Yanmar 2TNV70 Service Manual
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Yanmar 2TNV70 Service Manual

Yanmar 2TNV70 Service Manual

Industrial engines
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Summary of Contents for Yanmar 2TNV70

  • Page 1 SERVICE MANUAL INDUSTRIAL ENGINES 2TNV70 3TNV70 3TNV76...
  • Page 2 No part of this publication may be reproduced or used in any form by any means - graphic, electronic, or mechanical, including photocopying, recording, taping, or informa- tion storage and retrieval systems - without the written permission of YANMAR CO., LTD. Date of issue:...

  • Page 3: Table Of Contents

    TABLE OF TNV DI Service Manual CONTENTS Page Introduction ..................1-1 Yanmar Warranties................2-1 Safety....................3-1 General Service Information .............. 4-1 Periodic Maintenance ................. 5-1 Engine ....................6-1 Fuel System ..................7-1 Cooling System ................... 8-1 Lubrication System ................9-1 Starter Motor..................
  • Page 4 TABLE OF CONTENTS This Page Intentionally Left Blank TNV DI Service Manual...
  • Page 5 Refer to the documentation supplied by the optional equipment manufacturer for specific service instructions. Yanmar products are continuously undergoing improvement. This Service Manual might not address possible field modifications to the equipment. Contact an authorized Yanmar industrial engine dealer or distributor for answers to any questions relating to field modifications.
  • Page 6 INTRODUCTION This Page Intentionally Left Blank TNV IDI Service Manual...
  • Page 7 Warranty Modifications: ............2-5 Questions: ................. 2-5 Retail Purchaser Registration............ 2-5 Emission System Warranty ............. 2-6 Yanmar Co., Ltd. Limited Emission Control System Warranty - USA Only..................2-6 Your Warranty Rights and Obligations: ........2-6 Manufacturer’s Warranty Period:..........2-6 Warranty Coverage: ..............2-7 Warranted Parts: ...............

  • Page 8: Tnv Idi Service Manual

    YANMAR WARRANTIES This Page Intentionally Left Blank TNV IDI Service Manual...

  • Page 9: Yanmar Limited Warranty

    What the Engine Owner Must Do: If you believe your Yanmar engine has experienced a failure due to a defect in material and / or workmanship, you must contact an authorized Yanmar industrial engine dealer or distributor within thirty (30) days of discovering the failure.

  • Page 10: To Locate An Authorized Yanmar Industrial Engine Dealer Or Distributor

    • “Click” on the desired country or Associate company to locate your nearest authorized Yanmar industrial engine dealer or distributor. • You may also contact Yanmar by clicking on “Inquiry” in the website heading and typing in your question or comment.

  • Page 11: Warranty Limitations

    As soon as possible after the purchase of your engine, Yanmar highly recommends that you use the following website to register your purchase: http://www.yanmar.co.jp If it is not possible to access the web site, please contact the nearest Yanmar dealer or distributor. TNV IDI Service Manual...

  • Page 12: Emission System Warranty

    The California Air Resources Board (CARB), the Environmental Protection Agency (EPA) and Yanmar Co., Ltd. hereafter referred to as Yanmar, are pleased to explain the emission control system warranty on your industrial compression-ignition engine. In California, model year 2000 or later off-road compression- ignition engines must be designed, built and equipped to meet the State’s stringent anti-smog standards.

  • Page 13: Warranty Coverage

    Warranty Coverage: This warranty is transferable to each subsequent purchaser for the duration of the warranty period. Repair or replacement of any warranted part will be performed at an authorized Yanmar industrial engine dealer or distributor. Warranted parts not scheduled for replacement as required maintenance in the Operation Manual shall be warranted for the warranty period.

  • Page 14: Exclusions

    You are responsible for initiating the warranty process. You must present your engine to a Yanmar dealer as soon as a problem exists. The warranty repairs should be completed by the dealer as expeditiously as possible.

  • Page 15: Safety

    Section 3 TNV IDI Service Manual SAFETY Page Safety Statements ................3-3 Safety Precautions ................3-4 TNV IDI Service Manual...
  • Page 16 SAFETY This Page Intentionally Left Blank TNV IDI Service Manual...

  • Page 17: Periodic Maintenance

    Safety Statements SAFETY SAFETY STATEMENTS DANGER Yanmar is concerned for your safety and your Danger (the word “DANGER” is in white letters machine’s condition. Safety statements are one of with a red rectangle behind it) - indicates an the primary ways to call your attention to the...

  • Page 18: Fuel System

    SAFETY Safety Precautions SAFETY PRECAUTIONS DANGER DANGER FIRE AND EXPLOSION HAZARD! • Diesel fuel is flammable and SCALD HAZARD! explosive under certain • NEVER remove the radiator cap if conditions. the engine is hot. Steam and hot engine coolant will spurt out and seriously burn you.
  • Page 19 Safety Precautions SAFETY DANGER DANGER FIRE AND EXPLOSION HAZARD! CRUSH HAZARD! • When you need to transport an • Be sure to place the diesel fuel container on engine for repair, have a helper the ground when transferring the diesel fuel assist you to attach it to a hoist from the pump to the container.
  • Page 20 SAFETY Safety Precautions WARNING WARNING EXHAUST HAZARD! EXPOSURE HAZARD! • NEVER operate the engine in an • Wear personal protective enclosed area such as a garage, equipment such as gloves, work tunnel, underground room, shoes, eye and hearing protection manhole or ship’s hold without as required by the task at hand.
  • Page 21 • NEVER check for a fuel leak with your hands. hair, and keep your hands, other body parts ALWAYS use a piece of wood or cardboard. and clothing away from moving / rotating Have your authorized Yanmar industrial parts. engine dealer or distributor repair the damage.

  • Page 22: Starter Motor

    NOTICE engine coolant. If • Only use diesel fuels recommended by Yanmar contact with the eyes for the best engine performance, to prevent or skin should occur, engine damage and to comply with EPA / ARB flush eyes and wash warranty requirements.
  • Page 23 • The standard range of ambient temperatures for time (less than three minutes) at an angle greater the normal operation of Yanmar engines is from than (IDI = 30°, DI = 35°) in any direction, engine oil +5°F (-15°C) to +113°F (+45°C).
  • Page 24 NOTICE NEVER engage the starter motor while the engine is running. This may damage the starter motor For maximum engine life, Yanmar recommends that pinion and / or ring gear. when shutting the engine down, you allow the engine to idle, without load, for five minutes. This...

  • Page 25: General Service Information

    • NEVER operate the engine with the air cleaner the idle speed limit screws require adjustment, see element(s) removed. This may allow foreign your authorized Yanmar industrial engine dealer or material to enter the engine and damage it. distributor. NOTICE...
  • Page 26 SAFETY Safety Precautions NOTICE NOTICE It is important to perform daily checks. Do not operate the engine if the alternator is producing unusual sounds. Damage to the Periodic maintenance prevents unexpected alternator will result. downtime, reduces the number of accidents due to poor machine performance and helps extend the NOTICE life of the engine.

  • Page 27: Electric Wiring

    Do not use high-pressure wash engine’s life. Any alterations to this engine may or submerse the starter motor in water. void its warranty. Be sure to use Yanmar genuine NOTICE replacement parts. Use a specialized battery charger to recharge a NOTICE battery with a voltage of 8 volts or less.
  • Page 28 Keep the tool in constant • Tampering with or removing these devices may up-and-down motion. void the “Yanmar Limited Warranty.” NOTICE NOTICE Any part which is found defective as a result of The fuel return line is a one-piece assembly. Use inspection or any part whose measured value does care not to bend or twist the fuel return line.
  • Page 29 • Machine safety signs and labels are additional reminders for safe operating and maintenance techniques. • See your authorized Yanmar industrial engine dealer or distributor for additional training. TNV IDI Service Manual 3-15...
  • Page 30 SAFETY Safety Precautions This Page Intentionally Left Blank 3-16 TNV IDI Service Manual...

  • Page 31: Cooling System

    Section 4 TNV IDI Service Manual GENERAL SERVICE INFORMATION Page Component Identification..............4-3 Location of Labels ................4-4 EPA / ARB Emission Control Regulations - USA Only....4-4 Emission Control Labels..............4-4 EPA / CARB Labels (Typical) ............ 4-5 The 97/68/EC Directive Certified Engines........4-5 Engine Family..................
  • Page 32 GENERAL SERVICE INFORMATION Principal Engine Specifications ............4-22 2TNV70 ..................4-22 3TNV70 ..................4-23 3TNV76 ..................4-24 Engine Service Information ............4-25 Tightening Torques for Standard Bolts and Nuts ......4-26 Abbreviations and Symbols............4-28 Abbreviations................4-28 Symbols..................4-28 Unit Conversions ................4-29 Unit Prefixes ................

  • Page 33: Tnv Idi Service Manual

    Component Identification GENERAL SERVICE INFORMATION COMPONENT IDENTIFICATION Figure 4-1 shows where major engine components are located. (21) (19) (20) (18) (17) (16) (25) (15) (14) (24) (13) (12) (23) (11) (22) 0000583A (10) 1 – Lifting Eye (Flywheel End) 14 – Governor Lever 2 –...

  • Page 34: Location Of Labels

    EPA / ARB EMISSION CONTROL REGULATIONS - USA ONLY Figure 4-2 shows the location of regulatory and safety labels on Yanmar TNV series engines. Yanmar TNV engines meet Environmental Protection Agency (EPA) (U. S. Federal) emission control standards as well as the California Air Resources Board (ARB, California) regulations.

  • Page 35: Epa / Carb Labels (Typical)

    Engine Family designation: 1.33 Method of air aspiration Number of cylinders Engine speed specifications Displacement (liter) Non-road / Off-road engine Yanmar Diesel *2009 Model Year A*: 2010 B : 2011 C : 2012 TNV IDI Service Manual...

  • Page 36: Function Of Major Engine Components

    It is not part of the Air Cleaner basic engine package as shipped from the Yanmar factory. Periodic replacement of the air cleaner filter element is necessary. See the Periodic Maintenance Schedule on page 5-5 for the replacement frequency.
  • Page 37 Function of Major Engine Components GENERAL SERVICE INFORMATION Component Function The fuel tank is a reservoir that holds diesel fuel. When fuel leaves the fuel tank it goes to the fuel filter / water separator. Next, fuel is pumped to the fuel filter by the fuel pump. Next the fuel goes to the fuel injection pump.

  • Page 38: Function Of Cooling System Components

    The application specific items are not part of the basic engine package as shipped from the Yanmar factory. The engine cooling fan is driven by a V-belt which is powered by the Engine Cooling Fan crankshaft V-pulley.

