Yanmar 3TNV82A-B Service Manual Download Page 355

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TNV DI Service Manual

12-1

TNV DI Service Manual

Section 12

ALTERNATOR

Page

Before You Begin Servicing .......................................................... 12-3

Introduction.................................................................................... 12-6

Dynamo and Alternator Information .............................................. 12-6

3TNV82A to 4TNV106T - Standard and Optional Dynamos ... 12-6
3TNV82A to 4TNV106T - Standard and Optional Alternators . 12-6

Alternator Specifications................................................................ 12-7

Dynamo Specifications.................................................................. 12-7

Alternator Troubleshooting ............................................................ 12-8

Alternator Components ................................................................. 12-9

Alternator Wiring Diagram ........................................................... 12-10

Alternator Standard Output ........................................................ 12-11

Alternator .................................................................................... 12-12

Removal of Alternator............................................................  12-12
Disassembly of Alternator......................................................  12-12
Reassembly of Alternator ......................................................  12-14
Installation of Alternator.........................................................  12-16

Dynamo Component Location..................................................... 12-17

Dynamo Wiring Diagram ............................................................. 12-18

Operation of Dynamo .................................................................. 12-18

Dynamo Standard Output ........................................................... 12-19

Testing of Dynamo ...................................................................... 12-20

Testing Stator Coil Continuity ................................................  12-20
Testing Stator Coil Short-to-Ground ......................................  12-20
Testing Dynamo Regulated Output .......................................  12-20

TNV_DI_SM_A4.book 1 ページ２００７年１２月６日　木曜日　午前９時２３分

Summary of Contents for 3TNV82A-B

Page 1: ...JAPAN SERVICE MANUAL SERVICE MANUAL 3TNV82A 3TNV82A B 3TNV84 3TNV84T 3TNV84T B 3TNV88 3TNV88 B 3TNV88 U 4TNV84 4TNV84T 4TNV84T Z 4TNV88 4TNV88 B 4TNV88 U 4TNV94L 4TNV98 4TNV98 Z 4TNV98 E 4TNV98T 4TNV...

Page 2: ...ancer and reproductive harm Wash hands after handling Head Office Yanmar Co Ltd 1 32 Chayamachi Kita ku Osaka 530 8311 Japan http www yanmar co jp Yanmar America Corporation 951 Corporate Grove Drive...

Page 3: ...ervice Manual TNV series SERVICE MANUAL 3TNV82A B 3TNV84 3TNV84T B 3TNV88 B U 4TNV84 4TNV84T Z 4TNV88 B U 4TNV94L 4TNV98 Z E 4TNV98T Z 4TNV106 4TNV106T P N 0BTNV G00101 INDUSTRIAL ENGINES TNV_DI_SM_A4...

Page 4: ...test 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 po...

Page 5: ...Introduction 1 1 Yanmar Warranties 2 1 Safety 3 1 General Service Information 4 1 Periodic Maintenance 5 1 Engine 6 1 Fuel System 7 1 Cooling System 8 1 Lubrication System 9 1 Turbocharger 10 1 Starte...

Page 6: ...TABLE OF CONTENTS iv TNV DI Service Manual This Page Intentionally Left Blank TNV_DI_SM_A4 book iv...

Page 7: ...the 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 equipme...

Page 8: ...INTRODUCTION 1 2 TNV DI Service Manual This Page Intentionally Left Blank TNV_DI_SM_A4 book 2...

Page 9: ...or Distributor 2 4 What Yanmar Will Do 2 4 What is Not Covered by this Warranty 2 4 Warranty Limitations 2 5 Warranty Modifications 2 5 Questions 2 5 Retail Purchaser Registration 2 5 Emission System...

Page 10: ...YANMAR WARRANTIES 2 2 TNV DI Service Manual This Page Intentionally Left Blank TNV_DI_SM_A4 book 2...

Page 11: ...occurs first is provided for these specific parts only the cylinder block cylinder head crankshaft forging connecting rods flywheel flywheel housing camshaft timing gear and gear case The Warranty Per...

Page 12: ...any part s of the Yanmar product covered by this Warranty found to be defective in material and or workmanship Such repairs and or replacements will be made at a location designated by Yanmar at no c...

Page 13: ...ts and you may also have other rights which vary from state to state and country to country Limitations set forth in this paragraph shall not apply to the extent that they are prohibited by law Warran...

Page 14: ...d compression ignition engine at no charge to you including diagnosis parts and labor Manufacturer s Warranty Period The model year 1998 or later certified and labeled non road compression ignition en...

Page 15: ...of any warranted part during the warranty period Any replacement part which is functionally identical to the original equipment part in all respects may be used in the maintenance or repair of your e...

Page 16: ...s manual Yanmar recommends that you retain all documentation including receipts covering maintenance on your non road compression ignition engine but Yanmar cannot deny warranty solely for the lack o...

Page 17: ...TNV DI Service Manual 3 1 TNV DI Service Manual Section 3 SAFETY Page Safety Statements 3 3 Safety Precautions 3 4 TNV_DI_SM_A4 book 1...

Page 18: ...SAFETY 3 2 TNV DI Service Manual This Page Intentionally Left Blank TNV_DI_SM_A4 book 2...

Page 19: ...your safety is involved Please read and abide by the message that follows the safety alert symbol A DANGER Danger the word DANGER is in white letters with a red rectangle behind it indicates an immine...

Page 20: ...gnition away while the engine is running or battery is charging Failure to comply will result in death or serious injury 0000003en A DANGER FIRE AND EXPLOSION HAZARD Diesel fuel is flammable and explo...

Page 21: ...ilure to comply will result in death or serious injury 0000010en A DANGER FIRE AND EXPLOSION HAZARD Diesel fuel is flammable and explosive under certain conditions Only fill the fuel tank with diesel...

Page 22: ...014en A DANGER CRUSH HAZARD When you need to transport an engine for repair have a helper assist you to attach it to a hoist and load it on a truck NEVER stand under a hoisted engine If the hoist mech...

Page 23: ...you recharge it Failure to comply will result in death or serious injury 0000007en A DANGER FIRE AND EXPLOSION HAZARD Diesel fuel is flammable and explosive under certain conditions NEVER remove the f...

Page 24: ...ve been removed from the area Failure to comply could result in death or serious injury 0000002en A WARNING EXHAUST HAZARD NEVER operate the engine in an enclosed area such as a garage tunnel undergro...

Page 25: ...ar the alert signals Failure to comply could result in death or serious injury 0000005en A WARNING BURN HAZARD If you must drain the engine oil while it is still hot stay clear of the hot engine oil t...

Page 26: ...system Check the electrical harnesses for cracks abrasions and damaged or corroded connectors ALWAYS keep the connectors and terminals clean Failure to comply could result in death or serious injury...

Page 27: ...Failure to comply could result in death or serious injury 0000015en A WARNING To prevent possible eye injury always wear SAFETY GLASSES while servicing the engine 0000013en A WARNING FUME BURN HAZARD...

Page 28: ...ease in engine speed 9999998en A WARNING Replacing the fuel injection pump involves rewriting the fuel injection data in the E ECU Be sure to contact your local Yanmar dealer before replacing the fuel...

Page 29: ...the engine 0000009en A CAUTION PINCH HAZARD Carefully rotate the alternator toward the cylinder block while loosening the V belt Failure to comply may result in minor or moderate injury 0000014en A CA...

Page 30: ...in engine performance and avoid premature engine wear Avoid operating in extremely dusty conditions Avoid operating in the presence of chemical gases or fumes Avoid operating in a corrosive atmosphere...

Page 31: ...il NEVER overfill Overfilling may result in white exhaust smoke engine overspeed or internal damage 0000005en CAUTION Only use the engine coolant specified Other engine coolants may affect warranty co...

Page 32: ...per 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...

Page 33: ...num alloy 0000023enTNVDISM CAUTION If any indicator fails to illuminate when the key switch is in the ON position see your authorized Yanmar industrial engine dealer or distributor for service before...

Page 34: ...ssembly only Do not replace individual components 0000030en CAUTION Do not loosen or remove the four bolts retaining the fuel injection pump drive gear to the fuel injection pump hub Do not disassembl...

Page 35: ...e gear do not rotate the engine crankshaft Rotating the crankshaft will cause the fuel injection pump to become misaligned 0000048en CAUTION Do not use a high pressure wash directly on the alternator...

Page 36: ...he Electric Wiring Section of this manual The starter motor will malfunction and fail if the resistance is higher than the specified value 0000057en CAUTION Removing the battery cables or the battery...

Page 37: ...ately 275 psi 1 9 MPa 19 kgf cm2 Adding adjusting shims increases the threshold pressure Removing adjusting shims reduces the pressure threshold 0000081en CAUTION Do not rotate the crankshaft with the...

Page 38: ...to result 0000172en CAUTION Allow the engine to warm up for at least five minutes and the idle speed of the engine to return to normal before engaging the transmission or any PTOs Engaging the transmi...

Page 39: ...re of the connector pins resulting in malfunction of the E ECU Take care to prevent water from entering the couplers when plugging or unplugging the connector Water inside the couplers may cause corro...

Page 40: ...SAFETY 3 24 TNV DI Service Manual Safety Precautions This Page Intentionally Left Blank TNV_DI_SM_A4 book 24...

Page 41: ...ngine Components 4 8 MAIN ELECTRONIC CONTROL COMPONENTS AND FEATURES 4 9 Function of Cooling System Components 4 11 Diesel Fuel 4 12 Diesel Fuel Specifications 4 12 Filling The Fuel Tank 4 13 Priming...

Page 42: ...ier4 4 36 3TNV88 U complies with EPA Interim Tier4 4 37 3TNV88 B complies with EPA Interim Tier4 4 38 4TNV84T Z complies with EPA Interim Tier4 4 39 4TNV88 U complies with EPA Interim Tier4 4 40 4TNV8...

Page 43: ...ne Oil 9 Drain Plug Engine Oil 10 Fuel Injection Pump 11 Engine Oil Cooler 12 Engine Oil Filter 13 Dipstick Engine Oil 14 Governor Lever 15 Intake Manifold 16 Fuel Filter 17 Fuel Inlet 18 Fuel Return...

Page 44: ...il Cooler 12 Engine Oil Filter 13 Dipstick Engine Oil 14 Eco governor 15 Intake Manifold 16 Fuel Filter 17 Fuel Inlet 18 Fuel Return to Fuel Tank 19 Top Filler Port Engine Oil 20 Rocker Arm Cover 21 A...

Page 45: ...locker arm cover flywheel end Figure 4 3 left 1 On the exhaust side of the locker arm cover near the flywheel Figure 4 3 left 2 4TNV84 4TNV88 4TNV84T 4TNV88 B 4TNV88 U 4TNV84T Z On the top of the loc...

Page 46: ...t is necessary to identify which regulations a particular engine complies with We have listed several different types of labels you might find on your engine EPA ARB Labels Typical EPA EPA ARB 0003852...

Page 47: ...ion the 97 68 EC emission control label is affixed on the engines ENGINE FAMILY The EPA ARB labels and the 97 68 EC label all have an Engine Family field The following is an explanation of the Engine...

Page 48: ...el filter removes contaminants and sediments from the diesel fuel Periodic replacement of the fuel filter is necessary See the Periodic Maintenance Schedule on page 5 17 for the replacement frequency...

Page 49: ...valve that allows the fuel injection timing to advance and the injection quantity to increase thereby improving the cold start performance of the engine EGR valve Controls the exhaust gas recirculati...

