Volvo 3TNV76 Operating and installation instructions

Service Information
Document Title: Function Group: Information Type: Date:
Engine, description 200 Service Information 2014/4/14
Profile:
CEX, ECR28 [GB]
Engine, description
Model code (3TNV76)
Model code
Symbol Description Remarks
3 Number of cylinders
TNV Model series
76 Cylinder bore (mm)
The engine is a 3–cylinder, indirect injected, water cooled diesel engine.
Engine, front view
Figure 1
Engine, front view
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
Lifting eye
Cooling water pump
Lifting eye
Fan
V-belt
V-pulley
Filler port (lube oil)
Fuel oil inlet
Drain plug (lube oil)
Mechanical fuel feeding pump
Fuel priming lever
Dipstick
Oil filter
Governor lever
Fuel injection pump
Intake manifold
Fuel filter
Air intake port

Engine, rear view
Figure 2
Engine, rear view
1.
2.
3.
4.
5.
6.
7.
Filler port (lube oil)
Bonnet (rocker arm cover)
Engine name plate
Flywheel
Starter motor
Exhaust manifold
Alternator

Service Information
Document Title: Function Group: Information Type: Date:
Precautions 200 Service Information 2014/4/14
Profile:
CEX, ECR28 [GB]
Precautions
Make preparation as follows before starting engine inspection and service.





Fix the engine on a horizontal base.
Remove the coolant hoses, fuel oil pipes, wire harness, control wires etc. connecting the driven machine and
engine, and drain coolant, lubricating oil and fuel.
Remove soil, oil, dust, etc. from the engine by washing with solvent, air, steam, etc. Carefully operate so as not to let
any foreign matter enter the engine.
Any part which is found defective as a result of inspection or any part whose measured value does not satisfy the
standard or limit shall be replaced.
Any part predicted to dissatisfy the standard or limit before the next service as estimated from the state of use
should be replaced even when the measured value then satisfies the standard or limit.

Service Information
Document Title: Function Group: Information Type: Date:
Periodic inspection and
maintenance procedure
200 Service Information 2014/4/14
Profile:
CEX, ECR28 [GB]
Periodic inspection and maintenance procedure
Check before daily operation
Be sure to check the following points before starting the engine every day.
Visual check around engine






Oil leak from the lubrication system
Fuel leak from the fuel system
Cooling water leak from the cooling water system
Damaged parts
Loosened or lost bolts
Fuel, radiator rubber hoses, V belt cracked, loosened clamp
Fuel tank level check and fuel supply
Check the remaining fuel oil level in the fuel tank and refuel the recommended fuel if necessary.
Lube oil level check and replenishment
Checking oil level.
Check the engine oil level with the dipstick, after adjusting the posture of the machine unit so that the engine is
level. Insert the dipstick fully and check the oil level. The oil shall not be contaminated heavily and have appropriate
viscosity. No coolant or diesel oil shall be mixed.
The level shall be between the upper and lower limit lines on the dipstick.
Figure 1
Checking oil level and replenishing with engine oil
1.
2.
3.
4.
Filler port (lube oil)
Dipstick
Upper limit
Lower limit
Engine oil capacity, unit: liter (gal.)
Total volume Effective volume

3.5 (0.92) 1.6 (0.42)
Replenishing oil pan with engine oil.
If the remaining engine oil level is low, fill the oil pan with the specified engine oil to the specified level through the
filler port.
NOTE!
The oil should not be overfilled to exceed the upper limit line. Otherwise, oil may jet out from the breather or the
engine may become faulty.
Coolant inspection
Daily inspection of the coolant should be done only by sub-tank.
WARNING
Risk of scalding and burns when the expansion tank cap (radiator cap) is opened due to high pressure in the cooling
system.
WARNING
Risk of scalding and burns when the expansion tank cap (radiator cap) is opened due to high pressure in the cooling
system.
WARNING
Before removing the radiator cap, stop the engine and let it cool down sufficiently. When removing it, turn it slowly
to release the pressure.
NOTE!
Securely tighten the filler cap after checking the radiator. Steam can spurt out during operation, if the cap is not properly
tightened.
Checking coolant volume
Check the coolant level in the sub-tank. If the water level is close to the LOW mark, open the sub-tank cap and
replenish the sub-tank with clean soft water or premix to the FULL mark.
The coolant level of the sub-tank shall be between the upper and lower limit lines.
Figure 2
Checking, coolant level in the sub-tank
A.
B.
C.
Sub-tank
Upper limit
Lower limit
Replenishment engine with coolant
If the sub-tank coolant level is lower than the LOW mark, open the radiator cap and check the coolant level in the
radiator. Replenish the radiator with coolant, if the level is low.
Check the coolant level while the engine is cool. Checking when the engine is hot is dangerous. And the
coolant volume is expanded due to the heat.