  • Page 39: Diesel Fuel

    / or cause engine damage. • Fuel additives are not recommended. Some fuel additives may cause poor engine performance. Consult your Yanmar representative for more information. • Ash content not to exceed 0.01% by volume. • Carbon residue content not to exceed 0.35% by volume.
  • Page 40 "B 20" (a blend of 20 % 2. Approved Engines biodiesel and 80 % conventional diesel). Raw All of the following engine series of Yanmar can pressed vegetable oils are not considered to be be operated with biodiesel with concentrations biodiesel.
  • Page 41 (a) The original service interval of the below stated whichever comes first. services as indicated in the respective Yanmar (g) Before a long-term storage without operating engine standard operation manual, the...
  • Page 42 GENERAL SERVICE INFORMATION Diesel Fuel KIT PARTS LIST FOR B20 (TNV IDI Engines) KIT-V270BGS-BI KIT-V370BGS-BI 2TNV70 3TNV70, 76 D19446-59250 D19746-59250 Length 2000 2000 FUEL OIL TANK - Part No. 129946-59050 129946-59050 / - FUEL OIL TANK Part Name FO-T CMP...

  • Page 43: Filling The Fuel Tank

    GENERAL SERVICE INFORMATION Filling the Fuel Tank NOTICE DANGER • Only use diesel fuels recommended by Yanmar for the best engine performance, to prevent FIRE AND EXPLOSION HAZARD! engine damage and to comply with EPA / ARB • Diesel fuel is flammable and warranty requirements.

  • Page 44: Priming The Fuel System

    GENERAL SERVICE INFORMATION Diesel Fuel Priming the Fuel System 1. Operate the fuel priming lever (Figure 4-4, (1)) several times until the fuel filter cup DANGER (Figure 4-4, (2)) is filled with fuel. 2. NEVER use the starter motor to prime the fuel FIRE AND EXPLOSION HAZARD! system.

  • Page 45: Engine Oil

    / or shorten Viscosity Chart (Figure 4-5). engine life. 4. Yanmar does not recommend the use of • Prevent dirt and debris from contaminating the engine oil “additives.” engine oil. Carefully clean the oil cap / dipstick...

  • Page 46: Adding Engine Oil

    Refer to the operation manual provided by the driven machine manufacturer for the actual engine oil capacity of your machine. The following are the engine oil capacities for various Yanmar TNV engines: Dipstick Upper Engine Model Limit/ Lower Limit 2TNV70(VM) 1.9 / 1.3 qt...

  • Page 47: Engine Coolant

    Engine Coolant GENERAL SERVICE INFORMATION ENGINE COOLANT NOTICE DANGER • Only use the engine coolant specified. Other engine coolants may affect warranty coverage, SCALD HAZARD! cause an internal buildup of rust and scale and / or shorten engine life. • NEVER remove the radiator cap if the engine is hot.

  • Page 48: Engine Coolant Specifications

    2. Mix coolant and water per the mixing instructions on the coolant container. 3. Water quality is important to coolant performance. Yanmar recommends that soft, distilled, or demineralized water be used to mix with coolants. 4. NEVER mix extended or long life coolants and conventional (green) coolants.

  • Page 49: Engine Coolant Capacity (Typical)

    Refer to the operation manual provided by the driven machine manufacturer for actual engine coolant capacity on your machine. The following are the engine coolant capacities for various Yanmar TNV engines. Engine Coolant Engine Model Capacity 2TNV70 0.6 qt (0.6 L)

  • Page 50: Specifications

    GENERAL SERVICE INFORMATION Specifications SPECIFICATIONS Description of Model Number 0000 Customer Code Rated rpm Turbocharged (No symbol indicates naturally aspirated) Cylinder Bore (mm) Engine Series No. of Cylinders When ordering parts or making an inquiry about the engine you are working on, be sure to include the complete model and serial numbers as shown on the engine nameplate.

  • Page 51: Engine General Specifications

    Hg), Relative humidity 30% • Fuel Temperature at Fuel Injector Pump Inlet: 104°F (40°C) • With Cooling Fan, Air Cleaner, Muffler: Yanmar Standard • After Engine Break-In Period; Output Allowable Deviation: ± 3% • 1 PS = 0.7355 kW •...
  • Page 52 GENERAL SERVICE INFORMATION Principal Engine Specifications PRINCIPAL ENGINE SPECIFICATIONS 2TNV70 Engine Model 2TNV70 Version Type Vertical In-line Diesel Engine Combustion System Ball-Type Swirl Chamber Aspiration Natural No. of Cylinders Bore × Stroke 2.756 x 2.913 in. (70 × 74 mm) Displacement 34.777 cu in.
  • Page 53 Principal Engine Specifications GENERAL SERVICE INFORMATION 3TNV70 Engine Model 3TNV70 Version Type Vertical In-line Diesel Engine Combustion System Ball-Type Swirl Chamber Aspiration Natural No. of Cylinders Bore × Stroke 2.756 x 2.913 in. (70 × 74 mm) Displacement 52.105 cu in. (0.854 L) 1500 1800 3000...
  • Page 54 GENERAL SERVICE INFORMATION Principal Engine Specifications 3TNV76 Engine Model 3TNV76 Version Type Vertical In-line Diesel Engine Combustion System Ball-Type Swirl Chamber Aspiration Natural No. of Cylinders Bore × Stroke 2.992 x 3.228 in. (76 × 82 mm) Displacement 68.029 cu in. (1.115 L) 1500 1800 3000 3600 (min...
  • Page 55 Fuel Injection Pressure (11.8 - 12.8 MPa; 120 - 130 kgf / cm²) 470 ± 15 psi 370 ± 15 psi 2TNV70 (3.24 ± 0.1MPa; (2.55 ± 0.1 MPa; 3TNV70 33 ± 1 kgf / cm²) 26 ± 1 kgf / cm²) Compression Pressure at 250 rpm (250 min¯¹)

  • Page 56: Tightening Torques For Standard Bolts And Nuts

    GENERAL SERVICE INFORMATION Tightening Torques for Standard Bolts and Nuts TIGHTENING TORQUES FOR STANDARD BOLTS AND NUTS Use the correct amount of torque when you tighten NOTICE fasteners on the machine. Applying excessive torque may damage the fastener or component and The tightening torque in the Standard Torque not enough torque may cause a leak or component Chart in General Service Information should be...
  • Page 57 Tightening Torques for Standard Bolts and Nuts GENERAL SERVICE INFORMATION Nominal Thread Item x Pitch Tightening Torque Remarks Diameter 112 - 148 in·lb (12.7 - 16.7 N·m; 1.3 - 1.7 kgf·m) 173 - 225 in·lb (19.6 - 18.734 N·m,; 2.0 - 3.5 kgf·m) 18 - 25 ft·lb Pipe Joint Bolt (24.5 - 34.3 N·m;...

  • Page 58: Abbreviations And Symbols

    GENERAL SERVICE INFORMATION Abbreviations and Symbols ABBREVIATIONS AND SYMBOLS Abbreviations liter L/hr liter per hour ampere pound alternating current pond force Association des Constructeurs milliliter ACEA Européens d’Automobilies millimeter ampere-hour megapascal approx. approximately millivolt American Petroleum Institute newton Air Resources Board N·m newton meter ATDC...

  • Page 59: Unit Conversions

    Unit Conversions GENERAL SERVICE INFORMATION UNIT CONVERSIONS Units of Torque ft·lb 1.3558 = N·m Unit Prefixes ft·lb 0.1383 = kgf·m in·lb 0.1130 = N·m Prefix Symbol Power in·lb 0.0115 = kgf·m mega x 1,000,000 kgf·m 7.2330 = ft·lb kilo x 1,000 kgf·m 86.8000 = in·lb...
  • Page 60 GENERAL SERVICE INFORMATION Unit Conversions This Page Intentionally Left Blank 4-30 TNV IDI Service Manual...
  • Page 61 Precautions ..................5-4 The Importance of Periodic Maintenance........5-4 Performing Periodic Maintenance ..........5-4 Yanmar Replacement Parts ............5-4 Required EPA / ARB Maintenance - USA Only......5-4 EPA / ARB Installation Requirements - USA Only ....5-4 Periodic Maintenance Schedule............5-5 Periodic Maintenance Procedures ..........
  • Page 62 PERIODIC MAINTENANCE This Page Intentionally Left Blank TNV IDI Service Manual...

  • Page 63: Introduction

    Introduction PERIODIC MAINTENANCE INTRODUCTION This section of the Service Manual describes the procedures for proper care and maintenance of the engine. TNV IDI Service Manual...

  • Page 64: Precautions

    Maximum Exhaust Gas Restriction shall be: enclosed area. All internal combustion engines create carbon monoxide gas during • 2TNV70: 0.85 psi (5.88 kPa; 600 mm Aq) or less operation. Accumulation of this gas within an • 3TNV70 and 3TNV76: 1.70 psi (11.76 kPa; 1200 enclosure could cause illness or even death.

  • Page 65: Periodic Maintenance Schedule

    See Yanmar Warranties section. Consult your authorized Yanmar dealer or distributor for assistance when checking items marked with a . TNV IDI Service Manual...
  • Page 66 PERIODIC MAINTENANCE Periodic Maintenance Schedule :Check :Replace : Contact your authorized Yanmar industrial engine dealer or distributor Periodic Maintenance Interval Every Every Every Every Every Every System Check Item Daily 1000 1500 2000 hours hours hours hours hours hours Check and Refill Engine Coolant...

  • Page 67: Periodic Maintenance Procedures

    Periodic Maintenance Procedures PERIODIC MAINTENANCE PERIODIC MAINTENANCE NOTICE PROCEDURES • ALWAYS be environmentally responsible. After Initial 50 Hours of Operation Perform the following maintenance after the initial 50 hours of operation. • Follow the guidelines of the EPA or other governmental agencies for the proper disposal of •...
  • Page 68 (Figure 5-2, (3)) until it contacts the mounting surface. Tighten to 14 - 17 ft·lb (19.6 - 23.5 N·m, 2.0 - 2.4 kgf·m or one additional turn using the filter wrench. Applicable Engine Oil Filter Part No. 2TNV70 0000587B 3TNV70 119305-35151 Figure 5-1 3TNV76 6.
  • Page 69 Periodic Maintenance Procedures PERIODIC MAINTENANCE Check and Adjust Cooling Fan V-Belt The V-belt will slip if it does not have the proper tension. This will prevent the alternator from generating sufficient power. Also, the engine will overheat due to the engine coolant pump pulley slipping.

