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safety precautions - the Polaris International Extranet

1. OWNERS MANUAL FOR MAINTENANCE SPECIFICATIONS AND DJUSTMENTS YAN YANMAR CO LTD 021751 00X EPA EMISSION CONTROL INFORMATION 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 ENGINE FAMILY DISPLACEMENT __ LITERS ENGINE MODEL EMISSION CONTROL SYSTEM FUEL RATE LT L7 REFER TO OWNER S MANUAL FOR MAINTENANCE SPECIFICATIONS AND ADJUSTMENTS YAN MAH YANMAR CO LTD 021752 00X EPA amp ARB YANMAH TNM Series Service Manual GENERAL SERVICE INFORMATION 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 IMPORTANT ENGINE INFORMATION THIS ENGINE CONFORMS TO 97 68 EC DIRECTIVE ENGINEFAMLY ENGINE MODEL Mese APPROVAL NUMBER 2 YANMAR CO LTD 97 68 EC 4 5 2009 Yanmar Co Ltd GENERAL SERVICE INFORMATION Engine Family ENGINE FAMILY The EPA ARB labels and the 97 68 EC label all have an Engine Famil
2. 6 101 Final Assembling of the Engine 1 2 W 6 58 Install the starter motor Install the cylinder head See Assembling the Cylinder Head on page 6 27 Install the engine in the machine Connect the fuel and coolant lines Install the alternator Connect and adjust the throttle cable Connect all electrical connections Fill the engine with oil and coolant Connect the battery cables negative cable last 2010 Yanmar Co Ltd TNM Series Service Manual Cylinder Block gt
3. This Page Intentionally Left Blank ENGINE SERVICE CHAPTER 11 YANMAR ENGINE SERVICE IMPORTANT The following is YANMAR supplied service manual modified by Polaris to depict the correct service and repair of the 3TMN72 APL This manual contains generic repair and maintenance procedures Follow all directions and warnings Do not attempt service of engine components without proper diesel engine instruction and training Component failure from improper repairs may lead to engine failure Polaris gratefully acknowledges copyright permissions granted by Yanmar 9923516 O 2011 Polaris Industries Inc 1 1 41 YANMAR ENGINE SERVICE INTENTIONAL BLANK PAGE 9923516 O 2011 Polaris Industries Inc TNM series SERVICE MANUAL 3TNM72 HVIANVA Y INDUSTRIAL ENGINES This Service Manual has been developed for the exclusive use of service and repair This Service Manual has been developed for the exclusive use of service and repair professionals such as authorized Distributors and 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 repair or service professional before before working on your engine Disclaimers All information illustrations and specifications in this ma
4. 1 0006464 Figure 5 16 5 After draining the engine coolant flush the radiator and engine block to remove any rust scale and contaminants NOTICE 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 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 17 WARNING Scald Hazard ALWAYS tighten the radiator cap securely after you check the radiator Steam can escape during engine operation if the cap is loose Adjust Intake Exhaust Valve Clearance 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 30 TNM Series Service Manual YANMAMH 2009 Yanmar Co Ltd Periodic Maintenance Procedures Every 1500 Hours of Operation Perform the following maintenance every 1500 hours of operati
5. es 21251 Series Service Manual ENGINE Solvents will not adequately remove honing residue resulting in premature piston and ring wear Always wash cylinders using hot soapy water The cylinder wall is adequately cleaned when a white rag wiped in cylinder comes out clean Use brushes to clean all passages and crevices Rinse with hot water and dry with compressed air Apply clean engine oil to all steel surfaces to prevent rusting Assembling the Crankshaft and Piston Components Proceed slowly Make no forced assemblies unless a pressing operation is called for All parts must be perfectly clean and lightly lubricated when assembled NOTICE Use new gaskets seals and O rings during assembly Liberally apply clean engine oil to all internal parts during assembly Tighten all fasteners to the specified torque If a special torque is not provided in the Special Torque Chart on page 6 11 tighten to standard torque specifications See Tightening Torques for Standard Bolts and Nuts on page 4 25 6 49 2010 Yanmar Co Ltd Cylinder Block Assembling the Pistons Note The actual appearance of the match 1 3 marks will vary but they will always be in Select the parts needed to assemble the piston the same locations and connecting rod for one cylinder If removed install a new wrist pin bushing Figure 6 80 7 using a press and t
6. gees 4 27 Unts Of POWO 4 27 Units of 4 27 TNM Series Service Manual YANMAR 2009 Yanmar Co Ltd Safety Precautions SAFETY PRECAUTIONS Before performing any engine service procedures review the Safety section on page 3 1 COMPONENT IDENTIFICATION GENERAL SERVICE INFORMATION Figure 4 1 shows where major engine components are located Image is a typical engine representation Wes Xy 1 Coolant Temperature Sensor 2 Lifting Eye engine cooling end 3 Alternator 4 V Belt 5 Engine Coolant Pump 6 Fuel Return to Fuel Tank 7 Crankshaft V Pulley 8 SideFiller Port engine oil 9 Drain Plug engine oil 10 Engine Oil Filter 11 N A 12 N A 13 Fuel Inlet 0006458 14 Oil Pressure Switch 15 Dipstick engine oil 16 Governor Lever 17 Fuel Injection Pump 18 Top Filler Port engine oil 19 Intake Manifold 20 Air Intake Port from air cleaner 21 Lifting Eye flywheel end 22 Rocker Arm Cover 23 Stop Solenoid 24 Flywheel 25 Starter Motor 26 Exhaust Manifold Illustration is for general reference only Engine oil drain plug location may vary based on oil pan options TNM Series Service Manual 4 3 0 2009 Y anmar Co Ltd GENERAL SERVICE INFORMATION LOCATION OF LABELS Figure 4 2 shows the location of regulatory emission control
7. 35 911 mm 39 906 mm Oil Clearance 0 0016 0 0033 in 0 0061 in 0 040 0 085 mm 0 154 mm Tafaj 21141 Series Service Manual 6 5 2010 Yanmar Co Ltd Crankshaft and Piston Specifications Idler Gear Shaft and Bushing Inspection Item 3TNM68 72 3TNM68 3TNM72 Page Shaft Outside Diameter 1 1795 1 1803 in 1 1779 in See 29 959 29 980 mm 29 919 mm erei Te eee 1 1811 1 1821 in 1 1837 in the Idler 9 30 000 30 025 30 066 mm Gear and PNEU 0 0008 0 0026 in 0 0058 in Shaft on 0 020 0 066 mm 0 147mm page 6 48 Timing Gear Backlash Inspection Item 3TNM68 3TNM72 3TNM68 3TNM72 Page See Checking Timing Gear Backlash on page 6 34 Crank Gear Cam Gear Idler Gear 0 0024 0 0047 in 0 0055 in Fuel Injection Pump Gear 0 06 0 12 mm 0 14 mm CRANKSHAFT AND PISTON SPECIFICATIONS Crankshaft Note Check appropriate parts catalog for undersized replacement main bearing inserts nspection 3TNM68 3TNM72 3TNM68 3TNM72 Page 0 0008 in 0050 0 0004 0 01 0 0008 in Roundness or less 0 02 mm Journal Outside 1 4942 1 4946 in 1 4725 in See Diameter 87 952 37 962 mm 87 402 mm 5 45 Bearing Inside 1 4954 1 4965 in Crankshaft Connecting Rod Diameter 37 982 38 010 mm on page 6 46 Journals Bearing Insert 0 0592 0 0594 in Thickness 1 503 1 509 mm Clear
8. 8 Seat Angle Intake IEEE Valve Face Seat Correction Angle 40 150 BEEN on page 6 24 Valve Seat 1 E TNM Series Service Manual 6 3 2010 Yanmar Co Ltd Cylinder Head Specifications Intake Exhaust Valve and Guide Inspection Item 3TNM68 72 3TNM68 3TNM72 Page Guide Inside 0 2165 0 2172 in 0 2362 0 2367 in 0 2197 in 0 2394 in Diameter 5 500 5 516 mm 6 000 6 012 mm 5 580 mm 6 080 mm Valve Stem 0 2152 0 2157 in 0 2346 0 2356 in 0 2126 in 0 2323 Outside Diameter 5 465 5 480 mm 5 960 5 985 mm 5 400mm 5 900 ntake Clearance 0 0008 0 0020 0 0006 0 0020 in 0 0063 0 0063 0 020 0 051 mm 0 015 0 052 0 15 mm 0 15 mm See 0 0004 in Valve Stem Bend 0 01 0 Inspecting the Valve 6 Valve Stem 0 2144 0 2150 in 0 2341 0 2350 in 0 2126 in 0 2323 in Outside Diameter 5 445 5 460 mm 5 945 5 970 mm 5 40 mm 5 90 mm i 0 0067 in 0 17 mm 0 0004 in Valve Stem Bend 0 010 mm Head 8 30 8 75 mm 9 8 10 0 mm Assembling Valve Stem Seal Projection from 0 484 in 0 543 in the Valve Cylinder Head 12 3 mm 13 8 mm Guides on Valve Guide Installation Method Cold fitted _ gt np a aa Push Rod nspection P 3TNM68 3TNM72 3TNM68 3TNM72 Page Less than 0 0012 in 0 0012 in
9. Engine Model 3TNM72 Version CL VM CH VH Type Vertical In line Diesel Engine Combustion System Ball Type Swirl Chamber Aspiration Natural No of Cylinders 3 Bore xStroke 2 83 x 2 91 in 72 x 74 mm Displacement 55 1 cu in 0 904 L pm Continuous Rated hp SAE Output KW rpm Max Rated Output hp SAE Net rpm igh Idling mn in BE U oa EE U ms E 3840 c ngine Weight Dry ith Flywheel 187 Ib 85 kg ousing TO Position Flywheel End irection 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 34 8 63 8 psi 0 240 0 440 MPa 2 4 4 4 kgf cm Normal Oil Pressure at Low Idle S peed 8 5 psi 0 06 MPa 0 6 kgf cm or greater Electric Starting Starter Motor DC 12V 1 6 hp 1 2 kW Starting S ystem Dimensions 19 5 x 16 8 x 21 3 in LxW xH 497 x 427 x 542 mm Engine Oil Pan Capacity Engine Coolant Capacity ze Cooling Polaris Supplied Electric Fan Crank V pulley Dia Engine specifications without radiator Engine oil capacity for a Deep Standard oil pan Refer to the Operation Manual provided by the driven machine manufacturer for the actual engine oil
10. Inspecting the Pistons Piston Rings and Wrist Pin On engine with low hours the pistons and piston rings may be reused if they are found to be within specifications The pistons and piston rings must be installed in the same cylinders from which they were originally removed On engine with high hours the piston rings should be replaced and the cylinder honed see Honing and Boring on page 6 48 or replaced The piston should be replaced as necessary 1 Clean piston ring grooves using a piston ring groove cleaning tool Follow manufacturers instructions for correct operation 2 Wash the pistons in an appropriate solvent using a soft brush 3 Visually inspect each piston for cracks Pay particular attention to the ring lands between the piston ring grooves 4 Measure the diameter of the piston skirt at 90 to the wrist pin bore as shown Figure 6 61 Measurements must be taken at a specified distance Figure 6 61 1 from the bottom of the piston based on engine model Record the measurements See Piston on page 6 8 for specifications K0000235 00X Figure 6 61 6 43 2010 Yanmar Co Ltd 5 Subtract the piston measurement from the greatest measurement acquired during cylinder inspection see Inspecting the Cylinder Block on page 6 43 to obtain piston to cylinder clearance Record the measurements See Piston on page 6 8 for specifications 6 Measure the diam
11. Push Rod Bend on 0 03 mm 0 03 mm page 6 21 Oil Clearance 0 0016 0 0028 in 0 0012 0 0026 in 0 0067 in 0 040 0 071 mm 0 030 0 067 mm 0 17 mm Guide Inside 0 2165 0 2172 in 0 2362 0 2367 in 0 2197 in 0 2394 in Springs on Diameter 5 500 5 516 mm 6 000 6 012 mm 5 580 mm 6 080 mm page 6 24 Exhaust Push Rod Bend Valve Spring Inspection Item 68 72 3TNM68 3TNM72 Page Fres Lenath 1 3268 in 1 4882 in See 9 33 7 mm 37 8 mm Inspecting 7 Valve Squareness 0 0512 in Springs on 1 3 mm page 6 24 6 4 TNM Series Service Manual B 24 NM 2010 Yanmar Co Ltd Camshaft and Timing Gear Train Specifications ENGINE Rocker Arm and Shaft Inspection Item 3TNM68 3TNM72 3TNM68 3TNM72 Page nere ONE 0 8937 0 3945 in 0 4724 0 4732 in 0 3965 0 4752in poe 10 000 10 020 mm 12 000 12 020 mm 10 07 12 07 mm Inspecting 0 3925 0 3933 0 4711 0 4718 0 3913 in 0 4701 in the Rocker 9 97 9 99 mm 11 966 11 984 9 94 mm 11 94 mm Am Oll Clearance 0 0004 0 0020 in 0 0006 0 0021 in 0 0051 in 0 0051 in Assembly on 0 010 0 050 mm 0 016 0 054 mm 0 13 mm 0 13 Page 621 CAMSHAFT AND TIMING GEAR TRAIN SPECIFICATIONS Camshaft Inspection Item 3TNM68 3TNM72 3TNM68 3TNM72 Page See 0 0020 0 0059 in 0 0098
12. replace them R eplace the hoses atleast every two years NOTICE 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 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 23 TNM Series Service Manual YANMAH 2009 Yanmar Co Ltd BE PUE Section 6 Safety 6 3 me M 6 3 Cylinder Head 6 3 Adjustment 6 3 Cylinder AGA c 6 3 Intake Exhaust Valve and 6 4 Push erem T tt ara 6 4 V le SPNG EET 6 4 Rocker Arm ard Shall eemebree hp tei bordes 6 5 Camshaft and Timing Gear Train Specifications 6 5 6 5 Idler Gear Shaft and Bushirig i etes 6 6 Timing Gear BHOKIGSTIA anas serai tote rt estime aene 6 6 Crankshaft and Piston 6 6 rr cu EE 6 6 Cr
13. 1 to the proper height Figure 6 25 3 using the valve guide installation tool Figure 6 25 2 See Valve Guide Projection specification on page 6 4 Figure 6 25 Assembling the Intake and Exhaust Valves NOTICE Always install new valve stem seals For 3TNM72 engines the exhaust valve stem seals are different than the intake valve stem seals and can be identified by the color of the seal spring Figure 6 26 4 For 68 engines all stem seals are the same Ensure they are installed in the correct locations Engine Model intake Exhaust Silver Silver Seal Spring Seal Spring White White mark Seal Spring on the Body 1 Oil the lip of the valve stem seal Figure 6 26 2 Using the valve stem seal installation tool Figure 6 26 1 install a new valve stem seal on each of the valve guides Figure 6 26 3 Cylinder Head 2575 255050 444 52509 Qo Me be K0001873B 00X Figure 6 26 2 Measure the distance Figure 6 27 1 from the cylinder head to valve stem seal to ensure proper clearance Figure 6 27 2 between the valve guide and seal See Valve Stem Seal Projection specification on page 6 4 K0001874 00X Figure 6 27 3 Put the cylinder head assembly on its exhaust port side m 2 pe ES 7 BS ti e TNM Series Service Manual 2010 Yanmar Co
14. 2 from the bottom of the bore Remove the piston Measure the end gap Figure 6 65 3 of each piston ring Record the measurements See Piston Ring on page 6 8 for specifications TNM Series Service Manual B ss Pad ees 2010 Yanmar Co Ltd Cylinder Block 11 1 SS 2 A 3 3 K0001964 00X Figure 6 65 NOTICE Always check the piston ring end gap when installing new piston rings See Piston Ring on page 6 8for specifications Use a piston ring end gap filing tool to adjust the piston ring end gap on new piston rings Repeat the above steps for each cylinder and piston assembly Inspecting the Connecting Rod 1 Measure the wrist pin bushing bore using a bore gauge Figure 6 66 1 Replace the bushing if not within specifications If the bushing has been removed measure the inside diameter of the connecting rod small end Figure 6 66 2 Record the measurements See Connecting Rod on page 6 9 for specifications Tajuk T Series Service Manual ENGINE Figure 6 66 Measure the connecting rod twist Figure 6 67 1 and bend Figure 6 67 2 using a connecting rod alignment tool Figure 6 68 Record the measurements See Connecting Rod on page 6 9 for specifications K0001896 00X Figure 6 67 K0000242 00X Figure 6 68 6 45 2010 Yanmar
15. GENERAL SERVICE INFORMATION Specifications 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 P rincipal 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 25 C Atmospheric pressure 29 53 in Hg 100 kPa 750 mmHg 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 396 1 PS 0 7355 kW 1 hp SAE Society of Automotive Engineers 2 0 7457 kW 4 20 TNM Series Service Manual YANMAH 2009 Yanmar Co Ltd Principal Engine Specifications GENERAL SERVICE INFORMATION PRINCIPAL ENGINE SPECIFICATIONS This Page Intentionally Left Blank YANMAR TNM Series Service Manual 4 21 2009 Yanmar Co Ltd GENERAL SERVICE INFORMATION Principal Engine Specifications 3TNM72 EPA Tier 4
16. K0000199 00X Figure 6 17 es 2151 TNM Series Service Manual ENGINE Valve Recession The valve guides must be installed to perform this check Insert the valves into their original locations and press them down until they are fully seated Use a depth micrometer Figure 6 18 to measure the difference between the cylinder head gasket surface and the combustion surface of each exhaust and intake valve Figure 6 19 Record the measurements See Cylinder Head on page 6 3 for the service limit Figure 6 18 Figure 6 19 2010 Yanmar Co Ltd Valve Face and Valve Seat Always check the clearance between the valve and valve guide before grinding or lapping the valve seats See Intake Exhaust Valve and Guide on page 6 4 for the service limit If the clearance exceeds the limit replace the valve and or valve guide to bring the clearance within the limit Roughness or burrs will cause poor seating of a valve Visually inspect the seating surfaces of each valve and valve seat to determine if lapping or grinding is needed Visually inspect all valve faces and valve seats for pitting distortion cracking or evidence of overheating Usually the valves and valve seats can be lapped or ground to return them to serviceable condition Severely worn or damaged components will require replacement Coat the valve seat with a thin coat of bluing compound Install valv
