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Yanmar 2V750 V Engine Shop Manual – PDF DOWNLOAD
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Yanmar 2V750 V Engine Shop Manual
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Description
Yanmar 2V750 V Engine Shop Manual
FILE DETAILS:
LANGUAGE:ENGLISH
PAGES:291
DOWNLOADABLE:YES
FILE TYPE:PDF
YANMAR 2V750 V ENGINE SHOP MANUAL – PDF DOWNLOAD:
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
Yanmar 2V750 V Engine Shop Manual
INTRODUCTION:
This manual describes the service procedures for the 2V750-V series liquid-cooled, vertical twin- cylinder, 4-stroke. in-direct injection engines. These engines are certified by the US. EPA, California ARB and/or the 97/68/EC Directive for Industrial Use. The use of this manual is recommended for safe, efficient and accurate servicing of the engine. Use this manual together with the current model specific parts catalog for additional exploded part diagrams and identification of parts numbers.
- Part catalogs are intended for part number identification only. Exploded part diagrams within part catalogs should not be used as an assembly reference, follow the assembly procedures within the correct service manual for proper assembly instructions.
- The information and procedures within this manual are for a typical engine, some specifications and components may be different from your engine. All photographs and illustrations within this manual are intended as reference only and may not depict actual engine components or equipment. When servicing optional engine equipment refer to the documentation supplied by that optional equipment manufacturer for specific service instructions.
- This manual may not include current field modifications or service updates that were not available at the time of printing. Contact an authorized Yanmar industrial engine dealer or distributor for current field modifications and service information.
TABLE OF CONTENTS:
Yanmar 2V750 V Engine Shop Manual
COVER............................................................................... 1 COVER........................................................................... 2 Table of Contents................................................................... 6 Introduction........................................................................ 8 Yanmar Warranties................................................................... 10 Yanmar Limited Warranty......................................................... 12 What is Covered by this Warranty?........................................... 12 How Long is the Warranty Period?............................................ 12 What the Engine Owner Must Do:.............................................. 12 To Locate an Authorized Yanmar Industrial Engine Dealer or Distributor:..... 13 What Yanmar Will Do:........................................................ 13 What is Not Covered by this Warranty?....................................... 13 Warranty Limitations:....................................................... 14 Warranty Modifications:..................................................... 14 Questions:.................................................................. 14 Retail Purchaser Registration............................................... 14 Emission System Warranty........................................................ 15 Yanmar Co., Ltd. Limited Emission Control System Warranty - USA Only............ 15 Your Warranty Rights and Obligations:....................................... 15 California.............................................................. 15 Manufacturer’s Warranty Period:............................................. 15 Warranty Coverage:.......................................................... 16 Warranted Parts:............................................................ 16 Exclusions:................................................................. 17 Owner’s Warranty Responsibilities:.......................................... 17 Safety.............................................................................. 18 Safety Statements............................................................... 20 Before You Begin Servicing...................................................... 21 Safety Precautions.............................................................. 21 General Service Information......................................................... 36 Component Identification........................................................ 38 Location of Labels.............................................................. 40 Specifications.................................................................. 40 Description of Model Number................................................. 40 General Engine Specifications............................................... 41 EPA / ARB Emission Control Information.......................................... 43 EPA / ARB Regulations - USA Only............................................ 43 EPA / ARB Emission Control Labels - USA Only................................ 43 Description of Emission Control Engine Family Number........................ 44 Function of Major Engine Components............................................. 45 Function of Cooling System Components........................................... 46 Diesel Fuel..................................................................... 47 Diesel Fuel Specifications.................................................. 47 Additional Technical Fuel Requirements.................................. 47 Bio-Diesel Fuels........................................................ 47 Filling the Fuel Tank....................................................... 48 Priming the Fuel System..................................................... 50 Engine Oil...................................................................... 51 Engine Oil Specifications................................................... 51 Service Categories...................................................... 51 Definitions............................................................. 51 Additional Technical Engine oil Requirements:........................... 52 Engine Oil Viscosity........................................................ 52 Engine Oil Capacity (Typical)............................................... 52 Checking Engine Oil......................................................... 53 Adding Engine Oil........................................................... 53 Engine Coolant.................................................................. 54 Engine Coolant Specifications............................................... 55 Alternative Engine Coolant.................................................. 55 Additional Technical Coolant Specifications:................................ 55 Engine Coolant Capacity (Typical)........................................... 55 Checking Engine Coolant..................................................... 55 Adding Engine Coolant....................................................... 55 Abbreviations and Symbols....................................................... 57 Abbreviations............................................................... 57 Symbols..................................................................... 57 Unit Conversions................................................................ 