  • Page 70: Every 50 Hours Of Operation

    PERIODIC MAINTENANCE Periodic Maintenance Procedures 3. Tighten the V-belt to the proper tension. There Every 50 Hours of Operation must be clearance (Figure 5-6, (1)) between the V-belt and the bottom of the pulley groove. If there is no clearance (Figure 5-6, (2)) between After you complete the initial 50 hour maintenance the V-belt and the bottom of the pulley groove, procedures, perform the following procedures every...
  • Page 71 Periodic Maintenance Procedures PERIODIC MAINTENANCE The cup of the separator is made from NOTICE semi-transparent material. In the cup is a red-colored float ring. The float ring will rise to the • ALWAYS be environmentally surface of the water to show how much needs to be responsible.
  • Page 72 PERIODIC MAINTENANCE Periodic Maintenance Procedures 8. Put the float (Figure 5-7, (7)) and retaining WARNING spring (Figure 5-7, (6)) inside the cup. BURN HAZARD! 9. Reinstall the cup to the mounting flange (Figure 5-7, (8)) and turn the retaining ring •...

  • Page 73: Every 250 Hours Of Operation

    • If the engine still will not start after charging, have your authorized Yanmar industrial engine dealer • When you remove any fuel system component or distributor check the battery and the engine’s to perform maintenance (such as changing starting system.
  • Page 74 PERIODIC MAINTENANCE Periodic Maintenance Procedures 6. Check for fuel leaks. NOTICE Replace Engine Oil and Engine Oil • ALWAYS be environmentally Filter responsible. NOTICE • Only use the engine oil specified. Other engine oils may affect warranty coverage, cause internal •...
  • Page 75 If fins, apply detergent, thoroughly clean and rinse the idle speed limit screws require adjustment, see with tap water. your authorized Yanmar industrial engine dealer or NOTICE distributor. NEVER use high-pressure water or compressed air at greater than 28 psi (193 kPa;...
  • Page 76 PERIODIC MAINTENANCE Periodic Maintenance Procedures Clean Air Cleaner Element 2. If the governor lever does not make proper contact with the high idle stop or the low idle Note that a typical air cleaner is shown in speed limit screw, adjust the throttle cable or Figure 5-12 and Figure 5-13 for illustrative linkage as necessary.
  • Page 77 Periodic Maintenance Procedures PERIODIC MAINTENANCE 5. Clean inside of the air cleaner cover. 6. Install the element into the air cleaner case (Figure 5-12, (4)). Note: If there is a red line (Figure 5-13, (2)) in the outer element, reinsert the element until the overlap position of red line and end face of the air cleaner case.

  • Page 78: Every 500 Hours Of Operation

    (Figure 5-12, (4)). NOTICE If the air cleaner is equipped with a double element, For maximum engine life, Yanmar recommends that only remove and replace the inner element when shutting the engine down, you allow the (Figure 5-13, (1)) if the engine lacks power or the engine to idle, without load, for five minutes.
  • Page 79 • Follow the guidelines of the EPA or other governmental agencies for the proper disposal of Applicable Fuel Filter Part No. hazardous materials such as engine oil, diesel fuel and engine coolant. Consult the local 2TNV70 authorities or reclamation facility. 3TNV70 119810-55650 3TNV76 •...
  • Page 80 7. Replace the element with a new one. governmental agencies for the proper disposal of hazardous materials such as engine oil, diesel Applicable Mesh Filter Part No. fuel and engine coolant. Consult the local 2TNV70 authorities or reclamation facility. 3TNV70 171081-55910 3TNV76 •...

  • Page 81: Every 1000 Hours Of Operation

    Periodic Maintenance Procedures PERIODIC MAINTENANCE 10. Put the float (Figure 5-15, (7)) and retaining Every 1000 Hours of Operation spring (Figure 5-15, (6)) inside the cup. 11. Reinstall the cup to the mounting flange Perform the following maintenance every 1000 (Figure 5-15, (9)) and turn the retaining ring hours of operation.
  • Page 82 PERIODIC MAINTENANCE Periodic Maintenance Procedures 3. Remove the drain plug or open the drain cock CAUTION (Figure 5-16, (2)) at the lower position of the radiator and drain the engine coolant. COOLANT HAZARD! • Wear eye protection and rubber gloves when you handle long life or extended life engine coolant.

  • Page 83: Every 1500 Hours Of Operation

    1500 hours. See Testing of Fuel Injectors on page 7-23. This procedure is considered normal maintenance and is performed at the owner’s expense. This procedure is not covered by the Yanmar Limited Warranty. TNV IDI Service Manual 5-23...
  • Page 84 PERIODIC MAINTENANCE Periodic Maintenance Procedures Inspect Crankcase Breather System 2. Remove the diaphragm cover, spring, diaphragm plate (Figure 5-18, (5)) and Proper operation of the crankcase breather system diaphragm. is required to maintain the emission requirements 3. Inspect the diaphragm for tears. Inspect the of the engine.

  • Page 85: Every 2000 Hours Of Operation

    Periodic Maintenance Procedures PERIODIC MAINTENANCE Every 2000 Hours of Operation Perform the following maintenance every 2000 hours of operation. • Check and Replace Fuel Hoses and Engine Coolant Hoses • Lap the Intake and Exhaust Valves Check and Replace Fuel Hoses and Engine Coolant Hoses NOTICE •...
  • Page 86 PERIODIC MAINTENANCE Periodic Maintenance Procedures This Page Intentionally Left Blank 5-26 TNV IDI Service Manual...
  • Page 87 Section 6 TNV IDI Service Manual ENGINE Page Before You Begin Servicing ............6-3 Introduction..................6-4 Cylinder Head Specifications ............6-4 Adjustment Specifications ............6-4 Cylinder Head................6-4 Intake / Exhaust Valve and Guide ..........6-5 Push Rod................... 6-5 Valve Spring ................6-5 Rocker Arm and Shaft ...............
  • Page 88 ENGINE Cylinder Head ................6-18 Cylinder Head Components ............. 6-18 Disassembly of Cylinder Head ..........6-19 Cleaning of Cylinder Head Components ........6-23 Inspection of Cylinder Head Components........ 6-23 Reassembly of Cylinder Head..........6-27 Measuring and Adjusting Valve Clearance ......6-32 Cylinder Block ................

  • Page 89: Before You Begin Servicing

    Before You Begin Servicing ENGINE BEFORE YOU BEGIN SERVICING Before performing any service procedures within this section, read the following safety information and review the Safety section on page 3-1. TNV IDI Service Manual...

  • Page 90: Introduction

    ENGINE Introduction INTRODUCTION This section of the Service Manual describes servicing of the engine. CYLINDER HEAD SPECIFICATIONS Adjustment Specifications Model Valve Clearance 0.006 - 0.010 in. (0.15 - 0.25 mm) Cylinder Head Reference Inspection Item Standard Limit Page 0.0020 in. (0.05 mm) or 0.0059 in.

  • Page 91: Intake / Exhaust Valve And Guide

    Cylinder Head Specifications ENGINE Intake / Exhaust Valve and Guide Reference Inspection Item Standard Limit Page 0.2362 - 0.2367 in. 0.2394 in. Guide Inside Diameter (6.000 - 6.012 mm) (6.08 mm) Valve Stem Outside 0.2346 - 0.2352 in. 0.2323 in. Diameter (5.960 - 5.975 mm) (5.90 mm)

  • Page 92: Rocker Arm And Shaft

    ENGINE Camshaft and Timing Gear Train Specifications Rocker Arm and Shaft Reference Inspection Item Standard Limit Page 0.4724 - 0.4732 in. 0.4752 in. Arm Shaft Hole Diameter (12.000 - 12.020 mm) (12.07 mm) Inspection of 0.4711 - 0.4718 in. 0.4701 in. Shaft Outside Diameter Rocker Arm (11.966 - 11.984 mm)

  • Page 93: Idler Gear Shaft And Bushing

    0.0008 in. Bend (1/2 the dial gauge reading) (0.02 mm) 0.0004 in.(0.01 mm) 0.0008 in. Roundness or less (0.02 mm) 2TNV70 1.4942 - 1.4946 in. 1.4725 in. 3TNV70 (37.952 - 37.962 mm) (37.402 mm) Journal Outside Diameter 1.6517 - 1.6520 in.

  • Page 94: Crankshaft Reconditioning

    ENGINE Crankshaft and Pistons Specifications (Crankshaft Cont.) Reference Inspection Item Standard Limit Page Journal Outside 1.8485 - 1.8489 in. 1.8465 in. Diameter (46.952 - 46.962 mm) (46.902 mm) Bearing Inside 1.8497 - 1.8505 in. Diameter (46.982 - 47.002 mm) Inspection of Main Bearing Journal Crankshaft Bearing Insert...

  • Page 95: Piston

    Crankshaft and Pistons Specifications ENGINE Piston Reference Inspection Item Standard Limit Page 2.7543 - 2.7555 in. 2.7526 in. 2/3TNV70 (69.960 - 69.990 mm) (69.915 mm) Piston Outside Diameter (Measure at 90° to the Piston Pin.) 2.9904 - 2.9915 in. 2.9886 in. 3TNV76 (75.955 - 75.985 mm) (75.910 mm)

  • Page 96: Piston Ring

    (1.660 mm) See Inspection 0.0579 - 0.0587 in. 0.0571 in. Ring Width of Pistons, (1.470 - 1.490 mm) (1.950 mm) 2TNV70 Second Ring Piston Rings 3TNV70 0.0020 - 0.0035 in. 0.0083 in. and Wrist Pin on Side Clearance (0.050 - 0.090 mm) (0.210 mm)

  • Page 97: Connecting Rod

    Crankshaft and Pistons Specifications ENGINE (Piston Ring Cont.) Reference Model Inspection Item Standard Limit Page 0.0610 - 0.0618 in. Ring Groove Width (1.550 - 1.570 mm) 0.0579 - 0.0587 in. 0.0571 in. Ring Width (1.470 - 1.490 mm) (1.450 mm) Top Ring 0.0024 - 0.0039 in.

  • Page 98: Tappet

    (0.040 - 0.094 mm) (0.134 mm) CYLINDER BLOCK SPECIFICATIONS Cylinder Block Reference Inspection Item Model Standard Limit Page 2TNV70 2.7563 - 2.7567 in. 2.7638 in. 3TNV70 (70.010 - 70.020 mm) (70.200 mm) Cylinder Inside Diameter Inspection of 2.9925 - 2.9929 in. 3.0000 in.

  • Page 99: Special Torque Chart

    Special Torque Chart ENGINE SPECIAL TORQUE CHART Torque for Bolts and Nuts Lubricating Oil Thread Diameter and Application (Thread Component Tightening Torque Reference Page Pitch Portion and Seat Surface) 40 - 43 ft·lb See Reassembly of Cylinder Head Bolts M9 x 1.25 mm (53.9 - 57.9 N·m;...