17. Note Either fill location may be used 4 Wait 3 minutes and check oil level 5 Add more oil if necessary 6 Replace oil cap Figure 4 6 4 and hand tighten ver tightening may damage the cap 4 15 2009 Yanmar Co Ltd GENERAL SERVICE INFORMATION Engine Oil Capacity Typical Note These are the engine oil capacities associated with the 3TNM72 APL oil pan Refer to the operation manual provided by the driven machine manufacturer for the actual engine oil capacity of your machine The following is the engine oil capacities for Yanmar 3TNM72 APL engine Engine Model Engine Capacity Limit Lower Limit 3TNM72 APL 1 8 qt 1 701 4 16 Engine Coolant ENGINE COOLANT WARNING Scald Hazard ALWAYS check the level of engine coolant by observing the reserve tank CAUTION Coolant Hazard Wear eye protection and rubber gloves when you handle Long Life Coolant LLC or extended life engine coolant If contact with the eyes or skin should occur flush eyes and wash immediately with clean water Engine Coolant Specifications NOTICE 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 NOTICE NEVER mix different types of engine coolant This may adversely affect the properties of the engine coolant TNM Series Service Manual YANMAH 2009 Yanmar Co Ltd Engine
18. Rotate the crankshaft and measure the next cylinder Continue until all valves are adjusted L lalat I Series Service Manual 6 31 2010 Yanmar Co Ltd CYLINDER BLOCK Crankshaft and Camshaft Components Figure 6 37 2010 Yanmar Co Ltd TNM Series Service Manual Cylinder Block 026973 00X 7 pus feed R bim gt BE Y Cylinder Block 1 Flywheel Housing 2 Dowel 2 used 3 Crankshaft Rear Seal 4 Tappets 5 Camshaft 6 Camshaft Gear Key 7 Camshaft End Plate 8 Camshaft Gear 9 Gear Case Cover 10 Front Crankshaft Seal 11 Fuel Injection Pump Gear Cover 12 Idler Gear Shaft 13 ldler Gear Bushing 14 Idler Gear 15 Top Compression Ring 16 Second Compression Ring 17 Ring 18 Piston 19 Wrist Pin 20 Circlip 21 Wrist Pin Bushing 22 Connecting Rod 23 Connecting Rod Bearing Inserts 24 Connecting Rod Cap 25 Flywheel 26 Ring Gear 27 Crankshaft 28 Crankshaft Gear Key 29 Crankshaft Gear 30 Crankshaft Pulley 31 Thrust Bearings 32 Main Bearing Inserts 33 Oil Pickup O Ring 34 Oil Pickup 35 Oil Pan 36 Cylinder Block Tajuk T Series Service Manual ENGINE Disassembling the Cylinder Block Components Prepare a clean flat working surface on a work bench large eno
19. WARRANTY Emissions WaIranty eR YANMAR TNM Series Service Manual 2009 Yanmar Co Ltd WARRANTY Emission System Warranty EMISSION SYSTEM WARRANTY 2 2 TNM Series Service Manual YANMAR 2009 Yanmar Co Ltd Section 3 SAFETY Page Safety Statements sese nennen 3 3 Safety Precautions EE oo o 3 3 YANMAH TNM Series Service Manual 3 1 2009 Yanmar Co Ltd SAFETY This Page Intentionally Left Blank 3 2 TNM Series Service Manual YANMAH 2009 Yanmar Co Ltd Safety Statements SAFETY STATEMENTS Polaris 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 TNM 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 protectthe 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 safety is involved Please read and abide by the message that follows the safety alert symbol DANGER Indicates a hazardous situat
20. cylinder at top dead center TDC of the compression stroke When a piston is at TDC of the compression stroke both rocker arms will be loose and the cylinder TDC mark on the flywheel will be visible in the timing port of the flywheel housing If there is no valve clearance and the piston is at TDC of the compression stroke extreme wear or damage to the cylinder head or valves may be possible If adjusting each cylinder individually the cylinder to be adjusted first does not have to be the No 1 cylinder Select and adjust the cylinder where the piston is nearest to the top dead center after turning Adjust the remaining cylinders in the order of firing by turning the crankshaft each time To decrease the number of rotations required to check all cylinders use the chart as indicated below Example With the No 1 piston at TDC on the compression stroke both valves closed the valves indicated on the top line of the chart can be adjusted without rotating the crankshaft To adjust the remaining two valves rotate the crankshaft until the No 1 piston is at TDC on the exhaust stroke exhaust valve only open 2010 Yanmar Co Ltd Cylinder Head TNM Series Service Manual 16 7 pus feed R bim gt BE Y Cylinder Head ENGINE No 1 Cylinder at TDC Compression No 1 Cylinder at TDC Exhaust 1 Remove the intake manifold valve cover See Removing the Intake Manifold Val
21. me 0 0579 0 0587 in 0 0571 in jJ spon Ring Width p g Middle i 1 470 1 490 mm 1 450 mm the Pistons Compression Ring Side CI 0 0035 0 0049 in 0 0096 in Piston Rings 0 090 0 125 mm 0 245 mm and Wrist Pin 0 0098 0 0157 in 0 0193 in on page 0 43 0 250 0 400 0 490 mm Ring Groove 0 1185 0 1191 in 0 1232 in Width 3 010 3 025 mm 3 130 mm er 0 1170 0 1177 in 0 1161 in 2 970 2 990 2 950 Oil Control Ring Rens 0 0008 0 0022 in 0 0071 in 0 020 0 055 mm 0 180 mm End Clearance 0 0059 0 0138 in 0 0079 0 0177 0 0173 in 0 0217 in 0 150 0 350 mm 0 200 0 450 mm 0 440 mm 0 550 mm 6 8 TNM Series Service Manual B 24 2010 Yanmar Co Ltd Crankshaft and Piston Specifications Connecting Rod Connecting Rod Small End Oil Clearance Inspection Item 025 20 042 mm 22 025 22 042 mm 0 7902 in 0 7902 in 20 072 mm 20 072 mm 0 7872 0 7874 0 8659 0 8661 0 7861 in 0 7861 in 19 995 20 000 mm 21 995 22 000 mm 19 967 mm 19 967 mm 0 0010 0 0019 in 0 0041 in 0 025 0 047 mm 0 105 mm Connecting Rod Big End Inspection Item Bearing Inside Diameter and Clearance Connecting Rod Distortion Inspection Item Twist and Bend per 3 937 in 100 mm Tappet Inspection Item See Cr
22. 16 38700 fl oz U S x 0 02957 L fl oz U S x 29 57000 mL cm x 1 00000 cm X 0 03382 fl oz U S Units of Mass Ib X 0 45360 kg OZ X 28 35000 g kg x 2 20500 9 x 0 03527 02 Units of Force lof x 4 4480 Ibf X 0 4536 kgf N x 0 2248 bf N x 0 1020 kgf kof x 2 2050 bf kgf X 9 8070 YANMAR TNM Series Service Manual GENERAL SERVICE INFORMATION Units of Torque Ib ft Ib ft Ib in Ib in kgf m kgf m kgf m N m N m N m X X X X X X ox ox x 1 3558 0 1383 0 1130 0 0115 7 2330 86 8000 9 8070 0 7376 8 8510 0 1020 Units of Pressure psi psi psi bar bar bar kPa kPa kPa kgf cm kgf cm kgf cm in Hg 60 in Hg 60 in Hg 60 X X X X X X X X X X KK ox xx 0 0689 6 8950 0 0703 14 5030 100 0000 29 5300 0 1450 0 0100 0 0102 98 0700 0 9807 14 2200 0 0333 3 3770 0 0344 Units of Power hp metric or PS hp metric or PS hp SAE hp SAE kW kW Units of Temperature F 1 8 x 32 C 0 556 x F 32 x 0 9863201 0 7354988 1 0138697 0 7456999 1 3596216 1 3410221 kgf cm in Hg 60 F psi bar kgf cm psi bar kPa bar kPa kgf cm hp SAE kW hp metric or PS kW hp metric or PS hp SAE 2009 Yanmar Co Ltd GENERAL SERVICE INFORMATION Unit Conversions This Page Intentionall
23. Air Cleaner Element Replace Fuel Filter Water Separator Replace Air Cleaner Element NOTICE Protect the air cleaner and electric components from damage when you use steam or high pressure water to clean the engine Replace the air cleaner element Figure 5 11 2 every 150 hours even if itis not damaged or dirty NOTICE 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 When replacing the element clean the inside of the air cleaner case Figure 5 11 4 If the air cleaner is equipped with a double element only remove and replace the inner element Figure 5 12 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 Water Separator WARNING 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 put 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 NEVER use diesel fuel as a cleaning agent YANMAH TNM Series Service Manual PERIODIC MAINTENANCE WARNING Exposur
24. Co Ltd Cylinder Block 3 Place the connecting rod bearing inserts into Inspecting the Crankshaft the connecting rod and connecting rod cap 1 Putthe crankshaft end journals Install the rod cap and tighten the bolts to the Figure 6 71 4 on V blocks specified torque 4 Measure the inside diameter Record the measurements See Crankshaft on page 6 6 for specifications 2 Place a dial indicator Figure 6 71 3 on a center main bearing surface Inspecting the Tappets 1 Inspect the tappet contact surfaces for abnormal wear Figure 6 69 1 Normal wear will be even as shown in Figure 6 69 2 Slight surface defects can be corrected using an oilstone 1 2 K0002194 00X Figure 6 69 Figure 6 71 stem Figure 6 70 Record the measurements Record the measurements See Crankshaft on See Tappet on page 6 9 for the service limit page 6 6 for specifications 4 Usethe color check method or MAGNAFLUX to inspect the crankshaft for cracks Replace the crankshaft if evidence of fractures is found 5 Measure the outside diameter of each crankpin Figure 6 72 2 and main bearing journal Figure 6 72 1 See Crankshaft on page 6 6 for specifications Take measurements at several places around each bearing surface If not within specification grind the journals and install undersize bearings or replace the crankshaft Record the measurements Figure 6 70 3 Measure the tappet bores in the c
25. Coolant 2 4 4 4222122 1 4 16 Filling Radiator with Engine 4 17 Engine Coolant Capacity 4 18 YANMAR TNM Series Service Manual 2009 Yanmar Co Ltd GENERAL SERVICE INFORMATION Specifications E ante Eres e et du aee 4 19 Description of Model 4 19 Engine Speed 4 19 Engine General Specifications 4 20 Principal Engine 4 21 qe 4 22 Engine Service 4 23 Tightening Torques for Standard Bolts and Nuts 4 24 Abbreviations and 2 4 26 ile eia MN OP 4 26 me E 4 26 Unit Conversions TUO E EO 4 27 Unit PrefiIXES ce M 4 27 Units of Length successisse 4 27 Units of fo 4 27 mem ec 4 27 Units of Force T 4 27 Units rc 4 27 uae
26. Piston Inspection Item 3TNM68 3TNM72 3TNM68 3TNM72 Page Piston Outside Diameter 2 6756 2 6768 in 2 8331 2 8343 in 3 8550 in 2 8313 in 67 961 67 991 mm 71 960 71 990 mm 97 916 mm 71 915 mm Piston Diameter Measurement 0 3937 0 5118 in Location 10 18 mm See Inspecting the Pistons 0 0004 0 0027 in 0 0004 0 0028 in y 0 009 0 069 mm 0 010 0 070 mm Hole Inside 0 7874 0 7877 in 0 8661 0 8665in 0 7889 0 8677 in Piston Rings Diameter 20 000 20 008 mm 22 000 22 009 mm 20 039 mm 22 039 mm and Wrist Pin Pin Outside 0 7872 0 7874in 0 8659 0 8661 in 0 7860in 0 8648 27 Page 6 43 Diameter 19 995 20 000 mm 21 995 22 000 mm 19 965 mm 21 965 mm Clearance 0 0000 9 0005 0 0000 0 0006 in 0 0029 in 0 0029 in 0 000 0 013 mm 0 000 0 014 0 074 mm 0 074 mm Piston Ring Inspection Item 3TNM68 3TNM72 3TNM68 3TNM72 Page Ring Groove 0 0610 0 0618 in Width 1 550 1 570 mm 0 0579 0 0587 in 0 0571 in Ring Width Top Compression 1 470 1 490 mm 1 450 mm Ring Sida Gidaranes 0 0024 0 0039 in 0 060 0 100 mm End Clearance 0 0059 0 0118 in 0 0039 0 0098 in 0 0154 in 0 0013 in 0 150 0 300 mm 0 100 0 250 mm 0 390 mm 0 034 mm Ring Groove 0 0622 0 0628 in 0 0667 in Width 1 580 1 595 mm 1 695 mm See 2T
27. Piston Components 6 38 Inspecting the Crankshaft and Camshaft Components 6 42 Reconditioning the Crankshaft 6 47 Honing riesce 6 48 Assembling the Crankshaft and Piston Components 6 49 Assembling the Camshaft and Timing Components 6 55 TNM Series Service Manual 16 7 m feed R bim gt BE Y 2010 Yanmar Co Ltd Safety Precautions ENGINE SAFETY PRECAUTIONS INTRODUCTION Before performing any engine service procedures This section of the Service Manual describes review the following message and the Safety servicing of the engine section on page 3 1 Always protect the air cleaner and electric components including the relays and harness couplers from damage when you use steam or high pressure water to clean the engine CYLINDER HEAD SPECIFICATIONS Adjustment Specifications All 0 006 0 010 in 0 15 0 25 mm Cylinder Head Page 0 0269 0 0326 in 3TNM68 Top of Piston to Cylinder Head Surface 0 684 0 828 mm Clearance 0 0270 0 0326 in SINM72 0 685 0 828 mm Combustion Surface Distortion Flatness 0 0020 in 0 05 0 0059 55 0 15 mm 0 0157 0 0236 in 0 0354 in 96e Intake Hecession on 0 4 0 6 mm 0 9 mm Valve Recession page 6 23 Exhaust 0 0157 0 0236 in 0 0315 in 0 4 0 6 mm
28. Rocker Arm Assembly Removing the Cylinder Head 1 Remove the rocker arm shaft alignment 1 Loosen the cylinder head bolts following the setscrew Figure 6 5 6 from support sequence shown in Figure 6 6 8 ol iE 1 1 Cooling Fan End 2 Camshaft Side Figure 6 6 2 Remove the cylinder head bolts Figure 6 7 1 3 Lift the cylinder head away from the cylinder block Discard the cylinder head gasket Figure 6 7 2 Position the cylinder head on 2 Remove two circlips Figure 6 5 8 the work bench to prevent damage to the combustion surface The rocker arm shaft fits tightly in the rocker arm supports Clamp the support in a padded vise Twist and pull out on the rocker arm shaft to remove Reverse this process when installing the rocker arm shaft into the supports Figure 6 5 3 Slide the rocker arm shaft Figure 6 5 7 out of the rocker arm supports Figure 6 5 5 springs Figure 6 5 4 and rocker arms Figure 6 5 1 NOTICE Mark the rocker arms so they can be installed with the original matching valve and push rod 4 Remove the valve adjusting screw Figure 6 5 3 and lock nut Figure 6 5 2 Figure 6 7 from the rocker arms Mark parts so they can be installed on the same rocker arm Tajuk T Series Service Manual 6 19 2010 Yanmar Co Ltd Removing the Intake Exhaust Valves 1 Putthe cyli
29. Rua e dnt tae 8 1 Lubrication System 9 1 Starter Neneh eiseimdeatidant 10 1 Alternator RE SOS CES 11 1 Electric Wiring 12 1 Troubleshooting 22 22 4 1 13 1 YANMAR TNM Service Manual 2009 Yanmar Co Ltd TABLE OF CONTENTS This Page Intentionally Left Blank iv TNM Service Manual YANMAH 2009 Yanmar Co Ltd Section 1 INTRODUCTION This Service Manual describes the service procedures for the TNM 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 3TNM72 APL 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 YANMAH TNM Series Service Manual 1 1 2009 Yanmar Co Ltd INTRODUCTION This Page Intentionally Left Blank 1 2 TNM Series Service Manual YANMAMH 2009 Yanmar Co Ltd Section 2
30. and tighten the bolts to the specified torque See Special Torque Chart on page 6 11 027074 00X Figure 6 92 Cylinder Block Installing the Pistons Do not allow the connecting rod to contact the crankshaft journal during piston installation Damage to the crankshaft bearing journal may result 1 Lubricate piston piston rings and cylinder with clean engine oil or assembly lubricant 2 Rotate the crankshaft so the crankpin for the piston being installed is near bottom dead center 1 Top Compression Ring End Gap 2 Middle Compression Ring End Gap 3 Oil Control Ring End Gap Figure 6 93 Ensure piston ring gaps are located correctly Figure 6 93 3 Using a piston ring compressor compress the piston rings TNM Series Service Manual j Co Ee 1 2010 Yanmar Co Ltd Cylinder Block ENGINE 4 Carefully install the piston and rod assembly 5 Install the bearing inserts Figure 6 95 1 in sure the match marks Figure 6 94 4 the connecting rod and cap stamped into the connecting rod and cap are 6 Apply a liberal coat of clean engine oil to the facing the fuel injection pump side of the bearing inserts and crankshaft journal cylinder block and the piston identification mark Figure 6 94 2 stamped into the piston top is facing the camshaft side Figure 6 94 6 The embossed mark cast 7 Apply a light coat of clean engine oil to the rod ca
31. bearing and crankshaft into the engine The main bearings are numbered and have arrows for proper positioning The No 1 bearing is at the flywheel end Install the lower main bearing into the ladder frame Apply a light coat of clean engine oil to the ladder frame mounting bolts and tighten the bolts to the specified torque in two stages 1 2 then full torque See Special Torque Chart on page 6 11 NOTICE Apply plenty of liquid packing to these portions in the flywheel side until protruding to the oil seal insertion hole and wipe off the protruded liquid packing Figure 6 90 2010 Yanmar Co Ltd 7 10 11 12 The surface difference between the surfaces on the flywheel side and the gear case side and the ladder frame surface should be 0 004 in 0 1 mm or less o 3 o om o dx rub o E 3 ME od NZUC bd 06 00 Gio Bc 10 o 4 L So 2749 OC Sy lo r Vg 5 6 Se 20 1 Gear Case Side 2 Flywheel Side Figure 6 91 Rotate the crankshaft to ensure it turns freely Apply ThreeBond Liquid Gasket No 1212 Yanmar Part No 977770 01212 to the mounting flange of the flywheel housing Figure 6 92 2 Align the flywheel housing with the two dowel pins Figure 6 92 3 Install flywheel housing and seal assembly Install the flywheel Figure 6 92 1
