3. ENGINE
YANMAR WARRANTIESTNV IDI Service Manual2-3Yanmar Limited WarrantyYANMAR LIMITED WARRANTYWhat is Covered by this Warranty? Yanmar warrants to the origi
TNV IDI Service Manual6-1TNV IDI Service Manual Section 6ENGINEPageBefore You Begin Servicing ...
ENGINE6-2 TNV IDI Service ManualCylinder Head... 6-20Cylinder Head Compo
ENGINETNV IDI Service Manual6-3Before You Begin ServicingBEFORE YOU BEGIN SERVICINGA WARNINGTo prevent possible eye injury, always wear SAFETY GLASSES
ENGINE6-4 TNV IDI Service ManualBefore You Begin ServicingCAUTION• Only use the engine oil specified. Other engine oils may affect warranty coverage,
ENGINETNV IDI Service Manual6-5IntroductionINTRODUCTIONThis section of the Service Manual describes servicing of the engine.CYLINDER HEAD SPECIFICATIO
ENGINE6-6 TNV IDI Service ManualCylinder Head SpecificationsIntake / Exhaust Valve and GuidePush RodValve SpringInspection Item Standard LimitReferenc
ENGINETNV IDI Service Manual6-7Camshaft and Timing Gear Train SpecificationsRocker Arm and ShaftCAMSHAFT AND TIMING GEAR TRAIN SPECIFICATIONSCamshaftI
ENGINE6-8 TNV IDI Service ManualCrankshaft and Pistons SpecificationsIdler Gear Shaft and BushingTiming Gear BacklashCRANKSHAFT AND PISTONS SPECIFICAT
ENGINETNV IDI Service Manual6-9Crankshaft and Pistons Specifications(Crankshaft Cont.)Crankshaft ReconditioningThrust BearingInspection Item Standard
ENGINE6-10 TNV IDI Service ManualCrankshaft and Pistons SpecificationsPistonInspection Item Standard LimitReference PagePiston Outside Diameter(Measur
YANMAR WARRANTIES2-4 TNV IDI Service ManualYanmar Limited WarrantyYanmar Limited Warranty - ContinuedTo Locate an Authorized Yanmar Industrial Engine
ENGINETNV IDI Service Manual6-11Crankshaft and Pistons SpecificationsPiston RingModel Inspection Item Standard LimitReference Page3TNV72Top RingRing G
ENGINE6-12 TNV IDI Service ManualCrankshaft and Pistons SpecificationsConnecting RodConnecting Rod Small EndConnecting Rod Big EndConnecting Rod Disto
ENGINETNV IDI Service Manual6-13Cylinder Block SpecificationsCYLINDER BLOCK SPECIFICATIONSCylinder BlockInspection Item Model Standard LimitReference
ENGINE6-14 TNV IDI Service ManualSPECIAL TORQUE CHARTTorque for Bolts and NutsSee Tightening Torques for Standard Bolts and Nuts on page 4-22 for stan
ENGINETNV IDI Service Manual6-15Special Service ToolsSPECIAL SERVICE TOOLSNote: Tools not having Yanmar part numbers must be acquired locally.No Tool
ENGINE6-16 TNV IDI Service ManualSpecial Service Tools5Stem Seal Tool(for Installing Stem Seals)d1 d2 d3 L1 L2 L30.591 in.(15 mm)0.827 in.(21 mm)0.472
ENGINETNV IDI Service Manual6-17Measuring InstrumentsMEASURING INSTRUMENTSNo. Instrument Name Application Illustration1 Dial Indicator (Available Loca
ENGINE6-18 TNV IDI Service ManualMeasuring Instruments(Measuring instruments Cont.)No. Instrument Name Application Illustration9 V-Block (Available Lo
ENGINETNV IDI Service Manual6-19Measuring InstrumentsThis Page Intentionally Left BlankTNV_IDI_ServiceManual_(3TNV72 for YN only).book 19 ページ 2007年1
ENGINE6-20 TNV IDI Service ManualCylinder HeadCYLINDER HEADCylinder Head ComponentsFigure 6-10002130(1)(2)(3)(4)(5)(6)(7)(8)(9)(10)(11)(12)(23)(24)(25
YANMAR WARRANTIESTNV IDI Service Manual2-5Yanmar Limited WarrantyYanmar Limited Warranty - ContinuedWarranty Limitations: The foregoing is Yanmar&apos
ENGINETNV IDI Service Manual6-21Cylinder Head1 – Baffle Plate2 – Oil Fill Cap3 – Valve Cover / Intake Manifold4 – Gasket5 – Rocker Arm Shaft6 – Rocker
ENGINE6-22 TNV IDI Service ManualCylinder HeadRemoval of Intake Manifold / Valve Cover1. Remove the intake manifold bolts (Figure 6-2, (1)) and valve
ENGINETNV IDI Service Manual6-23Cylinder HeadDisassembly of Rocker Arm Assembly1. Remove the rocker arm shaft alignment set screw (Figure 6-5, (6)) fr
ENGINE6-24 TNV IDI Service ManualCylinder HeadRemoval of Intake / Exhaust Valves1. Put the cylinder head on the work bench with the combustion side do
ENGINETNV IDI Service Manual6-25Cylinder HeadCleaning of Cylinder Head ComponentsThoroughly clean all components using a non-metallic brush and an app
ENGINE6-26 TNV IDI Service ManualCylinder HeadInspection of Rocker Arm AssemblyRocker Arm Shaft Hole DiameterUse a telescoping gauge and micrometer to
ENGINETNV IDI Service Manual6-27Cylinder HeadIf distortion exceeds the service limit, resurface or replace the cylinder head. Remove only enough mater
ENGINE6-28 TNV IDI Service ManualCylinder HeadValve Face and Valve SeatAlways check the clearance between the valve and valve guide before grinding or
ENGINETNV IDI Service Manual6-29Cylinder HeadSquarenessUse a flat surface and a square to check each spring for squareness (Figure 6-22). See Valve Sp
ENGINE6-30 TNV IDI Service ManualCylinder Head3. Finish installing the valve guides (Figure 6-25, (1)) to the proper height (Figure 6-25, (3)) using t
YANMAR WARRANTIES2-6 TNV IDI Service ManualEmission System WarrantyEMISSION SYSTEM WARRANTYYANMAR CO., LTD. LIMITED EMISSION CONTROL SYSTEM WARRANTY -
