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Yanmar Industrial Engine 3TNM74F, 3TNV74F, 3TNV80F Service Repair Manual Yanmar Industrial Engine – PDF Download
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Description
Yanmar Industrial Engine 3TNM74F, 3TNV74F, 3TNV80F Service Repair Manual
File Details:
Yanmar Industrial Engine 3TNM74F, 3TNV74F, 3TNV80F Service Repair Manual
Size: 18.8
Format: PDF
Language: English
Number of Pages: 252 pages
Brand: Yanmar
Type of document: Service Manual
Model: 3TNM74F, 3TNV74F, 3TNV80F
YANMAR INDUSTRIAL ENGINE 3TNM74F, 3TNV74F, 3TNV80F SERVICE REPAIR MANUAL YANMAR INDUSTRIAL ENGINE – PDF DOWNLOAD:
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Description:
Yanmar Industrial Engine 3TNM74F, 3TNV74F, 3TNV80F Service Repair Manual
- This Service Manual describes the service procedures for the TNM and TNV series indirect injection engines. These engines are 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 engine. Since the directions in this manual are for a typical engine, some specifications and components may be different from your engine. Refer to the documentation supplied by the optional equipment manufacturer for specific service instructions.
- YANMAR products are continuously undergoing improvement. This Service Manual might not address possible field modifications to the equipment. Contact an authorized YANMAR industrial engine dealer or distributor for answers to any questions relating to field modifications.
Table of Contents:
Yanmar Industrial Engine 3TNM74F, 3TNV74F, 3TNV80F Service Repair Manual
Cover.............................................................................. 1 Table of Contents.................................................................. 3 Introduction....................................................................... 5 YANMAR Warranties.................................................................. 7 YANMAR Limited Warranty........................................................ 9 What is Covered by this Warranty?.......................................... 9 How Long is the Warranty Period?........................................... 9 What the Engine Owner must Do:............................................. 9 To Locate an Authorized YANMAR Industrial Engine Dealer or Distributor:.... 10 What YANMAR will Do:....................................................... 10 What is not Covered by this Warranty?...................................... 10 Warranty Limitations:...................................................... 11 Warranty Modifications:.................................................... 11 Questions:................................................................. 11 Emission System Warranty....................................................... 12 YANMAR Co., Ltd. Limited Emission Control System Warranty - USA Only........... 12 Your Warranty Rights and Obligations:...................................... 12 California............................................................. 12 Manufacturer’s Warranty Period:............................................ 12 Warranty Coverage:......................................................... 13 Warranted Parts:........................................................... 13 Exclusions:................................................................ 14 Owner’s Warranty Responsibilities:......................................... 14 Safety............................................................................. 15 Safety Statements.............................................................. 17 Safety Precautions............................................................. 18 General Service Information........................................................ 29 Component Identification....................................................... 31 Location of Labels............................................................. 32 Engine Nameplate (Typical)................................................. 32 EPA/ARB Emission Control Regulations - USA Only................................ 32 Emission Control Labels........................................................ 33 EPA/CARB labels (Typical).................................................. 33 EPA.................................................................... 33 EPA and CARB........................................................... 33 Engine Family.................................................................. 33 Function of Major Engine Components............................................ 34 Function of Cooling System Components.......................................... 36 Diesel Fuel.................................................................... 37 Diesel Fuel Specifications................................................. 37 Additional technical fuel requirements................................. 37 Bio-diesel fuels....................................................... 37 Filling the Fuel Tank...................................................... 41 Priming the Fuel System.................................................... 42 Engine Oil..................................................................... 43 Engine Oil Specifications.................................................. 43 Service categories..................................................... 43 Definitions............................................................ 43 Additional technical engine oil requirements:.......................... 43 Engine Oil Viscosity....................................................... 43 Checking Engine Oil........................................................ 44 Adding Engine Oil.......................................................... 44 Engine Oil Capacity (Typical).............................................. 44 Engine Coolant................................................................. 45 Engine Coolant Specifications.............................................. 46 Additional technical coolant specifications:........................... 46 Alternative engine coolant............................................. 46 Filling Radiator with Engine Coolant....................................... 46 Engine Coolant Capacity (Typical).......................................... 47 Specifications................................................................. 48 Description of Model Number................................................ 48 Engine General Specifications.............................................. 48 Principal Engine Specifications................................................ 49 3TNM74F.................................................................... 49 Engine Service Information..................................................... 52 Tightening Torques for Standard Bolts and Nuts................................. 53 Abbreviations and Symbols...................................................... 55 Abbreviations.............................................................. 55 Symbols.................................................................... 55 Unit Conversions............................................................... 56 Unit prefixes.............................................................. 56 Units of length............................................................ 