  • Page 100: Special Service Tools

    ENGINE Special Service Tools SPECIAL SERVICE TOOLS Note: Tools not having Yanmar part numbers must be acquired locally. Tool Name Applicable Model and Tool Size Illustration Valve Guide Tool 0.787 in. 2.953 in. 0.217 in. 0.374 in. (For Removing (20 mm) (75 mm) (5.5 mm)
  • Page 101 Flex-Hone 129400-92410 (70 - 76 mm) (For Preparing Cylinder Walls) 0000823 Piston Ring Yanmar Part No. 955500-02476 Compressor The Piston Insertion Tool is Applicable for (For Installing 2.362 - 4.921 in. (60 - 125 mm) Diameter Pistons Pistons) 0000824 Piston Ring Tool...

  • Page 102: Measuring Instruments

    ENGINE Measuring Instruments MEASURING INSTRUMENTS Instrument Name Application Illustration Dial Indicator (Available Locally) Measure shaft bend and end play 0000831 Measurements of narrow or deep portions that Test Indicator (Available Locally) cannot be measured by dial gauge 0000832 Magnetic Stand (Available Locally) For holding the dial gauge when measuring.
  • Page 103 Measuring Instruments ENGINE (Measuring instruments Cont.) Instrument Name Application Illustration V-Block (Available Locally) For measuring shaft bend 0000839 For tightening nuts and bolts to the specified Torque Wrench (Available Locally) torque 0000840 For measuring piston ring gaps, piston ring Feeler Gauge (Available Locally) clearance, and valve adjustment clearance 0000841 TNV IDI Service Manual...

  • Page 104: Cylinder Head

    ENGINE Cylinder Head CYLINDER HEAD Cylinder Head Components (30) (29) (28) (27) (26) (24) (25) (23) (11) (22) (10) (12) (13) (14) (21) (15) (16) (17) (18) (20) (19) 0002130 Figure 6-1 6-18 TNV IDI Service Manual...

  • Page 105: Disassembly Of Cylinder Head

    Cylinder Head ENGINE Disassembly of Cylinder Head 1 – Baffle Plate 2 – Oil Fill Cap Prepare a clean, flat working surface on a 3 – Valve Cover / Intake Manifold workbench large enough to accommodate the 4 – Gasket cylinder head assembly.
  • Page 106 ENGINE Cylinder Head Removal of Intake Manifold / Valve Cover 1. Remove the intake manifold bolts (Figure 6-2, (1)) and valve cover bolts (Figure 6-2, (2)). 2. Remove the valve cover / intake manifold (Figure 6-2, (3)). Discard gasket (Figure 6-2, (4)). Figure 6-3 Removal of Rocker Arm Assembly 1.
  • Page 107 Cylinder Head ENGINE Disassembly of Rocker Arm Assembly Removal of Cylinder Head 1. Remove the rocker arm shaft alignment set 1. Loosen the cylinder head bolts following the screw (Figure 6-5, (6)) from support sequence shown in Figure 6-6. (Figure 6-5, (5)). 0002148 1 –...
  • Page 108 ENGINE Cylinder Head Removal of Intake / Exhaust Valves 8. Turn the cylinder head so the exhaust port side faces down. Remove the intake and exhaust 1. Put the cylinder head on the work bench with valves (Figure 6-9, (6)) from the cylinder head. the combustion side down (Figure 6-8).

  • Page 109: Cleaning Of Cylinder Head Components

    Cylinder Head ENGINE Cleaning of Cylinder Head IMPORTANT Mark all valve train components so they can Components be installed in their original locations. WARNING Note: Record all measurements taken during inspection. FUME / BURN HAZARD! • Always read and Inspection of Push Rods follow safety related Push Rod Bend precautions found on...
  • Page 110 ENGINE Cylinder Head Inspection of Rocker Arm Assembly Inspection of Valve Guides Visually inspect the valve guides for distortions, Rocker Arm Shaft Hole Diameter scoring or other damage. Use a telescoping gauge and micrometer to measure the inside diameter of all the rocker arm Note: Measure valve guides while they are support brackets and the rocker arms installed in cylinder head.
  • Page 111 Cylinder Head ENGINE If distortion exceeds the service limit, resurface or Valve Recession replace the cylinder head. Remove only enough Note: The valve guides must be installed to material to make the cylinder head flat, but do not perform this check. remove more than 0.008 in.
  • Page 112 ENGINE Cylinder Head Valve Face and Valve Seat Always check the clearance between the valve and 150° 40° valve guide before grinding or lapping the valve seats. See Intake / Exhaust Valve and Guide on page 6-5 for the service limit. If the clearance exceeds the limit, replace the valve and / or valve guide to bring the clearance within the limit.

  • Page 113: Reassembly Of Cylinder Head

    Cylinder Head ENGINE Squareness Reassembly of Cylinder Head Use a flat surface and a square to check each Use new gaskets, O-rings and seals on reassembly spring for squareness (Figure 6-22). See Valve of cylinder head. Spring on page 6-5 for the service limit. IMPORTANT Liberally oil all components during assembly to prevent premature wear or...
  • Page 114 (Figure 6-26, (4)). Ensure they are installed in the correct locations. Marking Engine Model Intake Exhaust 2TNV70, 3TNV70, White (Seal Black (Seal 3TNV76 Spring) Spring) 0001874 Figure 6-27 1.
  • Page 115 Cylinder Head ENGINE 0002151 Figure 6-28 0002150 Figure 6-29 5. Put the cylinder head on the workbench with the combustion side down to install the valve 3. Lightly oil the threads of the cylinder head bolts springs. Reinstall the valve spring (Figure 6-29, (1)).
  • Page 116 ENGINE Cylinder Head 4. Insert the push rods in their respective Note: On 3-cylinder models, the set screw is positions. located in the center support. On 2-cylinder models, the set screw is Reassembly of Rocker Arm Assembly located in the front (cooling fan) end support.
  • Page 117 Cylinder Head ENGINE Reassembly of Intake Manifold / Valve Cover 1. Reinstall the glow plugs (Figure 6-33, (1)) and tighten to specification. Reinstall the electrical harness (Figure 6-33, (2)). 0002131 Figure 6-34 0002146 5. Reinstall the exhaust manifold using a new gasket.

  • Page 118: Measuring And Adjusting Valve Clearance

    ENGINE Cylinder Head Measuring and Adjusting Valve • If there is no valve clearance, and the piston is at TDC of the compression stroke, extreme wear or Clearance damage to the cylinder head or valves may be Measure and adjust while the engine is cold. possible.
  • Page 119 Cylinder Head ENGINE 6. Insert a feeler gauge of the correct thickness (Figure 6-37, (1)) between rocker arm and valve cap. Turn the valve adjustment screw to adjust the valve clearance so there is a slight “drag” on the feeler gauge when sliding it between the rocker arm and valve cap.

  • Page 120: Cylinder Block

    ENGINE Cylinder Block CYLINDER BLOCK Crankshaft and Camshaft Components 0002180 Figure 6-38 6-34 TNV IDI Service Manual...

  • Page 121: Disassembly Of Cylinder Block Components

    Cylinder Block ENGINE Disassembly of Cylinder Block 1 – Cylinder Block 2 – Camshaft Bushing Components 3 – Gear Case 4 – Dowel (2 used) Prepare a clean, flat working surface on a 5 – O-Ring workbench large enough to accommodate the 6 –...

  • Page 122: Disassembly Of Camshaft And Timing Components

    ENGINE Cylinder Block 5. Remove the engine from the machine. Mount the engine to a suitable engine repair stand having adequate weight capacity. 6. Clean the engine by washing with solvent, air or steam cleaning. Carefully operate to prevent any foreign matter or fluids from entering the engine, fuel system, or electrical components remaining on the engine.
  • Page 123 Cylinder Block ENGINE Measuring Idler Gear-to-Crankshaft Gear Removal of Timing Gears Backlash 1. Remove the bolts from the idler gear shaft (Figure 6-42, (1)). Remove the idler gear shaft, 1. Install a dial indicator as shown in Figure 6-41. idler gear (Figure 6-42, (3)) and bushing (Figure 6-42, (2)).
  • Page 124 ENGINE Cylinder Block 4. Do not remove the fuel injection pump drive Removal of Oil Pan gear unless absolutely necessary due to 1. Invert the engine (oil pan up) on the engine damage to the gear or pump. Do not loosen or stand.
  • Page 125 Cylinder Block ENGINE Removal of Camshaft 2. Remove two bolts (Figure 6-48, (3)) retaining the camshaft thrust plate (Figure 6-48, (1)). 1. Before removing the camshaft, check the camshaft end play. • Method A: Install a dial indicator (Figure 6-46, (1)) on the cylinder block. Move the camshaft and gear (Figure 6-46, (2)) in and out to measure the end play.

  • Page 126: Disassembly Of Crankshaft And Piston Components

    ENGINE Cylinder Block Removal of Gear Case Disassembly of Crankshaft and Piston Components Note: The camshaft must be removed before the gear case can be removed. See Removal of Camshaft on page 6-39. Removal of Pistons 1. Remove bolts (Figure 6-49, (4)). NOTICE Note: It is not necessary to remove the fuel Keep the piston pin parts, piston assemblies, and...
  • Page 127 Cylinder Block ENGINE 1. Using a feeler gauge, measure the connecting IMPORTANT rod side clearance (Figure 6-50). See Do not rotate crankshaft when using Connecting Rod on page 6-11 for the standard PLASTIGAGE. A false reading may result. limit. If the measurement is out of specification, 5.
  • Page 128 ENGINE Cylinder Block 11. Remove the bearing inserts (Figure 6-53, (2)). 12. Remove the compression rings (Figure 6-53, (3)) from the piston using a piston ring expander. 13. Remove the oil ring (Figure 6-53, (4)) from the piston using a piston ring expander. 0002188 Figure 6-54 3.
  • Page 129 Cylinder Block ENGINE • Method B: Use a feeler gauge to measure the clearance (Figure 6-56, (3)) between the thrust bearing (Figure 6-56, (1)) and crankshaft (Figure 6-56, (2)). Record the measurement. See Thrust Bearing on page 6-8 for the service limit. 0001899 Figure 6-58 9.

