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2TNV70
Service manual
Yanmar 2TNV70 Service Manual
Industrial
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Also See for 2TNV70
:
Service manual
(136 pages)
,
Operation manual
(142 pages)
,
Service manual
(264 pages)
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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
Safety Precautions
General Service Information
Component Identification
Location of Labels
EPA/ARB Emission Control Regulations
Emission Control Labels
Function of Major Engine Components
Function of Cooling System Components
Diesel Fuel
Diesel Fuel Specifications
Additional Technical Fuel Requirements
Bio-Diesel Fuels
General Description of Biodiesel
Approved Engines
Approved Fuel
Kit Parts List
Filling the Fuel Tank
Priming the Fuel System
Engine Oil
Engine Oil Specifications
Engine Oil Viscosity
Checking Engine Oil
Adding Engine Oil
Engine Oil Capacity
Engine Coolant
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
Abbreviations
Unit Conversions
Periodic Maintenance
Precautions
Performing Periodic Maintenance
EPA / ARB Installation Requirements
Periodic Maintenance Schedule
Periodic Maintenance Procedures
Replace Engine Oil and Engine Oil Filter
Check and Adjust Cooling Fan V-Belt
Drain Fuel Filter/Water Separator
Check Battery
Drain Fuel Tank
Check and Clean Radiator Fins
Check and Adjust Cooling Fan V-Belts
Clean Air Cleaner Element
Replace Air Cleaner Element
Replace Fuel Filter
Clean Fuel Filter /Water Separator
Adjust Intake/Exhaust Valve Clearance
Inspect, Clean and Test Fuel Injectors
Inspect Crankcase Breather System
Engine
Cylinder Head Specifications
Intake/Exhaust Valve and Guide
Camshaft and Timing Gear Train Specifications
Rocker Arm and Shaft
Camshaft
Crankshaft and Pistons Specifications
Idler Gear Shaft and Bushing
Timing Gear Backlash
Crankshaft
Crankshaft Reconditionining
Piston
Connecting Rod
Connecting Rod Small End
Cylinder Block Specifications
Connecting Rod Big End
Connecting Rod Distortion
Tappet
Special Torque Chart
Torque for Bolts and Nuts
Special Service Tools
Measuring Instruments
Cylinder Head
Cylinder Head Components
Disassembly of Cylinder Head
Removal of Intake Manifold/Valve Cover
Removal of Rocker Arm Assembly
Removal of Glow Plugs
Disassembly of Rocker Arm Assembly
Removal of Cylinder Head
Removal of Intake/Exhaust Valve
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
Rocker Arm Shaft Hole Diameter
Inspection of Valve Guides
Inspection of Cylinder Head
Inspection of Intake and Exhaust Valves
Valve Stem Diameter
Valve Recession
Valve Stem Bend
Valve Face and Valve Seat
Inspection of Valve Springs
Fractures
Corrosion
Reassembly of Cylinder Head
Squareness
Free Length
Reassembly of Valve Guides
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
Removal of Timing Gears
Measuring Idler Gear-To-Camshaft Gear Backlash
Removal of Oil Pan
Removal of Camshaft
Disassembly of Crankshaft and Piston Components
Removal of Gear Case
Removal of Pistons
Removal of Crankshaft
Inspection of Crankshaft and Camshaft Components
Crankshaft Bearing Oil Clearance
Inspection of Cylinder Block
Roundness
Taper
Inspection of Pistons, Piston Rings and Wrist Pin
Inspection of Connecting Rod
Inspection of Tappets
Inspection of Crankshaft
Reconditioning the Crankshaft
Inspection of Camshaft
Inspection of Camshaft Bushing and Bores
Inspection of Idler Gear and Shaft
Honing and Boring
Reassembly of Crankshaft and Piston Components
Reassembly of Pistons
Installation of Crankshaft
Installation of Pistons
Reassembly of Camshaft and Timing Components
Installation of Gear Case
Installation of Camshaft
Installation of Timing Gears
Installation of Gear Case Cover
Installation of Oil Pan
Final Assembly of Engine
Fuel System
Before You Begin Servicing
Fuel System Introduction
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
Checking Fuel Injection Timing
Fuel Injection Timing Chart
Fuel Injectors
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
Cooling System Diagram
Engine Coolant Pump Components
Engine Coolant System Check
Engine Coolant Pump
Disassembly of Engine Coolant Pump
Cleaning and Inspection
Temperature Switch
Radiator Cap
Thermostat
Reassembly of Engine Coolant Pump
Lubrication System
Oil Pump Service Information
Engine Oil Pressure
Outer Rotor Outside Clearance
Outer Rotor Side Clearance
Inner Rotor and Gear Boss Clearance
Lubrication System Diagram
Checking Engine Oil Pressure
Trochoid Oil Pump
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 Inner Rotor and Gear Boss Clearance
Reassembly of Oil Pump
Starter Motor
Starter Motor Information
Starter Motor Specifications
Starter Motor Troubleshooting
Starter Motor Components
Removal of Starter Motor
Disassembly of Starter Motor
Armature
Commutator Surface Inspection
Measure Commutator Outside Diameter
Measure Commutator Insulation Depth
Armature Coil Insulation Test
Armature Coil Continuity Test
Measure Armature and Commutator Run out
Field Coil Insulation Test
Field Coil Continuity Test
Measure Brush Length
Brush Holder
Solenoid Switch
Shunt Coil Continuity Test
Brush Spring Test
Contact Continuity Test
Pinion Clutch Assembly
Reassembly of Starter Motor
Check Pinion Projection Length
No-Load Test
Installation of Starter Motor
Alternator
Standard and Optional Dynamo Information
Standard and Optional Alternator Information
Alternator Specifications
Dynamo Specifications
Alternator Troubleshotoing
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
Removal of Dynamo
Testing Stator Coil Continuity
Testing Stator Coil Short-To-Ground
Disassembly of Dynamo
Reassembly of Dynamo
Installation of Dynamo
Electric Wiring
Electric Wiring Precautions
Electric Wire Resistance
Battery Cable Resistance
Electrical Wire Sizes - Voltage Drop
Conversion of AWG to European Standards
Troubleshooting
Troubleshooting by Measuring Compression Pressure
Standard Compression Pressure
Engine Speed and Compression Pressure
Quick Reference Table for Troubleshooting
Measured Value and Troubleshooting
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Quick Links
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Tightening Torques for Standard Bolts and Nuts
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See also:
Operating Manual
Table of
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Table of Contents
Troubleshooting
Starter motor troubleshooting
200
Troubleshooting
243
Troubleshooting by measuring compression pressure
246
Quick reference table for troubleshooting
248
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This manual is also suitable for:
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3tnv76
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