ENGINETNV IDI Service Manual6-31Cylinder HeadFigure 6-285. Put the cylinder head on the workbench with the combustion side down to install the valve s
ENGINE6-32 TNV IDI Service ManualCylinder HeadReassembly of Rocker Arm AssemblyFigure 6-31IMPORTANTEnsure the lubrication holes in the rocker arm shaf
ENGINETNV IDI Service Manual6-33Cylinder HeadReassembly of Intake Manifold / Valve Cover1. Reinstall the glow plugs (Figure 6-33, (1)) and tighten to
ENGINE6-34 TNV IDI Service ManualCylinder HeadMeasuring and Adjusting Valve ClearanceMeasure and adjust while the engine is cold.Notes:• The No. 1 pis
ENGINETNV IDI Service Manual6-35Cylinder HeadFigure 6-354. If adjustment is required, proceed to the next step.5. Loosen the valve adjusting screw loc
ENGINE6-36 TNV IDI Service ManualCylinder BlockCYLINDER BLOCKCrankshaft and Camshaft ComponentsFigure 6-380002180(1)(4)(3)(5)(6)(5)(2)(8)(7)(9)(10)(11
ENGINETNV IDI Service Manual6-37Cylinder Block1 – Cylinder Block2 – Camshaft Bushing3 – Gear Case4 – Dowel (2 used)5–O-Ring6 – Gear Case Cover7 – Fron
ENGINE6-38 TNV IDI Service ManualCylinder Block5. Remove the engine from the machine. Mount the engine to a suitable engine repair stand having adequa
ENGINETNV IDI Service Manual6-39Cylinder BlockMeasuring Idler Gear-to-Crankshaft Gear Backlash1. Install a dial indicator as shown in Figure 6-41.Figu
ENGINE6-40 TNV IDI Service ManualCylinder Block4. Do not remove the fuel injection pump drive gear unless absolutely necessary due to damage to the ge
YANMAR WARRANTIESTNV IDI Service Manual2-7Emission System WarrantyLimited Emission Control System Warranty - USA Only - ContinuedWarranty Coverage:Thi
ENGINETNV IDI Service Manual6-41Cylinder BlockRemoval of Camshaft1. Before removing the camshaft, check the camshaft end play.• Method A: Install a di
ENGINE6-42 TNV IDI Service ManualCylinder BlockRemoval of Gear CaseNote: The camshaft must be removed before the gear case can be removed. See Removal
ENGINETNV IDI Service Manual6-43Cylinder Block1. Using a feeler gauge, measure the connecting rod side clearance (Figure 6-50). See Connecting Rod on
ENGINE6-44 TNV IDI Service ManualCylinder Block11. Remove the bearing inserts (Figure 6-53, (2)).12. Remove the compression rings (Figure 6-53, (3)) f
ENGINETNV IDI Service Manual6-45Cylinder Block• Method B: Use a feeler gauge to measure the clearance (Figure 6-56, (3)) between the thrust bearing (F
ENGINE6-46 TNV IDI Service ManualCylinder Block11. Remove the crankshaft from the engine.12. Remove the bearing inserts (Figure 6-59, (1)) and thrust
ENGINETNV IDI Service Manual6-47Cylinder BlockFigure 6-614. Remove the rear oil seal (Figure 6-62, (1)) from the flywheel housing (Figure 6-62, (2)).F
ENGINE6-48 TNV IDI Service ManualCylinder BlockInspection of Pistons, Piston Rings and Wrist PinNotes:• On an engine with low hours, the pistons, pist
ENGINETNV IDI Service Manual6-49Cylinder Block• On an engine with high hours, the pistons rings should be replaced and the cylinder honed (See Honing
ENGINE6-50 TNV IDI Service ManualCylinder BlockFigure 6-692. Measure the connecting rod twist (Figure 6-70, (1)) and bend (Figure 6-70, (2)) using a c
YANMAR WARRANTIES2-8 TNV IDI Service ManualEmission System WarrantyLimited Emission Control System Warranty - USA Only - ContinuedExclusions:Failures
ENGINETNV IDI Service Manual6-51Cylinder BlockInspection of Crankshaft1. Put the crankshaft end journals (Figure 6-74, (4)) on V-blocks.2. Place a dia
ENGINE6-52 TNV IDI Service ManualCylinder BlockFigure 6-76Inspection of Camshaft1. Use V-blocks and a dial indicator to check camshaft bend (Figure 6-
ENGINETNV IDI Service Manual6-53Cylinder BlockInspection of Camshaft Bushing and Bores1. Measure the I.D. of the front bushing and the remaining bores
ENGINE6-54 TNV IDI Service ManualCylinder BlockFigure 6-81• Use a 50:50 mixture of diesel fuel and engine oil as a honing fluid.• Use a 300-grit hone
ENGINETNV IDI Service Manual6-55Cylinder BlockReassembly of Pistons1. Select the parts needed to assemble the piston and connecting rod for one cylind
ENGINE6-56 TNV IDI Service ManualCylinder Block1 – Fuel Injection Pump Side of Engine2 – Piston Identification Mark3 – Embossed Mark on Connecting Rod
ENGINETNV IDI Service Manual6-57Cylinder Block7. Reinstall the oil ring expander (Figure 6-88, (4)). Install the oil ring (Figure 6-88, (3)) with the
ENGINE6-58 TNV IDI Service ManualCylinder BlockFigure 6-903. Install the crankshaft in the engine.IMPORTANTThe main bearing caps are numbered and have
ENGINETNV IDI Service Manual6-59Cylinder Block1 – Top Compression Ring End Gap2 – Second Compression Ring End Gap3 – Oil Ring End GapFigure 6-92IMPORT
ENGINE6-60 TNV IDI Service ManualCylinder Block7. Apply a light coat of clean engine oil to the rod cap bolts. Reinstall the connecting rod cap (Figur
TNV IDI Service Manual3-1TNV IDI Service Manual Section 3SAFETYPageSafety Statements ...