  • Page 130: Inspection Of Crankshaft And Camshaft Components

    (Figure 6-61, (1)). 2. Apply a continuous bead of ThreeBond Liquid Gasket No. 1212, Yanmar Part No. 977770-01212 to the outside diameter of a new oil seal (Figure 6-61, (2)).
  • Page 131 20 mm (0.75 in.) Figure 6-62 5. Apply a continuous bead of ThreeBond Liquid 20 mm Gasket No. 1212, Yanmar Part No. (0.75 in.) 0000230B 977770-01212 to the outside diameter of a new oil seal (Figure 6-62, (1)). Figure 6-63 6.
  • Page 132 ENGINE Cylinder Block Inspection of Pistons, Piston Rings and 5. Subtract the piston measurement from the greatest measurement acquired during cylinder Wrist Pin inspection (see Inspection of Cylinder Block on Notes: page 6-45) to obtain piston-to-cylinder clearance. Record the measurements. See •...
  • Page 133 Cylinder Block ENGINE • On an engine with high hours, the pistons rings should be replaced and the cylinder honed (See Honing and Boring on page 6-51) or replaced. The piston should be replaced as necessary. 9. Place each compression piston ring in the groove as shown (Figure 6-67).
  • Page 134 ENGINE Cylinder Block 3. Place the connecting rod bearing inserts into the connecting rod and connecting rod cap. Install the rod cap and tighten the bolts to the specified torque. 4. Measure the inside diameter. Record the measurements. See Crankshaft on page 6-7 for specifications.

  • Page 135: Reconditioning The Crankshaft

    Cylinder Block ENGINE Inspection of Crankshaft 1. Put the crankshaft end journals (Figure 6-74, (4)) on V-blocks. 2. Place a dial indicator (Figure 6-74, (3)) on a center main bearing surface. 0001733A Figure 6-75 Reconditioning the Crankshaft If any of the crankshaft journals do not meet the 0000232A specifications, it may be possible to grind any or all Figure 6-74...
  • Page 136 ENGINE Cylinder Block 0001712A Figure 6-78 0000234A Figure 6-76 4. Measure the diameter of the gear end (Figure 6-79, (1)), intermediate Item Finishing Precision (Figure 6-79, (2)), and flywheel end Connecting Rod Journal 1.6418 - 1.6422 in. (Figure 6-79, (3)) bearing journals. Record the Undersize Finished Size (41.702 - 41.712 mm) measurements.

  • Page 137: Honing And Boring

    Cylinder Block ENGINE Inspection of Camshaft Bushing and Bores Honing and Boring 1. Measure the I.D. of the front bushing and the Pistons must move freely in the cylinders while remaining bores in the cylinder block. Record maintaining adequate compression and oil sealing. the measurements.

  • Page 138: Reassembly Of Crankshaft And Piston Components

    ENGINE Cylinder Block • When honing is completed, wash the cylinder NOTICE block with hot water and soap. The cylinder wall is adequately cleaned when a white rag wiped Do not allow the honing tool to operate in one in cylinder comes out clean. Use brushes to position for any length of time.
  • Page 139 Cylinder Block ENGINE Reassembly of Pistons Note: The actual appearance of the match marks will vary but they will always be in 1. Select the parts needed to assemble the piston the same locations. and connecting rod for one cylinder. 2.
  • Page 140 ENGINE Cylinder Block 0001705A 0000227A Figure 6-86 1 – Fuel Injection Pump Side of Engine Note: Reinstall the top and second piston rings 2 – Piston Identification Mark 3 – Embossed Mark on Connecting Rod with the stamped “makers mark” 4 –...
  • Page 141 Cylinder Block ENGINE 7. Reinstall the oil ring expander (Figure 6-88, (4)). Install the oil ring (Figure 6-88, (3)) with the end gap at 180° from the expander end gap. 8. Reinstall the second compression ring (Figure 6-88, (2)). This ring is identified by its dark color and tapered face profile.
  • Page 142 6-13. 6. Rotate the crankshaft to ensure it turns freely. 7. Apply ThreeBond Liquid Gasket No. 1212, Yanmar Part No. 977770-01212 to the mounting flange of the flywheel housing (Figure 6-91, (2)). 8. Align the flywheel housing with the two dowel pins (Figure 6-91, (3)).
  • Page 143 Cylinder Block ENGINE 4. Carefully reinstall the piston and rod assembly. Be sure the match marks (Figure 6-93, (4)) stamped into the connecting rod and cap are facing the fuel injection pump side of the cylinder block, and the piston identification mark (Figure 6-93, (2)) stamped into the piston top is facing the camshaft side (Figure 6-93, (6)).

  • Page 144: Reassembly Of Camshaft And Timing Components

    3. Reinstall and tighten the cap screws 2. Apply a continuous bead of ThreeBond Liquid (Figure 6-96, (3)). Gasket No. 1212, Yanmar Part No. 977770-01212 to the mounting area of the gear case. Be sure to circle each bolt hole.
  • Page 145 Installation of Gear Case Cover 1. Apply a continuous bead of ThreeBond Liquid Gasket No. 1212, Yanmar Part No. 977770-01212 to the mounting area of the gear case cover (Figure 6-99, (1)). Be sure to circle the bolt holes.
  • Page 146 9. Reconnect the battery cables, negative (-) cable last. 2. Apply a continuous bead of ThreeBond Liquid Gasket No. 1212, Yanmar Part No. 977770-01212 to the mounting surface of the oil pan (Figure 6-101, (2)) and crankcase extension (if equipped) (Figure 6-101, (1)). Be sure to circle each bolt hole.
  • Page 147 Section 7 TNV IDI Service Manual FUEL SYSTEM Page Before You Begin Servicing ............7-3 Introduction..................7-4 Fuel Injection Pump..............7-4 Stop Solenoid ................7-5 Fuel System Specifications ............. 7-6 Special Torque Chart..............7-6 Test and Adjustment Specifications .......... 7-6 Special Service Tools..............
  • Page 148 FUEL SYSTEM Disassembly and Inspection of Fuel Injectors ......7-26 Adjusting Fuel Injector Pressure ..........7-27 Reassembly of Fuel Injectors ........... 7-28 Installation of the Fuel Injectors..........7-28 TNV IDI Service Manual...

  • Page 149: Before You Begin Servicing

    Before You Begin Servicing FUEL SYSTEM BEFORE YOU BEGIN SERVICING Before performing any service procedures within this section, read the following safety information and review the Safety section on page 3-1. TNV IDI Service Manual...

  • Page 150: Introduction

    0002238 Figure 7-1 This section of the Service Manual describes the The Yanmar ML Fuel Injection Pump is an in-line procedures necessary to remove, install, and time type pump which consists of a fuel supply plunger the ML fuel injection pump and its associated (Figure 7-1, (1)) for each cylinder, a camshaft system components.

  • Page 151: Stop Solenoid

    • Tampering with or removing these devices may engine to start and run. void the “Yanmar Limited Warranty.” When the starter switch is returned to the ON or RUN position, the “pull coil” no longer receives current and the “hold coil”...

  • Page 152: Fuel System Specifications

    FUEL SYSTEM Fuel System Specifications FUEL SYSTEM SPECIFICATIONS Special Torque Chart Lubricating Oil Application Component Tightening Torque (Thread Portion and Seat Surface) 36.1 - 43.5 ft·lb Fuel Injector (49 - 59 N·m, Not Applied 5.0 - 60 kgf·m) 44 - 51 ft·lb Fuel Pump Drive Gear Nut (59 - 69 N·m;...

  • Page 153: Special Service Tools

    Special Service Tools FUEL SYSTEM SPECIAL SERVICE TOOLS Note: Tools not having Yanmar part numbers must be acquired locally. Tool Name Application Illustration For tightening nuts and bolts to the specified Torque Wrench (Locally Available) torque 0000840 MEASURING INSTRUMENTS Instrument Name...

  • Page 154: Fuel System Diagram

    FUEL SYSTEM Fuel System Diagram FUEL SYSTEM DIAGRAM (10) (12) (11) 0001058A 1 – Diesel Fuel Supply 6 – Fuel Filter 2 – Fuel Filter / Water Separator 7 – Fuel Injection Pump 3 – Mechanical Fuel Pump (Used in place of the 8 –...

  • Page 155: Fuel System Components

    Fuel System Components FUEL SYSTEM FUEL SYSTEM COMPONENTS (19) (18) (17) (16) (15) (11) (14) (10) (13) (12) 0002208 Figure 7-3 TNV IDI Service Manual...

  • Page 156: Fuel Injection Lines

    FUEL SYSTEM Fuel Injection Lines FUEL INJECTION LINES 1 – High-Pressure Fuel Injection Lines 2 – Fuel Return Line Nut 3 – Fuel Return Line Removal of High-Pressure Fuel 4 – Fuel Injector Injection Lines 5 – Gasket 6 – Protector NOTICE 7 –...

  • Page 157: Installation Of High-Pressure Fuel Injection Lines

    Fuel Injection Lines FUEL SYSTEM 6. Finish loosening all the fuel line nuts and Removal of Fuel Return Line remove the high-pressure fuel lines as an 1. Clean the area to keep contaminants from assembly being careful not to bend any of the entering the fuel system.

  • Page 158: Installation Of Fuel Return Line

    FUEL SYSTEM Fuel Injection Pump Installation of Fuel Return Line 1. Install a new copper gasket on each fuel injector. NOTICE The fuel return line is a one-piece assembly. Use care not to bend or twist the fuel return line. 2.
  • Page 159 Fuel Injection Pump FUEL SYSTEM 12. Remove the lube oil line (Figure 7-9, (1)) from the fuel injection pump and cylinder block. IMPORTANT Take care to not damage or bend the lube oil line. 0002239 Figure 7-9 0002210 13. Remove the fuel injection pump drive gear Figure 7-8 access cover (Figure 7-10, (1)) from the gear case cover (Figure 7-10, (2)).
  • Page 160 FUEL SYSTEM Fuel Injection Pump NOTICE After marking the position of the pump drive gear, do not rotate the engine crankshaft. Rotating the crankshaft will cause the fuel injection pump to become misaligned. Figure 7-12 16. Hold the gear train stationary using a large socket wrench on the crankshaft pulley bolt.

  • Page 161: Installation Of Fuel Injection Pump

    Do not rotate the crankshaft with the injection pump removed.. 21. If the fuel injection pump requires servicing, it must be sent to an authorized Yanmar FIE repair facility for repair and calibration, or replaced with a new fuel injection pump.
  • Page 162 FUEL SYSTEM Fuel Injection Pump 4. Align the key on the fuel injection pump shaft with the keyway in the fuel injection pump drive gear hub. Reinstall the fuel injection pump into the fuel injection pump drive gear and gear housing.
  • Page 163 7-6. 12. Apply ThreeBond Liquid Gasket No. 1212, 8. Reconnect the fuel supply and return lines to Yanmar Part No. 977770-01212, or equivalent the fuel injection pump. sealant to the sealing surface of the fuel 9. Reconnect the throttle linkage and stop injection pump drive gear access cover.