58 Unit Prefixes............................................................... 58 Prefix.................................................................. 58 Symbol.................................................................. 58 Power................................................................... 58 Units of Length............................................................. 58 Units of Volume............................................................. 58 Units of Mass............................................................... 58 Units of Force.............................................................. 58 Units of Torque............................................................. 58 Units of Pressure........................................................... 58 Units of Power.............................................................. 58 Units of Temperature........................................................ 58 Tightening Torques for Standard Bolts and Nuts.................................. 59 Tightening Torques for Special Bolts and Nuts................................... 61 Periodic Maintenance................................................................ 64 Before You Begin Servicing...................................................... 66 Introduction.................................................................... 79 The Importance of Periodic Maintenance...................................... 79 Performing Periodic Maintenance............................................. 79 The Importance of Daily Checks.............................................. 79 Keep a Log of Engine Hours and Daily Checks................................. 80 Yanmar Replacement Parts.................................................... 80 Tools Required.............................................................. 80 Tightening Fasteners........................................................ 80 Required EPA / ARB Maintenance - USA Only................................... 80 EPA / ARB Installation Requirements - USA Only.............................. 80 Periodic Maintenance Schedule................................................... 80 Periodic Maintenance Procedures................................................. 82 Daily, Before Operation..................................................... 82 Check Battery........................................................... 82 Check Battery Indicator (If Equipped)................................... 83 Daily, After Operation...................................................... 88 Check for Engine Oil Leakage............................................ 88 After Initial 50 Hours of Operation......................................... 90 Check Battery........................................................... 90 Drain Fuel Tank......................................................... 92 Clean Air Cleaner Element............................................... 93 Every 200 Hours of Operation................................................ 95 Check and Clean Radiator Fins........................................... 95 Adjust Intake/Exhaust Valve Clearance (First Time)...................... 95 Replace Engine Oil and Engine Oil Filter (Second Time and After)........ 96 Replace Air Cleaner Element............................................. 96 Every 400 Hours of Operation................................................ 96 Drain, Flush and Fill Engine Coolant.................................... 96 Check and Adjust the Idling Speed....................................... 99 Replace Fuel Filter..................................................... 99 Every 1000 Hours of Operation...............................................101 Flush the Cooling System and Check the Cooling System Components........101 Every 1500 Hours of Operation...............................................102 Inspect, Clean and Test Fuel Injectors..................................102 Every 2000 Hours of Operation...............................................102 Lap the Intake and Exhaust Valves.......................................102 Fuel Injection Pump Maintenance.........................................102 Check and Replace Fuel Hoses and Engine Coolant Hoses...................103 Engine..............................................................................104 Before You Begin Servicing......................................................106 Introduction....................................................................108 Specifications..................................................................108 Cylinder Head Assembly......................................................108 Adjustment Specifications...............................................108 Cylinder Head...........................................................108 Intake / Exhaust Valve and Guide........................................109 Push Rod................................................................109 Valve Spring............................................................109 Rocker Arm and Shaft....................................................109 Crankshaft, Pistons and Connection Rods.....................................110 Crankshaft..............................................................110 Piston..................................................................110 Piston Ring.............................................................111 Connecting Rod..........................................................111 Camshaft, Camshaft Gear and Tappets.........................................112 Camshaft................................................................112 Camshaft Gear Backlash..................................................112 Tappets.................................................................113 Cylinder Block and Crankcase Cover..........................................113 Cylinder Block..........................................................113 Crankcase Cover.........................................................113 Special Torque Specifications...............................................114 Special Service Tools...........................................................115 Measuring instruments...........................................................116 Engine Assembly Components......................................................118 Cylinder Head Assembly..........................................................119 Cylinder Head Components....................................................119 Removal of Cylinder Head....................................................120 Disassembly of Cylinder Head................................................121 Removal of Rocker Arms..................................................121 Removal of Valves.......................................................122 Inspection of Cylinder Head Components..................................122 Valve Face and Valve Seat...............................................123 Valves and Valve Guides.................................................124 Valve Springs...........................................................125 Push Rods and Rocker Arms...............................................125 Valve Clearance Adjusting Screw.........................................126 Cylinder Head Distortion................................................126 Reassembly of Cylinder