ENGINETNV IDI Service Manual6-61Cylinder Block4. Lubricate the camshaft lobes and tappets with clean oil or assembly lube. Reinstall the tappets in th
ENGINE6-62 TNV IDI Service ManualCylinder BlockIMPORTANTBe sure to align the flats on the oil pump with the flats on the crankshaft gear.3. Reinstall
TNV IDI Service Manual7-1TNV IDI Service Manual Section 7FUEL SYSTEMPageBefore You Begin Servicing ...
FUEL SYSTEM7-2 TNV IDI Service ManualDisassembly and Inspection of Fuel Injectors ... 7-27Adjusting Fuel Injector Pressure ...
FUEL SYSTEMTNV IDI Service Manual7-3Before You Begin ServicingBEFORE YOU BEGIN SERVICINGA WARNINGENTANGLEMENT HAZARD!• Stop the engine before you begi
FUEL SYSTEM7-4 TNV IDI Service ManualBefore You Begin ServicingCAUTION• NEVER remove or attempt to remove the tamper-proof devices from the full-load
FUEL SYSTEMTNV IDI Service Manual7-5IntroductionINTRODUCTIONFigure 7-1This section of the Service Manual describes the procedures necessary to remove,
FUEL SYSTEM7-6 TNV IDI Service ManualIntroductionThe fuel injector is essentially a spring-loaded valve. When fuel pressure from the fuel injection pu
FUEL SYSTEMTNV IDI Service Manual7-7Fuel System SpecificationsFUEL SYSTEM SPECIFICATIONSSpecial Torque ChartTest and Adjustment SpecificationsNote: Fu
FUEL SYSTEM7-8 TNV IDI Service ManualSpecial Service ToolsSPECIAL SERVICE TOOLSNote: Tools not having Yanmar part numbers must be acquired locally.MEA
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FUEL SYSTEMTNV IDI Service Manual7-9Fuel System DiagramFUEL SYSTEM DIAGRAMFigure 7-21 – Diesel Fuel Supply2 – Fuel Filter / Water Separator3 – Mechani
FUEL SYSTEM7-10 TNV IDI Service ManualFuel System ComponentsFUEL SYSTEM COMPONENTSFigure 7-30002208(1)(2)(3) (17) (18) (19) (4) (6) (7) (5) (9
FUEL SYSTEMTNV IDI Service Manual7-11Fuel Injection Lines1 – High-Pressure Fuel Injection Lines2 – Fuel Return Line Nut3 – Fuel Return Line4 – Fuel In
FUEL SYSTEM7-12 TNV IDI Service ManualFuel Injection Lines6. Finish loosening all the fuel line nuts and remove the high-pressure fuel lines as an ass
FUEL SYSTEMTNV IDI Service Manual7-13Fuel Injection Pump4. Remove the fuel return hose from the fuel return fitting on the fuel injection pump.5. Care
FUEL SYSTEM7-14 TNV IDI Service ManualFuel Injection PumpFigure 7-88. Remove the fuel supply line (Figure 7-8, (2)) from the fitting on the fuel injec
FUEL SYSTEMTNV IDI Service Manual7-15Fuel Injection PumpFigure 7-1115. Do not loosen or remove the four bolts (Figure 7-12, (3)) holding the pump driv
FUEL SYSTEM7-16 TNV IDI Service ManualFuel Injection Pump18. Once the fuel injection pump drive gear and hub assembly have “popped” loose from the tap
FUEL SYSTEMTNV IDI Service Manual7-17Fuel Injection PumpFigure 7-162. If installing the fuel injection pump on an engine with the front gear case cove
FUEL SYSTEM7-18 TNV IDI Service ManualFuel Injection PumpFigure 7-197. Tighten the fuel injection pump retaining nuts to specification. See Special To
SAFETYTNV IDI Service Manual3-3Safety StatementsSAFETY STATEMENTSYanmar is concerned for your safety and your machine’s condition. Safety statements a
FUEL SYSTEMTNV IDI Service Manual7-19Checking and Adjusting Fuel Injection TimingFigure 7-2115. Reinstall the cooling fan V-belt (Figure 7-21, (1)). A
FUEL SYSTEM7-20 TNV IDI Service ManualChecking and Adjusting Fuel Injection TimingFigure 7-236. Typical flywheel markings are as shown in (Figure 7-24
FUEL SYSTEMTNV IDI Service Manual7-21Checking and Adjusting Fuel Injection Timing• EXAMPLE: If the distance between the two “longer” marks is approxim
FUEL SYSTEM7-22 TNV IDI Service ManualChecking and Adjusting Fuel Injection TimingNote: As the injection pump injects fuel to a cylinder only once eve
FUEL SYSTEMTNV IDI Service Manual7-23Fuel InjectorsAdjusting Fuel Injection TimingIf the timing marks did not align when performing the Checking Fuel
FUEL SYSTEM7-24 TNV IDI Service ManualFuel InjectorsFigure 7-306. Remove the injector nozzle gaskets (Figure 7-30, (5)) and protector (Figure 7-30, (6
FUEL SYSTEMTNV IDI Service Manual7-25Fuel Injectors4. Pump the operating lever of the tester slowly, observing the pressure reading at the point where
FUEL SYSTEM7-26 TNV IDI Service ManualFuel InjectorsFuel Injector Test ResultsNote: If the fuel injector fails any tests, it should be serviced or rep
FUEL SYSTEMTNV IDI Service Manual7-27Fuel InjectorsDisassembly and Inspection of Fuel Injectors1. Clean carbon from used injectors using clean diesel
FUEL SYSTEM7-28 TNV IDI Service ManualFuel Injectors7. Perform a nozzle valve slide test:(a) Wash nozzle body and valve in clean diesel fuel.(b) While
SAFETY3-4 TNV IDI Service ManualSafety PrecautionsSAFETY PRECAUTIONSA DANGERSCALD HAZARD!• NEVER remove the radiator cap if the engine is hot. Steam a
FUEL SYSTEMTNV IDI Service Manual7-29Fuel Injectors4. Retest the fuel injector. See Testing of Fuel Injectors on page 7-24. If the injector cannot be
FUEL SYSTEM7-30 TNV IDI Service ManualFuel InjectorsThis Page Intentionally Left BlankTNV_IDI_ServiceManual_(3TNV72 for YN only).book 30 ページ 2007年11
TNV IDI Service Manual8-1TNV IDI Service Manual Section 8COOLING SYSTEMPageBefore You Begin Servicing ...
