3. ENGINE
TNV IDI Service Manual
TNV
SERVICE MANUAL
3TNV72
P/N: 0BTNV-U00300
series
INDUSTRIAL
ENGINES
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 properly and / or safely. Please contact an authorized Yanmar repair or service
professional before working on your Yanmar product.
Disclaimers:
All information, illustrations and specifications in this manual are based on the latest information available at
the time of publishing. The illustrations used in this manual are intended as representative reference views
only. Moreover, because of our continuous product improvement policy, we may modify information,
illustrations, and / or specifications to explain and / or exemplify a product, service, or maintenance
improvement. We reserve the right to make any change at any time.
Yanmar and are registered trademarks of Yanmar Co., Ltd. in Japan, the United States and / or
other countries.
All Rights Reserved:
No part of this publication may be reproduced or used in any form by any means - graphic, electronic, or
mechanical, including photocopying, recording, taping, or information storage and retrieval systems - without
the written permission of Yanmar Co., Ltd.
© 2005 Yanmar Co. Ltd.
ii TNV IDI Service Manual
TNV IDI Service Manual
TABLE OF
CONTENTS
Table of Contents................................................................................... iii
Introduction ......................................................................................... 1-1
Yanmar Warranties.............................................................................. 2-1
Safety.................................................................................................... 3-1
General Service Information .............................................................. 4-1
Periodic Maintenance ......................................................................... 5-1
Engine .................................................................................................. 6-1
Fuel System ......................................................................................... 7-1
Cooling System ................................................................................... 8-1
Page
Lubrication System............................................................................. 9-1
Starter Motor...................................................................................... 10-1
Alternator ........................................................................................... 11-1
Electric Wiring ................................................................................... 12-1
Troubleshooting................................................................................ 13-1
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iii
TABLE OF CONTENTS
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iv TNV IDI Service Manual
TNV IDI Service Manual
Section 1
INTRODUCTION
This Service Manual describes the service
procedures for the TNV series indirect injection
engines. These engines are certified by the U.S.
EPA, California ARB and/or the 97/68/EC Directive
for industrial use.
Please use this manual for accurate, quick and safe
servicing of the engine. Since the directions in this
manual are for a 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 field 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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1-1
INTRODUCTION
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1-2 TNV IDI Service Manual
TNV IDI Service Manual
WARRANTIES
Yanmar Limited Warranty................................................................ 2-3
What is Covered by this Warranty? .......................................... 2-3
How Long is the Warranty Period? ........................................... 2-3
What the Engine Owner Must Do: ............................................ 2-3
To Locate an Authorized Yanmar Industrial Engine Dealer
or Distributor:............................................................................. 2-4
What Yanmar Will Do: .............................................................. 2-4
What is Not Covered by this Warranty? ................................... 2-4
Warranty Limitations: ................................................................ 2-5
Warranty Modifications: ............................................................ 2-5
Questions: ................................................................................. 2-5
Retail Purchaser Registration.................................................... 2-5
Emission System Warranty ............................................................. 2-6
Yanmar Co., Ltd. Limited Emission Control System Warranty -
USA Only......................................................................................... 2-6
Your Warranty Rights and Obligations: ..................................... 2-6
Manufacturer’s Warranty Period:............................................... 2-6
Warranty Coverage: .................................................................. 2-7
Warranted Parts: ....................................................................... 2-7
Exclusions: ................................................................................ 2-8
Owner’s Warranty Responsibilities:........................................... 2-8
Section 2
YANMAR
Page
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2-1
YANMAR WARRANTIES
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2-2 TNV IDI Service Manual
Yanmar Limited Warranty
YANMAR WARRANTIES
YANMAR LIMITED WARRANTY
What is Covered by this Warranty?
Yanmar warrants to the original retail purchaser that a new Yanmar TNV Series Industrial Engine will be free
from defects in material and / or workmanship for the duration of the warranty period.
Note: Yanmar engines may be equipped with external components including, but not limited to: wiring
harnesses, electrical devices, control panels, radiators, air filters, fuel filters, and / or exhaust systems
that are supplied and / or installed by manufacturers other than Yanmar. For warranty information on
such external components, please contact the machine or component manufacturer directly or see
your authorized Yanmar dealer or distributor.
THIS WARRANTY IS PROVIDED IN LIEU OF ALL OTHER WARRANTIES, EXPRESSED OR IMPLIED.
YANMAR SPECIFICALLY DISCLAIMS ANY IMPLIED WARRANTIES OF MERCHANTABILITY OR
FITNESS FOR A PARTICULAR PURPOSE, except where such disclaimer is prohibited by law. IF SUCH
DISCLAIMER IS PROHIBITED BY LAW, THEN IMPLIED WARRANTIES SHALL BE LIMITED IN
DURATION TO THE LIFE OF THE EXPRESSED WARRANTY.
How Long is the Warranty Period?
The Yanmar standard limited warranty period runs for a period of twenty-four (24) months or
two-thousand (2000) engine operation hours, whichever occurs first. An extended limited warranty of
thirty-six (36) months or three thousand (3000) engine operating hours, whichever occurs first, is provided
for these specific parts only: the cylinder block, cylinder head, crankshaft forging, connecting rods, flywheel,
flywheel housing, camshaft, timing gear, and gear case. The Warranty Period for both the standard limited
warranty and the extended limited warranty (by duration or operation hours) begins on the date of delivery to
the original retail purchaser and is valid only until the applicable warranted duration has passed or the
operation hours are exceeded, whichever comes first.
What the Engine Owner Must Do:
If you believe your Yanmar engine has experienced a failure due to a defect in material and / or
workmanship, you must contact an authorized Yanmar industrial engine dealer or distributor within thirty (30)
days of discovering the failure. You must provide proof of ownership of the engine, proof of the date of the
engine purchase and delivery, and documentation of the engine operation hours. Acceptable forms of proof
of delivery date include, but are not limited to: the original warranty registration or sales receipts or other
documents maintained in the ordinary course of business by Yanmar dealers and / or distributors, indicating
the date of delivery of the Yanmar product to the original retail purchaser. This information is necessary to
establish whether the Yanmar product is still within the warranty period. Thus, Yanmar strongly recommends
you register your engine as soon as possible after purchase in order to facilitate any future warranty matters.
You are responsible for the transportation of the engine to and from the repair location as designated by
Yanmar.
TNV IDI Service Manual
2-3
YANMAR WARRANTIES
Yanmar Limited Warranty - Continued
Yanmar Limited Warranty
To Locate an Authorized Yanmar Industrial Engine Dealer or Distributor:
You can locate your nearest authorized Yanmar industrial engine dealer or distributor by visiting the Yanmar
Corp., LTD. website at:
http://www.yanmar.co.jp (The Japanese language page will be displayed.) For English language “click” on
“English Page.”)
• “Click” on “Network” in the website heading to view the “Yanmar Worldwide Network.”
• Choose and “Click” on the desired product group.
• “Click” on the Icon closest to your region.
• “Click” on the desired country or Associate company to locate your nearest authorized Yanmar industrial
engine dealer or distributor.
• You may also contact Yanmar by clicking on “Inquiry” in the website heading and typing in your question
or comment.
What Yanmar Will Do:
Yanmar warrants to the original retail purchaser of a new Yanmar engine that Yanmar will make such repairs
and / or replacements at Yanmar’s option, of any parts(s) of the Yanmar product covered by this Warranty
found to be defective in material and / or workmanship. Such repairs and / or replacements will be made at a
location designated by Yanmar at no cost to the purchaser for parts or labor.
What is Not Covered by this Warranty?
This Warranty does not cover parts affected by or damaged by any reason other than defective materials or
workmanship including, but not limited to, accident, misuse, abuse, “Acts of God”, neglect, improper
installation, improper maintenance, improper storage, the use of unsuitable attachments or parts, the use of
contaminated fuels, the use of fuels, oils, lubricants, or fluids other than those recommended in your Yanmar
Operation Manual, unauthorized alterations or modifications, ordinary wear and tear, and rust or corrosion.
This Warranty does not cover the cost of parts and / or labor required to perform normal / scheduled
maintenance on your Yanmar engine. This Warranty does not cover consumable parts such as, but not
limited to, filters, belts, hoses, fuel injector nozzles, lubricants and cleaning fluids. This warranty does not
cover the cost of shipping the product to or from the warranty repair facility.
2-4 TNV IDI Service Manual
Yanmar Limited Warranty
Yanmar Limited Warranty - Continued
YANMAR WARRANTIES
Warranty Limitations:
The foregoing is Yanmar's only obligation to you and your exclusive remedy for breach of warranty.
Failure to follow the requirements for submitting a claim under this Warranty may result in a waiver of all
claims for damages and other relief. In no event shall Yanmar or any authorized industrial engine dealer
or distributor be liable for incidental, special or consequential damages. Such consequential damages
may include, but not be limited to, loss of revenue, loan payments, cost of rental of substitute equipment,
insurance coverage, storage, lodging, transportation, fuel, mileage, and telephone costs. The limitations in
this Warranty apply regardless of whether your claims are based on breach of contract, tort (including
negligence and strict liability) or any other theory. Any action arising hereunder must be brought within one
(1) year after the cause of action accrues or it shall be barred. Some states and countries do not allow
certain limitations on warranties or for breach of warranties. This Warranty gives you specific legal rights,
and you may also have other rights which vary from state to state and country to country. Limitations
set forth in this paragraph shall not apply to the extent that they are prohibited by law.
Warranty Modifications:
Except as modified in writing and signed by the parties, this Warranty is and shall remain the complete and
exclusive agreement between the parties with respect to warranties, superseding all prior agreements,
written and oral, and all other communications between the parties relating to warranties. No person or
entity is authorized to give any other warranty or to assume any other obligation on behalf of
Yanmar, either orally or in writing.
Questions:
If you have any questions or concerns regarding this Warranty, please call or write to the nearest authorized
Yanmar industrial engine dealer / distributor or other authorized facility.
Retail Purchaser Registration
It is very important for the original retail purchaser to register the Yanmar product. Registration
enables Yanmar to provide the best support for your Yanmar product.
As soon as possible after the purchase of your engine, Yanmar highly recommends that you use the
following website to register your purchase:
http://www.yanmar.co.jp
If it is not possible to access the web site, please contact the nearest Yanmar dealer or distributor.
TNV IDI Service Manual
2-5
YANMAR WARRANTIES
Emission System Warranty
EMISSION SYSTEM WARRANTY
YANMAR CO., LTD. LIMITED EMISSION CONTROL SYSTEM
WARRANTY - USA ONLY
Your Warranty Rights and Obligations:
California
The California Air Resources Board (CARB), the Environmental Protection Agency (EPA) and Yanmar Co.,
Ltd. hereafter referred to as Yanmar, are pleased to explain the emission control system warranty on your
industrial compression-ignition engine. In California, model year 2000 or later off-road compression-ignition
engines must be designed, built and equipped to meet the State’s stringent anti-smog standards. In all
states, 1998 and later non-road compression-ignition engines must be designed, built and equipped to meet
the United States EPA emissions standards. Yanmar warrants the emission control system on your engine
for the periods of time listed below provided there has been no abuse, neglect or improper maintenance of
your engine.
Your emission control system may include parts such as the fuel injection system and the air induction
system. Also included may be hoses, belts, connectors and other emission-related assemblies.
Where a warrantable condition exists, Yanmar will repair your non-road compression-ignition engine at no
charge to you including diagnosis, parts and labor.
Manufacturer’s Warranty Period:
The model year 1998 or later certified and labeled non-road compression-ignition engines are warranted for
the periods listed below. If any emission-related part on your engine is found to be defective during the
applicable warranty period, the part will be replaced by Yanmar.
Engine Type Warranty Period by Number of Years or Hours of Operation
Constant speed engines rated at or above
50 hp SAE (37 kW)
Constant speed engines rated under 50 hp
SAE (37 kW) with rated speeds greater than
or equal to 3,000 rpm
Engines rated at or above 26 hp SAE
(19 kW)
Engines rated under 26 hp SAE (19 kW)
The warranty period is five (5) years or 3,000 hours of use, whichever occurs first.
In the absence of a device to measure the hours of use, the engine has a
warranty period of five (5) years.
The warranty period is two (2) years or 3,000 hours of use, whichever occurs first.
In the absence of a device to measure the hours of use, the engine has a
warranty period of two (2) years.
The warranty period is five (5) years or 3,000 hours of use, whichever occurs first.
In the absence of a device to measure the hours of use, the engine has a
warranty period of five (5) years.
The warranty period is two (2) years or 3,000 hours of use, whichever occurs first.
In the absence of a device to measure the hours of use, the engine has a
warranty period of two (2) years.
2-6 TNV IDI Service Manual
Emission System Warranty
Limited Emission Control System Warranty - USA Only - Continued
YANMAR WARRANTIES
Warranty Coverage:
This warranty is transferable to each subsequent purchaser for the duration of the warranty period. Repair or
replacement of any warranted part will be performed at an authorized Yanmar industrial engine dealer or
distributor.
Warranted parts not scheduled for replacement as required maintenance in the Operation Manual shall be
warranted for the warranty period. Warranted parts scheduled for replacement as required maintenance in
the operation manual are warranted for the period of time prior to the first scheduled replacement. Any part
repaired or replaced under warranty shall be warranted for the remaining warranty period.
During the warranty period, Yanmar is liable for damages to other engine components caused by the failure
of any warranted part during the warranty period.
Any replacement part which is functionally identical to the original equipment part in all respects may be
used in the maintenance or repair of your engine, and shall not reduce Yanmar’s warranty obligations. Addon or modified parts that are not exempted may not be used. The use of any non-exempted add-on or
modified parts shall be grounds for disallowing a warranty.
Warranted Parts:
This warranty covers engine components that are a part of the emission control system of the engine as
delivered by Yanmar to the original retail purchaser. Such components may include the following:
• Fuel Injection System
• Cold Start Enrichment System
• Intake Manifold
• Turbocharger Systems
• Exhaust Manifold
• Positive Crankcase Ventilation System
• Hoses, belts, connectors and assemblies associated with emission control systems
Since emissions-related parts may vary slightly between models, certain models may not contain all of these
parts and other models may contain the functional equivalents.
TNV IDI Service Manual
2-7
YANMAR WARRANTIES
Limited Emission Control System Warranty - USA Only - Continued
Emission System Warranty
Exclusions:
Failures other than those arising from defects in material and / or workmanship are not covered by this
warranty. The warranty does not extend to the following: malfunctions caused by abuse, misuse, improper
adjustment, modification, alteration, tampering, disconnection, improper or inadequate maintenance or use
of non-recommended fuels and lubricating oils; accident-caused damage, and replacement of expendable
items made in connection with scheduled maintenance. Yanmar disclaims any responsibility for incidental or
consequential damages such as loss of time, inconvenience, loss of use of equipment / engine or
commercial loss.
Owner’s Warranty Responsibilities:
As the engine owner, you are responsible for the performance of the required maintenance listed in
your owner’s manual. Yanmar recommends that you retain all documentation, including receipts, covering
maintenance on your non-road compression-ignition engine, but Yanmar cannot deny warranty solely for the
lack of receipts, or for your failure to ensure the performance of all scheduled maintenance.
Yanmar may deny your warranty coverage of your non-road compression-ignition engine if a part has failed
due to abuse, neglect, improper maintenance or unapproved modifications.
Your engine is designed to operate on diesel fuel only. Use of any other fuel may result in your engine no
longer operating in compliance with applicable emissions requirements.
You are responsible for initiating the warranty process. You must present your engine to a Yanmar dealer as
soon as a problem exists. The warranty repairs should be completed by the dealer as expeditiously as
possible. If you have any questions regarding your warranty rights and responsibilities, or would like
information on the nearest Yanmar dealer or authorized service center, you should contact Yanmar America
Corporation at 1-800-872-2867.
2-8 TNV IDI Service Manual
TNV IDI Service Manual
Safety Statements ........................................................................... 3-3
Safety Precautions .......................................................................... 3-4
Section 3
SAFETY
Page
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3-1
SAFETY
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3-2 TNV IDI Service Manual
Safety Statements
SAFETY
SAFETY STATEMENTS
Yanmar is concerned for your safety and your
machine’s condition. Safety statements are one of
the primary ways to call your attention to the
potential hazards associated with Yanmar TNV
engine operation. Follow the precautions listed
throughout the manual before operation, during
operation and during periodic maintenance
procedures for your safety, the safety of others and
to protect the performance of your engine. Keep the
labels from becoming dirty or torn and replace
them if they are lost or damaged. Also, if you need
to replace a part that has a label attached to it,
make sure you order the new part and label at the
same time.
This safety alert symbol appears
with most safety statements. It
means attention, become alert, your
A
safety is involved! Please read and
abide by the message that follows
the safety alert symbol.
A CAUTION
Caution (the word “CAUTION” is in black
letters with a yellow rectangle behind it)
– indicates a potentially hazardous
situation which, if not avoided, may
result in minor or moderate injury.
0000001en
CAUTION
Caution without the safety alert symbol
indicates a potentially hazardous
situation that can cause damage to the
machine, personal property and / or the
environment or cause the machine to
operate improperly.
0000001en
A DANGER
Danger (the word “DANGER” is in white
letters with a red rectangle behind
it) - indicates an imminently hazardous
situation which, if not avoided, will
result in death or serious injury. Danger
is limited to the most extreme
situations.
0000001en
A WARNING
Warning (the word “WARNING” is in
black letters with an orange rectangle
behind it) – indicates a potentially
hazardous situation which, if not
avoided, could result in death or serious
injury.
0000001en
TNV IDI Service Manual
3-3
SAFETY
Safety Precautions
SAFETY PRECAUTIONS
A DANGER
SCALD HAZARD!
• NEVER remove the radiator cap if the
engine is hot. Steam and hot engine
coolant will spurt out and seriously
burn you. Allow the engine to cool
down before you attempt to remove
the radiator cap.
• Tighten the radiator cap securely after
you check the radiator. Steam can
spurt out during engine operation if
the cap is loose.
• ALWAYS check the level of the engine
coolant by observing the reserve tank.
A DANGER
EXPLOSION HAZARD!
• Keep the area around the battery
well-ventilated. While the engine is
running or the battery is charging,
hydrogen gas is produced which can
be easily ignited.
• Keep sparks, open flame and any other
form of ignition away while the engine
is running or battery is charging.
• Failure to comply will result in death or
serious injury.
0000003en
• Failure to comply will result in death or
serious injury.
