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TNV DI Service Manual

This Service Manual has been developed for the exclusive use of service and repair professionals such as 
Yanmar authorized Distributors and Yanmar authorized Dealers. It is written with these professionals in 
mind and may not contain the necessary detail or safety statements that may be required for a non-
professional to perform the service or repair properly and / or safely. Please contact an authorized Yanmar 
repair or service professional before working on your Yanmar product.

Disclaimers:

All information, illustrations and specifications in this manual are based on the latest information available 
at the time of publishing. The illustrations used in this manual are intended as representative reference 
views only. Moreover, because of our continuous product improvement policy, we may modify information, 
illustrations, and / or specifications to explain and / or exemplify a product, service, or maintenance 
improvement. We reserve the right to make any change at any time.

Yanmar and 

 are registered trademarks of Yanmar Co., Ltd. in Japan, the United States and / 

or other countries.

All Rights Reserved:

No part of this publication may be reproduced or used in any form by any means - graphic, electronic, or 
mechanical, including photocopying, recording, taping, or information storage and retrieval systems - 
without the written permission of Yanmar Co., Ltd.

© 2005 Yanmar Co. Ltd.

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

Summary of Contents for 3TNV82A

Page 1: ...N 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 4TNV98T Z 4TNV106 4TNV106T ...

Page 2: ...cancer 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 Buffalo Grove IL 60089 4508 U S A TEL 1 847 541 1900 FAX 1 847 541 2161 http www yanmar com Yanmar Europe B V Brugplein11 1332 BS Almere de Vaart The Netherlands TEL 31 36 5493200 FAX 31 36 5493209 h...

Page 3: ...l 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 book i ページ ２００７年１２月６日 木曜日 午前９時２３分 ...

Page 4: ...ion available at the time of publishing The illustrations used in this manual are intended as representative reference views only Moreover because of our continuous product improvement policy we may modify information illustrations and or specifications to explain and or exemplify a product service or maintenance improvement We reserve the right to make any change at any time Yanmar and are regist...

Page 5: ... 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 Starter Motor 11 1 Alternator 12 1 ELECTRONIC CONTROL SYSTEM 13 1 Electric Wiring 14 1 TNV_DI_SM_A4 book iii ページ ２００７年１２月６日 木曜日 午前９時２３分 ...

Page 6: ...TABLE OF CONTENTS iv TNV DI Service Manual This Page Intentionally Left Blank TNV_DI_SM_A4 book iv ページ ２００７年１２月６日 木曜日 午前９時２３分 ...

Page 7: ...nce the directions in this manual are for a typical engine some specifications and components may be different from your engine Refer to the documentation supplied by the optional equipment manufacturer for specific service instructions Yanmar products are continuously undergoing improvement This Service Manual might not address possible field modifications to the equipment Contact an authorized Y...

Page 8: ...INTRODUCTION 1 2 TNV DI Service Manual This Page Intentionally Left Blank TNV_DI_SM_A4 book 2 ページ ２００７年１２月６日 木曜日 午前９時２３分 ...

Page 9: ...or 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 Warranty 2 6 Yanmar Co Ltd Limited Emission Control System Warranty USA Only 2 6 Your Warranty Rights and Obligations 2 6 Manufacturer s Warranty Period 2 6 Warranty Coverage 2 7 Warranted Parts 2 7 Exclusions 2 ...

Page 10: ...YANMAR WARRANTIES 2 2 TNV DI Service Manual This Page Intentionally Left Blank TNV_DI_SM_A4 book 2 ページ ２００７年１２月６日 木曜日 午前９時２３分 ...

Page 11: ...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 Period for both the standard limited warranty and the extended limited warranty by duration or operation hours begins on the date of delivery to the original retail purchaser and is valid only until the applicable wa...

Page 12: ...f 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 cost to the purchaser for parts or labor What is Not Covered by this Warranty This Warranty does not cover parts affected by or damaged by any reason other than defective materials or workmanship including but not ...

Page 13: ...ay 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 Warranty Modifications Except as modified in writing and signed by the parties this Warranty is and shall remain the complete and exclusive agreement between the parties with respect to warranties superseding all prior...

Page 14: ...n 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 engines are warranted for the periods listed below If any emission related part on your engine is found to be defective during the applicable warranty period the part will be replaced by Yanmar Engine Type Warranty...

Page 15: ...anted 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 engine and shall not reduce Yanmar s warranty obligations Add on or modified parts that are not exempted may not be used The use of any non exempted add on or modified parts shall be grounds for disallowing a warr...

Page 16: ...mar 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 of receipts or for your failure to ensure the performance of all scheduled maintenance Yanmar may deny your warranty coverage of your non road compression ignition engine if a part has failed due to abuse neglect i...

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 ページ ２００７年１２月６日 木曜日 午前９時２３分 ...

Page 18: ...SAFETY 3 2 TNV DI Service Manual This Page Intentionally Left Blank TNV_DI_SM_A4 book 2 ページ ２００７年１２月６日 木曜日 午前９時２３分 ...

Page 19: ...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 imminently hazardous situation which if not avoided will result in death or serious injury Danger is limited to the most extreme situations 0000001en A WARNING Warning the word WARNING is in black letters with an orang...

Page 20: ... 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 explosive under certain conditions When you remove any fuel system component to perform maintenance such as changing the fuel filter place an approved container under the opening to catch the fuel NEVER use a shop rag...

Page 21: ...ply 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 fuel Filling the fuel tank with gasoline may result in a fire and will damage the engine NEVER refuel with the engine running Wipe up all spills immediately Keep sparks open flames or any other form of ignition m...

Page 22: ...R 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 mechanism fails the engine will fall on you causing death or serious injury Failure to comply will result in death or serious injury 0000008en A DANGER FIRE AND EXPLOSION HAZARD Diesel fuel is flammable and explosive ...

Page 23: ... 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 fuel cap with the engine running Failure to comply will result in death or serious injury 0000011en A DANGER FIRE AND EXPLOSION HAZARD Diesel fuel is flammable and explosive under certain conditions NEVER use dies...

Page 24: ...ed 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 underground room manhole or ship s hold without proper ventilation NEVER block windows vents or other means of ventilation if the engine is operating in an enclosed area All internal combustion engines create carbon monox...

Page 25: ... 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 to avoid being burned ALWAYS wear eye protection Failure to comply could result in death or serious injury 0000011en A WARNING BURN HAZARD Batteries contain sulfuric acid NEVER allow battery fluid to come in conta...

Page 26: ... 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 0000009en A WARNING ENTANGLEMENT HAZARD Stop the engine before you begin to service it NEVER leave the key in the key switch when you are servicing the engine Someone may accidentally start the engine and not real...

Page 27: ...mply 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 Always read and follow safety related precautions found on containers of hazardous substances like parts cleaners primers sealants and sealant removers Failure to comply could result in death or serious injury 000...

Page 28: ...e 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 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 result in death or serious injury due to an...

Page 29: ...000009en 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 CAUTION If any oil pump component clearance exceeds its limit the oil pump must be replaced as an assembly 0000015en CAUTION Only use diesel fuels recommended by Yanmar for the best engine performance to prevent en...

Page 30: ...formance 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 such as salt water spray NEVER install the engine in a floodplain unless proper precautions are taken to avoid being subject to a flood NEVER expose the engine to the rain 0000003en CAUTION Observe the following ...

Page 31: ...rfill 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 coverage 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 you rem...

Page 32: ...l pressure diesel fuel leaks engine oil leaks coolant leaks and for proper operation of the indicators and or gauges During the first hour of operation vary the engine speed and the load on the engine Short periods of maximum engine speed and load are desirable Avoid prolonged operation at minimum or maximum engine speeds and loads for the next four to five hours During the break in period careful...

Page 33: ...0023enTNVDISM 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 operating the engine 0000028en CAUTION Establish a periodic maintenance plan according to the engine application and make sure you perform the required periodic maintenance at the intervals indicated Failure to fo...

Page 34: ... 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 disassemble the fuel injection pump drive gear from the hub Correct fuel injection timing will be very difficult or impossible to achieve 0000031en CAUTION The starter motor can be damaged if operated continuously longer t...

