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Yanmar 3TNV76 Service Manual

Yanmar 3TNV76
264 pages
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0BTNV-G00202
PRINTED IN JAPAN
2TNV70
3TNV70
3TNV76
INDUSTRIAL ENGINES
SERVICE MANUAL
INDUSTRIAL ENGINES 2TNV70 3TNV70 3TNV76
SERVICE MANUAL

Table of Contents

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Yanmar 3TNV76 Specifications

General IconGeneral
Engine Model3TNV76
AspirationNatural
Cooling SystemWater-cooled
Compression Ratio23.5:1
Lubrication SystemForced lubrication by trochoid pump
Bore x Stroke76.0 mm x 82.0 mm
Combustion SystemIndirect injection
Starting SystemElectric starter
Engine TypeVertical, water-cooled 4-cycle diesel
Displacement1.115 liters

Summary

Introduction

Yanmar Warranties

Yanmar Limited Warranty

Details coverage, duration, owner responsibilities, and limitations of the Yanmar limited warranty.

Emission System Warranty

Outlines the limited emission control system warranty for USA, including coverage and obligations.

Safety

SAFETY STATEMENTS

Explains safety alert symbols (DANGER, WARNING, CAUTION, NOTICE) and their meanings for safe operation.

Safety Precautions

Lists detailed safety precautions for various hazards like scald, explosion, crush, sever, fume, burn, etc.

General Service Information

Component Identification

Identifies and locates major engine components with a diagram and numbered list for easy reference.

Location of Labels

Shows the location of regulatory and safety labels on Yanmar TNV series engines.

EPA / ARB Emission Control Regulations - USA Only

Explains compliance of Yanmar TNV engines with US EPA and California ARB emission standards.

The 97/68/EC Directive Certified Engines

Details engines certified by the 97/68/EC Directive and how to identify them via the emission control label.

Engine Family

Explains the designation of the Engine Family field found on EPA/ARB and 97/68/EC labels.

Function of Major Engine Components

Describes the function of key engine components like Air Cleaner, Dynamo, Fuel Filter, etc.

Function of Cooling System Components

Explains the function of various components within the engine's liquid-cooling system.

Diesel Fuel

Details diesel fuel specifications, handling, and additives, including standards and requirements.

Engine Oil

Provides specifications, viscosity guidelines, and procedures for checking and adding engine oil.

Engine Coolant

Covers engine coolant specifications, hazards, and procedures for filling the radiator and reserve tank.

Specifications

Contains technical data including model number description, engine speed, and general engine specifications.

Principal Engine Specifications

Provides detailed specifications for the 2TNV70, 3TNV70, and 3TNV76 engines.

Periodic Maintenance

Precautions

Advises on the importance of periodic maintenance and lists safety precautions and requirements.

Periodic Maintenance Schedule

Summarizes maintenance items and intervals, serving as a general guideline for engine care.

Periodic Maintenance Procedures

Details specific maintenance tasks to be performed at different operating hour intervals.

ENGINE

Before You Begin Servicing

Advises reading safety information and reviewing the Safety section before performing engine service.

Cylinder Head Specifications

Lists specifications for cylinder head components, including valves, guides, springs, and related clearances.

Camshaft and Timing Gear Train Specifications

Details specifications for the camshaft and timing gears, including clearances and backlash.

Crankshaft and Pistons Specifications

Provides specifications for crankshaft, connecting rods, pistons, and piston rings.

Cylinder Block Specifications

Lists specifications for the cylinder block, including inside diameter, bore, roundness, and taper.

Special Torque Chart

Provides specific tightening torques for critical engine bolts and nuts, differentiating by application.

Special Service Tools

Lists special tools required for engine servicing, including their applicable models and sizes.

Measuring Instruments

Lists common measuring instruments used for engine service and their applications.

Fuel System

Before You Begin Servicing

Advises reading safety information and reviewing the Safety section before performing fuel system service.

Introduction

Introduces the fuel system, describing the fuel injection pump and its components.

Fuel System Specifications

Lists specifications for the fuel system, including torque values and test/adjustment parameters.

Special Service Tools

Lists special service tools and measuring instruments needed for fuel system maintenance.

Fuel System Components

Identifies and illustrates the various components of the fuel system with a diagram.

Fuel Injection Lines

Covers the removal and installation procedures for high-pressure fuel injection and fuel return lines.