56 Units of volume............................................................ 56 Units of mass.............................................................. 56 Units of force............................................................. 56 Units of torque............................................................ 56 Units of pressure.......................................................... 56 Units of power............................................................. 56 Units of temperature....................................................... 56 Periodic Maintenance............................................................... 57 Before You Begin Servicing..................................................... 59 Introduction................................................................... 60 The Importance of Periodic Maintenance..................................... 60 Performing Periodic Maintenance............................................ 60 YANMAR Replacement Parts................................................... 60 Required EPA/ARB Maintenance - USA Only.................................... 60 EPA/ARB Installation Requirements - USA Only............................... 60 Periodic Maintenance Schedule.................................................. 61 Periodic Maintenance Procedures................................................ 63 After Initial 50 Hours of Operation........................................ 63 Check and adjust cooling fan V-belt.................................... 63 Every 50 Hours of Operation................................................ 64 Drain fuel filter/water separator...................................... 64 Check battery.......................................................... 66 Every 250 Hours of Operation............................................... 67 Drain fuel tank........................................................ 67 Replace engine oil and engine oil filter............................... 68 Check and clean radiator fins.......................................... 70 Check and adjust cooling fan V-belt.................................... 70 Check and adjust the governor lever and engine speed control........... 70 Clean air cleaner element.............................................. 71 Every 500 Hours of Operation............................................... 72 Replace air cleaner element............................................ 72 Replace fuel filter.................................................... 73 Clean fuel filter/water separator...................................... 74 Every 1000 Hours of Operation.............................................. 75 Adjust intake/exhaust valve clearance.................................. 75 Every 1500 Hours of Operation.............................................. 76 Inspect, clean and test fuel injectors................................. 76 Inspect crankcase breather system...................................... 76 Every 2000 Hours of Operation.............................................. 77 Check and replace fuel hoses and engine coolant hoses.................. 77 Lap the intake and exhaust valves...................................... 77 Drain, flush and refill cooling system with new coolant................ 78 Engine............................................................................. 81 Before You Begin Servicing..................................................... 83 Introduction................................................................... 84 Cylinder Head Specifications................................................... 84 Adjustment Specifications.................................................. 84 Cylinder Head.............................................................. 84 Push Rod................................................................... 85 Valve Spring............................................................... 85 Rocker Arm and Shaft....................................................... 86 Camshaft and Timing Gear Train Specifications.................................. 86 Camshaft................................................................... 86 Idler Gear Shaft and Bushing............................................... 87 Timing Gear Backlash....................................................... 87 Crankshaft and Pistons Specifications.......................................... 88 Crankshaft................................................................. 88 Thrust Bearing............................................................. 89 Piston..................................................................... 89 Connecting Rod............................................................. 91 Connecting rod small end............................................... 91 Connecting rod big end................................................. 92 Connecting rod distortion.............................................. 92 Tappet..................................................................... 92 Cylinder Block Specifications.................................................. 92 Cylinder Block............................................................. 92 Special Torque Chart........................................................... 93 Torque for Bolts and Nuts.................................................. 93 Special Service Tools.......................................................... 94 Measuring Instruments.......................................................... 96 Cylinder Head.................................................................. 98 Cylinder Head Components................................................... 98 Disassembly of Cylinder Head............................................... 99 Removal of intake manifold/valve cover.................................100 Removal of glow plugs..................................................100 Removal of rocker arm assembly.........................................100 Disassembly of rocker arm assembly.....................................101 Removal of cylinder head...............................................101 Removal of intake/exhaust valves.......................................102 Removal of valve guides................................................102 Cleaning of Cylinder Head Components.......................................103 Inspection of Cylinder Head Components.....................................103 Inspection of push rods................................................103 Inspection of rocker arm assembly......................................103 Inspection of valve guides.............................................104 Inspection of cylinder head............................................104 Inspection of intake and exhaust valves................................104 Inspection of valve springs............................................106 Reassembly of Cylinder Head................................................107 Reassembly of valve guides.............................................107 Reassembly of intake and exhaust valves................................107 Reassembly of cylinder head............................................108 Reassembly of rocker arm assembly......................................109 Reassembly of intake manifold/valve cover..............................110 Measuring and Adjusting Valve