Cub-cadet Yanmar 3TNV72 Manuel d'utilisateur

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Page 2 - INDUSTRIAL

YANMAR WARRANTIESTNV IDI Service Manual2-3Yanmar Limited WarrantyYANMAR LIMITED WARRANTYWhat is Covered by this Warranty? Yanmar warrants to the origi

Page 3

TNV IDI Service Manual6-1TNV IDI Service Manual Section 6ENGINEPageBefore You Begin Servicing ...

Page 4 - CONTENTS

ENGINE6-2 TNV IDI Service ManualCylinder Head... 6-20Cylinder Head Compo

Page 5 - TABLE OF CONTENTS

ENGINETNV IDI Service Manual6-3Before You Begin ServicingBEFORE YOU BEGIN SERVICINGA WARNINGTo prevent possible eye injury, always wear SAFETY GLASSES

Page 6

ENGINE6-4 TNV IDI Service ManualBefore You Begin ServicingCAUTION• Only use the engine oil specified. Other engine oils may affect warranty coverage,

Page 7

ENGINETNV IDI Service Manual6-5IntroductionINTRODUCTIONThis section of the Service Manual describes servicing of the engine.CYLINDER HEAD SPECIFICATIO

Page 8 - WARRANTIES

ENGINE6-6 TNV IDI Service ManualCylinder Head SpecificationsIntake / Exhaust Valve and GuidePush RodValve SpringInspection Item Standard LimitReferenc

Page 9

ENGINETNV IDI Service Manual6-7Camshaft and Timing Gear Train SpecificationsRocker Arm and ShaftCAMSHAFT AND TIMING GEAR TRAIN SPECIFICATIONSCamshaftI

Page 10 - YANMAR LIMITED WARRANTY

ENGINE6-8 TNV IDI Service ManualCrankshaft and Pistons SpecificationsIdler Gear Shaft and BushingTiming Gear BacklashCRANKSHAFT AND PISTONS SPECIFICAT

Page 11 - What Yanmar Will Do:

ENGINETNV IDI Service Manual6-9Crankshaft and Pistons Specifications(Crankshaft Cont.)Crankshaft ReconditioningThrust BearingInspection Item Standard

Page 12 - Retail Purchaser Registration

ENGINE6-10 TNV IDI Service ManualCrankshaft and Pistons SpecificationsPistonInspection Item Standard LimitReference PagePiston Outside Diameter(Measur

Page 13 - WARRANTY - USA ONLY

YANMAR WARRANTIES2-4 TNV IDI Service ManualYanmar Limited WarrantyYanmar Limited Warranty - ContinuedTo Locate an Authorized Yanmar Industrial Engine

Page 14 - Warranted Parts:

ENGINETNV IDI Service Manual6-11Crankshaft and Pistons SpecificationsPiston RingModel Inspection Item Standard LimitReference Page3TNV72Top RingRing G

Page 15 - Exclusions:

ENGINE6-12 TNV IDI Service ManualCrankshaft and Pistons SpecificationsConnecting RodConnecting Rod Small EndConnecting Rod Big EndConnecting Rod Disto

Page 16 - Section 3

ENGINETNV IDI Service Manual6-13Cylinder Block SpecificationsCYLINDER BLOCK SPECIFICATIONSCylinder BlockInspection Item Model Standard LimitReference

Page 17 - 3-2 TNV IDI Service Manual

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

Page 18 - 0000001en

ENGINETNV IDI Service Manual6-15Special Service ToolsSPECIAL SERVICE TOOLSNote: Tools not having Yanmar part numbers must be acquired locally.No Tool

Page 19 - 0000002en

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

Page 20 - 0000012en

ENGINETNV IDI Service Manual6-17Measuring InstrumentsMEASURING INSTRUMENTSNo. Instrument Name Application Illustration1 Dial Indicator (Available Loca

Page 21

ENGINE6-18 TNV IDI Service ManualMeasuring Instruments(Measuring instruments Cont.)No. Instrument Name Application Illustration9 V-Block (Available Lo

Page 22 - 0000007en

ENGINETNV IDI Service Manual6-19Measuring InstrumentsThis Page Intentionally Left BlankTNV_IDI_ServiceManual_(3TNV72 for YN only).book 19 ページ 2007年1

Page 23

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

Page 24

YANMAR WARRANTIESTNV IDI Service Manual2-5Yanmar Limited WarrantyYanmar Limited Warranty - ContinuedWarranty Limitations: The foregoing is Yanmar&apos

Page 25

ENGINETNV IDI Service Manual6-21Cylinder Head1 – Baffle Plate2 – Oil Fill Cap3 – Valve Cover / Intake Manifold4 – Gasket5 – Rocker Arm Shaft6 – Rocker

Page 26

ENGINE6-22 TNV IDI Service ManualCylinder HeadRemoval of Intake Manifold / Valve Cover1. Remove the intake manifold bolts (Figure 6-2, (1)) and valve

Page 27

ENGINETNV IDI Service Manual6-23Cylinder HeadDisassembly of Rocker Arm Assembly1. Remove the rocker arm shaft alignment set screw (Figure 6-5, (6)) fr

Page 28 - Safety Precautions

ENGINE6-24 TNV IDI Service ManualCylinder HeadRemoval of Intake / Exhaust Valves1. Put the cylinder head on the work bench with the combustion side do

Page 29

ENGINETNV IDI Service Manual6-25Cylinder HeadCleaning of Cylinder Head ComponentsThoroughly clean all components using a non-metallic brush and an app

Page 30

ENGINE6-26 TNV IDI Service ManualCylinder HeadInspection of Rocker Arm AssemblyRocker Arm Shaft Hole DiameterUse a telescoping gauge and micrometer to

Page 31

ENGINETNV IDI Service Manual6-27Cylinder HeadIf distortion exceeds the service limit, resurface or replace the cylinder head. Remove only enough mater

Page 32

ENGINE6-28 TNV IDI Service ManualCylinder HeadValve Face and Valve SeatAlways check the clearance between the valve and valve guide before grinding or

Page 33

ENGINETNV IDI Service Manual6-29Cylinder HeadSquarenessUse a flat surface and a square to check each spring for squareness (Figure 6-22). See Valve Sp

Page 34

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

Page 35

YANMAR WARRANTIES2-6 TNV IDI Service ManualEmission System WarrantyEMISSION SYSTEM WARRANTYYANMAR CO., LTD. LIMITED EMISSION CONTROL SYSTEM WARRANTY -

