Yanmar 3TNV76 Manuals

Manuals and User Guides for Yanmar 3TNV76. We have 3 Yanmar 3TNV76 manuals available for free PDF download: Service Manual, Operation Manual

Yanmar 3TNV76 Service Manual (265 pages)

Industrial

Brand: Yanmar | Category: Engine | Size: 16 MB

Table of Contents
3
Introduction
5
Safety
17
Safety Precautions
18
General Service Information
31
Component Identification
33
Location of Labels
34
EPA/ARB Emission Control Regulations
34
Emission Control Labels
34
Function of Major Engine Components
36
Function of Cooling System Components
38
Diesel Fuel
39
Diesel Fuel Specifications
39
Additional Technical Fuel Requirements
39
Bio-Diesel Fuels
40
General Description of Biodiesel
40
Approved Engines
40
Approved Fuel
41
Kit Parts List
42
Filling the Fuel Tank
43
Priming the Fuel System
44
Engine Oil
45
Engine Oil Specifications
45
Engine Oil Viscosity
45
Checking Engine Oil
45
Adding Engine Oil
46
Engine Oil Capacity
46
Engine Coolant
47
Engine Coolant Specifications
48
Alternative Engine Coolant
48
Filling Radiator with Engine Coolant
48
Engine Coolant Capacity
49
Specifications
50
Description of Model Number
50
Engine Speed Specifications
50
Engine General Specifications
51
Principal Engine Specifications
52
Engine Service Information
55
Tightening Torques for Standard Bolts and Nuts
56
Abbreviations
58
Unit Conversions
59
Periodic Maintenance
61
Precautions
64
Performing Periodic Maintenance
64
EPA / ARB Installation Requirements
64
Periodic Maintenance Schedule
65
Periodic Maintenance Procedures
67
Replace Engine Oil and Engine Oil Filter
67
Check and Adjust Cooling Fan V-Belt
69
Drain Fuel Filter/Water Separator
70
Check Battery
72
Drain Fuel Tank
73
Check and Clean Radiator Fins
75
Check and Adjust Cooling Fan V-Belts
75
Clean Air Cleaner Element
76
Replace Air Cleaner Element
78
Replace Fuel Filter
78
Clean Fuel Filter /Water Separator
80
Adjust Intake/Exhaust Valve Clearance
83
Inspect, Clean and Test Fuel Injectors
83
Inspect Crankcase Breather System
84
Engine
87
Cylinder Head Specifications
90
Intake/Exhaust Valve and Guide
91
Camshaft and Timing Gear Train Specifications
92
Rocker Arm and Shaft
92
Camshaft
92
Crankshaft and Pistons Specifications
93
Idler Gear Shaft and Bushing
93
Timing Gear Backlash
93
Crankshaft
93
Crankshaft Reconditionining
94
Piston
95
Connecting Rod
97
Connecting Rod Small End
97
Cylinder Block Specifications
98
Connecting Rod Big End
98
Connecting Rod Distortion
98
Tappet
98
Special Torque Chart
99
Torque for Bolts and Nuts
99
Special Service Tools
100
Measuring Instruments
102
Cylinder Head
104
Cylinder Head Components
104
Disassembly of Cylinder Head
105
Removal of Intake Manifold/Valve Cover
106
Removal of Rocker Arm Assembly
106
Removal of Glow Plugs
106
Disassembly of Rocker Arm Assembly
107
Removal of Cylinder Head
107
Removal of Intake/Exhaust Valve
108
Removal of Valve Guides
108
Cleaning of Cylinder Head Components
109
Inspection of Cylinder Head Components
109
Inspection of Push Rods
109
Push Rod Bend
109
Inspection of Rocker Arm Assembly
110
Rocker Arm Shaft Hole Diameter
110
Inspection of Valve Guides
110
Inspection of Cylinder Head
110
Inspection of Intake and Exhaust Valves
111
Valve Stem Diameter
111
Valve Recession
111
Valve Stem Bend
111
Valve Face and Valve Seat
112
Inspection of Valve Springs
112
Fractures
112
Corrosion
112
Reassembly of Cylinder Head
113
Squareness
113
Free Length
113
Reassembly of Valve Guides
113
Reassembly of Intake and Exhaust Valves
114
Reassembly of Rocker Arm Assembly
116
Reassembly of Intake Manifold/Valve Cover
117
Measuring and Adjusting Valve Clearance
118
3-Cylinder Engines
118
Cylinder Block
120
Crankshaft and Camshaft Components
120
Disassembly of Cylinder Block Components
121
Disassembly of Camshaft and Timing Components
122
Removal of Timing Gear Case Cover
122
Checking Timing Gear Backlash
122
Removal of Timing Gears
123
Measuring Idler Gear-To-Camshaft Gear Backlash
123
Removal of Oil Pan
124
Removal of Camshaft
125
Disassembly of Crankshaft and Piston Components
126
Removal of Gear Case
126
Removal of Pistons
126
Removal of Crankshaft
128
Inspection of Crankshaft and Camshaft Components
130
Crankshaft Bearing Oil Clearance
131
Inspection of Cylinder Block
131
Roundness
131
Taper
131
Inspection of Pistons, Piston Rings and Wrist Pin
