Yanmar Industrial Engines 3TNM74F, 3TNV74F, 3TNV80F Repair Service Manual (0BTN4-EN0031)
Complete service repair manual with Electrical Wiring Diagrams for Yanmar Industrial Engines 3TNM74F, 3TNV74F, 3TNV80F, with all the technical information to maintain, diagnose, repair, rebuild like professional mechanics.
Yanmar Industrial Engines 3TNM74F, 3TNV74F, 3TNV80F Models workshop service repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
PRODUCT DETAILS:
Total Pages: 252 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
0BTN4-EN0031 - Yanmar Industrial Engines 3TNM74F, 3TNV74F, 3TNV80F Service Manual.pdf
MAIN SECTIONS
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...29
Component Identification...31
Location of Labels...32
Engine Nameplate (Typical)...32
EPA/ARB Emission Control Regulations - USA Only...32
Emission Control Labels...33
EPA/CARB labels (Typical)...33
EPA...33
EPA and CARB...33
Engine Family...33
Function of Major Engine Components...34
Function of Cooling System Components...36
Diesel Fuel...37
Diesel Fuel Specifications...37
Additional technical fuel requirements...37
Bio-diesel fuels...37
Filling the Fuel Tank...41
Priming the Fuel System...42
Engine Oil...43
Engine Oil Specifications...43
Service categories...43
Definitions...43
Additional technical engine oil requirements:...43
Engine Oil Viscosity...43
Checking Engine Oil...44
Adding Engine Oil...44
Engine Oil Capacity (Typical)...44
Engine Coolant...45
Engine Coolant Specifications...46
Additional technical coolant specifications:...46
Alternative engine coolant...46
Filling Radiator with Engine Coolant...46
Engine Coolant Capacity (Typical)...47
Specifications...48
Description of Model Number...48
Engine General Specifications...48
Principal Engine Specifications...49
3TNM74F...49
Engine Service Information...52
Tightening Torques for Standard Bolts and Nuts...53
Abbreviations and Symbols...55
Abbreviations...55
Symbols...55
Unit Conversions...56
Unit prefixes...56
Units of length...56
Units of volume...56
Units of mass...56
Units of force...56
Units of torque...56
Units of pressure...56
Units of power...56
Units of temperature...56
Periodic Maintenance...57
Before You Begin Servicing...59
Introduction...60
The Importance of Periodic Maintenance...60
Performing Periodic Maintenance...60
YANMAR Replacement Parts...60
Required EPA/ARB Maintenance - USA Only...60
EPA/ARB Installation Requirements - USA Only...60
Periodic Maintenance Schedule...61
Periodic Maintenance Procedures...63
After Initial 50 Hours of Operation...63
Check and adjust cooling fan V-belt...63
Every 50 Hours of Operation...64
Drain fuel filter/water separator...64
Check battery...66
Every 250 Hours of Operation...67
Drain fuel tank...67
Replace engine oil and engine oil filter...68
Check and clean radiator fins...70
Check and adjust cooling fan V-belt...70
Check and adjust the governor lever and engine speed control...70
Clean air cleaner element...71
Every 500 Hours of Operation...72
Replace air cleaner element...72
Replace fuel filter...73
Clean fuel filter/water separator...74
Every 1000 Hours of Operation...75
Adjust intake/exhaust valve clearance...75
Every 1500 Hours of Operation...76
Inspect, clean and test fuel injectors...76
Inspect crankcase breather system...76
Every 2000 Hours of Operation...77
Check and replace fuel hoses and engine coolant hoses...77
Lap the intake and exhaust valves...77
Drain, flush and refill cooling system with new coolant...78
Engine...81
Before You Begin Servicing...83
Introduction...84
Cylinder Head Specifications...84
Adjustment Specifications...84
Cylinder Head...84
Push Rod...85
Valve Spring...85
Rocker Arm and Shaft...86
Camshaft and Timing Gear Train Specifications...86
Camshaft...86
Idler Gear Shaft and Bushing...87
Timing Gear Backlash...87
Crankshaft and Pistons Specifications...88
Crankshaft...88
Thrust Bearing...89
Piston...89
Connecting Rod...91
Connecting rod small end...91
Connecting rod big end...92
Connecting rod distortion...92
Tappet...92
Cylinder Block Specifications...92
Cylinder Block...92
Special Torque Chart...93
Torque for Bolts and Nuts...93
Special Service Tools...94
Measuring Instruments...96
Cylinder Head...98
Cylinder Head Components...98
Disassembly of Cylinder Head...99
Removal of intake manifold/valve cover...100
Removal of glow plugs...100
Removal of rocker arm assembly...100
Disassembly of rocker arm assembly...101
Removal of cylinder head...101
Removal of intake/exhaust valves...102
Removal of valve guides...102
Cleaning of Cylinder Head Components...103
Inspection of Cylinder Head Components...103
Inspection of push rods...103
Inspection of rocker arm assembly...103
Inspection of valve guides...104
Inspection of cylinder head...104
Inspection of intake and exhaust valves...104
Inspection of valve springs...106
Reassembly of Cylinder Head...107
Reassembly of valve guides...107
Reassembly of intake and exhaust valves...107
Reassembly of cylinder head...108
Reassembly of rocker arm assembly...109
Reassembly of intake manifold/valve cover...110
Measuring and Adjusting Valve Clearance...111
Cylinder Block...113
Crankshaft and Camshaft Components...113
3TNV74F, 3TNV80F...113
3TNM74F...115
Disassembly of Cylinder Block Components...116
Disassembly of Camshaft and Timing Components...117
Removal of timing gear case cover...117
Checking timing gear backlash...117
Measuring idler gear-to-crankshaft gear backlash...118
Measuring idler gear-to-camshaft gear backlash...118