Page 36 - INFORMATION

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

Page 37 - GENERAL SERVICE INFORMATION

ENGINE6-32 TNV IDI Service ManualCylinder HeadReassembly of Rocker Arm AssemblyFigure 6-31IMPORTANTEnsure the lubrication holes in the rocker arm shaf

Page 38 - COMPONENT IDENTIFICATION

ENGINETNV IDI Service Manual6-33Cylinder HeadReassembly of Intake Manifold / Valve Cover1. Reinstall the glow plugs (Figure 6-33, (1)) and tighten to

Page 39 - 0000585A

ENGINE6-34 TNV IDI Service ManualCylinder HeadMeasuring and Adjusting Valve ClearanceMeasure and adjust while the engine is cold.Notes:• The No. 1 pis

Page 40 - ENGINE FAMILY

ENGINETNV IDI Service Manual6-35Cylinder HeadFigure 6-354. If adjustment is required, proceed to the next step.5. Loosen the valve adjusting screw loc

Page 41

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

Page 42

ENGINETNV IDI Service Manual6-37Cylinder Block1 – Cylinder Block2 – Camshaft Bushing3 – Gear Case4 – Dowel (2 used)5–O-Ring6 – Gear Case Cover7 – Fron

Page 43

ENGINE6-38 TNV IDI Service ManualCylinder Block5. Remove the engine from the machine. Mount the engine to a suitable engine repair stand having adequa

Page 44 - DIESEL FUEL

ENGINETNV IDI Service Manual6-39Cylinder BlockMeasuring Idler Gear-to-Crankshaft Gear Backlash1. Install a dial indicator as shown in Figure 6-41.Figu

Page 45

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

Page 46

YANMAR WARRANTIESTNV IDI Service Manual2-7Emission System WarrantyLimited Emission Control System Warranty - USA Only - ContinuedWarranty Coverage:Thi

Page 47 - 0000002A

ENGINETNV IDI Service Manual6-41Cylinder BlockRemoval of Camshaft1. Before removing the camshaft, check the camshaft end play.• Method A: Install a di

Page 48 - 0000649A

ENGINE6-42 TNV IDI Service ManualCylinder BlockRemoval of Gear CaseNote: The camshaft must be removed before the gear case can be removed. See Removal

Page 49 - Adding Engine Oil

ENGINETNV IDI Service Manual6-43Cylinder Block1. Using a feeler gauge, measure the connecting rod side clearance (Figure 6-50). See Connecting Rod on

Page 50

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

Page 51

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

Page 52

ENGINE6-46 TNV IDI Service ManualCylinder Block11. Remove the crankshaft from the engine.12. Remove the bearing inserts (Figure 6-59, (1)) and thrust

Page 53 - SPECIFICATIONS

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

Page 54 - Engine General Specifications

ENGINE6-48 TNV IDI Service ManualCylinder BlockInspection of Pistons, Piston Rings and Wrist PinNotes:• On an engine with low hours, the pistons, pist

Page 55

ENGINETNV IDI Service Manual6-49Cylinder Block• On an engine with high hours, the pistons rings should be replaced and the cylinder honed (See Honing

Page 56 - ENGINE SERVICE INFORMATION

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

Page 57 - 0000023enTNVIDISM

YANMAR WARRANTIES2-8 TNV IDI Service ManualEmission System WarrantyLimited Emission Control System Warranty - USA Only - ContinuedExclusions:Failures

Page 58

ENGINETNV IDI Service Manual6-51Cylinder BlockInspection of Crankshaft1. Put the crankshaft end journals (Figure 6-74, (4)) on V-blocks.2. Place a dia

Page 59 - ABBREVIATIONS AND SYMBOLS

ENGINE6-52 TNV IDI Service ManualCylinder BlockFigure 6-76Inspection of Camshaft1. Use V-blocks and a dial indicator to check camshaft bend (Figure 6-

Page 60 - UNIT CONVERSIONS

ENGINETNV IDI Service Manual6-53Cylinder BlockInspection of Camshaft Bushing and Bores1. Measure the I.D. of the front bushing and the remaining bores

Page 61

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

Page 62 - MAINTENANCE

ENGINETNV IDI Service Manual6-55Cylinder BlockReassembly of Pistons1. Select the parts needed to assemble the piston and connecting rod for one cylind

Page 63 - PERIODIC MAINTENANCE

ENGINE6-56 TNV IDI Service ManualCylinder Block1 – Fuel Injection Pump Side of Engine2 – Piston Identification Mark3 – Embossed Mark on Connecting Rod

Page 64

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

Page 65

ENGINE6-58 TNV IDI Service ManualCylinder BlockFigure 6-903. Install the crankshaft in the engine.IMPORTANTThe main bearing caps are numbered and have

Page 66

ENGINETNV IDI Service Manual6-59Cylinder Block1 – Top Compression Ring End Gap2 – Second Compression Ring End Gap3 – Oil Ring End GapFigure 6-92IMPORT

Page 67

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

Page 68

TNV IDI Service Manual3-1TNV IDI Service Manual Section 3SAFETYPageSafety Statements ...

Page 69

ENGINETNV IDI Service Manual6-61Cylinder Block4. Lubricate the camshaft lobes and tappets with clean oil or assembly lube. Reinstall the tappets in th

Page 70

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

Page 71

TNV IDI Service Manual7-1TNV IDI Service Manual Section 7FUEL SYSTEMPageBefore You Begin Servicing ...

Page 72 - 0000079en

FUEL SYSTEM7-2 TNV IDI Service ManualDisassembly and Inspection of Fuel Injectors ... 7-27Adjusting Fuel Injector Pressure ...