Clearance....................................111 Cylinder Block.................................................................113 Crankshaft and Camshaft Components.........................................113 3TNV74F, 3TNV80F.......................................................113 3TNM74F................................................................115 Disassembly of Cylinder Block Components...................................116 Disassembly of Camshaft and Timing Components..............................117 Removal of timing gear case cover......................................117 Checking timing gear backlash..........................................117 Measuring idler gear-to-crankshaft gear backlash.......................118 Measuring idler gear-to-camshaft gear backlash.........................118 Removal of timing gears................................................118 Removal of oil pan.....................................................119 Removal of oil pan (with ladder frame).................................120 Removal of camshaft....................................................120 Removal of gear case (3TNV74F, 3TNV80F only)...........................121 Disassembly of Crankshaft and Piston Components............................122 Removal of pistons.....................................................122 Removal of crankshaft..................................................123 Inspection of Crankshaft and Camshaft Components...........................125 Replacement of crankshaft oil seals....................................125 Crankshaft bearing oil clearance.......................................126 Inspection of cylinder block...........................................126 Inspection of pistons, piston rings and wrist pin......................127 Inspection of connecting rod...........................................128 Inspection of tappets..................................................129 Inspection of crankshaft...............................................130 Reconditioning the Crankshaft..............................................131 Inspection of camshaft.................................................131 Inspection of camshaft bushing and bores...............................132 Inspection of idler gear and shaft.....................................132 Honing and Boring..........................................................132 Reassembly of Crankshaft and Piston Components.............................133 Reassembly of pistons..................................................134 Installation of crankshaft.............................................136 Installation of pistons................................................137 Reassembly of Camshaft and Timing Components...............................139 Installation of gear case (3TNV74F, 3TNV80F)...........................139 Installation of camshaft...............................................139 Installation of timing gears...........................................139 Installation of gear case cover (3TNM74F)..............................140 Installation of oil pan................................................141 Final assembly of engine...............................................142 Fuel System........................................................................143 Before You Begin Servicing.....................................................145 Introduction...................................................................146 Fuel Injection Pump (ML: for 3TNV74F and 3TNV80F, MC: for 3TNM74F).........146 Stop Solenoid..............................................................147 3TNM74F, 3TNV74F, 3TNV80F..............................................148 Fuel System Specifications.....................................................150 Special Torque Chart.......................................................150 Test and Adjustment Specifications.........................................150 Special Service Tools..........................................................151 Measuring Instruments..........................................................151 Fuel System Diagram............................................................152 Fuel System Components.........................................................153 Fuel Injection Lines...........................................................154 Removal of High-Pressure Fuel Injection Lines..............................154 Installation of High-Pressure Fuel Injection Lines.........................154 Removal of Fuel Return Line................................................155 Installation of Fuel Return Line...........................................155 Fuel Injection Pump............................................................156 Removal of Fuel Injection Pump.............................................156 Installation of Fuel Injection Pump........................................159 Checking and Adjusting Fuel Injection Timing...................................161 Checking Fuel Injection Timing.............................................161 Adjusting Fuel Injection Timing............................................164 3TNV74F, 3TNV80F.......................................................164 3TNM74F................................................................165 Fuel Injectors.................................................................167 Removal of Fuel Injectors..................................................167 Testing of Fuel Injectors..................................................167 Disassembly and Inspection of Fuel Injectors...............................170 Adjusting Fuel Injector Pressure...........................................171 Reassembly of Fuel Injectors...............................................172 Installation of the Fuel Injectors.........................................172 Cooling System.....................................................................173 Before You Begin Servicing.....................................................175 Introduction...................................................................176 Cooling System Diagram.........................................................176 Engine Coolant Pump Components.................................................177 Engine Coolant System Check....................................................178 Engine Coolant Pump............................................................178 Disassembly of Engine Coolant Pump.........................................178 Cleaning and Inspection....................................................179 Temperature switch.....................................................179 Thermostat.............................................................180 Radiator cap...........................................................180 Reassembly of Engine Coolant Pump..........................................180 Lubrication System.................................................................183 Before You Begin Servicing.....................................................185 Introduction...................................................................186 Oil Pump Service Information...................................................186 Engine oil pressure........................................................186 Outer rotor outside