32. capacity of your machine May vary depending on application 4 22 Series Service Manual YANMAR 2009 Yanmar Co Ltd Engine Service Information ENGINE SERVICE INFORMATION Inspection Item GENERAL SERVICE INFORMATION Standard Intake Exhaust Valve Gap 0 006 0 010 in 0 15 0 25 mm Fuel Injection Timing See Checking and Adjusting Fuel Injection Timing on page 7 16 Fuel Injection Pressure 1784 1929 psi 12 3 13 3 MPa 125 136 kgf cm Compression Pressure at 250 rpm 250 min 3TNM72 470 15 psi 370 15 psi 3 24 0 1MPa 2 55 0 1 MPa 33 1 kgf cm 26 1 kgf cm At rated output 41 55 psi 0 28 0 38 MPa 2 86 3 87 kgf cm Lubricating Oil Pressure When idling 8 5 psi 0 06 MPa 0 6 kgf cm or greater Thermostat YANMAH TNM Series Service Manual Valve Opening Temperature Full Opening Lift Temperature 0 32 in 8 mm or Above 185 F 85 C 157 163 F 70 73 C 4 23 2009 Yanmar Co Ltd 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 the fasteners on the machine Applying excessive torque may damage the fastener or component and not enough torque may cause a leak or component failure NOTICE The tightening torque in the Standard Torque Chart see Gene
33. comes first even if the engine has been out of service Rubberized fuel lines tend to dry out and become brittle after 2 years or 2000 hours of engine operation whichever comes first Refer to Chapter 2 for more information 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 gauge and stop fueling when gauge shows the 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 YANMAH TNM Series Service Manual GENERAL SERVICE INFORMATION 0000002A Figure 4 3 Priming the Fuel System 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 or draining the fuel filter water separator or replacing a fuel system component To prime the fuel system if an electric fuel feed pump is installed Turn the key to the ON position for 10 to 15 seconds This will allow the electric fuel feed pump to prime the fuel system WARNING Fire and Explosion Hazard NEVER open the air vent valve while the fuel system is being primed NOTICE NEVER use the starter motor t
34. complete 4 Pourthe fuel into an approved container and dispose properly Hold the bottom of the cup with a shop towel to prevent fuel from dripping Wipe up any spills immediately NOTICE 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 5 Prime the fuel system by running the fuel pump 10 15 seconds 5 9 2009 Yanmar Co Ltd PERIODIC MAINTENANCE Check Battery WARNING Fire and 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 or voltage meeter to check the remaining battery charge If the electrolyte is frozen slowly warm the battery before you recharge it ALWAYS keep the area around the battery well ventilated While the engine is running or the battery is charging hydrogen gas is produced and can be easily ignited ALWAYS keep sparks open flame and any other form of ignition away while the engine is running or battery is charging WARNING Burn Hazard Batteries contain sulfuric acid NEVER allow battery fluid to come in contact with clothing
35. do not comply with the standards as agreed to by the diesel engine manufacturers and the diesel fuel injection equipment manufacturers or bio diesel fuels that have degraded as per the precautions and concerns above may affect the warranty coverage of your engine B6 To B20 Bio diesel Fuel Blend Usage B6 to B20 bio diesel is not approved for this engine application Approved Engines Only the Yanmar TNM engine series listed below may operate with bio diesel fuel concentrations up to B5 for Polaris applications NOTICE Do not exceed bio diesel fuel blend B5 for this Polaris application e 3TNM72 APL Approved Fuel NOTICE Raw pressed vegetable oils are not considered bio diesel and are unacceptable for use as fuel in any concentration in Yanmar engines Bio diesel fuel blends up to B5 must comply with the following standards e EN14214 European standard and or ASTM D 6751 American standard All applicable engines may operate with bio diesel fuel up to a maximum B5 596 bio diesel blend concentration 4 11 0 2009 Y anmar Co Ltd GENERAL SERVICE INFORMATION Operating Conditions with B5 Bio diesel Fuel Blends Engine Warranty Damages performance or service concerns determined to be caused by the use of bio diesel fuel not meeting the specifications outlined above are not considered to be defects in material or factory workmanship and are not covered under warranty The same applies
36. dust from fins and radiator with 28 psi 0 19 MPa 2 kgf cm or less of compressed air Figure 5 9 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 0000085A Figure 5 9 TNM Series Service Manual YANMAH 2009 Yanmar Co Ltd Periodic Maintenance Procedures Check and Adjust Cooling Pump V Belt Check and adjust the cooling pump V belt every 250 hours of operation after the initial 50 hour V belt maintenance See Check and Adjust Cooling Pump V Belt on page 5 7 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 NOTICE NEVER force the throttle cable or pedal to move This may deform the governor lever or stretch the cable and cause irregular operation of the engine speed control NOTICE Refer to Chapter 2 for throttle cable or linkage adjustment YANMAR TNM Series Service Manual PERIODIC MAINTE NANCE Replace Air Cleaner Element NOTICE When the engine is operated in dusty conditions clean the air cleaner element more frequently NOTICE NEVER operate the engine wi
37. groove replace the V belt i 1 2 0000584 5 5 Check the V belt for cracks oil or wear If any of these conditions exist replace the V belt NOTICE ALWAYS use the specified V belt Using a non specified V belt will cause inadequate charging and shorten the belt life Periodic Maintenance Procedures 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 Inspect the condition of the used V belt There must be clearance Figure 5 5 1 between the V belt and the bottom of the pulley groove If there is no clearance Figure 5 5 2 between the V belt and the bottom of the pulley groove replace the V belt Install the new V belt Refer to the table for proper tension New V Belt Tension A B 5 16 7 16 in 3 16 5 16 in 1 4 7 16 in 8 12 mm 5 8 mm 7 11 mm 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 A B 3 8 1 2 in 10 14 mm 1 4 3 8 in 7 10 mm 5 16 1 2 in 9 13 mm TNM Series Service Manual YANMAR 2009 Yanmar Co Ltd Periodic Maintenance Procedures Every 50 Hours of Operation After you complete the initia
38. in Removing the 0 05 0 15 mm 0 25 mm Camshafton page 6 37 End Play Bend O 0 0008 in 0 0020 in 0 0 02 mm 0 05 mm Cam Lobe Height 1 2100 1 2152 in 1 3596 1 3648 in 1 2287 in 1 3499 in 9 30 735 30 865 mm 34 535 34 665 mm 31 21 mm 34 287 mm inside Diameter 1 4173 1 4183 in 1 5748 1 5758 in 1 5807 in 1 5787 in 36 000 36 025 mm 40 000 40 025 mm 40 150 mm 40 100 mm Gear Camshaft 1 4150 1 4157 in 1 5724 1 5732 in 1 4138 in 1 5711 in End Outside Diameter 35 940 35 960 mm 39 940 39 960 mm 35 911 mm 39 906 mm Oil Clearance 0 0016 0 0033 in 0 0061 in 0 04 0 085 mm 0 154 mm See Shaft Inside Diameter 14173 1 4183 1 5748 1 5758 in 1 4210 in 1 5787 in 7 Outside 36 000 36 025 mm 40 000 40 025 mm 36 093 mm 40 100 mm Diameter Interme Camshaft 1 4138 1 4148 in 1 5713 1 5722 in 1 4126 in 1 5699 in page 6 47 Bearing diate Outside Diameter 35 910 35 935 mm 39 910 39 935 mm 35 881mm 39 875 mm p 0 0026 0 0045 in 0 0089 in 0 065 0 115 0 225 inside Diarmet r 1 4173 1 4183 in 1 5748 1 5758 in 1 4209 in 1 5787 in 36 000 36 025 mm 40 000 40 025 mm 36 092 mm 40 100 mm Flywheel Camshaft 1 4150 1 4157 in 1 5724 1 5732 in 1 4138 in 1 5711 in End Outside Diameter 35 940 35 960 mm 39 940 39 960 mm
39. of Engine Figure 6 94 Series Service Manual 6 55 2010 Yanmar Co Ltd 2 Lubricate the camshaft Figure 6 96 2 with clean engine oil or assembly lube Slowly insert the camshaft through the front of the engine Install and tighten the capscrews Figure 6 96 3 Figure 6 96 Lubricate the camshaft lobes and tappets with clean oil or assembly lube Install the tappets in their respective locations in the cylinder block Push the tappets fully into the tappet bores until they make solid contact with the camshaft If removed install the fuel injection pump Adjust the fuel injection timing after installation See Checking and Adjusting Fuel Injection Timing on page 7 17 6 56 Cylinder Block Installing the Timing Gears Set No piston to top dead center Rotate the camshaft until mark Figure 6 98 B is approximately at the 8 o clock position Lubricate the idler gear Figure 6 97 3 bushing Figure 6 97 2 and idler gear shaft Figure 6 97 1 with clean engine oil or assembly lube Figure 6 97 Align the timing gears as shown in Figure 6 98 Install the idler gear and idler gear shaft Be sure the oil hole in the bushing is facing toward the top of the engine Ensure all three timing marks Figure 6 98 A B and C are aligned TNM Series Service Manual 6 2010 Co Lt
40. on page 6 38 or Removing the Crankshaft on page 6 40 for specific information TNM Series Service Manual Ea Pad Fatin 2010 Yanmar Co Ltd Cylinder Block Inspecting the Cylinder Block 1 Ensure that oil passages are clear and unobstructed 2 Check for discoloration or evidence of cracks If a fracture is suspected use the color check method or the MAGNAFLUX method to determine if the cylinder block is fractured 3 Measure cylinders for roundness and taper and inspect for evidence of scoring Consider honing re boring or replacing the cylinder block if the measurements are not within specification Take measurements at three places Figure 6 60 a b and c and in two directions d and e in each cylinder Collect and record the measurements See Cylinder Block on page 6 10 for specifications TEER T VON 0000230 00 6 60 Roundness Roundness can be calculated by subtracting the smaller measured value from the larger measured value of d or e at each measuring location a b and c Taper Taper can be calculated by subtracting the minimum measured value from the maximum measured value of locations a b and c Calculate along both the d axis and e axis and use the larger of the two calculations as the value to compare to the specifications es 2151 TNM Series Service Manual ENGINE
41. pressure fuel injection lines from the retainers or bending any of the fuel lines will make it difficult to install the fuel lines 2010 Yanmar Co Ltd Cylinder Head Removing the Intake Manifold Valve Cover 1 Remove the intake manifold bolts Figure 6 2 1 and valve cover bolts Figure 6 2 2 2 Remove the valve cover intake manifold Figure 6 2 3 Discard gasket Figure 6 2 4 Figure 6 3 Removing the Rocker Arm Assembly 1 Remove the bolts Figure 6 4 1 that retain the rocker arm shaft supports 2 Remove the rocker arm shaft assembly from the cylinder head NOTICE Identify the push rods so they can be installed in their original locations 3 Remove the push rods identify for Figure 6 2 installation 3 Remove the exhaust manifold bolts Figure 6 2 5 and nuts Figure 6 2 6 Remove the exhaust manifold Figure 6 2 7 and the exhaust manifold gasket Figure 6 2 8 Removing the Glow Plugs The glow plugs must be removed from the cylinder head before the cylinder head is removed to prevent damage to the tips of the glow plugs 1 Disconnect the glow plug harness Figure 6 3 2 from the glow plugs Figure 6 3 1 2 Remove the glow plugs from the cylinder head 026969 00X Figure 6 4 6 18 TNM Series Service Manual 4 NM 2010 Yanmar Co Ltd Cylinder Head ENGINE Disassembling the
42. skin or eyes Severe burns will 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 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 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 atthe end of the day Store the battery in a warm place until the next use This will help startthe engine easily atlow ambient temperatures NOTICE Do not reverse the positive and negative ends of the battery cable The alternator diode and stator coil will be damaged 5 10 Periodic Maintenance Procedures Conventional Battery Level Check NOTICE 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 This information is provided in the event the OEM supplied low maintenance battery was replaced with a conventional lead acid battery When the amount of fluid nears the lower limit Figure 5 7 1 fill with distilled water Figure 5 7 2 so it is at
43. the diaphragm opens a passage that allows crankcase fumes to be routed to the intake manifold 026965 00X Figure 5 17 To inspect the diaphragm and spring Figure 5 17 3 1 Remove the bolts retaining the diaphragm cover Figure 5 17 4 2 Remove the diaphragm cover spring diaphragm plate Figure 5 17 5 and diaphragm 3 Inspectthe diaphragm for tears Inspect the spring for distortion Replace components if necessary 2009 Yanmar Co Ltd PERIODIC MAINTENANCE 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 24 NOTICE Failure ofthe 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 5 20 Periodic Maintenance Procedures 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 Regularly check the fuel system and engine coolant system hoses If they are cracked or degraded
44. the oil drain plug Figure 5 2 1 and tighten to 25 ft lb 33 8 N m TNM Series Service Manual YANMAH 2009 Yanmar Co Ltd Periodic Maintenance Procedures 8 Dispose of used oil properly NOTICE 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 Remove the engine oil filter as follows 1 Turn the engine oil filter Figure 5 2 2 counterclockwise Figure 5 2 3 using a filter wrench 0006465 Figure 5 2 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 to 17 ft Ib 19 6 to 23 5 2 0 to 2 4 kgf m or one additional turn using the filter wrench TNM Series Service Manual PERIODIC MAINTENANCE 4 Add new engine oil to the engine as specified in Adding Engine Oil on page 4 15 NOTICE NEVER overfill the engine with engine oil ALWAYS keep the oil level between the upper and lower lines on the oil cap dipstick Check and Adjust Cooling Pump V Bel
45. the upper limit Figure 5 7 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 0000067A Figure 5 7 Conventional Lead Acid Battery TNM Series Service Manual YANMAH 0 2009 Y anmar Co Ltd Periodic Maintenance Procedures PERIODIC MAINTENANCE At 50 Hours of Operation Break in Every 150 Hours of Operation Perform the following break in maintenance at 50 Perform the following maintenance every 150 hours hours of operation of operation Replace Engine Oil and Engine Filter Check and Adjust Cooling Pump V Belt Drain Fuel Filter Water Separator Element Check and Clean Radiator Fins Every 100 Hours of Operation Perform the following maintenance every 100 hours of operation Check and Clean Radiator Fins Check and Adjust Cooling Pump V Belt Replace Air Cleaner Element Replace Fuel Filter Water Separator Element Replace Engine Oil and Engine Filter Drain Fuel Filter Water Separator Element Check and Clean Radiator Fins YANMAR TNM Series Service Manual 5 11 2009 Yanmar Co Ltd PERIODIC MAINTENANCE Replace Engine Oil and Engine Oil Filter 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 NOTICE Only use the engine oil spe
46. to damages or other concerns induced by not complying with the recommended operating conditions of Yanmar engines with bio diesel fuel 4 12 Diesel Fuel Filling the Fuel Tank WARNING Fire and Explosion Hazard Diesel fuel is flammable and explosive under certain conditions NEVER refuel with the engine running Only fill the fuel tank with diesel fuel Filling the fuel tank with gasoline may result in a fire and will damage the engine Wipe up all spills immediately Keep sparks open flames or any other form of ignition match cigarette static electricity source well away when refueling NEVER remove the fuel cap while the engine is running NEVER overfill the fuel tank TNM Series Service Manual YANMAH 0 2009 Y anmar Co Ltd Diesel Fuel ALWAYS put 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 Store any containers containing fuel in a well ventilated area away from any combustibles or source of ignition 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 NOTICE Replace rubberized fuel hoses every 2 years or every 2000 hours of engine operation whichever
47. will seat properly After the cylinder has been bored and honed install the appropriate oversize pistons and piston rings Honing Minor cylinder imperfections may be corrected by using a rigid cylinder hone Figure 6 79 1 Be sure not to exceed the maximum cylinder bore specification Deglazing A used cylinder that did not require boring or honing should always be deglazed with a ball hone Figure 6 79 2 before installing new piston rings This will properly prepare the cylinder surface to allow new piston rings to seat properly When honing a cylinder with either a ridged hone or a ball hone Figure 6 78 1 move the rotating hone up and down in the cylinder bore to accomplish a 30 to 40 crosshatch pattern Figure 6 78 This will provide the ideal surface for the proper seating of new piston rings 8m amp zm d pe pss y E i Yd TNM Series Service Manual 2010 Yanmar Co Ltd Cylinder Block 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 s C MN NA YY Figure 6 78 Use a 50 50 mixture of diesel fuel and engine oil as a honing fluid Use a 300 grit hone at 300 to 1200 rpm min Figure 6 79 K0000249B 00X Figure 6 79 When honing is completed wash the cylinder block with hot water and soap