Page 73 - Introduction

FUEL SYSTEMTNV IDI Service Manual7-3Before You Begin ServicingBEFORE YOU BEGIN SERVICINGA WARNINGENTANGLEMENT HAZARD!• Stop the engine before you begi

Page 74

FUEL SYSTEM7-4 TNV IDI Service ManualBefore You Begin ServicingCAUTION• NEVER remove or attempt to remove the tamper-proof devices from the full-load

Page 75

FUEL SYSTEMTNV IDI Service Manual7-5IntroductionINTRODUCTIONFigure 7-1This section of the Service Manual describes the procedures necessary to remove,

Page 76 - 0000060en

FUEL SYSTEM7-6 TNV IDI Service ManualIntroductionThe fuel injector is essentially a spring-loaded valve. When fuel pressure from the fuel injection pu

Page 77 - 0000024enTNVIDISM

FUEL SYSTEMTNV IDI Service Manual7-7Fuel System SpecificationsFUEL SYSTEM SPECIFICATIONSSpecial Torque ChartTest and Adjustment SpecificationsNote: Fu

Page 78

FUEL SYSTEM7-8 TNV IDI Service ManualSpecial Service ToolsSPECIAL SERVICE TOOLSNote: Tools not having Yanmar part numbers must be acquired locally.MEA

Page 79

SAFETY3-2 TNV IDI Service ManualThis Page Intentionally Left BlankTNV_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

Page 80

FUEL SYSTEMTNV IDI Service Manual7-9Fuel System DiagramFUEL SYSTEM DIAGRAMFigure 7-21 – Diesel Fuel Supply2 – Fuel Filter / Water Separator3 – Mechani

Page 81

FUEL SYSTEM7-10 TNV IDI Service ManualFuel System ComponentsFUEL SYSTEM COMPONENTSFigure 7-30002208(1)(2)(3) (17) (18) (19) (4) (6) (7) (5) (9

Page 82

FUEL SYSTEMTNV IDI Service Manual7-11Fuel Injection Lines1 – High-Pressure Fuel Injection Lines2 – Fuel Return Line Nut3 – Fuel Return Line4 – Fuel In

Page 83

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

Page 84 - 0000025en

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

Page 85 - 0000067A

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

Page 86 - A DANGER

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

Page 87

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

Page 88

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

Page 89

FUEL SYSTEM7-18 TNV IDI Service ManualFuel Injection PumpFigure 7-197. Tighten the fuel injection pump retaining nuts to specification. See Special To

Page 90 - 0000071A

SAFETYTNV IDI Service Manual3-3Safety StatementsSAFETY STATEMENTSYanmar is concerned for your safety and your machine’s condition. Safety statements a

Page 91 - 0000046en

FUEL SYSTEMTNV IDI Service Manual7-19Checking and Adjusting Fuel Injection TimingFigure 7-2115. Reinstall the cooling fan V-belt (Figure 7-21, (1)). A

Page 92

FUEL SYSTEM7-20 TNV IDI Service ManualChecking and Adjusting Fuel Injection TimingFigure 7-236. Typical flywheel markings are as shown in (Figure 7-24

Page 93

FUEL SYSTEMTNV IDI Service Manual7-21Checking and Adjusting Fuel Injection Timing• EXAMPLE: If the distance between the two “longer” marks is approxim

Page 94

FUEL SYSTEM7-22 TNV IDI Service ManualChecking and Adjusting Fuel Injection TimingNote: As the injection pump injects fuel to a cylinder only once eve

Page 95

FUEL SYSTEMTNV IDI Service Manual7-23Fuel InjectorsAdjusting Fuel Injection TimingIf the timing marks did not align when performing the Checking Fuel

Page 96

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

Page 97

FUEL SYSTEMTNV IDI Service Manual7-25Fuel Injectors4. Pump the operating lever of the tester slowly, observing the pressure reading at the point where

Page 98

FUEL SYSTEM7-26 TNV IDI Service ManualFuel InjectorsFuel Injector Test ResultsNote: If the fuel injector fails any tests, it should be serviced or rep

Page 99

FUEL SYSTEMTNV IDI Service Manual7-27Fuel InjectorsDisassembly and Inspection of Fuel Injectors1. Clean carbon from used injectors using clean diesel

Page 100 - Section 6

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

Page 101 - 6-2 TNV IDI Service Manual

SAFETY3-4 TNV IDI Service ManualSafety PrecautionsSAFETY PRECAUTIONSA DANGERSCALD HAZARD!• NEVER remove the radiator cap if the engine is hot. Steam a

Page 102 - 0000009en

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

Page 103 - Before You Begin Servicing

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

Page 104 - CYLINDER HEAD SPECIFICATIONS

TNV IDI Service Manual8-1TNV IDI Service Manual Section 8COOLING SYSTEMPageBefore You Begin Servicing ...

Page 105 - Valve Spring

COOLING SYSTEM8-2 TNV IDI Service ManualThis Page Intentionally Left BlankTNV_IDI_ServiceManual_(3TNV72 for YN only).book 2 ページ 2007年11月29日 木曜日 午後2時

Page 106 - Camshaft

COOLING SYSTEMTNV IDI Service Manual8-3Before You Begin ServicingBEFORE YOU BEGIN SERVICINGA DANGERSCALD HAZARD!• NEVER remove the radiator cap if the

Page 107 - Crankshaft

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

Page 108 - Thrust Bearing

COOLING SYSTEMTNV IDI Service Manual8-5IntroductionINTRODUCTIONThis section of the Service Manual describes the procedures necessary to service the 3T

Page 109 - TNV IDI Service Manual

COOLING SYSTEM8-6 TNV IDI Service ManualEngine Coolant Pump ComponentsENGINE COOLANT PUMP COMPONENTSFigure 8-21 – Thermostat Cover2 – Thermostat3 – Sp

Page 110 - Piston Ring

COOLING SYSTEMTNV IDI Service Manual8-7Engine Coolant System CheckENGINE COOLANT SYSTEM CHECKCheck the engine coolant system for leakage.1. With the r

Page 111 - Connecting Rod

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

Page 112 - CYLINDER BLOCK SPECIFICATIONS

TNV IDI Service ManualTNV seriesSERVICE MANUAL3TNV72P/N: 0BTNV-U00300INDUSTRIALENGINESTNV_IDI_ServiceManual_(3TNV72 for YN only).book i ページ 2007年11月

Page 113 - SPECIAL TORQUE CHART

SAFETYTNV IDI Service Manual3-5Safety PrecautionsA DANGERFIRE AND EXPLOSION HAZARD!• Diesel fuel is flammable and explosive under certain conditions.•

Page 114 - SPECIAL SERVICE TOOLS

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.

Page 115 - Special Service Tools

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

Page 116 - MEASURING INSTRUMENTS

TNV IDI Service Manual9-1TNV IDI Service Manual Section 9LUBRICATION SYSTEMPageBefore You Begin Servicing ...