Page 50: ...tion is not available for glow plug engines Droop control Standard with VM series Reduces the engine speed by a certain percentage from no load to full rated load in steady state operation The same pe...

Page 51: ...the engine cooling fan circulates air through the radiator the heat is transferred to the air Radiator Cap The radiator cap controls the cooling system pressure The cooling system is pressurized to r...

Page 52: ...Less than 0 1 is preferred The total aromatics content should not exceed 35 by volume Less than 30 is preferred The PAH polycyclic aromatic hydrocarbons content should be below 10 by volume The metal...

Page 53: ...d or fuel storage containers may be necessary 6 The use of bio diesel fuels that do not comply with the standards as agreed to by the diesel engine manufacturers and the diesel fuel injection equipmen...

Page 54: ...14en A DANGER FIRE AND EXPLOSION HAZARD Diesel fuel is flammable and explosive under certain conditions Before you operate the engine check for fuel leaks Replace rubberized fuel hoses every two years...

Page 55: ...m 2 NEVER use the starter motor to 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 ENGINE OIL Engine Oil Sp...

Page 56: ...be changed when the Total Base Number TBN has been reduced to 1 0 mgKOH g test method JIS K 201 5 2 2 HCI ASTM D4739 HCI Engine Oil Viscosity Select the appropriate engine oil viscosity based on the...

Page 57: ...deep standard oil pan The oil capacity will vary dependant upon which optional oil pan is used Refer to the operation manual provided by the driven machine manufacturer for the actual engine oil capac...

Page 58: ...lant Hot engine coolant may splash and burn you Failure to comply could result in death or serious injury 0000016en A CAUTION COOLANT HAZARD Wear eye protection and rubber gloves when you handle long...

Page 59: ...nt 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 d...

Page 60: ...engine coolant will leak out instead of going into the reserve tank 7 Run the engine until it is at operating temperature Check the level of engine coolant in the reserve tank When the engine is runn...

Page 61: ...pirated Engine Sub Series Cylinder Bore mm Engine Series No of Cylinders Notation Available Engine Speed Intended Uses VH 3200 3600 RPM min 1 Lawn Mower Construction Industrial Machine VM 2000 3000 RP...

Page 62: ...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 V...

Page 63: ...0 17 5 19 0 20 4 21 9 PS 14 9 17 9 19 9 21 8 23 8 25 8 27 8 29 8 High Idling min 1 1600 25 1895 25 2180 25 2375 25 2570 25 2780 25 2995 25 3180 25 Engine Weight Dry with Flywheel Housing 138kg 128 kg...

Page 64: ...0 24 6 PS 16 8 20 1 22 3 24 6 26 8 29 0 31 3 33 5 High Idling min 1 1600 25 1895 25 2180 25 2400 25 2590 25 2810 25 2995 25 3210 25 Engine Weight Dry with Flywheel Housing 161kg 155kg PTO Position Fly...

Page 65: ...30 9 PS 21 5 25 5 34 0 36 5 39 5 42 0 High Idling min 1 1600 25 1895 25 2590 25 2810 25 2995 25 3210 25 Engine Weight Dry with Flywheel Housing 161 kg 155 kg PTO Position Flywheel End Direction of Ro...

Page 66: ...2 27 1 PS 18 4 22 1 24 5 27 0 29 4 31 9 34 2 36 8 High Idling min 1 1600 25 1895 25 2180 25 2400 25 2590 25 2810 25 2995 25 3210 25 Engine Weight Dry with Flywheel Housing 161kg 155kg PTO Position Fl...

Page 67: ...32 9 PS 22 3 26 5 29 8 32 8 35 8 38 7 41 7 44 7 High Idling min 1 1600 25 1895 25 2180 25 2400 25 2590 25 2810 25 2995 25 3210 25 Engine Weight Dry with Flywheel Housing 183kg 170kg PTO Position Flywh...

Page 68: ...6 41 2 PS 29 0 36 5 38 0 41 5 45 5 48 5 52 5 56 0 High Idling min 1 1600 25 1895 25 2180 25 2400 25 2590 25 2810 25 2995 25 3210 25 Engine Weight Dry with Flywheel Housing 183 kg 170 kg PTO Position F...

Page 69: ...4 PS 24 5 29 4 32 7 36 0 39 2 42 5 45 8 48 1 High Idling min 1 1600 25 1895 25 2180 25 2400 25 2590 25 2810 25 2995 25 3210 25 Engine Weight Dry with Flywheel Housing 183 kg 170 kg PTO Position Flywh...

Page 70: ...9 1 34 6 35 3 38 2 41 6 43 0 PS 39 5 47 0 48 0 52 0 56 5 58 5 High Idling min 1 1600 25 1895 25 2180 25 2400 25 2590 25 2700 25 Engine Weight Dry with Flywheel Housing 245 kg 235 kg PTO Position Flywh...

Page 71: ...6 41 2 41 9 45 6 49 3 51 1 PS 47 0 56 0 57 0 62 0 67 0 69 5 High Idling min 1 1600 25 1895 25 2180 25 2400 25 2590 25 2700 25 Engine Weight Dry with Flywheel Housing 248 kg 235 kg PTO Position Flywhe...

Page 72: ...00 kW 41 9 50 4 50 7 55 5 60 3 62 5 PS 57 0 68 5 69 0 75 5 82 0 85 0 High Idling min 1 1600 25 1895 25 2180 25 2400 25 2590 25 2700 25 Engine Weight Dry with Flywheel Housing 258 kg 245 kg PTO Positio...

Page 73: ...Idling min 1 1600 25 1895 25 2205 25 2420 25 2615 25 2725 25 Engine Weight Dry with Flywheel Housing 345kg 330kg PTO Position Flywheel End Direction of Rotation Counterclockwise Viewed From Flywheel E...

Page 74: ...g min 1 1600 25 1875 25 2205 25 2420 25 Engine Weight Dry with Flywheel Housing 355 kg 340 kg PTO Position Flywheel End Direction of Rotation Counterclockwise Viewed From Flywheel End Cooling System L...

Page 75: ...8 26 8 27 8 29 8 23 0 High Idling min 1 2375 25 2485 25 2570 25 2675 25 2780 25 2890 25 2995 25 3180 25 Engine Weight dry with Flywheel Housing 128kg PTO Position Flywheel End Direction of Rotation Co...

Page 76: ...5 High Idling min 1 2590 25 2700 25 2810 25 2920 25 2995 25 Engine Weight dry with Flywheel Housing 155kg PTO Position Flywheel End Direction of Rotation Counterclockwise Viewed From Flywheel End Gov...

Page 77: ...9 0 30 2 31 3 33 5 High Idling min 1 2400 25 2510 25 2590 25 2700 25 2810 25 2920 25 2995 25 3210 25 Engine Weight dry with Flywheel Housing 155kg PTO Position Flywheel End Direction of Rotation Count...

Page 78: ...33 1 34 2 36 8 High Idling min 1 1600 25 1895 25 2400 25 2510 25 2590 25 2700 25 2810 25 2920 25 2995 25 3210 25 Engine Weight dry with Flywheel Housing 161kg 155kg PTO Position Flywheel End Direction...

Page 79: ...0 50 5 52 5 56 0 High Idling min 1 1600 25 1895 25 2590 25 2700 25 2850 25 2950 25 3150 25 Engine Weight dry with Flywheel Housing 183kg 170kg PTO Position Flywheel End Direction of Rotation Countercl...

Page 80: ...igh Idling min 1 2920 25 2995 25 Engine Weight dry with Flywheel Housing 170kg PTO Position Flywheel End Direction of Rotation Counterclockwise Viewed From Flywheel End Governor Mechanical governor Al...

Page 81: ...0 37 6 39 2 40 9 42 5 44 2 45 8 48 1 High Idling min 1 1600 25 1895 25 2180 25 2290 25 2400 25 2510 25 2590 25 2700 25 2810 25 2920 25 2995 25 3210 25 Engine Weight dry with Flywheel Housing 183kg 170...

Page 82: ...0 52 0 54 0 56 5 58 5 High Idling min 1 2250 25 2350 25 2450 25 2550 25 2650 25 Engine Weight dry with Flywheel Housing 240kg PTO Position Flywheel End Direction of Rotation Counterclockwise Viewed F...

Page 83: ...1 PS 47 0 56 0 57 0 59 5 62 0 64 5 67 0 69 5 High Idling min 1 1530 25 1830 25 2150 25 2250 25 2350 25 2450 25 2550 25 2650 25 Engine Weight dry with Flywheel Housing 248kg 235kg PTO Position Flywhee...

Page 84: ...58 0 60 3 62 5 PS 57 0 68 5 75 5 78 8 82 0 85 0 High Idling min 1 1530 25 1830 25 2350 25 2450 25 2550 25 2650 25 Engine Weight dry with Flywheel Housing 258kg 245kg PTO Position Flywheel End Directio...

Page 85: ...By Measuring Compression Pressure on page 15 219 3TNV84 4TNV84 455 485 psi 3 14 3 34 MPa 32 34 kgf cm 355 385 psi 2 45 2 65 MPa 25 27 kgf cm 3TNV84T 4TNV84T 411 441 psi 2 84 3 04 MPa 29 31 kgf cm 340...

Page 86: ...ue when tightened to aluminum alloy 0000023enTNVDISM Item Nominal Thread Diameter x Pitch Tightening Torque Remarks Hexagon Bolt 7T and Nut M6 x 1 0 mm 7 9 ft lb 87 104 in lb 9 8 11 8 N m 1 0 1 2 kgf...

Page 87: ...rs unless otherwise specified Pipe Joint Bolt M8 9 12 ft lb 112 148 in lb 12 7 16 7 N m 1 3 1 7 kgf m M10 14 19 ft lb 173 225 in lb 19 6 18 734 N m 2 0 3 5 kgf m M12 18 25 ft lb 24 5 34 3 N m 2 5 3 5...

Page 88: ...per minute g gram gal gallon U S gal hr gallon U S per hour gal min gallon U S per minute GL gear lubricant hp horsepower U S hr hour I D inside diameter ID identification IDI indirect injection in i...

Page 89: ...2 20500 lb g x 0 03527 oz lbf x 4 4480 N lbf x 0 4536 kgf N x 0 2248 lbf N x 0 1020 kgf kgf x 2 2050 lbf kgf x 9 8070 N ft lb x 1 3558 N m ft lb x 0 1383 kgf m in lb x 0 1130 N m in lb x 0 0115 kgf m...

Page 90: ...GENERAL SERVICE INFORMATION 4 50 TNV DI Service Manual Unit Conversions This Page Intentionally Left Blank TNV_DI_SM_A4 book 50...

Page 91: ...s 5 16 Required EPA ARB Maintenance USA Only 5 16 EPA ARB Installation Requirements USA Only 5 16 Periodic Maintenance Schedule 5 17 Periodic Maintenance Procedures 5 20 After Initial 50 Hours of Oper...

Page 92: ...PERIODIC MAINTENANCE 5 2 TNV DI Service Manual This Page Intentionally Left Blank TNV_DI_SM_A4 book 2...

Page 93: ...ch to start the engine NEVER jump start the engine Sparks caused by shorting the battery to the starter terminals may cause a fire or explosion Failure to comply will result in death or serious injury...

Page 94: ...or sources of ignition Failure to comply will result in death or serious injury 0000005en A DANGER FIRE AND EXPLOSION HAZARD Diesel fuel is flammable and explosive under certain conditions Before you...