Page 35: ... 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 Water will damage the alternator and result in inadequate charging 0000049en CAUTION Do not reverse the positive and negative ends of the battery cable The alternator diode and stator coil will be damaged 0000050e...

Page 36: ...iring 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 while the engine is operating may cause damage to the current limiter depending on the electrical equipment being used This situation could cause loss of control of output voltage The continuous high voltage of 23...

Page 37: ...i 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 injection pump removed 0000083en CAUTION Keep the piston pin parts piston assemblies and connecting rod assemblies together to be returned to the same position during the reassembly process Label the parts using...

Page 38: ...00172en 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 transmission or PTO at an elevated engine speed could result in an unexpected movement of the equipment 0000159en CAUTION Shut down the engine if the fault indicator comes on Continuing running the engine with the fault...

Page 39: ...nnector 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 corrosion resulting in malfunction of the E ECU Avoid plugging unplugging the connector more than approx 10 times Frequent plugging unplugging of the connector may cause contact failure of the connector pins resulting...

Page 40: ...SAFETY 3 24 TNV DI Service Manual Safety Precautions This Page Intentionally Left Blank TNV_DI_SM_A4 book 24 ページ ２００７年１２月６日 木曜日 午前９時２３分 ...

Page 41: ...nts 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 the Fuel System 4 15 Engine Oil 4 15 Engine Oil Specifications 4 15 Engine Oil Viscosity 4 16 Checking Engine Oil 4 16 Adding Engine Oil 4 17 Engine Oil Capacity Typical 4 17 Engine Coolant 4 18 Engine Coolant Spe...

Page 42: ...V88 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 4TNV88 B complies with EPA Interim Tier4 4 41 4TNV98 E complies with EPA Interim Tier4 4 42 4TNV98 Z complies with EPA Interim Tier4 4 43 4TNV98T Z complies with EPA Tier3 4 44 Engine Service Standards 4 45 Tightening ...

Page 43: ...in 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 to Fuel Tank 19 Top Filler Port Engine Oil 20 Rocker Arm Cover 21 Air Intake Port From Air Cleaner 22 Flywheel 23 Starter Motor 24 Exhaust Manifold 25 Alternator Figure 4 1 Only applies to 3TNV84T 4TNV84T 4TNV98T...

Page 44: ... 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 Air Intake Port From Air Cleaner 22 Flywheel 23 Starter Motor 24 Exhaust Manifold 25 Alternator 26 EGR valve 27 EGR cooler 28 EGR pipe Figure 4 2 Only applies to 4TNV84T Z 4TNV98T Z Engine oil drain plug location ...

Page 45: ...over 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 locker arm cover cooling fan end Figure 4 3 left 4 On the top of the 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 1 4TNV94L 4TNV98 4TNV...

Page 46: ...ry 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 REFER TO OWNER S MANUAL FOR MAINTENANCE SPECIFICATIONS AND ADJUSTMENTS EMISSION CONTROL INFORMATION LOW SULFUR FUEL OR ULTRA LOW SULFUR FUEL ONLY THIS ENGINE COMPLIES WITH U S EPA REGULATIONS FOR M Y NONROAD DIE...

Page 47: ...8 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 Family designation 97 68 EC 97 68 EC DIRECTIVE 5 YDX L 1 33 M 3 N Method of air aspiration Number of cylinders Engine speed specifications Displacement liter Non road Off road engine Yanmar Diesel 2005 Model Year...

Page 48: ...oves 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 Please note that the word diesel is implied throughout this manual when the word fuel is used Fuel Filter Water Separator The fuel filter water separator removes contaminants sediments and water from the diesel fu...

Page 49: ...llows 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 recirculation flow rate depending on the engine speed load signals from the E ECU It is installed on the top of the exhaust manifold Accelerator sensor Unlike mechanical governors the Eco governor has no governor lever The a...

Page 50: ...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 percentage droop is maintained even when the load increases at any no load speed Isochronous control Standard with CL series Optional with VM series Offers a constant engine speed from no load to full load The engi...

Page 51: ...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 raise the boiling point of the engine coolant As the engine coolant temperature rises the system pressure and the coolant volume increases When the pressure reaches a preset value the release valve in the radiator...

Page 52: ... 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 content of Na Mg Si and Al should be equal to or lower than 1 mass ppm Test analysis method JPI 5S 44 95 Lubricity The wear mark of WS1 4 should be Max 0 018 in 460 µm at HFRR test Bio Diesel Fuels In Europe and i...

Page 53: ...rage 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 equipment manufacturers or bio diesel fuels that have degraded as per the precautions and concerns above may affect the warranty coverage of your engine See Yanmar Limited Warranty on page 2 3 Filling The Fuel Tank A DANG...

Page 54: ... 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 or every 2000 hours of engine operation whichever comes first even if the engine has been out of service Rubberized fuel lines tend to dry out and become brittle after two years or 2000 hours of engine operation ...

Page 55: ...e 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 Specifications Use an engine oil that meets or exceeds the following guidelines and classifications Service Categories API Service Categories CD or higher Grade CF or higher for EGR equipped engines 4TNV84T Z 4TNV9...

Page 56: ...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 ambient temperature and use the SAE Service Grade Viscosity Chart in Figure 4 5 Figure 4 5 Checking Engine Oil 1 Make sure the engine is level 2 Remove the dipstick Figure 4 6 1 and wipe it with clean cloth 3 Ful...

Page 57: ... 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 capacity of your machine The following are the engine oil capacities for various Yanmar TNV engines Engine Model Dipstick Upper Limit Lower Limit 3TNV82A B 5 8 3 8 qt 5 5 3 6 L 3TNV84 3TNV84T B 7 1 4 1 qt 6 7 3 9 L 3TN...

Page 58: ...ne 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 extended life engine coolant If contact with the eyes or skin should occur flush eyes and wash immediately with clean water Failure to comply may result in minor or moderate injury 0000005en CAUTION Only u...

Page 59: ...t performance Yanmar recommends that soft distilled or demineralized water be used to mix with coolants NEVER mix extended or long life coolants and conventional green coolants NEVER mix different types and or colors of extended life coolants Replace the coolant every 1000 engine hours or once a year Filling Radiator with Engine Coolant Fill the radiator and reserve tank as follows This procedure ...

Page 60: ...ant 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 running and the engine coolant is at normal temperature the coolant level in the tank should be at the FULL HOT mark Figure 4 7 6 If the engine coolant is not at the FULL HOT mark Figure 4 7 6 add additional engine c...

Page 61: ...ne 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 RPM min 1 Agricultural Construction Industrial Machines CH 3000 or 3600 RPM min 1 2 pole Generator Sets Irrigation Pumps CL 1500 or 1800 RPM min 1 4 pole Generator Sets Irrigation Pumps Governor Type Symbol Governo...

Page 62: ...l Type Starting System Electric Starting Cooling System Radiator Lubricating System Forced Lubrication with Trochoid Pump PTO Position Flywheel End Direction of Rotation Counterclockwise Viewed from Flywheel End Atmospheric Condition Room temperature 77 F 25 C Atmospheric pressure 29 53 in Hg 100 kPa 750 mm Hg Relative humidity 30 Fuel Temperature at Fuel Injector Pump Inlet 104 F 40 C Fuel Feedin...

Page 63: ... 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 PTO Position Flywheel End Direction of Rotation Counterclockwise Viewed From Flywheel End Cooling System Liquid Cooled with Radiator Lubricating System Forced Lubrication with Trochoid Pump Normal Oil Pressure at R...

Page 64: ... 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 Flywheel End Direction of Rotation Counterclockwise Viewed From Flywheel End Cooling System Liquid Cooled with Radiator Lubricating System Forced Lubrication with Trochoid Pump Normal Oil Pressure at Rated Engine Spee...

Page 65: ...5 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 Rotation Counterclockwise Viewed From Flywheel End Cooling System Liquid Cooled with Radiator Lubricating System Forced Lubrication with Trochoid Pump Normal Oil Pressure at Rated Engine Speed 0 29 0 44 MPa 0 34 0 49 ...