Removal of timing gears...118
Removal of oil pan...119
Removal of oil pan (with ladder frame)...120
Removal of camshaft...120
Removal of gear case (3TNV74F, 3TNV80F only)...121
Disassembly of Crankshaft and Piston Components...122
Removal of pistons...122
Removal of crankshaft...123
Inspection of Crankshaft and Camshaft Components...125
Replacement of crankshaft oil seals...125
Crankshaft bearing oil clearance...126
Inspection of cylinder block...126
Inspection of pistons, piston rings and wrist pin...127
Inspection of connecting rod...128
Inspection of tappets...129
Inspection of crankshaft...130
Reconditioning the Crankshaft...131
Inspection of camshaft...131
Inspection of camshaft bushing and bores...132
Inspection of idler gear and shaft...132
Honing and Boring...132
Reassembly of Crankshaft and Piston Components...133
Reassembly of pistons...134
Installation of crankshaft...136
Installation of pistons...137
Reassembly of Camshaft and Timing Components...139
Installation of gear case (3TNV74F, 3TNV80F)...139
Installation of camshaft...139
Installation of timing gears...139
Installation of gear case cover (3TNM74F)...140
Installation of oil pan...141
Final assembly of engine...142
Fuel System...143
Before You Begin Servicing...145
Introduction...146
Fuel Injection Pump (ML: for 3TNV74F and 3TNV80F, MC: for 3TNM74F)...146
Stop Solenoid...147
3TNM74F, 3TNV74F, 3TNV80F...148
Fuel System Specifications...150
Special Torque Chart...150
Test and Adjustment Specifications...150
Special Service Tools...151
Measuring Instruments...151
Fuel System Diagram...152
Fuel System Components...153
Fuel Injection Lines...154
Removal of High-Pressure Fuel Injection Lines...154
Installation of High-Pressure Fuel Injection Lines...154
Removal of Fuel Return Line...155
Installation of Fuel Return Line...155
Fuel Injection Pump...156
Removal of Fuel Injection Pump...156
Installation of Fuel Injection Pump...159
Checking and Adjusting Fuel Injection Timing...161
Checking Fuel Injection Timing...161
Adjusting Fuel Injection Timing...164
3TNV74F, 3TNV80F...164
3TNM74F...165
Fuel Injectors...167
Removal of Fuel Injectors...167
Testing of Fuel Injectors...167
Disassembly and Inspection of Fuel Injectors...170
Adjusting Fuel Injector Pressure...171
Reassembly of Fuel Injectors...172
Installation of the Fuel Injectors...172
Cooling System...173
Before You Begin Servicing...175
Introduction...176
Cooling System Diagram...176
Engine Coolant Pump Components...177
Engine Coolant System Check...178
Engine Coolant Pump...178
Disassembly of Engine Coolant Pump...178
Cleaning and Inspection...179
Temperature switch...179
Thermostat...180
Radiator cap...180
Reassembly of Engine Coolant Pump...180
Lubrication System...183
Before You Begin Servicing...185
Introduction...186
Oil Pump Service Information...186
Engine oil pressure...186
Outer rotor outside clearance...186
Outer rotor side clearance...186
Outer rotor to inner rotor tip clearance...186
Inner Rotor and Gear Boss Clearance (3TNV74F, 3TNV80F)...186
Lubrication System Diagram...187
Checking Engine Oil Pressure...188
Trochoid Oil Pump (3TNV74F, 3TNV80F)...188
Oil Pump Components...188
Disassembly of Oil Pump...189
Cleaning and Inspection...190
Check outer rotor outside clearance...190
Outer rotor to inner rotor tip clearance...190
Check outer rotor side clearance...190
Check inner rotor and gear boss clearance...191
Reassembly of Oil Pump...191
Trochoid Oil Pump (3TNM74F)...192
Components...192
Disassembling the Oil Pump...192
Cleaning and Inspection...193
Checking outer rotor outside clearance...193
Checking outer rotor to inner rotor tip clearance...193
Checking outer rotor side clearance...193
Checking rotor shaft clearance...194
Assembling the 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...202
Disassembly of Starter Motor...202
Cleaning and Inspection...205
Armature...205
Field coil...206
Brush holder...207
Solenoid switch...207
Pinion clutch assembly...208
Reassembly of Starter Motor...209
Check Pinion Projection Length...211
No-Load Test...211
Installation of Starter Motor...212
Alternator...213
Before You Begin Servicing...215
Introduction...216
Standard and Optional Dynamo Information...216
Standard and Optional Alternator Information...216
Alternator Specifications...217
Dynamo Specifications...217
Alternator Troubleshooting...218
Alternator Components...219
Alternator Wiring Diagram...220
Alternator Standard Output...221
Alternator...222
Removal of Alternator...222
Disassembly of Alternator...222
Reassembly of Alternator...224
Installation of Alternator...226
Dynamo Component Location...227
Dynamo Wiring Diagram...228
Operation of Dynamo...228
Dynamo Standard Output...229
Testing of Dynamo...230
Testing Stator Coil Continuity...230
Testing Stator Coil Short-to-Ground...230
Testing Dynamo Regulated Output...230
Dynamo...230
Removal of Dynamo...230
Disassembly of Dynamo...231
Reassembly of Dynamo...231
Installation of Dynamo...232
Electric Wiring...233
Electric Wiring Precautions...235
Electric Wire Resistance...236
Battery Cable Resistance...237
Electrical Wire Sizes - Voltage Drop...238
Conversion of AWG to European Standards...239
Troubleshooting...241
Special Service Tools...243
Troubleshooting By Measuring Compression Pressure...244
Compression Pressure Measurement Method...244
Engine speed and compression pressure (use for reference)...245
Quick Reference Table For Troubleshooting...246
Troubleshooting Charts...247