Page 95: ...oil hay or dried grass close to the engine during engine operation or shortly after shutdown Failure to comply will result in death or serious injury 0000014en A DANGER FIRE AND EXPLOSION HAZARD Dies...

Page 96: ...ON HAZARD Diesel fuel is flammable and explosive under certain conditions Place an approved container under the air bleed port when you prime the fuel system Never use a shop rag to catch the fuel Wip...

Page 97: ...h or serious injury 0000003en A WARNING SEVER HAZARD Keep hands and other body parts away from moving rotating parts such as the cooling fan flywheel or PTO shaft Wear tight fitting clothing and keep...

Page 98: ...engine surfaces such as the muffler exhaust pipe turbocharger if equipped and engine block during operation and shortly after you shut the engine down These surfaces are extremely hot while the engine...

Page 99: ...allow battery fluid to come in contact with clothing skin or eyes Severe burns could result ALWAYS wear safety goggles and protective clothing when servicing the battery If battery fluid contacts the...

Page 100: ...entally start the engine and not realize you are servicing it This could result in a serious injury If you must service the engine while it is operating remove all jewelry tie back long hair and keep...

Page 101: ...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 NEVER remove the primary strainer if eq...

Page 102: ...N Observe the following environmental operating conditions to maintain engine performance and avoid premature engine wear Avoid operating in extremely dusty conditions Avoid operating in the presence...

Page 103: ...g excessive engine speed and white exhaust smoke This may cause serious engine damage 0000010enTNV CAUTION New Engine Break in On the initial engine start up allow the engine to idle for approximately...

Page 104: ...the oil cap dipstick 0000015en CAUTION 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...

Page 105: ...tighten the air vent screw after the water has drained out 0000025en CAUTION When the engine is operated in dusty conditions clean the air cleaner element more frequently NEVER operate the engine wit...

Page 106: ...on page 5 17 and Periodic Maintenance Procedures on page 5 20 EPA ARB Installation Requirements USA Only The following are the installation requirements for the EPA ARB Unless these requirements are m...

Page 107: ...sh definitively The following should be treated only as a general guideline CAUTION Establish a periodic maintenance plan according to the engine application and make sure you perform the required per...

Page 108: ...l Equipment Check Indicators Check Battery Engine Oil Check Engine Oil Level Drain and Fill Engine Oil 1st time 2ndand after Replace Engine Oil Filter Engine Speed Control Check and Adjust Governor Le...

Page 109: ...expense Intake and Exhaust Clean or Replace Air Cleaner Element Complete Engine Overall Visual Check Daily Check Replace Contact your authorized Yanmar industrial engine dealer or distributor System...

Page 110: ...e the engine oil specified Other engine oils may affect warranty coverage cause internal engine components to seize and or shorten engine life Prevent dirt and debris from contaminating the engine oil...

Page 111: ...the engine to collect waste oil Figure 5 1 6 Remove the oil drain plug Figure 5 2 1 from the engine oil pan Allow oil to drain 7 After all oil has been drained from the engine reinstall the oil drain...

Page 112: ...he 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 slippin...

Page 113: ...a pry bar Figure 5 5 3 to tighten the V belt to the desired tension Then tighten the adjusting bolt Figure 5 5 3 Tighten the V belt to the proper tension There must be clearance Figure 5 6 1 between t...

Page 114: ...ension A B C 5 16 7 16 in 8 12 mm 3 16 5 16 in 5 8 mm 1 4 7 16 in 7 11 mm Used V Belt Tension A B C 3 8 1 2 in 10 14 mm 1 4 3 8 in 7 10 mm 5 16 1 2 in 9 13 mm Every 50 Hours of Operation A DANGER FIRE...

Page 115: ...l filter water separator is positioned higher than the fuel level in the fuel tank water may not drip out when the fuel filter water separator drain cock is opened If this happens turn the air vent sc...

Page 116: ...battery fluid to come in contact with clothing skin or eyes Severe burns could result ALWAYS wear safety goggles and protective clothing when servicing the battery If battery fluid contacts the eyes a...

Page 117: ...the battery in a warm place until the next use This will help start the engine easily at low ambient temperatures Perform the following maintenance every 250 hours of operation Drain Fuel Tank Replace...

Page 118: ...he 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...

Page 119: ...thoroughly clean and rinse with tap water CAUTION ALWAYS be environmentally responsible Follow the guidelines of the EPA or other governmental agencies for the proper disposal of hazardous materials s...

Page 120: ...edal to move This may deform the governor lever or stretch the cable and cause irregular operation of the engine speed control Checking and adjusting the governor lever 1 Check that the governor lever...

Page 121: ...to remove the particulates Use the lowest possible air pressure to remove the dust without damaging the element 4 If the air cleaner is equipped with a double element only remove and replace the inner...

Page 122: ...ven if it is not damaged or dirty When replacing the element clean the inside of the air cleaner case Figure 5 12 4 If the air cleaner is equipped with a double element only remove and replace the inn...

Page 123: ...ve Wipe up any spills immediately Wear eye protection The fuel system is under pressure and fuel could spray out when you remove any fuel system component Failure to comply will result in death or ser...

Page 124: ...rt No Standard Dust proof 3TNV82A 4TNV98 3TNV82A B 4TNV98 B 119802 55801 129907 55801 4TNV98T 4TNV98T Z 4TNV106T 123907 55801 0000072A 2 1 A DANGER FIRE AND EXPLOSION HAZARD Diesel fuel is flammable a...

Page 125: ...e cup Figure 5 15 6 If equipped disconnect the sensor wire Figure 5 15 7 from the cup before removing the cup 5 Carefully hold the cup to prevent fuel from spilling If you spill any fuel clean up the...

Page 126: ...Prime the fuel system See Priming the Fuel System on page 4 15 15 Check for leaks Perform the following maintenance every 1000 hours of operation Drain FlushandRefillCooling SystemWith New Coolant Ad...

Page 127: ...t engine coolant may splash and burn you Failure to comply could result in death or serious injury 0000016en A CAUTION COOLANT HAZARD Wear eye protection and rubber gloves when you handle long life or...

Page 128: ...ic Maintenance Procedures Figure 5 16 4 Drain the coolant from the engine block On models not equipped with an oil cooler remove the coolant drain plug Figure 5 17 1 from the engine block Figure 5 17...

Page 129: ...page 6 7 Perform the following maintenance every 1500 hours of operation Inspect Clean and Test Fuel Injectors Inspect Turbocharger Blower Wash as Necessary 3TNV84T 4TNV84T 4TNV98T and 4TNV106T 3TNV8...

Page 130: ...rbon accumulation inspect clean and test the valve at least every 1500 hours Consult your local Yanmar dealer for this service Inspect and Clean EGR Lead Valve 4TNV84T Z 4TNV98T Z The EGR lead valve i...

Page 131: ...5 20 2 Remove the diaphragm cover spring diaphragm plate Figure 5 20 5 and diaphragm 3 Inspect the diaphragm for tears Inspect the spring for distortion Replace components if necessary 4 Reinstall th...

Page 132: ...d Exhaust Valves Adjustment is necessary to maintain proper contact of the valves and seats See Inspection of Intake and Exhaust Valves on page 6 42 Every 2000 Hours of Operation CAUTION ALWAYS be env...

Page 133: ...Timing Gear Train Specifications 6 11 Camshaft 6 11 Idler Gear Shaft and Bushing 6 13 Timing Gear Backlash 6 13 Crankshaft and Piston Specifications 6 14 Crankshaft 6 14 Thrust Bearing 6 15 Piston 6...

Page 134: ...assembly of Cylinder Head 6 61 Measuring and Adjusting Valve Clearance 6 66 2 Valve Cylinder Heads 6 67 4 Valve Cylinder Heads 6 68 Crankshaft and Camshaft Components 6 71 Disassembly of Engine 6 72 D...

Page 135: ...away from moving rotating parts Failure to comply could result in death or serious injury 0000010en A WARNING FUME BURN HAZARD Always read and follow safety related precautions found on containers of...

Page 136: ...of the engine coolant 0000006en CAUTION Identify all parts and their location using an appropriate method It is important that all parts are returned to the same position during the reassembly proces...

Page 137: ...blies together to be returned to the same position during the reassembly process Label the parts using an appropriate method 0000088en CAUTION Do not allow the honing tool to operate in one position f...

Page 138: ...2A 2 Valve Head Intake 0 0138 0 0217 in 0 35 0 55 mm 0 0315 in 0 8 mm Exhaust 0 0118 0 0197 in 0 30 0 50 mm 0 0315 in 0 8 mm 3TNV84 3TNV84T 3TNV88 4TNV84 4TNV84T 4TNV88 2 Valve Head 4TNV84T 4 Valve He...

Page 139: ...0 3189 in 8 10 mm See Inspection of Valve Guides on page 6 41 Valve Stem Outside Diameter 0 3132 0 3140 in 7 955 7 975 mm 0 3110 in 7 90 mm Valve Stem Bend 0 0014 0 0028 in 0 035 0 070 mm 0 0071 in 0...

Page 140: ...Intake Guide Inside Diameter 0 2759 0 2764 in 7 008 7 020 mm 0 2787 in 7 08 mm See Inspection of Valve Guides on page 6 41 Valve Stem Outside Diameter 0 2734 0 2740 in 6 945 6 960 mm 0 2724 in 6 92 mm...

Page 141: ...than 0 0012 in 0 03 mm 0 0012 in 0 03 mm See Push Rod Bend on page 6 41 and 6 56 Model Inspection Item Standard Limit Reference Page 3TNV82A 3TNV84 3TNV84T 3TNV88 4TNV84 4TNV84T 4TNV88 Arm Shaft Hole...

Page 142: ...6535 in 42 0 mm 1 6339 in 41 5 mm 4TNV84T 4 Valve Head 1 4724 in 37 4 mm 1 4528 in 36 9 mm 4TNV94L 4TNV98 4TNV98T 4 Valve Head 1 5630 in 39 7 mm 1 5433 in 39 2 mm 4TNV106 4TNV106T 4 Valve Head 1 9921...

Page 143: ...Shaft Outside Diameter Bearing Inside Diameter 3TNV82A 3TNV84 3TNV84T 3TNV88 4TNV84 4TNV84T 4TNV88 Gear End Bushing Inside Diameter 1 7713 1 7738 in 44 990 45 055 mm 1 7768 in 45 130 mm See Inspection...

Page 144: ...50 000 50 025 mm 1 9724 in 50 100 mm Camshaft Outside Diameter 1 9655 1 9665 in 49 925 49 950 mm 1 7673 in 49 890 mm Oil Clearance 0 0020 0 0039 in 0 050 0 100 mm 0 0083 in 0 210 mm 4TNV106 4TNV106T...

Page 145: ...m 0 0069 in 0 175 mm Model Inspection Item Standard Limit Reference Page 3TNV82A 3TNV84 3TNV84T 3TNV88 4TNV84 4TNV84T 4TNV88 Crank Gear Cam Gear Idler Gear Fuel Injection Pump Gear and PTO Gear 0 0028...

Page 146: ...4TNV84 4TNV84T 4TNV88 Journal Outside Diameter 1 8879 1 8883 in 47 952 47 962 mm 1 8859 in 47 902 mm Bearing Inside Diameter 1 8898 1 8909 in 48 000 48 026 mm Bearing Insert Thickness 0 0587 0 0591 in...

