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Yanmar 3TNV88 Industrial Engine Service Manual – PDF DOWNLOAD
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Yanmar 3TNV88 Industrial Engine Service Manual
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Description
Yanmar 3TNV88 Industrial Engine Service Manual
TABLE OF CONTENTS:
Yanmar 3TNV88 Industrial Engine Service Manual
Cover.............................................................................. 1 Table of Contents.................................................................. 3 Introduction....................................................................... 5 YANMAR Warranties.................................................................. 7 YANMAR Limited Warranty........................................................ 9 What is Covered by this Warranty?.......................................... 9 How Long is the Warranty Period?........................................... 9 What the Engine Owner must Do:............................................. 9 To Locate an Authorized YANMAR Industrial Engine Dealer or Distributor:.... 10 What YANMAR will Do:....................................................... 10 What is not Covered by this Warranty?...................................... 10 Warranty Limitations:...................................................... 11 Warranty Modifications:.................................................... 11 Questions:................................................................. 11 Emission System Warranty....................................................... 12 YANMAR Co., Ltd. Limited Emission Control System Warranty - USA Only........... 12 Your Warranty Rights and Obligations:...................................... 12 California............................................................. 12 Manufacturer’s Warranty Period:............................................ 12 Warranty Coverage:......................................................... 13 Warranted Parts:........................................................... 13 Exclusions:................................................................ 14 Owner’s Warranty Responsibilities:......................................... 14 Safety............................................................................. 15 Safety Statements.............................................................. 17 Safety Precautions............................................................. 18 General Service Information........................................................ 33 Component Identification....................................................... 35 Location of Labels............................................................. 36 Location of labels/nameplates on direct injection model engines............ 36 Engine Nameplate (Typical)................................................. 36 Emission Control Regulations................................................... 37 EPA/ARB Regulations - USA Only............................................. 37 Emission Control Labels........................................................ 37 EPA/CARB Labels (Typical).................................................. 37 EPA.................................................................... 37 EPA and CARB........................................................... 37 Engine Family.................................................................. 38 Function of Major Engine Components............................................ 39 Main Electronic Control Components and Features................................ 40 Function of Cooling System Components.......................................... 42 Diesel Fuel.................................................................... 43 Diesel Fuel Specifications................................................. 43 Additional technical fuel requirements................................. 43 Bio-diesel fuels....................................................... 44 Filling The Fuel Tank...................................................... 47 Priming the Fuel System.................................................... 48 Engine Oil..................................................................... 49 Engine Oil Specifications.................................................. 49 Service categories..................................................... 49 Definitions............................................................ 49 Additional technical engine oil requirements:.......................... 49 Engine Oil Viscosity....................................................... 49 Checking Engine Oil........................................................ 50 Adding Engine Oil.......................................................... 50 Engine Oil Capacity (Typical).............................................. 50 Engine Coolant................................................................. 51 Engine Coolant Specifications.............................................. 52 Additional technical coolant specifications:........................... 52 Alternative engine coolant............................................. 52 Filling Radiator with Engine Coolant....................................... 52 Engine Coolant Capacity (Typical).......................................... 53 Specifications................................................................. 54 Description of Model Number................................................ 54 Engine General Specifications.............................................. 54 Principal Engine Specifications................................................ 55 Engine Service Standards....................................................... 56 Tightening Torques for Standard Bolts and Nuts................................. 57 Abbreviations and Symbols...................................................... 59 Abbreviations.............................................................. 59 Symbols.................................................................... 59 Unit Conversions............................................................... 60 Unit prefixes.............................................................. 60 Units of length............................................................ 60 Units of volume............................................................ 60 Units of mass.............................................................. 60 Units of force............................................................. 60 Units of torque............................................................ 60 Units of pressure.......................................................... 60 Units of power............................................................. 60 Units of temperature....................................................... 60 Periodic Maintenance............................................................... 61 Before You Begin Servicing..................................................... 63 Introduction................................................................... 64 The Importance of Periodic Maintenance..................................... 