  • Page 164: Checking And Adjusting Fuel Injection Timing

    FUEL SYSTEM Checking and Adjusting Fuel Injection Timing 2. Clean the area around the fuel injection pump. Note: The stop solenoid must be removed to allow fuel to flow through the fuel injection pump. 3. Remove two screws (Figure 7-22, (1)). Remove the stop solenoid (Figure 7-22, (2)) and O-ring (Figure 7-22, (3)).
  • Page 165 7. The flywheel shown in (Figure 7-24) is for a injection timing. Yanmar “Standard Specification” IDI engine. Flywheels used on some “OEM Specific” IDI engines may be marked differently. You should contact that specific OEM for information on the identification of the timing marks.
  • Page 166 2000 to 2300 to 2700 to 3000 to 3100 to 3500 to Engine Speed (rpm) 1500 1800 2200 2100 2600 3000 3600 3400 3600 2TNV70 15° 16° 18° 21° 20° 21° Injection 3TNV70 Timing BTDC 16° 15° 16° 18° 21° 20°...
  • Page 167 Checking and Adjusting Fuel Injection Timing FUEL SYSTEM Note: As the injection pump injects fuel to a Note: The fuel injection pump injects fuel to a cylinder only once every two engine cylinder only once every two engine revolutions, it may be necessary to rotate revolutions.

  • Page 168: Adjusting Fuel Injection Timing

    FUEL SYSTEM Fuel Injectors Adjusting Fuel Injection Timing 5. Adjust the position of the fuel injection pump and tighten the fuel injection pump mounting If the timing marks did not align when performing nuts. the Checking Fuel Injection Timing on page 7-18, 6.

  • Page 169: Testing Of Fuel Injectors

    Fuel Injectors FUEL SYSTEM Testing of Fuel Injectors NOTICE Never use a steel wire brush to clean fuel injectors. Damage to the nozzle and other components is likely to result. 1. Thoroughly clean the fuel injector nozzle using clean diesel fuel and a brass wire brush. 2.
  • Page 170 • NEVER check for a fuel leak with your hands. ALWAYS use a piece of wood or cardboard. Have your authorized Yanmar industrial engine dealer or distributor repair the damage. • Failure to comply could result in death or serious injury.
  • Page 171 Fuel Injectors FUEL SYSTEM Fuel Injector Test Results Injection Pattern Pressure Gauge Reading Gauge needle Gauge needle Gauge needle Although the Pressure does not fluctuates around fluctuates around stays at a position gauge needle increase even the valve opening the valve opening near the valve reaches the valve when the tester...

  • Page 172: Disassembly And Inspection Of Fuel Injectors

    FUEL SYSTEM Fuel Injectors Disassembly and Inspection of Fuel 2. Place the fuel injector in a soft-jawed vise with the nozzle pointing up. Injectors 3. Remove the nozzle case nut. NOTICE 4. Carefully remove the injector from the vise. 5. Turn the injector over and remove the nozzle Never use a steel wire brush to clean fuel injectors.

  • Page 173: Adjusting Fuel Injector Pressure

    (Figure 7-35, (4)). 10 – Nozzle Case Nut Figure 7-35 Fuel Injector Shim Kit Yanmar Part No. 129901-53800 The injection pressure will change by (Includes one each of the following shims) approximately 100 - 142 psi (0.69 - 0.98 MPa;...

  • Page 174: Reassembly Of Fuel Injectors

    FUEL SYSTEM Fuel Injectors 4. Retest the fuel injector. See Testing of Fuel Injectors on page 7-23. If the injector cannot be adjusted to the appropriate pressure, discard the fuel injector. Reassembly of Fuel Injectors 1. Secure the injector in a soft-jawed vise with the nozzle end up.
  • Page 175 Section 8 TNV IDI Service Manual COOLING SYSTEM Page Before You Begin Servicing ............8-3 Introduction..................8-4 Cooling System Diagram..............8-4 Engine Coolant Pump Components ..........8-5 Engine Coolant System Check............8-6 Engine Coolant Pump ..............8-6 Disassembly of Engine Coolant Pump ........8-6 Cleaning and Inspection ............
  • Page 176 COOLING SYSTEM This Page Intentionally Left Blank TNV IDI Service Manual...

  • Page 177: Before You Begin Servicing

    Before You Begin Servicing COOLING SYSTEM BEFORE YOU BEGIN SERVICING Before performing any service procedures within this section, read the following safety information and review the Safety section on page 3-1. TNV IDI Service Manual...

  • Page 178: Introduction

    COOLING SYSTEM Introduction INTRODUCTION This section of the Service Manual describes the procedures necessary to service the 2TNV70, 3TNV70 and 3TNV76 engine coolant pump. COOLING SYSTEM DIAGRAM 0002046 1 – Cylinder Head 4 – Radiator 2 – Thermostat 5 – Coolant Recovery Tank 3 –...

  • Page 179: Engine Coolant Pump Components

    Engine Coolant Pump Components COOLING SYSTEM ENGINE COOLANT PUMP COMPONENTS 0001959 1 – Thermostat Cover 7 – Engine Coolant Pump Gasket 2 – Thermostat 8 – V-Belt 3 – Special O-Ring 9 – Engine Coolant Pump V-Pulley 4 – Engine Coolant Pump 10 –...

  • Page 180: Engine Coolant System Check

    COOLING SYSTEM Engine Coolant System Check ENGINE COOLANT SYSTEM 2. Before removing the engine coolant pump or thermostat, it will be necessary to drain the CHECK engine coolant. Drain the coolant into a clean container if the coolant is to be reused. Check the engine coolant system for leakage.

  • Page 181: Cleaning And Inspection

    Engine Coolant Pump COOLING SYSTEM 3. Slowly increase temperature of the fluid using an external heat source. 4. The temperature switch is normal if the continuity light or ohmmeter indicates continuity when the fluid temperature reaches 225°F - 235°F (107°C - 113°C). Thermostat 1.

  • Page 182: Reassembly Of Engine Coolant Pump

    COOLING SYSTEM Engine Coolant Pump NOTICE Use a new special O-ring between the engine coolant pump and the joint. Be sure to use the special O-ring for each engine model. Although the O-ring dimensions are the same as a commercially available O-ring, the material is different.
  • Page 183 Engine Coolant Pump COOLING SYSTEM 0000584 Figure 8-11 9. Reinstall the V-belt. Tighten the V-belt to the proper tension. See Check and Adjust Cooling Fan V-Belt on page 5-15. 10. Reinstall and tighten the drain plug or close the drain cock in the radiator. Reinstall and tighten the engine block drain plug or reconnect the coolant hose at the oil cooler.
  • Page 184 COOLING SYSTEM Engine Coolant Pump This Page Intentionally Left Blank 8-10 TNV IDI Service Manual...

  • Page 185: Lubrication System

    Section 9 TNV IDI Service Manual LUBRICATION SYSTEM Page Before You Begin Servicing ............9-3 Introduction..................9-4 Oil Pump Service Information............9-4 Engine Oil Pressure..............9-4 Outer Rotor Outside Clearance ..........9-4 Outer Rotor Side Clearance ............9-4 Outer Rotor to Inner Rotor Tip Clearance ......... 9-4 Inner Rotor and Gear Boss Clearance ........
  • Page 186 LUBRICATION SYSTEM This Page Intentionally Left Blank TNV IDI Service Manual...

  • Page 187: Before You Begin Servicing

    Before You Begin Servicing LUBRICATION SYSTEM BEFORE YOU BEGIN SERVICING Before performing any service procedures within this section, read the following safety information and review the Safety section on page 3-1. TNV IDI Service Manual...

  • Page 188: Introduction

    Introduction INTRODUCTION This section of the Service Manual describes the procedures necessary to service the 2TNV70, 3TNV70 and 3TNV76 trochoid oil pumps. Note: See Replace Engine Oil and Engine Oil Filter on page 5-14 for engine oil and engine oil filter replacement procedures.

  • Page 189: Inner Rotor And Gear Boss Clearance

    Oil Pump Service Information LUBRICATION SYSTEM Inner Rotor and Gear Boss Clearance Standard Standard Standard Reference Item Parts Clearance Dimension Clearance Page Limit 2.0886 - 2.0925 in. Gear Boss Diameter (53.05 - 53.15 mm) Inside Clearance of 0.012 - 0.020 in. 0.024 in.

  • Page 190: Lubrication System Diagram

    LUBRICATION SYSTEM Lubrication System Diagram LUBRICATION SYSTEM DIAGRAM Oil Filter Bypass Valve Fuel Injection Pump Oil Pressure Switch Cylinder Body - Main Gallery Pressure Regulator Valve Camshaft Crank Idle Gear Oil Pump Bearing Journal Shaft Rocker Arm Crank Pin Oil Suction Pipe Bearing Strainer Rocker Arm...

  • Page 191: Checking Engine Oil Pressure

    Checking Engine Oil Pressure LUBRICATION SYSTEM CHECKING ENGINE OIL TROCHOID OIL PUMP PRESSURE Oil Pump Components Perform an engine oil pressure check if there is any indication of low oil pressure such as the oil pressure indicator is on or the oil pressure gauge indicates low oil pressure.

  • Page 192: Disassembly Of Oil Pump

    LUBRICATION SYSTEM Trochoid Oil Pump Disassembly of Oil Pump NOTICE If the oil pump must be replaced, replace it as an assembly only. Do not replace individual components. 1. Remove the engine cooling fan guard (if equipped), engine cooling fan (Figure 9-4, (1)), spacer (Figure 9-4, (2)), engine coolant pump V-pulley (Figure 9-4, (3)) and V-belt.

  • Page 193: Cleaning And Inspection

    Trochoid Oil Pump LUBRICATION SYSTEM Cleaning and Inspection Outer Rotor to Inner Rotor Tip Clearance Determine the outer rotor to inner rotor tip Wash the oil pump cover, the oil pressure regulator clearance. Insert a feeler gauge between the top of valve, the oil pump cavity and the inner and outer an inner rotor tooth (Figure 9-8, (1)) and the top of rotors.

  • Page 194: Reassembly Of Oil Pump

    LUBRICATION SYSTEM Trochoid Oil Pump Check Inner Rotor and Gear Boss 2. Reinstall the outer rotor in the gear case. The dot mark on the face of the outer rotor must Clearance face up toward the oil pump cover. 3. Reinstall the inner rotor into the gear case cover with the dot mark also facing up.
  • Page 195 Section 10 TNV IDI Service Manual STARTER MOTOR Page Before You Begin Servicing ............10-3 Introduction..................10-4 Starter Motor Information .............. 10-4 Starter Motor Specifications ............10-5 Starter Motor Troubleshooting............10-6 Starter Motor Components ............10-7 Starter Motor ................. 10-8 Removal of Starter Motor ............
  • Page 196 STARTER MOTOR This Page Intentionally Left Blank 10-2 TNV IDI Service Manual...

  • Page 197: Before You Begin Servicing

    Before You Begin Servicing STARTER MOTOR BEFORE YOU BEGIN SERVICING Before performing any service procedures within this section, read the following safety information and review the Safety section on page 3-1. TNV IDI Service Manual 10-3...