132
Inspection of Connecting Rod
133
Inspection of Tappets
134
Inspection of Crankshaft
135
Reconditioning the Crankshaft
135
Inspection of Camshaft
136
Inspection of Camshaft Bushing and Bores
137
Inspection of Idler Gear and Shaft
137
Honing and Boring
137
Reassembly of Crankshaft and Piston Components
138
Reassembly of Pistons
139
Installation of Crankshaft
141
Installation of Pistons
142
Reassembly of Camshaft and Timing Components
144
Installation of Gear Case
144
Installation of Camshaft
144
Installation of Timing Gears
145
Installation of Gear Case Cover
145
Installation of Oil Pan
146
Final Assembly of Engine
146
Fuel System
147
Before You Begin Servicing
149
Fuel System Introduction
150
Fuel Injection Pump
150
Stop Solenoid
151
Fuel System Specifications
152
Test and Adjustment Specifications
152
Fuel System Diagram
154
Fuel System Components
155
Fuel Injection Lines
156
Removal of High-Pressure Fuel Injection Lines
156
Installation of High-Pressure Fuel Injection Lines
157
Removal of Fuel Return Line
157
Installation of Fuel Return Line
158
Removal of Fuel Injection Pump
158
Installation of Fuel Injection Pump
161
Checking and Adjusting Fuel Injection Timing
164
Checking Fuel Injection Timing
164
Fuel Injection Timing Chart
166
Fuel Injectors
168
Adjusting Fuel Injection Timing
168
Removal of Fuel Injectors
168
Testing of Fuel Injectors
169
Fuel Injector Test Results
171
Disassembly and Inspection of Fuel Injectors
172
Adjusting Fuel Injector Pressure
173
Reassembly of Fuel Injectors
174
Installation of the Fuel Injectors
174
Cooling System
175
Cooling System Diagram
178
Engine Coolant Pump Components
179
Engine Coolant System Check
180
Engine Coolant Pump
180
Disassembly of Engine Coolant Pump
180
Cleaning and Inspection
181
Temperature Switch
181
Radiator Cap
181
Thermostat
181
Reassembly of Engine Coolant Pump
182
Lubrication System
185
Oil Pump Service Information
188
Engine Oil Pressure
188
Outer Rotor Outside Clearance
188
Outer Rotor Side Clearance
188
Inner Rotor and Gear Boss Clearance
189
Lubrication System Diagram
190
Checking Engine Oil Pressure
191
Trochoid Oil Pump
191
Oil Pump Components
191
Disassembly of Oil Pump
192
Check Outer Rotor Outside Clearance
193
Outer Rotor to Inner Rotor Tip Clearance
193
Check Outer Rotor Side Clearance
193
Check Inner Rotor and Gear Boss Clearance
194
Reassembly of Oil Pump
194
Starter Motor
195
Starter Motor Information
198
Starter Motor Specifications
199
Starter Motor Troubleshooting
200
Starter Motor Components
201
Removal of Starter Motor
203
Disassembly of Starter Motor
203
Armature
205
Commutator Surface Inspection
205
Measure Commutator Outside Diameter
205
Measure Commutator Insulation Depth
206
Armature Coil Insulation Test
206
Armature Coil Continuity Test
206
Measure Armature and Commutator Run out
207
Field Coil Insulation Test
207
Field Coil Continuity Test
207
Measure Brush Length
207
Brush Holder
208
Solenoid Switch
208
Shunt Coil Continuity Test
208
Brush Spring Test
208
Contact Continuity Test
209
Pinion Clutch Assembly
209
Reassembly of Starter Motor
210
Check Pinion Projection Length
212
No-Load Test
212
Installation of Starter Motor
213
Alternator
215
Standard and Optional Dynamo Information
218
Standard and Optional Alternator Information
218
Alternator Specifications
218
Dynamo Specifications
219
Alternator Troubleshotoing
220
Alternator Components
221
Alternator Wiring Diagram
222
Alternator Standard Output
223
Removal of Alternator
224
Disassembly of Alternator
224
Reassembly of Alternator
226
Installation of Alternator
228
Dynamo Component Location
229
Dynamo Wiring Diagram
230
Operation of Dynamo
230
Dynamo Standard Output
231
Testing of Dynamo
232
Removal of Dynamo
232
Testing Stator Coil Continuity
232
Testing Stator Coil Short-To-Ground
232
Disassembly of Dynamo
233
Reassembly of Dynamo
233
Installation of Dynamo
234
Electric Wiring
235
Electric Wiring Precautions
237
Electric Wire Resistance
238
Battery Cable Resistance
239
Electrical Wire Sizes - Voltage Drop
240
Conversion of AWG to European Standards
241
Troubleshooting
243
Troubleshooting by Measuring Compression Pressure
246
Standard Compression Pressure
247
Engine Speed and Compression Pressure
247
Quick Reference Table for Troubleshooting
248
Measured Value and Troubleshooting
248