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COOLING SYSTEMTNV IDI Service Manual8-3Before You Begin ServicingBEFORE YOU BEGIN SERVICINGA DANGERSCALD HAZARD!• NEVER remove the radiator cap if the
COOLING SYSTEM8-4 TNV IDI Service ManualBefore You Begin ServicingA WARNINGBURN HAZARD!• If you must drain the engine oil while it is still hot, stay
COOLING SYSTEMTNV IDI Service Manual8-5IntroductionINTRODUCTIONThis section of the Service Manual describes the procedures necessary to service the 3T
COOLING SYSTEM8-6 TNV IDI Service ManualEngine Coolant Pump ComponentsENGINE COOLANT PUMP COMPONENTSFigure 8-21 – Thermostat Cover2 – Thermostat3 – Sp
COOLING SYSTEMTNV IDI Service Manual8-7Engine Coolant System CheckENGINE COOLANT SYSTEM CHECKCheck the engine coolant system for leakage.1. With the r
COOLING SYSTEM8-8 TNV IDI Service ManualEngine Coolant Pump6. Remove the engine coolant pump (Figure 8-4, (4)). Discard the gasket.7. Remove the therm
TNV IDI Service ManualTNV seriesSERVICE MANUAL3TNV72P/N: 0BTNV-U00300INDUSTRIALENGINESTNV_IDI_ServiceManual_(3TNV72 for YN only).book i ページ 2007年11月
SAFETYTNV IDI Service Manual3-5Safety PrecautionsA DANGERFIRE AND EXPLOSION HAZARD!• Diesel fuel is flammable and explosive under certain conditions.•
COOLING SYSTEMTNV IDI Service Manual8-9Engine Coolant PumpFigure 8-82. Apply 10.8 - 14.8 psi (75 - 105 kPa; 0.75 - 1.05 kgf/cm²) to the radiator cap.
COOLING SYSTEM8-10 TNV IDI Service ManualEngine Coolant PumpFigure 8-119. Reinstall the V-belt. Tighten the V-belt to the proper tension. See Check an
TNV IDI Service Manual9-1TNV IDI Service Manual Section 9LUBRICATION SYSTEMPageBefore You Begin Servicing ...
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LUBRICATION SYSTEMTNV IDI Service Manual9-3Before You Begin ServicingBEFORE YOU BEGIN SERVICINGCAUTIONNEVER permit anyone to operate the engine or dri
LUBRICATION SYSTEM9-4 TNV IDI Service ManualBefore You Begin ServicingA WARNINGFUME / BURN HAZARD!• Always read and follow safety related precautions
LUBRICATION SYSTEMTNV IDI Service Manual9-5IntroductionINTRODUCTIONThis section of the Service Manual describes the procedures necessary to service th
LUBRICATION SYSTEM9-6 TNV IDI Service ManualOil Pump Service InformationInner Rotor and Gear Boss ClearanceItem PartsStandardDimensionStandardClearanc
LUBRICATION SYSTEMTNV IDI Service Manual9-7Lubrication System DiagramLUBRICATION SYSTEM DIAGRAMFigure 9-1Idle GearShaftPressureRegulator ValveOil Pump
LUBRICATION SYSTEM9-8 TNV IDI Service ManualChecking Engine Oil PressureCHECKING ENGINE OIL PRESSUREPerform an engine oil pressure check if there is a
SAFETY3-6 TNV IDI Service ManualSafety PrecautionsA DANGERFIRE AND EXPLOSION HAZARD!• Diesel fuel is flammable and explosive under certain conditions.
LUBRICATION SYSTEMTNV IDI Service Manual9-9Trochoid Oil PumpDisassembly of Oil Pump1. Remove the engine cooling fan guard (if equipped), engine coolin
LUBRICATION SYSTEM9-10 TNV IDI Service ManualTrochoid Oil PumpCleaning and InspectionWash the oil pump cover, the oil pressure regulator valve, the oi
LUBRICATION SYSTEMTNV IDI Service Manual9-11Trochoid Oil PumpCheck Inner Rotor and Gear Boss Clearance1 – Crank Gear2 – Inner Rotor3 – Inside Width Ac
LUBRICATION SYSTEM9-12 TNV IDI Service ManualTrochoid Oil PumpThis Page Intentionally Left BlankTNV_IDI_ServiceManual_(3TNV72 for YN only).book 12 ペー
TNV IDI Service Manual10-1TNV IDI Service Manual Section 10STARTER MOTORPageBefore You Begin Servicing ...