  • Page 198: Introduction

    Introduction INTRODUCTION This section of the Service Manual covers the servicing of starter motor. Yanmar Part No. 119717-77010 is standard equipment on 3TNV76 model engines and is used in this section to show the service procedures for a representative starter motor. For specific part detail, see the Yanmar Parts Catalog for the engine being serviced.

  • Page 199: Starter Motor Specifications

    Starter Motor Specifications STARTER MOTOR STARTER MOTOR SPECIFICATIONS Yanmar Part Number 119717-77010 119515-77010 Nominal Output 1.5 hp (1.1 kW) 1.34 hp (1.0 kW) 6.6 lb 6.3 lb Weight (3.0 kg) (2.85 kg) Revolution Direction (As Viewed From Pinion) Clockwise Clockwise...

  • Page 200: Starter Motor Troubleshooting

    STARTER MOTOR Starter Motor Troubleshooting STARTER MOTOR TROUBLESHOOTING 0000102 10-6 TNV IDI Service Manual...

  • Page 201: Starter Motor Components

    Starter Motor Components STARTER MOTOR STARTER MOTOR COMPONENTS (14) (13) (12) (11) (10) (15) (17) (16) (19) (21) (20) (18) (22) (23) (24) 0002486 Figure 10-1 TNV IDI Service Manual 10-7...

  • Page 202: Starter Motor

    STARTER MOTOR Starter Motor STARTER MOTOR 1 – Nut 2 – Needle Bearing 3 – Pinion Housing WARNING 4 – Pinion Retaining Ring 5 – Pinion Stop SHOCK HAZARD! 6 – Pinion • Turn off the battery switch (if 7 – Shift Lever equipped) or disconnect the 8 –...

  • Page 203: Removal Of Starter Motor

    Starter Motor STARTER MOTOR Removal of Starter Motor 3. Remove the two bolts or nuts retaining the solenoid switch assembly (Figure 10-4, (1)) to 1. Disconnect the battery cables at the battery, the pinion housing. Remove the solenoid switch negative (-) cable first. assembly and dust covers (Figure 10-4, (2)).
  • Page 204 STARTER MOTOR Starter Motor 6. Pull the brush springs up using a brush spring 11. Remove the shift lever (Figure 10-8, (2)), pin, puller. On the negative (-) side, bring the brush and spacer (Figure 10-8, (1)). spring into contact with the side of the brushes to hold the brushes clear of the commutator surface.

  • Page 205: Cleaning And Inspection

    Starter Motor STARTER MOTOR 13. Remove the pinion stop (Figure 10-10, (3)), 15. Inspect the intermediate bushing return spring (if equipped), and pinion clutch (Figure 10-11, (2)) and replace if worn or assembly (Figure 10-10, (2)), from the pinion damaged. shaft (Figure 10-10, (1)).
  • Page 206 STARTER MOTOR Starter Motor Measure Commutator Insulation Depth Measure the depth of the insulating material (Figure 10-14, (1)) between commutator segments (Figure 10-14, (2)). If the depth measures less than the limit, use a hacksaw blade (Figure 10-14, (3)) to remove the insulating material until the depth is within the limit.
  • Page 207 Starter Motor STARTER MOTOR Measure Armature and Commutator Run-Out Field Coil Insulation Test Measure the armature core run-out and the Check for continuity between either field coil commutator run-out using a dial indicator terminal and the yoke using a multimeter (Figure 10-17).
  • Page 208 STARTER MOTOR Starter Motor Brush Holder Solenoid Switch If the starter motor becomes wet, replace the Brush Holder Insulation Test solenoid switch even if the solenoid switch Check for continuity between each brush holder assembly function is normal. and the base using a multimeter (Figure 10-21). The multimeter should not indicate continuity.
  • Page 209 Starter Motor STARTER MOTOR Coil Resistance Test See Starter Motor Specifications on page 10-5 for service limit. Contact Continuity Test Depress the plunger at the bottom of the solenoid switch. Check for continuity between the “B” and “M” terminals using a multimeter (Figure 10-25). The multimeter should indicate continuity.

  • Page 210: Reassembly Of Starter Motor

    STARTER MOTOR Starter Motor Reassembly of Starter Motor 1. Apply a appropriate starter bendix grease (obtain locally) to the pinion shaft. 2. Reassemble the reduction gear (Figure 10-28, (4)), pinion shaft (Figure 10-28, (5)), planetary gears (Figure 10-28, (6)), and washers into the intermediate housing (Figure 10-28, (3)).
  • Page 211 Starter Motor STARTER MOTOR 8. Reinstall the plate onto the intermediate 13. Reinstall the two through bolts and tighten housing and carefully reinstall the armature securely. assembly (Figure 10-31, (2)) into the pinion 14. Reinstall the return spring (if equipped) shaft assembly.

  • Page 212: Check Pinion Projection Length

    STARTER MOTOR Starter Motor Check Pinion Projection Length No-Load Test 1. Connect the positive (+) lead from a battery to Test the characteristics of the starter motor by the “S” terminal. performing a no load test. 2. Connect the negative (-) lead to the “M” NOTICE terminal.

  • Page 213: Installation Of Starter Motor

    Starter Motor STARTER MOTOR 5. Install a switch (Figure 10-37, (6)) in a circuit Installation of Starter Motor between the battery positive (+) terminal 1. Reinstall the starter motor to the flywheel (Figure 10-37, (2)) and the starter solenoid housing. switch terminal (Figure 10-37, (8)) on the 2.
  • Page 214 STARTER MOTOR Starter Motor This Page Intentionally Left Blank 10-20 TNV IDI Service Manual...
  • Page 215 Section 11 TNV IDI Service Manual ALTERNATOR Page Before You Begin Servicing ............11-3 Introduction..................11-4 Standard and Optional Dynamo Information ......... 11-4 Standard and Optional Alternator Information....... 11-4 Alternator Specifications..............11-4 Dynamo Specifications..............11-5 Alternator Troubleshooting ............11-6 Alternator Components ..............11-7 Alternator Wiring Diagram .............
  • Page 216 ALTERNATOR Dynamo..................11-18 Removal of Dynamo............... 11-18 Disassembly of Dynamo............11-19 Reassembly of Dynamo ............11-19 Installation of Dynamo............11-20 11-2 TNV IDI Service Manual...

  • Page 217: Before You Begin Servicing

    Before You Begin Servicing ALTERNATOR BEFORE YOU BEGIN SERVICING Before performing any service procedures within this section, read the following safety information and review the Safety section on page 3-1. TNV IDI Service Manual 11-3...

  • Page 218: Introduction

    Introduction INTRODUCTION This section of the Service Manual describes the servicing of the dynamos and alternators. Yanmar Part No. 129423-77200 alternator is used in this section to show the service procedures for the representative alternator. Yanmar Part No. 171301-77201 dynamo is used in this section to show the service procedures for the representative dynamo.

  • Page 219: Dynamo Specifications

    Dynamo Specifications ALTERNATOR DYNAMO SPECIFICATIONS Yanmar Part Number 119910-77200 Nominal Output 20 Amps Weight 3.97 lb (1.8 kg) Revolution Direction (As Viewed From Pulley) Clockwise Rating Continuous Battery Voltage 12 Volts Rated Revolution 3500 rpm Operating Range 1400 - 6600 rpm...

  • Page 220: Alternator Troubleshooting

    ALTERNATOR Alternator Troubleshooting ALTERNATOR TROUBLESHOOTING 11-6 TNV IDI Service Manual...

  • Page 221: Alternator Components

    Alternator Components ALTERNATOR ALTERNATOR COMPONENTS Yanmar Part No. 129423-77200 alternator is used in this section to show the service procedures for the representative alternator. For specific part detail, see the Parts Catalog for the engine you are working on. 0000255 1 –...

  • Page 222: Alternator Wiring Diagram

    ALTERNATOR Alternator Wiring Diagram ALTERNATOR WIRING DIAGRAM 1 – Key Switch 4 – Battery 2 – Charge Lamp (3.4 Watts Max.) 5 – Alternator Assembly 3 – Load 6 – IC Regulator Assembly Figure 11-2 NOTICE NOTICE Do not short-circuit the charging system between Do not remove the positive (+) battery cable from alternator terminals IG and L.

  • Page 223: Alternator Standard Output

    Alternator Standard Output ALTERNATOR ALTERNATOR STANDARD OUTPUT Output Current Cold Alternator RPM (x10³ min¯¹) Figure 11-3 TNV IDI Service Manual 11-9...

  • Page 224: Alternator

    ALTERNATOR Alternator ALTERNATOR WARNING SHOCK HAZARD! • Turn off the battery switch (if equipped) or disconnect the negative battery cable before servicing the electrical system. • Check the electrical harnesses for cracks, 0000264 abrasions, and damaged or corroded Figure 11-4 connectors.
  • Page 225 Alternator ALTERNATOR 2. Remove the three bolts (Figure 11-6, (1)) 5. Remove the bolts retaining the holder retaining the rear cover (Figure 11-6, (2)) to the (Figure 11-7, (2)) to the rear frame housing. rear frame assembly. Remove the holder. 6.

  • Page 226: Reassembly Of Alternator

    ALTERNATOR Alternator 9. Remove the stator assembly Reassembly of Alternator (Figure 11-10, (1)) from the front frame 1. If removed, reinstall the two thrust washers housing. (Figure 11-12, (3)) and bearing cover (Figure 11-12, (2)) in the rear frame housing. Lubricate the outside diameter of a new bearing (Figure 11-12, (1)).
  • Page 227 Alternator ALTERNATOR 3. Position the stator assembly (Figure 11-13, (1)) on the front frame housing studs. 4. Lubricate the shaft of the rotor assembly (Figure 11-14, (1)). Press the rotor assembly into the front frame housing (Figure 11-14, (2)) and rear frame housing (Figure 11-14, (3)). 0000258A Figure 11-16 100266A...

  • Page 228: Installation Of Alternator

    ALTERNATOR Alternator 4. Start the engine. Listen for any unusual sounds from the alternator. NOTICE Do not operate the engine if the alternator is producing unusual sounds. Damage to the alternator will result. 5. Verify that the charge indicator is ON while the engine is operating.

  • Page 229: Dynamo Component Location

    Dynamo Component Location ALTERNATOR DYNAMO COMPONENT LOCATION Yanmar Part No. 171301-77201 dynamo is used in this section to show the service procedures for the representative dynamo. For specific part detail, see the Parts Catalog for the engine you are working on. 0002140...

  • Page 230: Dynamo Wiring Diagram

    ALTERNATOR Dynamo Wiring Diagram DYNAMO WIRING DIAGRAM 0002137 1 – Dynamo 4 – Charge Lamp (3.4 Watts Max.) 2 – Current Limiter Assembly 5 – Battery 3 – Key Switch 6 – Load Figure 11-21 OPERATION OF DYNAMO The dynamo consists of a series of permanent magnets that rotate around a stationary stator coil.