Page 117 - Measuring Instruments

LUBRICATION SYSTEM9-2 TNV IDI Service ManualThis Page Intentionally Left BlankTNV_IDI_ServiceManual_(3TNV72 for YN only).book 2 ページ 2007年11月29日 木曜日 

Page 118

LUBRICATION SYSTEMTNV IDI Service Manual9-3Before You Begin ServicingBEFORE YOU BEGIN SERVICINGCAUTIONNEVER permit anyone to operate the engine or dri

Page 119 - CYLINDER HEAD

LUBRICATION SYSTEM9-4 TNV IDI Service ManualBefore You Begin ServicingA WARNINGFUME / BURN HAZARD!• Always read and follow safety related precautions

Page 120 - 0000080en

LUBRICATION SYSTEMTNV IDI Service Manual9-5IntroductionINTRODUCTIONThis section of the Service Manual describes the procedures necessary to service th

Page 121 - Removal of Glow Plugs

LUBRICATION SYSTEM9-6 TNV IDI Service ManualOil Pump Service InformationInner Rotor and Gear Boss ClearanceItem PartsStandardDimensionStandardClearanc

Page 122 - Removal of Cylinder Head

LUBRICATION SYSTEMTNV IDI Service Manual9-7Lubrication System DiagramLUBRICATION SYSTEM DIAGRAMFigure 9-1Idle GearShaftPressureRegulator ValveOil Pump

Page 123 - Removal of Valve Guides

LUBRICATION SYSTEM9-8 TNV IDI Service ManualChecking Engine Oil PressureCHECKING ENGINE OIL PRESSUREPerform an engine oil pressure check if there is a

Page 124 - 0000120en

SAFETY3-6 TNV IDI Service ManualSafety PrecautionsA DANGERFIRE AND EXPLOSION HAZARD!• Diesel fuel is flammable and explosive under certain conditions.

Page 125 - Inspection of Cylinder Head

LUBRICATION SYSTEMTNV IDI Service Manual9-9Trochoid Oil PumpDisassembly of Oil Pump1. Remove the engine cooling fan guard (if equipped), engine coolin

Page 126

LUBRICATION SYSTEM9-10 TNV IDI Service ManualTrochoid Oil PumpCleaning and InspectionWash the oil pump cover, the oil pressure regulator valve, the oi

Page 127 - Inspection of Valve Springs

LUBRICATION SYSTEMTNV IDI Service Manual9-11Trochoid Oil PumpCheck Inner Rotor and Gear Boss Clearance1 – Crank Gear2 – Inner Rotor3 – Inside Width Ac

Page 128 - Reassembly of Cylinder Head

LUBRICATION SYSTEM9-12 TNV IDI Service ManualTrochoid Oil PumpThis Page Intentionally Left BlankTNV_IDI_ServiceManual_(3TNV72 for YN only).book 12 ペー

Page 129 - IMPORTANT

TNV IDI Service Manual10-1TNV IDI Service Manual Section 10STARTER MOTORPageBefore You Begin Servicing ...

Page 130

STARTER MOTOR10-2 TNV IDI Service ManualThis Page Intentionally Left BlankTNV_IDI_ServiceManual_(3TNV72 for YN only).book 2 ページ 2007年11月29日 木曜日 午後2時

Page 131

STARTER MOTORTNV IDI Service Manual10-3Before You Begin ServicingBEFORE YOU BEGIN SERVICINGA WARNINGENTANGLEMENT HAZARD!• Stop the engine before you b

Page 132

STARTER MOTOR10-4 TNV IDI Service ManualBefore You Begin ServicingA CAUTIONFLYING OBJECT HAZARD!• ALWAYS wear eye protection when servicing the engine

Page 133 - Clearance

STARTER MOTORTNV IDI Service Manual10-5IntroductionINTRODUCTIONThis section of the Service Manual covers the servicing of starter motor. Yanmar Part N

Page 134

STARTER MOTOR10-6 TNV IDI Service ManualStarter Motor SpecificationsSTARTER MOTOR SPECIFICATIONSYanmar Part Number 119717-77010 119515-77010Nominal Ou

Page 135 - CYLINDER BLOCK

SAFETYTNV IDI Service Manual3-7Safety PrecautionsA DANGERFIRE AND EXPLOSION HAZARD!• Diesel fuel is flammable and explosive under certain conditions.•

Page 136

STARTER MOTORTNV IDI Service Manual10-7Starter Motor TroubleshootingSTARTER MOTOR TROUBLESHOOTINGIs the shift lever at NEUTRAL position? Does engine c

Page 137 - Components

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

Page 138

STARTER MOTORTNV IDI Service Manual10-9Starter Motor1–Nut2 – Needle Bearing3 – Pinion Housing4 – Pinion Retaining Ring5 – Pinion Stop6 – Pinion7–Shift

Page 139 - Removal of Oil Pan

STARTER MOTOR10-10 TNV IDI Service ManualStarter MotorRemoval of Starter Motor1. Disconnect the battery cables at the battery, negative (-) cable firs

Page 140 - Removal of Camshaft

STARTER MOTORTNV IDI Service Manual10-11Starter Motor6. Pull the brush springs up using a brush spring puller. On the negative (-) side, bring the bru

Page 141 - 0000088en

STARTER MOTOR10-12 TNV IDI Service ManualStarter Motor13. Remove the pinion stop (Figure 10-10, (3)), return spring (if equipped), and pinion clutch a

Page 142

STARTER MOTORTNV IDI Service Manual10-13Starter MotorMeasure Commutator Insulation DepthMeasure the depth of the insulating material (Figure 10-14, (1

Page 143 - Removal of Crankshaft

STARTER MOTOR10-14 TNV IDI Service ManualStarter MotorMeasure Armature and Commutator Run-OutMeasure the armature core run-out and the commutator run-

Page 144

STARTER MOTORTNV IDI Service Manual10-15Starter MotorBrush HolderBrush Holder Insulation TestCheck for continuity between each brush holder and the ba

Page 145

STARTER MOTOR10-16 TNV IDI Service ManualStarter MotorCoil Resistance TestSee Starter Motor Specifications on page 10-6 for service limit.Contact Cont

Page 146 - Inspection of Cylinder Block

SAFETY3-8 TNV IDI Service ManualSafety PrecautionsA WARNINGSEVER HAZARD!• Keep hands and other body parts away from moving / rotating parts such as th

Page 147 - Wrist Pin

STARTER MOTORTNV IDI Service Manual10-17Starter MotorReassembly of Starter Motor1. Apply a appropriate starter bendix grease (obtain locally) to the p

Page 148 - Inspection of Connecting Rod

STARTER MOTOR10-18 TNV IDI Service ManualStarter Motor8. Reinstall the plate onto the intermediate housing and carefully reinstall the armature assemb

Page 149 - Inspection of Tappets

STARTER MOTORTNV IDI Service Manual10-19Starter MotorCheck Pinion Projection Length1. Connect the positive (+) lead from a battery to the “S” terminal

Page 150 - Reconditioning the Crankshaft

STARTER MOTOR10-20 TNV IDI Service ManualStarter Motor5. Install a switch (Figure 10-37, (6)) in a circuit between the battery positive (+) terminal (

Page 151 - Inspection of Camshaft

TNV IDI Service Manual11-1TNV IDI Service Manual Section 11ALTERNATORPageBefore You Begin Servicing ...