Page 147: ...aring Insert Thickness 0 0785 0 0791 in 1 995 2 010 mm Oil Clearance 0 0015 0 0027 in 0 038 0 068 mm 0 0059 in 0 150 mm 4TNV94L 4TNV98 4TNV98T Journal Outside Diameter 2 5572 2 5576 in 64 952 64 962 m...

Page 148: ...3 3029 in 83 895 mm 3TNV88 4TNV88 3 4622 3 4634 in 87 940 87 970 mm 3 4604 in 87 895 mm 4TNV94L 3 6982 3 6994 in 93 935 93 965 mm 3 6968 in 93 900 mm 4TNV98 4TNV98T 3 8555 3 8567 in 97 930 97 960 mm 3...

Page 149: ...eter 1 0236 1 0240 in 26 000 26 009 mm 1 0252 in 26 039 mm Pin Outside Diameter 1 0234 1 0236 in 25 995 26 000 mm 1 0222 in 25 965 mm Oil Clearance 0 0000 0 0006 in 0 000 0 014 mm 0 0029 in 0 074 mm 4...

Page 150: ...End Gap 0 0079 0 0157 in 0 200 0 400 mm 0 0193 in 0 490 mm Second Ring Ring Groove Width 0 0801 0 0807 in 2 035 2 050 mm 0 0846 in 2 150 mm Ring Width 0 0776 0 0783 in 1 970 1 990 mm 0 0768 in 2 150 m...

Page 151: ...0079 0 157 in 0 200 0400 mm 0 0193 in 0 490 mm Second Ring Ring Groove Width 0 0797 0 0803 in 2 025 2 040 mm 0 0843 in 2 140 mm Ring Width 0 0776 0 0783 in 1 970 1 990 mm 0 0768 in 1 950 mm Side Clear...

Page 152: ...0 0098 0 0177 in 0 250 0 450 mm 0 0213 in 0 540 mm Second Ring Ring Groove Width 0 0819 0 0825 in 2 080 2 095 mm 0 0864 in 2 195 mm Ring Width 0 0776 0 0783 in 1 970 1 990 mm 0 0768 in 1 950 mm Side C...

Page 153: ...118 0 0177 in 0 300 0 450 mm 0 0213 in 0 540 mm Second Ring Ring Groove Width 0 0815 0 0821 in 2 070 2 085 mm 0 0860 in 2 185 mm Ring Width 0 0776 0 0783 in 1 970 1 990 mm 0 0768 in 1 950 mm Side Clea...

Page 154: ...mm 1 0263 in 26 068 mm Wrist Pin Outside Diameter 1 0234 1 0236 in 25 995 26 000 mm 1 0223 in 25 967 mm Oil Clearance 0 0010 0 0017 in 0 025 0 043 mm 0 0040 in 0 101 mm 4TNV94L 4TNV98 4TNV98T Wrist P...

Page 155: ...Clearance 0 0004 0 0020 in 0 010 0 050 mm 0 0035 in 0 090 mm 4TNV94L 4TNV98 4TNV98T Tappet Bore Block Inside Diameter 0 4724 0 4731 in 12 000 12 018 mm 0 4739 in 12 038 mm Tappet Stem Outside Diamete...

Page 156: ...r Block on page 6 83 3TNV84 3TNV84T 4TNV84 4TNV84T 3 3071 3 3083 in 84 000 84 030 mm 3 3150 in 84 200 mm 3TNV88 4TNV88 3 4646 3 4657 in 88 000 88 030 mm 3 4724 in 88 200 mm 4TNV94L 3 7008 3 7020 in 94...

Page 157: ...146 ft lb 188 0 112 9 N m 19 0 20 0 kgf m Connecting Rod Bolt 3TNV82A M8 x 1 0 mm 27 30 ft lb 37 2 41 2 N m 3 8 4 2 kgf m Applied 3TNV82A 3TNV84 3TNV84T 3TNV88 4TNV84 4TNV84T 4TNV88 M9 x 1 0 mm 33 36...

Page 158: ...plied Steel metal S45C 83 91 ft lb 112 7 122 7 N m 11 5 12 5 kgf m 4TNV94L 4TNV98 4TNV98T 4TNV106 4TNV106T M14 x 1 5 mm 80 94 ft lb 107 9 127 5 N m 11 0 13 0 kgf m Fuel Injector Bolt 3TNV82A 3TNV84 3T...

Page 159: ...and Seat Surface Fuel Return Line Joint Bolt 4TNV94L 4TNV98 4TNV98T 4TNV106 4TNV106T M6 x 1 0 mm 70 86 in lb 7 8 9 8 N m 0 8 1 0 kgf m Not Applied Rocker Arm Cover Bolt 4TNV106 4TNV106T M8 x 1 25 mm 1...

Page 160: ...m 0 217 in 5 5 mm 0 354 in 9 mm Locally Manufactured 2 Valve Guide Tool For Installing Valve Guide Model L1 L2 d1 d2 3TNV82A 0 472 in 12 mm 2 362 in 60 mm 0 512 in 13 mm 0 748 in 19 mm 4TNV84 3TNV84 3...

Page 161: ...5 Valve Spring Compressor For Removal Installation of Valve Spring Yanmar Part No 129100 92630 6 Stem Seal Installer for Installing Valve Stem Seal Model d1 d2 d3 L1 L2 L3 3TNV82A 0 598 in 15 2 mm 0...

Page 162: ...4TNV106T 0 709 in 18 mm 2 756 in 70 mm 2 283 in 58 mm 2 402 in 61 mm Allowance d1 d2 Locally Manufactured 9 Flex Hone For Preparation of Cylinder Walls Model Yanmar Part No Cylinder Bore 3TNV82A 1294...

Page 163: ...TNV98 T series Knurl knob 1 13 CrankshaftPulley Installing Tool For straight pilot Locally Manufactured 4TNV94L 4TNV98 T series 14 Pulley Installing Tool 3TNV82A 4TNV88 For all series 1 0002134 000082...

Page 164: ...hen measuring 4 Micrometer Locally Available For measuring the outside diameters of crankshaft pistons piston pins etc 5 Cylinder Bore Gauge Locally Available For measuring the inside diameters of cyl...

Page 165: ...t bend 10 Torque Wrench Locally Available For tightening nuts and bolts to the specified torque 11 Feeler Gauge Locally Available For measuring piston ring gaps piston ring clearance and valve adjustm...

Page 166: ...vice Manual 2 Valve Cylinder Head 2 VALVE CYLINDER HEAD 2 Valve Cylinder Head Components Figure 6 1 0001919 27 28 22 21 29 30 31 32 26 23 24 25 20 19 18 17 12 14 15 16 13 8 7 2 1 5 6 4 3 11 10 33 9 34...

Page 167: ...ort Bolt 16 Rocker Arm Shaft Support 17 Valve Cap 18 Valve Keepers 19 Spring Retainer 20 Valve Spring 21 Valve Stem Seal 22 Valve Guide 23 Cylinder Head 24 Intake Valve 25 Exhaust Valve 26 Cylinder He...

Page 168: ...gure 6 4 1 on the fuel injection pump Figure 6 4 4 Remove the intake manifold bolts Figure 6 5 1 Remove the intake manifold Figure 6 5 2 Discard the intake manifold gasket Figure 6 5 3 Figure 6 5 5 Re...

Page 169: ...es that the glow plugs be removed in advance Failure to remove the glow plugs in advance could result in damages to the glow plugs because their tips are protruding from the cylinder head combustion c...

Page 170: ...dded vise Twist and pull out on the rocker arm shaft to remove Reverse this process when you reinstall the rocker arm shaft into the supports 2 Slide the rocker arm shaft Figure 6 9 3 out of the rocke...

Page 171: ...Place the cylinder head on the work bench with the combustion side down 2 Remove the valve cap Figure 6 13 1 and keep with the valve it was installed on 3 Using the valve spring compressor tool compr...

Page 172: ...nder head Figure 6 14 Cleaning of Cylinder Head Components Thoroughly clean all components using a non metallic brush and an appropriate solvent Each part must be free of carbon metal filings and othe...

Page 173: ...e within the specified limits See Rocker Arm and Shaft on page 6 9 for the service limit Inspect the contact areas Figure 6 16 1 for excessive wear or damage Figure 6 16 Rocker Arm Shaft Outside Diame...

Page 174: ...st 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 c...

Page 175: ...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 the valve and r...

Page 176: ...d replace the valve spring Corrosion Check for corrosion of the spring material caused by oxidation Squareness Use a flat surface and a square to check each spring for squareness Figure 6 26 See Valve...

Page 177: ...m seals and can be identified by either the paint marks on the outside of the seals or by the color of the seal spring Figure 6 30 4 Ensure they are installed in the correct locations 1 Oil the lip of...

Page 178: ...e 6 32 5 6 Using the valve spring compressor tool compress the valve spring 7 Insert the valve keepers Figure 6 32 2 and slowly release the tension on the valve spring Install the valve cap Figure 6 3...

Page 179: ...port in a padded vise Twist and push on the rocker arm shaft to reinstall Note To properly align the rocker arm shaft with the rocker arm shaft supports first reinstall a rocker arm support Figure 6 3...

Page 180: ...he specified torque Figure 6 37 5 Reinstall the intake manifold using a new gasket Tighten the bolts to the specified torque 6 Install each glow plug Figure 6 38 1 and tighten it with the specified to...

Page 181: ...ual 6 49 4 Valve Cylinder Head 4 VALVE CYLINDER HEAD 4 Valve Cylinder Head Components Figure 6 39 0001861 5 6 8 35 7 1 2 3 4 36 33 24 22 21 23 25 26 28 29 30 31 32 13 14 16 17 18 19 15 9 10 12 11 27 3...

Page 182: ...e Bridge 30 Valve Bridge Seat 31 Valve Adjusting Screw Lock Nut Secondary 32 Valve Adjusting Screw Secondary 33 Push Rod 34 Rocker Arm Shaft 35 Crankcase Breather Components 36 Valve Cover Disassembly...

Page 183: ...1 12 7 Remove the intake manifold bolts Figure 6 41 11 Remove the intake manifold Figure 6 41 10 Discard the intake manifold gasket Figure 6 41 9 8 Disconnect the turbocharger oil supply Figure 6 41 2...

Page 184: ...on line grommets Figure 6 43 1 from the valve cover Figure 6 43 3 and fuel injectors Figure 6 43 2 There is a notch at the 3 o clock position in the valve cover opening to insert the screwdriver Figur...

Page 185: ...at they will be reinstalled in their original locations Figure 6 44 Disassembly of Rocker Arm Assembly Note Identify the rocker arms so they can be reinstalled with the original matching valve and pus...

Page 186: ...r block Discard the cylinder head gasket Figure 6 47 2 Place the cylinder head on the work bench to prevent damage to the combustion surface Figure 6 47 Removal of Intake and Exhaust Valves 1 Place th...

Page 187: ...e intake and exhaust valves Figure 6 49 5 from the cylinder head 9 Remove the valve stem seals Figure 6 49 4 Removal of Valve Guides Note Removal of the valve guides should be postponed until inspecti...

Page 188: ...gure 6 51 See Push Rod on page 6 9 for the service limit Figure 6 51 Inspection of Rocker Arm Assembly Rocker Arm Shaft Hole Diameter 1 Use a telescoping gauge and micrometer to determine if the insid...

Page 189: ...are installed in cylinder head Use a telescoping gauge and micrometer to measure the inside diameter at each end of the valve guide Measure in three places and 90 apart Figure 6 54 See Intake Exhaust...