0000002en
3-4 TNV IDI Service Manual
Safety Precautions
SAFETY
A DANGER
FIRE AND EXPLOSION HAZARD!
• Diesel fuel is flammable and explosive
under certain conditions.
• When you remove any fuel system
component to perform maintenance
(such as changing the fuel filter) place
an approved container under the
opening to catch the fuel.
• NEVER use a shop rag to catch the
fuel. Vapors from the rag are
flammable and explosive.
• Wipe up any spills immediately.
• Wear eye protection. The fuel system
is under pressure and fuel could spray
out when you remove any fuel system
component.
• Failure to comply will result in death or
serious injury.
0000009en
A DANGER
FIRE AND EXPLOSION HAZARD!
• Diesel fuel is flammable and explosive
under certain conditions.
• NEVER remove the fuel cap with the
engine running.
• Failure to comply will result in death or
serious injury.
0000011en
A DANGER
FIRE AND EXPLOSION HAZARD!
• Diesel fuel is flammable and explosive
under certain conditions.
• NEVER use diesel fuel as a cleaning
agent.
A DANGER
FIRE AND EXPLOSION HAZARD!
• Only use the key switch to start the
engine.
• NEVER jump-start the engine. Sparks
caused by shorting the battery to the
starter terminals may cause a fire or
explosion.
• Failure to comply will result in death or
serious injury.
0000004en
• Failure to comply will result in death or
serious injury.
0000012en
TNV IDI Service Manual
3-5
SAFETY
Safety Precautions
A DANGER
FIRE AND EXPLOSION HAZARD!
• Diesel fuel is flammable and explosive
under certain conditions.
• Only fill the fuel tank with diesel fuel.
Filling the fuel tank with gasoline may
result in a fire and will damage the
engine.
• NEVER refuel with the engine running.
• Wipe up all spills immediately.
• Keep sparks, open flames or any other
form of ignition (match, cigarette,
static electric source) well away when
refueling.
• NEVER overfill the fuel tank.
• Fill the fuel tank. Store any containers
containing fuel in a well-ventilated
area, away from any combustibles or
sources of ignition.
A DANGER
FIRE AND EXPLOSION HAZARD!
• Diesel fuel is flammable and explosive
under certain conditions.
• If the unit has an electric fuel pump,
when you prime the fuel system, turn
the key switch to the ON position for
10 to 15 seconds to allow the electric
fuel pump to prime the system.
• If the unit has a mechanical fuel pump,
when you prime the fuel system,
operate the fuel priming lever of the
mechanical fuel pump several times
until the fuel filter cup is filled with
fuel.
• Failure to comply will result in death or
serious injury.
0000010en
• Failure to comply will result in death or
serious injury.
0000005en
3-6 TNV IDI Service Manual
Safety Precautions
SAFETY
A DANGER
FIRE AND EXPLOSION HAZARD!
• Diesel fuel is flammable and explosive
under certain conditions.
• Be sure to place the diesel fuel
container on the ground when
transferring the diesel fuel from the
pump to the container. Hold the hose
nozzle firmly against the side of the
container while filling it. This prevents
static electricity buildup which could
cause sparks and ignite fuel vapors.
• NEVER place diesel fuel or other
flammable material such as oil, hay or
dried grass close to the engine during
engine operation or shortly after
shutdown.
A DANGER
CRUSH HAZARD!
• When you need to transport an engine
for repair, have a helper assist you to
attach it to a hoist and load it on a
truck.
• NEVER stand under a hoisted engine.
If the hoist mechanism fails, the
engine will fall on you, causing death
or serious injury.
• Failure to comply will result in death or
serious injury.
0000008en
A DANGER
• Failure to comply will result in death or
serious injury.
0000014en
EXPLOSION HAZARD!
• NEVER check the remaining battery
charge by shorting out the terminals.
This will result in a spark and may
cause an explosion or fire. Use a
hydrometer to check the remaining
battery charge.
• If the electrolyte is frozen, slowly warm
the battery before you recharge it.
• Failure to comply will result in death or
serious injury.
0000007en
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3-7
SAFETY
Safety Precautions
A WARNING
SEVER HAZARD!
• Keep hands and other body parts
away from moving / rotating parts
such as the cooling fan, flywheel or
PTO shaft.
• Wear tight-fitting clothing and keep
your hair short or tie it back while the
engine is running.
• Remove all jewelry before you operate
or service the machine.
• NEVER start the engine in gear.
Sudden movement of the engine
and / or machine could cause death or
serious personal injury.
• NEVER operate the engine without the
guards in place.
• Before you start the engine make sure
that all bystanders are clear of the
area.
A WARNING
EXHAUST HAZARD!
• NEVER operate the engine in an
enclosed area such as a garage,
tunnel, underground room, manhole or
ship’s hold without proper ventilation.
• NEVER block windows, vents, or other
means of ventilation if the engine is
operating in an enclosed area. All
internal combustion engines create
carbon monoxide gas during
operation. Accumulation of this gas
within an enclosure could cause
illness or even death.
• Make sure that all connections are
tightened to specifications after repair
is made to the exhaust system.
• Failure to comply could result in death
or serious injury.
0000003en
• Keep children and pets away while the
engine is operating.
• Check before starting the engine that
any tools or shop rags used during
maintenance have been removed from
the area.
• Failure to comply could result in death
or serious injury.
0000002en
A WARNING
ALCOHOL AND DRUG HAZARD!
• NEVER operate the engine while you
are under the influence of alcohol or
drugs.
• NEVER operate the engine when you
are feeling ill.
• Failure to comply could result in death
or serious injury.
0000004en
3-8 TNV IDI Service Manual
Safety Precautions
SAFETY
A WARNING
EXPOSURE HAZARD!
• Wear personal protective equipment
such as gloves, work shoes, eye and
hearing protection as required by the
task at hand.
• NEVER wear jewelry, unbuttoned
cuffs, ties or loose-fitting clothing
when you are working near
moving / rotating parts such as the
cooling fan, flywheel or PTO shaft.
• ALWAYS tie back long hair when you
are working near moving / rotating
parts such as a cooling fan, flywheel,
or PTO shaft.
• NEVER operate the engine while
wearing a headset to listen to music or
radio because it will be difficult to hear
the alert signals.
• Failure to comply could result in death
or serious injury.
0000005en
A WARNING
BURN HAZARD!
• If you must drain the engine oil while it
is still hot, stay clear of the hot engine
oil to avoid being burned.
• ALWAYS wear eye protection.
• Failure to comply could result in death
or serious injury.
0000011en
A WARNING
BURN HAZARD!
• Batteries contain sulfuric acid. NEVER
allow battery fluid to come in contact
with clothing, skin or eyes. Severe
burns could result. ALWAYS wear
safety goggles and protective clothing
when servicing the battery. If battery
fluid contacts the eyes and / or skin,
immediately flush the affected area
with a large amount of clean water and
obtain prompt medical treatment.
TNV IDI Service Manual
• Failure to comply could result in death
or serious injury.
0000007en
3-9
SAFETY
Safety Precautions
A WARNING
HIGH-PRESSURE HAZARD!
• Avoid skin contact with the
high-pressure diesel fuel spray caused
by a fuel system leak such as a broken
fuel injection line. High-pressure fuel
can penetrate your skin and result in
serious injury. If you are exposed to
high-pressure fuel spray, obtain
prompt medical treatment.
• NEVER check for a fuel leak with your
hands. ALWAYS use a piece of wood
or cardboard. Have your authorized
Yanmar industrial engine dealer or
distributor repair the damage.
• Failure to comply could result in death
or serious injury.
0000008en
A WARNING
ENTANGLEMENT HAZARD!
• Stop the engine before you begin to
service it.
• NEVER leave the key in the key switch
when you are servicing the engine.
Someone may accidentally start the
engine and not realize you are
servicing it. This could result in a
serious injury.
• If you must service the engine while it
is operating, remove all jewelry, tie
back long hair, and keep your hands,
other body parts and clothing away
from moving / rotating parts.
• Failure to comply could result in death
or serious injury.
0000010en
A WARNING
SHOCK HAZARD!
• Turn off the battery switch (if
equipped) or disconnect the negative
battery cable before servicing the
electrical system.
• Check the electrical harnesses for
cracks, abrasions, and damaged or
corroded connectors. ALWAYS keep
the connectors and terminals clean.
• Failure to comply could result in death
or serious injury.
0000009en
A WARNING
BURN HAZARD!
• Wait until the engine cools before you
drain the engine coolant. Hot engine
coolant may splash and burn you.
• Failure to comply could result in death
or serious injury.
0000016en
3-10 TNV IDI Service Manual
Safety Precautions
SAFETY
A WARNING
To prevent possible eye injury, always
wear SAFETY GLASSES while servicing
the engine.
0000013en
A WARNING
BURN HAZARD!
• Keep your hands and other body parts
away from hot engine surfaces such
as the muffler, exhaust pipe,
turbocharger (if equipped) and engine
block during operation and shortly
after you shut the engine down. These
surfaces are extremely hot while the
engine is operating and could
seriously burn you.
• Failure to comply could result in death
or serious injury.
0000015en
A WARNING
FUME / BURN HAZARD!
• Always read and follow safety related
precautions found on containers of
hazardous substances like parts
cleaners, primers, sealants and
sealant removers.
• Failure to comply could result in death
or serious injury.
0000014en
A CAUTION
COOLANT HAZARD!
• Wear eye protection and rubber gloves
when you handle long life or extended
life engine coolant. If contact with the
eyes or skin should occur, flush eyes
and wash immediately with clean
water.
• Failure to comply may result in minor
or moderate injury.
0000005en
TNV IDI Service Manual
3-11
SAFETY
Safety Precautions
A CAUTION
FLYING OBJECT HAZARD!
• ALWAYS wear eye protection when
servicing the engine and when using
compressed air or high-pressure
water. Dust, flying debris, compressed
air, pressurized water or steam may
injure your eyes.
• Failure to comply may result in minor
or moderate injury.
0000003en
A CAUTION
Be sure to secure the engine solidly to
prevent injury or damage to parts due to
the engine falling during work on the
engine.
0000009en
A CAUTION
A CAUTION
If any oil pump component clearance
exceeds its limit, the oil pump must be
replaced as an assembly.
0000015en
CAUTION
• Only use diesel fuels recommended by
Yanmar for the best engine
performance, to prevent engine
damage and to comply with EPA / ARB
warranty requirements.
• Only use clean diesel fuel.
• NEVER remove the primary strainer (if
equipped) from the fuel tank filler port.
If removed, dirt and debris could get
into the fuel system causing it to clog.
0000004en
CAUTION
If any problem is noted during the visual
check, the necessary corrective action
should be taken before you operate the
engine.
0000021en
PINCH HAZARD!
Carefully rotate the alternator toward the
cylinder block while loosening the
V-belt. Failure to comply may result in
minor or moderate injury.
0000014en
CAUTION
NEVER hold the key in the START
position for longer than 15 seconds or
the starter motor will overheat.
0000007en
3-12 TNV IDI Service Manual
Safety Precautions
SAFETY
CAUTION
Make sure the engine is installed on a
level surface. If a continuously running
engine is installed at an angle greater
than (IDI = 25°, DI = 30°) in any direction
or if an engine runs for short periods of
time (less than three minutes) at an
angle greater than (IDI = 30°, DI = 35°) in
any direction, engine oil may enter the
combustion chamber causing excessive
engine speed and white exhaust smoke.
This may cause serious engine damage.
0000010enTNV
CAUTION
Protect the air cleaner, turbocharger (if
equipped) and electric components
from damage when you use steam or
high-pressure water to clean the engine.
0000014en
CAUTION
Observe the following environmental
operating conditions to maintain engine
performance and avoid premature
engine wear:
• Avoid operating in extremely dusty
conditions.
• Avoid operating in the presence of
chemical gases or fumes.
• Avoid operating in a corrosive
atmosphere such as salt water spray.
• NEVER install the engine in a
floodplain unless proper precautions
are taken to avoid being subject to a
flood.
• NEVER expose the engine to the rain.
0000003en
CAUTION
Do not loosen or remove the four bolts
retaining the fuel injection pump drive
gear to the fuel injection pump hub. Do
not disassemble the fuel injection pump
drive gear from the hub. Correct fuel
injection timing will be very difficult or
impossible to achieve.
0000031en
CAUTION
If the oil pump must be replaced, replace
it as an assembly only. Do not replace
individual components.
0000030en
CAUTION
Observe the following environmental
operating conditions to maintain engine
performance and avoid premature
engine wear:
• The standard range of ambient
temperatures for the normal operation
of Yanmar engines is from +5°F (-15°C)
to +113°F (+45°C).
• If the ambient temperature exceeds
+113°F (+45°C) the engine may
overheat and cause the engine oil to
break down.
• If the ambient temperature is below
+5°F (-15°C) the engine will be hard to
start and the engine oil may not flow
easily.
• Contact your authorized Yanmar
industrial engine dealer or distributor
if the engine will be operated outside
of this standard temperature range.
0000065en
TNV IDI Service Manual
3-13
SAFETY
Safety Precautions
CAUTION
If any indicator illuminates during
engine operation, stop the engine
immediately. Determine the cause and
repair the problem before you continue
to operate the engine.
0000029en
CAUTION
• Only use the engine oil specified.
Other engine oils may affect warranty
coverage, cause internal engine
components to seize and / or shorten
engine life.
• Prevent dirt and debris from
contaminating the engine oil. Carefully
clean the oil cap / dipstick and the
surrounding area before you remove
the cap.
• NEVER mix different types of engine
oil. This may adversely affect the
lubricating properties of the engine oil.
• NEVER overfill. Overfilling may result
in white exhaust smoke, engine
overspeed or internal damage.
0000005en
CAUTION
• NEVER overfill the engine with engine
oil.
• ALWAYS keep the oil level between the
upper and lower lines on the oil
cap / dipstick.
0000015en
CAUTION
For maximum engine life, Yanmar
recommends that when shutting the
engine down, you allow the engine to
idle, without load, for five minutes. This
will allow the engine components that
operate at high temperatures, such as
the turbocharger (if equipped) and
exhaust system, to cool slightly before
the engine itself is shut down.
0000008en
CAUTION
NEVER use an engine starting aid such
as ether. Engine damage will result.
0000009en
CAUTION
• Only use the engine coolant specified.
Other engine coolants may affect
warranty coverage, cause an internal
buildup of rust and scale and / or
shorten engine life.
• Prevent dirt and debris from
contaminating the engine coolant.
Carefully clean the radiator cap and
the surrounding area before you
remove the cap.
• NEVER mix different types of engine
coolants. This may adversely affect the
properties of the engine coolant.
0000006en
3-14 TNV IDI Service Manual
Safety Precautions
SAFETY
CAUTION
• ALWAYS be environmentally
responsible.
• Follow the guidelines of the EPA or
other governmental agencies for the
proper disposal of hazardous
materials such as engine oil, diesel
fuel and engine coolant. Consult the
local authorities or reclamation facility.
• NEVER dispose of hazardous
materials irresponsibly by dumping
them into a sewer, on the ground, or
into ground water or waterways.
• Failure to follow these procedures may
seriously harm the environment.
0000013en
CAUTION
New Engine Break-in:
• On the initial engine start-up, allow the
engine to idle for approximately 15
minutes while you check for proper
engine oil pressure, diesel fuel leaks,
engine oil leaks, coolant leaks, and for
proper operation of the indicators
and / or gauges.
• During the first hour of operation, vary
the engine speed and the load on the
engine. Short periods of maximum
engine speed and load are desirable.
Avoid prolonged operation at
minimum or maximum engine speeds
and loads for the next four to five
hours.
• During the break-in period, carefully
observe the engine oil pressure and
engine temperature.
• During the break-in period, check the
engine oil and coolant levels
frequently.
0000011en
CAUTION
NEVER engage the starter motor while
the engine is running. This may damage
the starter motor pinion and / or ring
gear.
0000012en
TNV IDI Service Manual
3-15
SAFETY
Safety Precautions
CAUTION
• NEVER attempt to modify the engine’s
design or safety features such as
defeating the engine speed limit
control or the fuel injection quantity
control.
• Failure to comply may impair the
engine’s safety and performance
characteristics and shorten the
engine’s life. Any alterations to this
engine may affect the warranty
coverage of your engine. Yan ma r
Limited Warranty on page 2-3.
0000044TNVIDISM
CAUTION
NEVER use high-pressure water or
compressed air at greater than 28 psi
(193 kPa; 19 686 mmAq) or a wire brush
to clean the radiator fins. Radiator fins
damage easily.
0000016en
CAUTION
NEVER attempt to adjust the low or high
idle speed limit screw. This may impair
the safety and performance of the
machine and shorten its life. If the idle
speed limit screws require adjustment,
see your authorized Yanmar industrial
engine dealer or distributor.
0000017en
CAUTION
The starter motor can be damaged if
operated continuously longer than
10 seconds while performing the
no-load test.
0000034en
CAUTION
The tightening torque in the Standard
Torque Chart in General Service
Information should be applied only to
the bolts with a “7” head. (JIS strength
classification: 7T)
• Apply 60% torque to bolts
that are not listed.
• Apply 80% torque when
tightened to aluminum alloy.
0000023enTNVIDISM
CAUTION
Establish a periodic maintenance plan
according to the engine application and
make sure you perform the required
periodic maintenance at intervals
indicated. Failure to follow these
guidelines will impair the engine’s safety
and performance characteristics,
shorten the engine’s life and may affect
the warranty coverage on your engine.
See Yanmar Warranties section.
Consult your authorized Yanmar dealer
or distributor for assistance when
checking items marked with a
z.
0000024enTNVIDISM
CAUTION
If the fuel filter / water separator is
positioned higher than the fuel level in
the fuel tank, water may not drip out
when the fuel filter / water separator
drain cock is opened. If this happens,
turn the air vent screw on the top of the
fuel filter / water separator 2-3 turns
counterclockwise.
Be sure to tighten the air vent screw
after the water has drained out.
0000025en
3-16 TNV IDI Service Manual
Safety Precautions
SAFETY
CAUTION
• When the engine is operated in dusty
conditions, clean the air cleaner
element more frequently.
• NEVER operate the engine with the air
cleaner element(s) removed. This may
allow foreign material to enter the
engine and damage it.
0000026en
CAUTION
The maximum air intake restriction, in
terms of differential pressure
measurement, must not exceed 0.90 psi
(6.23 kPa; 635 mmAq). Clean or replace
the air cleaner element if the air intake
restriction exceeds the above
mentioned value.