Page 152 - Honing and Boring

ALTERNATOR11-2 TNV IDI Service ManualDynamo... 11-20Removal of Dy

Page 153 - Piston Components

ALTERNATORTNV IDI Service Manual11-3Before You Begin ServicingBEFORE YOU BEGIN SERVICINGA WARNINGENTANGLEMENT HAZARD!• Stop the engine before you begi

Page 154 - 80 80

ALTERNATOR11-4 TNV IDI Service ManualBefore You Begin ServicingA WARNINGFUME / BURN HAZARD!• Always read and follow safety related precautions found o

Page 155

ALTERNATORTNV IDI Service Manual11-5Before You Begin ServicingCAUTIONDo not connect a load between alternator terminals L and E. Damage to the alterna

Page 156 - Installation of Crankshaft

ALTERNATOR11-6 TNV IDI Service ManualIntroductionINTRODUCTIONThis section of the Service Manual describes the servicing of the dynamos and alternators

Page 157 - Installation of Pistons

SAFETYTNV IDI Service Manual3-9Safety PrecautionsA WARNINGEXPOSURE HAZARD!• Wear personal protective equipment such as gloves, work shoes, eye and hea

Page 158

ALTERNATORTNV IDI Service Manual11-7Dynamo SpecificationsDYNAMO SPECIFICATIONSYanmar Part Number 119910-77200Nominal Output 20 AmpsWeight 3.97 lb (1.8

Page 159

ALTERNATOR11-8 TNV IDI Service ManualAlternator TroubleshootingALTERNATOR TROUBLESHOOTINGTurn key switch ON.Does battery indicator turn ON?At idle, do

Page 160 - Installation of Timing Gears

ALTERNATORTNV IDI Service Manual11-9Alternator ComponentsALTERNATOR COMPONENTSYanmar Part No. 129423-77200 alternator is used in this section to show

Page 161 - Final Assembly of Engine

ALTERNATOR11-10 TNV IDI Service ManualAlternator Wiring DiagramALTERNATOR WIRING DIAGRAM1–Key Switch2 – Charge Lamp (3.4 Watts Max.)3–Load4–Battery5 –

Page 162 - FUEL SYSTEM

ALTERNATORTNV IDI Service Manual11-11Alternator Standard OutputALTERNATOR STANDARD OUTPUT Figure 11-3Alternator RPM (x10³ min¯¹)13.5 Volts, Constant A

Page 163

ALTERNATOR11-12 TNV IDI Service ManualAlternatorALTERNATOR Removal of Alternator1. Disconnect the electrical wires from the alternator.2. Loosen the V

Page 164

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

Page 165

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

Page 166

ALTERNATORTNV IDI Service Manual11-15Alternator3. Position the stator assembly (Figure 11-13, (1)) on the front frame housing studs.4. Lubricate the s

Page 167 - 0000146en

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

Page 168 - FUEL SYSTEM SPECIFICATIONS

SAFETY3-10 TNV IDI Service ManualSafety PrecautionsA WARNINGHIGH-PRESSURE HAZARD!• Avoid skin contact with the high-pressure diesel fuel spray caused

Page 169

ALTERNATORTNV IDI Service Manual11-17Dynamo Component LocationDYNAMO COMPONENT LOCATIONYanmar Part No. 171301-77201 dynamo is used in this section to

Page 170 - FUEL SYSTEM DIAGRAM

ALTERNATOR11-18 TNV IDI Service ManualDynamo Wiring DiagramDYNAMO WIRING DIAGRAMFigure 11-211–Dynamo2 – Current Limiter Assembly3–Key Switch4 – Charge

Page 171 - FUEL SYSTEM COMPONENTS

ALTERNATORTNV IDI Service Manual11-19Dynamo Standard OutputDYNAMO STANDARD OUTPUT Figure 11-220002138TNV_IDI_ServiceManual_(3TNV72 for YN only).book

Page 172 - 0000047en

ALTERNATOR11-20 TNV IDI Service ManualTesting of DynamoTESTING OF DYNAMOUse a circuit tester or multimeter to perform the following tests.Testing Stat

Page 173 - Fuel Injection Lines

ALTERNATORTNV IDI Service Manual11-21DynamoDisassembly of Dynamo1. Remove the rear cover (Figure 11-24, (1)).2. Remove the nut (Figure 11-23, (2)), lo

Page 174 - FUEL INJECTION PUMP

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,

Page 175

TNV IDI Service Manual12-1TNV IDI Service Manual Section 12ELECTRIC WIRINGPageElectric Wiring Precautions ...

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Page 177

ELECTRIC WIRINGTNV IDI Service Manual12-3Electric Wiring PrecautionsELECTRIC WIRING PRECAUTIONS Failure to follow these precautions may result in the

Page 178

ELECTRIC WIRING12-4 TNV IDI Service ManualElectric Wire ResistanceELECTRIC WIRE RESISTANCEWiring voltage drop should not exceed 5% [0.05] x 12 Volts =

Page 179

SAFETYTNV IDI Service Manual3-11Safety PrecautionsA WARNINGTo prevent possible eye injury, always wear SAFETY GLASSES while servicing the engine.00000

Page 180 - FUEL INJECTION TIMING

ELECTRIC WIRINGTNV IDI Service Manual12-5Battery Cable ResistanceBATTERY CABLE RESISTANCENote: Total allowable resistance of the complete battery cabl

Page 181

ELECTRIC WIRING12-6 TNV IDI Service ManualElectrical Wire Sizes - Voltage DropELECTRICAL WIRE SIZES - VOLTAGE DROPTotal current on circuit in amps.Len

Page 182

ELECTRIC WIRINGTNV IDI Service Manual12-7Conversion of AWG to European StandardsCONVERSION OF AWG TO EUROPEAN STANDARDSConductor Size (AWG)Conductor D

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ELECTRIC WIRING12-8 TNV IDI Service ManualConversion of AWG to European StandardsThis Page Intentionally Left BlankTNV_IDI_ServiceManual_(3TNV72 for Y

Page 184 - FUEL INJECTORS

TNV IDI Service Manual13-1TNV IDI Service Manual Section 13TROUBLESHOOTINGPageSpecial Service Tools...