Yanmar 3TNV76 Service Manual (264 pages)

industrial engines

Brand: Yanmar | Category: Engine | Size: 28 MB

Table of Contents

3
Section 2

7
- Yanmar Warranties
  8
- Safety
  15
- Periodic Maintenance
  17
- Fuel System
  18
  - Starter Motor
    22
- General Service Information
  25
- Electric Wiring
  27
Section 4

31
- Cooling System
  31
  - Component Identification
    33
  - Location of Labels
    34
  - EPA / ARB Emission Control Regulations - USA Only
    34
  - Emission Control Labels
    34
    
    EPA / CARB Labels (Typical)
    35
  - The 97/68/EC Directive Certified Engines
    35
  - Engine Family
    35
  - Function of Major Engine Components
    36
  - Function of Cooling System Components
    38
  - Diesel Fuel
    39
    
    Diesel Fuel Specifications
    39
    
    Filling the Fuel Tank
    43
    
    Priming the Fuel System
    44
  - Engine Oil
    45
    
    Checking Engine Oil
    45
    
    Engine Oil Specifications
    45
    
    Engine Oil Viscosity
    45
    
    Service Categories
    45
    
    Adding Engine Oil
    46
    
    Engine Oil Capacity (Typical)
    46
  - Engine Coolant
    47
    
    Engine Coolant Specifications
    48
    
    Filling Radiator with Engine Coolant
    48
    
    Engine Coolant Capacity (Typical)
    49
  - Specifications
    50
    
    Description of Model Number
    50
    
    Engine Speed Specifications
    50
    
    Engine General Specifications
    51
    
    Tightening Torques for Standard Bolts and Nuts
    56
    
    Abbreviations and Symbols
    58
    
    Unit Conversions
    59
Periodic Maintenance

61
Engine

87
- Before You Begin Servicing
  89
- Cylinder Head Specifications
  90
  - Adjustment Specifications
    90
  - Cylinder Head
    90
  - Intake / Exhaust Valve and Guide
    91
  - Push Rod
    91
  - Valve Spring
    91
  - Rocker Arm and Shaft
    92
- Introduction
  90
- Camshaft and Timing Gear Train Specifications
  92
  - Camshaft
    92
  - Idler Gear Shaft and Bushing
    93
  - Timing Gear Backlash
    93
- Crankshaft and Pistons Specifications
  93
  - Crankshaft
    93
  - Crankshaft Reconditioning
    94
  - Thrust Bearing
    94
  - Piston
    95
  - Piston Ring
    96
  - Connecting Rod
    97
  - Tappet
    98
- Cylinder Block Specifications
  98
  - Cylinder Block
    98
- Special Torque Chart
  99
  - Torque for Bolts and Nuts
    99
- Special Service Tools
  100
- Measuring Instruments
  102
- Cylinder Head
  104
  - Cylinder Head Components
    104
  - Disassembly of Cylinder Head
    105
  - Cleaning of Cylinder Head Components
    109
  - Inspection of Cylinder Head Components
    109
  - Reassembly of Cylinder Head
    113
  - Measuring and Adjusting Valve Clearance
    118
- Cylinder Block
  120
Fuel System

147
- Before You Begin Servicing
  149
- Introduction
  150
  - Fuel Injection Pump
    150
  - Stop Solenoid
    151
- Fuel System Specifications