64 Performing Periodic Maintenance............................................ 64 YANMAR Replacement Parts................................................... 64 Required EPA/ARB Maintenance - USA Only.................................... 64 EPA/ARB Installation Requirements - USA Only............................... 64 Periodic Maintenance Schedule.................................................. 65 Periodic Maintenance Procedures................................................ 67 After Initial 50 Hours of Operation........................................ 67 Replace engine oil and engine oil filter............................... 67 Check and adjust cooling fan V-belt.................................... 69 Every 50 Hours of Operation................................................ 71 Drain fuel filter/water separator...................................... 71 Check battery.......................................................... 72 Every 250 Hours of Operation............................................... 74 Drain fuel tank........................................................ 74 Replace engine oil and engine oil filter............................... 75 Check and clean radiator fins.......................................... 75 Check and adjust cooling fan V-belt.................................... 76 Clean air cleaner element.............................................. 76 Every 500 Hours of Operation............................................... 77 Replace air cleaner element............................................ 77 Replace fuel filter.................................................... 77 Clean fuel filter/water separator...................................... 78 Every 1000 Hours of Operation.............................................. 80 Drain, flush and refill cooling system with new coolant................ 80 Adjust intake/exhaust valve clearance.................................. 81 Every 1500 Hours of Operation.............................................. 82 Inspect, clean and test fuel injectors................................. 82 Inspect crankcase breather system...................................... 82 Every 2000 Hours of Operation.............................................. 83 Check and replace fuel hoses and engine coolant hoses.................. 83 Lap the intake and exhaust valves...................................... 83 Every 3000 Hours of Operation.............................................. 84 Inspect, clean and test EGR valve...................................... 84 Inspect and clean EGR lead valve....................................... 84 Engine............................................................................. 85 Before You Begin Servicing..................................................... 87 Introduction................................................................... 88 Cylinder Head Specifications................................................... 88 Adjustment Specifications.................................................. 88 Cylinder Head.............................................................. 88 Intake/Exhaust Valve and Guide............................................. 88 Rocker Arm and Shaft....................................................... 89 Valve Spring............................................................... 89 Camshaft and Timing Gear Train Specifications.................................. 90 Camshaft................................................................... 90 Idler Gear Shaft and Bushing............................................... 90 Timing Gear Backlash....................................................... 90 Crankshaft and Piston Specifications........................................... 91 Crankshaft................................................................. 91 Thrust Bearing............................................................. 91 Piston..................................................................... 91 Connecting Rod............................................................. 92 Connecting rod small end............................................... 92 Connecting rod big end................................................. 92 Cylinder Block Specifications.................................................. 93 Cylinder Block............................................................. 93 Special Torque Chart........................................................... 94 Torque for Bolts and Nuts.................................................. 94 Special Service Tools.......................................................... 95 Measuring Instruments.......................................................... 97 Cylinder Head.................................................................. 99 Cylinder Head Components................................................... 99 Components of a Cylinder Head..............................................100 Cylinder head with glow plugs..........................................100 Disassembly of Cylinder Head...............................................101 Removing the glow plugs................................................102 Removal of valve cover.................................................102 Removal of rocker arm assembly.........................................103 Disassembly of rocker arm assembly.....................................103 Removal of cylinder head...............................................103 Removal of intake/exhaust valves.......................................104 Removal of valve guides................................................105 Cleaning of Cylinder Head Components.......................................105 Inspection of Cylinder Head Components.....................................105 Inspection of push rods................................................106 Inspection of rocker arm assembly......................................106 Inspection of valve guides.............................................107 Inspection of cylinder head............................................107 Inspection of intake and exhaust valves................................107 Inspection of valve springs............................................109 Reassembly of Cylinder Head................................................110 Reassembly of valve guides.............................................110 Reassembly of intake and exhaust valves................................110 Reassembly of cylinder head............................................111 Reassembly of rocker arm reassembly....................................112 Reassembly of the valve cover..........................................113 Measuring and Adjusting Valve Clearance........................................114 3-cylinder engines.........................................................114 Crankshaft and Camshaft Components.............................................116 Disassembly of Engine......................................................117 Disassembly of Camshaft and Timing Components..............................118 Removal of timing gear case cover......................................118 