for YN only).
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TNV_IDI_ServiceManual_(3TNV72 for YN only).book 1 ページ２００７年１１月２９日 TNV IDI Service Manual 木曜日午後２時５８分 Section 13 TROUBLESHOOTING Page Special Service Tools.................................................................... 13-3 Troubleshooting By Measuring Compression Pressure ................ Compression Pressure Measurement Method ........................ Standard Compression Pressure ............................................ Engine Speed and Compression Pressure (Use for Reference) ............
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TNV_IDI_ServiceManual_(3TNV72 for YN only).
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TNV_IDI_ServiceManual_(3TNV72 for YN only).book 3 ページ２００７年１１月２９日木曜日午後２時５８分 Special Service Tools TROUBLESHOOTING SPECIAL SERVICE TOOLS Compression Gauge Kit For measuring compression pressure Yanmar Part No.
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TNV_IDI_ServiceManual_(3TNV72 for YN only).book TROUBLESHOOTING 4 ページ２００７年１１月２９日木曜日午後２時５８分 Troubleshooting By Measuring Compression Pressure TROUBLESHOOTING BY MEASURING COMPRESSION PRESSURE Compression pressure drop is one of major causes of increasing blow-by gas (engine oil contamination or increased engine oil consumption as a resultant phenomenon) or starting failure. The compression pressure is affected by the following factors: 3. Turn off the fuel supply valve in the fuel supply line.
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TNV_IDI_ServiceManual_(3TNV72 for YN only).book 5 ページ２００７年１１月２９日木曜日午後２時５８分 Troubleshooting By Measuring Compression Pressure TROUBLESHOOTING Standard Compression Pressure Engine compression pressure list (reference value) Compression Pressure at 250 rpm (250 min-1) Engine Model 3TNV72 Deviation Between Cylinders Standard Limit 470 ± 15 psi (3.24 ± 0.1 MPa; 33 ± 1 kgf/cm²) 370 ± 15 psi (2.55 ± 0.1 MPa; 26 ± 1 kgf/cm²) 29 to 43 psi (0.2 to 0.
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TNV_IDI_ServiceManual_(3TNV72 for YN only).book 6 ページ２００７年１１月２９日 TROUBLESHOOTING 木曜日午後２時５８分 Quick Reference Table For Troubleshooting Measured Value and Troubleshooting When the measured compression pressure is below the limit value, inspect each part by referring to the table below. No. 1 Item Air Cleaner Element Cause Corrective Action Clogged element Clean the element. Broken element Defect at element seal portion Replace the element.
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Engine Does Not Start O O Worn Piston Ring, Piston or Cylinder Seized Crankpin Metal or Bearing TNV IDI Service Manual Improper Arrangement of Piston Ring Gaps O Seized or Broken Piston Ring Cylinder Head Gasket Blowout O O O O O O O O Intake/Exhaust Valve Seizure O None O Much O O Ordinary Compression Leakage from Valve Seat Improper Intake/Exhaust Valve Clearance Cause Exhaust Smoke Little Exhaust Color O O O White Engine Starts But Stops Soon.
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13-8 TROUBLESHOOTING TNV_IDI_ServiceManual_(3TNV72 for YN only).
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Engine System - Continued Engine Does Not Start.
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13-10 TROUBLESHOOTING TNV_IDI_ServiceManual_(3TNV72 for YN only).
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Engine Does Not Start.
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13-12 TROUBLESHOOTING TNV_IDI_ServiceManual_(3TNV72 for YN only).
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O None Engine Does Not Start. O Clogged Fuel Filter TNV IDI Service Manual O Water in Fuel System O O O O Much Incorrect Diesel Fuel O Ordinary O Little Exhaust Color White Too Late Timing of Fuel Injection Pump Too Early Timing of Fuel Injection Pump Cause Exhaust Smoke Engine Starts but Stops Soon.
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13-14 TROUBLESHOOTING TNV_IDI_ServiceManual_(3TNV72 for YN only).
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O Insufficient Fuel Supply to Fuel Injection Pump None Ordinary TNV IDI Service Manual Clogged Strainer at Feed Pump Inlet Priming Failure O O O O During Work O O O O Much Poor Spray Pattern from Fuel Injection Nozzle O O O O White O O O O Little Exhaust Color White Excessive Fuel Injection Volume O O Clogged or Cracked Fuel Line Uneven Injection Volume from Fuel Injection Pump O Engine Does Not Start.
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13-16 TROUBLESHOOTING TNV_IDI_ServiceManual_(3TNV72 for YN only).
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Much Engine Does Not Start. O O O O Alternator Defect Open-Circuit in Wiring Battery Voltage Drop TNV IDI Service Manual O Starting Motor Defect O None Clogged Exhaust Pipe O Ordinary O Little Exhaust Color White Engine Used at High Temperatures or at High Altitude Clogged Air Filter Cause Exhaust Smoke Engine Starts but Stops Soon.
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13-18 TROUBLESHOOTING TNV_IDI_ServiceManual_(3TNV72 for YN only).
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19 ページ２００７年１１月２９日木曜日 TNV IDI Service Manual 午後２時５８分 TNV IDI Service Manual LA206 YAZAKI NO. 7123 - 3010 GLOW PLUG 11V-9 ±1.0 A/PER ONE 119717 - 77800 PRE-HEAT TIME 3 sec YAZAKI NO. 7122 - 3016 KEY SWITCH* EMERGENCY STOP SWITCH* 30A FUSE* Items marked with * are not provided by Yanmar. 0002427A 13-19 WIRING DIAGRAM Note: The following wiring diagram is “representative” of a common installation using a Yanmar engine.
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13-20 WIRING DIAGRAM TNV_IDI_ServiceManual_(3TNV72 for YN only).