0000046en
CAUTION
Do not short-circuit the charging system
between alternator terminals IG and L.
Damage to the alternator will result.
0000035en
CAUTION
Do not connect a load between
alternator terminals L and E. Damage to
the alternator will result.
0000036en
CAUTION
Do not remove the positive (+) battery
cable from alternator terminal B while
the engine is operating. Damage to the
alternator will result.
0000037en
CAUTION
Do not turn the battery switch OFF while
the engine is operating. Damage to the
alternator will result.
0000038en
CAUTION
Do not operate the engine if the
alternator is producing unusual sounds.
Damage to the alternator will result.
0000039en
CAUTION
If the engine coolant pump must be
replaced, replace the engine coolant
pump as an assembly only. Do not
attempt to repair the engine coolant
pump or replace individual components.
0000041en
CAUTION
Use a new special O-ring between the
engine coolant pump and the joint. Be
sure to use the special O-ring for each
engine model. Although the O-ring
dimensions are the same as a
commercially available O-ring, the
material is different.
0000042en
CAUTION
Remove or install the high-pressure fuel
injection lines as an assembly whenever
possible. Disassembling the
high-pressure fuel injection lines from
the retainers or bending any of the fuel
lines will make it difficult to reinstall the
fuel lines.
0000047en
TNV IDI Service Manual
3-17
SAFETY
Safety Precautions
CAUTION
After marking the position of the pump
drive gear, do not rotate the engine
crankshaft. Rotating the crankshaft will
cause the fuel injection pump to become
misaligned.
0000048en
CAUTION
Do not use a high-pressure wash
directly on the alternator. Water will
damage the alternator and result in
inadequate charging.
0000049en
CAUTION
Do not reverse the positive (+) and
negative (-) ends of the battery cable.
The alternator diode and stator coil will
be damaged.
0000050en
CAUTION
Agricultural or other chemicals,
especially those with a high sulfur
content, can adhere to the IC regulator.
This will corrode the conductor and
result in battery over-charging (boiling)
and charging malfunctions. Consult
Yanmar before using the equipment in
such an environment or the warranty is
voided.
0000053en
CAUTION
Make sure that the combined total
resistance of the battery cable in both
directions between the starter motor
and the battery is within the value
indicated on the wiring diagram. The
starter motor will malfunction or break
down if the resistance is higher than the
specified value.
0000054en
CAUTION
When the battery indicator goes out, it
should not come on again. The battery
indicator only comes on during
operation if the alternator fails. However,
if an LED is used in the battery indicator,
the LED will shine faintly during normal
operation.
0000051en
CAUTION
Using a non-specified V-belt will cause
inadequate charging and shorten the
belt life. Use the specified belt.
0000052en
CAUTION
The starter motor is water-proofed
according to JIS D 0203, R2 which
protects the motor from rain or general
cleaning. Do not use high-pressure
wash or submerse the starter motor in
water.
0000055en
CAUTION
Use a specialized battery charger to
recharge a battery with a voltage of
8 volts or less. Booster starting a battery
with a voltage of 8 volts or less will
generate an abnormally high voltage
and destroy electrical equipment.
0000056en
3-18 TNV IDI Service Manual
Safety Precautions
SAFETY
CAUTION
Make sure that the combined total
resistance of the battery cable in both
directions between the starter motor
and the battery is within the value
indicated in the Battery Cable
Resistance chart in the Electric Wiring
Section of this manual. The starter
motor will malfunction and fail if the
resistance is higher than the specified
value.
0000057en
CAUTION
Removing the battery cables or the
battery while the engine is operating
may cause damage to the current limiter
depending on the electrical equipment
being used. This situation could cause
loss of control of output voltage. The
continuous high voltage of 23-24 volts
(for 5000 rpm dynamo) will damage the
current limiter and other electrical
equipment.
0000058en
CAUTION
CAUTION
• NEVER attempt to modify the engine’s
design or safety features such as
defeating the engine speed limit
control or the diesel fuel injection
quantity control.
• Modifications may impair the engine’s
safety and performance
characteristics and shorten the
engine’s life. Any alterations to this
engine may void its warranty. Be sure
to use Yanmar genuine replacement
parts.
0000079en
CAUTION
Identify all parts and their location using
an appropriate method. It is important
that all parts are returned to the same
position during the reassembly process.
0000080en
CAUTION
Do not rotate the crankshaft with the
injection pump removed.
0000083en
Reversing the battery cable connections
at the battery or on the engine will
destroy the SCR diode in the current
limiter. This will cause the charging
system to malfunction and may cause
damage to the electrical harnesses.
0000059en
CAUTION
It is important to perform daily checks.
Periodic maintenance prevents
unexpected downtime, reduces the
number of accidents due to poor
machine performance and helps extend
the life of the engine.
0000060en
CAUTION
Keep the piston pin parts, piston
assemblies, and connecting rod
assemblies together to be returned to
the same position during the
reassembly process. Label the parts
using an appropriate method.
0000088en
TNV IDI Service Manual
3-19
SAFETY
Safety Precautions
CAUTION
Do not allow the honing tool to operate
in one position for any length of time.
Damage to the cylinder wall will occur.
Keep the tool in constant up-and-down
motion.
0000090en
CAUTION
Any part which is found defective as a
result of inspection or any part whose
measured value does not satisfy the
standard or limit must be replaced.
0000119en
CAUTION
Any part determined to not meet the
service standard or limit before the next
service, as determined from the state of
current rate of wear, should be replaced
even though the part currently meets the
service standard limit.
0000120en
CAUTION
• NEVER remove or attempt to remove
the tamper-proof devices from the
full-load fuel adjusting screw or the
high-speed throttle limit screw on the
fuel injection pump and governor
assembly. These adjustments have
been made at the factory to meet all
applicable emissions regulations and
then sealed.
• NEVER attempt to make any
adjustments to these sealed
adjustment screws. If adjustments are
required, they can be made only by a
qualified fuel injection shop that will
ensure the injection pump continues
to meet all applicable emissions
regulations and then replace the
tamper-proof seals.
• Tampering with or removing these
devices may void the “Yanmar Limited
Warranty.”
0000146en
CAUTION
Never use a steel wire brush to clean
fuel injectors. Damage to the nozzle and
other components is likely to result.
0000172en
CAUTION
The fuel return line is a one-piece
assembly. Use care not to bend or twist
the fuel return line.
0000171en
3-20 TNV IDI Service Manual
TNV IDI Service Manual
Section 4
GENERAL SERVICE
INFORMATION
Component Identification................................................................. 4-3
Location of Labels ........................................................................... 4-4
EPA / ARB Emission Control Regulations - USA Only.................... 4-4
Emission Control Labels.................................................................. 4-4
EPA / ARB Labels ..................................................................... 4-5
The 97/68/EC Directive Certified Engines....................................... 4-5
Engine Family.................................................................................. 4-5
Function of Major Engine Components ........................................... 4-6
Function of Cooling System Components ....................................... 4-8
Page
Diesel Fuel ...................................................................................... 4-9
Diesel Fuel Specifications ......................................................... 4-9
Filling the Fuel Tank ................................................................ 4-10
Priming the Fuel System ......................................................... 4-12
Engine Oil...................................................................................... 4-13
Engine Oil Specifications ........................................................ 4-13
Service Categories .................................................................. 4-13
Engine Oil Viscosity................................................................. 4-14
Checking Engine Oil ................................................................ 4-14
Adding Engine Oil.................................................................... 4-14
Engine Oil Capacity (Typical) .................................................. 4-15
Engine Coolant.............................................................................. 4-15
Engine Coolant Specifications................................................. 4-16
Filling Radiator with Engine Coolant........................................ 4-16
Engine Coolant Capacity (Typical) .......................................... 4-17
Specifications ................................................................................ 4-18
Description of Model Number .................................................. 4-18
Engine General Specifications ................................................ 4-19
TNV IDI Service Manual
4-1
GENERAL SERVICE INFORMATION
Principal Engine Specifications ..................................................... 4-20
3TNV72 ................................................................................... 4-20
Engine Service Information ........................................................... 4-21
Tightening Torques for Standard Bolts and Nuts .......................... 4-22
Abbreviations and Symbols........................................................... 4-24
Abbreviations........................................................................... 4-24
Symbols................................................................................... 4-24
Unit Conversions........................................................................... 4-25
Unit Prefixes ............................................................................ 4-25
Units of Length ........................................................................ 4-25
Units of Volume ....................................................................... 4-25
Units of Mass........................................................................... 4-25
Units of Force .......................................................................... 4-25
Units of Torque........................................................................ 4-25
Units of Pressure..................................................................... 4-25
Units of Power ......................................................................... 4-25
Units of Temperature............................................................... 4-25
4-2 TNV IDI Service Manual
Component Identification
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
(12)
(13)
(14)
(15)
(16)
(17)
(18)
(19)
(20)
(21)
(22)
(23)
(24)
(25)
(3)
(2)
(1)
0000583A
GENERAL SERVICE INFORMATION
COMPONENT IDENTIFICATION
Figure 4-1 shows where major engine components are located.
Figure 4-1
1 – Lifting Eye (Flywheel End)
2 – Engine Coolant Pump
3 – Lifting Eye (Engine Cooling Fan End)
4 – Engine Cooling Fan
5–V-Belt
6 – Crankshaft V-Pulley
7 – Side Filler Port (Engine Oil)
8 – Drain Plug (Engine Oil)*
9 – Fuel Inlet
10 – Mechanical Fuel Pump (If Equipped)
11 – Fuel Priming Lever
12 – Dipstick (Engine Oil)
13 – Engine Oil Filter
14 – Governor Lever
15 – Fuel Injection Pump
16 – Intake Manifold
17 – Air Intake Port (From Air Cleaner)
18 – Fuel Filter
19 – Fuel Re t u rn To Fuel Ta n k
20 – Top Filler Port (Engine Oil)
21 – Rocker Arm Cover
22 – Flywheel
23 – Starter Motor
24 – Exhaust Manifold
25 – Alternator
* Engine oil drain plug location may vary based on oil pan options.
TNV IDI Service Manual
4-3
GENERAL SERVICE INFORMATION
0003852
Location of Labels
LOCATION OF LABELS
Figure 4-2 shows the location of regulatory and
safety labels on Yanmar TNV series engines.
(2)
Figure 4-2
The typical location of the emission control
information label is shown (Figure 4-2, (1)).
Typical location of the engine nameplate is shown
(Figure 4-2, (2)).
Engine Nameplate (Typical)
(1)
0000585A
EPA / ARB EMISSION CONTROL
REGULATIONS - USA ONLY
Yanmar TNV engines meet Environmental
Protection Agency (EPA) (U. S. Federal) emission
control standards as well as the California Air
Resources Board (ARB, California) regulations.
Only engines that conform to ARB regulations can
be sold in the State of California.
Refer to the specific EPA / ARB installation (page
5-16) and maintenance (page 5-16) in the
Periodic Maintenance section of this manual. Also
refer to theYanmar Co., Ltd. Limited Emission
Control System Warranty - USA Only Yanmar Co.,
Ltd. Limited Emission Control System Warranty USA Only on page 2-6.
EMISSION CONTROL LABELS
Since emission control regulations are being issued
on a global basis, it is necessary to identify which
regulations a particular engine complies with. We
have listed several different types of labels you
might find on your engine.
4-4 TNV IDI Service Manual
The 97/68/EC Directive Certified Engines
REFER TO OWNER'S MANUAL FOR MAINTENANCE SPECIFICATIONS AND
ADJUSTMENTS
EMISSION CONTROL INFORMATION
ENGINE FAMILY : DISPLACEMENT : LITERS
ENGINE MODEL : EMISSION CONTROL SYSTEM :
FUEL RATE :
MM3/STROKE @ kW /
RPM
THIS ENGINE COMPLIES WITH U. S. EPA AND CALIFORNIA REGULATIONS
FOR M. Y. NONROAD/OFF-ROAD DIESEL ENGINES.
LOW SULFUR FUEL OR ULTRA LOW SULFUR FUEL ONLY
021752-00X
(97/68/EC)
97/68/EC DIRECTIVE
GENERAL SERVICE INFORMATION
EPA / ARB Labels (Typical)
EMISSION CONTROL INFORMATION
THIS ENGINE COMPLIES WITH U.S. EPA REGULATIONS FOR M. Y.
NONROAD DIESEL ENGINES.
LOW SULFUR FUEL OR ULTRA LOW SULFUR FUEL ONLY
ENGINE FAMILY : DISPLACEMENT : LITERS
ENGINE MODEL : EMISSION CONTROL SYSTEM :
FUEL RATE :
REFER TO OWNER'S MANUAL FOR MAINTENANCE SPECIFICATIONS AND
ADJUSTMENTS
MM3/STROKE @ kW /
(EPA) Less Than 50 HP SAE (37kW)
RPM
THE 97/68/EC DIRECTIVE
CERTIFIED ENGINES
The engines described in this manual have been
certified by the 97/68/EC Directive.
To identify the engines that meet this certification,
the 97/68/EC emission control label is affixed on
the engines.
021751-00X
(EPA & ARB)
ENGINE FAMILY
The EPA / ARB labels and the 97/68/EC label all
have an Engine Family field. The following is an
explanation of the Engine Family designation:
3YDXL1.33M 3 N
TNV IDI Service Manual
Method of air aspiration
Number of cylinders
Engine speed specifications
Displacement (liter)
Non-road / Off-road engine
Yanmar Diesel
*2005 Model Year
5*: 2005
6 : 2006
7 : 2007
4-5
GENERAL SERVICE INFORMATION
Function of Major Engine Components
FUNCTION OF MAJOR ENGINE COMPONENTS
Component Function
The air cleaner prevents airborne contaminants from entering the
engine. Since the air cleaner is application specific, it must be
carefully selected by an application engineer. It is not part of the
Air Cleaner
Dynamo
Dipstick (Engine Oil)
Electric Fuel Pump
basic engine package as shipped from the Yanmar factory. Periodic
replacement of the air cleaner filter element is necessary. See the
Periodic Maintenance Schedule on page 5-16 for the replacement
frequency.
The dynamo is driven by a V-belt which is powered by the
crankshaft V-pulley. The dynamo supplies electricity to the engine
systems and charges the battery while the engine is running.
The engine oil dipstick is used to determine the amount of engine
oil in the crankcase.
The electric fuel pump makes sure there is a constant supply of
diesel fuel to the fuel injection pump. The electric fuel pump is
electro-magnetic and runs on 12 VDC. An electric fuel pump may
be installed as standard equipment based on engine model and
specification. If an electric fuel pump is installed, turn the key switch
to the ON position for 10 to 15 seconds to prime the fuel system.
Engine Oil Filter
Fuel Filter
Fuel Filter / Water Separator
Fuel Priming Lever
The engine oil filter removes contaminants and sediments from the
engine oil. Periodic replacement of the engine oil filter is necessary.
See the Periodic Maintenance Schedule on page 5-16 for the
replacement frequency.
The fuel filter removes contaminants and sediments from the diesel
fuel. Periodic replacement of the fuel filter is necessary. See the
Periodic Maintenance Schedule on page 5-16 for the replacement
frequency. Please note that the word “diesel” is implied
throughout this manual when the word “fuel” is used.
The fuel filter / water separator removes contaminants, sediments
and water from diesel fuel going to the fuel filter. This is a required
component of the fuel system. This is standard equipment with
every engine. The separator is installed between the fuel tank and
the fuel pump. Periodically drain the water from the fuel filter / water
separator using the drain cock at the bottom of the separator.
If the unit has a mechanical fuel pump, a fuel priming lever on the
mechanical fuel pump primes the fuel system. The fuel system
needs to be primed before you start the engine for the first time, if
you run out of fuel, or if fuel system service is performed. To prime
the fuel system, operate the fuel priming lever until the cup in the
fuel filter is full of fuel.
4-6 TNV IDI Service Manual
Function of Major Engine Components
Component Function
The fuel tank is a reservoir that holds diesel fuel. When fuel leaves
the fuel tank it goes to the fuel filter / water separator. Next, fuel is
pumped to the fuel filter by the fuel pump. Next the fuel goes to the
Fuel Tank
Mechanical Fuel Pump
Side and Top Filler Port (Engine
Oil)
Starter Motor
fuel injection pump. Since fuel is used to keep the fuel injection
pump cool and lubricated, more fuel than necessary enters the
injection pump. When the injection pump pressure reaches a preset
value, a relief valve allows excess fuel to be returned back to the
fuel tank. The fuel tank is a required engine component.
The mechanical fuel pump is a diaphragm type of pump and is
installed on the fuel injection pump body. The mechanical fuel
pump is standard equipment on some engine models and is driven
by a cam on the camshaft of the fuel injection pump. The
mechanical fuel pump is not installed on the fuel injection pump if
the electric fuel pump is installed.
You can fill the crankcase with engine oil from either the side or
top filler port depending upon which one is most convenient.
The starter motor is powered by the battery. When you turn the key
switch in the operator’s console to the START position, the starter
motor engages with the ring gear installed on the flywheel and
starts the flywheel in motion.
GENERAL SERVICE INFORMATION
TNV IDI Service Manual
4-7
GENERAL SERVICE INFORMATION
Function of Cooling System Components
FUNCTION OF COOLING SYSTEM COMPONENTS
Component Function
The TNV engine is liquid-cooled by means of a cooling system. The
cooling system consists of a radiator, radiator cap, engine cooling
fan, engine coolant pump, thermostat, and reserve tank. Note that
Cooling System
Engine Cooling Fan
Engine Coolant Pump
Radiator
Radiator Cap
all cooling system components are required for proper engine
operation. Since some of the components are application
specific, they must be carefully selected by an application
engineer. The application specific items are not part of the
basic engine package as shipped from the Yanmar factory.
The engine cooling fan is driven by a V-belt which is powered by the
crankshaft V-pulley. The purpose of the engine cooling fan is to
circulate air through the radiator.
The engine coolant pump circulates the engine coolant through the
cylinder block and cylinder head and returns the engine coolant to
the radiator.
The radiator acts as a heat exchanger. As the engine coolant
circulates through the cylinder block it absorbs heat. The heat in the
engine coolant is dissipated in the radiator. As the engine cooling
fan circulates air through the radiator, the heat is transferred to the
air.