Page 66: ... 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 Flywheel End Direction of Rotation Counterclockwise Viewed From Flywheel End Cooling System Liquid Cooled with Radiator Lubricating System Forced Lubrication with Trochoid Pump Normal Oil Pressure at Rated Engine Spee...

Page 67: ...6 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 Flywheel End Direction of Rotation Counterclockwise Viewed From Flywheel End Cooling System Liquid Cooled with Radiator Lubricating System Forced Lubrication with Trochoid Pump Normal Oil Pressure at Rated Engine Speed ...

Page 68: ... 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 Flywheel End Direction of Rotation Counterclockwise Viewed From Flywheel End Cooling System Liquid Cooled with Radiator Lubricating System Forced Lubrication with Trochoid Pump Normal Oil Pressure at Rated Engine Sp...

Page 69: ... 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 Flywheel End Direction of Rotation Counterclockwise Viewed From Flywheel End Cooling System Liquid Cooled with Radiator Lubricating System Forced Lubrication with Trochoid Pump Normal Oil Pressure at Rated Engine Speed 0...

Page 70: ...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 Flywheel End Direction of Rotation Counterclockwise Viewed From Flywheel End Cooling System Liquid Cooled with Radiator Lubricating System Forced Lubrication with Trochoid Pump Normal Oil Pressure at Rated Engine Speed ...

Page 71: ...5 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 Flywheel End Direction of Rotation Counterclockwise Viewed From Flywheel End Cooling System Liquid Cooled with Radiator Lubricating System Forced Lubrication with Trochoid Pump Normal Oil Pressure at Rated Engine Speed 0...

Page 72: ... 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 Position Flywheel End Direction of Rotation Counterclockwise Viewed From Flywheel End Cooling System Liquid Cooled with Radiator Lubricating System Forced Lubrication with Trochoid Pump Normal Oil Pressure at Rated Engin...

Page 73: ...600 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 End Cooling System Liquid Cooled with Radiator Lubricating System Forced Lubrication with Trochoid Pump Normal Oil Pressure at Rated Engine Speed 0 31 0 49 MPa With balancer 0 34 0 44 MPa Without balancer 0 39 0 49 ...

Page 74: ...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 Liquid Cooled with Radiator Lubricating System Forced Lubrication with Trochoid Pump Normal Oil Pressure at Rated Engine Speed 0 31 0 49 MPa With balancer 0 34 0 44 MPa Without balancer 0 39 0 49 MPa Normal Oil Pre...

Page 75: ...9 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 Counterclockwise Viewed From Flywheel End Governor Mechanical governor All speed governor Cooling System Liquid Cooled with Radiator Lubricating System Forced Lubrication with Trochoid Pump Normal Oil Pressure Rated...

Page 76: ... 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 Governor Electronic governor All speed governor Cooling System Liquid Cooled with Radiator Lubricating System Forced Lubrication with Trochoid Pump Normal Oil Pressure Rated Engine Speed 0 34 0 49 3 5 5 0 MPa 0 39 0 5...

Page 77: ...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 Counterclockwise Viewed From Flywheel End Governor Mechanical governor All speed governor Cooling System Liquid Cooled with Radiator Lubricating System Forced Lubrication with Trochoid Pump Normal Oil Pressure Rated Eng...

Page 78: ... 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 of Rotation Counterclockwise Viewed From Flywheel End Governor Mechanical governor All speed governor Cooling System Liquid Cooled with Radiator Lubricating System Forced Lubrication with Trochoid Pump Normal Oil ...

Page 79: ... 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 Counterclockwise Viewed From Flywheel End Governor Electronic governor All speed governor Cooling System Liquid Cooled with Radiator Lubricating System Forced Lubrication with Trochoid Pump Normal Oil Pressure Rated Engine ...

Page 80: ... 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 All speed governor Cooling System Liquid Cooled with Radiator Lubricating System Forced Lubrication with Trochoid Pump Normal Oil Pressure Rated Engine Speed 0 32 0 47 3 3 4 8 MPa Low Idle Speed 0 06 0 6 MPa Starting...

Page 81: ... 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 170kg PTO Position Flywheel End Direction of Rotation Counterclockwise Viewed From Flywheel End Governor Mechanical governor All speed governor Cooling System Liquid Cooled with Radiator Lubricating System Forced Lubr...

Page 82: ...6 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 From Flywheel End Governor Electronic governor All speed governor Cooling System Liquid Cooled with Radiator Lubricating System Forced Lubrication with Trochoid Pump Normal Oil Pressure Rated Engine Speed 0 29 0 39 ...

Page 83: ...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 Flywheel End Direction of Rotation Counterclockwise Viewed From Flywheel End Governor Electronic governor All speed governor Cooling System Liquid Cooled with Radiator Lubricating System Forced Lubrication with Trochoid P...

Page 84: ... 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 Direction of Rotation Counterclockwise Viewed From Flywheel End Governor Electronic governor All speed governor Cooling System Liquid Cooled with Radiator Lubricating System Forced Lubrication with Trochoid Pump Normal Oil...

Page 85: ...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 340 370 psi 2 35 2 55 MPa 24 26 kgf cm 3TNV88 4TNV88 4TNV94L 4TNV98 4TNV98T 4TNV106 4TNV106T 483 513 psi 3 33 3 53 MPa 34 36 kgf cm 384 414 psi 2 65 2 85 MPa 27 29 kgf cm Deviation Between Cylinders All Models 29 43 p...

Page 86: ...ened 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 m Use 80 of the value at left when the tightening part is aluminum Use 60 of the value at left for 4T bolts and lock nuts M8 x 1 25 mm 17 21 ft lb 200 251 in lb 22 6 28 4 N m 2 3 2 9 kgf m M10 x 1 5 mm 33 40 ft lb...

Page 87: ...herwise 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 kgf m M14 29 36 ft lb 39 2 49 0 N m 4 0 5 0 kgf m M16 36 43 ft lb 49 0 58 8 N m 5 0 6 0 kgf m Item Nominal Thread Diameter x Pitch Tightening Torque Remarks TNV_DI_SM_A4 book 47 ページ ２００７年１２月６日 木曜日 午前９時２３分 ...

Page 88: ...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 inch in Aq inches Aqueous water in Hg inches Mercury in lb inch pound j joule JASO Japanese Automobile Standards Organization k kelvin kg kilogram kgf cm kilogram force per square centimeter kgf m kilogram force per...

Page 89: ...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 kgf m x 7 2330 ft lb kgf m x 86 8000 in lb kgf m x 9 8070 N m N m x 0 7376 ft lb N m x 8 8510 in lb N m x 0 1020 kgf m psi x 0 0689 bar psi x 6 8950 kPa psi x 0 0703 kg cm bar x 14 5030 psi bar x 100 0000 kPa ba...

Page 90: ...GENERAL SERVICE INFORMATION 4 50 TNV DI Service Manual Unit Conversions This Page Intentionally Left Blank TNV_DI_SM_A4 book 50 ページ ２００７年１２月６日 木曜日 午前９時２３分 ...

Page 91: ...red 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 Operation 5 20 Every 50 Hours of Operation 5 24 Every 250 Hours of Operation 5 27 Every 500 Hours of Operation 5 32 Every 1000 Hours of Operation 5 36 Every 1500 Hours of Operation 5 39 Every 2000 Hours of Operation ...

Page 92: ...PERIODIC MAINTENANCE 5 2 TNV DI Service Manual This Page Intentionally Left Blank TNV_DI_SM_A4 book 2 ページ ２００７年１２月６日 木曜日 午前９時２３分 ...

Page 93: ...he 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 0000004en A DANGER SCALD HAZARD NEVER remove the radiator cap if the engine is hot Steam and hot engine coolant will spurt out and seriously burn you Allow the engine to cool down before you attempt to remove the...

Page 94: ... 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 operate the engine check for fuel leaks Replace rubberized fuel hoses every two years or every 2000 hours of engine operation whichever comes first even if the engine has been out of service Rubberized fuel lines ...