Checking timing gear backlash..........................................118 Measuring idler gear-to-crankshaft gear backlash.......................118 Measuring idler gear-to-camshaft gear backlash.........................119 Removal of timing gears................................................119 Removal of oil pan.....................................................119 Removal of camshaft....................................................120 Removal of gear case or front plate....................................121 Disassembly of Crankshaft and Piston Components............................121 Removal of pistons.....................................................121 Removal of crankshaft..................................................123 Inspection of Crankshaft and Camshaft Components...........................124 Replacement of crankshaft oil seals....................................125 Measure crankshaft bearing oil clearance...............................125 Inspection of cylinder block...........................................125 Inspection of pistons, piston rings and wrist pin......................125 Inspection of connecting rod...........................................127 Inspection of tappets..................................................128 Inspection of crankshaft...............................................128 Inspection of camshaft.................................................129 Inspection of camshaft bushing and bores...............................130 Inspection of idler gear and shaft.....................................130 Honing and Boring..........................................................130 Reassembly of Crankshaft and Piston Components.............................131 Reassembly of pistons..................................................131 Installation of crankshaft.............................................134 Installation of pistons................................................135 Reassembly of Camshaft and Timing Components...............................137 Installation of gear case or front plate...............................137 Installation of camshaft...............................................137 Installation of timing gears...........................................138 Installation of gear case cover........................................138 Installation of oil pan................................................139 Final Reassembly of Engine.................................................140 EGR system.....................................................................141 EGR System.................................................................141 Inspecting/Cleaning EGR Related Components.................................144 EGR valve..............................................................144 EGR valve operation checks.............................................144 Cleaning the EGR valves................................................145 Lead valves............................................................145 Precautions for installation...........................................146 EGR pipe and other connecting elbows...................................146 Installing EGR related components/parts................................146 Fuel System........................................................................147 Before You Begin Servicing.....................................................149 Trochoid Fuel Pump.........................................................150 Electronically Controlled Governor.........................................150 Fuel System Specifications.....................................................151 Special Torque Chart.......................................................151 Special Service Tools..........................................................153 Measuring Instruments..........................................................153 Fuel System Diagram............................................................154 Fuel System Components.........................................................155 Fuel Injection Pump............................................................157 Removal of Fuel Injection Pump.............................................157 Installation of Fuel Injection Pump........................................161 Checking and Adjusting Fuel Injection Timing...................................166 Determining the Fuel Injection Timing Specification........................166 (6.8 × 2) = 13.6 + 4 = 17.6° fuel injection timing.....................167 Checking Fuel Injection Timing.............................................167 Adjusting Fuel Injection Timing............................................170 Fuel Injectors.................................................................171 Removal of Fuel Injectors..................................................171 Testing of Fuel Injectors..................................................173 Disassembly and Inspection of Fuel Injectors...............................174 Adjusting Fuel Injector Pressure...........................................176 Reassembly of Fuel Injectors...............................................176 Installation of the Fuel Injectors.........................................177 Cooling System.....................................................................179 Before You Begin Servicing.....................................................181 Introduction...................................................................182 Cooling System Diagram.........................................................182 Engine Coolant Pump Components.................................................183 Engine Coolant System Check....................................................184 Engine Coolant Pump............................................................184 Removal of Engine Coolant Pump.............................................184 Disassembly of Engine Coolant Pump.........................................186 Cleaning and Inspection....................................................186 Temperature switch.....................................................186 Water temperature sensor...............................................187 Thermostat.............................................................187 Radiator cap...........................................................187 Reassembly of Engine Coolant Pump..........................................188 Installation of Engine Coolant Pump........................................188 Lubrication System.................................................................191 Before You Begin Servicing.....................................................193 Introduction...................................................................194 Oil Pump Service Information...................................................194 Engine oil pressure........................................................194 Rotor shaft clearance......................................................194 Lubrication System Diagram.....................................................195 Checking Engine Oil