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STARTER MOTORTNV IDI Service Manual10-3Before You Begin ServicingBEFORE YOU BEGIN SERVICINGA WARNINGENTANGLEMENT HAZARD!• Stop the engine before you b
STARTER MOTOR10-4 TNV IDI Service ManualBefore You Begin ServicingA CAUTIONFLYING OBJECT HAZARD!• ALWAYS wear eye protection when servicing the engine
STARTER MOTORTNV IDI Service Manual10-5IntroductionINTRODUCTIONThis section of the Service Manual covers the servicing of starter motor. Yanmar Part N
STARTER MOTOR10-6 TNV IDI Service ManualStarter Motor SpecificationsSTARTER MOTOR SPECIFICATIONSYanmar Part Number 119717-77010 119515-77010Nominal Ou
SAFETYTNV IDI Service Manual3-7Safety PrecautionsA DANGERFIRE AND EXPLOSION HAZARD!• Diesel fuel is flammable and explosive under certain conditions.•
STARTER MOTORTNV IDI Service Manual10-7Starter Motor TroubleshootingSTARTER MOTOR TROUBLESHOOTINGIs the shift lever at NEUTRAL position? Does engine c
STARTER MOTOR10-8 TNV IDI Service ManualStarter Motor ComponentsSTARTER MOTOR COMPONENTSFigure 10-10002486 (1)(2)(3)(4)(5)(6)(7)(9)(10)(11)(12)(13)(14
STARTER MOTORTNV IDI Service Manual10-9Starter Motor1–Nut2 – Needle Bearing3 – Pinion Housing4 – Pinion Retaining Ring5 – Pinion Stop6 – Pinion7–Shift
STARTER MOTOR10-10 TNV IDI Service ManualStarter MotorRemoval of Starter Motor1. Disconnect the battery cables at the battery, negative (-) cable firs
STARTER MOTORTNV IDI Service Manual10-11Starter Motor6. Pull the brush springs up using a brush spring puller. On the negative (-) side, bring the bru
STARTER MOTOR10-12 TNV IDI Service ManualStarter Motor13. Remove the pinion stop (Figure 10-10, (3)), return spring (if equipped), and pinion clutch a
STARTER MOTORTNV IDI Service Manual10-13Starter MotorMeasure Commutator Insulation DepthMeasure the depth of the insulating material (Figure 10-14, (1
STARTER MOTOR10-14 TNV IDI Service ManualStarter MotorMeasure Armature and Commutator Run-OutMeasure the armature core run-out and the commutator run-
STARTER MOTORTNV IDI Service Manual10-15Starter MotorBrush HolderBrush Holder Insulation TestCheck for continuity between each brush holder and the ba
STARTER MOTOR10-16 TNV IDI Service ManualStarter MotorCoil Resistance TestSee Starter Motor Specifications on page 10-6 for service limit.Contact Cont
SAFETY3-8 TNV IDI Service ManualSafety PrecautionsA WARNINGSEVER HAZARD!• Keep hands and other body parts away from moving / rotating parts such as th
STARTER MOTORTNV IDI Service Manual10-17Starter MotorReassembly of Starter Motor1. Apply a appropriate starter bendix grease (obtain locally) to the p
STARTER MOTOR10-18 TNV IDI Service ManualStarter Motor8. Reinstall the plate onto the intermediate housing and carefully reinstall the armature assemb
STARTER MOTORTNV IDI Service Manual10-19Starter MotorCheck Pinion Projection Length1. Connect the positive (+) lead from a battery to the “S” terminal
STARTER MOTOR10-20 TNV IDI Service ManualStarter Motor5. Install a switch (Figure 10-37, (6)) in a circuit between the battery positive (+) terminal (
TNV IDI Service Manual11-1TNV IDI Service Manual Section 11ALTERNATORPageBefore You Begin Servicing ...
ALTERNATOR11-2 TNV IDI Service ManualDynamo... 11-20Removal of Dy
ALTERNATORTNV IDI Service Manual11-3Before You Begin ServicingBEFORE YOU BEGIN SERVICINGA WARNINGENTANGLEMENT HAZARD!• Stop the engine before you begi
ALTERNATOR11-4 TNV IDI Service ManualBefore You Begin ServicingA WARNINGFUME / BURN HAZARD!• Always read and follow safety related precautions found o
ALTERNATORTNV IDI Service Manual11-5Before You Begin ServicingCAUTIONDo not connect a load between alternator terminals L and E. Damage to the alterna
ALTERNATOR11-6 TNV IDI Service ManualIntroductionINTRODUCTIONThis section of the Service Manual describes the servicing of the dynamos and alternators
SAFETYTNV IDI Service Manual3-9Safety PrecautionsA WARNINGEXPOSURE HAZARD!• Wear personal protective equipment such as gloves, work shoes, eye and hea
ALTERNATORTNV IDI Service Manual11-7Dynamo SpecificationsDYNAMO SPECIFICATIONSYanmar Part Number 119910-77200Nominal Output 20 AmpsWeight 3.97 lb (1.8
ALTERNATOR11-8 TNV IDI Service ManualAlternator TroubleshootingALTERNATOR TROUBLESHOOTINGTurn key switch ON.Does battery indicator turn ON?At idle, do
ALTERNATORTNV IDI Service Manual11-9Alternator ComponentsALTERNATOR COMPONENTSYanmar Part No. 129423-77200 alternator is used in this section to show
ALTERNATOR11-10 TNV IDI Service ManualAlternator Wiring DiagramALTERNATOR WIRING DIAGRAM1–Key Switch2 – Charge Lamp (3.4 Watts Max.)3–Load4–Battery5 –
ALTERNATORTNV IDI Service Manual11-11Alternator Standard OutputALTERNATOR STANDARD OUTPUT Figure 11-3Alternator RPM (x10³ min¯¹)13.5 Volts, Constant A
ALTERNATOR11-12 TNV IDI Service ManualAlternatorALTERNATOR Removal of Alternator1. Disconnect the electrical wires from the alternator.2. Loosen the V
ALTERNATORTNV IDI Service Manual11-13Alternator2. Remove the three bolts (Figure 11-6, (1)) retaining the rear cover (Figure 11-6, (2)) to the rear fr
ALTERNATOR11-14 TNV IDI Service ManualAlternator9. Remove the stator assembly (Figure 11-10, (1)) from the front frame housing.Figure 11-1010. If it i
ALTERNATORTNV IDI Service Manual11-15Alternator3. Position the stator assembly (Figure 11-13, (1)) on the front frame housing studs.4. Lubricate the s
ALTERNATOR11-16 TNV IDI Service ManualAlternatorFigure 11-1811. Reassemble the pulley (Figure 11-18, (2)) and nut (Figure 11-18, (1)) to the shaft of
SAFETY3-10 TNV IDI Service ManualSafety PrecautionsA WARNINGHIGH-PRESSURE HAZARD!• Avoid skin contact with the high-pressure diesel fuel spray caused
ALTERNATORTNV IDI Service Manual11-17Dynamo Component LocationDYNAMO COMPONENT LOCATIONYanmar Part No. 171301-77201 dynamo is used in this section to
ALTERNATOR11-18 TNV IDI Service ManualDynamo Wiring DiagramDYNAMO WIRING DIAGRAMFigure 11-211–Dynamo2 – Current Limiter Assembly3–Key Switch4 – Charge
ALTERNATORTNV IDI Service Manual11-19Dynamo Standard OutputDYNAMO STANDARD OUTPUT Figure 11-220002138TNV_IDI_ServiceManual_(3TNV72 for YN only).book
ALTERNATOR11-20 TNV IDI Service ManualTesting of DynamoTESTING OF DYNAMOUse a circuit tester or multimeter to perform the following tests.Testing Stat
ALTERNATORTNV IDI Service Manual11-21DynamoDisassembly of Dynamo1. Remove the rear cover (Figure 11-24, (1)).2. Remove the nut (Figure 11-23, (2)), lo
ALTERNATOR11-22 TNV IDI Service ManualDynamo6. Reinstall the flat washer (Figure 11-28, (4)), lock washer (Figure 11-28, (3)), and nut (Figure 11-28,
TNV IDI Service Manual12-1TNV IDI Service Manual Section 12ELECTRIC WIRINGPageElectric Wiring Precautions ...