The radiator cap controls the cooling system pressure. The cooling
system is pressurized to raise the boiling point of the engine
coolant. As the engine coolant temperature rises, the system
pressure and the coolant volume increases. When the pressure
reaches a preset value, the release valve in the radiator cap opens
and the excess engine coolant flows into the reserve tank. As the
engine coolant temperature is reduced, the system pressure and
volume is reduced and the vacuum valve in the radiator cap opens
allowing engine coolant to flow from the reserve tank back into the
radiator.
The reserve tank contains the overflow of engine coolant from the
Reserve Tank
Thermostat
4-8 TNV IDI Service Manual
radiator. If you need to add engine coolant to the system, add it to
the reserve tank, not to the radiator.
A thermostat is placed in the cooling system to prevent engine
coolant from circulating into the radiator until the engine coolant
temperature reaches a preset temperature. When the engine is
cold, no engine coolant flows through the radiator. Once the engine
reaches its operating temperature the thermostat opens. By letting
the engine warm up as quickly as possible, the thermostat reduces
engine wear, deposits and emissions.
Diesel Fuel
GENERAL SERVICE INFORMATION
DIESEL FUEL
Diesel Fuel Specifications
Diesel fuel should comply with the following
specifications. The table lists several worldwide
specifications for diesel fuels.
Diesel Fuel Specification Location
No. 2-D, No. 1-D,
ASTM D975-94
EN590:96
ISO 8217 DMX International
BS 2869-A1 or A2
JIS K2204 Grade No. 2 Japan
KSM-2610 Korea
GB252 China
Additional Technical Fuel Requirements
• The fuel cetane number should be equal to 45
or higher.
• The sulfur content must not exceed 0.5% by
volume. Less than 0.05% is preferred.
Especially in U.S.A. and Canada, Low Sulfur
(300-500mg/kg sulfur content) or Ultra Low
Sulfur fuel should be used.
• Bio-Diesel fuels. See Bio-Diesel Fuels on
page 4-9.
• NEVER mix kerosene, used engine oil, or
residual fuels with the diesel fuel.
• Water and sediment in the fuel should not
exceed 0.05% by volume.
• Keep the fuel tank and fuel-handling
equipment clean at all times.
• Poor quality fuel can reduce engine
performance and / or cause engine damage.
USA
European
Union
United
Kingdom
• Carbon residue content not to exceed 0.35%
by volume. Less than 0.1% is preferred.
• Total aromatics content should not exceed
35% by volume. Less than 30% is preferred.
• PAH (polycyclic aromatic hydrocarbons)
content should be below 10% by volume.
• Metal content of Na, Mg, Si, and Al should be
equal to or lower than 1 mass ppm. (Test
analysis method JPI-5S-44-95)
• Lubricity: Wear mark of WS1.4 should be Max.
0.018 in. (460 µm) at HFRR test.
Bio-Diesel Fuels
In Europe and in the United States, as well as some
other countries, non-mineral oil based fuel
resources such as RME (Rapeseed Methyl Ester)
and SOME (Soybean Methyl Ester), collectively
known as FAME (Fatty Acid Methyl Esters), are
being used as extenders for mineral oil derived
diesel fuels.
Yanmar approves the use of bio-diesel fuels that do
not exceed a blend of 5% (by volume) of FAME with
95% (by volume) of approved mineral oil derived
diesel fuel. Such bio-diesel fuels are known in the
marketplace as B5 diesel fuels.
These B5 diesel fuels must meet certain
requirements.
1. The bio-fuels must meet the minimum
specifications for the country in which they are
used.
• In Europe, bio-diesel fuels must comply with
the European Standard EN14214.
• In the United States, bio-diesel fuels must
comply with the American Standard
ASTM D-6751.
2. Bio-fuels should be purchased only from
recognized and authorized diesel fuel suppliers.
• Fuel additives are not recommended. Some
fuel additives may cause poor engine
performance. Consult your Yanmar
representative for more information.
• Ash content not to exceed 0.01% by volume.
TNV IDI Service Manual
4-9
GENERAL SERVICE INFORMATION
Diesel Fuel
Precautions and concerns regarding the use of
bio-fuels:
1. Free methanol in FAME may result in corrosion
of aluminum and zinc FIE components.
2. Free water in FAME may result in plugging of
fuel filters and increased bacterial growth.
3. High viscosity at low temperatures may result in
fuel delivery problems, injection pump seizures,
and poor injection nozzle spray atomization.
4. FAME may have adverse effects on some
elastomers (seal materials) and may result in
fuel leakage and dilution of the engine
lubricating oil.
5. Even bio-diesel fuels that comply with a suitable
standard as delivered, will require additional
care and attention to maintain the quality of the
fuel in the equipment or other fuel tanks. It is
important to maintain a supply of clean, fresh
fuel. Regular flushing of the fuel system,
and / or fuel storage containers, may be
necessary.
6. The use of bio-diesel fuels that do not comply
with the standards as agreed to by the diesel
engine manufacturers and the diesel fuel
injection equipment manufacturers, or biodiesel fuels that have degraded as per the
precautions and concerns above, may affect
the warranty coverage of your engine. See
Yanmar Limited Warranty on page 2-3.
Filling the Fuel Tank
A DANGER
FIRE AND EXPLOSION HAZARD!
• Diesel fuel is flammable and explosive
under certain conditions.
• Only fill the fuel tank with diesel fuel.
Filling the fuel tank with gasoline may
result in a fire and will damage the
engine.
• NEVER refuel with the engine running.
• Wipe up all spills immediately.
• Keep sparks, open flames or any other
form of ignition (match, cigarette,
static electric source) well away when
refueling.
• NEVER overfill the fuel tank.
• Fill the fuel tank. Store any containers
containing fuel in a well-ventilated
area, away from any combustibles or
sources of ignition.
• Failure to comply will result in death or
serious injury.
0000005en
4-10 TNV IDI Service Manual
Diesel Fuel
GENERAL SERVICE INFORMATION
A DANGER
FIRE AND EXPLOSION HAZARD!
• Diesel fuel is flammable and explosive
under certain conditions.
• Be sure to place the diesel fuel
container on the ground when
transferring the diesel fuel from the
pump to the container. Hold the hose
nozzle firmly against the side of the
container while filling it. This prevents
static electricity buildup which could
cause sparks and ignite fuel vapors.
• NEVER place diesel fuel or other
flammable material such as oil, hay or
dried grass close to the engine during
engine operation or shortly after
shutdown.
A DANGER
FIRE AND EXPLOSION HAZARD!
• Diesel fuel is flammable and explosive
under certain conditions.
• Before you operate the engine, check
for fuel leaks. Replace rubberized fuel
hoses every two years or every 2000
hours of engine operation, whichever
comes first, even if the engine has
been out of service. Rubberized fuel
lines tend to dry out and become
brittle after two years or 2000 hours of
engine operation, whichever comes
first.
• Failure to comply will result in death or
serious injury.
0000015en
• Failure to comply will result in death or
serious injury.
0000014en
CAUTION
• Only use diesel fuels recommended by
Yanmar for the best engine
performance, to prevent engine
damage and to comply with EPA / ARB
warranty requirements.
• Only use clean diesel fuel.
• NEVER remove the primary strainer (if
equipped) from the fuel tank filler port.
If removed, dirt and debris could get
into the fuel system causing it to clog.
0000004en
TNV IDI Service Manual
4-11
GENERAL SERVICE INFORMATION
0000002A
(1)
(2)
(3)
Diesel Fuel
Note that a typical fuel tank is shown. The fuel tank
on the equipment being serviced may be different.
1. Clean the area around the fuel cap
(Figure 4-3, (1)).
2. Remove the fuel cap (Figure 4-3, (1)) from the
fuel tank (Figure 4-3, (2)).
3. Observe the fuel level sight gauge
(Figure 4-3, (3)) and stop fueling when gauge
shows fuel tank is full. NEVER overfill the fuel
tank.
4. Replace the fuel cap and hand-tighten. Over
tightening the fuel cap will damage it.
Priming the Fuel System
A DANGER
FIRE AND EXPLOSION HAZARD!
• Diesel fuel is flammable and explosive
under certain conditions.
• If the unit has an electric fuel pump,
when you prime the fuel system, turn
the key switch to the ON position for
10 to 15 seconds to allow the electric
fuel pump to prime the system.
• If the unit has a mechanical fuel pump,
when you prime the fuel system,
operate the fuel priming lever of the
mechanical fuel pump several times
until the fuel filter cup is filled with
fuel.
• Failure to comply will result in death or
serious injury.
0000010en
Figure 4-3
The fuel system needs to be primed under certain
conditions:
• Before starting the engine for the first time
• After running out of fuel and fuel has been
added to the fuel tank
• After fuel system maintenance such as
changing the fuel filter and draining the fuel
filter / water separator, or replacing a fuel
system component
To prime the fuel system if an electric fuel pump is
installed:
1. Turn the key to the ON position for 10 to 15
seconds. This will allow the electric fuel pump
to prime the fuel system.
2. NEVER use the starter motor to prime the fuel
system. This may cause the starter motor to
overheat and damage the coils, pinion and / or
ring gear.
4-12 TNV IDI Service Manual
Engine Oil
GENERAL SERVICE INFORMATION
To prime the fuel system if a mechanical fuel pump
is installed:
1. Operate the fuel priming lever (Figure 4-4, (1))
several times until the fuel filter cup
(Figure 4-4, (2)) is filled with fuel.
2. NEVER use the starter motor to prime the fuel
system. This may cause the starter motor to
overheat and damage the coils, pinion and / or
ring gear.
(2)
(1)
0000649A
Figure 4-4
ENGINE OIL
CAUTION
• Only use the engine oil specified.
Other engine oils may affect warranty
coverage, cause internal engine
components to seize and / or shorten
engine life.
• Prevent dirt and debris from
contaminating the engine oil. Carefully
clean the oil cap / dipstick and the
surrounding area before you remove
the cap.
• NEVER mix different types of engine
oil. This may adversely affect the
lubricating properties of the engine oil.
• NEVER overfill. Overfilling may result
in white exhaust smoke, engine
overspeed or internal damage.
0000005en
Engine Oil Specifications
Use an engine oil that meets or exceeds the
following guidelines and classifications:
Service Categories
• API Service Categories CD or higher
• ACEA Service Categories E-3, E-4, and E-5
• JASO Service Category DH-1
Definitions
• API Classification (American Petroleum
Institute)
• ACEA Classification (Association des
Constructeurs Européens d'Automobilies)
• JASO (Japanese Automobile Standards
Organization)
Note:
1. Be sure the engine oil, engine oil storage
containers, and engine oil filling equipment are
free of sediments and water.
TNV IDI Service Manual
4-13
GENERAL SERVICE INFORMATION
Engine Oil
2. Change the engine oil after the first 50 hours of
operation and then every 250 hours thereafter.
3. Select the oil viscosity based on the ambient
temperature where the engine is being
operated. See the SAE Service Grade Viscosity
Chart (Figure 4-5).
4. Yanmar does not recommend the use of engine
oil “additives.”
Additional Technical Engine oil
Requirements:
The engine oil must be changed when the Total
Base Number (TBN) has been reduced to 1.0
(mgKOH/g) test method; JIS K-201-5.2-2 (HCI),
ASTM D4739 (HCI).
Engine Oil Viscosity
Select the appropriate engine oil viscosity based on
the ambient temperature and use the SAE Service
Grade Viscosity Chart in Figure 4-5.
SAE 10W
SAE 20W
SAE 10W-30
SAE 15W-40
SAE 20
SAE 30
SAE 40
SAE 20W - 50
-4°F 14°F 32°F 50°F 68°F 86°F 104°F
(-20°C) (-10°C) (0°C) (10°C) (20°C) (30°C) (40°C)
122°F
(50°C)
0000005A
Figure 4-5
Checking Engine Oil
1. Make sure engine is level.
2. Remove dipstick (Figure 4-6, (1)) and wipe with
clean cloth.
3. Fully reinsert dipstick.
4. Remove dipstick. The oil level should be
between upper (Figure 4-6, (2)) and lower
(Figure 4-6, (3)) lines on the dipstick.
5. Fully reinsert dipstick.
(4)
(4)
(5)
(1)
(2)
(3)
0000587C
Figure 4-6
Adding Engine Oil
1. Make sure engine is level.
2. Remove oil cap (Figure 4-6, (4)).
3. Add indicated amount of engine oil at the top or
side engine oil filler port (Figure 4-6, (5)).
4. Wait three minutes and check oil level.
5. Add more oil if necessary.
6. Replace oil cap (Figure 4-6, (4)) and
hand-tighten. Over-tightening may damage the
cap.
4-14 TNV IDI Service Manual
Engine Coolant
GENERAL SERVICE INFORMATION
Engine Oil Capacity (Typical)
Note: These are the engine oil capacities
associated with a “deep standard” oil
pan. Oil capacity will vary dependant
upon which optional oil pan is used.
Refer to the operation manual provided
by the driven machine manufacturer for
the actual engine oil capacity of your
machine.
The following are the engine oil capacities for
various Yanmar TNV engines:
Engine Model
3TNV72
Dipstick Upper
Limit/ Lower Limit
2.5 / 1.5qt
(2.4 / 1.4L)
ENGINE COOLANT
A DANGER
SCALD HAZARD!
• NEVER remove the radiator cap if the
engine is hot. Steam and hot engine
coolant will spurt out and seriously
burn you. Allow the engine to cool
down before you attempt to remove
the radiator cap.
• Tighten the radiator cap securely after
you check the radiator. Steam can
spurt out during engine operation if
the cap is loose.
• ALWAYS check the level of the engine
coolant by observing the reserve tank.
• Failure to comply will result in death or
serious injury.
0000002en
A WARNING
BURN HAZARD!
• Wait until the engine cools before you
drain the engine coolant. Hot engine
coolant may splash and burn you.
• Failure to comply could result in death
or serious injury.
0000016en
TNV IDI Service Manual
4-15
GENERAL SERVICE INFORMATION
Engine Coolant
A CAUTION
COOLANT HAZARD!
• Wear eye protection and rubber gloves
when you handle long life or extended
life engine coolant. If contact with the
eyes or skin should occur, flush eyes
and wash immediately with clean
water.
• Failure to comply may result in minor
or moderate injury.
0000005en
CAUTION
• Only use the engine coolant specified.
Other engine coolants may affect
warranty coverage, cause an internal
buildup of rust and scale and / or
shorten engine life.
• Prevent dirt and debris from
contaminating the engine coolant.
Carefully clean the radiator cap and
the surrounding area before you
remove the cap.
• NEVER mix different types of engine
coolants. This may adversely affect the
properties of the engine coolant.
0000006en
Engine Coolant Specifications
Use a Long Life Coolant (LLC) or an Extended Life
Coolant (ELC) that meets or exceeds the following
guidelines and specifications:
Additional Technical Coolant
Specifications:
• ASTM D6210, D4985 (US)
• JIS K-2234 (Japan)
• SAE J814C, J1941, J1034 or J2036
(International)
Alternative Engine Coolant
If an Extended or Long Life Coolant is not available,
you may use an ethylene glycol or propylene glycol
based conventional coolant (green).
Notes:
1. ALWAYS use a mix of coolant and water.
NEVER use water only.
2. Mix coolant and water per the mixing
instructions on the coolant container.
3. Water quality is important to coolant
performance. Yanmar recommends that soft,
distilled, or demineralized water be used to mix
with coolants.
4. NEVER mix extended or long life coolants and
conventional (green) coolants.
5. NEVER mix different types and / or colors of
extended life coolants.
6. Replace the coolant every 1000 engine hours
or once a year.
Filling Radiator with Engine Coolant
Fill the radiator and reserve tank as follows. This
procedure is for filling the radiator for the first time
or refilling it after it is flushed. Note that a typical
radiator is illustrated.
4-16 TNV IDI Service Manual
Engine Coolant
(2)
(5)
(3)
(6)
(4)
(1)
1. Check to be sure the radiator drain plug is
installed and tightened or the drain cock
(Figure 4-7, (1)) is closed. Also make sure the
coolant drain plug (Figure 4-8, (1)) in the
cylinder block is closed.
FULL
LOW
Figure 4-7
0000029A
GENERAL SERVICE INFORMATION
5. Remove the cap of the reserve tank
(Figure 4-7, (3)), and fill it to the LOW (COLD)
mark (Figure 4-7, (4)) with engine coolant.
Reinstall the cap.
6. Check the hose (Figure 4-7, (5)) that connects
the reserve tank (Figure 4-7, (3)) to the
radiator. Be sure it is securely connected and
there are no cracks or damage. If the hose is
damaged, engine coolant will leak out instead
of going into the reserve tank.
7. Run the engine until it is at operating
temperature. Check the level of engine coolant
in the reserve tank. When the engine is running
and the engine coolant is at normal
temperature, the coolant level in the tank should
be at or near the FULL (HOT) mark
(Figure 4-7, (6)). If the engine coolant is not at
the FULL (HOT) mark (Figure 4-7, (6)), add
additional engine coolant to the reserve tank to
bring the level to the FULL (HOT) mark.
OIL
(1)
0002923
Figure 4-8
2. Remove the radiator cap (Figure 4-7, (2)) by
turning it counterclockwise about 1/3 of a turn.
3. Pour the engine coolant slowly into the radiator
until it is even with the lip of the engine coolant
filler port. Make sure that air bubbles do not
develop as you fill the radiator.
4. Reinstall the radiator cap (Figure 4-7, (2)).
Align the tabs on the back of the radiator cap
with the notches on the engine coolant filler
port. Press down and turn the cap clockwise
about 1/3 of a turn.
Engine Coolant Capacity (Typical)
Note: Capacities listed are for engine only
without a radiator. Refer to the operation
manual provided by the driven machine
manufacturer for actual engine coolant
capacity on your machine.
The following are the engine coolant capacities for
various Yanmar TNV engines.
Engine Model
3TNV72 1.0 qt (0.9 L)
Engine Coolant
Capacity
TNV IDI Service Manual
4-17
GENERAL SERVICE INFORMATION
Specifications
SPECIFICATIONS
Description of Model Number
3 TNV 72 - 0 0000
Customer Code
Rated rpm
Cylinder Bore (mm)
Engine Series
No. of Cylinders
When ordering parts or making an inquiry about the engine you are working on, be sure to include the
complete model and serial numbers as shown on the engine nameplate. See Location of Labels on
page 4-4.