  152
  - Special Torque Chart
    152
  - Test and Adjustment Specifications
    152
- Measuring Instruments
  153
- Special Service Tools
  153
- Fuel System Diagram
  154
- Fuel System Components
  155
- Fuel Injection Lines
  156
- Fuel Injection Pump
  158
  - Removal of Fuel Injection Pump
    158
  - Installation of Fuel Injection Pump
    161
- Checking and Adjusting Fuel Injection Timing
  164
  - Checking Fuel Injection Timing
    164
  - Adjusting Fuel Injection Timing
    168
- Fuel Injectors
  168
  - Removal of Fuel Injectors
    168
  - Testing of Fuel Injectors
    169
- Disassembly and Inspection of Fuel Injectors
  172
- Adjusting Fuel Injector Pressure
  173
- Installation of the Fuel Injectors
  174
- Reassembly of Fuel Injectors
  174
Cooling System

175
- Before You Begin Servicing
  177
- Cooling System Diagram
  178
- Introduction
  178
- Engine Coolant Pump Components
  179
- Engine Coolant Pump
  180
  - Disassembly of Engine Coolant Pump
    180
  - Cleaning and Inspection
    181
  - Reassembly of Engine Coolant Pump
    182
- Engine Coolant System Check
  180
Lubrication System

185
- Before You Begin Servicing
  187
- Introduction
  188
- Oil Pump Service Information
  188
  - Engine Oil Pressure
    188
  - Outer Rotor Outside Clearance
    188
  - Outer Rotor Side Clearance
    188
  - Outer Rotor to Inner Rotor Tip Clearance
    188
  - Inner Rotor and Gear Boss Clearance
    189
- Lubrication System Diagram
  190
- Checking Engine Oil Pressure
  191
- Trochoid Oil Pump
  191
  - Oil Pump Components
    191
- Troubleshooting
  191
  - Disassembly of Oil Pump
    192
    
    Cleaning and Inspection
    193
    
    Reassembly of Oil Pump
    194
Starter Motor

195
- Before You Begin Servicing
  197
- Introduction
  198
- Starter Motor Information
  198
- Starter Motor Specifications
  199
- Starter Motor Troubleshooting
  200
- Starter Motor Components
  201
- Starter Motor
  202
  - Removal of Starter Motor
    203
  - Disassembly of Starter Motor
    203
  - Cleaning and Inspection
    205
  - Reassembly of Starter Motor
    210
  - Check Pinion Projection Length
    212
  - No-Load Test
    212
  - Installation of Starter Motor
    213
Alternator

215
- Before You Begin Servicing
  217
- Alternator Specifications
  218
- Introduction
  218
- Standard and Optional Alternator Information
  218
- Standard and Optional Dynamo Information
  218
- Dynamo Specifications
  219
- Alternator Troubleshooting
  220
- Alternator Components
  221
- Alternator Wiring Diagram
  222
- Alternator Standard Output
  223
- Alternator
  224
  - Removal of Alternator
    224
  - Disassembly of Alternator
    224
  - Reassembly of Alternator
    226
  - Installation of Alternator
    228
- Dynamo Component Location
  229
- Dynamo Wiring Diagram
  230
- Operation of Dynamo
  230
- Dynamo Standard Output
  231
- Testing of Dynamo
  232
Electric Wiring