Page 95: ...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 Diesel fuel is flammable and explosive under certain conditions NEVER use diesel fuel as a cleaning agent Failure to comply will result in death or serious injury 0000012en A DANGER CRUSH HAZARD When you need to tran...

Page 96: ...sel 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 Wipe up any spills immediately ALWAYS close the air bleed port after you complete priming the system Wear eye protection The fuel system is under pressure and fuel could spray out when you open the air bleed port If ...

Page 97: ... 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 your hair short or tie it back while the engine is running Remove all jewelry before you operate or service the machine NEVER start the engine in gear Sudden movement of the engine and or machine could cause deat...

Page 98: ...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 operating and could seriously burn you Failure to comply could result in death or serious injury 0000015en A WARNING ALCOHOL AND DRUG HAZARD NEVER operate the engine while you are under the influence of alcoh...

Page 99: ...y 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 and or skin immediately flush the affected area with a large amount of clean water and obtain prompt medical treatment Failure to comply could result in death or serious injury 0000007en A WARNING HIGH PRESS...

Page 100: ...t 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 your hands other body parts and clothing away from moving rotating parts Failure to comply could result in death or serious injury 0000010en A WARNING BURN HAZARD If you must drain the engine oil while it is stil...

Page 101: ...ended 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 equipped from the fuel tank filler port If removed dirt and debris could get into the fuel system causing it to clog 0000004en CAUTION Only use the engine oil specified Other engine oils may affect warranty coverag...

Page 102: ... following environmental operating conditions to maintain 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 such as salt water spray NEVER install the engine in a floodplain unless proper precautions are taken to avoid being subject to a flood NEVER ex...

Page 103: ...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 15 minutes while you check for proper engine oil pressure diesel fuel leaks engine oil leaks coolant leaks and for proper operation of the indicators and or gauges During the first hour of operation vary the eng...

Page 104: ...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 0000016en CAUTION NEVER attempt to adjust the low or high idle speed limit screw This may impair the safety and performance of the machine and shorten its life If the idle speed limit screws require adjustment s...

Page 105: ... 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 with the air cleaner element s removed This may allow foreign material to enter the engine and damage it 0000026en CAUTION The maximum air intake restriction in terms of differential pressure measurement must not ex...

Page 106: ... 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 met the exhaust gas emissions will not be within the limits specified by the EPA and ARB Maximum Exhaust Gas Restriction shall be 3TNV84T 4TNV84T 4TNV98T 4TNV106T 1 71 psi 11 8kPa 1200mmAq or less 3TNV82A 3TNV84 3...

Page 107: ...ely 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 periodic maintenance at the intervals indicated Failure to follow these guidelines will impair the engine s safety and performance characteristics shorten the engine s life and may affect the warranty coverage on yo...

Page 108: ...heck 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 Lever and Engine Speed Control Emission Control Warranty Inspect Clean And Test Fuel Injectors Inspect Turbocharger Blower Wash as Necessary 3TNV84T 4TNV84T 4TNV98T 4TNV106T 3TNV84T B 4TNV84T Z 4TNV98T Z Inspect Cle...

Page 109: ...ake 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 Check Item Daily Periodic Maintenance Interval Every 50 hours Every 250 hours Every 500 hours Every 1000 hours Every 1500 hours Every 2000 hours TNV_DI_SM_A4 book 19 ページ ２００７年１２月６日 木曜日 午前９時２３分 ...

Page 110: ... 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 Carefully clean the oil cap dipstick and the surrounding area before you remove the cap NEVER mix different types of engine oil This may adversely affect the lubricating properties of the engine oil NEVER overfi...

Page 111: ...o 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 plug Figure 5 2 1 and tighten to 139 8 47 0 ft lb 53 9 63 7 N m 5 5 6 5 kgf m 8 Dispose of used oil properly Remove the engine oil filter as follows 1 Turn the engine oil filter Figure 5 2 2 counterclockwise Figu...

Page 112: ...ll slip if it does not have the proper tension This will prevent the alternator from generating sufficient power Also the engine will overheat due to the engine coolant pump pulley slipping Check and adjust the V belt tension deflection as follows 1 Press the V belt down with your thumb with a force of approximately 22 ft lb 98 N m 10 kgf to check the deflection There are three positions to check ...

Page 113: ...ure 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 the V belt and the bottom of the pulley groove If there is no clearance Figure 5 6 2 between the V belt and the bottom of the pulley groove replace the V belt Figure 5 6 Used V Belt Tension A B C 3 8 1 2 in 10 14 m...

Page 114: ...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 AND EXPLOSION HAZARD Diesel fuel is flammable and explosive under certain conditions When you remove any fuel system component to perform maintenance such as changing the fuel filter place an approved container u...

Page 115: ...er 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 screw on the top of the fuel filter water separator 2 3 turns counterclockwise Be sure to tighten the air vent screw after the water has drained out 0000025en CAUTION ALWAYS be environmentally responsible Follow th...

Page 116: ... 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 and or skin immediately flush the affected area with a large amount of clean water and obtain prompt medical treatment Failure to comply could result in death or serious injury 0000007en CAUTION ALWAYS be environme...

Page 117: ...n 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 Engine Oil and Engine Oil Filter Check and Clean Radiator Fins Check and Adjust Cooling Fan V Belt Check and Adjust the Governor Lever and Engine Speed Control Clean Air Cleaner Element Drain Fuel Tank 0000067A 3...

Page 118: ...sposal of hazardous materials such as engine oil diesel fuel and engine coolant Consult the local authorities or reclamation facility NEVER dispose of hazardous materials irresponsibly by dumping them into a sewer on the ground or into ground water or waterways Failure to follow these procedures may seriously harm the environment 0000013en 0000065A 1 2 3 CAUTION Only use the engine oil specified O...

Page 119: ...ean 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 such as engine oil diesel fuel and engine coolant Consult the local authorities or reclamation facility NEVER dispose of hazardous materials irresponsibly by dumping them into a sewer on the ground or into ground w...

Page 120: ... 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 Figure 5 11 1 makes uniform contact with the high idle Figure 5 11 2 and low idle Figure 5 11 3 speed limit screws when the engine speed control is in the high idle speed or low idle speed position Figure 5 11 2...

Page 121: ...e 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 element Figure 5 13 1 if the engine lacks power or the dust indicator actuates if equipped Figure 5 13 5 The inner element should not be removed when cleaning or replacing the outer element The inner element is ...

Page 122: ... 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 inner element Figure 5 13 1 if the engine lacks power or the dust indicator actuates if equipped This is in addition to replacing the outer element CAUTION When the engine is operated in dusty conditions clean the a...

Page 123: ...y 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 serious injury 0000009en CAUTION For maximum engine life Yanmar recommends that when shutting the engine down you allow the engine to idle without load for five minutes This will allow the engine components that oper...

Page 124: ...rd 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 and explosive under certain conditions NEVER use diesel fuel as a cleaning agent Failure to comply will result in death or serious injury 0000012en A DANGER FIRE AND EXPLOSION HAZARD Diesel fuel is flammable and e...

Page 125: ...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 spill completely CAUTION ALWAYS be environmentally responsible Follow the guidelines of the EPA or other governmental agencies for the proper disposal of hazardous materials such as engine oil diesel fuel and engi...

Page 126: ...el 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 Adjust Intake Exhaust Valve Clearance Drain Flush and Refill Cooling System With New Coolant Applicable Element Part No All Models 119802 55710 Every 1000 Hours of Operation A DANGER SCALD HAZARD NEVER remove the ra...

Page 127: ...lant 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 extended life engine coolant If contact with the eyes or skin should occur flush eyes and wash immediately with clean water Failure to comply may result in minor or moderate injury 0000005en CAUTION ALWAYS be en...

Page 128: ...ce 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 FULL LOW 0000074A 2 1 1 0000027B TNV_DI_SM_A4 book 38 ページ ２００７年１２月６日 木曜日 午前９時２３分 ...