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ELECTRIC WIRINGTNV IDI Service Manual12-3Electric Wiring PrecautionsELECTRIC WIRING PRECAUTIONS Failure to follow these precautions may result in the
ELECTRIC WIRING12-4 TNV IDI Service ManualElectric Wire ResistanceELECTRIC WIRE RESISTANCEWiring voltage drop should not exceed 5% [0.05] x 12 Volts =
SAFETYTNV IDI Service Manual3-11Safety PrecautionsA WARNINGTo prevent possible eye injury, always wear SAFETY GLASSES while servicing the engine.00000
ELECTRIC WIRINGTNV IDI Service Manual12-5Battery Cable ResistanceBATTERY CABLE RESISTANCENote: Total allowable resistance of the complete battery cabl
ELECTRIC WIRING12-6 TNV IDI Service ManualElectrical Wire Sizes - Voltage DropELECTRICAL WIRE SIZES - VOLTAGE DROPTotal current on circuit in amps.Len
ELECTRIC WIRINGTNV IDI Service Manual12-7Conversion of AWG to European StandardsCONVERSION OF AWG TO EUROPEAN STANDARDSConductor Size (AWG)Conductor D
ELECTRIC WIRING12-8 TNV IDI Service ManualConversion of AWG to European StandardsThis Page Intentionally Left BlankTNV_IDI_ServiceManual_(3TNV72 for Y
TNV IDI Service Manual13-1TNV IDI Service Manual Section 13TROUBLESHOOTINGPageSpecial Service Tools...
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TROUBLESHOOTINGTNV IDI Service Manual13-3Special Service ToolsSPECIAL SERVICE TOOLSCompression Gauge KitFor measuring compression pressureYanmar Part
TROUBLESHOOTING13-4 TNV IDI Service ManualTroubleshooting By Measuring Compression PressureTROUBLESHOOTING BY MEASURING COMPRESSION PRESSURECompressio
TROUBLESHOOTINGTNV IDI Service Manual13-5Troubleshooting By Measuring Compression PressureStandard Compression PressureEngine compression pressure lis
TROUBLESHOOTING13-6 TNV IDI Service ManualQuick Reference Table For TroubleshootingMeasured Value and TroubleshootingWhen the measured compression pre
SAFETY3-12 TNV IDI Service ManualSafety PrecautionsA CAUTIONFLYING OBJECT HAZARD!• ALWAYS wear eye protection when servicing the engine and when using
TNV IDI Service Manual13-7Troubleshooting ChartsTNV IDI Service ManualTROUBLESHOOTINGTroubleshooting ChartsTrouble Symptom Starting ProblemInsufficien
TROUBLESHOOTING13-8 TNV IDI Service ManualTroubleshooting ChartsThis Page Intentionally Left BlankTNV_IDI_ServiceManual_(3TNV72 for YN only).book 8 ペ
TROUBLESHOOTINGTNV IDI Service Manual13-9Troubleshooting ChartsTrouble Symptom Starting ProblemInsufficient Engine OutputPoor Exhaust ColorHigh Knocki
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TROUBLESHOOTINGTNV IDI Service Manual13-11Troubleshooting ChartsTrouble Symptom Starting ProblemInsufficientEngine OutputPoorExhaustColorHigh Knocking
TROUBLESHOOTING13-12 TNV IDI Service ManualTroubleshooting ChartsThis Page Intentionally Left BlankTNV_IDI_ServiceManual_(3TNV72 for YN only).book 12
TROUBLESHOOTINGTNV IDI Service Manual13-13Troubleshooting ChartsTrouble Symptom Starting ProblemInsufficientEngine OutputPoorExhaustColorHigh Knocking
TROUBLESHOOTING13-14 TNV IDI Service ManualTroubleshooting ChartsThis Page Intentionally Left BlankTNV_IDI_ServiceManual_(3TNV72 for YN only).book 14
TROUBLESHOOTINGTNV IDI Service Manual13-15Troubleshooting ChartsTrouble Symptom Starting ProblemInsufficientEngine OutputPoorExhaustColorHigh Knocking
TROUBLESHOOTING13-16 TNV IDI Service ManualTroubleshooting ChartsThis Page Intentionally Left BlankTNV_IDI_ServiceManual_(3TNV72 for YN only).book 16
SAFETYTNV IDI Service Manual3-13Safety PrecautionsCAUTIONMake sure the engine is installed on a level surface. If a continuously running engine is ins
TROUBLESHOOTINGTNV IDI Service Manual13-17Troubleshooting ChartsTrouble Symptom Starting ProblemInsufficientEngine OutputPoorExhaustColorHigh Knocking
TROUBLESHOOTING13-18 TNV IDI Service ManualTroubleshooting ChartsThis Page Intentionally Left BlankTNV_IDI_ServiceManual_(3TNV72 for YN only).book 18
TNV IDI Service Manual13-19Electric WiringTNV IDI Service ManualWIRING DIAGRAMELECTRIC WIRINGNote: The following wiring diagram is “representative” of
WIRING DIAGRAM13-20 TNV IDI Service ManualElectric WiringThis Page Intentionally Left BlankTNV_IDI_ServiceManual_(3TNV72 for YN only).book 20 ページ 20
SAFETY3-14 TNV IDI Service ManualSafety PrecautionsCAUTIONIf any indicator illuminates during engine operation, stop the engine immediately. Determine
ii TNV IDI Service ManualThis Service Manual has been developed for the exclusive use of service and repair professionals such as Yanmar authorized Di
SAFETYTNV IDI Service Manual3-15Safety PrecautionsCAUTION• ALWAYS be environmentally responsible. • Follow the guidelines of the EPA or other governme
SAFETY3-16 TNV IDI Service ManualSafety PrecautionsCAUTION• NEVER attempt to modify the engine’s design or safety features such as defeating the engin
SAFETYTNV IDI Service Manual3-17Safety PrecautionsCAUTION• When the engine is operated in dusty conditions, clean the air cleaner element more frequen
SAFETY3-18 TNV IDI Service ManualSafety PrecautionsCAUTIONAfter marking the position of the pump drive gear, do not rotate the engine crankshaft. Rota
SAFETYTNV IDI Service Manual3-19Safety PrecautionsCAUTIONMake sure that the combined total resistance of the battery cable in both directions between
SAFETY3-20 TNV IDI Service ManualSafety PrecautionsCAUTIONDo not allow the honing tool to operate in one position for any length of time. Damage to th
TNV IDI Service Manual4-1TNV IDI Service Manual Section 4GENERAL SERVICE INFORMATIONPageComponent Identification...