235

Yanmar 3TNV76 Operation Manual (142 pages)

TNV series

Brand: Yanmar | Category: Engine | Size: 10 MB

Yanmar Limited Warranty
7
Introduction

14
- Record of Ownership
  14
- Table of Contents
  15
Table of Contents

19
Safety

19
- Safety Statements
  19
- Safety Precautions
  20
  - During Operation and Maintenance
    20
Product Overview

33
- Yanmar TNV Engine Features and Applications
  33
- Component Identification
  34
- Location of Labels
  36
- EPA / ARB Emission Control Regulations - USA Only
  37
- Emission Control Labels
  37
  - EPA / ARB Labels
    37
- The 97/68/EC Directive Certified Engines
  38
- Engine Family
  38
- Function of Major Engine Components
  39
- Function of Cooling System Components
  41
- Gauges and Indicators
  42
  - Gauges
    42
  - Indicators
    43
- Controls
  44
  - Key Switch
    44
  - Inlet Air Heater
    45
  - Glow Plugs
    45
  - Governor Lever
    46
  - Engine Stop Solenoid
    46
- Before You Operate
  
  47
  - Diesel Fuel
    51
    
    Diesel Fuel Specifications
    51
    
    Filling the Fuel Tank
    52
    
    Priming the Fuel System
    54
  - Engine Oil
    56
    
    Engine Oil Specifications
    56
    
    Engine Oil Viscosity
    56
    
    Checking Engine Oil
    56
    
    Adding Engine Oil
    57
    
    Engine Oil Capacity (Typical)
    57
  - Engine Coolant
    58
    
    Engine Coolant Specifications
    59
    
    Filling Radiator with Engine Coolant
    60
    
    Daily Check of the Cooling System
    61
    
    Engine Coolant Capacity (Typical)
    61
  - Daily Checks
    62
    
    Visual Checks
    62
    
    Check Diesel Fuel, Engine Oil, and Engine Coolant Levels
    62
    
    Check Engine Speed Control
    62
    
    Check Operator's Console
    63
    
    Check Indicators
    63
Engine Operation

65
- Starting Engine
  71
- Cold Start Device
  73
- Checking the Engine During Operation
  73
- Adjust Engine Speed
  75
- Shutting down the Engine
  76
Periodic Maintenance

77
Troubleshooting

117
- Troubleshooting Chart
  117
- Troubleshooting Information
  120
Long Term Storage

121
- Before You Place the Engine in Long Term Storage
  121
- Returning the Engine to Service
  122
Specifications

123
- General
  123
- Description of Model Number
  123
- Engine Speed Specifications
  124
- Engine General Specifications
  124
- Principal Engine Specifications
  125
  - 2Tnv70
    125
  - 3Tnv70
    126
  - 3Tnv76
    127
  - 3Tnv82A
    128
  - 3Tnv84
    129
  - 3Tnv84T
    130
  - 3Tnv88
    131
  - 4Tnv84
    132
  - 4Tnv84T
    133
  - 4Tnv88
    134
  - 4Tnv94L
    135
  - 4Tnv98
    136
  - 4Tnv98T
    137
  - 4Tnv106
    138
  - 4Tnv106T
    139

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Yanmar 3TNV76 Manuals

Yanmar 3TNV76 Service Manual (265 pages)

Table of Contents

Yanmar 3TNV76 Service Manual (264 pages)

Table of Contents

Table of Contents

Section 2

Section 4

Periodic Maintenance

Engine

Fuel System

Cooling System

Lubrication System

Starter Motor

Alternator

Electric Wiring

Yanmar 3TNV76 Operation Manual (142 pages)

Table of Contents

Introduction

Table of Contents

Safety

Product Overview

Before You Operate

Engine Operation

Periodic Maintenance

Troubleshooting

Long Term Storage

Specifications

Related Products

Yanmar Categories