Yanmar 3TNM68 Manuals

Manuals and User Guides for Yanmar 3TNM68. We have 1 Yanmar 3TNM68 manual available for free PDF download: Service Manual

Yanmar 3TNM68 Service Manual (281 pages)

indirect injenction engine

Brand: Yanmar | Category: Engine | Size: 18.12 MB

Table of Contents
5
Introduction
7
Safety Contents
17
Safety Statements
19
Safety Precautions
20
General Service Information Contents
37
Component Identification
39
Location of Labels
40
Engine Family
42
Function of Major Engine Components
43
Function of Cooling System Components
45
Diesel Fuel Specifications
46
Additional Technical Fuel Requirements
46
Bio-Diesel Fuels
46
Filling the Fuel Tank
47
Priming the Fuel System
49
Engine Oil Specifications
50
Service Categories
50
Definitions
50
Engine Oil Viscosity
51
Checking Engine Oil
51
Adding Engine Oil
51
Engine Coolant
52
Engine Oil Capacity
52
Engine Coolant Specifications
53
Alternative Engine Coolant
53
Filling Radiator with Engine Coolant
53
Engine Coolant Capacity
54
Specifications
55
Description of Model Number
55
Engine Speed Specifications
55
Engine General Specifications
56
Principal Engine Specifications
57
Engine Service Information
59
Tightening Torques for Standard Bolts and Nuts
60
Abbreviation and Symbols
62
Unit Conversions
63
Periodic Maintenance Contents
65
Precautions
79
The Importance of Periodic Maintenance
79
Performing Periodic Maintenance
79
Periodic Maintenance Schedule
80
After Initial 50 Hours of Operation
82
Replace Engine Oil and Engine Oil Filter
82
Check and Adjust Cooling Fan V-Belt
84
Every 50 Hours of Operation
86
Drain Fuel Filter/Water Separator
86
Check Battery
87
Every 250 Hours of Operation
89
Drain Fuel Tank
89
Check and Clean Radiator Fins
91
Check and Adjust the Governor Lever and Engine Speed Control
91
Clean Air Cleaner Element
92
Every 500 Hours of Operation
94
Replace Air Cleaner Element
94
Replace Fuel Filter
94
Clean Fuel Filter/Water Separator
96
Every 1000 Hours of Operation
97
Adjust Intake/Exhaust Valve Clearance
99
Every 1500 Hours of Operation
100
Inspect, Clean and Test Fuel Injectors
100
Inspect Crankcase Breather System
100
Every 2000 Hours of Operation
101
Check and Replace Fuel Hoses and Engine Coolant Hoses
101
Lap the Intake and Exhaust Valves
101
Engine Contents
103
Before You Begin Servicing
105
Cylinder Head Specifications
107
Adjustment Specifications
107
Cylinder Head
107
Intake/Exhaust Valve and Guide
108
Push Rod
108
Valve Spring
108
Camshaft and Timing Gear Train Specifications
109
Rocker Arm and Shaft
109
Crankshaft and Pistons Specifications
110
Idler Gear Shaft and Bushing
110
Timing Gear Backlash
110
Crankshaft Reconditioning
111
Thrust Bearing
111
Piston
112
Piston Ring
112
Connecting Rod Small End
113
Connecting Rod Big End
113
Connecting Rod Distortion
113
Tappet
113
Cylinder Block Specifications
114
Special Torque Chart
115
Tightening Torque for Special Bolts
115
Special Service Tools
116
Measuring Instruments
118
Cylinder Head Components
120
Disassembly of Cylinder Head
121
Removal of Intake Manifold/Valve Cover
122
Removal of Glow Plugs
122
Removal of Rocker Arm Assembly
122
Disassembly of Rocker Arm Assembly
123
Removal of Cylinder Head
123
Removal of Intake/Exhaust Valves
124
Removal of Valve Guides
124
Cleaning of Cylinder Head Components
125
Inspection of Cylinder Head Components
125
Inspection of Push Rods
125
Push Rod Bend
125
Inspection of Rocker Arm Assembly
126
Inspection of Valve Guides
126
Rocker Arm Shaft Hole Diameter
126
Rocker Arm Shaft Outside Diameter
126
Inspection of Intake and Exhaust Valves
127
Valve Stem Diameter
127
Valve Stem Bend
127
Valve Recession
127
Inspection of Valve Springs
128
Valve Face and Valve Seat
128
Fractures
128
Corrosion
128
Reassembly of Cylinder Head
129
Reassembly of Valve Guides
129
Squareness
129
Free Length
129
Reassembly of Intake and Exhaust Valves
130
Reassembly of Rocker Arm Assembly
132
Reassembly of Intake Manifold/Valve Cover
133
Measuring and Adjusting Valve Clearance
134
3-Cylinder Engines
134
Cylinder Block
136
Crankshaft and Camshaft Components
136
Disassembly of Cylinder Block Components
137
Disassembly of Camshaft and Timing Components
138
Removal of Timing Gear Case Cover
138
Checking Timing Gear Backlash
138
Measuring Idler Gear-To-Crankshaft Gear Backlash
139
Measuring Idler Gear-To-Camshaft Gear Backlash
139
Removal of Timing Gears
139
Removal of Oil Pan
140
Removal of Camshaft