48. 10 Yanmar Co Ltd Cylinder Block Disassembling the Crankshaft and Piston Components Mark the connecting rod caps and connecting Removing the Pistons rods so the caps and connecting rods stay together Keep the piston pin parts piston assemblies and 2 Remove the bearing cap Do not remove the connecting rod assemblies together to be bearing inserts at this time returned to the same position during the 3 Wipe oil from the bearing insert and crankshaft assembly process Label the parts using an journal surfaces appropriate method 4 Place a piece of PLASTIGAGE Engines with high operating hours may Figure 6 48 1 along the full width of the ridge near the top of the cylinders that will catch bearing insert the piston rings and make it impossible to remove the pistons Use a suitable ridge reamer to remove ridges and carbon prior to removing the 22 pistons 1 Pistons can fall from the cylinder block if the d engine is inverted Rotate the engine so the connecting rods are horizontal before removing the connecting rod caps Nurse 122 Figure 6 48 1 Using a feeler gauge measure the connecting rod side clearance Figure 6 47 See Connecting Rod on page 6 9 for the standard limit If the measurement is of specification Do not rotate crankshaft when using replace the crankshaft connecting rod or both PLASTIGAGE A false reading may result 5 Install the bear
49. 2nd time and after Drain Flush and Refill Cooling System with New or Coolant every 2 yr which ever comes first Cylinder Adjust Intake Exhaust Valve Clearance e Head Lap Intake Exhaust Valve Seats if required Electrical Check Indicators Equipment Check Battery Engine Oil Check Engine Oil Level Drain and Fill Engine Oil Olst o Replace Engine Oil Filter Emission Inspect Clean and TestFuel Injectors if necessary e Control Inspect Crankcase Breather S ystem e Warranty Fuel Check and Refill Fuel Tank Level Drain Fuel Filter Water Separator Check Fuel Filter Water Separator Inspect Fuel Filter Water Separator Lines F ittings Replace Fuel Filter Water Separator Hoses Replace Fuel System and Cooling System Hoses or every 2 yrs Intake and Clean or Replace Air Cleaner Element o Exhaust Complete Overall Visual Check Daily Engine Note These procedures are considered normal maintenance and are performed at the owner s expense YANMAH TNM Series Service Manual 5 5 2009 Yanmar Co Ltd PERIODIC MAINTENANCE 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 Pump V Belt Replace Engine Oil and Engine Oil Filter WARNING Burn Hazard If you must drain the engine oil while it is still
50. 4 0 5 0 kgf m 36 43 ft lb 49 0 58 8 N m 5 0 6 0 Note Torque values shown in this manual are for clean non lubricated fasteners unless otherwise specified YANMAH TNM Series Service Manual 4 25 2009 Yanmar Co Ltd GENERAL SERVICE INFORMATION ABBREVIATIONS AND SYMBOLS Abbreviations A ampere AC alternating current ACEA Association des Constructeurs Europ ens d Automobilies Ah ampere hour API American Petroleum Institute ARB Air Resources Board ATDC after top dead center BTDC before top dead center Celsius CARB California Air Resources Board CCA cold cranking amp cm centimeter cm cubic centimeter 3 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 Ib foot pound ft Ibf min foot pound force per minute g gram gal gallon U S gal hr gallon U S per hour GL gear lubricant hp horsepower metric hrs hours inside diameter IDI indirect injection in inch in Aq inches of water in Hg inches of mercury in Ib inch pound JASO Japanese Automobile Standards Organization kg kilogram kgf cm kilogram force per square centimeter kgf cm kilogram force centimeter kgf m kilogram force meter km kilome
51. Coolant Altemative Engine Coolant ONLY use an ethylene glycol or propylene glycol based conventional coolant NOTICE ALWAYS use a mix of coolant and water NEVEH use water only Mix coolant and water per the mixing instructions on the coolant container Water quality is important to coolant performance Yanmar recommends that soft distilled or demineralized water be used to mix with coolants NEVER mix Extended or Long Life Coolants and conventional green coolants NEVER mix different types and or colors of extended life coolants Replace the coolant every 2000 engine hours or once every two 2 years which ever comes first YANMAH TNM Series Service Manual GENERAL SERVICE INFORMATION 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 WARNING Burn Hazard Wait until the engine cools before you drain the engine coolant Hot engine coolant may splash and burn you 0000029A Figure 4 7 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 installed 0 6 AN 1 0006464 Figure 4 8 4 17 2009 Yanmar Co Ltd GE
52. Figure 4 2 1 and engine nameplate Figure 4 2 2 labels on Yanmar TNM series engines In addition to the engine nameplate the engine model and serial numbers are stamped on flat pads on the left side of the crankcase 1 2 0006459 Figure 4 2 Engine Nameplate Typical MODEL DISPLACEMENT ENGINE NO YANMAR CO LTD Q MADE IN JAPAN Q 0003852 4 4 Location of Labels EPA CARB EMISSION CONTROL REGULATIONS USA ONLY Yanmar TNM engines meet Environmental Protection Agency EPA U S Federal emission control standards as well as the California Air Resources Board CARB regulations Only engines that conform to CARB regulations can be sold in the State of California TNM Series Service Manual YANMAR 2009 Yanmar Co Ltd Emission Control Labels EMISSION CONTROL LABELS Since emission control regulations are being issued on a global basis it is necessary to identify with which regulations a particular engine complies We have listed several different types of labels you might find on your engine EPA ARB Labels Typical EMISSION CONTROL INFORMATION THIS ENGINE COMPLIES WITH U S EPA REGULATIONS FOR 7 M Y ONROAD DIESEL ENGINES LOW SULFUR FUEL OR ULTRA LOW SULFUR FUEL ONLY ENGINE FAMILY DISPLACEMENT T LITERS ENGINE MODEL EMISSION CONTROL SYSTEM L FUEL RATE IMe STROKE GL IM C RPM R A
53. Head Assembling the Intake Manifold Valve Cover 1 Install the glow plugs Figure 6 33 1 and tighten to specification Install the electrical harness Figure 6 33 2 Be Figure 6 33 2 Lightly grease a new valve cover gasket Figure 6 34 4 Place the gasket in the groove of the intake manifold valve cover Figure 6 34 3 3 Place the intake manifold valve cover on the cylinder head 4 nstall and tighten bolts Figure 6 34 1 and 2 securely lalai 21251 Series Service Manual ENGINE Figure 6 34 Install the exhaust manifold using a new gasket Figure 6 34 8 Tighten the bolts and nuts Figure 6 34 5 and 6 securely Install the fuel injectors See nstalling the Fuel Injectors on page 7 26 Install the high pressure and return fuel injection lines See nstalling the Fuel Injectors on page 7 26 Install the coolant pump See Assembling the Engine Coolant Pump on page 8 8 Install the alternator See nstalling the Alternator on page 11 14 2010 Yanmar Co Ltd Measuring Adjusting Valve Clearance Measure and adjust while the engine is cold The No 1 piston position is on the flywheel end of the engine opposite end of the radiator The firing order is 1 3 2 Engines fire every 240 of crankshaft rotation Valve clearance of both the intake and exhaust valves can be checked with the piston for that
54. Ltd Cylinder Head 4 Install all the valves Figure 6 28 6 in their proper location in the cylinder head 026972 00X Figure 6 28 Put the cylinder head on the work bench with the combustion side down to install the valve springs Install the valve spring Figure 6 28 4 and spring retainer Figure 6 28 5 Using a valve spring compressor tool compress the valve spring Insert the valve keeper Figure 6 28 2 and slowly release the tension in the valve spring Install the valve cap Figure 6 28 1 Repeat steps on all remaining valves Assembling the Cylinder Head 1 Carefully clean both the combustion surface of the cylinder head and the top surface of the cylinder block Install a new cylinder head gasket Figure 6 29 2 on the cylinder block Position the cylinder head on the cylinder head gasket NUI CM 1 Series Service Manual ENGINE ES UO s NS QC FO 6 29 3 Lightly oil the threads of the cylinder head bolts Figure 6 29 1 Tighten the bolts to the specified torque shown in the chart below Tighten in the sequence shown in Figure 6 30 See Tightening Torque for Special Bolts on page 6 11 Ta oi inalog Second Step 1 Cooling Fan End 2 Camshaft Side Figure 6 30 4 Insert the push rods in their respective positions 2010 Yanmar Co Ltd Assembling th
55. Ltd SAFETY The safety messages that follow have WARNING level hazards Fire and Explosion Hazard Diesel fuel is flammable and explosive under certain conditions Refer to Chapter 3 for fuel safety information Before you operate the engine check for fuel leaks If the unithas an electric fuel feed 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 feed pump to prime the system Only use the key switch to start the engine NEVER jump start the engine S parks caused by shorting the battery to the starter terminals may cause a fire or explosion NEVER use a shop rag to catch diesel fuel Vapors from the rag are flammable and explosive Wipe up any spills immediately NEVER use diesel fuel as a cleaning agent 3 4 Safety Precautions Entanglement Sever Hazard ALWAYS tie back long hair at 13 and keep hands and other 47 body parts away from moving rotating parts such as the cooling fan flywheel or PTO shaft ALWAY S wear tight fitting clothing and keep your hair short or tie it back while the engine is running ALWAY S remove all jewelry before you operate or service the engine NEVER startthe 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 startthe engine make sure that all bystanders ar
56. NERAL SERVICE INFORMATION 2 Clean all dirt and debris surrounding the radiator cap NOTICE Prevent dirt and debris from contaminating the engine coolant Carefully clean the radiator cap and surrounding area before you remove the cap Remove the radiator cap Figure 4 7 2 by turning it counterclockwise about 1 3 of a turn WARNING Scald Hazard NEVER remove the radiator cap if the engine is hot Steam and hot engine coolant will spray out and seriously burn you Allow the engine to cool down before you attempt to remove the radiator cap Pour the engine coolant s owly into the radiator until itis even with the lip of the engine coolant filler port Make sure that air bubbles do not develop as you fill the radiator 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 WARNING Scald Hazard ALWAYS tighten the radiator cap securely after you check the radiator Steam can spray out during engine operation if the cap is loose Remove the cap of the reserve tank Figure 4 7 3 and fill itto the LOW COLD mark Figure 4 7 4 with engine coolant Reinstall the cap 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 wi
57. NEVER use a shop rag to catch the fuel Vapors from the rag are flammable and explosive Wipe up any spills immediately NOTICE Wear eye protection The fuel system is under pressure and fuel could spray out when you remove any fuel system component NOTICE NEVER use diesel fuel as a cleaning agent Periodic Maintenance Procedures NOTICE 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 TNM Series Service Manual YANMAH 2009 Yanmar Co Ltd Periodic Maintenance Procedures Every 1000 Hours of Operation 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 WARNING Scald Hazard ALWAYS check the level of engine coolant by observing the reserve tank WARNING Burn Hazard Wait until the engine cools before you drain the engine coolant Hot engine coolant may splash and burn you YANMAH TNM Series Service Manual PERIODIC MAINTENANCE CAUTION Exposure Hazard ALWAYS wear eye protection and rubber gloves w
58. Removing Installing Valve Springs Yanmar Part No 129100 92630 6 12 2010 Yanmar Co Ltd Allowance d1 Allowance d2 0 0118 to 0 0236 in 0 3 to 0 6 mm 010931 00X TNM Series Service Manual B ss Pad Fatin Special Service Tools ENGINE No ToolName Applicable Model and Tool Size Ge pom omes ome Troie L1 12 0 591 in 0 827 in 0 472 in 0 433 in 2 559 in 1 15 mm 21 mm 12 11 mm 65 mm nore Allowance d1 0 00787 in 0 2 mm L1 0 00393 in 0 1 mm Locally Manufactured Stem Seal Tool For Installing Stem Seals 001422 00 Flex Hone 129400 92410 2 756 2 992 in For Preparing 70 76 mm Cylinder Walls 010930 00X Piston Ring Compressor For Installing Pistons Yanmar Part No 955500 02476 The Piston Insertion Tool is Applicable for 2 362 4 921 in 60 125 mm Diameter Pistons Piston Ring Tool For Removing Installing Piston Rings Available Locally 215 Series Service Manual 6 13 2010 Yanmar Co Ltd E 3 MEASURING INSTRUMENTS mo isrann Name Dial Indicator Available Locally Test Indicator Available Locally Magnetic Stand Available Locally Micrometer Available Locally Cylinder Bore Gauge Available Locally Calipers Available Locally Depth Micrometer Available L
59. Safety section on page 3 1 INTRODUCTION This section of the Service Manual describes the procedures for proper care and maintenance of the engine 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 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 YANMAH TNM Series Service Manual PERIODIC MAINTENANCE Required EPA ARB Maintenance USA Only To maintain optimum engine performance and compliance with the Environmental P rotection Agency EPA Regulations Non road Engines and the California Air Resources Board ARB California itis essential that you follow the Periodic Maintenance Schedule on page 5 4 and Periodic Maintenance Procedures on page 5 6 5 3 2009 Yanmar Co Ltd PERIODIC MAINTENANCE 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 inte
60. aining on the engine 7 Drain the engine oil into a suitable container Remove oil filter 8 Remove the cylinder head See Disassembling the Cylinder Head on page 6 17 9 Remove the fuel injection pump from the gear case only if it must be sent out for repair or will interfere with other procedures such as hot tank cleaning See Hemoving the Fuel Injection Pump on page 7 12 10 Remove the starter motor See Removing the Starter Motor on page 10 8 Disassembling the Camshaft and Timing Components Discard all gaskets O rings and seals Use new gaskets O rings and seals on assembling the camshaft and timing components Removing the Timing Gear Case Cover 1 Remove the bolt and washer retaining the crankshaft pulley NOTICE Use care notto damage the threads in the end of the crankshaft when removing the crankshaft pulley 2 Remove the crankshaft pulley with a gear puller 3 Remove the bolts that retain the gear case cover to the cylinder block and oil pan 4 Remove the gear case cover Figure 6 38 1 5 Remove the dowel pins Figure 6 38 2 Cylinder Block Figure 6 38 Checking Timing Gear Backlash Prior to removing the timing gears measure the gear backlash and determine the gear wear Check the backlash between each pair of mating gears If not within specification replace both mating gears Do not allow the gear being checked to move axially as excess end play cou
61. ance 0 0008 0 0023 0 0043 in 0 020 0 058 mm 0 110 mm 6 6 TNM Series Service Manual B 24 2010 Yanmar Co Ltd Crankshaft and Piston Specifications ENGINE Crankshaft Cont Inspection Item 3TNM68 3TNM72 3TNM68 3TNM72 Page Journal Outside 1 7311 1 7315 in 1 7293 in Diameter 43 970 43 980 mm 43 924 mm Bearing Inside 1 7328 1 7338 in See Main Bearing Diameter 44 014 44 038 mm i cq e Journal Bearing Insert 0 0786 0 0791 in Crankshaft Thickness 1 996 2 008 mm on page 6 46 Oil Clearance 0 0013 0 0027 in 0 0047 in 0 034 0 068 mm 0 120 mm Crankshaft Reconditioning 2 1 4853 1 4857 in Connecting Rod Journal Undersize Finished Size 87 726 37 736 mm 3 zm 1 7219 1 7223 in Main Bearing Journal Undersize Finished Size See 43 736 43 746 mm Heconditioning Journal Radius 0 138 0 150 in the Crankshaft 3 5 3 8 mm on page 6 47 Journal Face Finish 0 8S Super Polish Thrust Face Finish Thrust Bearing nspection P 3TNM68 3TNM72 3TNM68 3TNM72 Page 0 0044 0 0098 in 0 0110 in See Crankshaft End Play All Models 0 111 0 250 mm 0 28 mm Removing the Bearing Thickness dos 12 n Crankshaft 1 930 1 980 mm 1 850 mm on page 6 40 PUDE Series Service Manual 6 7 2010 Yanmar Co Ltd Crankshaft and Piston Specifications
62. ankshaft 0 6 7 Thrust Beatilig austro feni exe ci need PE DR 6 7 PISTON EE D EMI ON RR UR IRR 6 8 PISTON C 6 8 ROA DP 6 9 MAD POT S 6 9 Cylinder Block 6 10 Cylinder BlOGK fusi ti 6 10 Special Torque 6 11 Tightening Torque for Special Bolts 6 11 Special Service Tools e 6 12 Measuring Instruments eese 6 14 21251 Series Service Manual 2010 Yanmar Co Ltd 6 1 Cylinder Head E 6 16 Cylinder Head Components 444 2422 2 6 16 Disassembling the Cylinder 6 17 Cleaning the Cylinder Head Components 6 21 Inspecting the Cylinder Head Components 6 21 Assembling the Cylinder 0 6 25 Measuring and Adjusting Valve Clearance 6 30 Cylinder BlOGK dem 6 32 Crankshaft and Camshaft Components 6 32 Disassembling the Cylinder Block Components 6 33 Disassembling the Camshaft and Timing Components 6 34 Disassembling the Crankshaft and