Page 190: ...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 f...

Page 191: ...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 the valve and...

Page 192: ...s on the inside and outside portions of the springs If the valve spring is fractured replace the valve spring Corrosion Check for corrosion of spring material caused by oxidation Squareness Use a flat...

Page 193: ...des Figure 6 66 1 into the cylinder head to the proper height Figure 6 66 3 using the valve guide installation tool Figure 6 66 2 See Intake Exhaust Valve and Guide on page 6 7 Figure 6 66 Reassembly...

Page 194: ...he workbench with the combustion side down Install the valve spring Figure 6 69 3 and spring retainer Figure 6 69 2 6 Using the valve spring compressor tool compress the valve spring 7 Insert the valv...

Page 195: ...ge 6 25 for specification 1 Fan End 2 Camshaft Side Figure 6 71 Reassembly of Rocker Arm Assembly 1 Reinstall the valve bridges Figure 6 72 3 in their original locations and ensure each seat Figure 6...

Page 196: ...nment stud Figure 6 75 5 Align the hole in the rocker arm shaft and the hole in the rocker arm support bracket Reinstall the alignment stud Figure 6 75 Note Figure 6 75 shows components for one cylind...

Page 197: ...using a new gasket Tighten the bolts to specification 6 Reinstall the intake manifold using a new gasket Tighten the bolts to specification 7 Reconnect the fuel injector return hose and fuel injectio...

Page 198: ...le 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 aft...

Page 199: ...the next step 5 Loosen the valve adjusting screw lock nut Figure 6 78 1 and valve adjusting screw Figure 6 78 2 on the rocker arm and check the valve for inclination of the valve cap entrance of dirt...

Page 200: ...eel Position where both the intake and exhaust valves are closed 3 Make sure there is clearance Figure 6 80 5 between the valve bridge Figure 6 80 1 and the rocker arm Figure 6 80 3 IMPORTANT Do not l...

Page 201: ...rocker arm Figure 6 85 2 and valve bridge Figure 6 85 3 Record the results and use this value as an indication of wear Figure 6 85 9 If adjustment is required proceed to the next step 10 Loosen the v...

Page 202: ...6 4 while tightening the valve adjusting screw lock nut Figure 6 86 5 Recheck the clearance 13 Apply oil to the contact surface between the adjusting screw and push rod 14 Rotate the crankshaft to mea...

Page 203: ...71 Crankshaft and Camshaft Components CRANKSHAFT AND CAMSHAFT COMPONENTS Figure 6 87 0001963 1 6 4 5 3 2 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 35 34 36 37 38 3...

Page 204: ...inary 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 c...

Page 205: ...haft and timing components Removal of Timing Gear Case Cover 1 Remove the bolt and washer retaining the crankshaft pulley IMPORTANT Use care not to damage the threads in the end of the crankshaft when...

Page 206: ...to prevent the idler gear from rotating 2 Install the dial indicator to read the camshaft gear backlash Rotate the camshaft drive gear against the idler gear to measure the backlash Record the measure...

Page 207: ...hub attached to the gear Remove the pump drive gear and hub as an assembly using a gear puller Figure 6 92 Removal of Oil Pan 1 Invert the engine oil pan up on the engine stand 2 Remove the oil pan Fi...

Page 208: ...1 on the cylinder block Move the camshaft Figure 6 95 2 back and forth to measure the end play Record the measurement See Camshaft on page 6 11 for the service limit Figure 6 95 Method B Use a feeler...

Page 209: ...e gear Figure 6 97 4 only if the gear or camshaft require replacement Use a knife edge puller and a press to remove the gear The gear is a shrink fit and will need to be heated to 356 392 F 180 200 C...

Page 210: ...rted Rotate the engine so the connecting rods are horizontal before removing the connecting rod caps 1 Using a feeler gauge measure the connecting rod side clearance as shown Figure 6 100 See Connecti...

Page 211: ...dth of the flattened PLASTIGAGE will indicate the bearing oil clearance Figure 6 102 g Repeat with remaining connecting rods IMPORTANT Do not allow the connecting rod to contact the crankshaft journal...

Page 212: ...kshaft end play Use either of the following two methods Method A Install a dial gauge Figure 6 105 1 on the cylinder block Move the crankshaft Figure 6 105 2 in and out to measure the end play Record...

Page 213: ...of PLASTIGAGE Figure 6 108 1 along the full width of each bearing insert Figure 6 108 IMPORTANT Do not rotate the crankshaft when using PLASTIGAGE A false reading may result c Reinstall bearing caps...

Page 214: ...iquid Gasket No 1212 Yanmar Part No 977770 01212 to the outside diameter of a new oil seal Figure 6 111 2 and install in the gear case cover Apply lithium grease to the lip of the seal Figure 6 111 3...

Page 215: ...cylinders from which they were originally removed On an engine with high hours the pistons rings should be replaced and the cylinder honed See Honing and Boring on page 6 88 or replaced The piston sh...

Page 216: ...the pistons pistonringsandcylindersmay bereusedifthey are found to be within specifications On an engine with high hours the pistons rings should be replaced and the cylinder honed see Honing and Bori...

Page 217: ...new piston rings 11 Repeat the above steps for each cylinder and piston assembly Inspection of Connecting Rod 1 Measure the wrist pin bushing bore using a bore gauge Figure 6 119 1 Replace the bushing...

Page 218: ...face Figure 6 122 3 Rotate the crankshaft and observe runout See Crankshaft on page 6 14 for specifications 4 Use the color check method or Magnaflux to inspect the crankshaft for cracks Replace the c...

Page 219: ...tion of Camshaft Bushing and Bores 1 Measure the I D of the front bushing and the remaining bores in the cylinder block See Camshaft on page 6 11 for specifications 2 If the camshaft bushing is not wi...

Page 220: ...by using a rigid cylinder hone Figure 6 129 1 Be sure not to exceed the maximum cylinder bore specification Deglazing A used cylinder that did not require boringorhoning shouldalwaysbedeglazedwith a b...

Page 221: ...pecifications See Tightening Torques for Standard Bolts and Nuts on page 4 46 Reassembly of Pistons 1 Select the parts needed to reassemble the piston and connecting rod for one cylinder 2 If removed...

Page 222: ...side of the connecting rod as the match marks Figure 6 132 4 stamped into the connecting rod and connecting rod cap When installed in the cylinder the piston identification mark Figure 6 132 2 stampe...

Page 223: ...rks 5 Flywheel End of Engine 6 Camshaft Side of Engine Figure 6 133 1 Lubricate and reinstall the wrist pin Figure 6 134 3 through the piston and connecting rod 2 Reinstall the second circlip Figure 6...

Page 224: ...gure 6 136 3 end gap Figure 6 136 6 Stagger the piston ring end gaps at 120 intervals Figure 6 137 1 2 3 Do not position the top piston ring end gap in line with the wrist pin 1 Top Compression Ring E...

Page 225: ...tallation of Pistons IMPORTANT Do not allow the connecting rod to contact the crankshaft journal during piston installation Damage to the crankshaft bearing journal may result 1 Lubricate the piston p...

Page 226: ...Engine Figure 6 141 Piston Installation Only TNV models 106 T When correctly assembled the identification mark Figure 6 142 2 stamped into the top of the piston will be on the opposite side of the con...

Page 227: ...que See Special Torque Chart on page 6 25 for specifications Figure 6 143 7 Reinstall the remaining pistons in their respective cylinders Reassembly of Camshaft and Timing Components Installation of G...

Page 228: ...out of the way of the camshaft lobes when the camshaft is being reinstalled Note If the engine is not installed on an engine repair fixture stand the engine upright on the flywheel end mounting flange...

Page 229: ...sure the oil hole in the bushing is facing toward the top of the engine 6 Ensure all three timing marks Figure 6 147 A B C are aligned 7 When all gears are properly aligned tighten the idler gear reta...

Page 230: ...150 4 Reinstall the washer and bolt Tighten the bolt to the specified torque See Special Torque Chart on page 6 25 for specifications Installation of Oil Pan 1 Reinstall the oil pickup tube Figure 6 1...

Page 231: ...Head on page 6 46 for the 2 valve cylinder head or 6 62 for the 4 valve cylinder head 3 Reinstall the engine in the machine 4 Reconnect the fuel and coolant lines 5 Reinstall the alternator 6 Reconne...

Page 232: ...ENGINE 6 100 TNV DI Service Manual EGR system EGR SYSTEM EGR system Applicable engines 4TNV98 E 4TNV98 Z Figure 6 153 1 4 5 8 11 12 TNV_DI_SM_A4 book 100...

Page 233: ...ooler inlet 3 EGR cooler 4 EGR pipe 5 EGR valve 6 Spacer EGR lead valve 7 Lead valve EGR 8 Intake manifold 9 Cooling water hose EGR cooler inlet 10 Cooling water hose EGR cooler outlet 11 Cooling wate...

Page 234: ...ces such as the muffler exhaust pipe turbocharger if equipped and engine block during operation and shortly after you shut the engine down These surfaces are extremely hot while the engine is operatin...

Page 235: ...03en A CAUTION COOLANT HAZARD Wear eye protection and rubber gloves when you handle long life or extended life engine coolant If contact with the eyes or skin should occur flush eyes and wash immediat...

Page 236: ...e 2 Loosen the bolts in the coupling flanges of the EGR pipe and EGR valve and remove the EGR pipe 1 EGR pipe Figure 6 155 3 Remove the EGR valve 4TNV84T Z 4TNV98T Z 1 Disconnect the cooling water inl...

Page 237: ...te before measuring the resistances EGR valve operation checks 1 After removing each EGR valve from the engine connect the valve with the connector 2 Connect the valve to the battery s minus terminal...

Page 238: ...ause as exhaust gas circulates through them for a prolonged time carbon is deposited on their inner surfaces possibly deteriorating the EGR ratio To remove carbon deposited inside the lead valves disa...

Page 239: ...The EGR cooler must be periodically cleaned every 1500 hours because the exhaust gas passage is subject to carbon deposition and the cooling water transit portion to scale deposition and these deposi...

Page 240: ...ove the system s components parts and reinstall them replace the steel gaskets between them with new correct ones CAUTION ALWAYS be environmentally responsible Follow the guidelines of the EPA or othe...

Page 241: ...11 Test and Adjustment Specifications 7 12 Special Service Tools 7 13 Measuring Instruments 7 13 Fuel System Diagram 7 14 Fuel System Components 7 15 2 Valve Cylinder Head 7 15 4 Valve Cylinder Head 7...

Page 242: ...s 7 35 Removal of Fuel Injectors 7 35 Testing of Fuel Injectors 7 38 Disassembly and Inspection of Fuel Injectors 7 39 Adjusting Fuel Injector Pressure 7 41 Reassembly of Fuel Injectors 7 41 Installat...

Page 243: ...ailure to comply could result in death or serious injury 0000006en A WARNING Never inject fuel toward you Since the fuel is injected at high pressure from the nozzle it may penetrate the skin resultin...

Page 244: ...aler before replacing the fuel injection pump Failure to rewrite the fuel injection data before replacing the fuel injection pump will void the engine warranty Improper use or misuse of the E ECU may...

Page 245: ...ese adjustments have been made at the factory to meet all applicable emissions regulations and then sealed NEVER attempt to make any adjustments to these sealed adjustment screws If adjustments are re...