Page 129: ...rform 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 3TNV84T B 4TNV84T Z 4TNV98T Z Inspect Clean and Test EGR Valve 4TNV84T Z 4TNV98T E 4TNV98 Z 4TNV98T Z Inspect and Clean EGR Lead Valve 4TNV84T Z 4TNV98T Z Clean EGR Cooler 4TNV84T Z 4TNV98T Z Inspect Crankcase Breathe...

Page 130: ...tion 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 is located in the passage of recirculated gas To prevent carbon accumulation in or clogging of the lead valve inspect and clean the lead valve at regular intervals Consult your local Yanmar dealer for this service ...

Page 131: ...ve 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 the diaphragm diaphragm plate spring and diaphragm cover Tighten the diaphragm bolts to specified torque Failure of the diaphragm and or spring will cause the loss of pressure control and allow an excessive amount ...

Page 132: ...ves 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 environmentally responsible Follow the guidelines of the EPA or other governmental agencies for the proper disposal of hazardous materials such as engine oil diesel fuel and engine coolant Consult the local authoriti...

Page 133: ...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 16 Piston Ring 6 18 Connecting Rod 6 22 Tappet 6 23 Cylinder Block Specifications 6 24 Cylinder Block 6 24 Special Torque Chart 6 25 Torque for Bolts and Nuts 6 25 Special Service Tools 6 28 Measuring Instruments ...

Page 134: ...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 Disassembly of Camshaft and Timing Components 6 73 Disassembly of Crankshaft and Piston Components 6 78 Inspection of Crankshaft and Camshaft Components 6 82 Honing and Boring 6 88 Reassembly of Crankshaft and Pis...

Page 135: ...ving 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 hazardous substances like parts cleaners primers sealants and sealant removers Failure to comply could result in death or serious injury 0000014en A CAUTION FLYING OBJECT HAZARD ALWAYS wear eye protection when se...

Page 136: ...ne 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 process 0000080en CAUTION Any part which is found defective as a result of inspection or any part whose measured value does not satisfy the standard or limit must be replaced 0000119en CAUTION Any part determined to no...

Page 137: ...er 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 for any length of time Damage to the cylinder wall will occur Keep the tool in constant up and down motion 0000090en TNV_DI_SM_A4 book 5 ページ ２００７年１２月６日 木曜日 午前９時２３分 ...

Page 138: ...ad 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 Head Intake 0 0118 0 0197 in 0 30 0 50 mm 0 0315 in 0 8 mm Exhaust 0 0118 0 0197 in 0 30 0 50 mm 0 0315 in 0 8 mm 4TNV94L 4TNV98 4TNV98T 4 Valve Head Intake 0 0142 0 0220 in 0 36 0 56 mm 0 0315 in 0 8 mm Exhaust 0 0...

Page 139: ...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 18 mm Exhaust Guide Inside Diameter 0 3156 0 3161 in 8 015 8 030 mm 0 3189 in 8 10 mm Valve Stem Outside Diameter 0 3132 3134 in 7 955 7 960 mm 0 3110 in 7 90 mm Valve Stem Bend 0 0018 0 0030 in 0 045 0 075 mm 0 ...

Page 140: ...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 Valve Stem Bend 0 0019 0 0030 in 0 048 0 075 mm 0 0063 in 0 16 mm Exhaust Guide Inside Diameter 0 2759 0 2764 in 7 008 7 020 mm 0 2787 in 7 08 mm Valve Stem Outside Diameter 0 2740 0 2746 in 6 960 6 975 mm 0 2717...

Page 141: ...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 Diameter 0 6299 0 6307 in 16 000 16 020 mm 0 6327 in 16 07 mm See Inspection of Rocker Arm Assembly on page 6 41 and 6 56 Shaft Outside Diameter 0 6286 0 6293 in 15 966 15 984 mm 0 6276 in 15 94 mm Oil Clearance ...

Page 142: ...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 in 50 6 mm 1 9724 in 50 1 mm Squareness 3TNV82A 2 Valve Head 0 0551 in 1 4 mm 4TNV84 3TNV84 3TNV84T 4TNV88 2 Valve Head 0 0551 in 1 4 mm 4TNV84T 4 Valve Head 0 0551 in 1 3 mm 4TNV94L 4TNV98 4TNV98T 4 Valve Head 0 ...

Page 143: ... 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 of Camshaft on page 6 87 Camshaft Outside Diameter 1 7687 1 7697 in 44 925 44 950 mm 1 7673 in 44 890 mm Oil Clearance 0 0016 0 0051 in 0 040 0 130 mm 0 0094 in 0 240 mm Intermediate Bore Inside Diameter 1 7716 1...

Page 144: ...5 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 Gear End Bushing Inside Diameter 2 2827 2 2854 in 57 980 58 050 mm 2 2876 in 58 105 mm Camshaft Outside Diameter 2 2799 2 2811 in 57 910 57 940 mm 2 2785 in 57 875 mm Oil Clearance 0 0016 0 0055 in 0 040 0 140 mm ...

Page 145: ...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 0 0059 in 0 07 0 15 mm 0 0067 in 0 17 mm See Checking Timing Gear Backlash on page 6 73 4TNV94L 4TNV98 4TNV98T 4TNV106 4TNV106T Crank Gear Cam Gear Idler Gear Fuel Injection Pump Gear and PTO Gear 0 0031 0 0055 ...

Page 146: ...T 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 1 492 1 500 mm Oil Clearance 0 0015 0 0029 in 0 038 0 074 mm 0 0059 in 0 150 mm 4TNV94L 4TNV98 4TNV98T Journal Outside Diameter 2 2816 2 2820 in 57 952 57 962 mm 2 2796 in 57 902 mm Bearing Inside Diameter 2 2835...

Page 147: ...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 mm 2 5552 in 64 902 mm Bearing Inside Diameter 2 5590 2 5598 in 65 000 65 020 mm Bearing 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 4TNV106 4TN...

Page 148: ... 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 8541 in 97 895 mm 4TNV106 4TNV106T 4 1705 4 1716 in 105 930 105 960 mm 4 1685 in 105 880 mm Piston Diameter Measure Location Upward From the Bottom of the Piston 3TNV82A 0 6299 in 16 mm 3TNV84 3TNV84T 4TNV84 4TN...

Page 149: ... 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 4TNV94L 4TNV98 4TNV98T Hole Inside Diameter 1 1811 1 1815 in 30 000 30 009 mm 1 1826 in 30 039 mm Pin Outside Diameter 1 1807 1 1811 in 29 989 30 000 mm 1 1795 in 29 959 mm Oil Clearance 0 0000 0 0008 in 0 000 0 02...

Page 150: ...9 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 mm Side Gap 0 0018 0 0031 in 0 045 0 080 mm 0 0079 in 0 200 mm End Gap 0 0079 0 0157 in 0 200 0 400 mm 0 0193 in 0 490 mm Oil Ring Ring Groove Width 0 1581 0 1587 in 4 015 4 030 mm 0 1626 in 4 130 mm Ring Width 0 1...

Page 151: ... 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 Clearance 0 0014 0 0028 in 0 035 0 070 mm 0 0075 in 0 190 mm End Gap 0 0079 0 0157 in 0 200 0 400 mm 0 0193 in 0 490 mm Oil Ring Ring Groove Width 0 1581 0 1587 in 4 015 4 030 mm 0 1626 in 4 130 mm Ring Width 0 1563 15...

Page 152: ...7 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 Clearance 0 0035 0 0049 in 0 090 0 125 mm 0 0096 in 0 245 mm End Gap 0 0177 0 0256 in 0 450 0 650 mm 0 0287 in 0 730 mm Oil Ring Ring Groove Width 0 1187 0 1193 in 3 015 3 030 mm 0 1232 in 3 130 mm Ring Width 0 11...

Page 153: ...n 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 Clearance 0 0031 0 0045 in 0 080 0 115 mm 0 0093 in 0 235 mm End Gap 0 0177 0 0236 in 0 450 0 600 mm 0 0268 in 0 680 mm Oil Ring Ring Groove Width 0 1187 0 1193 in 3 015 3 030 mm 0 1232 in 3 130 mm Ring Width 0 1169 ...