63. ankshaft on page 6 6 Standard Less than 0 001 in 0 03 mm 68 3TNM72 3TNM68 3TNM72 Tappet Bore Block Inside Diameter 0 7087 0 7094 in 0 8268 0 8276 in 0 7102 in 0 8284 in PP 18 000 18 018 mm 21 000 21 021 mm 18 038 mm 21 041 mm Toga 0 7067 0 7074 in 0 8239 0 8252 0 7059 0 8231 in 17 950 17 968 mm 20 927 20 960 mm 17 930mm 20 907 mm 0 0013 0 0027 in 0 0016 0 0037 in 0 0043 in 0 0053 in 0 032 0 068 mm 0 040 0 094 mm 0 108 mm 0 134 mm a E TNM Series Service Manual owe 2010 Yanmar Co Ltd ENGINE 3TNM68 3TNM72 3TNM68 3TNM72 Wrist Pin Bushing Inside Diameter ioe toe 0867 TE O Page See Inspecting the Connecting Rod on page 6 45 Reference 3TNM68 3TNM72 3TNM68 3TNM72 Side Clearance 0 0079 0 0157 in 0 20 0 40 mm Page See Inspecting the Connecting Rod on page 6 45 Reference Page Inspecting the Connecting Rod page 6 45 3TNM68 3TNM72 3TNM68 3TNM72 Page See Inspecting the Tappets on page 6 46 6 9 Cylinder Block Specifications CYLINDER BLOCK SPECIFICATIONS Cylinder Block Inspection Item 3TNM68 3TNM72 3TNM68 3TNM72 Page Inside Bore 2 6772 2 6783 in 2 8346 2 8358 in 2 6850 in 2 8425 in See y 68 000 68 030 mm 72 000 72 030
64. cified Other engine oils may affect warranty coverage cause internal engine components to seize or shorten engine life NOTICE NEVER mix different types of engine oil This may adversely affect the lubricating properties of the engine oil NOTICE Prevent dirt and debris from contaminating the engine oil Carefully clean the oil cap dipstick and the surrounding area before you remove the cap NOTICE NEVER overfill Overfilling may result in white exhaust smoke engine overspeed or internal damage Change the engine oil every 100 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 6 5 12 Periodic Maintenance Procedures Check and Clean Radiator Fins 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 NOTICE 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 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 9 for illustrative purposes only Blow off dirt and
65. d Cylinder Block ENGINE Install the dowels Figure 6 99 2 Install the timing gear case cover Install and tighten the gear case cover bolts Install the crankshaft pulley Install the washer and bolt Tighten to the specified torque See Special Torque Chart on page 6 11 for specifications o gr Bmw Installing the Oil Pan 1 Install the oil pickup tube Figure 6 100 1 and a new O ring Figure 6 100 2 1 Fuel Injection Pump Gear 2 Camshaft Gear 3 Crankshaft Gear 4 lIdler Gear 5 Oil Pump Gear Figure 6 98 7 When all gears are properly aligned tighten the idler gear retaining bolts to specified torque See Special Torque Chart on page 6 11 for specifications Installing the Gear Case Cover 1 Apply a continuous bead of ThreeBond Liquid Gasket No 1212 Yanmar Part No Figure 6 100 977770 01212 to the mounting area of the UNE gear case cover Figure 6 99 1 Be sure to Apply a continuous bead of ThreeBond Liquid circle the bolt holes Gasket 1212 Yanmar Part No 977770 01212 to the mounting surface of the oil pan Figure 6 101 2 and crankcase extension if equipped Figure 6 101 1 Be sure to circle each bolt hole 027273 00 N 3 If equipped install the crankcase extension Install the oil pan and tighten the bolts securely Figure 6 99 L lalat I Series Service Manual 6 57 2010 Yanmar Co Ltd
66. d sealant removers 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 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 Thoroughly clean all components using a brush and appropriate solvent Each part must be free of carbon gasket material metal filings and other debris NOTICE Record all measurements taken during inspection Replacing the Crankshaft Oil Seals 1 Remove the seal Figure 6 58 2 from the gear case cover Figure 6 58 1 2 Install a new seal in the gear case cover with the lip facing in away from the crankshaft pulley Apply lithium grease to the lip of the seal 6 42 Cylinder Block Figure 6 58 3 Remove the rear oil seal Figure 6 59 1 from the flywheel housing Figure 6 59 2 Figure 6 59 4 Install a new seal in the flywheel housing with the lip facing in away from the flywheel Apply lithium grease to the lip of the seal Measuring Crankshaft Bearing Oil Clearance Oil clearance should be checked during disassembly to determine the extent of wear and during assembly to ensure long engine life The same procedure is done for both connecting rods and main bearings See Removing the Pistons
67. e Hazard Wear eye protection The fuel system is under pressure and fuel could spray out when you remove any fuel system component Replace the fuel filter water separator at specified intervals to prevent contaminants from adversely affecting the diesel fuel flow 1 Stop the engine and allow itto cool 2 Position an approved container under the fuel filter water separator Figure 5 13 1 to collect the contaminants Polaris 2010 Figure 5 13 3 Open the drain petcock Figure 5 13 2 Allow filter separator draining 4 Close the drain petcock Figure 5 13 2 once filter separator draining is complete 5 Pourthe fuel into an approved container and dispose properly Hold the bottom of the cup with a shop towel to prevent fuel from dripping Wipe up any spills immediately 6 Remove the filter element Figure 5 13 3 by turning it counter clockwise as viewed from the bottom 7 Replace the element with a new one by threading it onto the assembly Turn the filter an additional 1 2 to 3 4 turn after gasket contact with the sealing surface 2009 Yanmar Co Ltd PERIODIC MAINTENANCE Fuel Safety Reminders WARNING Fire and Explosion Hazard Diesel fuel is flammable and explosive under certain conditions NOTICE When you remove any fuel system component to perform maintenance such as changing the fuel filter put an approved container under the opening to catch the fuel NOTICE
68. e Manual YANMAH 2009 Yanmar Co Ltd Engine Oil Additional Technical E ngine oil Requirements The engine oil must be changed when the Total Base Number TBN has been reduced to 1 0 mgKOH g test method IS K 201 5 2 2 ASTM D4739 HCI Engine Oil Viscosity S electthe appropriate engine oil viscosity based on the ambient temperature and use the SAE Service Grade Viscosity Chart in Figure 4 5 25 45 F 486F 104 31 C 15 C 30 40 C 0000005P Figure 4 5 Checking Engine Oil 1 Make sure engine is level 2 Remove dipstick Figure 4 6 1 and wipe with clean cloth NOTICE Prevent dirt and debris from contaminating the engine oil Carefully clean the oil cap dipstick and the surrounding area before you remove the cap 3 Fully reinsert dipstick Remove dipstick The oil level should be between upper Figure 4 6 2 and lower Figure 4 6 3 lines on the dipstick NOTICE ALWAYS keep the oil level between the upper and lower lines on the dipstick 5 Fully reinsert dipstick NOTICE NEVER overfill Overfilling may result in white exhaust smoke engine overspeed or internal damage YANMAH TNM Series Service Manual GENERAL SERVICE INFORMATION 0006463 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 atthe top or side engine oil filler port Figure 4 6 5
69. e Rocker Arm Assembly K0001914 00X Figure 6 31 Ensure the lubrication holes in the rocker arm shaft Figure 6 31 1 are oriented correctly with respect to the rocker arms Figure 6 31 2 The hole in the shaft for the setscrew must be installed to the flywheel side 1 Lubricate the rocker arm shaft Slide the rocker arm supports Figure 6 32 5 springs Figure 6 32 4 and rocker arms Figure 6 32 1 onto the shaft 026970 00 6 32 6 28 Cylinder Head The rocker arm shaft fits tightly in the rocker arm supports Clamp the support in a padded vise Twist and push on the rocker arm shaft to install setscrew is located in the flywheel side support Align the hole in the rocker arm shaft Figure 6 32 7 and the hole in the rocker arm support Install the alignment setscrew Figure 6 32 6 Place the rocker arm shaft assembly onto the cylinder head If removed install the valve adjusting screws Figure 6 32 3 and lock nuts Figure 6 32 2 Align the push rods with their respective rocker arms Install and tighten the rocker arm shaft retaining bolts to the specified torque Tighten the rocker arm shaft alignment screw Adjust the valve clearance See Measuring and Adjusting Valve Clearance on page 6 30 TNM Series Service Manual Ea Pad Faltin 2010 Yanmar Co Ltd Cylinder
70. e and rotate to distribute bluing onto the valve face The contact pattern should be approximately centered on the valve face Figure 6 20 1 and even in width Figure 6 20 Also visually inspect the valve seat for even contact Light cutting can be performed using a hand operated cutter Figure 6 21 3 Cylinder Head Yo cane 150 40 e 2 Figure 6 21 Valve seat diameter can be adjusted by top grinding with a 150 stone to make the seat diameter smaller and bottom grinding using a 40 stone to make the seat diameter larger Once the seat location has been corrected grind and lap the seat angle Figure 6 21 1 to specification See Cylinder Head on page 6 3 for the service limit Grind the valve face and or valve seat only enough to return them to serviceable condition Grinding is needed if the valve and the valve seat do not contact correctly Check the valve recession after grinding If the valve or seat require grinding lap the valve after grinding Lap the valve face to the valve seat using a mixture of valve lapping compound and engine oil Be sure to thoroughly wash all parts to remove all grinding powder or compound Inspecting the Valve Springs Inspect the valve springs If damage or corrosion is seen or if measurements exceed the specified limits replace the springs Record the measurements Fractures Check for fractures on the inside and outside portions of the springs If th
71. e clear of the area Keep children and pets away while the engine is operating NEVER wear jewelry unbuttoned cuffs ties or loose fitting clothing when you are working near moving rotating parts such as the flywheel or PTO shaft Check before starting the engine that any tools or shop rags used during maintenance have been removed from the area 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 TNM Series Service Manual YANMAR 2009 Yanmar Co Ltd Safety Precautions Sudden Movement Hazard 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 NEVER engage the transmission or PTO at an elevated engine speed ALWAYS allow the engine to warm up for at least 5 minutes and allow the idle speed of the engine to return to normal before engaging the transmission or any PTOs Burn Hazard ALWAYS keep your hands and other gt body parts away from hot engine surfaces such as the muffler exhaust pipe 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 Seek immediate medical attention for burns NEVER operate the engine while wearing headset to listen to music or radio because it
72. e 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 n Europe bio diesel fuels must comply with the European Standard EN 14214 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 Precautions and concerns regarding the use of bio fuels 1 Free methanol FAME may result in corrosion of aluminum and zinc fuel injection components 2 Free water in FAME may result in plugging of fuel filters and increased bacterial growth 3 High viscosity atlow 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 YANMAR TNM Series Service Manual GENERAL SERVICE INFORMATION 6 The use of bio diesel fuels that
73. e valve spring is fractured replace the valve spring Corrosion Check for corrosion of spring material caused by oxidation m 2 R o RUN ES 7 BS ti e TNM Series Service Manual E 2010 Yanmar Co Ltd Cylinder Head ENGINE Squareness Use a flat surface and a square to check each spring for squareness Figure 6 22 See Valve Spring on page 6 4 for the service limit Free Length Use a caliper to measure the length of the spring Figure 6 23 See Valve Spring on page 6 4 for Assembling the Cylinder Head Use new gaskets O rings and seals for the assembling the cylinder head Liberally oil all components during assembly to prevent premature wear or damage Assembling the Valve Guides 1 The valve guides are installed into the cylinder head with an extremely tight press fit Before installing the valve guides place the valve Figure 6 22 guides in a freezer for at least 20 minutes This will cause the valve guides to contract making it easier to install the valve guides in place 2 Immediately after removing the valve guides K0000201 00X the service limit from the freezer insert the valve guides Figure 6 24 1 in their proper positions Figure 6 23 Figure 6 24 BE BU 21251 Series Service Manual 6 25 2010 Yanmar Co Ltd 3 Finish installing the valve guides Figure 6 25
74. ene used engine oil or residual fuels with the diesel fuel Water and sediment in the fuel should not exceed 0 0596 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 Fuel additives are not recommended Some fuel additives may cause poor engine performance Ash content not to exceed 0 0196 by volume Carbon residue content not to exceed 0 3596 by volume Less than 0 196 is preferred Total aromatics content should not exceed 3596 by volume Less than 30 is preferred PAH polycyclic aromatic hydrocarbons content should be below 1096 by volume Metal content of Na Mg Si and Al should be equal to or lower than 1 mass ppm Testanalysis method 55 44 95 Lubricity Wear mark of WS 1 4 should be Max 0 018 in 460 um at HFRR test TNM Series Service Manual YANMAH 0 2009 Y anmar Co Ltd Diesel Fuel 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 596 by volume of FAME with 95 by volume of approved mineral oil derived diesel fuel Such bio diesel fuels ar
75. eter of the wrist pin bore on both sides of the piston Figure 6 62 See Piston on page 6 8 for specifications Record the measurements K0000237 00X Figure 6 62 7 Measure the outside diameter of the wrist pin in three places and at 90 Figure 6 63 See Piston on page 6 8 for specifications Record the measurements QUES 0001889 00 6 63 8 Using micrometer measure the thickness of each piston ring See Piston Ring on page 6 8 for specifications Record the measurements Cylinder Block Onan engine with low hours the pistons piston rings and cylinders may be reused if they are found to be within specifications Onan engine with high hours the piston rings should be replaced and the cylinder honed see Honing and Boring on page 6 48 or replaced The piston should be replaced as necessary Place each compression piston ring in the groove as shown Figure 6 64 Use a feeler gauge to measure the clearance between the piston ring and the piston ring land Record the measurements See Piston Ring on page 6 8 for specifications Replace the piston if not within specification K0001892 00X Figure 6 64 Io measure piston ring end gap insert each compression piston ring Figure 6 65 1 one at a time into the cylinder Use a piston with the piston rings removed to slide the ring into the cylinder bore until it is approximately 1 18 in 30 mm Figure 6 65
76. gap Figure 6 11 See Push Hod on page 6 4 for the service limit K0000204 00X Figure 6 11 Inspecting the Rocker Arm Assembly Rocker Arm Shaft Hole Diameter Use a telescoping gauge and micrometer to measure the inside diameter of all the rocker arm support brackets and the rocker arms Figure 6 12 Record the measurements See Hocker Arm and Shaft on page 6 5 for the service limit Inspect contact areas Figure 6 12 1 for excessive wear or damage K0001916 00X Figure 6 12 2010 Yanmar Co Ltd Rocker Arm Shaft Outside Diameter Use a micrometer to measure rocker arm shaft diameter Measure at each rocker arm location in two directions 90 apart Figure 6 13 Record the measurements See Hocker Arm and Shaft on page 6 5 for the service limit Figure 6 13 Inspecting the Valve Guides Visually inspect the valve guides for distortions Scoring or other damage NOTICE Measure valve guides while they are installed in cylinder head Use a telescoping gauge and micrometer to measure the inside diameter of the valve guide Measure in three places and 90 apart Figure 6 14 Record the measurements See Intake Exhaust Valve and Guide on page 6 4 for the service limit Replace valve guides if not within specification 001869 00 ft Figure 6 14 Cylinder Head Inspecting the Cylinder Head Cylinder Head Distortion Put the cylinder