Daily coolant level check and replenishing shall be done only at the sub-tank. Usually do not open the
radiator cap to check or replenish.
Figure 3
Replenishment, coolant
A.
B.
C.
Tighten
Loosen
Radiator cap
NOTE!
If the coolant runs short quickly or when the radiator runs short of coolant with the sub-tank level unchanged, coolant may
be leaking or the air tightness may be lost. Increase in the sub-tank level during operation is not abnormal. The increased
coolant in the sub-tank returns to the radiator when the engine is cooled down. If the level is normal in the sub-tank but low
in the radiator, check for loosened clamping of the rubber hose between the radiator and sub-tank or a tear in the hose.
Engine: The radiator shall be filled up.
Coolant capacity, unit: liter (gal)
Coolant volume in the engine
0.9 (0.23)
Fuel pipe and cooling water pipe inspection and maintenance
Check the rubber hoses for fuel and cooling water pipes cracked. If the cracked hose is found, replace it with new one. Check
the loosened clamp. If found, tighten it.
Warning lamp & instruments function check
Before and after starting the engine, check to see that the alarm function normally. Failure of alarm cannot warn the lack of
the engine oil or the cooling water. Make it a rule to check the alarm operation before and after starting engine every day.
Checking accelerator operation
Make sure the accelerator of the machine unit can be operated smoothly before starting the engine. If it feels heavy to
manipulate, lubricate the accelerator cable joints and pivots. Adjust the accelerator cable if there is a dislocation or excessive
play between the accelerator and the governor lever.
Inspection after initial 50 hours operation
WARNING
Hot oil and hot engine coolant can cause severe burns!
NOTE!
Replace engine oil after the engine oil becomes warm. It is most effective to drain the engine oil while the engine is still
warm.
In early period of use, the engine oil gets dirty rapidly because of the initial wear of internal parts. Replace the engine oil
earlier. Engine oil filter should also be replaced when the engine oil is replaced. Engine oil and engine oil filter replacing
procedures are as follows. Remove the oil filler cap to drain easily while draining the engine oil.
Drain engine oil



Prepare a waste oil container collecting waste oil.
Remove the drain plug using a wrench to drain the engine oil.
Securely tighten the drain plug after draining the engine oil.

Figure 4
Dipstick gauge, oil pan and drain plug
1.
2.
3.
4.
5.
Dipstick
Oil filler cap
Oil filter
Oil pan
Drain plug
Replacing oil filter





Turn the engine oil filter counterclockwise using a filter wrench to remove it.
Clean the mounting face of the oil filter.
Moisten the new oil filter gasket with the engine oil and install the new engine oil filter manually turning it
clockwise until it comes into contact with the mounting surface, and tighten it further to 3/4 of a turn with
the filter wrench.
Tightening torque: 2.0 ~ 2.4 kgf·m (14.4 ~ 17.3 lbf·ft).
Applicable oil filter part number: 119305-35150.
Figure 5
Replacement, engine oil filter
A.
B.
Loosen
Tighten

C. Engine oil filter
Filling oil and inspection



Filling oil and inspection
NOTE!
Do not overfill the oil pan with engine oil. Be sure to keep the specified level between upper and lower
limit on the dipstick.
Warm up the engine by running for 5 minutes while checking any oil leakage.
Stop the engine after warming up and leave it stopped for about 10 minutes then recheck the engine oil
level with dipstick and replenish the engine oil. If any oil is spilled, wipe it away with a clean cloth.
Checking and adjusting radiator fan V-belt
When there is not enough tension in the V-belt, the V-belt will slip making it impossible for the alternator to generate power
and water pump and cooling fan will not work causing the engine to overheat. Check and adjust the V-belt tension
(deflection) in the following manner.
Press the V-belt with your thumb [approx. 98N (10kgf)] at the middle of the V-belt span to check the tension
(deflection).
Available positions to check and adjust the V-belt tension (deflection) are at the A, B or C direction as shown in the
illustration right.
You may choose a position whichever you can easily carry out the check and adjustment on the machine unit.



"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.
The specified deflection to be measured at each position should be as follows.
Figure 6
Checking and adjustment, radiator fan V-belt
1.
2.
3.
4.
5.
6.
7.
Radiator fan
V-belt
Crankshaft V-pulley
Press with thumb
Deflection
Alternator
Set screw
V-belt deflection, unit: mm (in)
Direction A B C
For used V-belt 10 ~ 14
(0.39 ~ 0.55)
7 ~ 10
(0.28 ~ 0.39)
9 ~ 13
(0.35 ~ 0.51)
For new V-belt 8 ~ 12
(0.31 ~ 0.47)
5 ~ 8
(0.20 ~ 0.31)
7 ~ 11
(0.28 ~ 0.43)



If necessary, adjust the V-belt tension (deflection). To adjust the V-belt tension, loosen the set screw and move the
alternator to tighten the V-belt.
After replacing with a new V-belt and adjusting it, run the engine for 5 minutes and readjust the deflection to the
value in the table above.
Visually check the V-belt for cracks, oiliness or wear.
If any, replace the V-belt with a new one.
Figure 7
Adjustment, V-belt tension
A.
B.
C.
Bar
Adjuster
Alternator
Inspection 50 hours
Be sure to check the following points every 50 hours operation.
Draining of the fuel tank
Figure 8
Draining, fuel tank
1.
2.
3.
Fuel tank
Drain plug
Oil container




Prepare a waste oil container.
Turn the drain cock valve of the fuel tank to drain (water, dirt, etc.) from the fuel tank bottom.
Drain until fuel with no water and dirt flow out. Then tighten the drain cock valve firmly.
Draining of the oil/water separator
Figure 9
Draining, oil/water separator
1.
2.
3.
4.
5.
Air bleeding screw
Float ring
Retaining spring
Retaining ring
Fuel cock
A.
B.
C.
D.
Inlet
Outlet
Close
Open
Drain off the oil/water separator whenever there is a lot of drain collected in the oil/water separator at the bottom of the
cup even if not the time for periodic inspection hour. The cup of the oil/water separator is made from semi-transparency
material and in the cup, the red colored float ring which rises on the surface of the drain is installed to visualize the amount
of drain. Also, the oil/water separator with a sensor to detect the drain for warning device on the control panel is provided as
an option.
Drain off the oil/water separator in the following manner.




Close the fuel cock.
Loosen the retainer ring, and remove the cup, then throw collected water and trash away.
Put a float ring and a spring in the cup and tighten the retainer ring.
Tightening torque: 13 ~ 16 Nm (1.3 ~ 1.6 Kgf.m).
Be sure to bleed off any air in the fuel system.
Bleeding the fuel system