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Page 186 - 0000008en

TROUBLESHOOTINGTNV IDI Service Manual13-3Special Service ToolsSPECIAL SERVICE TOOLSCompression Gauge KitFor measuring compression pressureYanmar Part

Page 187

TROUBLESHOOTING13-4 TNV IDI Service ManualTroubleshooting By Measuring Compression PressureTROUBLESHOOTING BY MEASURING COMPRESSION PRESSURECompressio

Page 188 - Injectors

TROUBLESHOOTINGTNV IDI Service Manual13-5Troubleshooting By Measuring Compression PressureStandard Compression PressureEngine compression pressure lis

Page 189

TROUBLESHOOTING13-6 TNV IDI Service ManualQuick Reference Table For TroubleshootingMeasured Value and TroubleshootingWhen the measured compression pre

Page 190 - Reassembly of Fuel Injectors

SAFETY3-12 TNV IDI Service ManualSafety PrecautionsA CAUTIONFLYING OBJECT HAZARD!• ALWAYS wear eye protection when servicing the engine and when using

Page 191

TNV IDI Service Manual13-7Troubleshooting ChartsTNV IDI Service ManualTROUBLESHOOTINGTroubleshooting ChartsTrouble Symptom Starting ProblemInsufficien

Page 192 - COOLING SYSTEM

TROUBLESHOOTING13-8 TNV IDI Service ManualTroubleshooting ChartsThis Page Intentionally Left BlankTNV_IDI_ServiceManual_(3TNV72 for YN only).book 8 ペ

Page 193

TROUBLESHOOTINGTNV IDI Service Manual13-9Troubleshooting ChartsTrouble Symptom Starting ProblemInsufficient Engine OutputPoor Exhaust ColorHigh Knocki

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Page 195 - A CAUTION

TROUBLESHOOTINGTNV IDI Service Manual13-11Troubleshooting ChartsTrouble Symptom Starting ProblemInsufficientEngine OutputPoorExhaustColorHigh Knocking

Page 196 - COOLING SYSTEM DIAGRAM

TROUBLESHOOTING13-12 TNV IDI Service ManualTroubleshooting ChartsThis Page Intentionally Left BlankTNV_IDI_ServiceManual_(3TNV72 for YN only).book 12

Page 197 - COMPONENTS

TROUBLESHOOTINGTNV IDI Service Manual13-13Troubleshooting ChartsTrouble Symptom Starting ProblemInsufficientEngine OutputPoorExhaustColorHigh Knocking

Page 198 - ENGINE COOLANT SYSTEM

TROUBLESHOOTING13-14 TNV IDI Service ManualTroubleshooting ChartsThis Page Intentionally Left BlankTNV_IDI_ServiceManual_(3TNV72 for YN only).book 14

Page 199 - Cleaning and Inspection

TROUBLESHOOTINGTNV IDI Service Manual13-15Troubleshooting ChartsTrouble Symptom Starting ProblemInsufficientEngine OutputPoorExhaustColorHigh Knocking

Page 200

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Page 201 - 0000006en

SAFETYTNV IDI Service Manual3-13Safety PrecautionsCAUTIONMake sure the engine is installed on a level surface. If a continuously running engine is ins

Page 202 - LUBRICATION

TROUBLESHOOTINGTNV IDI Service Manual13-17Troubleshooting ChartsTrouble Symptom Starting ProblemInsufficientEngine OutputPoorExhaustColorHigh Knocking

Page 203 - LUBRICATION SYSTEM

TROUBLESHOOTING13-18 TNV IDI Service ManualTroubleshooting ChartsThis Page Intentionally Left BlankTNV_IDI_ServiceManual_(3TNV72 for YN only).book 18

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TNV IDI Service Manual13-19Electric WiringTNV IDI Service ManualWIRING DIAGRAMELECTRIC WIRINGNote: The following wiring diagram is “representative” of

Page 205 - 0000030en

WIRING DIAGRAM13-20 TNV IDI Service ManualElectric WiringThis Page Intentionally Left BlankTNV_IDI_ServiceManual_(3TNV72 for YN only).book 20 ページ 20

Page 206 - OIL PUMP SERVICE INFORMATION

SAFETY3-14 TNV IDI Service ManualSafety PrecautionsCAUTIONIf any indicator illuminates during engine operation, stop the engine immediately. Determine

Page 207

ii TNV IDI Service ManualThis Service Manual has been developed for the exclusive use of service and repair professionals such as Yanmar authorized Di

Page 208 - LUBRICATION SYSTEM DIAGRAM

SAFETYTNV IDI Service Manual3-15Safety PrecautionsCAUTION• ALWAYS be environmentally responsible. • Follow the guidelines of the EPA or other governme

Page 209 - TROCHOID OIL PUMP

SAFETY3-16 TNV IDI Service ManualSafety PrecautionsCAUTION• NEVER attempt to modify the engine’s design or safety features such as defeating the engin

Page 210 - Disassembly of Oil Pump

SAFETYTNV IDI Service Manual3-17Safety PrecautionsCAUTION• When the engine is operated in dusty conditions, clean the air cleaner element more frequen

Page 211

SAFETY3-18 TNV IDI Service ManualSafety PrecautionsCAUTIONAfter marking the position of the pump drive gear, do not rotate the engine crankshaft. Rota

Page 212 - Reassembly of Oil Pump

SAFETYTNV IDI Service Manual3-19Safety PrecautionsCAUTIONMake sure that the combined total resistance of the battery cable in both directions between

Page 213

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

Page 214 - STARTER MOTOR

TNV IDI Service Manual4-1TNV IDI Service Manual Section 4GENERAL SERVICE INFORMATIONPageComponent Identification...

Page 215

GENERAL SERVICE INFORMATION4-2 TNV IDI Service ManualPrincipal Engine Specifications ... 4-203TNV72

Page 216

GENERAL SERVICE INFORMATIONTNV IDI Service Manual4-3Component IdentificationCOMPONENT IDENTIFICATIONFigure 4-1 shows where major engine components are

Page 217 - 0000056en

GENERAL SERVICE INFORMATION4-4 TNV IDI Service ManualLocation of LabelsLOCATION OF LABELSFigure 4-2 shows the location of regulatory and safety labels

Page 218 - STARTER MOTOR INFORMATION

TNV IDI Service ManualiiiTNV IDI Service ManualTABLE OF CONTENTSPageTable of Contents...