Page 246: ...ith the injection pump removed 0000083en CAUTION Each pressure adjusting shim removed or added changes the pressure threshold by approximately 275 psi 1 9 MPa 19 kgf cm2 Adding adjusting shims increas...

Page 247: ...t failure of the connector pins resulting in malfunction of the E ECU Take care to prevent water from entering the couplers when plugging or unplugging the connector Water inside the couplers may caus...

Page 248: ...which consists of a single fuel supply plunger a distributor shaft a hydraulic head and a pump housing The hydraulic head has a delivery valve for each cylinder The fuel injection pump housing contain...

Page 249: ...to the OFF position Use a multimeter or continuity light to check for 12V at the stop solenoid connector in the correct sequence Electronically controlled engines 4TNV84T Z 4TNV98 Z 4TNV98 E and 4TNV...

Page 250: ...de of the MP fuel injection pump is not a fuel supply pump The function of this pump is to raise the pressure of the fuel supplied by the electric fuel supply pump to the internal fuel pressure requir...

Page 251: ...NV106T 83 91 ft lb 113 123 N m 11 5 12 5 kgf m Not Applied High Pressure Fuel Injection Line Nuts 22 25 ft lb 29 34 N m 3 0 3 5 kgf m Not Applied Fuel Return Line Bolts 69 87 in lb 7 8 9 8 N m 0 8 1 0...

Page 252: ...ark Figure 7 3 1 The first character starts with V or W Figure 7 3 Fuel injector identification is critical as each engine has a unique fuel injection pressure The fuel nozzle is specifically matched...

Page 253: ...ring injection pressure 2 Dial Indicator Mituotoyo 2050SB Locally Available Check and adjust fuel injection timing Extension Rod Mituotoyo 303613 Locally Available 3 Fuel Injection Pump Plunger Adapte...

Page 254: ...sure Gallery 8 Pressure Control Valve 9 Trochoid Pump 10 Oil Seal 11 Fuel Injection Pump Cam 12 Engine Crankcase 13 Tappet 14 High Pressure Gallery 15 Overflow Orifice 16 Accumulator 17 Timer Piston 1...

Page 255: ...FUEL SYSTEM TNV DI Service Manual 7 15 Fuel System Components FUEL SYSTEM COMPONENTS 2 Valve Cylinder Head Figure 7 5 0002128 1 2 3 4 5 6 7 8 9 10 19 11 17 18 12 13 14 15 16 TNV_DI_SM_A4 book 15...

Page 256: ...ump Drive Gear Assembly DO NOT remove or loosen the four bolts that fasten the injection pump drive gear to the injection pump drive gear hub 9 Coolant Lines for Cold Start Device 10 Fuel Injection Pu...

Page 257: ...FUEL SYSTEM TNV DI Service Manual 7 17 Fuel System Components 4 Valve Cylinder Head Figure 7 6 0002017 1 18 6 7 8 9 10 11 12 21 16 14 15 13 19 20 17 2 3 5 4 TNV_DI_SM_A4 book 17...

Page 258: ...ub 11 Coolant Lines for Cold Start Device 12 Fuel Injection Pump Insulator 13 Diesel Fuel Injection Pump 14 Rear Fuel Injection Pump Support 15 Fuel Filter Water Separator 16 Electric Fuel Supply Pump...

Page 259: ...fuel injection pump 7 Finish loosening all the fuel line nuts and remove the high pressure fuel lines as an assembly being careful not to bend any of the fuel lines Be sure to protect the fuel system...

Page 260: ...or Figure 7 10 6 13 Remove the rear fuel injection pump bracket s Figure 7 11 1 from the fuel injection pump Note Configuration of the fuel injection pump rear brackets may vary depending upon engine...

Page 261: ...nger opening Using a wrench on the crankshaft pulley bolt rotate the crankshaft until the dial indicator shows that injection pump plunger is at the bottom of it s stroke 17 To aid in reassembly make...

Page 262: ...old the gear train using a large socket wrench on the crankshaft pulley nut Loosen the fuel injection pump drive gear retaining nut Figure 7 16 1 and turn it out to the end of the fuel injection pump...

Page 263: ...1 Figure 7 19 Note Some model engines may require the intake manifold and fuel injection pump insulator Figure 7 20 2 be removed to access the inner fuel injection pump Figure 7 20 1 retaining nuts Fi...

Page 264: ...e emissions regulations and then sealed NEVER attempt to make any adjustments to these sealed adjustment screws If adjustments are required they can be made only by a qualified fuel injection shop tha...

Page 265: ...ce is needed in locating the engine timing index number See To Locate an Authorized Yanmar Industrial Engine Dealer or Distributor on page 2 4 and follow the instructions to locate an authorized Yanma...

Page 266: ...injection pump into the fuel injection pump drive gear and gear housing Reinstall the pump retaining nuts finger tight 5 Reinstall the fuel injection pump drive gear lock washer Figure 7 26 2 and nut...

Page 267: ...ming to compensate for the difference in pump timing index numbers Calculation Example If the difference between the timing index numbers is a positive number the fuel injection pump mounting position...

Page 268: ...fuel injection pump aligns with the 0 5 mark on the timing sticker Figure 7 31 Tighten the fuel injection pump mounting nuts to specification See Special Torque Chart on page 7 11 6 Reinstall the rea...

Page 269: ...engine oil to the fuel injection pump to provide lubrication for initial start up Add 5 7 oz 150 200 cc of clean engine oil to the fuel injection pump at the fill plug located in the upper outside sec...

Page 270: ...IR number for the engine being serviced use the Fuel Injection Reference FIR Chart under FIE Specs on the Yanmar Distributor Website http distributor yanmar co jp The FIR number is determined by the c...

Page 271: ...pump plunger plug Figure 7 39 2 on the top of the fuel injection pump 4 Install a dial indicator adapter and clamp into the pump plunger opening Note Use the Yanmar part no 158090 51831 M14 adapter f...

Page 272: ...wheels used on some OEM Specific DI engines may be marked differently You should contact that specific OEM for information on the identification of the timing marks 1 10 BTDC Before Top Dead Center 2...

Page 273: ...ight the TDC Top Dead Center mark Figure 7 44 1 on the flywheel 9 Highlight the target timing mark Figure 7 45 1 on the flywheel as calculated in Determining the Fuel Injection Timing Specification on...

Page 274: ...igure 7 46 3 Note the reading on the dial indicator Figure 7 47 1 If the reading is less than 2 5 mm 0 098 in the fuel injection timing is retarded If the dial indicator reading is greater than 2 5 mm...

Page 275: ...t wrench When loosening the fuel line nuts always hold the fuel injection pump delivery valves with a back up wrench to prevent loosening Loosen the fuel line nuts at the fuel injectors and then at th...

Page 276: ...ctor out of the cylinder head using the slide hammer 7 Remove the injector nozzle protector Figure 7 49 3 and seat Figure 7 49 4 from the cylinder head 8 Repeat the steps to remove the remaining fuel...

Page 277: ...ectors can be removed by manually pulling them out of the fuel injector wells 6 Remove the injector nozzle protector Figure 7 51 5 and seat Figure 7 51 6 from the cylinder head Discard both items 7 Re...

Page 278: ...See Figure 7 55 for injector ID location See Test and Adjustment Specifications on page 7 12 for correct pressure readings Note The opening pressure of a new fuel injector will be approximately 725 p...

Page 279: ...n is seen Figure 7 54 service or replace the injector Figure 7 53 Figure 7 54 If the fuel injector fails any of these tests it should be serviced or replaced as necessary If the pressure is outside sp...

Page 280: ...top spacer and nozzle body for nicks or scratches Check the contact area between the valve stop spacer and the nozzle valve Figure 7 56 1 for scoring or pitting Use a magnifier glass to inspect the ar...

Page 281: ...pection of Fuel Injectors on page 7 39 2 Remove or add adjusting shims as needed 3 Reassemble the fuel injector assembly See Reassembly of Fuel Injectors on page 7 41 4 Retest the fuel injector See Te...

Page 282: ...the Fuel System on page 4 15 8 Operate the engine and check for fuel and coolant leaks 4 Valve Cylinder Head 1 Reinsert a new nozzle seat Figure 7 60 6 and nozzle protector Figure 7 60 5 in the cylind...

Page 283: ...n the nozzle valve specifications but also in the nozzle holder specifications Therefore it is marked as follows take care not to install a wrong part when replacing it with new one Identifying the fu...

Page 284: ...FUEL SYSTEM 7 44 TNV DI Service Manual Fuel Injectors This Page Intentionally Left Blank TNV_DI_SM_A4 book 44...

Page 285: ...6 Cooling System Diagram 8 6 Engine Coolant Pump Components 8 7 Engine Coolant System Check 8 8 Engine Coolant Pump 8 8 Removal of Engine Coolant Pump 8 8 Disassembly of Engine Coolant Pump 8 10 Clean...

Page 286: ...COOLING SYSTEM 8 2 TNV DI Service Manual This Page Intentionally Left Blank TNV_DI_SM_A4 book 2...

Page 287: ...e coolant may splash and burn you Failure to comply could result in death or serious injury 0000016en A WARNING ENTANGLEMENT HAZARD Stop the engine before you begin to service it NEVER leave the key i...

Page 288: ...D Carefully rotate the alternator toward the cylinder block while loosening the V belt Failure to comply may result in minor or moderate injury 0000014en CAUTION Only use the engine coolant specified...

Page 289: ...AUTION Use a new special O ring between the engine coolant pump and the joint Be sure to use the special O ring for each engine model Although the O ring dimensions are the same as a commercially avai...

Page 290: ...nt pump is representative of the coolant pumps used on other TNV model engines For specific part detail see the parts catalog for the engine you are working on COOLING SYSTEM DIAGRAM 1 Cylinder Head 2...

Page 291: ...et 3 Thermostat 4 Thermostat O Ring 5 Special O Ring 6 Engine Coolant Pump 7 Temperature Switch 8 Gasket 9 Engine Coolant Pump Gasket 10 V Belt 11 Engine Coolant Pump V Pulley 12 Spacer 13 Engine Cool...

Page 292: ...ny of these conditions are present IMPORTANT Make sure the engine and engine coolant are not hot 1 Before removing the engine coolant pump or thermostat it will be necessary to drain the engine coolan...

Page 293: ...gine coolant fan guard if equipped engine coolant fan Figure 8 7 1 spacer Figure 8 7 2 and engine coolant pump V pulley Figure 8 7 3 Figure 8 7 7 Disconnect the coolant hoses and the temperature switc...

Page 294: ...ch Figure 8 9 1 and the other lead to the metal portion of the switch Figure 8 9 2 Figure 8 9 2 Place the temperature switch and an accurate thermometer Figure 8 9 3 in engine coolant 3 Slowly increas...

Page 295: ...11 2 Slowly increase the temperature of the water using an external heat source 3 The thermostat is operating properly if it starts to open at the temperature value stamped on the flange of the thermo...

Page 296: ...ct the condition of the V belt There must be clearance Figure 8 15 1 between the V belt and the bottom of the pulley groove If there is no clearance Figure 8 15 2 between the V belt and the bottom of...

Page 297: ...e cause an internal buildup of rust and scale and or shorten engine life Prevent dirt and debris from contaminating the engine coolant Carefully clean the radiator cap and the surrounding area before...

Page 298: ...COOLING SYSTEM 8 14 TNV DI Service Manual Engine Coolant Pump This Page Intentionally Left Blank TNV_DI_SM_A4 book 14...

