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Engine
3TNM68
Service manual
Yanmar 3TNM68 Service Manual
Indirect injenction engine
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Table Of Contents
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Contents
Table of Contents
Troubleshooting
Bookmarks
Table of Contents
Table of Contents
Introduction
Safety Contents
Safety Statements
Safety Precautions
General Service Information Contents
Component Identification
Location of Labels
Engine Family
Function of Major Engine Components
Function of Cooling System Components
Diesel Fuel Specifications
Additional Technical Fuel Requirements
Bio-Diesel Fuels
Filling the Fuel Tank
Priming the Fuel System
Engine Oil Specifications
Service Categories
Definitions
Engine Oil Viscosity
Checking Engine Oil
Adding Engine Oil
Engine Coolant
Engine Oil Capacity
Engine Coolant Specifications
Alternative Engine Coolant
Filling Radiator with Engine Coolant
Engine Coolant Capacity
Specifications
Description of Model Number
Engine Speed Specifications
Engine General Specifications
Principal Engine Specifications
Engine Service Information
Tightening Torques for Standard Bolts and Nuts
Abbreviation and Symbols
Unit Conversions
Periodic Maintenance Contents
Precautions
The Importance of Periodic Maintenance
Performing Periodic Maintenance
Periodic Maintenance Schedule
After Initial 50 Hours of Operation
Replace Engine Oil and Engine Oil Filter
Check and Adjust Cooling Fan V-Belt
Every 50 Hours of Operation
Drain Fuel Filter/Water Separator
Check Battery
Every 250 Hours of Operation
Drain Fuel Tank
Check and Clean Radiator Fins
Check and Adjust the Governor Lever and Engine Speed Control
Clean Air Cleaner Element
Every 500 Hours of Operation
Replace Air Cleaner Element
Replace Fuel Filter
Clean Fuel Filter/Water Separator
Every 1000 Hours of Operation
Adjust Intake/Exhaust Valve Clearance
Every 1500 Hours of Operation
Inspect, Clean and Test Fuel Injectors
Inspect Crankcase Breather System
Every 2000 Hours of Operation
Check and Replace Fuel Hoses and Engine Coolant Hoses
Lap the Intake and Exhaust Valves
Engine Contents
Before You Begin Servicing
Cylinder Head Specifications
Adjustment Specifications
Cylinder Head
Intake/Exhaust Valve and Guide
Push Rod
Valve Spring
Camshaft and Timing Gear Train Specifications
Rocker Arm and Shaft
Crankshaft and Pistons Specifications
Idler Gear Shaft and Bushing
Timing Gear Backlash
Crankshaft Reconditioning
Thrust Bearing
Piston
Piston Ring
Connecting Rod Small End
Connecting Rod Big End
Connecting Rod Distortion
Tappet
Cylinder Block Specifications
Special Torque Chart
Tightening Torque for Special Bolts
Special Service Tools
Measuring Instruments
Cylinder Head Components
Disassembly of Cylinder Head
Removal of Intake Manifold/Valve Cover
Removal of Glow Plugs
Removal of Rocker Arm Assembly
Disassembly of Rocker Arm Assembly
Removal of Cylinder Head
Removal of Intake/Exhaust Valves
Removal of Valve Guides
Cleaning of Cylinder Head Components
Inspection of Cylinder Head Components
Inspection of Push Rods
Push Rod Bend
Inspection of Rocker Arm Assembly
Inspection of Valve Guides
Rocker Arm Shaft Hole Diameter
Rocker Arm Shaft Outside Diameter
Inspection of Intake and Exhaust Valves
Valve Stem Diameter
Valve Stem Bend
Valve Recession
Inspection of Valve Springs
Valve Face and Valve Seat
Fractures
Corrosion
Reassembly of Cylinder Head
Reassembly of Valve Guides
Squareness
Free Length
Reassembly of Intake and Exhaust Valves
Reassembly of Rocker Arm Assembly
Reassembly of Intake Manifold/Valve Cover
Measuring and Adjusting Valve Clearance
3-Cylinder Engines
Cylinder Block
Crankshaft and Camshaft Components
Disassembly of Cylinder Block Components
Disassembly of Camshaft and Timing Components
Removal of Timing Gear Case Cover
Checking Timing Gear Backlash
Measuring Idler Gear-To-Crankshaft Gear Backlash
Measuring Idler Gear-To-Camshaft Gear Backlash
Removal of Timing Gears
Removal of Oil Pan
Removal of Camshaft
Disassembly of Crankshaft and Piston Components
Removal of Pistons
Removal of Crankshaft