Head.................................................127 Installation of Valve Seals.............................................127 Installation of Valves..................................................127 Installation of Rocker Arm Assembly.....................................128 Installation of Cylinder Head...............................................128 Measuring and Adjusting Valve Clearance.....................................130 Engine..........................................................................132 Engine Components...........................................................132 Removal of Engine...........................................................133 Disassembly of Engine.......................................................135 Removal and Inspection of Crankcase Breather Components.................135 Measuring Camshaft Endplay and Gear Backlash............................136 Measuring Crankshaft Endplay............................................137 Removal of Crankcase Cover..............................................137 Removal of Crankshaft, Camshaft, Pistons and Connecting Rods............138 Disassembly of Pistons and Connecting Rods..............................140 Inspection of Engine Components.............................................141 Pistons, Piston Rings, and Wrist Pins...................................141 Connecting Rods.........................................................143 Camshaft................................................................143 Tappets.................................................................144 Crankshaft..............................................................144 Cylinder Block..........................................................145 Crankshaft and Camshaft Bearings........................................146 Honing..................................................................147 Reassembly of Engine........................................................148 Reassembly of Pistons and Connecting Rods...............................148 Installation of Crankshaft..............................................150 Installation of Pistons and Connecting Rods.............................150 Installation of Camshaft................................................152 Installation of Crankcase Cover.........................................152 Final Engine Assembly...................................................154 Installation of Engine......................................................157 Fuel System.........................................................................158 Before You Begin................................................................160 Introduction....................................................................162 Specifications..................................................................162 Test and Adjustment Specifications..........................................162 Special Torque Specifications...............................................162 Special Service Tools...........................................................163 Measuring Instruments...........................................................164 Operation.......................................................................165 Fuel Injection Pump.........................................................165 Fuel Injector...............................................................165 Fuel System Diagram.............................................................166 Fuel System Components..........................................................167 Checking and Adjusting Fuel Injection Timing....................................168 Checking Fuel Injection Timing..............................................168 Adjusting Fuel Injection Timing.............................................170 Low Idle Speed Adjustment.......................................................173 Fuel Injection Pump.............................................................174 Removal of High Pressure Fuel Injection Lines and Fuel Return Lines.........174 Removal of Fuel Injection Pump..............................................176 Inspection of Fuel Injection Pump Components................................177 Installation of Fuel Injection Pump.........................................178 Installation of High Pressure Fuel Injection Lines and Fuel Return Lines....178 Fuel Injectors..................................................................179 Removal of Fuel Injectors...................................................179 Testing of Fuel Injectors...................................................180 Disassembly and Inspection of Fuel Injectors................................181 Adjusting Fuel Injector Pressure............................................183 Assembly of Fuel Injectors..................................................183 Installation of the Fuel Injectors..........................................184 Governor........................................................................184 Removal of Governor and Fuel Injection Pump Assembly........................185 Removal and Installation of the Stop Solenoid...............................187 Removal of Stop Solenoid................................................187 Installation of Stop Solenoid...........................................187 Installation of Governor....................................................188 Cooling System......................................................................194 Before You Begin Servicing......................................................196 Introduction....................................................................198 Specifications..................................................................198 General Specifications......................................................198 Coolant Pump Drive Shaft Clearance Specifications...........................198 Special Torque Specifications...............................................199 Special Service Tools...........................................................199 Cooling System Diagram..........................................................200 Cooling System Components.......................................................201 Testing Cooling System..........................................................202 System Pressure Testing.....................................................202 Temperature Switch Testing..................................................202 Thermostat Testing..........................................................202 Radiator Cap Testing........................................................203 Cooling System..................................................................203 Radiator, Cooling Fan and Thermostat............................................204 Removal of Radiator.........................................................204 Removal of Coolant Fan......................................................205 Removal of Thermostat and Housing...........................................206 Installation of Thermostat and Housing......................................207 Installation of Coolant Fan.................................................207 Installation of Radiator....................................................208 Coolant Pump....................................................................208 Removal of Coolant Pump.....................................................208 