Yanmar 3TNV88F Industrial Engine Service Manual – PDF DOWNLOAD
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Yanmar 3TNV88F Industrial Engine Service Manual – PDF DOWNLOADYanmar 3TNV88F Industrial Engine Service Manual – PDF DOWNLOAD
YANMAR 3TNV88F INDUSTRIAL ENGINE SERVICE MANUAL – PDF DOWNLOAD:
DESCRIPTION:
Yanmar 3TNV88F Industrial Engine Service Manual – PDF DOWNLOAD
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. lt is written with these professionals in mind and may not contain the necessary detail or safety statements that may Π¬Π΅ required for Π° non-professional to perform the service or repair properly and/or safely. Please contact an authorized YANMAR repair or service professional before working ΠΎΠΏ your YANMAR product.
INTRODUCTION:
This Service Manual describes the service procedures for the TNV series direct injection engines. These engines are certified Π¬Ρ the U.S. ΠΠ Π, California ARB for industrial use. Please use this manual for accurate, quick and safe servicing of the engine. Since the directions in this manual are for Π° typical engine, some specifications and components may Π¬Π΅ different from your engine.
Refer to the documentation supplied Π¬Ρ the optional equipment manufacturer for specific service instructions. YANMAR products are continuously undergoing improvement. This Service Manual might not address possiΠ«e field modifications to the equipment. Contact an authorized YANMAR industrial engine dealer or distributor for answers to any questions relating to field modifications.
TABLE OF CONTENTS:
Yanmar 3TNV88F Industrial Engine Service Manual – PDF DOWNLOAD
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
Manufacturerβs Warranty Period:............................................ 12
Warranty Coverage:......................................................... 13
Warranted Parts:........................................................... 13
Exclusions:................................................................ 14
Ownerβs 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 Γ 2) = 13.6 + 4 = 17.6Β° 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
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