Page 154: ... 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 Pin Bushing Inside Diameter 1 1821 1 1826 in 30 025 30 038 mm 1 1838 in 30 068 mm Wrist Pin Outside Diameter 1 1806 1 1811 in 29 987 30 000 mm 1 1795 in 29 959 mm Oil Clearance 0 0010 0 0020 in 0 025 0 51 mm 0 0043...

Page 155: ... 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 Diameter 0 4715 0 4720 in 11 975 11 990 mm 0 4707 in 11 955 mm Oil Clearance 0 0004 0 0017 in 0 010 0 043 mm 0 0033 in 0 083 mm 4TNV106 4TNV106T Tappet Bore Block Inside Diameter 0 5512 0 5519 in 14 000 14 018 mm 0 5527...

Page 156: ...age 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 94 000 94 030 mm 3 7059 in 94 130 mm 4TNV98 4TNV98T 3 8583 3 8594 in 98 000 98 030 mm 3 8634 in 98 130 mm 4TNV106 4TNV106T 4 1732 4 1744 in 106 000 106 030 mm 4 1783 in 106 130 mm Cylinder Bore Roundness 0 0004 in ...

Page 157: ... 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 ft lb 44 1 49 0 N m 4 5 5 0 kgf m 4TNV94L 4TNV98 4TNV98T M10 x 1 0 mm 40 43 ft lb 53 9 58 8 N m 5 5 6 0 kgf m 4TNV106 4TNV106T M11 x 1 0 mm 58 62 ft lb 78 5 83 4 N m 8 0 8 5 kgf m Flywheel Bolt 3TNV82A 3TNV84 3TNV...

Page 158: ...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 3TNV84T 3TNV88 4TNV84 4TNV84T 4TNV88 M8 x 1 25 mm 18 21 ft lb 24 4 28 4 N m 2 5 2 9 kgf m Not Applied 4TNV94L 4TNV98 4TNV98T 4TNV106 4TNV106T M8 x 1 25 mm 17 21 ft lb 22 6 28 4 N m 2 3 2 9 kgf m Fuel Pump Drive Gea...

Page 159: ...face 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 148 199 in lb 16 7 22 5 N m 1 7 2 3 kgf m Not Applied Glow Plug 3TNV82A B 3TNV88 B U 4TNV88 B U M10 x 1 25 mm 133 177 in lb 15 20 N m 1 53 2 04 kgf m Not Applied Glow Connector Nut 3TNV82A B 3TNV88 B U 4TNV88 B U ...

Page 160: ... 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 3TNV84T 4TNV88 4TNV88 0 591 in 15 mm 2 559 in 65 mm 0 551 in 14 mm 0 787 in 20 mm 4TNV84T 0 335 in 8 5 mm 2 362 in 60 mm 0 433 in 11 mm 0 669 in 17 mm 4TNV94L 4TNV98 4TNV98T 0 276 in 7 mm 2 362 in 60 mm 0 512 in 1...

Page 161: ...ing 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 0 827 in 21 mm 0 472 in 12 mm 0 622 in 15 8 mm 2 559 in 65 mm 0 157 in 4 mm 3TNV84 3TNV84T 3TNV88 4TNV84 4TNV88 0 638 in 16 2 mm 0 866 in 22 mm 0 531 in 13 5 mm 0 740 in 18 8 mm 2 559 in 65 mm 0 157 in 4 mm 4TNV84T...

Page 162: ...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 129400 92420 3 071 3 307 in 78 84 mm 3TNV88 4TNV88 4TNV94L 129400 92430 3 268 3 740 in 83 95 mm 4TNV98 129400 92440 3 504 3 976 in 89 101 mm 4TNV106 4TNV106T 129400 92450 3 740 4 252 in 95 108 mm 10 Piston Ring Compr...

Page 163: ...nurl 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 0000826 30 26 20 6 ø42 0 075 0 063 ø0 03 A 1 6 ø29 7 17 R 1 25 C 1 C 0 5 C 0 5 M14 1 5 C 1 Knuri knob m0 3 25 A 0 2 A A 20 16 36 16 0 1 A A M14 x 1 5 52 0 05 6 3 C 0 5 C 0 5 C 1 C 1 ø 6 ø 35 4 0 05 0 15 3 Knurling TNV_DI_S...

Page 164: ...g 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 cylinder liners bearing bores etc 6 Calipers Locally Available For measuring outside diameters depth thickness and width 7 Depth Micrometer Locally Available For measuring of valve recession 8 Square Locally Availab...

Page 165: ...que 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 adjustment clearance No Instrument Name Application Illustration 0000839 0000840 0000841 TNV_DI_SM_A4 book 33 ページ ２００７年１２月６日 木曜日 午前９時２３分 ...

Page 166: ...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 TNV_DI_SM_A4 book 34 ページ ２００７年１２月６日 木曜日 午前９時２３分 ...

Page 167: ...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 Head Gasket 27 Fuel Injector Retainer 28 Washer 29 Fuel Injector Retainer Bolt 30 Fuel Injector Nozzle Protector 31 Fuel Injector Nozzle Seat 32 Push Rod 33 Crankcase Breather Components 34 Valve Cover Components o...

Page 168: ... 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 Remove the exhaust manifold bolts Figure 6 5 4 and nuts Figure 6 5 5 Remove the exhaust manifold Figure 6 5 6 and the exhaust manifold gasket Figure 6 5 7 6 Remove the coolant pump See Disassembly of Engine Coolant ...

Page 169: ...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 chamber surface Removal of Valve Cover 1 Remove the valve cover nuts Figure 6 7 1 2 Remove the O ring Figure 6 7 2 on each valve cover nut Figure 6 7 3 Remove the valve cover Figure 6 7 3 and the valve cover gaske...

Page 170: ...st 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 rocker arm supports Figure 6 9 5 springs Figure 6 9 1 and rocker arms Figure 6 9 2 Note Mark the rocker arms so they can be reinstalled with the original matching valve and pushrod Figure 6 9 3 Remove the valve adjusti...

Page 171: ...ylinder 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 compress one of the valve springs Figure 6 12 Figure 6 12 4 Remove the valve keepers Figure 6 13 2 5 Slowly release the tension on the valve spring 6 Remove the spring retainer Figure 6 13 3 and valve spring Figure 6 ...

Page 172: ...ure 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 other debris Inspection of Cylinder Head Components Visually inspect the parts Replace any parts that are obviously discolored heavily pitted or otherwise damaged Discard any parts that do not meet its specified limit...

Page 173: ... 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 Diameter Use a micrometer to measure the rocker arm shaft diameter Measure at each rocker arm location in two directions 90 apart Figure 6 17 See Rocker Arm and Shaft on page 6 9 for the service limit Figure 6 17 Insp...

Page 174: ...lace any valves that are obviously discolored heavily pitted or otherwise damaged Valve Stem Diameter Use a micrometer to measure the valve stem diameter Measure the valve stem near the combustion end and near the opposite end Figure 6 20 1 See Intake Exhaust Valve and Guide on page 6 7 for the service limit Figure 6 20 Valve Stem Bend Place the valve stem on a flat inspection block or layout bed ...

Page 175: ...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 rotate it to distribute bluing onto the valve face The contact pattern should be approximately centered on the valve face Figure 6 24 1 and even in width Figure 6 24 Also visually inspect the valve seat for even co...

Page 176: ... 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 Spring on page 6 10 for the service limit Figure 6 26 Free Length Use a caliper to measure the length of the spring Figure 6 27 See Valve Spring on page 6 10 for the service limit Figure 6 27 Reassembly of Cylind...

Page 177: ...an 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 the valve stem seal Figure 6 30 2 Using the valve stem seal installation tool Figure 6 30 1 install a new valve stem seal on each of the valve guides Figure 6 30 3 Figure 6 30 2 Measure the distance Figure 6 31 1...

Page 178: ...ing 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 32 1 Repeat the steps on all the remaining valves Reassembly of Cylinder Head 1 Carefully clean both the combustion surface of the cylinder head and the top surface of the cylinder block Then place a new cylinder h...