clearance..............................................186 Outer rotor side clearance.................................................186 Outer rotor to inner rotor tip clearance...................................186 Inner Rotor and Gear Boss Clearance (3TNV74F, 3TNV80F).....................186 Lubrication System Diagram.....................................................187 Checking Engine Oil Pressure...................................................188 Trochoid Oil Pump (3TNV74F, 3TNV80F)...........................................188 Oil Pump Components........................................................188 Disassembly of Oil Pump....................................................189 Cleaning and Inspection....................................................190 Check outer rotor outside clearance....................................190 Outer rotor to inner rotor tip clearance...............................190 Check outer rotor side clearance.......................................190 Check inner rotor and gear boss clearance..............................191 Reassembly of Oil Pump.....................................................191 Trochoid Oil Pump (3TNM74F)....................................................192 Components.................................................................192 Disassembling the Oil Pump.................................................192 Cleaning and Inspection....................................................193 Checking outer rotor outside clearance.................................193 Checking outer rotor to inner rotor tip clearance......................193 Checking outer rotor side clearance....................................193 Checking rotor shaft clearance.........................................194 Assembling the Oil Pump....................................................194 Starter Motor......................................................................195 Before You Begin Servicing.....................................................197 Introduction...................................................................198 Starter Motor Information......................................................198 Starter Motor Specifications...................................................199 Starter Motor Troubleshooting..................................................200 Starter Motor Components.......................................................201 Starter Motor..................................................................202 Removal of Starter Motor...................................................202 Disassembly of Starter Motor...............................................202 Cleaning and Inspection....................................................205 Armature...............................................................205 Field coil.............................................................206 Brush holder...........................................................207 Solenoid switch........................................................207 Pinion clutch assembly.................................................208 Reassembly of Starter Motor................................................209 Check Pinion Projection Length.............................................211 No-Load Test...............................................................211 Installation of Starter Motor..............................................212 Alternator.........................................................................213 Before You Begin Servicing.....................................................215 Introduction...................................................................216 Standard and Optional Dynamo Information.......................................216 Standard and Optional Alternator Information...................................216 Alternator Specifications......................................................217 Dynamo Specifications..........................................................217 Alternator Troubleshooting.....................................................218 Alternator Components..........................................................219 Alternator Wiring Diagram......................................................220 Alternator Standard Output.....................................................221 Alternator.....................................................................222 Removal of Alternator......................................................222 Disassembly of Alternator..................................................222 Reassembly of Alternator...................................................224 Installation of Alternator.................................................226 Dynamo Component Location......................................................227 Dynamo Wiring Diagram..........................................................228 Operation of Dynamo............................................................228 Dynamo Standard Output.........................................................229 Testing of Dynamo..............................................................230 Testing Stator Coil Continuity.............................................230 Testing Stator Coil Short-to-Ground........................................230 Testing Dynamo Regulated Output............................................230 Dynamo.........................................................................230 Removal of Dynamo..........................................................230 Disassembly of Dynamo......................................................231 Reassembly of Dynamo.......................................................231 Installation of Dynamo.....................................................232 Electric Wiring....................................................................233 Electric Wiring Precautions....................................................235 Electric Wire Resistance.......................................................236 Battery Cable Resistance.......................................................237 Electrical Wire Sizes - Voltage Drop...........................................238 Conversion of AWG to European Standards........................................239 Troubleshooting....................................................................241 Special Service Tools..........................................................243 Troubleshooting By Measuring Compression Pressure..............................244 Compression Pressure Measurement Method....................................244 Engine speed and compression pressure (use for reference)..............245 Quick Reference Table For Troubleshooting......................................246 Troubleshooting Charts.....................................................247
Please Note:
- This is not a physical manual but a digital manual – meaning no physical copy will be couriered to you. The manual can be yours in the next 2 mins as once you make the payment, you will be directed to the download page IMMEDIATELY.
- This is the same manual used by the dealers inorder to diagnose your vehicle of its faults.
- Require some other service manual or have any queries: please WRITE to us at [email protected]
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