Page 219 - STARTER MOTOR SPECIFICATIONS

GENERAL SERVICE INFORMATIONTNV IDI Service Manual4-5The 97/68/EC Directive Certified EnginesEPA / ARB Labels (Typical)(EPA) Less Than 50 HP SAE (37kW

Page 220 - STARTER MOTOR TROUBLESHOOTING

GENERAL SERVICE INFORMATION4-6 TNV IDI Service ManualFunction of Major Engine ComponentsFUNCTION OF MAJOR ENGINE COMPONENTSComponent FunctionAir Clean

Page 221 - STARTER MOTOR COMPONENTS

GENERAL SERVICE INFORMATIONTNV IDI Service Manual4-7Function of Major Engine ComponentsFuel TankThe fuel tank is a reservoir that holds diesel fuel. W

Page 222

GENERAL SERVICE INFORMATION4-8 TNV IDI Service ManualFunction of Cooling System ComponentsFUNCTION OF COOLING SYSTEM COMPONENTSComponent FunctionCooli

Page 223 - 0000142A

GENERAL SERVICE INFORMATIONTNV IDI Service Manual4-9Diesel FuelDIESEL FUELDiesel Fuel SpecificationsDiesel fuel should comply with the following speci

Page 224 - 0000144A

GENERAL SERVICE INFORMATION4-10 TNV IDI Service ManualDiesel FuelPrecautions and concerns regarding the use of bio-fuels:1. Free methanol in FAME may

Page 225

GENERAL SERVICE INFORMATIONTNV IDI Service Manual4-11Diesel FuelA DANGERFIRE AND EXPLOSION HAZARD!• Diesel fuel is flammable and explosive under certa

Page 226

GENERAL SERVICE INFORMATION4-12 TNV IDI Service ManualDiesel FuelNote that a typical fuel tank is shown. The fuel tank on the equipment being serviced

Page 227

GENERAL SERVICE INFORMATIONTNV IDI Service Manual4-13Engine OilTo prime the fuel system if a mechanical fuel pump is installed:1. Operate the fuel pri

Page 228

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

Page 229

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Page 230 - Reassembly of Starter Motor

GENERAL SERVICE INFORMATIONTNV IDI Service Manual4-15Engine CoolantEngine Oil Capacity (Typical)Note: These are the engine oil capacities associated w

Page 231

GENERAL SERVICE INFORMATION4-16 TNV IDI Service ManualEngine CoolantEngine Coolant SpecificationsUse a Long Life Coolant (LLC) or an Extended Life Coo

Page 232 - No-Load Test

GENERAL SERVICE INFORMATIONTNV IDI Service Manual4-17Engine CoolantFigure 4-71. Check to be sure the radiator drain plug is installed and tightened or

Page 233 - Installation of Starter Motor

GENERAL SERVICE INFORMATION4-18 TNV IDI Service ManualSpecificationsSPECIFICATIONSDescription of Model NumberWhen ordering parts or making an inquiry

Page 234 - ALTERNATOR

GENERAL SERVICE INFORMATIONTNV IDI Service Manual4-19SpecificationsEngine General SpecificationsNote: The information described in Principal Engine Sp

Page 235

GENERAL SERVICE INFORMATION4-20 TNV IDI Service ManualPrincipal Engine SpecificationsPRINCIPAL ENGINE SPECIFICATIONS3TNV72Engine Model 3TNV72Version V

Page 236

GENERAL SERVICE INFORMATIONTNV IDI Service Manual4-21Engine Service InformationENGINE SERVICE INFORMATIONInspection Item Standard LimitIntake / Exhaus

Page 237 - 0000035en

GENERAL SERVICE INFORMATION4-22 TNV IDI Service ManualTightening Torques for Standard Bolts and NutsTIGHTENING TORQUES FOR STANDARD BOLTS AND NUTSUse

Page 238

GENERAL SERVICE INFORMATIONTNV IDI Service Manual4-23Tightening Torques for Standard Bolts and NutsNote: Torque values shown in this manual are for cl

Page 239 - ALTERNATOR SPECIFICATIONS

GENERAL SERVICE INFORMATION4-24 TNV IDI Service ManualAbbreviations and SymbolsABBREVIATIONS AND SYMBOLSAbbreviationsSymbolsA ampereAC alternating cur

Page 240 - DYNAMO SPECIFICATIONS

TNV IDI Service Manual1-1TNV IDI Service Manual Section 1INTRODUCTIONThis Service Manual describes the service procedures for the TNV series indirect

Page 241 - ALTERNATOR TROUBLESHOOTING

GENERAL SERVICE INFORMATIONTNV IDI Service Manual4-25Unit ConversionsUNIT CONVERSIONSUnit PrefixesUnits of LengthUnits of VolumeUnits of MassUnits of

Page 242 - ALTERNATOR COMPONENTS

GENERAL SERVICE INFORMATION4-26 TNV IDI Service ManualUnit ConversionsThis Page Intentionally Left BlankTNV_IDI_ServiceManual_(3TNV72 for YN only).boo

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TNV IDI Service Manual5-1TNV IDI Service Manual Section 5PERIODIC MAINTENANCEPageIntroduction...

Page 244 - Temperature at 77˚F (25˚C)

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Page 245

PERIODIC MAINTENANCETNV IDI Service Manual5-3IntroductionINTRODUCTIONThis section of the Service Manual describes the procedures for proper care and m

Page 246

PERIODIC MAINTENANCE5-4 TNV IDI Service ManualIntroductionA DANGERFIRE AND EXPLOSION HAZARD!• Diesel fuel is flammable and explosive under certain con

Page 247 - Reassembly of Alternator

PERIODIC MAINTENANCETNV IDI Service Manual5-5IntroductionA DANGERFIRE AND EXPLOSION HAZARD!• Diesel fuel is flammable and explosive under certain cond

Page 248

PERIODIC MAINTENANCE5-6 TNV IDI Service ManualIntroductionA DANGERFIRE AND EXPLOSION HAZARD!• Diesel fuel is flammable and explosive under certain con

Page 249 - Installation of Alternator

PERIODIC MAINTENANCETNV IDI Service Manual5-7IntroductionA WARNINGEXHAUST HAZARD!• NEVER operate the engine in an enclosed area such as a garage, tunn

Page 250 - DYNAMO COMPONENT LOCATION

PERIODIC MAINTENANCE5-8 TNV IDI Service ManualIntroductionA WARNINGBURN HAZARD!• Keep your hands and other body parts away from hot engine surfaces su

Page 251 - OPERATION OF DYNAMO

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Page 252 - DYNAMO STANDARD OUTPUT