4-18 TNV IDI Service Manual
Specifications
GENERAL SERVICE INFORMATION
Engine General Specifications
Type Vertical In-line, Water Cooled, 4-Cycle Diesel Engine
Combustion System Swirl Chamber (Ball Type)
Starting System Electric Starting
Cooling System Radiator
Lubricating System Forced Lubrication with Trochoid Pump
PTO Position Flywheel End
Direction of Rotation Counterclockwise Viewed from Flywheel End
Note: The information described in Principal Engine Specifications is for a “standard” engine. To obtain the
information for the engine installed in your driven machine, please refer to the manual provided by the
driven machine manufacturer. Engine rating conditions are as follows (SAE J1349, ISO 3046/1):
• Atmospheric Condition: Room temperature 77°F (25°C), Atmospheric pressure 29.53 in Hg (100 kPa,
750 mm Hg), Relative humidity 30%
• Fuel Temperature at Fuel Injector Pump Inlet: 104°F (40°C)
• With Cooling Fan, Air Cleaner, Muffler: Yanmar Standard
• After Engine Break-In Period; Output Allowable Deviation: ± 3%
• 1 PS = 0.7355 kW
• 1 hp SAE (Society of Automotive Engineers) = 0.7457 kW
TNV IDI Service Manual
4-19
GENERAL SERVICE INFORMATION
Principal Engine Specifications
PRINCIPAL ENGINE SPECIFICATIONS
3TNV72
Engine Model 3TNV72
Version VH
Type Vertical In-line Diesel Engine
Combustion System Ball-Type Swirl Chamber
Aspiration Natural
No. of Cylinders 3
Bore × Stroke 2.835 x 2.913in. (72 x 74mm)
Displacement 55.104 cu in. (0.903L)
RPM
-1
)
(min
Max. Rated Output (Net)
High Idling
Engine Weight (Dry)
with Flywheel Housing
PTO Position Flywheel End
Direction of Rotation Counterclockwise Viewed from Flywheel End
Cooling System Liquid-Cooled with Radiator
Lubricating System Forced Lubrication with Trochoid Pump
Normal Oil Pressure at Rated
Engine Speed
Normal Oil Pressure at Low
Idle Speed
Starting System
Dimensions (L × W × H)*
Engine Oil Pan Capacity
Engine Coolant Capacity 0.2 gal (0.9 L) Engine Only
Standard Cooling Fan 11.81 in. (300 mm) O.D., 5 Blade Puller-Type
hp SAE 20.1
kW 15.0
PS 20.4
RPM
-1
(min
)
178.6lb (81kg)
42 - 64 psi (0.29 -0.44 MPa, 2.96 - 4.49 kgf/cm
8.5 psi (0.06 MPa, 0.6 kgf/cm
Electric Starting - Starter Motor: DC12V, 1.6hp (1.2kW)
Dynamo: DC12V, 40A
Recommended Battery Capacity: 12V, 36 Amp-Hour (5h rating)
19.53 x 17.36 x 24.84 in.
(496 x 441 x 631 mm)
2.5 / 1.5 qt (2.4 / 1.4 L)
(Dipstick Upper Limit / Lower Limit)
* Engine specifications without radiator
3300
3520 ± 25
2
) or greater
2
)
4-20 TNV IDI Service Manual
Engine Service Information
GENERAL SERVICE INFORMATION
ENGINE SERVICE INFORMATION
Inspection Item Standard Limit
Intake / Exhaust Valve Gap
Fuel Injection Timing See Checking and Adjusting Fuel Injection Timing on page 7-19
Fuel Injection Pressure
Compression Pressure at
250 rpm (250 min¯¹)
Lubricating Oil Pressure
Thermostat
Temperature Coolant Switch
3TNV72
At rated output
When idling
0.006 - 0.010 in
(0.15 - 0.25 mm)
1711 - 1842 psi
(11.8 - 12.8 MPa;
120 - 130 kgf / cm²)
470 ± 15 psi
(3.24 ± 0.1MPa;
33 ± 1 kgf / cm²)
42 - 64 psi (0.29 - 0.44 MPa;
2.96 - 4.49 kgf/cm
8.5 psi (0.06 MPa;
0.6 kgf/cm
Valve Opening Temperature
2
) or greater
157 - 163°F
(70 - 73°C)
225 - 235°F
(107 - 113°C)
2
)
-
-
370 ± 15 psi
(2.55 ± 0.1 MPa;
26 ± 1 kgf / cm²)
-
-
Full Opening Lift
Temperature
0.32 in. (8 mm) or
Above
185°F (85°C)
-
TNV IDI Service Manual
4-21
GENERAL SERVICE INFORMATION
Tightening Torques for Standard Bolts and Nuts
TIGHTENING TORQUES FOR STANDARD BOLTS AND NUTS
Use the correct amount of torque when you tighten
fasteners on the machine. Applying excessive
torque may damage the fastener or component and
not enough torque may cause a leak or component
failure.
The tightening torque in the Standard
Torque Chart in General Service
Information should be applied only to
the bolts with a “7” head. (JIS strength
classification: 7T)
• Apply 60% torque to bolts
that are not listed.
• Apply 80% torque when
tightened to aluminum alloy.
CAUTION
0000023enTNVIDISM
Item
Hexagon Bolt (7T)
and Nut
PT Plug
Nominal Thread
Diameter
M6 x 1.0 mm
M8 x 1.25 mm
M10 x 1.5 mm
M12 x 1.75 mm
M14 x 1.5 mm
M16 x 1.5 mm
1/8 mm
1/4 mm
3/8 mm
1/2 mm
x Pitch Tightening Torque Remarks
87 - 104 in·lb
(9.8 - 11.8 N·m;
1.0 - 1.2 kgf·m)
200 - 251 in·lb
(22.6 - 28.4 N·m;
2.3 - 2.9 kgf·m)
33 - 40 ft·lb
(44.1 - 53.9 N·m;
4.5 - 5.5 kgf·m)
58 - 72 ft·lb
(78.4 - 98.0 N·m;
8.0 - 10 kgf·m)
94 - 108 ft·lb
(127.5 - 147.1 N·m;
13 - 15 kgf·m)
159 - 174 ft·lb
(215.7 - 235.4 N·m;
22 - 24 kgf·m)
87 in·lb
(9.8 N·m; 1.0 kgf·m)
173 in·lb
(19.6 N·m; 2.0 kgf·m)
22 ft·lb
(29.4 N·m; 3.0 kgf·m)
43 ft·lb
(58.8 N·m; 6.0 kgf·m)
Use 80% of the value at left
when the tightening part is
aluminum.
Use 60% of the value at left
for 4T bolts and lock nuts.
-
4-22 TNV IDI Service Manual
Tightening Torques for Standard Bolts and Nuts
GENERAL SERVICE INFORMATION
Item
Pipe Joint Bolt
Nominal Thread
Diameter
M8
M10
M12
M14
M16
x Pitch Tightening Torque Remarks
112 - 148 in·lb
(12.7 - 16.7 N·m;
1.3 - 1.7 kgf·m)
173 - 225 in·lb
(19.6 - 18.734 N·m,;
2.0 - 3.5 kgf·m)
18 - 25 ft·lb
(24.5 - 34.3 N·m;
2.5 - 3.5 kgf·m)
29 - 36 ft·lb
(39.2 - 49.0 N·m;
4.0 - 5.0 kgf·m)
36 - 43 ft·lb
(49.0 - 58.8 N·m;
5.0 - 6.0 kgf·m)
-
Note: Torque values shown in this manual are for clean, non-lubricated fasteners unless otherwise
specified.
TNV IDI Service Manual
4-23
GENERAL SERVICE INFORMATION
ABBREVIATIONS AND SYMBOLS
Abbreviations and Symbols
Abbreviations
A ampere
AC alternating current
ACEA
Ah ampere-hour
approx. approximately
API American Petroleum Institute
ARB Air Resources Board
ATDC after top dead center
BTDC before top dead center
°C degree Celsius
CARB California Air Resources Board
CCA cold cranking amp
cm centimeter
cm³ cubic centimeter
cm³/min cubic centimeter per minute
cu in cubic inch
DC direct current
DI direct injection
DVA direct volt adapter
EPA Environmental Protection Agency
ESG electronic speed governor
°F degree Fahrenheit
fl oz fluid ounce (U.S.)
fl oz/min fluid ounce (U.S.) per minute
ft foot
ft·lb foot pound
ft·lbf/min foot pound force per minute
ggram
gal/hr gallon (U.S.) per hour
gal gallon (U.S.)
GL gear lubricant
hp horsepower (U.S.)
hrs hours
I.D. inside diameter
IDI indirect injection
in inch
in·lb inch pound
JASO
kg kilogram
kgf/cm²
kgf·m kilogram force meter
km kilometers
kPa kilopascal
kW kilowatt
Association des Constructeurs
Européens d’Automobilies
Japanese Automobile Standards
Organization
kilogram force per square
centimeter
L liter
L/hr liter per hour
lb pound
lbf pond force
mL milliliter
mm millimeter
MPa megapascal
mV millivolt
N newton
N·m newton meter
No. number
O.D. outside diameter
oz ounce
PS horsepower (metric)
psi pound per square inch
qt quart (U.S.)
RPM revolutions per minute
SAE Society of Automotive Engineers
sec. second
t short ton 2000lb
TBN Total Base Number
TDC top dead center
Vvolt
VAC volt alternating current
VDC volt direct current
Wwatt
Symbols
° angular degree
+plus
-minus
± plus or minus
Ω ohm
μ micro
% percent
~ approximate
4-24 TNV IDI Service Manual
Unit Conversions
GENERAL SERVICE INFORMATION
UNIT CONVERSIONS
Unit Prefixes
Prefix Symbol Power
mega M x 1,000,000
kilo k x 1,000
centi c x 0.01
milli m x 0.001
micro μ x 0.000001
Units of Length
mile x 1.6090 = km
ft x 0.3050 = m
in x 2.5400 = cm
in x 25.4000 = mm
km x 0.6210 = mile
m x 3.2810 = ft
cm x 0.3940 = in
mm x 0.0394 = in
Units of Volume
gal (U.S.) x 3.78540 = L
qt (U.S.) x 0.94635 = L
cu in x 0.01639 = L
cu in x 16.38700 = mL
fl oz (U.S.) x 0.02957 = L
fl oz (U.S.) x 29.57000 = mL
cm³ x 1.00000 = mL
cm³ x 0.03382 = fl oz (U.S.)
Units of Mass
lb x 0.45360 = kg
oz x 28.35000 = g
kg x 2.20500 = lb
g x 0.03527 = oz
Units of Force
lbf x 4.4480 = N
lbf x 0.4536 = kgf
N x 0.2248 = lbf
N x 0.1020 = kgf
kgf x 2.2050 = lbf
kgf x 9.8070 = N
Units of Torque
ft·lb x 1.3558 = N·m
ft·lb x 0.1383 = kgf·m
in·lb x 0.1130 = N·m
in·lb x 0.0115 = kgf·m
kgf·m x 7.2330 = ft·lb
kgf·m x 86.8000 = in·lb
kgf·m x 9.8070 = N·m
N·m x 0.7376 = ft·lb
N·m x 8.8510 = in·lb
N·m x 0.1020 = kgf·m
Units of Pressure
psi x 0.0689 = bar
psi x 6.8950 = kPa
psi x 0.0703 = kg/cm²
bar x 14.5030 = psi
bar x 100.0000 = kPa
bar x 29.5300
kPa x 0.1450 = psi
kPa x 0.0100 = bar
kPa x 0.0102 = kg/cm²
kg/cm² x 98.0700 = psi
kg/cm² x 0.9807 = bar
kg/cm² x 14.2200 = kPa
in Hg (60°) x 0.0333 = bar
in Hg (60°) x 3.3770 = kPa
in Hg (60°) x 0.0344 = kg/cm²
= in Hg
(60°F)
Units of Power
hp (metric or
PS)
hp (metric or
PS)
hp SAE x 1.0138697
hp SAE x 0.7456999 = kW
kW x 1.3596216
kW x 1.3410221 = hp SAE
x 0.9863201 = hp SAE
x 0.7354988 = kW
= hp (metric
or PS)
= hp (metric
or PS)
Units of Temperature
°F = (1.8 x °C) + 32
°C = 0.556 x (°F - 32)
TNV IDI Service Manual
4-25
GENERAL SERVICE INFORMATION
Unit Conversions
This Page Intentionally Left Blank
4-26 TNV IDI Service Manual
TNV IDI Service Manual
MAINTENANCE
Introduction...................................................................................... 5-3
Precautions ................................................................................... 5-15
The Importance of Periodic Maintenance................................ 5-15
Performing Periodic Maintenance ........................................... 5-15
Yanmar Replacement Parts .................................................... 5-16
Required EPA / ARB Maintenance - USA Only....................... 5-16
EPA / ARB Installation Requirements - USA Only .................. 5-16
Periodic Maintenance Schedule.................................................... 5-16
Periodic Maintenance Procedures ................................................ 5-18
After Initial 50 Hours of Operation ........................................... 5-18
Every 50 Hours of Operation................................................... 5-21
Every 250 Hours of Operation................................................. 5-25
Every 500 Hours of Operation................................................. 5-30
Every 1000 Hours of Operation............................................... 5-33
Every 1500 Hours of Operation............................................... 5-36
Every 2000 Hours of Operation............................................... 5-37
Section 5
PERIODIC
Page
TNV IDI Service Manual
5-1
PERIODIC MAINTENANCE
This Page Intentionally Left Blank
5-2 TNV IDI Service Manual
Introduction
PERIODIC MAINTENANCE
INTRODUCTION
This section of the Service Manual describes the
procedures for proper care and maintenance of the
engine.
A DANGER
EXPLOSION HAZARD!
• NEVER check the remaining battery
charge by shorting out the terminals.
This will result in a spark and may
cause an explosion or fire. Use a
hydrometer to check the remaining
battery charge.
• If the electrolyte is frozen, slowly warm
the battery before you recharge it.
• Failure to comply will result in death or
serious injury.
0000007en
A DANGER
SCALD HAZARD!
• NEVER remove the radiator cap if the
engine is hot. Steam and hot engine
coolant will spurt out and seriously
burn you. Allow the engine to cool
down before you attempt to remove
the radiator cap.
• Tighten the radiator cap securely after
you check the radiator. Steam can
spurt out during engine operation if
the cap is loose.
• ALWAYS check the level of the engine
coolant by observing the reserve tank.
• Failure to comply will result in death or
serious injury.
0000002en
A DANGER
FIRE AND EXPLOSION HAZARD!
• Only use the key switch to start the
engine.
• NEVER jump-start the engine. Sparks
caused by shorting the battery to the
starter terminals may cause a fire or
explosion.
• Failure to comply will result in death or
serious injury.
0000004en
TNV IDI Service Manual
5-3
PERIODIC MAINTENANCE
Introduction
A DANGER
FIRE AND EXPLOSION HAZARD!
• Diesel fuel is flammable and explosive
under certain conditions.
• Only fill the fuel tank with diesel fuel.
Filling the fuel tank with gasoline may
result in a fire and will damage the
engine.
• NEVER refuel with the engine running.
• Wipe up all spills immediately.
• Keep sparks, open flames or any other
form of ignition (match, cigarette,
static electric source) well away when
refueling.
• NEVER overfill the fuel tank.
• Fill the fuel tank. Store any containers
containing fuel in a well-ventilated
area, away from any combustibles or
sources of ignition.
A DANGER
FIRE AND EXPLOSION HAZARD!
• Diesel fuel is flammable and explosive
under certain conditions.
• Before you operate the engine, check
for fuel leaks. Replace rubberized fuel
hoses every two years or every 2000
hours of engine operation, whichever
comes first, even if the engine has
been out of service. Rubberized fuel
lines tend to dry out and become
brittle after two years or 2000 hours of
engine operation, whichever comes
first.
• Failure to comply will result in death or
serious injury.
0000015en
• Failure to comply will result in death or
serious injury.
0000005en
5-4 TNV IDI Service Manual
Introduction
PERIODIC MAINTENANCE
A DANGER
FIRE AND EXPLOSION HAZARD!
• Diesel fuel is flammable and explosive
under certain conditions.
• Be sure to place the diesel fuel
container on the ground when
transferring the diesel fuel from the
pump to the container. Hold the hose
nozzle firmly against the side of the
container while filling it. This prevents
static electricity buildup which could
cause sparks and ignite fuel vapors.
• NEVER place diesel fuel or other
flammable material such as oil, hay or
dried grass close to the engine during
engine operation or shortly after
shutdown.
• Failure to comply will result in death or
serious injury.
0000014en
A DANGER
A DANGER
FIRE AND EXPLOSION HAZARD!
• Diesel fuel is flammable and explosive
under certain conditions.
• NEVER remove the fuel cap with the
engine running.
• Failure to comply will result in death or
serious injury.
0000011en
A DANGER
CRUSH HAZARD!
• When you need to transport an engine
for repair, have a helper assist you to
attach it to a hoist and load it on a
truck.
• NEVER stand under a hoisted engine.
If the hoist mechanism fails, the
engine will fall on you, causing death
or serious injury.
FIRE AND EXPLOSION HAZARD!
• Diesel fuel is flammable and explosive
under certain conditions.
• NEVER use diesel fuel as a cleaning
agent.
• Failure to comply will result in death or
serious injury.
0000012en
TNV IDI Service Manual
• Failure to comply will result in death or
serious injury.
0000008en
5-5
PERIODIC MAINTENANCE
Introduction
A DANGER
FIRE AND EXPLOSION HAZARD!
• Diesel fuel is flammable and explosive
under certain conditions.
• When you remove any fuel system
component to perform maintenance
(such as changing the fuel filter) place
an approved container under the
opening to catch the fuel.
• NEVER use a shop rag to catch the
fuel. Vapors from the rag are
flammable and explosive.
• Wipe up any spills immediately.
• Wear eye protection. The fuel system
is under pressure and fuel could spray
out when you remove any fuel system
component.
• Failure to comply will result in death or
serious injury.
0000009en
A DANGER
FIRE AND EXPLOSION HAZARD!
• Diesel fuel is flammable and explosive
under certain conditions.
• Place an approved container under the
air bleed port when you prime the fuel
system. Never use a shop rag to catch
the fuel. Wipe up any spills
immediately. ALWAYS close the air
bleed port after you complete priming
the system.
• Wear eye protection. The fuel system
is under pressure and fuel could spray
out when you open the air bleed port.
• If the unit has an electric fuel pump,
turn the key switch to the ON position
for 10 to 15 seconds, or until the fuel
coming out of the air bleed port is free
of bubbles, to allow the electric fuel
pump to prime the system.