GENERAL SERVICE INFORMATION4-2 TNV IDI Service ManualPrincipal Engine Specifications ... 4-203TNV72
GENERAL SERVICE INFORMATIONTNV IDI Service Manual4-3Component IdentificationCOMPONENT IDENTIFICATIONFigure 4-1 shows where major engine components are
GENERAL SERVICE INFORMATION4-4 TNV IDI Service ManualLocation of LabelsLOCATION OF LABELSFigure 4-2 shows the location of regulatory and safety labels
TNV IDI Service ManualiiiTNV IDI Service ManualTABLE OF CONTENTSPageTable of Contents...
GENERAL SERVICE INFORMATIONTNV IDI Service Manual4-5The 97/68/EC Directive Certified EnginesEPA / ARB Labels (Typical)(EPA) Less Than 50 HP SAE (37kW
GENERAL SERVICE INFORMATION4-6 TNV IDI Service ManualFunction of Major Engine ComponentsFUNCTION OF MAJOR ENGINE COMPONENTSComponent FunctionAir Clean
GENERAL SERVICE INFORMATIONTNV IDI Service Manual4-7Function of Major Engine ComponentsFuel TankThe fuel tank is a reservoir that holds diesel fuel. W
GENERAL SERVICE INFORMATION4-8 TNV IDI Service ManualFunction of Cooling System ComponentsFUNCTION OF COOLING SYSTEM COMPONENTSComponent FunctionCooli
GENERAL SERVICE INFORMATIONTNV IDI Service Manual4-9Diesel FuelDIESEL FUELDiesel Fuel SpecificationsDiesel fuel should comply with the following speci
GENERAL SERVICE INFORMATION4-10 TNV IDI Service ManualDiesel FuelPrecautions and concerns regarding the use of bio-fuels:1. Free methanol in FAME may
GENERAL SERVICE INFORMATIONTNV IDI Service Manual4-11Diesel FuelA DANGERFIRE AND EXPLOSION HAZARD!• Diesel fuel is flammable and explosive under certa
GENERAL SERVICE INFORMATION4-12 TNV IDI Service ManualDiesel FuelNote that a typical fuel tank is shown. The fuel tank on the equipment being serviced
GENERAL SERVICE INFORMATIONTNV IDI Service Manual4-13Engine OilTo prime the fuel system if a mechanical fuel pump is installed:1. Operate the fuel pri
GENERAL SERVICE INFORMATION4-14 TNV IDI Service ManualEngine Oil2. Change the engine oil after the first 50 hours of operation and then every 250 hour
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GENERAL SERVICE INFORMATIONTNV IDI Service Manual4-15Engine CoolantEngine Oil Capacity (Typical)Note: These are the engine oil capacities associated w
GENERAL SERVICE INFORMATION4-16 TNV IDI Service ManualEngine CoolantEngine Coolant SpecificationsUse a Long Life Coolant (LLC) or an Extended Life Coo
GENERAL SERVICE INFORMATIONTNV IDI Service Manual4-17Engine CoolantFigure 4-71. Check to be sure the radiator drain plug is installed and tightened or
GENERAL SERVICE INFORMATION4-18 TNV IDI Service ManualSpecificationsSPECIFICATIONSDescription of Model NumberWhen ordering parts or making an inquiry
GENERAL SERVICE INFORMATIONTNV IDI Service Manual4-19SpecificationsEngine General SpecificationsNote: The information described in Principal Engine Sp
GENERAL SERVICE INFORMATION4-20 TNV IDI Service ManualPrincipal Engine SpecificationsPRINCIPAL ENGINE SPECIFICATIONS3TNV72Engine Model 3TNV72Version V
GENERAL SERVICE INFORMATIONTNV IDI Service Manual4-21Engine Service InformationENGINE SERVICE INFORMATIONInspection Item Standard LimitIntake / Exhaus
GENERAL SERVICE INFORMATION4-22 TNV IDI Service ManualTightening Torques for Standard Bolts and NutsTIGHTENING TORQUES FOR STANDARD BOLTS AND NUTSUse
GENERAL SERVICE INFORMATIONTNV IDI Service Manual4-23Tightening Torques for Standard Bolts and NutsNote: Torque values shown in this manual are for cl
GENERAL SERVICE INFORMATION4-24 TNV IDI Service ManualAbbreviations and SymbolsABBREVIATIONS AND SYMBOLSAbbreviationsSymbolsA ampereAC alternating cur
TNV IDI Service Manual1-1TNV IDI Service Manual Section 1INTRODUCTIONThis Service Manual describes the service procedures for the TNV series indirect
GENERAL SERVICE INFORMATIONTNV IDI Service Manual4-25Unit ConversionsUNIT CONVERSIONSUnit PrefixesUnits of LengthUnits of VolumeUnits of MassUnits of
GENERAL SERVICE INFORMATION4-26 TNV IDI Service ManualUnit ConversionsThis Page Intentionally Left BlankTNV_IDI_ServiceManual_(3TNV72 for YN only).boo
TNV IDI Service Manual5-1TNV IDI Service Manual Section 5PERIODIC MAINTENANCEPageIntroduction...