Page 179: ...ded 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 36 5 having a hole for the shaft alignment stud Figure 6 36 4 Align the hole in the rocker arm shaft and the hole in the rocker arm support Reinstall the alignment stud Figure 6 36 Note Figure 6 36 shows components...

Page 180: ... 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 torque Install each electrical harness Figure 6 38 1 and tighten it with the specified torque Figure 6 38 7 Reinstall the fuel injectors See Installation of the Fuel Injectors on page 7 42 8 Reinstall the high pres...

Page 181: ...lve 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 34 20 TNV_DI_SM_A4 book 49 ページ ２００７年１２月６日 木曜日 午前９時２３分 ...

Page 182: ...alve 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 of 4 Valve Cylinder Head Prepare a clean flat working surface on a workbench large enough to accommodate the cylinder head assembly Discard all gaskets O rings and seals Use new gaskets O rings and seals on reass...

Page 183: ...e 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 and the return lines Figure 6 41 4 if equipped 9 Remove the exhaust manifold bolts Figure 6 41 7 Remove the exhaust manifold Figure 6 41 6 with the turbocharger attached Discard the exhaust manifold gasket Figur...

Page 184: ...ets 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 Figure 6 42 3 Remove the valve cover nuts Figure 6 43 4 4 Remove the O ring Figure 6 43 5 on each valve cover nut Figure 6 43 5 Remove the valve cover Figure 6 43 3 Discard the valve cover gasket Figure 6 43 6 6 Inspec...

Page 185: ...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 pushrod 1 Remove the rocker arm shaft alignment studs Figure 6 45 5 from the rocker arm shaft supports Figure 6 45 6 2 Slide the supports wave washers Figure 6 45 7 rocker arms Figure 6 45 8 and fuel injector retaine...

Page 186: ...rd 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 the cylinder head on the work bench with the combustion side down 2 Using the valve spring compressor tool compress one of the valve springs Figure 6 48 Figure 6 48 1 2 0001864 16 13 11 9 7 5 3 1 14 15 17 18 6 8 10 ...

Page 187: ...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 inspection and measurement procedures have been performed See Inspection of Valve Guides on page 6 57 1 Using a drift pin and hammer drive the valve guides Figure 6 50 1 out of the cylinder head Figure 6 50 Cleaning of Cy...

Page 188: ...e 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 inside diameter of all the rocker arm support brackets and the rocker arms Figure 6 52 are within the specified limits See Rocker Arm and Shaft on page 6 9 for the service limit 2 Inspect the contact areas Figure 6 52...

Page 189: ...d 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 Valve and Guide on page 6 7 for the service limit Replace the valve guides if not within specification Figure 6 54 Inspection of Cylinder Head Cylinder Head Distortion Place the cylinder head flat and inverted co...

Page 190: ...nd Place the valve stem on a flat inspection block or layout bed Roll the valve until a gap can be observed between a portion of the valve stem and the surface of the block or bed Use a feeler gauge to measure the gap Figure 6 57 See Intake Exhaust Valve and Guide on page 6 7 for the service limit Figure 6 57 Valve Recession Note The valve guides must be installed to perform this check Insert the ...

Page 191: ... 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 rotate to distribute bluing onto the valve face The contact pattern should be approximately centered on the valve face Figure 6 60 1 and even in width Figure 6 60 Also visually inspect the valve seat for even cont...

Page 192: ...ide 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 surface and a square to check each spring for squareness Figure 6 62 See Valve Spring on page 6 10 for the service limit Figure 6 62 Free Length Use a caliper to measure the length of the spring Figure 6 63 See ...

Page 193: ...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 of Intake and Exhaust Valves IMPORTANT When installing valve stem seals use new ones instead of reusing removed seals Exhaust valve and intake valve stem seals are different They can be distinguished based on the ...

Page 194: ...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 valve keepers Figure 6 69 1 and slowly release the tension in the valve spring Repeat the steps on all the remaining valves Reassembly of Cylinder Head 1 Carefully clean both the combustion surface of the cylinder hea...

Page 195: ...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 72 4 is in place 2 Insert the push rods Figure 6 72 2 in their original locations Figure 6 72 First Step 1 2 of final torque Second Step Final torque 2 1 0001872 1 2 0001875 3 6 8 10 12 14 16 18 5 4 2 1 13 11 9 7...

Page 196: ...gure 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 cylinder Components for all remaining cylinders are assembled in the same order 4 Position the rocker arm assembly on a flat surface Reinstall the alignment studs Figure 6 75 5 5 Place the rocker arm shaft assembly onto...

Page 197: ...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 injection pump coolant hoses 8 Reinstall the high pressure fuel line grommets into the valve cover 9 Reinstall the high pressure and fuel return lines See Installation of the Fuel Injectors on page 7 42 10 Reinstall the c...

Page 198: ...ing each cylinder individually the cylinder to be adjusted first does not have to be the No 1 cylinder Select and adjust the cylinder where the piston is nearest to the top dead center after turning Make adjustment for the remaining cylinders in the order of firing by turning the crankshaft each time To decrease the number of rotations required to check all cylinders other cylinders can also be ch...

Page 199: ...p 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 or wear Figure 6 78 6 Insert a feeler gauge of the correct thickness Figure 6 79 1 see Adjustment Specifications on page 6 6 between the rocker arm and valve cap Turn the valve adjustment screw to adjust the valv...

Page 200: ...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 loosen or tighten the valve adjusting screw lock nut without holding the valve bridge Always hold the valve bridge using a wrench to prevent bending of the valve stems 4 Loosen the valve bridge adjusting screw lock...

Page 201: ...igure 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 valve adjusting screw lock nut Figure 6 86 5 and valve adjusting screw Figure 6 86 4 on the rocker arm Figure 6 86 3 and check the clearance gap Figure 6 86 2 for evidence of dirt or wear Note There is a tendency f...

Page 202: ...htening 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 measure and adjust the set of valves Continue until all valves are measured and adjusted 0001918 1 2 3 4 5 TNV_DI_SM_A4 book 70 ページ ２００７年１２月６日 木曜日 午前９時２３分 ...

Page 203: ...t 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 39 40 41 8 TNV_DI_SM_A4 book 71 ページ ２００７年１２月６日 木曜日 午前９時２３分 ...

Page 204: ...should be performed 1 Disconnect the battery cables at the battery Always disconnect the negative cable first 2 Remove the throttle cable electrical connections intake and exhaust system connections and fuel supply lines from the engine 3 Remove the alternator See Removal of Alternator on page 12 12 4 Drain the engine coolant from the radiator and cylinder block See Drain Flush and Refill Cooling ...

Page 205: ...ng 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 removing the crankshaft pulley 2 Remove the crankshaft pulley using a gear puller 3 Remove the bolts that retain the gear case cover to the cylinder block and oil pan 4 Remove the gear case cover Figure 6 88 1 Fi...

Page 206: ...he 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 measurement 3 Check the idler gear to fuel injection pump drive gear backlash in the same manner as the camshaft drive gear Record the measurement Removal of Timing Gears 1 Remove the bolts from the idler gear shaft Fig...

Page 207: ... 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 Figure 6 93 1 Figure 6 93 CAUTION Do not loosen or remove the four bolts retaining the fuel injection pump drive gear to the fuel injection pump hub Do not disassemble the fuel injection pump drive gear from the hu...

Page 208: ...nder 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 gauge to measure the clearance between the thrust plate Figure 6 96 1 and front camshaft bearing Figure 6 96 2 See Thrust Bearing on page 6 15 for the service limit Figure 6 96 0001696A 1 2 0 1 0 2 0 3 0 4 0 5 0 6...

Page 209: ... 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 to remove Removal of Gear Case or Front Plate Note The camshaft must be removed before the gear case front plate can be removed See Inspection of Camshaft on page 6 87 1 TNV94 TNV106 Remove the oil pump Note It is...

Page 210: ...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 Connecting Rod on page 6 22 for the standard limit If the measurement is out of specification replace the crankshaft connecting rod or both Figure 6 100 2 Measure bearing oil clearance prior to removing the pistons and c...

