Yanmar 3TNV 4TNV Series Diesel Engine Service Manual – PDF DOWNLOAD
FILE DETAILS:
Yanmar 3TNV 4TNV Series Diesel Engine Service Manual – PDF DOWNLOAD
Size: 12.9 MB
Format: PDF
Language: English
Number of Pages : 213 pages
DESCRIPTION:
Yanmar 3TNV 4TNV Series Diesel Engine Service Manual – PDF DOWNLOAD
PREFACE:
- PREFACE This manual describes the service procedures for the TNV series engines of indirect injection system that have been certified by the US 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 said engine.
- Since the explanation in this manual assumes the standard type engine, the specifications and components may partially be different from the engine installed on individual work equipment (power generator, pump, compressor, etc.). Please also refer to the service manual for each work equipment for details. The specifications and components may be subject to change for improvement of the engine quality without notice. If any modification of the contents described herein becomes necessary, it will be notified in the form of correction information each time.
TABLE OF CONTENTS:
Yanmar 3TNV 4TNV Series Diesel Engine Service Manual – PDF DOWNLOAD
1 General 1
11 Engine Nomenclature 1
12 Specifications 1
13 Fuel Oil, Lubricating Oil and Cooling Water 14
131 Fuel oil14
132 Lubricating oil 15
133 Cooling water 15
14 Engine External Views 16
15 Structural Description 17
16 Exhaust gas emission regulation 18
161 The Emission Standard in USA 18
162 Engine identification 19
163 Guarantee Conditions for the EPA Emission Standard20
2 Inspection and Adjustment 22
21 Periodic Maintenance Schedule 22
22 Periodic Inspection and Maintenance Procedure 23
221 Check before Daily Operation 23
222 inspection after initial 50 hours operation 25
223 Inspection every 50 hours 28
224 Inspection every 250 hours or 3 months 32
225 Inspection every 500 hours or 6 months 35
226 Inspection every 1,000 hours or one year 37
227 Inspection every 2000 hours or 2 years 46
23 Adjusting the no-load maximum or minimum speed 49
24 Sensor Inspection 50
241 Oil pressure switch50
242 Thermo switch 50
25 Water leak check in cooling water system 50
26 Radiator cap inspection 51
27 Thermostat Inspection 51
28 Adjusting Operation 52
29 Long storage 52
3 TROUBLESHOOTING 53
31 Preparation before troubleshooting 53
32 Quick Reference Table for Troubleshooting 54
33 Troubleshooting by measuring Compression Pressure 57
4 Disassembly, Inspection and Reassembly of Engines 59
41 Complete disassembly and reassembly 59
411 Introduction 59
412 Special service tools60
413 Complete disassembly 65
414 Precautions before and during reassembly 69
415 Adjusting operation69
42 Cylinder Head: Disassembly, Inspection and Reassembly 70
421 Components (2-valve cylinder head)70
422 Disassembly procedure:70
423 Reassembly procedure: 71
424 Servicing points 72
425 Parts Inspection and measurement76
426 Valve seat correction 80
427 Valve guide replacement 81
428 Valve stem seal replacement82
43 Gear Train and Camshaft 83
431 Components83
432 Disassembly procedure:83
433 Reassembly procedure: 83
434 Servicing points 84
435 Parts inspection and measurement 87
436 Oil seal replacement (Gear case side) 89
437 Camshaft bushing replacement89
44 Cylinder Block 90
441 Components90
442 Disassembly procedure:90
443 Reassembly procedure: 90
444 Servicing points 91
445 Parts inspection and measurement 95
446 Cylinder bore correction 106
447 Piston pin bushing replacement 107
448 Oil seal replacement (Flywheel housing side) 107
5 LUBRICATION SYSTEM 108
51 Lubrication System Diagram 108
52 Trochoid Pump Components 109
53 Disassembly(Reverse the procedure below for assembly) 109
54 Servicing Points 109
55 Parts Inspection and Measurement110
551 Trochoid pump inspection and measurement110
6 COOLING SYSTEM112
61 Cooling Water System112
62 Cooling Water Pump Components 112
63 Disassembly (Reverse the procedure below for assembly) 113
64 Servicing Points113
7 FUEL INJECTION PUMP/GOVERNOR114
71 Introduction 114
72 Fuel Injection Pump114
721 Fuel system diagram114
722 External view and components115
723 Disassembly procedure:115
724 Assembly procedure116
725 Servicing points 116
8 TURBOCHAGER: Disassembly, inspection and reassembly118
81 Structure and Functions118
811 Main specifications 118
812 Construction 118
813 Structural and functional outline 119
814 Components120
82 Service Standards and Tightening Torque 121
821 Service standards121
822 Tightening torque122
83 Periodic Inspection Procedure 123
831 Periodic inspection intervals 123
832 Inspection procedure124
833 Waste gate valve adjustment procedure 125
84 Disassembly Procedure 127
841 Preparation for disassembly127
842 Inspection before disassembly 128
843 Disassembly128
85 Washing and Inspection procedure 130
851 Washing 130
852 Inspection procedure131
86 Reassembly Procedure 134
861 Preparation for reassembly134
862 Reassembly 134
87 Handling after Disassembly and Reassembly 137
871 Instructions for turbocharger installation137
88 Troubleshooting 138
881 Excessively exhaust smoke 138
882 White smoke generation138
883 Sudden oil decrease139
884 Decrease in output 139
885 Poor (slow) response (starting) of turbocharger 139
886 Abnormal sound or vibration139
9 STARTING MOTOR 140
91 For 4TNV94L/ 98 140
911 Specifications 140
912 Components141
913 Troubleshooting142
914 Names of parts and disassembly procedure 143
915 Inspection and Maintenance 147
916 Service standards152
917 Assembly153
918 Characteristic test155
92 For 4TNV106(T) 156
921 Specifications 156
922 Congiguration drawing 156
923 Troubleshooting 157
924 Component names and disassembly procedure 158
925 Disassembly procedure159
926 Inspection and maintenance 167
927 Assembly173
928 Adjustment 174
929 Service standards175
10 ALTERNATOR 176
101 The 40A Alternator for 3TNV84 and other models 176
1011 Components 176
1012 Specifications 177
1013 Wiring diagram 177
1014 Standard output characteristics 178
1015 Inspection178
102 Troubleshooting 179
11 ELECTRIC WIRING 180
111 Electric Wiring Diagram 180
112 PRECAUTION ON ELECTRIC WIRING 181
1121 Alternator 181
1122 Starter 182
1123 Current limiter 183
1124 Section area and resistance of electric wire 184
12 SERVICE STANDARDS 185
121 Engine Tuning 185
122 Engine Body 186
1221 Cylinder head 186
1222 Gear train and camshaft189
1223 Cylinder block190
123 Lubricating Oil System (Trochoid Pump) 195
1231 Outside clearance of outer rotor 195
1232 Side clearance of outer rotor 195
1233 Inside clearance of inner rotor 195
1234 Rotor shaft clearance 195
13 TIGHTENING TORQUE for BOLTS and NUTS 196
131 Tightening Torques for Main Bolts and Nuts 196
132 Tightening Torques for Standard Bolts and Nuts 197
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PLEASE NOTE:
- This is the SAME manual used by the dealers to troubleshoot any faults in your vehicle. This can be yours in 2 minutes after the payment is made.
- Contact us at [email protected] should you have any queries before your purchase or that you need any other service / repair / parts operators manual.
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