Yanmar 3TNM72 - Check and Clean Radiator Fins; Check and Adjust the Governor Lever and Engine Speed Control

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Table of Contents5
Introduction7
Safety Contents17
Safety Statements19
Safety Precautions20
General Service Information Contents37
Component Identification39
Location of Labels40
Engine Family42
Function of Major Engine Components43
Function of Cooling System Components45
Diesel Fuel Specifications46
Additional Technical Fuel Requirements46
Bio-Diesel Fuels46
Filling the Fuel Tank47
Priming the Fuel System49
Engine Oil Specifications50
Service Categories50
Definitions50
Engine Oil Viscosity51
Checking Engine Oil51
Adding Engine Oil51
Engine Coolant52
Engine Oil Capacity52
Engine Coolant Specifications53
Alternative Engine Coolant53
Filling Radiator with Engine Coolant53
Engine Coolant Capacity54
Specifications55
Description of Model Number55
Engine Speed Specifications55
Engine General Specifications56
Principal Engine Specifications57
Engine Service Information59
Tightening Torques for Standard Bolts and Nuts60
Abbreviation and Symbols62
Unit Conversions63
Periodic Maintenance Contents65
Precautions79
The Importance of Periodic Maintenance79
Performing Periodic Maintenance79
Periodic Maintenance Schedule80
After Initial 50 Hours of Operation82
Replace Engine Oil and Engine Oil Filter82
Check and Adjust Cooling Fan V-Belt84
Every 50 Hours of Operation86
Drain Fuel Filter/Water Separator86
Check Battery87
Every 250 Hours of Operation89
Drain Fuel Tank89
Check and Clean Radiator Fins91
Check and Adjust the Governor Lever and Engine Speed Control91
Clean Air Cleaner Element92
Every 500 Hours of Operation94
Replace Air Cleaner Element94
Replace Fuel Filter94
Clean Fuel Filter/Water Separator96
Every 1000 Hours of Operation97
Adjust Intake/Exhaust Valve Clearance99
Every 1500 Hours of Operation100
Inspect, Clean and Test Fuel Injectors100
Inspect Crankcase Breather System100
Every 2000 Hours of Operation101
Check and Replace Fuel Hoses and Engine Coolant Hoses101
Lap the Intake and Exhaust Valves101
Engine Contents103
Before You Begin Servicing105
Cylinder Head Specifications107
Adjustment Specifications107
Cylinder Head107
Intake/Exhaust Valve and Guide108
Push Rod108
Valve Spring108
Camshaft and Timing Gear Train Specifications109
Rocker Arm and Shaft109
Crankshaft and Pistons Specifications110
Idler Gear Shaft and Bushing110
Timing Gear Backlash110
Crankshaft Reconditioning111
Thrust Bearing111
Piston112
Piston Ring112
Connecting Rod Small End113
Connecting Rod Big End113
Connecting Rod Distortion113
Tappet113
Cylinder Block Specifications114
Special Torque Chart115
Tightening Torque for Special Bolts115
Special Service Tools116
Measuring Instruments118
Cylinder Head Components120
Disassembly of Cylinder Head121
Removal of Intake Manifold/Valve Cover122
Removal of Glow Plugs122
Removal of Rocker Arm Assembly122
Disassembly of Rocker Arm Assembly123
Removal of Cylinder Head123
Removal of Intake/Exhaust Valves124
Removal of Valve Guides124
Cleaning of Cylinder Head Components125
Inspection of Cylinder Head Components125
Inspection of Push Rods125
Push Rod Bend125
Inspection of Rocker Arm Assembly126
Inspection of Valve Guides126
Rocker Arm Shaft Hole Diameter126
Rocker Arm Shaft Outside Diameter126
Inspection of Intake and Exhaust Valves127
Valve Stem Diameter127
Valve Stem Bend127
Valve Recession127
Inspection of Valve Springs128
Valve Face and Valve Seat128
Fractures128
Corrosion128
Reassembly of Cylinder Head129
Reassembly of Valve Guides129
Squareness129
Free Length129
Reassembly of Intake and Exhaust Valves130
Reassembly of Rocker Arm Assembly132
Reassembly of Intake Manifold/Valve Cover133
Measuring and Adjusting Valve Clearance134
3-Cylinder Engines134
Cylinder Block136
Crankshaft and Camshaft Components136
Disassembly of Cylinder Block Components137
Disassembly of Camshaft and Timing Components138
Removal of Timing Gear Case Cover138
Checking Timing Gear Backlash138
Measuring Idler Gear-To-Crankshaft Gear Backlash139
Measuring Idler Gear-To-Camshaft Gear Backlash139
Removal of Timing Gears139
Removal of Oil Pan140
Removal of Camshaft141
Disassembly of Crankshaft and Piston Components142
Removal of Pistons142
Removal of Crankshaft143
Inspection of Crankshaft and Camshaft Components146
