Yanmar TNV Industrial Engines Workshop Repair Service Manual PDF 2TNV70 3TNV70 3TNV76 3TNV88C Troubleshooting - MYANMTNVOPEK.zip
A full service and repair guide featuring Electrical Wiring Diagrams for Yanmar TNV-series Industrial Engines, containing every technical detail needed to service, troubleshoot, fix, and overhaul these engines to a professional mechanic's standard.
Yanmar TNV-series Industrial Engines 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: 3,813 pages
File Format: PDF
Language: English
0ATNV-G00101 - Yanmar TNV-series (3TNV82A(-B), 3TNV84(T)(-B), 3TNV88(-B)(-U), 4TNV84(T)(-Z), 4TNV88(-B)(-U), 4TNV94L, 4TNV98(T)(-Z)(-E), 4TNV106(T)) Service Manual.pdf.pdf
0ATNVG00100 - Yanmar TNV-series Industrial Engines Operation Manual.pdf
0ATNVG00101 - Yanmar TNV-series Industrial Engines (2TNV70, 3TNV70, 3TNV82A(-B), 3TNV84(T)(-B), 3TNV88(-B)(-U), 4TNV84(T)(-Z), 4TNV88(-B)(-U), 4TNV94L, 4TNV98(T)(-Z)(-E), 4TNV106(T)) Operation Manual.pdf
0BTNV0-G0000 - Yanmar TNV-series (3TNV82A, 3TNV84(T), 3TNV88, 4TNV84(T), 4TNV88, 4TNV94L, 4TNV98(T), 4TNV106(T)) Service Manual.pdf
0BTNV0-G0100 - Yanmar TNV-series (2TNV70, 3TNV70, 3TNV76 Industrial Engines) Service Manual.pdf
0BTNV-G00200 - Yanmar TNV-series (2TNV70, 3TNV70, 3TNV76 Industrial Engines) Service Manual.pdf
0BTNV-G00200 - Yanmar TNV-series (2TNV70, 3TNV70, 3TNV76 Industrial Engines) Service Manual.pdf
M9961-02E050 - Yamar Industrial Diesel Engine 3TNV·4TNV Series (Direct Injection System) Service Manual.pdf
OBTN4G00200 - Yanmar TNV-series (3TNV88C, 3TNV86CT, 4TNV88C, 4TNV86CT, 4TNV98C, 4TNV98CT) Industrial Engines) Service Manual.pdf
OBTN4G00300 - Yanmar TNV-series (3TNM74F, 3TNV74F, 3TNV80F Industrial Engines) Service Manual.pdf
OBTNV-U00102 - Yanmar TNV-series (3TNV82A(-B), 3TNV84(T)(-B), 3TNV88(-B)(-U), 4TNV84(T)(-Z), 4TNV88(-B)(-U), 4TNV94L, 4TNV98(T)(-Z)(-E), 4TNV106(T)) Service Manual.pdf
ODTN4G00200 - Yanmar TNV-series Industrial Engines) Troubleshooting Manual.xps.pdf
Yanmar TNV-Series Diagnostic Service Tool Manual.pdf
MAIN SECTIONS
1. GENERAL...17
2. INSPECTION ADJUSTMENT...38
3. TROUBLESHOOTING...69
4. DISASSEMBLY, INSPECTION AND REASSEMBLY OF ENGINES...75
5. LUBRICATION SYSTEM...124
6. COOLING SYSTEM...128
7. FUEL INJECTION PUMP/GOVERNOR...130
8. TRBOCHAGER: DISASSEMBLY, INSPECTION AND REASSEMBLY...134
9. STARTING MOTOR...156
10. ALTERNATOR...192
11. ELECTRIC WIRING...196
12. SERVICE STANDARDS...201
13. TIGHTENING TORQUE for BOLTS and NUTS...212
TABLE OF CONTENTS
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
Retail Purchaser Registration...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...37
Engine Nameplate (Typical)...38
Emission Control Regulations...38
EPA / ARB Regulations - USA Only...38
Emission Control Labels...38
The 97/68/EC Directive Certified Engines...39
Engine Family...39
Function of Major Engine Components...40
MAIN ELECTRONIC CONTROL COMPONENTS AND FEATURES...41
Function of Cooling System Components...43
Diesel Fuel...44
Diesel Fuel Specifications...44
Additional Technical Fuel Requirements...44
Bio-Diesel Fuels...45
KIT PARTS LIST FOR B20 (TNV DI Engines)...47
Filling The Fuel Tank...49
Priming the Fuel System...50
Engine Oil...51
Engine Oil Specifications...51
Service Categories...51
Definitions...51
Additional Technical Engine Oil Requirements:...51
Engine Oil Viscosity...51
Checking Engine Oil...52
Adding Engine Oil...52
Engine Oil Capacity (Typical)...52
Engine Coolant...53
Engine Coolant Specifications...54
Additional Technical Coolant Specifications:...54