Fuel Injection Pump

Details the removal and installation procedures for the fuel injection pump, including timing checks.

Fuel Injectors

Covers the removal, testing, and adjustment procedures for fuel injectors.

Cooling System

Before You Begin Servicing

Advises reading safety information and reviewing the Safety section before servicing the cooling system.

Cooling System Diagram

Illustrates the engine coolant system, showing the flow between major components.

Engine Coolant Pump Components

Identifies and labels the components of the engine coolant pump assembly with a diagram.

Engine Coolant System Check

Explains how to check the engine coolant system for leaks using a cooling system tester.

Engine Coolant Pump

Covers the disassembly, cleaning, inspection, and reassembly of the engine coolant pump.

Lubrication System

Before You Begin Servicing

Advises reading safety information and reviewing the Safety section before servicing the lubrication system.

Introduction

Introduces the service procedures for trochoid oil pumps and engine oil/filter replacement.

Oil Pump Service Information

Provides information on engine oil pressure and clearances for oil pump components.

Lubrication System Diagram

Illustrates the engine lubrication system, showing oil flow through various parts.

Checking Engine Oil Pressure

Details how to check engine oil pressure and troubleshoot low pressure issues.

Trochoid Oil Pump

Covers the disassembly, cleaning, inspection, and reassembly of the trochoid oil pump.

Starter Motor

Before You Begin Servicing

Advises reading safety information and reviewing the Safety section before servicing the starter motor.

Starter Motor Information

Provides basic information and specifications for Yanmar starter motors, including performance data.

Starter Motor Specifications

Lists detailed specifications for starter motors, including output, weight, brush length, and commutator dimensions.

Starter Motor Troubleshooting

Offers a flowchart to diagnose and troubleshoot common starter motor problems based on symptoms.

Starter Motor Components

Identifies and labels the various components of the starter motor with a diagram.

Starter Motor

Covers the removal, disassembly, cleaning, inspection, and installation of the starter motor.

Alternator

Before You Begin Servicing

Advises reading safety information and reviewing the Safety section before servicing the alternator.

Introduction

Introduces the servicing of dynamos and alternators, listing part numbers and specifications.

Alternator Specifications

Provides detailed specifications for the Yanmar 129423-77200 alternator, including output, voltage, and speed.

Dynamo Specifications

Lists detailed specifications for the Yanmar 119910-77200 dynamo, including output, voltage, and speed.

Alternator Troubleshooting

Offers a flowchart to diagnose and troubleshoot common alternator problems based on indicator and voltage readings.

Alternator Components

Identifies and labels the various components of the alternator with a diagram.

Alternator Wiring Diagram

Illustrates the wiring diagram for the alternator, showing connections for key switch, battery, and regulator.

Alternator Standard Output

Shows a graph illustrating the standard output current of the alternator at different RPMs and temperatures.

Alternator

Covers the removal, disassembly, reassembly, and installation of the alternator.

Dynamo Component Location

Identifies and labels the components of the dynamo with a diagram.

Dynamo Wiring Diagram

Illustrates the wiring diagram for the dynamo, showing connections for key switch, battery, and load.

Dynamo Standard Output

Shows a graph illustrating the standard output current of the dynamo at different speeds.

Testing of Dynamo

Details tests for dynamo stator coil continuity, short-to-ground, and regulated output.

Electric Wiring

Electric Wiring Precautions

Lists critical precautions for electrical wiring to prevent component failure and warranty issues.

Electric Wire Resistance

Provides resistance values for various AWG wire sizes and their metric equivalents for calculating voltage drop.

Battery Cable Resistance

Lists maximum total battery cable lengths for different AWG sizes based on starter motor output and voltage.

Electrical Wire Sizes - Voltage Drop

Provides a chart to determine the correct wire size (AWG) based on current, voltage, and desired voltage drop.

Troubleshooting

Special Service Tools

Lists special service tools required for troubleshooting, specifically a compression gauge kit.

Troubleshooting By Measuring Compression Pressure

Details the procedure for measuring engine compression pressure and troubleshooting based on results.

Quick Reference Table For Troubleshooting

Summarizes general trouble symptoms, causes, and corrective actions for quick diagnosis.

Troubleshooting Charts

Provides comprehensive charts linking trouble symptoms to potential causes and corrective actions with reference pages.

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