77. gure 6 85 10 Stagger the piston ring end gaps at 120 Cylinder Block K0000226A 00X 1 Top Compression Ring End Gap 2 Middle Compression Ring End Gap Oil Control Ring End Gap Figure 6 86 Installing the Crankshaft 1 If removed install the key and timing gear on crankshaft 2 Install new bearing inserts Figure 6 87 1 and thrust bearing Figure 6 87 2 in the cylinder block and main bearing caps Be sure the oil holes in the upper bearing shells align with the oil ports in the cylinder block Apply a liberal coat of clean engine oil to the bearings intervals Figure 6 86 1 2 and 3 Do not and crankshaft journals position the top piston ring end gap in line with the wrist pin 6 52 TNM Series Service Manual Ea Pad Faltin 2010 Yanmar Co Ltd Cylinder Block 027073 00 6 87 3 Install the thrust bearing side gap Install the thrust bearing on the flywheel side Theinstallation procedure is indicated as follows the same procedure for both sides a Install the thrust bearing without a tab to the cylinder block after the crankshaft assembly the crankshaft is omitted 027483 00X Figure 6 88 b Mount the thrust bearing with a tab and turn it 90 degrees counterclockwise lalai 21251 Series Service Manual ENGINE Figure 6 89 Install the upper main bearing thrust
78. haft 6 Rocker Arm Shaft Support 7 Adjuster Lock Nut 8 Valve Adjuster Screw 9 Rocker Arm 10 Circlip 11 Valve Cap 12 Keeper 13 Valve Spring Retainer 14 Valve Spring 15 Valve Stem Seal 16 Valve Guide 17 Cylinder Head 18 Exhaust Valve 19 Intake Valve 20 Cylinder Head Gasket 21 Push Rod 2 per cylinder 22 Glow Plug 23 Glow Plug Wiring Harness 24 Cylinder Head Bolt Tajal Series Service Manual ENGINE Disassembling the Cylinder Head Prepare a clean flat working surface on a work bench large enough to accommodate the cylinder head assembly Discard all gaskets O rings and seals Use new gaskets O rings and seals when assembling the cylinder head Identify all parts and their location using an appropriate method It is important that all parts are returned to the same position during the assembly process Record all measurements taken during disassembly 1 Drain coolant from engine into a suitable container See Draining Flushing and Refilling Cooling System with New Coolant on page 5 18 2 Remove the coolant pump See Disassembling the Engine Coolant Pump on page 8 6 3 Remove the high pressure fuel lines and fuel injectors from the cylinder head See Removing the Fuel Injectors on page 7 22 NOTICE Remove and install the high pressure fuel injection lines as an assembly whenever possible Disassembling the high
79. he appropriate service tool Be sure to align the oil holes Figure 6 80 Install one circlip Figure 6 80 5 into the piston Ensure the circlip is securely seated in the groove NOTICE The piston and connecting rod must be assembled with the correct orientation When correctly assembled the piston identification mark Figure 6 81 1 stamped into the top of the piston will be on the opposite side of the connecting rod as the match marks Figure 6 81 3 stamped into the connecting rod and connecting rod cap When installed in the cylinder the embossed mark Figure 6 81 2 cast into the beam of connecting rod will face the flywheel end of the engine Figure 6 81 6 50 TNM Series Service Manual c NM E ES 2010 Yanmar Co Ltd Cylinder Block 4 Place the connecting rod into the piston The match marks Figure 6 82 4 on the connecting rod and cap must be on the opposite side as the piston identification mark Figure 6 82 2 on the top of the piston i 1 1 Fuel Injection Pump Side of Engine 2 Piston Identification Mark 3 Embossed Mark on Connecting Rod 4 Connecting Rod and Cap Match Marks 5 Flywheel End of Engine 6 Camshaft Side of Engine Figure 6 82 5 Lubricate and install the wrist pin Figure 6 83 6 through the piston and connecting rod Install the second circlip Figure 6 83 5 and ensure i
80. head and returns the engine coolant to the radiator Radiator Radiator Cap The radiator acts as a heat exchanger As the engine coolant circulates through the cylinder block itabsorbs heat The heatin the engine coolant is dissipated in the radiator As the cooling fan circulates air through the radiator the heatis 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 Reserve Tank The reserve tank contains the overflow of engine coolant from the radiator If you need to add engine coolant to the system add it to the reserve tank not to the radiator Thermostat 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 ope
81. head flat and inverted combustion side up on the bench Use a straightedge and feeler gauge to measure cylinder head distortion Figure 6 15 Measure diagonally and along each side Record the measurements See Cylinder Head on page 6 3 for the service limit 0000192 00 6 15 If distortion exceeds the service limit resurface or replace the cylinder head NOTICE Remove only enough material to make the cylinder head flat Do not remove more than 0 008 in 0 20 mm or head will need to be replaced TNM Series Service Manual B ss Pad Faltin 2010 Yanmar Co Ltd Cylinder Head Inspecting the Intake and Exhaust Valves Visually inspect the intake and exhaust valves Replace any valves that are obviously discolored heavily pitted or otherwise damaged Valve Stem Diameter Use a micrometer to measure the valve stem diameter Measure the valve stem near the combustion end and near the opposite end Figure 6 16 1 Record the measurements See Intake Exhaust Valve and Guide on page 6 4 for the service limit Figure 6 16 Valve Stem Bend Place the valve stem on a flat inspection block or layout bed Roll the valve until a gap can be observed between a portion of the valve stem and the surface of the block or bed Use a feeler gauge to measure the gap Figure 6 17 Record the measurements See ntake Exhaust Valve and Guide on page 6 4 for the service limit
82. hen you handle coolant If contact with the eyes or skin should occur flush eyes and wash immediately with clean water NOTICE 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 NOTICE NEVER mix different types of engine coolant This may adversely affect the properties of the engine coolant Engine coolant contaminated with rust or scale reduces the cooling effect Drain flush and refill the cooling system with new coolant every 1000 hours or once a year whichever comes first 2009 Yanmar Co Ltd PERIODIC MAINTENANCE 1 Allow engine and coolant to cool WARNING Scald Hazard NEVER remove the radiator cap if the engine is hot Steam and hot engine coolant will spray out and seriously burn you Allow the engine to cool down before you attempt to remove the radiator cap Remove the radiator cap Figure 5 15 1 NOTICE Prevent dirt and debris from contaminating the engine coolant Carefully clean the radiator cap and surrounding area before you remove the cap Remove the drain plug or open the drain cock Figure 5 15 2 at the lower position of the radiator and drain the engine coolant 2 0000074A Figure 5 15 4 Drain the coolant from the engine block Remove the coolant drain plug Figure 5 16 1 from the engine block Periodic Maintenance Procedures 2
83. hot stay clear of the hot engine oil to avoid being burned NOTICE Only use the engine oil specified Other engine oils may affect warranty coverage cause internal engine components to seize or shorten engine life NOTICE NEVER mix different types of engine oil This may adversely affect the lubricating properties of the engine oil NOTICE Prevent dirt and debris from contaminating the engine oil Carefully clean the oil cap dipstick and the surrounding area before you remove the cap NOTICE NEVER overfill Overfiling may result in white exhaust smoke engine overspeed or internal damage 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 Startthe engine and bring it up to operating temperature 3 Stop the engine Periodic Maintenance Procedures Remove the oil filler cap Figure 5 1 1 to ventthe engine crankcase and allow the engine oil to drain more easily Position a container under the engine to collect waste oil 0006469 Figure 5 1 Remove the oil drain plug Figure 5 2 1 Allow oil to drain After all oil has been drained from the engine reinstall
84. ing cap and tighten to specification See Special Torque Chart on page 6 11 6 Remove the bearing cap 0000219 00 K0001899 00X Figure 6 47 Figure 6 49 6 38 TNM Series Service Manual P js NM E LIA 2010 Yanmar Co Ltd Cylinder Block ENGINE 7 Compare the width of the flattened 14 Remove the circlips Figure 6 50 5 from the PLASTIGAGE Figure 6 49 1 to the wrist pin graduation marks on the package The mark 15 Remove the wrist pin Figure 6 50 6 and that most closely matches the width of the oil clearance Record the measurements See Crankshaft on page 6 6 8 Hepeat with the remaining connecting rods disassembled Do not allow the connecting rod to contact the crankshaft journal during piston removal Damage to the bearing journal may result 9 Use a wooden dowel against the connecting rod and tap the piston connecting rod assembly out of the cylinder 10 Mark the cylinder number on the piston and connecting rod 11 Remove the bearing inserts Figure 6 50 2 12 Remove the compression rings Figure 6 50 3 from the piston using a piston ring expander 13 Remove the oil control ring Figure 6 50 4 from the piston using a piston ring expander 027272 00X Figure 6 50 connecting rod Figure 6 50 8 from the flattened PLASTIGAGE will indicate the bearing piston Figure 6 50 9 16 Repeat steps until all
85. ion which if not avoided will result in death or serious injury Indicates a hazardous situation which if not avoided could result in death or serious injury Indicates a hazardous situation which if not avoided could result in minor or moderate injury NOTICE Indicates a situation which can cause damage to the machine personal property and or the environment or cause the equipment to operate improperly YANMAR TNM Series Service Manual SAFETY SAFETY PRECAUTIONS DANGER The safety messages that follow have DANGER level hazards Crush Hazard AA NEVER stand under a hoisted engine If the hoist mechanism fails the engine will fall on you ALWAYS ensure the engine is solidly secured during service work ALWAYS have a helper assist you attach the engine to a hoist and load it on a truck when you need to transport the engine for repair 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 ALWAYS make sure that all connections are tightened to specifications after repair is made to the exhaust system 2009 Yanmar Co
86. l 50 hour maintenance procedures perform the following procedures every 50 hours thereafter Drain Fuel Filter Water Separator Check Battery Drain Fuel Filter Water Separator WARNING 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 put 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 NEVER use diesel fuel as a cleaning agent WARNING Exposure Hazard Wear eye protection The fuel system is under pressure and fuel could spray out when you remove any fuel system component Drain the fuel filter water separator periodically to check for contaminants such as water etc that may be collected in the filter NEVER waituntil the scheduled periodic maintenance interval if contaminants are discovered to replace the filter YANMAH TNM Series Service Manual PERIODIC MAINTENANCE Drain the fuel filter water separator as follows l Position an approved container under the fuel filter water separator Figure 5 6 1 to collect the contaminants Polaris 2010 Figure 5 6 2 Open the drain petcock Figure 5 6 2 Allow filter separator 3 Close the drain petcock Figure 5 6 2 once filter separator draining is
87. ld cause a false reading See Timing Gear Backlash on page 6 6 for service limits TNM Series Service Manual B ss Pad ees 2010 Yanmar Co Ltd Cylinder Block 1 Fuel Injection Pump Drive Gear 2 Camshaft Drive Gear 3 Crankshaft Drive Gear 4 Gear 5 Oil Pump Gear Figure 6 39 Measuring Idler Gear to Crankshaft Gear Backlash 1 Install a dial indicator as shown in Figure 6 40 0002192 00 6 40 2 Rotate the idler gear back and forth to check idler gear to crankshaft gear backlash Total indicator reading is backlash Record the measurement alali 2151 TNM Series Service Manual ENGINE Measuring Idler Gear to Camshaft Gear Backlash 1 Drive a small wooden wedge between the crankshaft gear and idler gear to prevent the idler gear from rotating Install a dial indicator to read camshaft gear backlash Rotate camshaft drive gear against idler gear to measure backlash Record the measurement Check the idler gear to fuel injection pump drive gear backlash in the same manner as the camshaft drive gear Record the measurement Removing the Timing Gears 16 Remove the bolts from the idler gear shaft Figure 6 41 1 Remove the idler gear shaft idler gear Figure 6 41 3 and bushing Figure 6 41 2 Figure 6 41 2 Do not remove the crankshaft gear unless it is damaged and require
88. li Gallon eoe 4 3 Location 546 c 4 4 Engine Nameplate 4 4 EPA CARB Emission Control Regulations USA Only 4 4 Emission Control Labels o enero 4 5 EPA ARB Labels 4 5 The 97 68 EC Directive Certified Engines 4 5 Engine Family ec 4 6 Function of Major Engine 4 7 Function of Cooling System 4 9 e 4 10 Diesel Fuel Specifications 4 10 Filling the Fuel Tank er m 4 12 Priming the Fuel Syster uiestenese Sema a eatur Er rede Eua 4 13 Engine C 4 14 Engine Specifications tio rid ooa artc l 4 14 Service 4 14 Engine 4 15 Checking Engine Oll 4 15 Adding Engine 4 15 Engine Oil Capacity Typical 4 16 zsr n eM 4 16 Engine
89. ll leak out instead of going into the reserve tank Run the engine until itis 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 ator near the FULL HOT mark Figure 4 7 6 If the engine coolantis 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 4 18 Engine Coolant 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 Refer to Chapter 3 for engine coolant capacity and bleeding procedure for the Yanmar 3TNM72 APL engine Engine Coolant Engine Model Capacity 3TNM72 Refer to Chapter 3 TNM Series Service Manual YANMAH 2009 Yanmar Co Ltd Specifications GENERAL SERVICE INFORMATION SPECIFICATIONS Description of Model Number 3 TNM 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 YANMAR TNM Series Service Manual 4 19 2009 Yanmar Co Ltd
90. mar Co Ltd Cylinder Block Removing the Camshaft Before removing the camshaft check the camshaft end play Method A Install a dial indicator Figure 6 44 1 on the cylinder block Move the camshaft and gear Figure 6 44 2 in and out to measure the end play Record the measurement See Camshaft on page 6 5 for the service limit tit E NM coy tt IX 477 die E 2 NS d Figure 6 44 Method B Use a feeler gauge to measure the clearance between the thrust plate Figure 6 45 1 and front camshaft bearing Figure 6 45 2 Record the measurement See Thrust Bearing on page 6 7 for the service limit Tajuk T Series Service Manual ENGINE K0001710B 00X Figure 6 45 2 Remove two bolts Figure 6 46 3 retaining the camshaft thrust plate Figure 6 46 1 026979 00X Figure 6 46 Extract the tappets Figure 6 46 5 through the top of the cylinder block Mark the tappets so they can be installed in the same location Slowly pull the camshaft Figure 6 46 2 assembly out of the engine being careful not to damage the front camshaft bushing Remove the camshaft gear Figure 6 46 4 only if the gear or camshaft require replacement Use a knife edge puller and a press to remove the gear The gear is shrink fit and will need to be heated to 356 to 392 F 180 to 200 C to remove 20
91. mm 68 200 mm 72 200 mm Inspecting the Cylinder Roundness 0 0004 in 0 01 mm 0 0012 in Cylinder Bore y or ns 0 03 mm page 6 43 6 10 TNM Series Service Manual 4 2010 Yanmar Co Ltd Special Torque Chart ENGINE SPECIAL TORQUE CHART Tightening Torque for Special Bolts Thread Diameter and Lubricating 31 34 ft Ib 3TNM68 M8 x 1 25 42 1 46 1 Applied x bi 3 4 7 kgf ir See Assembling the Cylinder Head Bolts Cylinder Head on 40 43 ft lb 6 27 STNM72 M9 x 1 25 mm 53 9 57 9 Applied page 5 5 5 9 kgf m 17 20 ft lb See Installing the Connecting Rod Bolts M7 x 1 0 mm Ere RIO Applied Pistons on page 6 54 59 64 ft Ib See Installing the Flywheel Bolts M10 x 1 25 mm 80 4 86 4 N Applied Crankshaft on 8 2 8 8 kgf m page 6 52 61 69 ft lb cast i See Installing the 8 5 9 5 kgf Crankshaft M12 x 1 25 mm gm Applied Crankshaft on Pulley Bolts 83 90 ft lb page 6 52 Forged 38 123 11 5 12 5 CPN m 11 15 ft lb M10 x 1 25 14 7 19 6 N Not Applied T 5 2 0 kgf i a a See Assembling the Glow Plug p Intake Manifold Valve 1 1 1 4 ft Ib Cover on page 6 29 1 5 2 0 N m Not Applied pag 0 15 0 20 kgf m 33 1 5 ft lb Main Cap Bolt M9 x 1 25 mm 45 x 2 N m Applied 4 5 x 0 2 kgf m 33 1 5 ft lb Ladder Frame Bolt M9 x 1 25 mm 45 x 2 Applied 4
92. n see your authorized dealer or distributor for service before operating the engine Formaximum engine life Yanmar recommends that before shutting the engine down you allow the engine to idle without load for 5 minutes This will allow the engine components that operate at high temperatures such as the exhaust system to cool Slightly before the engine is shut down The engine itself may be shut down at that time NEVER use an engine starting aid such as ether Engine damage will result New Engine Break in 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 4 to 5 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 TNM Series Service Manual YANMAMH 2009 Yanmar Co Ltd Safety Precautions NOTICE 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