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PERIODIC MAINTENANCETNV IDI Service Manual5-3IntroductionINTRODUCTIONThis section of the Service Manual describes the procedures for proper care and m
PERIODIC MAINTENANCE5-4 TNV IDI Service ManualIntroductionA DANGERFIRE AND EXPLOSION HAZARD!• Diesel fuel is flammable and explosive under certain con
PERIODIC MAINTENANCETNV IDI Service Manual5-5IntroductionA DANGERFIRE AND EXPLOSION HAZARD!• Diesel fuel is flammable and explosive under certain cond
PERIODIC MAINTENANCE5-6 TNV IDI Service ManualIntroductionA DANGERFIRE AND EXPLOSION HAZARD!• Diesel fuel is flammable and explosive under certain con
PERIODIC MAINTENANCETNV IDI Service Manual5-7IntroductionA WARNINGEXHAUST HAZARD!• NEVER operate the engine in an enclosed area such as a garage, tunn
PERIODIC MAINTENANCE5-8 TNV IDI Service ManualIntroductionA WARNINGBURN HAZARD!• Keep your hands and other body parts away from hot engine surfaces su
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PERIODIC MAINTENANCETNV IDI Service Manual5-9IntroductionA WARNINGBURN HAZARD!• Batteries contain sulfuric acid. NEVER allow battery fluid to come in
PERIODIC MAINTENANCE5-10 TNV IDI Service ManualIntroductionA WARNINGBURN HAZARD!• If you must drain the engine oil while it is still hot, stay clear o
PERIODIC MAINTENANCETNV IDI Service Manual5-11IntroductionCAUTION• Only use diesel fuels recommended by Yanmar for the best engine performance, to pre
PERIODIC MAINTENANCE5-12 TNV IDI Service ManualIntroductionCAUTIONObserve the following environmental operating conditions to maintain engine performa
PERIODIC MAINTENANCETNV IDI Service Manual5-13IntroductionCAUTIONNew Engine Break-in:• On the initial engine start-up, allow the engine to idle for ap
PERIODIC MAINTENANCE5-14 TNV IDI Service ManualIntroductionCAUTIONNEVER use high-pressure water or compressed air at greater than 28 psi (193 kPa; 19
PERIODIC MAINTENANCETNV IDI Service Manual5-15PrecautionsPRECAUTIONSThe Importance of Periodic MaintenanceEngine deterioration and wear occurs in prop
PERIODIC MAINTENANCE5-16 TNV IDI Service ManualPeriodic Maintenance SchedulePerform periodic maintenance procedures in an open, level area free from t
PERIODIC MAINTENANCETNV IDI Service Manual5-17Periodic Maintenance ScheduleNote: These procedures are considered normal maintenance and are performed
PERIODIC MAINTENANCE5-18 TNV IDI Service ManualPeriodic Maintenance ProceduresPERIODIC MAINTENANCE PROCEDURESPerform the following maintenance after t
TNV IDI Service Manual2-1TNV IDI Service Manual Section 2YANMAR WARRANTIESPageYanmar Limited Warranty...
PERIODIC MAINTENANCETNV IDI Service Manual5-19Periodic Maintenance ProceduresThe engine oil on a new engine becomes contaminated from the initial brea
PERIODIC MAINTENANCE5-20 TNV IDI Service ManualPeriodic Maintenance ProceduresCheck and adjust the V-belt tension (deflection) as follows:1. Press the
PERIODIC MAINTENANCETNV IDI Service Manual5-21Periodic Maintenance Procedures3. Tighten the V-belt to the proper tension. There must be clearance (Fig
PERIODIC MAINTENANCE5-22 TNV IDI Service ManualPeriodic Maintenance ProceduresDrain the fuel filter / water separator whenever there are contaminants,
PERIODIC MAINTENANCETNV IDI Service Manual5-23Periodic Maintenance Procedures8. Put the float (Figure 5-7, (7)) and retaining spring (Figure 5-7, (6))
PERIODIC MAINTENANCE5-24 TNV IDI Service ManualPeriodic Maintenance Procedures• When the amount of fluid nears the lower limit (Figure 5-8, (1)), fill
PERIODIC MAINTENANCETNV IDI Service Manual5-25Periodic Maintenance ProceduresPerform the following maintenance every 250 hours of operation.• Drain Fu
PERIODIC MAINTENANCE5-26 TNV IDI Service ManualPeriodic Maintenance Procedures4. Drain the tank until clean diesel fuel with no water or dirt flows ou
PERIODIC MAINTENANCETNV IDI Service Manual5-27Periodic Maintenance ProceduresCheck and Clean Radiator FinsDirt and dust adhering to the radiator fins
PERIODIC MAINTENANCE5-28 TNV IDI Service ManualPeriodic Maintenance Procedures2. If the governor lever does not make proper contact with the high idle
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PERIODIC MAINTENANCETNV IDI Service Manual5-29Periodic Maintenance ProceduresFigure 5-133. Blow air (Figure 5-12, (3)) through the element from the in
PERIODIC MAINTENANCE5-30 TNV IDI Service ManualPeriodic Maintenance ProceduresPerform the following maintenance every 500 hours of operation.• Replace
PERIODIC MAINTENANCETNV IDI Service Manual5-31Periodic Maintenance ProceduresReplace the fuel filter at specified intervals to prevent contaminants fr
PERIODIC MAINTENANCE5-32 TNV IDI Service ManualPeriodic Maintenance ProceduresClean Fuel Filter / Water SeparatorPeriodically clean the fuel filter /
PERIODIC MAINTENANCETNV IDI Service Manual5-33Periodic Maintenance Procedures3. Turn the retaining ring (Figure 5-15, (4)) to the left (Figure 5-15, (
PERIODIC MAINTENANCE5-34 TNV IDI Service ManualPeriodic Maintenance ProceduresEngine coolant contaminated with rust or scale reduces the cooling effec
PERIODIC MAINTENANCETNV IDI Service Manual5-35Periodic Maintenance ProceduresFigure 5-164. Drain the coolant from the engine block. Remove the coolant
PERIODIC MAINTENANCE5-36 TNV IDI Service ManualPeriodic Maintenance ProceduresPerform the following maintenance every 1500 hours of operation.• Inspec
PERIODIC MAINTENANCETNV IDI Service Manual5-37Periodic Maintenance Procedures2. Remove the diaphragm cover, spring, diaphragm plate (Figure 5-18, (5))
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