Inspection of Crankshaft and Camshaft Components
Replacement of Crankshaft Oil Seals
Crankshaft Bearing Oil Clearance
Inspection of Cylinder Block
Inspection of Pistons, Piston Rings and Wrist Pin
Roundness
Taper
Inspection of Connecting Rod
Inspection of Tappets
Inspection of Crankshaft
Reconditioning the Crankshaft
Inspection of Camshaft
Honing and Boring
Inspection of Camshaft Insert Bores
Inspection of Idler Gear and Shaft
Reassembly of Crankshaft and Piston Components
Reassembly of Pistons
Installation of Crankshaft
Installation of Pistons
Reassembly of Camshaft and Timing Components
Installation of Camshaft
Installation of Timing Gears
Installation of Gear Case Cover
Installation of Oil Pan
Final Assembly of Engine
Fuel System Contents
Fuel Injection Pump
Stop Solenoid
Fuel System Specifications
Test and Adjustment Specifications
Fuel System Diagram
Fuel System Components
Fuel Injection Lines
Removal of High-Pressure Fuel Injection Lines
Installation of High-Pressure Fuel Injection Lines
Removal of Fuel Return Line
Installation of Fuel Return Line
Removal of Fuel Injection Pump
Installation of Fuel Injection Pump
Checking and Adjusting Fuel Injection Timing
Removal of Fuel Injectors
Testing of Fuel Injectors
Fuel Injector Test Results
Disassembly and Inspection of Fuel Injectors
Adjusting Fuel Injector Pressure
Reassembly of Fuel Injectors
Installation of the Fuel Injectors
Cooling System Contents
Cooling System Diagram
Engine Coolant Pump Components
Engine Coolant System Check
Disassembly of Engine Coolant Pump
Cleaning and Inspection
Temperature Switch
Thermostat
Radiator Cap
Reassembly of Engine Coolant Pump
Lubrication System Contents
Oil Pump Service Information
Lubrication System Diagram
Trochoid Oil Pump
Components
Disassembly of Oil Pump
Check Outer Rotor Outside Clearance
Outer Rotor to Inner Rotor Tip Clearance
Check Outer Rotor Side Clearance
Check Rotor Shaft Clearance
Reassembly of Oil Pump
Starter Motor Contents
Starter Motor Information
Starter Motor Specifications
Starter Motor Troubleshooting
Starter Motor Components
Starter Motor
Removal of Starter Motor
Disassembly of Starter Motor
Armature
Commutator Surface Inspection
Measure Commutator Outside Diameter
Measure Commutator Insulation Depth
Armature Coil Continuity Test
Armature Coil Insulation Test
Measure Armature and Commutator Run-Out
Field Coil Continuity Test
Fiel Coil Insulation Test
Measure Brush Length
Solenoid Switch
Brush Holder Insulation Test
Brush Spring Test
Shunt Coil Continuity Test
Coil Resistance Test
Contact Continuity Test
Pinion Clutch Assembly Inspection
Reassembly of Starter Motor
Check Pinion Projection Length
No-Load Test
Installation of Starter Motor
Alternator Contents
Standard and Optional Dynamo Information
Standard and Optional Alternator Information
Alternator Specifications
Dynamo Specifications
Alternator Troubleshooting
Alternator Components
Alternator Wiring Diagram
Alternator Standard Output
Removal of Alternator
Disassembly of Alternator
Reassembly of Alternator
Installation of Alternator
Dynamo Component Location
Dynamo Wiring Diagram
Operation of Dynamo
Dynamo Standard Output
Testing of Dynamo
Testing Stator Coil Continuity
Testing Stator Coil Short-To-Ground
Testing Dynamo Regulated Output
Disassembly of Dynamo
Reassembly of Dynamo
Installation of Dynamo
Electric Wiring Contents
Electric Wiring Precautions
Electric Wire Resistance
Battery Cable Resistance
Electrical Wire Sizes - Voltage Drop
Conversion of AWG to European Standards
Troubleshooting Contents
Troubleshooting by Measuring Compression Pressure
Quick Reference Table for Troubleshooting
Standard Compression Pressure
Measured Value and Troubleshooting
Troubleshooting Charts
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Table of
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Table of Contents
Troubleshooting
Starter Motor Troubleshooting
217
Alternator Troubleshooting
238
Troubleshooting Contents
261
Troubleshooting by Measuring Compression Pressure
264
Quick Reference Table for Troubleshooting
265
Troubleshooting Charts
267
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