Inspection of Coolant Pump..................................................209 Installation of Coolant Pump................................................209 Lubrication System..................................................................212 Before You Begin Servicing......................................................214 Introduction....................................................................216 Specifications..................................................................216 General Specifications......................................................216 Oil Pump Clearance Specifications...........................................216 Special Torque Specifications...............................................217 Special Service Tools...........................................................217 Measuring Instruments...........................................................217 Oil Flow Diagram................................................................218 Lubrication System Components...................................................219 Testing Engine Oil Pressure Switch and Oil Pressure.............................220 Oil Pressure Switch.........................................................220 Oil Pressure................................................................220 Oil Pump........................................................................221 Disassembly of Oil Pump.....................................................221 Inspection of Oil Pump Components...........................................221 Inner and Outer OIl Pump Rotors.........................................221 Oil Pump Drive Shaft and Bore...........................................222 OIl Pressure Relief and Oil Strainer Components.........................223 Reassembly of Oil Pump......................................................223 Starter Motor.......................................................................226 Before You Begin Servicing......................................................228 Introduction....................................................................230 Specifications..................................................................231 General Specifications......................................................231 Special Torque Specifications...............................................232 Special Service Tools...........................................................233 Measuring Instruments...........................................................233 Starter Motor Components........................................................234 Starter Motor Troubleshooting...................................................235 Testing Starter Motor Operation.................................................236 Checking Pinion Engagement Length...........................................236 No Load Test................................................................236 Starter Motor...................................................................237 Removal of Starter Motor....................................................237 Disassembly of Starter Motor................................................238 Starter Motor and Housing...............................................238 Pinion Clutch...........................................................240 Inspection and Testing of Starter Motor Components..........................241 Armature................................................................241 Field Coil..............................................................242 Measure Brush Length....................................................243 Brush Holder............................................................243 Solenoid Switch.........................................................244 Reassembly of Starter Motor.................................................244 Pinion Clutch...........................................................244 Starter Motor and Housing...............................................246 Installation of Starter Motor...............................................250 Charging System.....................................................................252 Before You Begin Servicing......................................................254 Introduction....................................................................256 Specifications..................................................................256 General Specifications......................................................256 Special Torque Specifications...............................................256 Special Service Tools...........................................................257 Measuring Instruments...........................................................257 Operation.......................................................................258 Charging System Wiring Diagram..................................................258 Charging System Components......................................................259 Testing Charging System.........................................................260 Testing Regulated Output....................................................260 Testing Stator Winding Continuity...........................................260 Testing Stator Winding Short to Ground......................................260 Stator..........................................................................261 Removal of Flywheel and Stator..............................................261 Installation of Flywheel and Stator.........................................262 Electric Wiring.....................................................................266 Electric Wiring Precautions.....................................................268 Electric Wiring Diagram.........................................................269 Electric Wire Resistance........................................................269 Battery Cable Resistance........................................................270 Electrical Wire Sizes - Voltage Drop............................................271 Conversion of AWG to European Standards.........................................272 Troubleshooting.....................................................................274 Before You Begin Servicing......................................................276 Introduction....................................................................277 Specifications..................................................................277 Cylinder Compression Pressure...............................................277 Measuring Instruments...........................................................277 Troubleshooting By Measuring Compression Pressure...............................278 Measuring Compression Pressure..............................................278 Low Compression Troubleshooting Chart.......................................280 Troubleshooting Quick Reference Charts..........................................280 BACK COVER..........................................................................291
PLEASE NOTE:
- This is the SAME manual used by the dealers to troubleshoot any faults in your vehicle. This can be yours in 2 minutes after the payment is made.
- Contact us at [email protected] should you have any queries before your purchase or that you need any other service / repair / parts operators manual.