  • Page 231: Dynamo Standard Output

    Dynamo Standard Output ALTERNATOR DYNAMO STANDARD OUTPUT 0002138 Figure 11-22 TNV IDI Service Manual 11-17...

  • Page 232: Testing Of Dynamo

    ALTERNATOR Testing of Dynamo TESTING OF DYNAMO DYNAMO Use a circuit tester or multimeter to perform the Removal of Dynamo following tests. 1. Disconnect the output wire connector from the Testing Stator Coil Continuity dynamo. 1. Disconnect the dynamo output wire connector. 2.
  • Page 233 Dynamo ALTERNATOR Disassembly of Dynamo 1. Remove the rear cover (Figure 11-24, (1)). 2. Remove the nut (Figure 11-23, (2)), lock washer (Figure 11-24, (3)), and flat washer (Figure 11-24, (4)). 0002145 Figure 11-26 Reassembly of Dynamo 1. Reinstall the rear bearing (Figure 11-26, (3)). 0002143 2.
  • Page 234 ALTERNATOR Dynamo 6. Reinstall the flat washer (Figure 11-28, (4)), Installation of Dynamo lock washer (Figure 11-28, (3)), and nut 1. Position the dynamo on the gear case. Loosely (Figure 11-28, (2)). Tighten the nut to the reinstall the nut (Figure 11-29, (2)) on the gear specified torque.
  • Page 235 Section 12 TNV IDI Service Manual ELECTRIC WIRING Page Electric Wiring Precautions ............12-3 Electric Wire Resistance ............... 12-4 Battery Cable Resistance.............. 12-5 Electrical Wire Sizes - Voltage Drop ..........12-6 Conversion of AWG to European Standards......... 12-7 TNV IDI Service Manual 12-1...
  • Page 236 ELECTRIC WIRING This Page Intentionally Left Blank 12-2 TNV IDI Service Manual...

  • Page 237: Electric Wiring Precautions

    Electric Wiring Precautions ELECTRIC WIRING ELECTRIC WIRING NOTICE PRECAUTIONS Reversing the battery cable connections at the battery or on the engine will destroy the SCR diode Failure to follow these precautions may result in the in the current limiter. This will cause the charging failure of an electrical component and the loss of system to malfunction and may cause damage to warranty coverage on that item as well as related...

  • Page 238: Electric Wire Resistance

    ELECTRIC WIRING Electric Wire Resistance ELECTRIC WIRE RESISTANCE Metric Ohms / Foot Nominal mm² 0.009967 0.006340 1.25 0.004359 0.002685 0.001704 0.001073 0.000707 0.000421 0.000270 0.000158 0.000130 0 (1/0) 0.000103 00 (2/0) 0.000087 000 (3/0) 0.000066 0000 (4/0) 0.000051 Wiring voltage drop should not exceed 5% [0.05] x 12 Volts = 0.6 Volts. Voltage Drop = Current [Amps] x Length of Wire [Feet] x Resistance per Foot [Ohms] Example: Current draw of 100 Amps x 3 feet of 4 AWG wire...

  • Page 239: Battery Cable Resistance

    Battery Cable Resistance ELECTRIC WIRING BATTERY CABLE RESISTANCE Maximum Total Battery Cable Length (Positive Cable + Negative Cable + a*) 12V Starter Motor Output mm² Less Than 2.68 hp (2 kW) Greater Than 2.68 hp (2 kW) 4.75 12.6 15.3 0 (1/0) 19.5 11.6...

  • Page 240: Electrical Wire Sizes - Voltage Drop

    ELECTRIC WIRING Electrical Wire Sizes - Voltage Drop ELECTRICAL WIRE SIZES - VOLTAGE DROP Total Length of conductor from source of current to device and back to source (in feet) current on circuit in 100 110 120 130 140 150 160 170 amps.

  • Page 241: Conversion Of Awg To European Standards

    Conversion of AWG to European Standards ELECTRIC WIRING CONVERSION OF AWG TO EUROPEAN STANDARDS Conductor Size Conductor Diameter Conductor Cross-sectional Area (AWG) (mm) 0.455 0.163 0.511 0.205 0.573 0.259 0.644 0.325 0.723 0.412 0.812 0.519 0.992 0.653 1.024 0.823 1.15 1.04 1.29 1.31...
  • Page 242 ELECTRIC WIRING Conversion of AWG to European Standards This Page Intentionally Left Blank 12-8 TNV IDI Service Manual...
  • Page 243 Section 13 TNV IDI Service Manual TROUBLESHOOTING Page Special Service Tools..............13-3 Troubleshooting By Measuring Compression Pressure ....13-4 Compression Pressure Measurement Method ......13-4 Quick Reference Table For Troubleshooting ........ 13-6 TNV IDI Service Manual 13-1...
  • Page 244 TROUBLESHOOTING This Page Intentionally Left Blank 13-2 TNV IDI Service Manual...

  • Page 245: Special Service Tools

    Special Service Tools TROUBLESHOOTING SPECIAL SERVICE TOOLS For measuring compression pressure Compression Gauge Kit Yanmar Part No. TOL-97190080 0000849 TNV IDI Service Manual 13-3...

  • Page 246: Troubleshooting By Measuring Compression Pressure

    TROUBLESHOOTING Troubleshooting By Measuring Compression Pressure TROUBLESHOOTING BY 3. Turn off the fuel supply valve in the fuel supply line. Disconnect the fuel injection stop solenoid MEASURING COMPRESSION at the connector. Crank the engine for a few PRESSURE seconds with the stop solenoid disconnected (no injection state) before installing the Compression pressure drop is one of major causes compression gauge adapter (Figure 13-1, (1)),...
  • Page 247 Compression Pressure at 250 rpm (250 min Engine Model Deviation Between Cylinders Standard Limit 2TNV70 470 ± 15 psi 370 ± 15 psi 3TNV70 (3.24 ± 0.1 MPa; 33 ± 1 kgf/cm²) (2.55 ± 0.1 MPa; 26 ± 1 kgf/cm²) 29 to 43 psi (0.2 to 0.3 MPa;...

  • Page 248: Quick Reference Table For Troubleshooting

    TROUBLESHOOTING Quick Reference Table For Troubleshooting Measured Value and Troubleshooting When the measured compression pressure is below the limit value, inspect each part by referring to the table below. Item Cause Corrective Action Clogged element Clean the element. Air Cleaner Element Broken element Replace the element.
  • Page 249 Troubleshooting Charts TROUBLESHOOTING TNV IDI Service Manual Troubleshooting Charts Insufficient Poor Engine Engine Trouble Symptom Starting Problem Engine Exhaus Engine Oil Surging Coolant Intake Output t Color Engine Exhaust During Starts But Color Work Stops Soon. Exhaust Corrective Action Reference Page Smoke Cause Improper Intake/Exhaust Valve...
  • Page 250 TROUBLESHOOTING Troubleshooting Charts This Page Intentionally Left Blank 13-8 TNV IDI Service Manual...
  • Page 251 Troubleshooting Charts TROUBLESHOOTING Insufficient Poor Engine Engine Trouble Symptom Starting Problem Engine Exhaus Engine Oil Surging Coolant Intake Output t Color Engine Exhaust During Starts But Color Work Stops Soon. Exhaust Corrective Action Reference Page Smoke Cause See “Reassembly of Pistons” on Reverse Assembly of Piston Rings Reassemble Correctly.
  • Page 252 TROUBLESHOOTING Troubleshooting Charts This Page Intentionally Left Blank 13-10 TNV IDI Service Manual...
  • Page 253 Troubleshooting Charts TROUBLESHOOTING Poor Insufficient Exhaus Engine Engine Trouble Symptom Starting Problem Engine Engine Oil Surging Coolant Intake Output Color Engine Starts Exhaust During but Stops Color Work Soon. Corrective Action Reference Page Exhaust Smoke Cause See “Disassembly of Engine Excessive Radiator Cooling Replace Thermostat.
  • Page 254 TROUBLESHOOTING Troubleshooting Charts This Page Intentionally Left Blank 13-12 TNV IDI Service Manual...
  • Page 255 Troubleshooting Charts TROUBLESHOOTING Poor Insufficient Exhaus Engine Engine Trouble Symptom Starting Problem Engine Engine Oil Surging Coolant Intake Output Color Engine Starts Exhaust During but Stops Color Work Soon. Corrective Action Reference Page Exhaust Smoke Cause See “Checking and Adjusting Fuel Too Early Timing of Fuel Injection Pump Check and Adjust.
  • Page 256 TROUBLESHOOTING Troubleshooting Charts This Page Intentionally Left Blank 13-14 TNV IDI Service Manual...
  • Page 257 Troubleshooting Charts TROUBLESHOOTING Poor Insufficient Exhaus Engine Engine Trouble Symptom Starting Problem Engine Engine Oil Surging Coolant Intake Output Color Engine Starts Exhaust During but Stops Color Work Soon. Corrective Action Reference Pages Exhaust Smoke Cause See “Priming the Fuel System” on Air in Fuel System Bleed the Air.
  • Page 258 TROUBLESHOOTING Troubleshooting Charts This Page Intentionally Left Blank 13-16 TNV IDI Service Manual...
  • Page 259 Troubleshooting Charts TROUBLESHOOTING Poor Insufficient Exhaus Engine Engine Trouble Symptom Starting Problem Engine Engine Oil Surging Coolant Intake Output Color Engine Starts Exhaust During but Stops Color Work Soon. Corrective Action Reference Pages Exhaust Smoke Cause See “Clean Air Cleaner Element” Clogged Air Filter Clean Air Filter.
  • Page 260 TROUBLESHOOTING Troubleshooting Charts This Page Intentionally Left Blank 13-18 TNV IDI Service Manual...
  • Page 261 TNV IDI Service Manual ELECTRIC WIRING Note: The following wiring diagram is “representative” of a common installation using a Yanmar engine. The actual installation may be equipped with a variety of electrical components and wiring harnesses. Contact the machine manufacturer for specific information.
  • Page 262 WIRING DIAGRAM Electric Wiring This Page Intentionally Left Blank 13-20 TNV IDI Service Manual...
  • Page 263 SERVICE MANUAL 2TNV70, 3TNV70, 3TNV76 1st edition: August 2007 2nd edition: August 2008 2nd edition 1st rev. : November 2009 2nd edition 2nd rev. : March 2012 Issued by: Yanmar Co., Ltd. Edited by : Yanmar Technical Service Co., Ltd.
  • Page 264 0BTNV-G00202 PRINTED IN JAPAN...

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