• If the unit has a mechanical fuel pump,
operate the fuel priming pump several
times until the fuel coming out of the
air bleed port is free of bubbles.
• Failure to comply will result in death or
serious injury.
0000006en
5-6 TNV IDI Service Manual
Introduction
PERIODIC MAINTENANCE
A WARNING
EXHAUST HAZARD!
• NEVER operate the engine in an
enclosed area such as a garage,
tunnel, underground room, manhole or
ship’s hold without proper ventilation.
• NEVER block windows, vents, or other
means of ventilation if the engine is
operating in an enclosed area. All
internal combustion engines create
carbon monoxide gas during
operation. Accumulation of this gas
within an enclosure could cause
illness or even death.
• Make sure that all connections are
tightened to specifications after repair
is made to the exhaust system.
• Failure to comply could result in death
or serious injury.
0000003en
A WARNING
SEVER HAZARD!
• Keep hands and other body parts
away from moving / rotating parts
such as the cooling fan, flywheel or
PTO shaft.
• Wear tight-fitting clothing and keep
your hair short or tie it back while the
engine is running.
• Remove all jewelry before you operate
or service the machine.
• NEVER start the engine in gear.
Sudden movement of the engine
and / or machine could cause death or
serious personal injury.
• NEVER operate the engine without the
guards in place.
• Before you start the engine make sure
that all bystanders are clear of the
area.
• Keep children and pets away while the
engine is operating.
• Check before starting the engine that
any tools or shop rags used during
maintenance have been removed from
the area.
• Failure to comply could result in death
or serious injury.
0000002en
TNV IDI Service Manual
5-7
PERIODIC MAINTENANCE
Introduction
A WARNING
BURN HAZARD!
• Keep your hands and other body parts
away from hot engine surfaces such
as the muffler, exhaust pipe,
turbocharger (if equipped) and engine
block during operation and shortly
after you shut the engine down. These
surfaces are extremely hot while the
engine is operating and could
seriously burn you.
• Failure to comply could result in death
or serious injury.
0000015en
A WARNING
A WARNING
EXPOSURE HAZARD!
• Wear personal protective equipment
such as gloves, work shoes, eye and
hearing protection as required by the
task at hand.
• NEVER wear jewelry, unbuttoned
cuffs, ties or loose-fitting clothing
when you are working near
moving / rotating parts such as the
cooling fan, flywheel or PTO shaft.
• ALWAYS tie back long hair when you
are working near moving / rotating
parts such as a cooling fan, flywheel,
or PTO shaft.
ALCOHOL AND DRUG HAZARD!
• NEVER operate the engine while you
are under the influence of alcohol or
drugs.
• NEVER operate the engine when you
are feeling ill.
• Failure to comply could result in death
or serious injury.
0000004en
• NEVER operate the engine while
wearing a headset to listen to music or
radio because it will be difficult to hear
the alert signals.
• Failure to comply could result in death
or serious injury.
0000005en
5-8 TNV IDI Service Manual
Introduction
PERIODIC MAINTENANCE
A WARNING
BURN HAZARD!
• Batteries contain sulfuric acid. NEVER
allow battery fluid to come in contact
with clothing, skin or eyes. Severe
burns could result. ALWAYS wear
safety goggles and protective clothing
when servicing the battery. If battery
fluid contacts the eyes and / or skin,
immediately flush the affected area
with a large amount of clean water and
obtain prompt medical treatment.
• Failure to comply could result in death
or serious injury.
0000007en
A WARNING
A WARNING
SHOCK HAZARD!
• Turn off the battery switch (if
equipped) or disconnect the negative
battery cable before servicing the
electrical system.
• Check the electrical harnesses for
cracks, abrasions, and damaged or
corroded connectors. ALWAYS keep
the connectors and terminals clean.
• Failure to comply could result in death
or serious injury.
0000009en
A WARNING
HIGH-PRESSURE HAZARD!
• Avoid skin contact with the
high-pressure diesel fuel spray caused
by a fuel system leak such as a broken
fuel injection line. High-pressure fuel
can penetrate your skin and result in
serious injury. If you are exposed to
high-pressure fuel spray, obtain
prompt medical treatment.
• NEVER check for a fuel leak with your
hands. ALWAYS use a piece of wood
or cardboard. Have your authorized
Yanmar industrial engine dealer or
distributor repair the damage.
• Failure to comply could result in death
or serious injury.
0000008en
ENTANGLEMENT HAZARD!
• Stop the engine before you begin to
service it.
• NEVER leave the key in the key switch
when you are servicing the engine.
Someone may accidentally start the
engine and not realize you are
servicing it. This could result in a
serious injury.
• If you must service the engine while it
is operating, remove all jewelry, tie
back long hair, and keep your hands,
other body parts and clothing away
from moving / rotating parts.
• Failure to comply could result in death
or serious injury.
0000010en
TNV IDI Service Manual
5-9
PERIODIC MAINTENANCE
Introduction
A WARNING
BURN HAZARD!
• If you must drain the engine oil while it
is still hot, stay clear of the hot engine
oil to avoid being burned.
• ALWAYS wear eye protection.
• Failure to comply could result in death
or serious injury.
0000011en
A CAUTION
FLYING OBJECT HAZARD!
• ALWAYS wear eye protection when
servicing the engine and when using
compressed air or high-pressure
water. Dust, flying debris, compressed
air, pressurized water or steam may
injure your eyes.
• Failure to comply may result in minor
or moderate injury.
0000003en
A CAUTION
COOLANT HAZARD!
• Wear eye protection and rubber gloves
when you handle long life or extended
life engine coolant. If contact with the
eyes or skin should occur, flush eyes
and wash immediately with clean
water.
• Failure to comply may result in minor
or moderate injury.
0000005en
CAUTION
• Only use the engine oil specified.
Other engine oils may affect warranty
coverage, cause internal engine
components to seize and / or shorten
engine life.
• Prevent dirt and debris from
contaminating the engine oil. Carefully
clean the oil cap / dipstick and the
surrounding area before you remove
the cap.
• NEVER mix different types of engine
oil. This may adversely affect the
lubricating properties of the engine oil.
• NEVER overfill. Overfilling may result
in white exhaust smoke, engine
overspeed or internal damage.
0000005en
5-10 TNV IDI Service Manual
Introduction
PERIODIC MAINTENANCE
CAUTION
• Only use diesel fuels recommended by
Yanmar for the best engine
performance, to prevent engine
damage and to comply with EPA / ARB
warranty requirements.
• Only use clean diesel fuel.
• NEVER remove the primary strainer (if
equipped) from the fuel tank filler port.
If removed, dirt and debris could get
into the fuel system causing it to clog.
0000004en
CAUTION
• Only use the engine oil specified.
Other engine oils may affect warranty
coverage, cause internal engine
components to seize and / or shorten
engine life.
• Prevent dirt and debris from
contaminating the engine oil. Carefully
clean the oil cap / dipstick and the
surrounding area before you remove
the cap.
• NEVER mix different types of engine
oil. This may adversely affect the
lubricating properties of the engine oil.
• NEVER overfill. Overfilling may result
in white exhaust smoke, engine
overspeed or internal damage.
0000005en
CAUTION
• Only use the engine coolant specified.
Other engine coolants may affect
warranty coverage, cause an internal
buildup of rust and scale and / or
shorten engine life.
• Prevent dirt and debris from
contaminating the engine coolant.
Carefully clean the radiator cap and
the surrounding area before you
remove the cap.
• NEVER mix different types of engine
coolants. This may adversely affect the
properties of the engine coolant.
0000006en
CAUTION
• NEVER attempt to modify the engine’s
design or safety features such as
defeating the engine speed limit
control or the diesel fuel injection
quantity control.
• Modifications may impair the engine’s
safety and performance
characteristics and shorten the
engine’s life. Any alterations to this
engine may void its warranty. Be sure
to use Yanmar genuine replacement
parts.
0000079en
TNV IDI Service Manual
5-11
PERIODIC MAINTENANCE
Introduction
CAUTION
Observe the following environmental
operating conditions to maintain engine
performance and avoid premature
engine wear:
• Avoid operating in extremely dusty
conditions.
• Avoid operating in the presence of
chemical gases or fumes.
• Avoid operating in a corrosive
atmosphere such as salt water spray.
• NEVER install the engine in a
floodplain unless proper precautions
are taken to avoid being subject to a
flood.
• NEVER expose the engine to the rain.
0000003en
CAUTION
Observe the following environmental
operating conditions to maintain engine
performance and avoid premature
engine wear:
• The standard range of ambient
temperatures for the normal operation
of Yanmar engines is from +5°F (-15°C)
to +113°F (+45°C).
• If the ambient temperature exceeds
+113°F (+45°C) the engine may
overheat and cause the engine oil to
break down.
• If the ambient temperature is below
+5°F (-15°C) the engine will be hard to
start and the engine oil may not flow
easily.
CAUTION
NEVER hold the key in the START
position for longer than 15 seconds or
the starter motor will overheat.
0000007en
CAUTION
For maximum engine life, Yanmar
recommends that when shutting the
engine down, you allow the engine to
idle, without load, for five minutes. This
will allow the engine components that
operate at high temperatures, such as
the turbocharger (if equipped) and
exhaust system, to cool slightly before
the engine itself is shut down.
0000008en
CAUTION
NEVER use an engine starting aid such
as ether. Engine damage will result.
0000009en
CAUTION
Make sure the engine is installed on a
level surface. If a continuously running
engine is installed at an angle greater
than (IDI = 25°, DI = 30°) in any direction
or if an engine runs for short periods of
time (less than three minutes) at an
angle greater than (IDI = 30°, DI = 35°) in
any direction, engine oil may enter the
combustion chamber causing excessive
engine speed and white exhaust smoke.
This may cause serious engine damage.
0000010enTNV
• Contact your authorized Yanmar
industrial engine dealer or distributor
if the engine will be operated outside
of this standard temperature range.
0000065en
5-12 TNV IDI Service Manual
Introduction
PERIODIC MAINTENANCE
CAUTION
New Engine Break-in:
• On the initial engine start-up, allow the
engine to idle for approximately 15
minutes while you check for proper
engine oil pressure, diesel fuel leaks,
engine oil leaks, coolant leaks, and for
proper operation of the indicators
and / or gauges.
• During the first hour of operation, vary
the engine speed and the load on the
engine. Short periods of maximum
engine speed and load are desirable.
Avoid prolonged operation at
minimum or maximum engine speeds
and loads for the next four to five
hours.
• During the break-in period, carefully
observe the engine oil pressure and
engine temperature.
• During the break-in period, check the
engine oil and coolant levels
frequently.
0000011en
CAUTION
NEVER engage the starter motor while
the engine is running. This may damage
the starter motor pinion and / or ring
gear.
0000012en
CAUTION
• ALWAYS be environmentally
responsible.
• Follow the guidelines of the EPA or
other governmental agencies for the
proper disposal of hazardous
materials such as engine oil, diesel
fuel and engine coolant. Consult the
local authorities or reclamation facility.
• NEVER dispose of hazardous
materials irresponsibly by dumping
them into a sewer, on the ground, or
into ground water or waterways.
• Failure to follow these procedures may
seriously harm the environment.
0000013en
CAUTION
Protect the air cleaner, turbocharger (if
equipped) and electric components
from damage when you use steam or
high-pressure water to clean the engine.
0000014en
CAUTION
• NEVER overfill the engine with engine
oil.
TNV IDI Service Manual
• ALWAYS keep the oil level between the
upper and lower lines on the oil
cap / dipstick.
0000015en
5-13
PERIODIC MAINTENANCE
Introduction
CAUTION
NEVER use high-pressure water or
compressed air at greater than 28 psi
(193 kPa; 19 686 mmAq) or a wire brush
to clean the radiator fins. Radiator fins
damage easily.
0000016en
CAUTION
NEVER attempt to adjust the low or high
idle speed limit screw. This may impair
the safety and performance of the
machine and shorten its life. If the idle
speed limit screws require adjustment,
see your authorized Yanmar industrial
engine dealer or distributor.
0000017en
CAUTION
Establish a periodic maintenance plan
according to the engine application and
make sure you perform the required
periodic maintenance at intervals
indicated. Failure to follow these
guidelines will impair the engine’s safety
and performance characteristics,
shorten the engine’s life and may affect
the warranty coverage on your engine.
See Yanmar Warranties section.
Consult your authorized Yanmar dealer
or distributor for assistance when
checking items marked with a
z.
0000024enTNVIDISM
CAUTION
If the fuel filter / water separator is
positioned higher than the fuel level in
the fuel tank, water may not drip out
when the fuel filter / water separator
drain cock is opened. If this happens,
turn the air vent screw on the top of the
fuel filter / water separator 2-3 turns
counterclockwise.
Be sure to tighten the air vent screw
after the water has drained out.
0000025en
CAUTION
• When the engine is operated in dusty
conditions, clean the air cleaner
element more frequently.
• NEVER operate the engine with the air
cleaner element(s) removed. This may
allow foreign material to enter the
engine and damage it.
0000026en
CAUTION
The maximum air intake restriction, in
terms of differential pressure
measurement, must not exceed 0.90 psi
(6.23 kPa; 635 mmAq). Clean or replace
the air cleaner element if the air intake
restriction exceeds the above
mentioned value.
0000046en
5-14 TNV IDI Service Manual
Precautions
PERIODIC MAINTENANCE
CAUTION
The tightening torque in the Standard
Torque Cha rt in General Service
Information should be applied only to
the bolts with a “7” head. (JIS strength
classification: 7T)
• Apply 60% torque to bolts
that are not listed.
• Apply 80% torque when
tightened to aluminum alloy.
0000023enTNVIDISM
CAUTION
It is important to perform daily checks.
Periodic maintenance prevents
unexpected downtime, reduces the
number of accidents due to poor
machine performance and helps extend
the life of the engine.
0000060en
PRECAUTIONS
The Importance of Periodic
Maintenance
Engine deterioration and wear occurs in proportion
to length of time the engine has been in service and
the conditions the engine is subject to during
operation. Periodic maintenance prevents
unexpected downtime, reduces the number of
accidents due to poor machine performance and
helps extend the life of the engine.
Performing Periodic Maintenance
A WARNING
EXHAUST HAZARD!
• NEVER operate the engine in an
enclosed area such as a garage,
tunnel, underground room, manhole or
ship’s hold without proper ventilation.
• NEVER block windows, vents, or other
means of ventilation if the engine is
operating in an enclosed area. All
internal combustion engines create
carbon monoxide gas during
operation. Accumulation of this gas
within an enclosure could cause
illness or even death.
• Make sure that all connections are
tightened to specifications after repair
is made to the exhaust system.
• Failure to comply could result in death
or serious injury.
0000003en
TNV IDI Service Manual
5-15
PERIODIC MAINTENANCE
Periodic Maintenance Schedule
Perform periodic maintenance procedures in an
open, level area free from traffic. If possible,
perform the procedures indoors to prevent
environmental conditions, such as rain, wind, or
snow, from damaging the machine.
Yanmar Replacement Parts
Yanmar recommends that you use genuine Yanmar
parts when replacement parts are needed.
Genuine replacement parts help ensure long
engine life.
Required EPA / ARB Maintenance USA Only
To maintain optimum engine performance and
compliance with the Environmental Protection
Agency (EPA) Regulations Non-road Engines and
the California Air Resources Board (ARB,
California), it is essential that you follow the
Periodic Maintenance Schedule on page 5-16 and
Periodic Maintenance Procedures on page 5-18.
EPA / ARB Installation Requirements
- USA Only
The following are the installation requirements for
the EPA / ARB. Unless these requirements are met,
the exhaust gas emissions will not be within the
limits specified by the EPA and ARB.
PERIODIC MAINTENANCE
SCHEDULE
Daily and periodic maintenance is important to
keep the engine in good operating condition. The
following is a summary of maintenance items by
periodic maintenance intervals. Periodic
maintenance intervals vary depending on engine
application, loads, diesel fuel and engine oil used
and are hard to establish definitively. The following
should be treated only as a general guideline.
CAUTION
Establish a periodic maintenance plan
according to the engine application and
make sure you perform the required
periodic maintenance at intervals
indicated. Failure to follow these
guidelines will impair the engine’s safety
and performance characteristics,
shorten the engine’s life and may affect
the warranty coverage on your engine.
See Yanmar Warranties section.
Consult your authorized Yanmar dealer
or distributor for assistance when
checking items marked with a
z.
0000024enTNVIDISM
Maximum Exhaust Gas Restriction shall be:
• 3TNV72: 1.71 psi (11.8 kPa; 1200 mm Aq) or
less
Maximum air intake restriction shall be 0.90 psi
(6.23kPa; 635mm Aq) or less. Clean or replace the
air cleaner element if the air intake restriction
exceeds the above mentioned value.
5-16 TNV IDI Service Manual
Periodic Maintenance Schedule
c:Check :Replace z: Contact your authorized Yanmar industrial engine dealer or distributor
System Check Item Daily
Check and Refill Engine Coolant c
Check and Clean Radiator Fins c
Check and Adjust Cooling Fan V-
Cooling
System
Cylinder
Head
Electrical
Equipment
Engine Oil
Engine
Speed
Control
Emission
Control
Warranty
Fuel
Hoses
Intake and
Exhaust
Complete
Engine
Belt
Drain, Flush and Refill Cooling
System with New Coolant
Adjust Intake / Exhaust Valve
Clearance
Lap Intake / Exhaust Valve Seats z
Check Indicators c
Check Battery c
Check Engine Oil Level c
Drain and Fill Engine Oil
Replace Engine Oil Filter
Check and Adjust Governor Lever
and Engine Speed Control
Inspect, Clean and Test Fuel
Injectors (if required)
Inspect Crankcase Breather System z
Check and Refill Fuel Tank Level c
Drain Fuel Tank c
Drain Fuel Filter / Water Separator c
Check Fuel Filter / Water Separator c
Clean Fuel Filter / Water Separator c
Replace Fuel Filter
Replace Fuel System and Cooling
System Hoses
Clean or Replace Air Cleaner
Element
Overall Visual Check Daily c
PERIODIC MAINTENANCE
Periodic Maintenance Interval
Every
50
hours
c1st
time
1st
time
cc
Every
250
hours
c 2nd
and after
2nd
and
after
c
Every
500
hours
yr. which-
Every
1000
hours
or
every 1
ever
comes
first
z
Every
1500
hours
z
Every
2000
hours
z or
every 2
yrs.