93. n 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 Side and Top Filler P ort Engine Oil You can fill the crankcase with engine oil from either the side or top filler port depending upon which one is most convenient Refer to Chapter 2 for oil viscosity and type recommendation Starter Motor 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 TNM Series Service Manual YANMAH 0 2009 Y anmar Co Ltd Function of Cooling System Components FUNCTION OF COOLING SYSTEM COMPONENTS Component Cooling S ystem Function The TNM engine is liquid cooled by means of a cooling system The cooling system consists of a radiator radiator cap electric cooling fan engine coolant pump thermostat and reserve tank Note that all cooling system components are required for proper engine operation GENERAL SERVICE INFORMATION Engine Cooling Fan The cooling fan is driven by an electric motor controlled by a ther mostatic relay system The purpose of the engine cooling fan is to circulate air through the radiator Engine Coolant Pump The engine coolant pump circulates the engine coolantthrough the cylinder block and cylinder
94. nder Block 7 Install the ladder frame and tighten to specification See Special Torque Chart on page 6 11 1 Gear Case Side i 2 Flywheel Side Figure 6 55 8 Remove the ladder frame 026981 00 6 56 9 Compare the width of the flattened PLASTIGAGE Figure 6 56 1 to the graduation marks on the package The mark that most closely matches the width of the flattened PLASTIGAGE will indicate the bearing oil clearance Record the measurement See Crankshaft on page 6 6 for clearance specifications lalai 2151 TNM Series Service Manual ENGINE 10 Repeat with the remaining main bearings Be sure to note the markings on the main bearing or make marks so they can be installed in the same order as they were removed 11 Remove the crankshaft from the engine Do not remove the crankshaft gear unless the gear or crankshaft are damaged and require replacement 12 If necessary remove the crankshaft gear Figure 6 57 1 and key Figure 6 57 2 If using a gear puller be careful not to damage the threads in the end of the crankshaft 0002193 00 6 57 6 41 2010 Yanmar Co Ltd Inspecting the Crankshaft and Camshaft Components Fume Burn Hazard Always read and follow safety related precautions found on containers of hazardous substances like parts cleaners primers sealants an
95. nder head on the work bench with the combustion side down Figure 6 8 Figure 6 8 2 Remove the valve stem cap Figure 6 9 1 and keep with the valve it was installed on 3 Using the valve spring compressor tool compress one of the valve springs Figure 6 8 4 Remove the valve keepers Figure 6 9 2 5 Slowly release the tension on the valve spring 6 Remove the spring retainer Figure 6 9 3 and valve spring Figure 6 9 4 Figure 6 9 Cylinder Head 7 Repeat procedure with all remaining valves If the valves are to be reused identify them so they can be installed in their original location 8 Turn the cylinder head so the exhaust port side faces down Remove the intake and exhaust valves Figure 6 9 6 from the cylinder head 9 Remove the valve stem seals Figure 6 9 5 Removing the Valve Guides Removing the valve guides should be postponed until inspection and measurement procedures have been performed See Inspecting the Valve Guides on page 6 22 If the valve guides are not within specifications use a drift pin and hammer to drive the valve guides Figure 6 10 1 out of the cylinder head 2 ilh 4 lee 027134 00 6 10 Series Service Manual B ss Pad Faltin 2010 Yanmar Co Ltd Cylinder Head Cleaning the Cylinder Head Components Fume Burn Hazard Always read and follow safety
96. ns By letting the engine warm up as quickly as possible the thermostat reduces engine wear deposits and emissions YANMAH TNM Series Service Manual 4 9 2009 Yanmar Co Ltd GENERAL SERVICE INFORMATION DIESEL FUEL Diesel Fuel Specifications NOTICE 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 Diesel fuel should comply with the following specifications The table lists several worldwide specifications for diesel fuels Diesel Fuel Specification Location ASTM D975 No 1D S15 S500 USA No 2D S15 S500 EN590 96 European Union International United Kingdom ISO 8217 DMX BS 2869 A1 or A2 115 K2204 Grade No 2 KSM 2610 GB252 Diesel Fuel Temperature Specification USA TEMPERATURE F C NO 2 NO 1 15 9 100 0 Down to 20 29 5096 5096 Below 20 29 0 100 4 10 Diesel Fuel Additional Technical Fuel Requirements The fuel cetane number should be equal to 45 or higher The sulfur content must not exceed 0 596 by volume Less than 0 05 is preferred Especially in U S A and Canada Low Sulfur 300 to 500 ppm mg kg or Ultra Low Sulfur fuel should be used Bio Diesel fuels See Bio Diesel Fuels on page 4 10 NEVER mix keros
97. nual 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 YANMAR are registered trademarks of Yanmar Co Ltd in the United States 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 Copyright permission granted to Polaris Industries 2009 Yanmar Co Ltd 0709 ii TNM Series Service Manual YANMAH 2009 Yanmar Co Ltd TABLE CONTENTS Page Introduction ee 1 1 Yanmar 2 2 22222 224001021 2 1 RT T 3 1 General Service Information 2 2 4 22 2 4 1 Periodic Maintenance 4 4 222222 5 1 pen me 6 1 FHBESUSIBITL a ut 7 1 Cooling System
98. o crank the engine in order to prime the fuel system This may cause the starter motor to overheat and damage the coils pinion and or ring gear 4 13 2009 Yanmar Co Ltd GENERAL SERVICE INFORMATION ENGINE OIL Engine Oil Specifications NOTICE Only use the engine oil specified Other engine oils may affect warranty coverage cause internal engine components to seize or shorten engine life NOTICE NEVER mix different types of engine oil This may adversely affect the lubricating properties of the engine oil 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 Europ ens d Automobilies JASO Japanese Automobile Standards Organization 4 14 Note 1 Engine Oil Be sure the engine oil engine storage containers and engine oil filling equipment are free of sediments and water Change the engine oil after the first 50 hours of operation and then every 100 hours thereafter Selectthe oil viscosity based on the ambient temperature where the engine is being operated See the SAE Service Grade Viscosity Chart Figure 4 5 Yanmar does not recommend the use of engine oil additives TNM Series Servic
99. ocally Square Available Locally Measuring Instruments Measure shaft bend and end play 001429 00 Measurements of narrow or deep portions that cannot be measured by dial gauge For holding the dial gauge when measuring For measuring the outside diameters of crankshaft pistons piston pins etc 001432 00 For measuring the inside diameters of cylinder liners bearing bores etc For measuring outside diameters depth thickness and width cx For measuring of valve recession CEG SIGN 001435 00 For measuring valve spring inclination and straightness of parts 001436 00 TNM Series Service Manual 16 i 2010 Yanmar Co Ltd Measuring Instruments ENGINE Instrument Name Application Illustration V Block Available Locally For measuring shaft bend Torque Wrench Available Locally For tightening ei to the specified For measuring piston ring gaps piston ring Feeler Gauge Available Locally clearance and valve adjustment clearance 21251 Series Service Manual 6 15 2010 Yanmar Co Ltd E 3 Cylinder Head ENGINE CYLINDER HEAD Cylinder Head Components 026966 00 6 1 TNM Series Service Manual 6 16 2010 Yanmar Co Ltd Cylinder Head 1 Plate 2 Oil Fill Cap 3 Valve Cover Intake Manifold 4 Gasket 5 Rocker Arm S
100. on Inspect Clean and Test Fuel Injectors if necessary Inspect Crankcase Breather System Inspect Clean and Test Fuel Injectors WARNING Exposure Hazard ALWAYS 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 P roper operation of the fuel injectors is required to obtain the optimum injection pattern for full engine performance The EPA ARB requires thatthe fuel injectors are inspected cleaned and tested every 1500 hours See Testing of Fuel Injectors on page 7 21 This procedure is considered normal maintenance and is performed atthe owner s expense This procedure is not covered by the Limited Warranty YANMAH TNM Series Service Manual PERIODIC MAINTENANCE Inspect Crankcase Breather System P roper 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 The TNM engines use a crankcase breather system that has a spring backed diaphragm Figure 5 17 1 in the valve cover Figure 5 17 2 When the crankcase pressure reaches a predetermined value
101. p bolts Install the connecting rod cap Figure 6 95 2 Tighten the connecting rod bolts to the specified torque in two stages 1 2 into the connecting rod beam Figure 6 94 3 will be facing the flywheel end of the engine then full torque See Special Torque Chart on Figure 6 94 5 page 6 11 The piston and connecting rod must be installed with the correct orientation When installed correctly the identification mark Figure 6 94 2 stamped into the top of the piston will be on the same side of the engine as the fuel injection pump Figure 6 94 1 andthe embossed mark Figure 6 94 3 cast into the connecting rod beam will face the flywheel end of the engine Figure 6 94 5 6 1 4 gt Figure 6 95 8 Install the remaining pistons in their respective cylinders D Assembling the Camshaft and Timing 2 Components Installing the Camshaft 3 The gear housing must be installed prior to installing the camshaft n 9 TS 1 If removed install the camshaft end plate 1 Fuel Injection Pump Side of Engine Figure 6 96 1 key and camshaft gear 2 Piston Identification Mark Figure 6 96 4 onto the camshaft using a 3 Embossed Mark on Connecting Rod press 4 Rod and Cap Match Marks Heat the gear to 356 to 392 F 180 to 200 C 5 Flywheel End of Engine and press onto the end of the camshaft 6 Camshaft Side
102. pistons are removed and lalai 2151 TNM Series Service Manual 2010 Yanmar Co Ltd Cylinder Block Removing the Crankshaft Method B Use a feeler gauge to measure the clearance Figure 6 53 3 between the thrust bearing Figure 6 53 1 and crankshaft Figure 6 53 2 Record the 2 Remove the bolts from the flywheel housing measurement See Thrust Bearing on assembly Figure 6 51 2 Remove the page 6 7 for the service limit flywheel housing from the engine 1 Remove the flywheel Figure 6 51 1 from the crankshaft 0001962 00 6 53 6 51 4 Remove the ladder frame Do not remove the 3 Before removing the main bearing measure the bearing inserts at this time crankshaft end play Use either of the following two methods Method A Install a dial gauge Figure 6 52 1 on the cylinder block Move 6 Place a piece of PLASTIGAGE the crankshaft Figure 6 52 2 in and out to Figure 6 54 1 along the full width of the measure the end play Record the bearing insert measurement NOTICE Do not rotate the crankshaft when using PLASTIGAGE A false reading may result 5 Wipe oil from the bearing insert and crankshaft journal surfaces Figure 6 52 IDN i 4 026980 00 6 54 6 40 TNM Series Service Manual ER 2010 Yanmar Co Ltd Cyli
103. ral Service Information section should be applied only to the bolts with a 7 head IS strength classification 7T Apply 6096 torque to bolts that are not listed 7 Apply 80 torque when tightened to aluminum alloy 4 24 Hexagon Bolt 7T and Nut Nominal Thread Diameter M6 x 1 0 mm M8 x 1 25 mm M10 x 1 5 mm x Pitch M12 x 1 75 mm M14 x 1 5 mm M16 x 1 5 mm Tightening Torque 87 104 in Ib 9 8 11 8 N m 1 0 1 2 kgf m 200 251 in Ib 22 6 28 4 2 3 2 9 kgf m 33 40 ft Ib 44 1 58 9 4 5 5 5 kgf m 58 72 ft lb 78 4 98 0 8 0 10 kgf m 94 108 ft Ib 127 5 147 1 N m 13 15 kgf m 159 174 ft lb 215 7 235 4 22 24 kgf m 87 in lb 9 8 1 0 kgf m 173 in Ib 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 Remarks 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 TNM Series Service Manual YANMAMH 2009 Yanmar Co Ltd Tightening Torques for Standard Bolts and Nuts GENERAL SERVICE INFORMATION Nominal Thread Diameter x Pitch Tightening Torque Remarks 112 148 in Ib 12 7 16 7 N m 1 8 1 7 kgf m 173 225 in Ib 19 6 18 734 N m 2 0 3 5 kgf m 18 25 ft lb Pipe Joint Bolt 24 5 34 3 N m 2 5 3 5 kgf m 29 36 ft lb 39 2 49 0 N m
104. related precautions found on containers of hazardous substances like parts cleaners primers sealants and sealant removers Thoroughly clean all components using a non metallic brush and an appropriate solvent Each part must be free of carbon metal filings and other debris Inspecting the Cylinder Head Components Visually inspect the parts Replace any parts that are obviously discolored heavily pitted or otherwise damaged Discard any parts that do not meet specified limits NOTICE 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 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 Mark all valve train components so they can be installed in their original locations Record all measurements taken during inspection Inspecting the Push Rods Push Rod Bend Determine if the bend of the push rods is within the specified limit alali 21251 Series Service Manual ENGINE 1 Place the push rods on a flat inspection block or layout bed 2 Roll the push rods until a gap be observed between a portion of the push rod and the surface of the block or layout bed 3 Use a feeler gauge to measure the
105. rvals 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 Establish a periodic maintenance plan according to the engine application and make sure you perform the required periodic maintenance at intervals indicated CAUTION Unsafe Operation Hazard 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 Consult assistance when checking items marked with a e NOTICE Itis 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 Periodic Maintenance Schedule TNM Series Service Manual YANMAMH 2009 Yanmar Co Ltd Periodic Maintenance Schedule O Check O Replace 6 Contact an authorized Polaris dealer PERIODIC MAINTENANCE Periodic Maintenance Interval System Check Item Daily Every Every Every Every Every Every 50 100 150 1000 1500 2000 hours hours hours hours hours hours Cooling Check and Refill Engine Coolant System Check and Clean Radiator Fins Check and Adjust Cooling Pump V Belt Olst O
106. s replacement If the gear must be removed remove it with a gear puller 3 Removing the camshaft gear requires the gear to be removed with a press Do not remove the camshaft gear unless it or the camshaft is damaged and requires replacement See Removing the Camshaft on page 6 37 2010 Yanmar Co Ltd Do not loosen or remove the four bolts retaining the fuel injection pump drive gear to the fuel injection pump hub Do not remove the fuel injection pump drive gear unless absolutely necessary due to damage to the gear or pump Do not loosen or remove the four bolts Figure 6 42 3 retaining pump drive gear to the hub Only remove the nut Figure 6 42 1 and washer Figure 6 42 2 leaving the hub attached to the gear Remove the pump drive gear and hub as an assembly using a gear puller 027136 00X Figure 6 42 Cylinder Block Removing the Oil Pan Invert the engine oil pan up on the engine stand 2 Remove the oil pan Figure 6 43 4 3 Remove the ladder frame Figure 6 43 1 Figure 6 43 4 Remove the oil pickup tube Figure 6 43 3 and O ring Figure 6 43 2 Note Torx bolts are used for oil sump mounting bolts and ladder frame mounting bolts Specialized tool Torx bolt wrench is required Oil Sump Bolts TORX E8 Ladder Frame TORX E12 m z d pe 7 t ES Yu TNM Series Service Manual 2010 Yan
107. s to maintain engine performance and avoid premature engine wear Avoid operating in the presence of chemical gases or fumes Avoid operating in a corrosive atmosphere such as salt water spray NEVER operate the engine in a floodplain unless proper precautions are taken to avoid being subject to a flood NEVER expose the engine to the rain The standard range of ambient temperatures for the normal operation of Yanmar engines is from 5 F 15 C to 104 F 40 If the ambient temperature exceeds 104 F 40 C the engine may overheat and cause the engine oil to break down If ambient temperature is between 25 F 31 C and 5 15 C the engine will be hard to start and the engine oil may not flow easily Polaris recommends the use of a cold start kit Contact your authorized dealer or distributor if the engine will be operated outside the standard temperature range The illustrations and descriptions of optional equipment in this manual such as the operator s console are for a typical engine installation Refer to the documentation supplied by the optional equipment manufacturer for specific operation and maintenance instructions 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 Safety Precautions If any indicator fails to illuminate when the key Switch is in the ON positio