Page 299: ...ump Components 9 9 Disassembly of Oil Pump 9 10 Cleaning and Inspection 9 11 Reassembly of Oil Pump 9 12 Trochoid Oil Pump 9 13 3TNV82A B 3TNV88 B 3TNV88 U 4TNV88 B4TNV88 U 3TNV84T Z 4TNV84T Z Oil Pum...

Page 300: ...LUBRICATION SYSTEM 9 2 TNV DI Service Manual This Page Intentionally Left Blank TNV_DI_SM_A4 book 2...

Page 301: ...ing parts Failure to comply could result in death or serious injury 0000010en A WARNING BURN HAZARD Keep your hands and other body parts away from hot engine surfaces such as the muffler exhaust pipe...

Page 302: ...00015en CAUTION Only use the engine oil specified Other engine oils may affect warranty coverage cause internal engine components to seize and or shorten engine life Prevent dirt and debris from conta...

Page 303: ...m2 0 06MPa 0 6kgf cm2 or greater 3TNV82A B 0 31 0 46MPa 3 2 4 7kgf cm2 0 36 0 51MPa 3 7 5 2kgf cm2 3TNV84 3TNV88 4TNV84 4TNV88 0 34 0 49MPa 3 5 5 0kgf cm2 0 39 0 54MPa 4 0 5 5kgf cm2 3TNV88 B 3TNV88 U...

Page 304: ...TNV84 3TNV84T 3TNV88 4TNV84 4TNV88 4TNV84T 0 0008 0 0028 in 0 02 0 07 mm 0 0047 in 0 12 mm Check Outer Rotor Side Clearance on page 9 12 3TNV82A B 3TNV88 B 3TNV88 U 4TNV88 B 4TNV88 U 3TNV84T Z 4TNV84T...

Page 305: ...1 9665 1 9705 in 49 95 50 05 mm Model Inspection Item Standard Limit Reference Page 3TNV82A B 3TNV88 B 3TNV88 U 4TNV88 B 4TNV88 U 3TNV84T Z 4TNV84T Z v g a 0 3937 0 3943 in 10 000 10 015 mm 0 3953 in...

Page 306: ...t on all models Piston Cooling Nozzles Idle Gear Shaft Pressure Regulator Valve Oil Pump Oil Suction Pipe Strainer Cylinder Body Main Gallery Camshaft Bearing Rocker Arm Bearing Rocker Arm Tappet Cam...

Page 307: ...e indicates good oil pressure replace the faulty oil pressure switch or sending unit or faulty machine oil pressure gauge in instrument panel If the mechanical oil pressure test gauge indicates low oi...

Page 308: ...gure 9 5 1 screws Figure 9 5 2 Note The oil pump cover screws are installed using a liquid thread lock It may be necessary to use a localized heat small propane torch and an impact type screwdriver or...

Page 309: ...inner rotor is flush with the top surface of the outer rotor 2 Determine the outside clearance of the outer rotor Insert a feeler gauge between the outer rotor Figure 9 8 1 and the gear case oil pump...

Page 310: ...type 3TNV82A 4TNV88 on page 9 7 for the service limits Reassembly of Oil Pump 1 Lubricate the outer rotor Figure 9 12 1 inner rotor Figure 9 12 2 and pump bore in the gear case cover with clean engine...

Page 311: ...t to the proper tension as described in Check and Adjust Cooling Fan V Belt on page 5 22 TROCHOID OIL PUMP 3TNV82A B 3TNV88 B 3TNV88 U 4TNV88 B4TNV88 U 3TNV84T Z 4TNV84T Z Oil Pump Components The oil...

Page 312: ...9 14 5 and outer rotor Figure 9 14 4 Figure 9 16 Cleaning and inspection Clean the lubricating oil pump pressure regulator valve Figure 9 14 7 and rotor inserting portion Check the parts for wear or f...

Page 313: ...Rotor Tip Clearance on page 9 6 for the service limits Check Outer Rotor Side Clearance Inspect the side clearance between the lubricating oil pump body and the outer rotor To measure the side cleara...

Page 314: ...stall the cover 3 Replace the packing with new one 4 Install the lubricating oil pump assembly to the gear case flange by tightening the bolts with the specified torque 5 Install the gear case cover F...

Page 315: ...ve Gear Figure 9 22 Disassembly of Oil Pump Remove the engine cooling fan guard if equipped engine cooling fan Figure 9 23 3 spacer Figure 9 23 2 engine coolant pump V pulley Figure 9 23 1 and V belt...

Page 316: ...rotor to inner rotor tip clearance Insert a feeler gauge between the top of an inner rotor tooth Figure 9 26 1 and the top of an outer rotor tooth Figure 9 26 2 and measure the clearance Figure 9 26 R...

Page 317: ...Reinstall the outer rotor in the gear case housing The punch mark Figure 9 29 1 on the end of the outer rotor must face away from the gear case housing Figure 9 29 2 Figure 9 29 3 Reinstall the oil pu...

Page 318: ...LUBRICATION SYSTEM 9 20 TNV DI Service Manual Trochoid Oil Pump This Page Intentionally Left Blank TNV_DI_SM_A4 book 20...

Page 319: ...ting of Turbocharger 10 7 Abnormal Sound or Vibration 10 7 Turbocharger Components 10 8 Turbocharger Component Functions 10 10 Theory of Operation 10 11 Compressor Side Sealing Mechanism 10 11 Waste G...

Page 320: ...TURBOCHARGER 10 2 TNV DI Service Manual This Page Intentionally Left Blank TNV_DI_SM_A4 book 2...

Page 321: ...containers of hazardous substances like parts cleaners primers sealants and sealant removers Failure to comply could result in death or serious injury 0000014en A WARNING Never apply over 40 psi 2 8...

Page 322: ...wash fluid or water into the turbocharger Spraying too much wash fluid or water or spraying too quickly will damage the turbocharger 0000063en CAUTION Do not allow any material to fall into the oil li...

Page 323: ...e Model application 3TNV84T CL VM 4TNV84T CL 3TNV84T VM 4TNV98T 4TNV106T CL VM Turbocharger Model RHB31 RHB51 RHF5 RHF5 Turbocharger Specification Standard w waste gate Turbine Type Radial flow Blower...

Page 324: ...ir facility 3a Repair turbocharger Send to qualified repair facility 3b Inspect the lubricating oil line for problem Correct the condition and replace lubricating oil 3c Repair the turbocharger Send t...

Page 325: ...e turbocharger Send to a qualified repair facility Cause Corrective action Hard carbon deposit on the turbine side wheel sealing portion causing abnormal revolution of the turbine shaft Repair the tur...

Page 326: ...informational purposes only Yanmar does not offer individual service parts for turbochargers If the turbocharger is worn or damaged it should be replaced or repaired by a qualified repair facility Fi...

Page 327: ...9 Seal Plate 10 Journal Bearing 11 Thrust Bearing 12 Compressor Housing 13 Flanged Bolt 14 Spring Washer 15 Clamp 16 Turbine Housing 17 Bolt 18 Lock Plate 19 Bearing Housing 20 Retaining Ring 21 Bolt...

Page 328: ...Bolt 9 M5 Spring Washer 10 Compressor Side Clamp 11 Turbine Housing 12 M6 Hex Bolt 13 Turbine Side Clamp 14 Lock Washer 15 Bearing Housing 16 Retaining Ring 17 M3 Countersunk Flat Head Bolt 18 Compres...

Page 329: ...insulating plate thermally isolate heat energy at the turbine side from the bearings and the induction air at the compressor side Bearings Thrust Bearing A thrust force is continuously imposed on the...

Page 330: ...0 3 Figure 10 3 3 Continue to operate the engine under the same load for three to four minutes 4 While the engine is still operating at normal load 75 80 of maximum slowly and evenly spray 2 3 oz 60 9...

Page 331: ...r or have it repaired by a qualified repair facility Inspection of Rotor Play To inspect the rotor the turbocharger must be removed Inspect for maximum rotor end play and run out limits before reinsta...

Page 332: ...un out measurements are outside specified limits See table above Figure 10 5 Waste Gate Valve Test Before reinstalling the turbocharger verify the operation of the waste gate valve Poor waste gate ope...

Page 333: ...eading is less than 15 9 psi 0 11 MPa 1 1 kgf cm2 the waste gate actuator is leaking Replace the turbocharger or have it repaired by a qualified repair facility Installation of Turbocharger 1 Pour 2 o...

Page 334: ...TURBOCHARGER 10 16 TNV DI Service Manual Periodic Inspection This Page Intentionally Left Blank TNV_DI_SM_A4 book 16...

Page 335: ...ard and Optional 11 5 Starter Motor Specifications 11 7 Starter Motor Troubleshooting 11 8 Starter Motor Components 11 9 Starter Motor 11 10 Removal of Starter Motor 11 10 Disassembly of Starter Motor...

Page 336: ...STARTER MOTOR 11 2 TNV DI Service Manual This Page Intentionally Left Blank TNV_DI_SM_A4 book 2...

Page 337: ...from moving rotating parts Failure to comply could result in death or serious injury 0000010en A WARNING SHOCK HAZARD Turn off the battery switch if equipped or disconnect the negative battery cable b...

Page 338: ...al resistance of the battery cable in both directions between the starter motor and the battery is within the value indicated on the wiring diagram The starter motor will malfunction or break down if...

Page 339: ...ge Amperag e Draw rpm Terminal Voltage Amperag e Draw Torque rpm 129129 77010 Denso 228000 0251 DC12V 1 6 hp 1 2 kW 11 5 90A MAX 3000 8 280 Max 87 in lb 9 81N m 1 0 kgf m 900 129407 77010 Denso 228000...

Page 340: ...0 7 7 400 Max 97 in lb 11 0 N m 1 1 kgf m 1400 129940 77010 Hitachi S14 102 DC12V 4 0 hp 3 0 kW 12 160A MAX 3600 10 85 300 Max 60 in lb 6 9 N m 0 7 kgf m 2000 119131 77010 Hitachi S24 13 DC24V 4 8 hp...

Page 341: ...ber of Teeth M3 9 Difference O ring Oil Seal Dry none Application Standard Brush Spring Force 7 868 lbf 35 N 3 6 kgf Height Standard 0 591 in 15 mm Limit 0 354 in 9 mm Magnetic Switch Series Coil Resi...

Page 342: ...ion length Inspect shift lever for deformation return spring for fatigue and pinion for sliding Repair meshing between pinion and ring gear or replace as needed Replace engine oil Repair or replace st...

Page 343: ...8 Gear Housing 9 Shift Lever 10 Torsion Spring 11 Plunger 12 Dust Covers Shims 13 Magnetic Switch Assembly Solenoid 14 Cover 15 M6 Bolts 2 used 16 Armature Assembly 17 Field Coil Assembly 18 Positive...

Page 344: ...wheel housing Figure 11 2 Disassembly of Starter Motor 1 Loosen the M8 nut from the magnetic switch solenoid assembly Figure 11 3 Disconnect the wire from the magnetic switch Figure 11 3 2 Remove the...

Page 345: ...rush holder assembly Figure 11 5 1 Figure 11 5 5 Remove the brush holder assembly Figure 11 6 1 from the armature assembly Figure 11 6 3 Figure 11 6 6 Pull the armature assembly Figure 11 6 3 out from...

Page 346: ...1 from the shaft of the pinion Figure 11 10 12 Disassemble the pinion stop Figure 11 11 3 return spring Figure 11 11 4 pinion clutch assembly Figure 11 11 1 and pinion shaft Figure 11 11 5 Figure 11 1...