Note: These procedures are considered normal maintenance and are performed at the owner’s expense.
TNV IDI Service Manual
5-17
PERIODIC MAINTENANCE
Periodic Maintenance Procedures
PERIODIC MAINTENANCE
PROCEDURES
After Initial 50 Hours of Operation
Perform the following maintenance after the initial
50 hours of operation.
• Replace Engine Oil and Engine Oil Filter
• Check and Adjust Cooling Fan V-Belt
Replace Engine Oil and Engine Oil Filter
A WARNING
BURN HAZARD!
• If you must drain the engine oil while it
is still hot, stay clear of the hot engine
oil to avoid being burned.
CAUTION
• Only use the engine oil specified.
Other engine oils may affect warranty
coverage, cause internal engine
components to seize and / or shorten
engine life.
• Prevent dirt and debris from
contaminating the engine oil. Carefully
clean the oil cap / dipstick and the
surrounding area before you remove
the cap.
• NEVER mix different types of engine
oil. This may adversely affect the
lubricating properties of the engine oil.
• NEVER overfill. Overfilling may result
in white exhaust smoke, engine
overspeed or internal damage.
0000005en
CAUTION
• ALWAYS wear eye protection.
• Failure to comply could result in death
or serious injury.
0000011en
• ALWAYS be environmentally
responsible.
• Follow the guidelines of the EPA or
other governmental agencies for the
proper disposal of hazardous
materials such as engine oil, diesel
fuel and engine coolant. Consult the
local authorities or reclamation facility.
• NEVER dispose of hazardous
materials irresponsibly by dumping
them into a sewer, on the ground, or
into ground water or waterways.
• Failure to follow these procedures may
seriously harm the environment.
0000013en
5-18 TNV IDI Service Manual
Periodic Maintenance Procedures
0000587B
(1)
(1)
0000651B
(4)
(3)
(2)
(1)
PERIODIC MAINTENANCE
The engine oil on a new engine becomes
contaminated from the initial break-in of internal
parts. It is very important that the initial oil and filter
change is performed as scheduled.
Note: The oil drain plug may be in another
location if an optional oil pan is used.
Drain the engine oil as follows:
1. Make sure the engine is level.
2. Start the engine and bring it up to operating
temperature.
3. Stop the engine.
4. Remove the oil filler cap (Figure 5-1, (1)) to
vent the engine crankcase and allow the engine
oil to drain more easily.
5. Position a container under the engine to collect
waste oil.
Remove the engine oil filter as follows:
1. Turn the engine oil filter (Figure 5-2, (2))
counterclockwise (Figure 5-2, (4)) using a filter
wrench.
Figure 5-2
Figure 5-1
6. Remove the oil drain plug (Figure 5-2, (1)).
Allow oil to drain.
7. After all oil has been drained from the engine,
reinstall the oil drain plug (Figure 5-2, (1)) and
tighten to 39.8 - 47.0 ft·lb (53.9 - 63.7 N·m, 5.5 -
6.5 kgf·m).
8. Dispose of used oil properly.
2. Clean the engine oil filter mounting face.
3. Lightly coat the gasket on the new oil filter with
clean engine oil. Install the new engine oil filter
manually by turning it clockwise
(Figure 5-2, (3)) until it contacts the mounting
surface. Tighten to 14 - 17 ft·lb (19.6 - 23.5 N·m,
2.0 - 2.4 kgf·m or one additional turn using the
filter wrench.
Applicable Engine Oil Filter Part No.
3TNV72 119305-35150
4. Add new engine oil to the engine as specified in
Adding Engine Oil on page 4-14.
Check and Adjust Cooling Fan V-Belt
The V-belt will slip if it does not have the proper
tension. This will prevent the alternator from
generating sufficient power. Also, the engine will
overheat due to the engine coolant pump pulley
slipping.
TNV IDI Service Manual
5-19
PERIODIC MAINTENANCE
(4)
(5)
(1)
0000587C
(4)
(2)
(3)
(3)
(1)
(2)
0000653B
Check and adjust the V-belt tension (deflection) as
follows:
1. Press the V-belt down with your thumb with a
force of approximately 22 ft·lb (98 N·m,
10 kgf·m) to check the deflection.
There are three positions to check for V-belt
tension (Figure 5-4, (A), (B) and (C)). You can
check the tension at whichever position is the
most accessible. The proper deflection of a used
V-belt at each position is:
Periodic Maintenance Procedures
B
A
C
0000652B
Figure 5-4
Used V-Belt Tension
ABC
3/8 - 1/2 in.
(10 - 14 mm)
1/4 - 3/8 in.
(7 - 10 mm)
5/16 - 1/2 in.
(9 - 13 mm)
2. If necessary, adjust the V-belt tension. Loosen
the adjusting bolt (Figure 5-5, (1)) and move
the alternator (Figure 5-5, (2)) with a pry bar
(Figure 5-5, (3)) to tighten the V-belt to the
desired tension. Then tighten the adjusting bolt.
Figure 5-3
Figure 5-5
5-20 TNV IDI Service Manual
Periodic Maintenance Procedures
3. Tighten the V-belt to the proper tension. There
must be clearance (Figure 5-6, (1)) between
the V-belt and the bottom of the pulley groove. If
there is no clearance (Figure 5-6, (2)) between
the V-belt and the bottom of the pulley groove,
replace the V-belt.
PERIODIC MAINTENANCE
Every 50 Hours of Operation
After you complete the initial 50 hour maintenance
procedures, perform the following procedures every
50 hours thereafter.
• Drain Fuel Filter / Water Separator
• Check Battery
(2)
(1)
0000584
Figure 5-6
4. Check the V-belt for cracks, oil or wear. If any of
these conditions exist, replace the V-belt.
• “New V-belt” refers to a V-belt which has been
used less than 5 minutes on a running engine.
• “Used V-belt” refers to a V-belt which has been
used on a running engine for 5 minutes or
more.
5. Inspect the condition of the used V-belt. There
must be clearance (Figure 5-6, (1)) between
the V-belt and the bottom of the pulley groove. If
there is no clearance (Figure 5-6, (2)) between
the V-belt and the bottom of the pulley groove,
replace the V-belt.
6. Install the new V-belt. Refer to the table for
proper tension.
New V-Belt Tension
ABC
5/16 - 7/16 in.
(8 - 12 mm)
3/16 - 5/16 in.
(5 - 8 mm)
1/4 - 7/16 in.
(7 - 11 mm)
Drain Fuel Filter / Water Separator
A DANGER
FIRE AND EXPLOSION HAZARD!
• Diesel fuel is flammable and explosive
under certain conditions.
• When you remove any fuel system
component to perform maintenance
(such as changing the fuel filter) place
an approved container under the
opening to catch the fuel.
• NEVER use a shop rag to catch the
fuel. Vapors from the rag are
flammable and explosive.
• Wipe up any spills immediately.
• Wear eye protection. The fuel system
is under pressure and fuel could spray
out when you remove any fuel system
component.
• Failure to comply will result in death or
serious injury.
0000009en
7. After adjusting, run the engine for 5 minutes or
more. Check the tension again using the
specifications for a used V-belt.
Used V-Belt Tension
ABC
3/8 - 1/2 in.
(10 - 14 mm)
1/4 - 3/8 in.
(7 - 10 mm)
TNV IDI Service Manual
5/16 - 1/2 in.
(9 - 13 mm)
5-21
PERIODIC MAINTENANCE
c
o
(8)
(6)
(7)
0000590A
(5)
(1)
(3)
(9)
(2)
(4)
(10)
(11)
CAUTION
If the fuel filter / water separator is
positioned higher than the fuel level in
the fuel tank, water may not drip out
when the fuel filter / water separator
drain cock is opened. If this happens,
turn the air vent screw on the top of the
fuel filter / water separator 2-3 turns
counterclockwise.
Be sure to tighten the air vent screw
after the water has drained out.
CAUTION
0000025en
Periodic Maintenance Procedures
The cup of the separator is made from
semi-transparent material. In the cup is a
red-colored float ring. The float ring will rise to the
surface of the water to show how much needs to be
drained. Also, some optional fuel filter / water
separators are equipped with a sensor to detect the
amount of contaminants. This sensor sends a
signal to an indicator to alert the operator.
Drain the fuel filter / water separator as follows:
1. Position an approved container under the fuel
filter / water separator (Figure 5-7, (1)) to
collect the contaminants.
• ALWAYS be environmentally
responsible.
• Follow the guidelines of the EPA or
other governmental agencies for the
proper disposal of hazardous
materials such as engine oil, diesel
fuel and engine coolant. Consult the
local authorities or reclamation facility.
• NEVER dispose of hazardous
materials irresponsibly by dumping
them into a sewer, on the ground, or
into ground water or waterways.
• Failure to follow these procedures may
seriously harm the environment.
0000013en
Drain the fuel filter / water separator whenever
there are contaminants, such as water, collected in
the bottom of the cup. NEVER wait until the
scheduled periodic maintenance if contaminants
are discovered.
Figure 5-7
2. Close (Figure 5-7, (2)) the fuel cock
(Figure 5-7, (3)).
3. Turn the retaining ring (Figure 5-7, (4)) to the
left (Figure 5-7, (9)).
4. Carefully remove the cup (Figure 5-7, (1)).
Remove the retaining spring (Figure 5-7, (6))
and float (Figure 5-7, (7)) from the cup. Pour
the fuel into an approved container and dispose
properly. Hold the bottom of the cup with a shop
towel to prevent the fuel from dripping. Wipe up
any spills immediately.
5. Clean the inside of the cup.
6. Inspect the condition of the mesh filter
(Figure 5-7, (10)). Clean the mesh filter if
necessary.
7. Inspect the condition of the O-ring
(Figure 5-7, (11)). Replace the O-ring if
necessary.
5-22 TNV IDI Service Manual
Periodic Maintenance Procedures
PERIODIC MAINTENANCE
8. Put the float (Figure 5-7, (7)) and retaining
spring (Figure 5-7, (6)) inside the cup.
9. Reinstall the cup to the mounting flange
(Figure 5-7, (8)) and turn the retaining ring
(Figure 5-7, (4)) to the right (Figure 5-7, (5)).
Hand-tighten only.
10. Open the fuel cock (Figure 5-7, (3)).
11. Be sure to prime the fuel system. See Priming
the Fuel System on page 4-12.
12. Check for fuel leaks.
CAUTION
If the fuel filter / water separator is
positioned higher than the fuel level in
the fuel tank, water may not drip out
when the fuel filter / water separator
drain cock is opened. If this happens,
turn the air vent screw on the top of the
fuel filter / water separator 2-3 turns
counterclockwise.
Be sure to tighten the air vent screw
after the water has drained out.
0000025en
Check Battery
A DANGER
EXPLOSION HAZARD!
• NEVER check the remaining battery
charge by shorting out the terminals.
This will result in a spark and may
cause an explosion or fire. Use a
hydrometer to check the remaining
battery charge.
• If the electrolyte is frozen, slowly warm
the battery before you recharge it.
• Failure to comply will result in death or
serious injury.
0000007en
A WARNING
BURN HAZARD!
• Batteries contain sulfuric acid. NEVER
allow battery fluid to come in contact
with clothing, skin or eyes. Severe
burns could result. ALWAYS wear
safety goggles and protective clothing
when servicing the battery. If battery
fluid contacts the eyes and / or skin,
immediately flush the affected area
with a large amount of clean water and
obtain prompt medical treatment.
• Failure to comply could result in death
or serious injury.
0000007en
TNV IDI Service Manual
5-23
PERIODIC MAINTENANCE
CAUTION
• ALWAYS be environmentally
responsible.
• Follow the guidelines of the EPA or
other governmental agencies for the
proper disposal of hazardous
materials such as engine oil, diesel
fuel and engine coolant. Consult the
local authorities or reclamation facility.
• NEVER dispose of hazardous
materials irresponsibly by dumping
them into a sewer, on the ground, or
into ground water or waterways.
Periodic Maintenance Procedures
• If the engine cranking speed is so slow that the
engine does not start, recharge the battery.
• If the engine still will not start after charging,
have your authorized Yanmar industrial engine
dealer or distributor check the battery and the
engine’s starting system.
• If operating the machine where the ambient
temperature could drop to 5°F (-15°C) or less,
remove the battery from the machine at the end
of the day. Store the battery in a warm place
until the next use. This will help start the engine
easily at low ambient temperatures.
• Failure to follow these procedures may
seriously harm the environment.
0000013en
• When the amount of fluid nears the lower limit
(Figure 5-8, (1)), fill with distilled water
(Figure 5-8, (2)) so it is at the upper limit
(Figure 5-8, (3)). If operation continues with
insufficient battery fluid, the battery life is
shortened, and the battery may overheat and
explode. During the summer, check the fluid
level more often than specified.
(3)
(2)
(1)
0000067A
Figure 5-8
5-24 TNV IDI Service Manual
Periodic Maintenance Procedures
0000065A
(1)
(2)
(3)
PERIODIC MAINTENANCE
Every 250 Hours of Operation
Perform the following maintenance every 250 hours
of operation.
• Drain Fuel Tank
• Replace Engine Oil and Engine Oil Filter
• Check and Clean Radiator Fins
• Check and Adjust Cooling Fan V-Belt
• Check and Adjust the Governor Lever and
Engine Speed Control
• Clean Air Cleaner Element
Drain Fuel Tank
A DANGER
FIRE AND EXPLOSION HAZARD!
CAUTION
• ALWAYS be environmentally
responsible.
• Follow the guidelines of the EPA or
other governmental agencies for the
proper disposal of hazardous
materials such as engine oil, diesel
fuel and engine coolant. Consult the
local authorities or reclamation facility.
• NEVER dispose of hazardous
materials irresponsibly by dumping
them into a sewer, on the ground, or
into ground water or waterways.
• Failure to follow these procedures may
seriously harm the environment.
0000013en
• Diesel fuel is flammable and explosive
under certain conditions.
• When you remove any fuel system
component to perform maintenance
(such as changing the fuel filter) place
an approved container under the
opening to catch the fuel.
• NEVER use a shop rag to catch the
fuel. Vapors from the rag are
flammable and explosive.
• Wipe up any spills immediately.
• Wear eye protection. The fuel system
is under pressure and fuel could spray
out when you remove any fuel system
component.
• Failure to comply will result in death or
serious injury.
0000009en
Note that a typical fuel tank is illustrated.
1. Position an approved container under the diesel
fuel tank (Figure 5-9, (1)) to collect the
contaminates.
Figure 5-9
2. Remove the fuel cap (Figure 5-9, (3)).
3. Remove the drain plug (Figure 5-9, (2)) of the
fuel tank to drain the contaminates (water, dirt,
etc.) from the bottom of the tank.
TNV IDI Service Manual
5-25
PERIODIC MAINTENANCE
4. Drain the tank until clean diesel fuel with no
water or dirt flows out. Reinstall and tighten the
drain plug firmly.
5. Reinstall the fuel cap.
6. Check for fuel leaks.
Replace Engine Oil and Engine Oil Filter
CAUTION
• Only use the engine oil specified.
Other engine oils may affect warranty
coverage, cause internal engine
components to seize and / or shorten
engine life.
• Prevent dirt and debris from
contaminating the engine oil. Carefully
clean the oil cap / dipstick and the
surrounding area before you remove
the cap.
• NEVER mix different types of engine
oil. This may adversely affect the
lubricating properties of the engine oil.
Periodic Maintenance Procedures
CAUTION
• ALWAYS be environmentally
responsible.
• Follow the guidelines of the EPA or
other governmental agencies for the
proper disposal of hazardous
materials such as engine oil, diesel
fuel and engine coolant. Consult the
local authorities or reclamation facility.
• NEVER dispose of hazardous
materials irresponsibly by dumping
them into a sewer, on the ground, or
into ground water or waterways.
• Failure to follow these procedures may
seriously harm the environment.
0000013en
• NEVER overfill. Overfilling may result
in white exhaust smoke, engine
overspeed or internal damage.
0000005en
Change the engine oil every 250 hours of operation
after the initial change at 50 hours. Replace the
engine oil filter at the same time. See Replace
Engine Oil and Engine Oil Filter on page 5-18.
5-26 TNV IDI Service Manual
Periodic Maintenance Procedures
Check and Clean Radiator Fins
A CAUTION
PERIODIC MAINTENANCE
FLYING OBJECT HAZARD!
• ALWAYS wear eye protection when
servicing the engine and when using
compressed air or high-pressure
water. Dust, flying debris, compressed
air, pressurized water or steam may
injure your eyes.
• Failure to comply may result in minor
or moderate injury.
0000003en
Dirt and dust adhering to the radiator fins reduce
the cooling performance, causing overheating.
Make it a rule to check the radiator fins daily and
clean as needed.
Note that a typical radiator is shown in Figure 5-10
for illustrative purposes only.
• Blow off dirt and dust from fins and radiator with
2
28 psi (0.19 MPa; 2 kgf/cm
) or less of
compressed air (Figure 5-10, (1)). Be careful
not to damage the fins with the compressed air.
• If there is a large amount of contamination on
the fins, apply detergent, thoroughly clean and
rinse with tap water.
CAUTION
NEVER use high-pressure water or
compressed air at greater than 28 psi
(193 kPa; 19 686 mmAq) or a wire brush
to clean the radiator fins. Radiator fins
damage easily.
0000016en
FULL
LOW
(1)
0000085A
Figure 5-10
Check and Adjust Cooling Fan V-Belt
Check and adjust the cooling fan V-belt every 250
hours of operation after the initial 50 hour V-belt
maintenance. See Check and Adjust Cooling Fan
V-Belt on page 5-19.
Check and Adjust the Governor Lever and
Engine Speed Control
The governor lever and engine speed control
(throttle lever, accelerator pedal etc.), are
connected together by a cable or linkage. If the
cable becomes stretched, or the linkage wears or
loosens, the governor lever may not respond to a
change in the position of the engine speed control.
CAUTION
NEVER attempt to adjust the low or high
idle speed limit screw. This may impair
the safety and performance of the
machine and shorten its life. If the idle
speed limit screws require adjustment,
see your authorized Yanmar industrial
engine dealer or distributor.
0000017en
1. Check that the governor lever (Figure 5-11, (1))
makes firm contact with the high idle stop
(Figure 5-11, (2)) and the low idle speed limit
screw (Figure 5-11, (3)) when the engine
speed control is in the full speed or low idle
speed positions.