Pressure...................................................196 Trochoid Oil Pump..............................................................196 Oil Pump Components........................................................196 Disassembly of Oil Pump....................................................197 Cleaning and Inspection....................................................197 Check outer rotor outside clearance....................................197 Outer rotor to inner rotor tip clearance...............................198 Check outer rotor side clearance.......................................198 Check rotor shaft clearance............................................198 Reassembly of Oil Pump.....................................................199 Starter Motor......................................................................201 Before You Begin Servicing.....................................................203 Introduction...................................................................204 Starter Motor Information......................................................204 Standard and Optional......................................................204 Starter Motor Specifications...................................................205 Starter Motor Troubleshooting..................................................206 Starter Motor Components.......................................................207 Starter Motor..................................................................208 Removal of Starter Motor...................................................208 Disassembly of Starter Motor...............................................208 Inspection and Maintenance.................................................211 No-load Test...............................................................218 Installation of Starter Motor..............................................218 Alternator.........................................................................219 Before You Begin Servicing.....................................................221 Introduction...................................................................222 Dynamo and Alternator Information..............................................222 Standard and Optional Dynamos..............................................222 Standard and Optional Alternators..........................................222 Alternator Specifications......................................................223 Dynamo Specifications..........................................................223 Alternator Troubleshooting.....................................................224 Alternator Components..........................................................225 Alternator Wiring Diagram......................................................226 Alternator Standard Output.....................................................227 Alternator.....................................................................228 Removal of Alternator......................................................228 Disassembly of Alternator..................................................228 Reassembly of Alternator...................................................230 Installation of Alternator.................................................232 Dynamo Component Location......................................................233 Dynamo Wiring Diagram..........................................................234 Operation of Dynamo............................................................234 Dynamo Standard Output.........................................................235 Testing of Dynamo..............................................................236 Testing Stator Coil Continuity.............................................236 Testing Stator Coil Short-to-Ground........................................236 Testing Dynamo Regulated Output............................................236 Dynamo.........................................................................236 Removal of Dynamo..........................................................236 Disassembly of Dynamo......................................................237 Reassembly of Dynamo.......................................................237 Installation of Dynamo.....................................................238 ELECTRONIC CONTROL SYSTEM..........................................................239 Before You Begin Servicing.....................................................241 Introduction...................................................................242 Electronic Control System......................................................242 Electronic control harness connections.........................................243 Electric Wiring....................................................................245 Electric Wiring Precautions....................................................247 Electrical Wire Resistance.....................................................248 Battery Cable Resistance.......................................................249 Electrical Wire Sizes - Voltage Drop...........................................250 Conversion of AWG to European Standards........................................251 Failure Diagnosis..................................................................253 Special Service Tools..........................................................255 Troubleshooting By Measuring Compression Pressure..............................256 Compression Pressure Measurement Method....................................256 Standard compression pressure (reference value)........................258 Engine speed and compression pressure (use for reference)..............258 Measured value and troubleshooting.....................................259 Quick Reference Table For Troubleshooting......................................259 Failure Diagnostic List....................................................261
DESCRIPTION:
Yanmar 3TNV88 Industrial Engine Service Manual
FOREWORD:
This Service Manual has been developed for the exclusive use of service and repair professionals such as YANMAR authorized distributors and YANMAR authorized dealers. It is written with these professionals in mind and may not contain the necessary detail or safety statements that may be required for a non-professional to perform the service or repair property and/or safely. Please contact an authorized YANMAR repair or service professional before working on your YANMAR product.
INTRODUCTION:
- This Service Manual describes the service procedures for the TNV series direct injection engines. These engines are certified by the US. EPA. Caiifomia ARB for industrial use. Please use this rnanual for accurate. quick and safe servicing of the engine. Since the directions in this manual are fora typical engine.
- some specifications and components may be different from your engine. 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 lieid modifications to the equipment. Contact an authorized YANMAR industrial engine dealer or distributor for answers to any questions relating to field modifications.
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