Page 347: ...al commutator condition is indicated in Figure 11 14 5 Figure 11 14 See Starter Motor Specifications on page 11 7 for the service limit Armature Coil Continuity Test Check for continuity between the c...

Page 348: ...r Figure 11 18 The multimeter should indicate continuity If the multimeter does not indicate continuity replace the field coil assembly Figure 11 18 Field Coil Insulation Test Check for continuity bet...

Page 349: ...e 11 21 The multimeter should indicate continuity If the multimeter does not indicate continuity replace the magnetic switch Figure 11 21 Series Coil Continuity Test Check for continuity between the S...

Page 350: ...rive direction and is locked by turning it in the opposite direction Replace the pinion clutch assembly if the results are different Figure 11 24 Slide the pinion clutch assembly on the shaft It shoul...

Page 351: ...aring retainer assembly and pinion assembly to the gear housing Reinstall and tighten the three M4 bolts 4 Apply a small amount of high temperature lithium grease obtain locally to the sliding portion...

Page 352: ...r to the brush holder assembly Securely tighten the two bolts 12 Reinstall the two M4 through bolts Figure 11 32 Securely tighten the through bolts Reconnect the wire to the magnetic switch assembly T...

Page 353: ...3 Connect a wire lead between the mounting base of the starter motor Figure 11 35 4 and the battery negative terminal Figure 11 35 5 4 Connect a voltmeter Figure 11 35 7 to the battery negative termin...

Page 354: ...mounting bolts Figure 11 36 1 Tighten the bolts to specification See Tightening Torques for Standard Bolts and Nuts on page 4 46 Figure 11 36 3 Reconnect the electrical wires to the magnetic switch a...

Page 355: ...ternator Troubleshooting 12 8 Alternator Components 12 9 Alternator Wiring Diagram 12 10 Alternator Standard Output 12 11 Alternator 12 12 Removal of Alternator 12 12 Disassembly of Alternator 12 12 R...

Page 356: ...ALTERNATOR 12 2 TNV DI Service Manual Dynamo 12 20 Removal of Dynamo 12 20 Disassembly of Dynamo 12 21 Reassembly of Dynamo 12 21 Installation of Dynamo 12 22 TNV_DI_SM_A4 book 2...

Page 357: ...serious injury 0000010en A WARNING SHOCK HAZARD Turn off the battery switch if equipped or disconnect the negative battery cable before servicing the electrical system Check the electrical harnesses f...

Page 358: ...003en A CAUTION PINCH HAZARD Carefully rotate the alternator toward the cylinder block while loosening the V belt Failure to comply may result in minor or moderate injury 0000014en CAUTION NEVER permi...

Page 359: ...ll be damaged 0000050en CAUTION When the battery indicator goes out it should not come on again The battery indicator only comes on during operation if the alternator fails However if an LED is used i...

Page 360: ...engine you are working on DYNAMO AND ALTERNATOR INFORMATION 3TNV82A to 4TNV106T Standard and Optional Dynamos 3TNV82A to 4TNV106T Standard and Optional Alternators YANMAR Part Number Mfg Mfg Part Num...

Page 361: ...ics Negative Side of Circuit Integrated Regulator IC Regulator Outside Diameter of Pulley 2 724 in 69 2 mm Belt Shape Type A Yanmar Part Number 119910 77200 Nominal Output 20 Amps Weight 3 97 lb 1 8 k...

Page 362: ...k method is also applicable to the bench test With engine idling measure voltage at L terminal and at battery With engine idling turn light switch ON Replace the battery indicator Battery indicator is...

Page 363: ...tor Assembly 6 Stud 2 used 7 Front Frame Housing Bearing 8 Bearing Cover 9 Bearing Cover Bolt 4 used 10 Rotor Assembly 11 Rear Frame Housing Bearing 12 Bearing Cover 13 Thrust Washer 14 Thrust Washer...

Page 364: ...1 5 6 2 4 3 3 B A T CAUTION Do not short circuit the charging system between alternator terminals IG and L Damage to the alternator will result 0000035en CAUTION Do not connect a load between alterna...

Page 365: ...l 12 11 Alternator Standard Output ALTERNATOR STANDARD OUTPUT Figure 12 3 Alternator RPM x10 min 13 5 Volts Constant Ambient Temperature at 77 F 25 C Output Current Cold Hot 60 50 40 30 20 10 0 1 2 3...

Page 366: ...Remove the pulley Figure 12 5 2 Figure 12 5 A WARNING SHOCK HAZARD Turn off the battery switch if equipped or disconnect the negative battery cable before servicing the electrical system Check the ele...

Page 367: ...7 5 Remove the bolts retaining the holder Figure 12 7 2 to the rear frame housing Remove the holder 6 Remove the nut Figure 12 7 3 retaining the insulation bushing Figure 12 7 4 Remove the insulation...

Page 368: ...Discard the bearing 11 If it is necessary to replace the bearing Figure 12 11 1 in the rear frame housing use a puller to remove Discard the bearing Remove the bearing cover Figure 12 11 2 and two thr...

Page 369: ...studs 4 Lubricate the shaft of the rotor assembly Figure 12 14 1 Press the rotor assembly into the front frame housing Figure 12 14 2 and rear frame housing Figure 12 14 3 Figure 12 14 5 Align the fro...

Page 370: ...nut Figure 12 19 2 on the gear case stud and the V belt adjuster bolt Figure 12 19 1 Figure 12 19 2 Reconnect the electrical wires to the alternator Tighten the nuts to 15 20 in lb 1 7 2 3 N m 17 23...

Page 371: ...presentative dynamo For specific part detail see the Parts Catalog for the engine you are working on 1 Rear Cover 2 Nut 3 Lock Washer 4 Flat Washer 5 Rear Bearing 6 Output Wire and Connector 7 Plate 8...

Page 372: ...mo consists of a series of permanent magnets that rotate around a stationary stator coil The magnets are attached to the flywheel which is rotated via the engine cooling fan drive belt The resultant o...

Page 373: ...ALTERNATOR TNV DI Service Manual 12 19 Dynamo Standard Output DYNAMO STANDARD OUTPUT Figure 12 22 0002138 TNV_DI_SM_A4 book 19...

Page 374: ...Dynamo Regulated Output 1 Test and record the battery voltage with the engine not running 2 Start the engine and operate it at normal operating rpm 3 Again check the battery voltage with the engine ru...

Page 375: ...ure 12 25 2 flywheel Figure 12 25 3 flat washer Figure 12 25 4 bearings Figure 12 25 5 and spacer Figure 12 25 6 Figure 12 25 4 Remove the screws Figure 12 26 1 and the stator assembly Figure 12 26 2...

Page 376: ...sely reinstall the nut Figure 12 30 2 on the gear case stud and the V belt adjuster bolt Figure 12 30 1 Figure 12 30 2 Reconnect the dynamo output wire connector 3 Reinstall the V belt Tighten the V b...

Page 377: ...l Section 13 ELECTRONIC CONTROL SYSTEM Page Engines available with the electronic control system 13 2 Before You Begin Servicing 13 2 Introduction 13 4 ELECTRONIC CONTROL SYSTEM 13 4 Electronic contro...

Page 378: ...ELECTRONIC CONTROL SYSTEM 13 2 TNV DI Service Manual This Page Intentionally Left Blank TNV_DI_SM_A4 book 2...

Page 379: ...increase in engine speed 9999998en A WARNING Replacing the fuel injection pump involves rewriting the fuel injection data in the E ECU Be sure to contact your local Yanmar dealer before replacing the...

Page 380: ...or pins of the E ECU with bare hands Doing so may result in corrosion of the connector pins and or damage to the internal circuits of the E ECU due to static electricity Do not force a measuring probe...

Page 381: ...kept clean according to the emission control regulations Figure 13 1 illustrates the electronic engine control system Features of the electronic engine control system include Engine speed control sch...

Page 382: ...ELECTRONIC CONTROL SYSTEM 13 6 TNV DI Service Manual Electronic control harness connections ELECTRONIC CONTROL HARNESS CONNECTIONS TNV_DI_SM_A4 book 6...

Page 383: ...ELECTRONIC CONTROL SYSTEM TNV DI Service Manual 13 7 Electronic control harness connections TNV_DI_SM_A4 book 7...

Page 384: ...ELECTRONIC CONTROL SYSTEM 13 8 TNV DI Service Manual Electronic control harness connections This Page Intentionally Left Blank TNV_DI_SM_A4 book 8...

Page 385: ...e Manual Section 14 ELECTRIC WIRING Page Electric Wiring Precautions 14 3 Electrical Wire Resistance 14 4 Battery Cable Resistance 14 5 Electrical Wire Sizes Voltage Drop 14 6 Conversion of AWG to Eur...

Page 386: ...ELECTRIC WIRING 14 2 TNV DI Service Manual This Page Intentionally Left Blank TNV_DI_SM_A4 book 2...

Page 387: ...bined total resistance of the battery cable in both directions between the starter motor and the battery is within the value indicated in the Battery Cable Resistance chart in the Electric Wiring Sect...

Page 388: ...e per Foot Example Current draw of 100 Amps x 3 feet of 4 AWG wire 100 Amps x 3 Feet x 0 000270 0 08 Volts Voltage Drop AWG Metric Nominal mm Ohms Foot Resistance 20 0 5 0 009967 18 0 8 0 006340 16 1...

Page 389: ...be less than 0 002 For starter motors of greater than 2 68 HP 2 kW the total resistance must be less than 0 0012 AWG mm Maximum Total Battery Cable Length Positive Cable Negative Cable a 12V Starter M...

Page 390: ...0 2 0 2 0 3 0 3 0 4 0 4 0 4 0 60 6 4 4 2 2 1 0 2 0 3 0 3 0 4 0 4 0 4 0 70 6 4 2 2 1 0 2 0 3 0 3 0 4 0 4 0 80 6 4 2 2 1 0 3 0 3 0 4 0 4 0 90 4 2 2 1 0 2 0 3 0 4 0 4 0 100 4 2 2 1 0 2 0 3 0 4 0 24 Volt...

Page 391: ...4 0 325 21 0 723 0 412 20 0 812 0 519 19 0 992 0 653 18 1 024 0 823 17 1 15 1 04 16 1 29 1 31 15 1 45 1 65 14 1 63 2 08 13 1 83 2 63 12 2 05 3 31 11 2 30 4 15 10 2 59 5 27 9 2 91 6 62 8 3 26 8 35 7 3...

Page 392: ...ELECTRIC WIRING 14 8 TNV DI Service Manual Conversion of AWG to European Standards This Page Intentionally Left Blank TNV_DI_SM_A4 book 8...

Page 393: ...ancer and reproductive harm Wash hands after handling Head Office Yanmar Co Ltd 1 32 Chayamachi Kita ku Osaka 530 8311 Japan http www yanmar co jp Yanmar America Corporation 951 Corporate Grove Drive...

Page 394: ...JAPAN SERVICE MANUAL SERVICE MANUAL 3TNV82A 3TNV82A B 3TNV84 3TNV84T 3TNV84T B 3TNV88 3TNV88 B 3TNV88 U 4TNV84 4TNV84T 4TNV84T Z 4TNV88 4TNV88 B 4TNV88 U 4TNV94L 4TNV98 4TNV98 Z 4TNV98 E 4TNV98T 4TNV...

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