Alternative Engine Coolant...54
Filling Radiator with Engine Coolant...54
Engine Coolant Capacity (Typical)...55
Specifications...56
Description of Model Number...56
Engine Speed Specifications...56
Principal Engine Specifications...58
3TNV82A (~ EPA Tier2)...58
Engine Service Standards...83
Tightening Torques for Standard Bolts and Nuts...84
Abbreviations and Symbols...86
Abbreviations...86
Symbols...86
Unit Conversions...87
Unit Prefixes...87
Units of Length...87
Units of Volume...87
Units of Mass...87
Units of Force...87
Units of Torque...87
Units of Pressure...87
Units of Power...87
Units of Temperature...87
Periodic Maintenance...89
Before You Begin Servicing...91
Introduction...92
The Importance of Periodic Maintenance...92
Performing Periodic Maintenance...92
Yanmar Replacement Parts...92
Required EPA / ARB Maintenance - USA Only...92
EPA / ARB Installation Requirements - USA Only...92
Periodic Maintenance Schedule...93
Periodic Maintenance Procedures...96
After Initial 50 Hours of Operation...96
Replace Engine Oil and Engine Oil Filter...96
Check and Adjust Cooling Fan V-Belt...98
Every 50 Hours of Operation...100
Drain Fuel Filter / Water Separator...100
Check Battery...101
Every 250 Hours of Operation...103
Drain Fuel Tank...103
Replace Engine Oil and Engine Oil Filter...104
Check and Clean Radiator Fins...105
Check and Adjust Cooling Fan V-Belt...105
Check and Adjust the Governor Lever and Engine Speed Control (This does not apply to the following electronically controlled engines: 4TNV84T-Z, 4TNV98-E, Z, and 4TNV98T-Z.)...105
Clean Air Cleaner Element...106
Every 500 Hours of Operation...108
Replace Air Cleaner Element...108
Replace Fuel Filter...108
Clean Fuel Filter / Water Separator...110
Every 1000 Hours of Operation...111
Drain, Flush and Refill Cooling System With New Coolant...111
Adjust Intake / Exhaust Valve Clearance...113
Every 1500 Hours of Operation...113
Inspect, Clean and Test Fuel Injectors...113
Clean EGR Cooler 4TNV84T-Z, 4TNV98T-Z...114
Inspect Crankcase Breather System...114
Every 2000 Hours of Operation...115
Check and Replace Fuel Hoses and Engine Coolant Hoses...115
Lap the Intake and Exhaust Valves...116
Every 3000 Hours of Operation...116
Inspect Turbocharger (Blower Wash as Necessary) - 3TNV84T, 4TNV98T, 4TNV84T, and 4TNV106T, 3TNV84T-Z, 4TNV84T-Z, 4TNV98T-Z...116
Inspect, Clean and Test EGR Valve 4TNV84T-Z, 4TNV98T-E, 4TNV98-Z, 4TNV98T-Z...116
Inspect and Clean EGR Lead Valve 4TNV84T-Z, 4TNV98T-Z...116
Engine...117
Before You Begin Servicing...119
Introduction...120
Cylinder Head Specifications...120
Adjustment Specifications...120
Cylinder Head...120
Intake / Exhaust Valve and Guide...121
Push Rod...123
Rocker Arm and Shaft...123
Valve Spring...124
Camshaft and Timing Gear Train Specifications...125
Camshaft...125
Idler Gear Shaft and Bushing...127
Timing Gear Backlash...127
Crankshaft and Piston Specifications...128
Crankshaft...128
Thrust Bearing...129
Piston...130
Piston Ring...132
Connecting Rod...136
Connecting Rod Small End...136
Connecting Rod Big End...136
Tappet...137
Cylinder Block Specifications...138
Cylinder Block...138
Special Torque Chart...139
Torque for Bolts and Nuts...139
Special Service Tools...142
Measuring Instruments...146
2-Valve Cylinder Head...148
2-Valve Cylinder Head Components...148
Components of a two-valve cylinder head...149
Disassembly of 2-Valve Cylinder Head...150
Removing the glow plugs...151
Removal of Valve Cover...151
Removal of Rocker Arm Assembly...152
Disassembly of Rocker Arm Assembly...152