141
Disassembly of Crankshaft and Piston Components
142
Removal of Pistons
142
Removal of Crankshaft
143
Inspection of Crankshaft and Camshaft Components
146
Replacement of Crankshaft Oil Seals
146
Crankshaft Bearing Oil Clearance
146
Inspection of Cylinder Block
146
Inspection of Pistons, Piston Rings and Wrist Pin
147
Roundness
147
Taper
147
Inspection of Connecting Rod
149
Inspection of Tappets
150
Inspection of Crankshaft
150
Reconditioning the Crankshaft
151
Inspection of Camshaft
151
Honing and Boring
152
Inspection of Camshaft Insert Bores
152
Inspection of Idler Gear and Shaft
152
Reassembly of Crankshaft and Piston Components
153
Reassembly of Pistons
154
Installation of Crankshaft
156
Installation of Pistons
158
Reassembly of Camshaft and Timing Components
159
Installation of Camshaft
159
Installation of Timing Gears
160
Installation of Gear Case Cover
161
Installation of Oil Pan
161
Final Assembly of Engine
162
Fuel System Contents
163
Fuel Injection Pump
167
Stop Solenoid
168
Fuel System Specifications
169
Test and Adjustment Specifications
169
Fuel System Diagram
171
Fuel System Components
172
Fuel Injection Lines
173
Removal of High-Pressure Fuel Injection Lines
173
Installation of High-Pressure Fuel Injection Lines
174
Removal of Fuel Return Line
174
Installation of Fuel Return Line
175
Removal of Fuel Injection Pump
175
Installation of Fuel Injection Pump
178
Checking and Adjusting Fuel Injection Timing
180
Removal of Fuel Injectors
184
Testing of Fuel Injectors
184
Fuel Injector Test Results
186
Disassembly and Inspection of Fuel Injectors
187
Adjusting Fuel Injector Pressure
188
Reassembly of Fuel Injectors
189
Installation of the Fuel Injectors
189
Cooling System Contents
191
Cooling System Diagram
195
Engine Coolant Pump Components
196
Engine Coolant System Check
197
Disassembly of Engine Coolant Pump
197
Cleaning and Inspection
198
Temperature Switch
198
Thermostat
198
Radiator Cap
199
Reassembly of Engine Coolant Pump
199
Lubrication System Contents
201
Oil Pump Service Information
205
Lubrication System Diagram
206
Trochoid Oil Pump
207
Components
207
Disassembly of Oil Pump
207
Check Outer Rotor Outside Clearance
208
Outer Rotor to Inner Rotor Tip Clearance
208
Check Outer Rotor Side Clearance
209
Check Rotor Shaft Clearance
209
Reassembly of Oil Pump
209
Starter Motor Contents
211
Starter Motor Information
215
Starter Motor Specifications
216
Starter Motor Troubleshooting
217
Starter Motor Components
218
Starter Motor
219
Removal of Starter Motor
220
Disassembly of Starter Motor
220
Armature
222
Commutator Surface Inspection
222
Measure Commutator Outside Diameter
222
Measure Commutator Insulation Depth
223
Armature Coil Continuity Test
223
Armature Coil Insulation Test
223
Measure Armature and Commutator Run-Out
224
Field Coil Continuity Test
224
Fiel Coil Insulation Test
224
Measure Brush Length
224
Solenoid Switch
225
Brush Holder Insulation Test
225
Brush Spring Test
225
Shunt Coil Continuity Test
225
Coil Resistance Test
226
Contact Continuity Test
226
Pinion Clutch Assembly Inspection
226
Reassembly of Starter Motor
227
Check Pinion Projection Length
229
No-Load Test
229
Installation of Starter Motor
230
Alternator Contents
231
Standard and Optional Dynamo Information
236
Standard and Optional Alternator Information
236
Alternator Specifications
236
Dynamo Specifications
237
Alternator Troubleshooting
238
Alternator Components
239
Alternator Wiring Diagram
240
Alternator Standard Output
241
Removal of Alternator
242
Disassembly of Alternator
242
Reassembly of Alternator
244
Installation of Alternator
246
Dynamo Component Location
247
Dynamo Wiring Diagram
248
Operation of Dynamo
248
Dynamo Standard Output
249
Testing of Dynamo
250
Testing Stator Coil Continuity
250
Testing Stator Coil Short-To-Ground
250
Testing Dynamo Regulated Output
250
Disassembly of Dynamo
251
Reassembly of Dynamo
251
Installation of Dynamo
252
Electric Wiring Contents
253
Electric Wiring Precautions
255
Electric Wire Resistance
256
Battery Cable Resistance
257
Electrical Wire Sizes - Voltage Drop
258
Conversion of AWG to European Standards
259
Troubleshooting Contents
261
Troubleshooting by Measuring Compression Pressure
264
Quick Reference Table for Troubleshooting
265
Standard Compression Pressure
265
Measured Value and Troubleshooting
265
Troubleshooting Charts
267

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