Part of the Yanmar Repair Manuals.
Set the crankshaft in the block and you will want main bearing clearances, endplay limits, and the rod bolt torque before anything else goes back together. This 175 page Yanmar service manual covers the 3TN100E, 4TN100E, and turbocharged 4TN100TE industrial diesels of the TN 100 series, delivered as a PDF download under factory publication 0000AOC1927 T 8905.
The chapters follow the engine from the inside out: cylinder block, head, pistons, connecting rods, crankshaft, and timing gear in Basic Engine, then full disassembly, reassembly, and inspection of the governor and fuel injection pump, followed by the lubricating, cooling, air induction, and electrical systems, including a wiring diagram, starter, alternator, and starting aids.
Whether the engine drives a generator, a pump, or something else entirely, you are usually working on it alone. The closing Disassembly and Reassembly chapter puts the bolt and nut tightening torques in one table so the rebuild goes together right the first time.
What's Inside This Manual
| System | Pages | Key Topics |
|---|---|---|
| Yanmar Service Manual | 1 | |
| Preface | 2-3 | |
| General | 4-19 | Specifications, Performance Curves, Cross Sectional Views, Dimensions, Maintenance |
| Basic Engine | 20-52 | Cylinder Block, Cylinder Head, Piston and Piston Pins, Connecting Rod, Crankshaft and Main Bearing, Camshaft and Tappets, Timing Gear, Flywheel |
| Fuel Injection Equipment | 53-96 | Fuel Supply System, Disassembly, Reassembly and Inspection of Governor, Reassembly and Inspection of Fuel Injection Pump |
| Lubricating System | 97-109 | Lubrication System, Lube Oil Pump, Lube Oil Filter & Oil Pressure Control Valve, Oil Cooler, Piston Cooling Nozzle, Oil Pressure Control Valve |
| Cooling System | 110-119 | Radiator Fan Belt, Thermostat, Cooling Water Pump |
| Air Induction System | 120-136 | Air Cleaner, Turbocharger |
| Electrical System | 137-158 | Wiring Diagram, Starter Motor, Alternator, Starting Aids |
| Disassembly and Reassembly | 159-174 | Disassembly, Reassembly, Bolt/Nut Tightening Torque |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| Nozzle opening pressure | 200 - 210 kg/cm² | p. 87 |
| Fuel injection nozzle retainer nut tightening torque (to cylinder head) | 0.4 ~ 0.5 kg-m (2.9 ~ 3.6 ft-lb) | p. 171 |
| Fuel injection pump driving gear nut torque | 11.5 ~ 12.5 kg-m | p. 174 |
| Water pump impeller to body clearance (Standard) | 0.3 ~ 0.7 mm | p. 117 |
| Cooling water pump support tightening torque | 1.8 ~ 2.3 kg-m (13 ~ 16.7 ft-lb) | p. 171 |
| Valve clearance (Intake and exhaust) | 0.27 – 0.33 mm (0.0106 – 0.0130 in) | p. 32 |
| Radiator cap working pressure | 0.9 kg/cm² (0.98/12.8 PSI) | p. 112 |
| Alternator nominal output | 12V-40A | p. 149 |
| Connecting rod clamping bolt torque | 11.5 – 12.5 kg-m | p. 174 |