108. s x 0 2 kgf m n 36 39 ft lb eee nection Nozzle M20 x 1 5 mm 49 0 52 9 mi Not Applied Es 0 5 4 kgf m M4 x 0 7 mm 22 25 itib Pressure M12 x 1 5 mm 29 4 34 3 N m Not Applied P 3 0 3 5 kgf m 24 27 ft lb Fuel Pump Gear Bolt M8 x 1 0 mm 32 3 36 3 N m Not Applied 3 3 3 7 kgf m 43 51 ft lb Fuel Pump End Nut M12 x 1 25 mm 58 8 68 6 N m Applied 6 0 7 0 kgf m Oil Sump Bolts M6 x 1 0 mm i See Tightening Torques for Standard Bolts and Nuts on page 4 25 for standard hardware torque values Note Torx bolts are used for oil sump mounting bolts and rudder frame mounting bolts Specialized tool Torx bolt wrench is required Oil Sump Bolts TORX E8 Ladder Frame TORX E12 Tafaj 21141 Series Service Manual 6 11 2010 Yanmar Co Ltd SPECIAL SERVICE TOOLS Note Tools without Yanmar part numbers must be acquired locally Ne TesiName Valve Guide Tool For Removing Valve Guides Locally Manufactured Valve Guide Tool For Installing Valve Guides 0 433 in 11 mm 2 362 in 60 mm Applicable Model and Tool Size Special Service Tools 0 669 in 17 mm Allowance L1 Locally Manufactured O to 0 0118 in 0 to 0 3 mm Wrist Pin Bushing Tool For Removing Installing Wrist Pin Bushings 0 0118 to 0 0236 in 0 3 to 0 6 mm Locally Manufactured Valve Spring Compressor For
109. specting the Camshaft Insert Bores Camshaft bushing is not applicable in TNM eng ines Therefore measure the bore I D of the camshaft insertion portion in the cylinder block If the bore D is not within specification replace the cylinder block Ins 1 6 48 pecting the Idler Gear and Shaft Measure the outside diameter Figure 6 77 1 of the idler gear shaft Figure 6 77 2 Record the measurements See Idler Gear Shaft and Bushing on page 6 6 for specifications Measure the inside diameter Figure 6 77 3 of the idler gear bushing Figure 6 77 4 Record the measurements See Idler Gear Shaft and Bushing on page 6 6 for specifications K0001714A 00X Figure 6 77 Cylinder Block Honing and Boring Pistons must move freely in the cylinders while maintaining adequate compression and oil sealing If the cylinder walls are scuffed scored out of round or tapered beyond specifications rebore and hone to restore cylinders to usable condition Slight imperfections can be corrected by honing alone 1 Boring Significant cylinder damage may be corrected by boring the cylinder to an oversize dimension Refer to the appropriate parts catalog for available oversize pistons and piston rings Boring a cylinder should always be done in a properly equipped machine shop A bored cylinder should always be finished with ahoneto properly prepare the cylinder surface so the new piston rings
110. t 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 NOTICE NEVER get any oil on the belt s Oil on the belt causes slipping and stretching Replace the belt if damaged Check and adjustthe 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 3 A B and C You can check the tension at whichever position is the mostaccessible The proper deflection of a used V belt at each position is 0006466 Figure 5 3 2009 Yanmar Co Ltd PERIODIC MAINTENANCE 5 8 Used V Belt Tension A B 3 8 1 2 in 10 14 mm 1 4 3 8 in 7 10 mm 5 16 1 2 in 9 13 mm If necessary adjust the V belt tension Loosen the adjusting bolt Figure 5 4 1 and move the alternator Figure 5 4 2 with a pry bar Figure 5 4 3 to tighten the V belt to the desired tension Then tighten the adjusting bolt 0000653B Figure 5 4 Tighten the V belt to the proper tension There must be clearance Figure 5 5 1 between the V belt and the bottom of the pulley groove If there is no clearance Figure 5 5 2 between the V belt and the bottom of the pulley
111. t is securely seated in the groove If installing new piston rings the gap must be checked and adjusted as necessary See Inspecting the Pistons Piston Rings and Wrist Pin on page 6 43 Use a piston ring end gap filing tool to adjust the piston ring end gap on new piston rings Tajuk T Series Service Manual ENGINE 027272 00X Figure 6 83 NOTICE Install the top and second piston rings with the stamped makers mark Figure 6 84 1 facing the top of the piston The makers mark may vary in appearance but will always be located on the top surface of the piston ring adjacent to the piston ring gap The oil ring and oil ring expander can be installed either side up TK K0000225A Q00X Figure 6 84 Always use a piston ring expander when installing piston rings Never attempt to install piston rings by hand 2010 Yanmar Co Ltd 7 Install the oil ring expander Figure 6 85 4 Install the oil ring Figure 6 85 3 with the end gap at 180 from the expander end gap 8 Install the middle compression ring Figure 6 85 2 This ring is identified by its dark color and tapered face profile 9 Install the top compression ring Figure 6 85 1 This ring is identified by its silver color and barrel shaped face profile The oil ring expander end gap must be located 180 from the oil ring end gap Fi
112. tch to the ON position for 10 to 15 seconds to prime the fuel system Engine Oil Filter The engine oil filter removes contaminants and sediments from the engine oil P eriodic replacement of the engine oil filter is necessary See thePeriodic Maintenance Schedule on page 5 4 for the replacement frequency FuelFilter Water Separator 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 pump and the engine P eriodically drain the water from the fuel filter water separator using the drain cock at the bottom of the separator Fuel P riming The fuel system needs to be primed before you start the engine for the first time if your run out of fuel or if fuel system service is performed To prime the system operate the fuel pump for 10 15 seconds until the fuel filter is full YANMAH TNM Series Service Manual 4 7 2009 Yanmar Co Ltd GENERAL SERVICE INFORMATION Function of Major Engine Components Component Function Fuel Tank The fuel tank is a reservoir that holds diesel fuel When fuel leaves the tank via the fuel pump it goes to the fuel filter water separator Next the fuel goes to the fuel injection pump Since fuel is used to keep the fuel injection pump cool and lubricated more fuel tha
113. ters kPa kilopascal kW kilowatt L liter L hr liter per hour Ib pound 4 26 Ibf Ib ft Ib in min mL mm mm st mmAq MPa mV O D oz PS psi qt rpm SAE sec TBN TDC V AC V DC WOT Symbols o Abbreviations and Symbols pound force pound foot Tightening Torque pound inch Tightening Torque minute milliliter millimeter millimeters cubed stere millimeters of water megapascal millivolt newton newton meter number outside diameter ounce horsepower Deutsch pound per square inch quart U S revolutions per minute Society of Automotive Engineers second short ton 2000 Ib Total Base Number top dead center volt volt alternating current volt direct current watt Wide Open Throttle angular degree plus minus plus or minus ohm micro percent approximate Work torque such as engine torque Work torque such as starter motor torque TNM Series Service Manual YANMAMH 2009 Yanmar Co Ltd Unit Conversions UNIT CONVERSIONS Unit Prefixes Prefix Symbol Power mega M x 1 000 000 kilo k x 1 000 centi x 0 01 milli m x 0 001 micro u x 0 000001 Units of Length mile X 1 6090 lt km ft X 0 3050 2m in x 2 5400 cm in 25 4000 mm 0 6210 mile x 3 2810 ft cm x 0 3940 in mm 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
114. th the air cleaner element s removed This may allow foreign material to enter the engine and damage it Note that a typical air cleaner is shown in Figure 5 11 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 1 Unlatch and remove the air cleaner cover Figure 5 11 4 2 Remove the element Figure 5 11 2 2009 Yanmar Co Ltd PERIODIC MAINTENANCE 1 0000070P Figure 5 11 3 Replace the element with a new one if the element is damaged excessively dirty or oily 4 Apply grease to the air filter sealing surface 5 Clean inside of the air cleaner cover 6 Install the element into the air cleaner case Figure 5 11 1 7 Install the air cleaner cover seal if removed Figure 5 11 3 8 Latch the air cleaner cover to the case making sure the clips are secured Figure 5 11 4 5 14 Periodic Maintenance Procedures Replace the Fuel Filter Water Separator Element NOTICE Polaris recommends that the fuel filter water separator element be replaced at 150 hours Refer to the element replacement instructions in the 150 hour interval on page 5 15 TNM Series Service Manual YANMAH 0 2009 Y anmar Co Ltd Periodic Maintenance Procedures Every 150 Hours of Operation Perform the following maintenance every 150 hours of operation Replace
115. 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 See the Warranty in the owner s manual Identify all parts and their location using an appropriate method It is importantthat all parts are returned to the same position during the reassembly process NEVER attemptto adjustthe low or high idle speed limit screws This may impair the safety and performance of the machine and shorten its life If adjustment is ever required contact your authorized dealer or distributor Tampering with limit screws may void warranty ALWAY S be environmentally responsible amp 9 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 TNM Series Service Manual SAFETY 3 7 2009 Yanmar Co Ltd SAFETY Safety Precautions This Page Intentionally Left Blank 3 8 TNM Series Service Manual YANMAH 2009 Yanmar Co Ltd Section 4 GENERAL SERVICE INFORMATION Page Safety Precautions I 4 3 Component Identi
116. ugh to accommodate the engine components Discard all used gaskets O rings and seals Use new gaskets O rings and seals for assembling the engine Identify all parts and their location using an appropriate method It is important that all parts are returned to the same position during the assembly process Record all measurements taken during disassembly If the engine will be completely disassembled the following preliminary steps should be performed 1 Disconnect the battery cables at the battery Always disconnect the negative cable first 2 Remove the throttle cable electrical connections intake and exhaust system connections and fuel supply lines from the engine 3 Remove the alternator See Removing the Alternator on page 11 10 4 Drain the engine coolant from the radiator and cylinder block See Draining Flushing and Refilling Cooling System with New Coolant on page 5 18 Remove the cooling system components from the engine 5 Remove the engine from the machine Mount the engine to a suitable engine repair stand having adequate weight capacity Crush Hazard When working on the engine make sure it is solidly secured to prevent injury or damage to parts 2010 Yanmar Co Ltd 6 Clean the engine by washing with solvent air steam cleaning Carefully operate to prevent any foreign matter or fluids from entering the engine fuel system or electrical components rem
117. ve Cover on page 6 18 2 Rotate the crankshaft clockwise as seen from the coolant pump end to bring No 1 piston to TDC of the compression stroke while watching the rocker arm motion and timing grid on the flywheel Position so both the intake and exhaust valves are closed 3 Insert a feeler gauge Figure 6 35 1 between rocker arm and valve cap and record the measured valve clearance Use the data for estimating wear Figure 6 36 6 Insert a feeler gauge of the correct thickness Figure 6 35 1 between rocker arm and valve cap Turn the valve adjustment screw to adjust the valve clearance so there is a slight drag on the feeler gauge when sliding it between the rocker arm and valve cap Hold the adjusting screw while tightening the valve adjusting screw locknut Figure 6 36 1 Recheck the clearance see Adjustment Specifications on page 6 3 K0001782A 00X Figure 6 35 There is a tendency for the clearance to roae ausiment IS decrease slightly when the locknutis tightened It step et Te is suggested thatthe initial clearance adjustment 5 Loosen the valve adjusting screw locknut be made slightly on the loose side before Figure 6 36 1 and valve adjusting screw tightening the locknut Figure 6 36 2 on the rocker arm Check the valve for inclination of the valve cap entrance of dirt or wear 7 Apply oil to the contact surface between adjusting screw and push rod 8
118. will be difficult to hear any warning signals Exposure Hazard ALWAYS wear personal protective equipment such as gloves work shoes eye and hearing protection as required by the task at hand pode ALWAYS wear safety glasses while servicing the engine to prevent possible eye injury TNM Series Service Manual SAFETY Alcohol and Drug Hazard NEVER operate or service the engine while you are under the influence of alcohol or drugs NEVER operate or service the engine when you are feeling ill The safety messages that follow have CAUTION level hazards 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 NOTICE The safety messages that follow have NOTICE level hazards If any problem is noted during the visual check the necessary corrective action should be taken before you operate the engine If a continuously running engine is operated at greater than 20 in any direction or if an engine runs for short periods of time less than 3 minutes at an angle greater than 20 in any direction the engine oil may enter the combustion chamber causing excessive speed and smoke This may cause serious engine damage 2009 Yanmar Co Ltd 5 Observe the following environmental operating condition
119. y Left Blank 4 28 TNM Series Service Manual YANMAH 2009 Yanmar Co Ltd Section 5 PERIODIC MAINTENANCE i is em The Importance of Periodic Performing P eriodic Maintenance Yanmar Replacement P arte ncc sste ier peek ra era Required EPA ARB Maintenance USA Only Periodic Maintenance 5 Periodic Maintenance Procedures After Initial 50 Hours of Every 50 Hours 04 242 4 2 2 Every 250 Hours OF Operalioli etuer rta ettet ea Every 500 Hours Every 1000 Hours of Operation creme Every 1500 Hours of Operation eer Every 2000 Hours YANMAR TNM Series Service Manual 5 1 2009 Yanmar Co Ltd PERIODIC MAINTENANCE This Page Intentionally Left Blank 5 2 TNM Series Service Manual YANMAH 2009 Yanmar Co Ltd Safety Precautions SAFETY PRECAUTIONS Before performing any maintenance procedures review the
120. y field The following is an explanation of the Engine Family designation 8 YDX L 0 78 V 3 L Method of air aspiration Number of cylinders Engine speed specifications Displacement liter Non road Off road engine Yanmar Diesel 2008 Model Year 8 2008 9 2009 10 2010 etc 4 6 TNM Series Service Manual YANMAH 2009 Yanmar Co Ltd Function of Major Engine Components GENERAL SERVICE INFORMATION FUNCTION OF MAJ OR ENGINE COMPONENTS Component Function Air Cleaner The air cleaner prevents airborne contaminants from entering the engine Periodic replacement of the air cleaner filter element is necessary See the Periodic Maintenance Schedule on page 5 4 for the replacement frequency Alternator The alternator is driven by a V belt which is powered by the crankshaft V pulley The alternator supplies electricity to the engine systems and charges the battery while the engine is running Dipstick E ngine Oil The engine oil dipstick is used to determine the amount of engine oil in the crankcase Electric Fuel Feed Pump The electric fuel feed pump makes sure there is a constant supply of diesel fuel to the fuel injection pump The electric fuel feed pump is electro magnetic and runs on 12 VDC An electric fuel feed pump may be installed as standard equipment based on engine model and specification If an electric fuel feed pump is installed turn the key swi
121. ylinder block Record the measurements See Tappet on page 6 9 for the service limit 6 46 TNM Series Service Manual BEBE as 2010 Yanmar Co Ltd Cylinder Block ENGINE Inspecting the Camshaft 1 Use V blocks and a dial indicator to check camshaft bend Figure 6 74 Place the indicator on the center bearing journal Figure 6 74 2 2 Rotate the camshaft and observe the runout Figure 6 72 Record the measurements See Camshaft on MES page 6 5 for specifications Reconditioning the Crankshaft 3 Measure the height of each lobe If any of the crankshaft journals do not meet the Figure 6 75 1 Record the measurements specifications it may be possible to grind any or all See Camshaft on page 6 5 for specifications of them to an undersize The connecting rod bearings main bearings and thrust bearing inserts are available as 0 010 in 0 25 mm undersize If the journals are ground undersize the following finishing standards Figure 6 73 must be adhered to K0001712A 00X Figure 6 75 Figure 6 73 B 5 PURUS E TNM Series Service Manual 6 47 2010 Yanmar Co Ltd 4 Measure the diameter of the gear end Figure 6 76 1 intermediate Figure 6 76 2 and flywheel end Figure 6 76 3 bearing journals Record the measurements See Camshaft on page 6 5 for specifications K0001713A 00X Figure 6 76 In

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