Removal of Cylinder Head...152
Removal of Intake / Exhaust Valves...153
Removal of Valve Guides...154
Cleaning of Cylinder Head Components...154
Inspection of Cylinder Head Components...154
Inspection of Push Rods...155
Inspection of Rocker Arm Assembly...155
Inspection of Valve Guides...155
Inspection of Cylinder Head...156
Inspection of Intake and Exhaust Valves...156
Inspection of Valve Springs...158
Reassembly of Cylinder Head...158
Reassembly of Valve Guides...158
Reassembly of Intake and Exhaust Valves...159
Reassembly of Cylinder Head...160
Reassembly of Rocker Arm Reassembly...161
Reassembly of the Valve Cover...162
4-Valve Cylinder Head...163
4-Valve Cylinder Head Components...163
Disassembly of 4-Valve Cylinder Head...164
Removal of Valve Cover...166
Removal of Rocker Arm Assembly...167
Disassembly of Rocker Arm Assembly...167
Removal of Cylinder Head...168
Removal of Intake and Exhaust Valves...168
Removal of Valve Guides...169
Cleaning of Cylinder Head Components...169
Inspection of Cylinder Head Components...170
Inspection of Push Rods...170
Inspection of Rocker Arm Assembly...170
Inspection of Valve Guides...171
Inspection of Cylinder Head...171
Inspection of Intake and Exhaust Valves...172
Inspection of Valve Springs...174
Inspection of Valve Bridges...174
Reassembly of Cylinder Head...175
Reassembly of Valve Guides...175
Reassembly of Intake and Exhaust Valves...175
Reassembly of Cylinder Head...176
Reassembly of Rocker Arm Assembly...177
Reassembly of the Valve Cover...179
Measuring and Adjusting Valve Clearance...180
2-Valve Cylinder Heads...181
4-Valve Cylinder Heads...182
Crankshaft and Camshaft Components...185
Disassembly of Engine...186
Disassembly of Camshaft and Timing Components...187
Removal of Timing Gear Case Cover...187
Checking Timing Gear Backlash...187
Measuring Idler Gear-to-Crankshaft Gear Backlash...188
Measuring Idler Gear-to-Camshaft Gear Backlash...188
Removal of Timing Gears...188
Removal of Oil Pan...189
Removal of Camshaft...190
Removal of Gear Case or Front Plate...191
Disassembly of Crankshaft and Piston Components...192
Removal of Pistons...192
Removal of Crankshaft...194
Inspection of Crankshaft and Camshaft Components...196
Replacement of Crankshaft Oil Seals...196
Measure Crankshaft Bearing Oil Clearance...196
Inspection of Cylinder Block...197
Inspection of Pistons, Piston Rings and Wrist Pin...197
Inspection of Connecting Rod...199
Inspection of Tappets...199
Inspection of Crankshaft...200
Inspection of Camshaft...201
Inspection of Camshaft Bushing and Bores...201
Inspection of Idler Gear and Shaft...201
Honing and Boring...202
Reassembly of Crankshaft and Piston Components...203
Reassembly of Pistons...203
Installation of Crankshaft...206
Installation of Pistons...207
Reassembly of Camshaft and Timing Components...209
Installation of Gear Case or Front Plate...209
Installation of Camshaft...210
Installation of Timing Gears...211
Installation of Gear Case Cover...211
Installation of Oil Pan...212
Final Reassembly of Engine...213
EGR system...214
EGR system...214
EGR system...216
4TNV98-E, 4TNV98-Z...218
4TNV84T-Z, 4TNV98T-Z...218
Inspecting/cleaning EGR related components...219
EGR Valve...219
EGR valve operation checks...219
Cleaning the EGR valves...220
Lead valves...220
Precautions for installation...221
EGR cooler...221
EGR pipe and other connecting elbows...221
Installing EGR related components/parts...222
Fuel System...223
Before You Begin Servicing...225
Introduction...226
Fuel Injection Pump...226