TNV IDI Service Manual
5-27
PERIODIC MAINTENANCE
(2)
(3)
(1)
Periodic Maintenance Procedures
2. If the governor lever does not make proper
contact with the high idle stop or the low idle
speed limit screw, adjust the throttle cable or
linkage as necessary.
Note: DO NOT FORCE the throttle cable or
linkage to move. This may damage the
the governor lever, the throttle cable or
linkage and cause irregular operation of
the engine speed control.
IMPORTANT
The engine speed control (throttle lever,
accelerator pedal etc.), should be equipped
with stops to prevent the application of
excessive pressure by the governor lever to
either the high idle stop or low idle speed
limit screw.
Clean Air Cleaner Element
Note that a typical air cleaner is shown in
Figure 5-12 and Figure 5-13 for illustrative
purposes only.
The engine performance is adversely affected
when the air cleaner element is clogged with dust.
Be sure to clean the air filter element periodically.
CAUTION
• When the engine is operated in dusty
conditions, clean the air cleaner
element more frequently.
• NEVER operate the engine with the air
cleaner element(s) removed. This may
allow foreign material to enter the
engine and damage it.
0000026en
1. Unlatch and remove the air cleaner cover
(Figure 5-12, (1)).
2. Remove the element (Figure 5-12, (2)) (outer
element if equipped with two elements).
Figure 5-11
(3)
(6)
(4)
Figure 5-12
(2)
(5)
(1)
0000070A
5-28 TNV IDI Service Manual
Periodic Maintenance Procedures
(1)
0000071A
Figure 5-13
A CAUTION
PERIODIC MAINTENANCE
The inner element should not be removed when
cleaning or replacing the outer element. The
inner element is used to prevent dust from
entering the engine while servicing the outer
element.
4. Replace the element with a new one if the
element is damaged, excessively dirty or oily.
5. Clean inside of the air cleaner cover.
6. Install the element into the air cleaner case
(Figure 5-12, (4)).
7. Install the air cleaner cover making sure you
match the arrow (Figure 5-12, (5)) on the cover
with the arrow on the case (Figure 5-12, (6)).
8. Latch the air cleaner cover to the case.
FLYING OBJECT HAZARD!
• ALWAYS wear eye protection when
servicing the engine and when using
compressed air or high-pressure
water. Dust, flying debris, compressed
air, pressurized water or steam may
injure your eyes.
• Failure to comply may result in minor
or moderate injury.
0000003en
3. Blow air (Figure 5-12, (3)) through the element
from the inside out using 42 - 71 psi
(0.29 - 0.49 MPa; 3.0 - 5.0 kgf/cm2)
compressed air to remove the particulates. Use
the lowest possible air pressure to remove the
dust without damaging the element.
If the air cleaner is equipped with a double
element, only remove and replace the inner
element (Figure 5-13, (1)) if the engine lacks
power or the dust indicator actuates (if
equipped).
TNV IDI Service Manual
5-29
PERIODIC MAINTENANCE
Periodic Maintenance Procedures
Every 500 Hours of Operation
Perform the following maintenance every 500 hours
of operation.
• Replace Air Cleaner Element
• Replace Fuel Filter
• Clean Fuel Filter / Water Separator
Replace Air Cleaner Element
CAUTION
The maximum air intake restriction, in
terms of differential pressure
measurement, must not exceed 0.90 psi
(6.23 kPa; 635 mmAq). Clean or replace
the air cleaner element if the air intake
restriction exceeds the above
mentioned value.
0000046en
Replace the air cleaner element (Figure 5-12, (2))
every 500 hours even if it is not damaged or dirty.
When replacing the element, clean the inside of the
air cleaner case (Figure 5-12, (4)).
If the air cleaner is equipped with a double element,
only remove and replace the inner element
(Figure 5-13, (1)) if the engine lacks power or the
dust indicator actuates (if equipped). This is in
addition to replacing the outer element.
Replace Fuel Filter
A DANGER
FIRE AND EXPLOSION HAZARD!
• Diesel fuel is flammable and explosive
under certain conditions.
• When you remove any fuel system
component to perform maintenance
(such as changing the fuel filter) place
an approved container under the
opening to catch the fuel.
• NEVER use a shop rag to catch the
fuel. Vapors from the rag are
flammable and explosive.
• Wipe up any spills immediately.
• Wear eye protection. The fuel system
is under pressure and fuel could spray
out when you remove any fuel system
component.
• Failure to comply will result in death or
serious injury.
0000009en
CAUTION
For maximum engine life, Yanmar
recommends that when shutting the
engine down, you allow the engine to
idle, without load, for five minutes. This
will allow the engine components that
operate at high temperatures, such as
the turbocharger (if equipped) and
exhaust system, to cool slightly before
the engine itself is shut down.
0000008en
5-30 TNV IDI Service Manual
Periodic Maintenance Procedures
CAUTION
PERIODIC MAINTENANCE
• ALWAYS be environmentally
responsible.
• Follow the guidelines of the EPA or
other governmental agencies for the
proper disposal of hazardous
materials such as engine oil, diesel
fuel and engine coolant. Consult the
local authorities or reclamation facility.
• NEVER dispose of hazardous
materials irresponsibly by dumping
them into a sewer, on the ground, or
into ground water or waterways.
• Failure to follow these procedures may
seriously harm the environment.
0000013en
Replace the fuel filter at specified intervals to
prevent contaminants from adversely affecting the
diesel fuel flow.
1. Stop the engine and allow it to cool.
2. Close the fuel cock of the fuel filter / water
separator.
3. Turn the retaining ring (Figure 5-14, (1)) to the
left (Figure 5-14, (2)).
(6)
(5)
(1)
(2)
(4)
(3)
0000589A
Figure 5-14
4. Carefully remove the cup (Figure 5-14, (3)) and
pour the fuel into an approved container and
dispose of waste properly. Hold the bottom of
the cup with a shop towel to prevent the fuel
from dripping. Wipe up any spills immediately.
5. Remove the element (Figure 5-14, (4)) by
pulling it down.
6. Replace the element with a new one.
Applicable Fuel Filter Part No.
3TNV72 119810-55650
7. Wash the inside of the cup with clean fuel.
8. Check the condition of the cup O-ring
(Figure 5-14, (6)). Replace if necessary.
9. Reinstall the cup to the mounting flange and
turn the retaining ring (Figure 5-14, (1)) to the
right (Figure 5-14, (2)). Hand-tighten only.
10. Open the fuel cock of the fuel filter / water
separator.
11. Prime the fuel system. See Priming the Fuel
System on page 4-12.
12. Check for fuel leaks.
TNV IDI Service Manual
5-31
PERIODIC MAINTENANCE
Periodic Maintenance Procedures
Clean Fuel Filter / Water Separator
A DANGER
FIRE AND EXPLOSION HAZARD!
• Diesel fuel is flammable and explosive
under certain conditions.
• NEVER use diesel fuel as a cleaning
agent.
• Failure to comply will result in death or
serious injury.
A DANGER
FIRE AND EXPLOSION HAZARD!
• Diesel fuel is flammable and explosive
under certain conditions.
• When you remove any fuel system
component to perform maintenance
(such as changing the fuel filter) place
an approved container under the
opening to catch the fuel.
• NEVER use a shop rag to catch the
fuel. Vapors from the rag are
flammable and explosive.
0000012en
CAUTION
• ALWAYS be environmentally
responsible.
• Follow the guidelines of the EPA or
other governmental agencies for the
proper disposal of hazardous
materials such as engine oil, diesel
fuel and engine coolant. Consult the
local authorities or reclamation facility.
• NEVER dispose of hazardous
materials irresponsibly by dumping
them into a sewer, on the ground, or
into ground water or waterways.
• Failure to follow these procedures may
seriously harm the environment.
0000013en
Periodically clean the fuel filter / water separator
element and inside the cup.
1. Position an approved container under the cup
(Figure 5-15, (1)) of the fuel filter / water
separator to collect the contaminants.
(2)
(9)
c
o
• Wipe up any spills immediately.
• Wear eye protection. The fuel system
is under pressure and fuel could spray
out when you remove any fuel system
(10)
(3)
(5)
(4)
(1)
(7)
component.
• Failure to comply will result in death or
serious injury.
0000009en
2. Close (Figure 5-15, (2)) the fuel cock
Figure 5-15
(Figure 5-15, (3)).
5-32 TNV IDI Service Manual
(6)
(8)
0000590B
Periodic Maintenance Procedures
3. Turn the retaining ring (Figure 5-15, (4)) to the
left (Figure 5-15, (10)).
PERIODIC MAINTENANCE
Every 1000 Hours of Operation
4. Carefully remove the cup (Figure 5-15, (1)) and
pour the fuel into an approved container and
dispose of properly. Hold the bottom of the cup
with a shop towel to prevent the fuel from
dripping. Wipe up any spills immediately.
5. Keep the retaining spring (Figure 5-15, (6)) and
float (Figure 5-15, (7)) handy for reassembly.
6. Remove the element (Figure 5-15, (8)) by
pulling it down.
7. Replace the element with a new one.
Applicable Mesh Filter Part No.
3TNV72 171081-55910
8. Wash the inside of the cup with clean diesel
fuel.
9. Check the condition of the cup O-ring. Replace
if necessary.
10. Put the float (Figure 5-15, (7)) and retaining
spring (Figure 5-15, (6)) inside the cup.
11. Reinstall the cup to the mounting flange
(Figure 5-15, (9)) and turn the retaining ring
(Figure 5-15, (4)) to the right (Figure 5-15, (5)).
Hand-tighten only.
12. Open the fuel cock (Figure 5-15, (3)).
13. Prime the fuel system. See Priming the Fuel
System on page 4-12.
14. Check for fuel leaks.
Perform the following maintenance every 1000
hours of operation.
• Drain, Flush and Refill Cooling System with
New Coolant
• Adjust Intake / Exhaust Valve Clearance
Drain, Flush and Refill Cooling System with
New Coolant
A DANGER
SCALD HAZARD!
• NEVER remove the radiator cap if the
engine is hot. Steam and hot engine
coolant will spurt out and seriously
burn you. Allow the engine to cool
down before you attempt to remove
the radiator cap.
• Tighten the radiator cap securely after
you check the radiator. Steam can
spurt out during engine operation if
the cap is loose.
• ALWAYS check the level of the engine
coolant by observing the reserve tank.
TNV IDI Service Manual
• Failure to comply will result in death or
serious injury.
0000002en
5-33
PERIODIC MAINTENANCE
Periodic Maintenance Procedures
A WARNING
BURN HAZARD!
• Wait until the engine cools before you
drain the engine coolant. Hot engine
coolant may splash and burn you.
• Failure to comply could result in death
or serious injury.
0000016en
A CAUTION
COOLANT HAZARD!
• Wear eye protection and rubber gloves
when you handle long life or extended
life engine coolant. If contact with the
eyes or skin should occur, flush eyes
and wash immediately with clean
water.
• Failure to comply may result in minor
or moderate injury.
0000005en
CAUTION
• ALWAYS be environmentally
responsible.
• Follow the guidelines of the EPA or
other governmental agencies for the
proper disposal of hazardous
materials such as engine oil, diesel
fuel and engine coolant. Consult the
local authorities or reclamation facility.
• NEVER dispose of hazardous
materials irresponsibly by dumping
them into a sewer, on the ground, or
into ground water or waterways.
• Failure to follow these procedures may
seriously harm the environment.
0000013en
Engine coolant contaminated with rust or scale
reduces the cooling effect. Even when extended life
engine coolant is properly mixed, the engine
coolant gets contaminated as its ingredients
deteriorate. Drain, flush and refill the cooling
system with new coolant every 1000 hours or once
a year, whichever comes first.
1. Allow engine and coolant to cool.
2. Remove the radiator cap (Figure 5-16, (1)).
3. Remove the drain plug or open the drain cock
(Figure 5-16, (2)) at the lower position of the
radiator and drain the engine coolant.
5-34 TNV IDI Service Manual
Periodic Maintenance Procedures
(1)
0002923A
OIL
PERIODIC MAINTENANCE
Adjust Intake / Exhaust Valve Clearance
(1)
FULL
LOW
(2)
0000074A
Figure 5-16
4. Drain the coolant from the engine block.
Remove the coolant drain plug
(Figure 5-17, (1)) from the engine block.
Proper adjustment is necessary to maintain the
correct timing for opening and closing the valves.
Improper adjustment will cause the engine to run
noisily, resulting in poor engine performance and
engine damage. See Measuring and Adjusting
Valve Clearance on page 6-34.
Figure 5-17
5. After draining the engine coolant, flush the
radiator and engine block to remove any rust,
scale and contaminants.
6. Reinstall and tighten the drain plug or close the
drain cock at the radiator. Reinstall and tighten
the engine block drain plug.
7. Fill radiator and engine with engine coolant.
See Filling Radiator with Engine Coolant on
page 4-16.
TNV IDI Service Manual
5-35
PERIODIC MAINTENANCE
(3)
(2)
(4)
(5)
(1)
0004055
Periodic Maintenance Procedures
Every 1500 Hours of Operation
Perform the following maintenance every 1500
hours of operation.
• Inspect, Clean and Test Fuel Injectors
• Inspect Crankcase Breather System
Inspect, Clean and Test Fuel Injectors
(if required)
A WARNING
HIGH-PRESSURE HAZARD!
• Avoid skin contact with the
high-pressure diesel fuel spray caused
by a fuel system leak such as a broken
fuel injection line. High-pressure fuel
can penetrate your skin and result in
serious injury. If you are exposed to
high-pressure fuel spray, obtain
prompt medical treatment.
Inspect Crankcase Breather System
Proper operation of the crankcase breather system
is required to maintain the emission requirements
of the engine. The EPA / ARB requires that the
crankcase breather system is inspected every 1500
hours.
There are three different crankcase breather
systems used on the TNV engines. Only the
non-turbo TNV engines crankcase breather system
requires periodic maintenance.
The non-turbo TNV engines use a crankcase
breather system that has a spring-backed
diaphragm (Figure 5-18, (1)) in the valve cover
(Figure 5-18, (2)). When the crankcase pressure
reaches a predetermined value, the diaphragm
opens a passage that allows crankcase fumes to
be routed to the intake manifold.
• NEVER check for a fuel leak with your
hands. ALWAYS use a piece of wood
or cardboard. Have your authorized
Yanmar industrial engine dealer or
distributor repair the damage.
• Failure to comply could result in death
or serious injury.
0000008en
Proper operation of the fuel injectors is required to
obtain the optimum injection pattern for full engine
performance. The EPA / ARB requires that the fuel
injectors are inspected, cleaned and tested (if
required) every 1500 hours. See Testing of Fuel
Injectors on page 7-24.
This procedure is considered normal maintenance
and is performed at the owner’s expense. This
procedure is not covered by the Yanmar Limited
Warranty.
Figure 5-18
To inspect the diaphragm and spring
(Figure 5-18, (3)):
1. Remove the bolts retaining the diaphragm
cover (Figure 5-18, (4)).
5-36 TNV IDI Service Manual
Periodic Maintenance Procedures
2. Remove the diaphragm cover, spring,
diaphragm plate (Figure 5-18, (5)) and
diaphragm.
3. Inspect the diaphragm for tears. Inspect the
spring for distortion. Replace components if
necessary.
4. Reinstall the diaphragm, diaphragm plate,
spring and diaphragm cover. Tighten the
diaphragm bolts to the specified torque. See
Tightening Torques for Standard Bolts and Nuts
on page 4-22.
Failure of the diaphragm and / or spring will cause
the loss of pressure control and allow an excessive
amount of crankcase fumes to be routed to the
intake manifold. This could result in excessive
deposits in the intake system, high engine exhaust
smoke levels, excessive engine oil consumption,
and / or engine run-on due to the burning of the
engine oil.
PERIODIC MAINTENANCE
Every 2000 Hours of Operation
Perform the following maintenance every 2000
hours of operation.
• Check and Replace Fuel Hoses and Engine
Coolant Hoses
• Lap the Intake and Exhaust Valves
Check and Replace Fuel Hoses and Engine
Coolant Hoses
CAUTION
• ALWAYS be environmentally
responsible.
• Follow the guidelines of the EPA or
other governmental agencies for the
proper disposal of hazardous
materials such as engine oil, diesel
fuel and engine coolant. Consult the
local authorities or reclamation facility.
• NEVER dispose of hazardous
materials irresponsibly by dumping
them into a sewer, on the ground, or
into ground water or waterways.
• Failure to follow these procedures may
seriously harm the environment.
0000013en
Regularly check the fuel system and engine coolant
system hoses. If they are cracked or degraded,
replace them. Replace the hoses at least every two
years. See Check and Replace Fuel Hoses and
Engine Coolant Hoses on page 5-37.
Lap the Intake and Exhaust Valves
Adjustment is necessary to maintain proper contact
of the valves and seats. See Inspection of Intake
and Exhaust Valves on page 6-27.
TNV IDI Service Manual
5-37
PERIODIC MAINTENANCE
Periodic Maintenance Procedures
This Page Intentionally Left Blank
5-38 TNV IDI Service Manual
TNV IDI Service Manual
Before You Begin Servicing ............................................................ 6-3
Introduction...................................................................................... 6-5
Cylinder Head Specifications .......................................................... 6-5
Adjustment Specifications ......................................................... 6-5
Cylinder Head............................................................................ 6-5
Intake / Exhaust Valve and Guide ............................................. 6-6
Push Rod................................................................................... 6-6
Valve Spring .............................................................................. 6-6
Rocker Arm and Shaft ............................................................... 6-7
Camshaft and Timing Gear Train Specifications............................. 6-7
Camshaft ................................................................................... 6-7
Idler Gear Shaft and Bushing .................................................... 6-8
Timing Gear Backlash ............................................................... 6-8
Crankshaft and Pistons Specifications ............................................ 6-8
Crankshaft ................................................................................. 6-8
Crankshaft Reconditioning ........................................................ 6-9
Thrust Bearing........................................................................... 6-9
Piston....................................................................................... 6-10
Piston Ring .............................................................................. 6-11
Connecting Rod....................................................................... 6-12
Tappet ..................................................................................... 6-13
Cylinder Block Specifications ........................................................ 6-13
Cylinder Block.......................................................................... 6-13
Special Torque Chart .................................................................... 6-14
Torque for Bolts and Nuts........................................................ 6-14
Section 6
ENGINE
Page
Special Service Tools.................................................................... 6-15
Measuring Instruments.................................................................. 6-17
TNV IDI Service Manual
6-1
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