PERIODIC MAINTENANCETNV IDI Service Manual5-9IntroductionA WARNINGBURN HAZARD!• Batteries contain sulfuric acid. NEVER allow battery fluid to come in

Page 253

PERIODIC MAINTENANCE5-10 TNV IDI Service ManualIntroductionA WARNINGBURN HAZARD!• If you must drain the engine oil while it is still hot, stay clear o

Page 254 - Reassembly of Dynamo

PERIODIC MAINTENANCETNV IDI Service Manual5-11IntroductionCAUTION• Only use diesel fuels recommended by Yanmar for the best engine performance, to pre

Page 255 - Installation of Dynamo

PERIODIC MAINTENANCE5-12 TNV IDI Service ManualIntroductionCAUTIONObserve the following environmental operating conditions to maintain engine performa

Page 256 - ELECTRIC WIRING

PERIODIC MAINTENANCETNV IDI Service Manual5-13IntroductionCAUTIONNew Engine Break-in:• On the initial engine start-up, allow the engine to idle for ap

Page 257

PERIODIC MAINTENANCE5-14 TNV IDI Service ManualIntroductionCAUTIONNEVER use high-pressure water or compressed air at greater than 28 psi (193 kPa; 19

Page 258 - 0000059en

PERIODIC MAINTENANCETNV IDI Service Manual5-15PrecautionsPRECAUTIONSThe Importance of Periodic MaintenanceEngine deterioration and wear occurs in prop

Page 259 - ELECTRIC WIRE RESISTANCE

PERIODIC MAINTENANCE5-16 TNV IDI Service ManualPeriodic Maintenance SchedulePerform periodic maintenance procedures in an open, level area free from t

Page 260 - BATTERY CABLE RESISTANCE

PERIODIC MAINTENANCETNV IDI Service Manual5-17Periodic Maintenance ScheduleNote: These procedures are considered normal maintenance and are performed

Page 261

PERIODIC MAINTENANCE5-18 TNV IDI Service ManualPeriodic Maintenance ProceduresPERIODIC MAINTENANCE PROCEDURESPerform the following maintenance after t

Page 262

TNV IDI Service Manual2-1TNV IDI Service Manual Section 2YANMAR WARRANTIESPageYanmar Limited Warranty...

Page 263

PERIODIC MAINTENANCETNV IDI Service Manual5-19Periodic Maintenance ProceduresThe engine oil on a new engine becomes contaminated from the initial brea

Page 264 - TROUBLESHOOTING

PERIODIC MAINTENANCE5-20 TNV IDI Service ManualPeriodic Maintenance ProceduresCheck and adjust the V-belt tension (deflection) as follows:1. Press the

Page 265

PERIODIC MAINTENANCETNV IDI Service Manual5-21Periodic Maintenance Procedures3. Tighten the V-belt to the proper tension. There must be clearance (Fig

Page 266

PERIODIC MAINTENANCE5-22 TNV IDI Service ManualPeriodic Maintenance ProceduresDrain the fuel filter / water separator whenever there are contaminants,

Page 267

PERIODIC MAINTENANCETNV IDI Service Manual5-23Periodic Maintenance Procedures8. Put the float (Figure 5-7, (7)) and retaining spring (Figure 5-7, (6))

Page 268 - Standard Compression Pressure

PERIODIC MAINTENANCE5-24 TNV IDI Service ManualPeriodic Maintenance Procedures• When the amount of fluid nears the lower limit (Figure 5-8, (1)), fill

Page 269 - FOR TROUBLESHOOTING

PERIODIC MAINTENANCETNV IDI Service Manual5-25Periodic Maintenance ProceduresPerform the following maintenance every 250 hours of operation.• Drain Fu

Page 270 - Troubleshooting Charts

PERIODIC MAINTENANCE5-26 TNV IDI Service ManualPeriodic Maintenance Procedures4. Drain the tank until clean diesel fuel with no water or dirt flows ou

Page 271

PERIODIC MAINTENANCETNV IDI Service Manual5-27Periodic Maintenance ProceduresCheck and Clean Radiator FinsDirt and dust adhering to the radiator fins

Page 272

PERIODIC MAINTENANCE5-28 TNV IDI Service ManualPeriodic Maintenance Procedures2. If the governor lever does not make proper contact with the high idle

Page 273

YANMAR WARRANTIES2-2 TNV IDI Service ManualThis Page Intentionally Left BlankTNV_IDI_ServiceManual_(3TNV72 for YN only).book 2 ページ 2007年11月29日 木曜日 午

Page 274

PERIODIC MAINTENANCETNV IDI Service Manual5-29Periodic Maintenance ProceduresFigure 5-133. Blow air (Figure 5-12, (3)) through the element from the in

Page 275

PERIODIC MAINTENANCE5-30 TNV IDI Service ManualPeriodic Maintenance ProceduresPerform the following maintenance every 500 hours of operation.• Replace

Page 276

PERIODIC MAINTENANCETNV IDI Service Manual5-31Periodic Maintenance ProceduresReplace the fuel filter at specified intervals to prevent contaminants fr

Page 277

PERIODIC MAINTENANCE5-32 TNV IDI Service ManualPeriodic Maintenance ProceduresClean Fuel Filter / Water SeparatorPeriodically clean the fuel filter /

Page 278

PERIODIC MAINTENANCETNV IDI Service Manual5-33Periodic Maintenance Procedures3. Turn the retaining ring (Figure 5-15, (4)) to the left (Figure 5-15, (

Page 279

PERIODIC MAINTENANCE5-34 TNV IDI Service ManualPeriodic Maintenance ProceduresEngine coolant contaminated with rust or scale reduces the cooling effec

Page 280

PERIODIC MAINTENANCETNV IDI Service Manual5-35Periodic Maintenance ProceduresFigure 5-164. Drain the coolant from the engine block. Remove the coolant

Page 281

PERIODIC MAINTENANCE5-36 TNV IDI Service ManualPeriodic Maintenance ProceduresPerform the following maintenance every 1500 hours of operation.• Inspec

Page 282

PERIODIC MAINTENANCETNV IDI Service Manual5-37Periodic Maintenance Procedures2. Remove the diaphragm cover, spring, diaphragm plate (Figure 5-18, (5))

Page 283 - WIRING DIAGRAM

PERIODIC MAINTENANCE5-38 TNV IDI Service ManualPeriodic Maintenance ProceduresThis Page Intentionally Left BlankTNV_IDI_ServiceManual_(3TNV72 for YN o

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