Replacement of Crankshaft Oil Seals146
Crankshaft Bearing Oil Clearance146
Inspection of Cylinder Block146
Inspection of Pistons, Piston Rings and Wrist Pin147
Roundness147
Taper147
Inspection of Connecting Rod149
Inspection of Tappets150
Inspection of Crankshaft150
Reconditioning the Crankshaft151
Inspection of Camshaft151
Honing and Boring152
Inspection of Camshaft Insert Bores152
Inspection of Idler Gear and Shaft152
Reassembly of Crankshaft and Piston Components153
Reassembly of Pistons154
Installation of Crankshaft156
Installation of Pistons158
Reassembly of Camshaft and Timing Components159
Installation of Camshaft159
Installation of Timing Gears160
Installation of Gear Case Cover161
Installation of Oil Pan161
Final Assembly of Engine162
Fuel System Contents163
Fuel Injection Pump167
Stop Solenoid168
Fuel System Specifications169
Test and Adjustment Specifications169
Fuel System Diagram171
Fuel System Components172
Fuel Injection Lines173
Removal of High-Pressure Fuel Injection Lines173
Installation of High-Pressure Fuel Injection Lines174
Removal of Fuel Return Line174
Installation of Fuel Return Line175
Removal of Fuel Injection Pump175
Installation of Fuel Injection Pump178
Checking and Adjusting Fuel Injection Timing180
Removal of Fuel Injectors184
Testing of Fuel Injectors184
Fuel Injector Test Results186
Disassembly and Inspection of Fuel Injectors187
Adjusting Fuel Injector Pressure188
Reassembly of Fuel Injectors189
Installation of the Fuel Injectors189
Cooling System Contents191
Cooling System Diagram195
Engine Coolant Pump Components196
Engine Coolant System Check197
Disassembly of Engine Coolant Pump197
Cleaning and Inspection198
Temperature Switch198
Thermostat198
Radiator Cap199
Reassembly of Engine Coolant Pump199
Lubrication System Contents201
Oil Pump Service Information205
Lubrication System Diagram206
Trochoid Oil Pump207
Components207
Disassembly of Oil Pump207
Check Outer Rotor Outside Clearance208
Outer Rotor to Inner Rotor Tip Clearance208
Check Outer Rotor Side Clearance209
Check Rotor Shaft Clearance209
Reassembly of Oil Pump209
Starter Motor Contents211
Starter Motor Information215
Starter Motor Specifications216
Starter Motor Troubleshooting217
Starter Motor Components218
Starter Motor219
Removal of Starter Motor220
Disassembly of Starter Motor220
Armature222
Commutator Surface Inspection222
Measure Commutator Outside Diameter222
Measure Commutator Insulation Depth223
Armature Coil Continuity Test223
Armature Coil Insulation Test223
Measure Armature and Commutator Run-Out224
Field Coil Continuity Test224
Fiel Coil Insulation Test224
Measure Brush Length224
Solenoid Switch225
Brush Holder Insulation Test225
Brush Spring Test225
Shunt Coil Continuity Test225
Coil Resistance Test226
Contact Continuity Test226
Pinion Clutch Assembly Inspection226
Reassembly of Starter Motor227
Check Pinion Projection Length229
No-Load Test229
Installation of Starter Motor230
Alternator Contents231
Standard and Optional Dynamo Information236
Standard and Optional Alternator Information236
Alternator Specifications236
Dynamo Specifications237
Alternator Troubleshooting238
Alternator Components239
Alternator Wiring Diagram240
Alternator Standard Output241
Removal of Alternator242
Disassembly of Alternator242
Reassembly of Alternator244
Installation of Alternator246
Dynamo Component Location247
Dynamo Wiring Diagram248
Operation of Dynamo248
Dynamo Standard Output249
Testing of Dynamo250
Testing Stator Coil Continuity250
Testing Stator Coil Short-To-Ground250
Testing Dynamo Regulated Output250
Disassembly of Dynamo251
Reassembly of Dynamo251
Installation of Dynamo252
Electric Wiring Contents253
Electric Wiring Precautions255
Electric Wire Resistance256
Battery Cable Resistance257
Electrical Wire Sizes - Voltage Drop258
Conversion of AWG to European Standards259
Troubleshooting Contents261
Troubleshooting by Measuring Compression Pressure264
Quick Reference Table for Troubleshooting265
Standard Compression Pressure265
Measured Value and Troubleshooting265
Troubleshooting Charts267

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Yanmar 3TNM72 - Check and Clean Radiator Fins; Check and Adjust the Governor Lever and Engine Speed Control

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