Page 211: ...attened 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 during piston removal Damage to the bearing journal may result 3 Use a wooden dowel against the connecting rod and tap the piston connecting rod assembly out of the cylinder 4 Mark the cylinder number on the pist...

Page 212: ...lay 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 the measurement Figure 6 105 Method B Use a feeler gauge to measure the clearance Figure 6 106 3 between the thrust bearing Figure 6 106 1 and crankshaft Figure 6 106 2 Record the measurement See Thrust Bearing o...

Page 213: ...GE 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 and tighten to specification See Special Torque Chart on page 6 25 d Remove bearing caps e Compare the width of the flattened PLASTIGAGE to the graduation marks on the package Figure 6 109 1 The mark that most cl...

Page 214: ...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 Remove the rear oil seal Figure 6 112 3 from the seal housing Figure 6 112 2 4 Apply a continuous bead of ThreeBond Liquid Gasket No 1212 Yanmar Part No 977770 01212 to the outside diameter of a new oil seal Figur...

Page 215: ...om 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 should be replaced as necessary 1 Clean piston ring grooves using a piston ring groove cleaning tool Follow manufacturer s instructions for correct operation 2 Wash the pistons in an appropriate solvent using a soft...

Page 216: ...istonringsandcylindersmay 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 Boring on page 6 88 or replaced The piston should be replaced as necessary 9 Place each compression piston ring in the groove as shown Figure 6 117 Use a feeler gauge to measure the clearance between the piston ring a...

Page 217: ...ngs 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 if not within specifications If the bushing has been removed measure the inside diameter of the connecting rod small end Figure 6 119 2 See Connecting Rod on page 6 22 for specifications Figure 6 119 2 Place the ...

Page 218: ...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 crankshaft if evidence of fractures are found 5 Measure the outside diameter of each crankpin Figure 6 123 2 and main bearing journal Figure 6 123 1 See Crankshaft on page 6 14 for specifications Take measurements...

Page 219: ...haft 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 within specification replace it using the appropriate service tool If the remaining bores are not within specification the cylinder block will require replacement as there are no bearing inserts used Inspection of ...

Page 220: ...gid 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 ball hone Figure 6 129 2 before installing new piston rings This will properly prepare the cylinder surface to allow new piston rings to seat properly Note When honing a cylinder with either a ridged hone or a ball...

Page 221: ... 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 install a new wrist pin bushing Figure 6 130 7 using a press and the appropriate service tool Be sure to align the oil holes Figure 6 130 3 Reinstall one circlip Figure 6 130 5 into the piston Ensure the circlip i...

Page 222: ... 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 stamped on the top of the piston must face the fuel injection pump side Figure 6 132 1 of the engine and the embossed mark on the connecting rod Figure 6 132 3 must face the flywheel end Figure 6 132 5 of the engine 1 ...

Page 223: ...l 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 6 134 4 and ensure it is securely seated in the groove Figure 6 134 Note If installing new piston rings the end gap must be checked and adjusted as necessary See Inspection of Pistons Piston Rings and Wrist Pin on ...

Page 224: ... 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 End Gap 2 Second Compression Ring End Gap 3 Oil Ring End Gap Figure 6 137 Installation of Crankshaft 1 If removed reinstall the keys and timing gear on the crankshaft 2 Reinstall new bearing inserts Figure 6 138 1...

Page 225: ... 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 piston rings and cylinder with clean engine oil or assembly lubricant 2 Rotate the crankshaft so the crankpin for the piston being installed is near bottom dead center IMPORTANT Ensure the piston ring gaps are loc...

Page 226: ... 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 connecting rod as the match marks Figure 6 142 4 stamped into the connecting rod and connecting rod cap When installed in the cylinder the piston identification mark Figure 6 142 2 stamped on the top of the piston mu...

Page 227: ...al 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 Gear Case or Front Plate 1 If removed install a new camshaft bushing Figure 6 144 3 using the appropriate service tool 2 Apply a continuous bead of ThreeBond Liquid Gasket No 1212 Yanmar Part No 977770 01212 to the...

Page 228: ...y 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 Note The tappets are mushroom shaped and must be installed from inside the engine crankcase 3 Lubricate the tappets with clean oil or assembly lube Reinstall the tappets in their respective locations in the cylin...

Page 229: ... 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 retaining bolts to specified torque See Special Torque Chart on page 6 25 for specifications Installation of Gear Case Cover 1 Apply a continuous bead of ThreeBond Liquid Gasket No 1212 Yanmar Part No 977770 01212 to...

Page 230: ...all 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 6 151 1 using a new O ring Figure 6 151 2 Figure 6 151 2 Apply a continuous bead of ThreeBond Liquid Gasket No 1212 Yanmar Part No 977770 01212 to the mounting surface of the oil pan Figure 6 152 1 Be sure to circle...

Page 231: ... 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 Reconnect and adjust the throttle cable 7 Reconnect all electrical connections 8 Fill the engine with oil and coolant 9 Reconnect the battery cables negative cable last TNV_DI_SM_A4 book 99 ページ ２００７年１２月６日 木曜日 午前９時２３分 ...

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 ページ ２００７年１２月６日 木曜日 午前９時２３分 ...

Page 233: ...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 water hose EGR valve inlet 12 Cooling water hose EGR valve outlet 13 Turbocharger 2 9 3 10 4 5 13 1 8 6 7 11 12 TNV_DI_SM_A4 book 101 ページ ２００７年１２月６日 木曜日 午前９時２３分 ...

Page 234: ...he 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 operating and could seriously burn you Failure to comply could result in death or serious injury 0000015en A WARNING ENTANGLEMENT HAZARD Stop the engine before you begin to service it NEVER leave the key in the key switch...

Page 235: ...N 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 immediately with clean water Failure to comply may result in minor or moderate injury 0000005en CAUTION When it is necessary to replace an EGR valve be sure to replace the entire EGR valve assembly Neither attempt to disa...

Page 236: ...e 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 inlet and outlet hoses from the EGR cooler by loosening the hose clips When loosening the clips put waste cloth or the like beneath the hose joints in case water leaks 2 Loosen the nuts used to connect the exhaust ma...

Page 237: ...uring 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 3 Turn on the key switch Note that turning on the key switch causes the E ECU to check whether the valve functions properly by opening and shutting it 4 From the exhaust gas inlet visually check whether the valve o...

Page 238: ...ust 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 disassemble and clean them 1 Case 2 Stopper 3 Valve 4 Machine screw Figure 6 158 A WARNING FUME BURN HAZARD Always read and follow safety related precautions found on containers of hazardous substances like parts cle...

Page 239: ...ler 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 depositions gradually deteriorate the cooling of recirculated gas thus resulting in higher gas temperatures and lower effective circulation amounts EGR ratio To remove deposited carbon from the gas passage use compress...

Page 240: ...em 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 other governmental agencies for the proper disposal of hazardous materials such as engine oil diesel fuel and engine coolant Consult the local authorities or reclamation facility NEVER dispose of hazardous materials ...

Page 241: ...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 17 Fuel Injection Pump 7 19 Removal of Fuel Injection Pump 7 19 Installation of Fuel Injection Pump 7 24 Checking and Adjusting Fuel Injection Timing 7 30 Determining the Fuel Injection Timing Specification 7 30...

Page 242: ...al 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 Installation of the Fuel Injectors 7 42 TNV_DI_SM_A4 book 2 ページ ２００７年１２月６日 木曜日 午前９時２３分 ...

Page 243: ...ply 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 resulting in injury Never inject fuel toward a fire source Atomized fuel is highly flammable and may cause a fire or burn skin 0000028en A WARNING FUME BURN HAZARD Always read and follow safety related precautions found o...

Page 244: ...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 result in death or serious injury due to an abrupt and unexpected increase in engine speed 9999997en A WARNING Replacing the E ECU involves migrating the fuel injection data to the existing E ECU to the new unit ...

Page 245: ...nts 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 required they can be made only by a qualified fuel injection shop that will ensure the injection pump continues to meet all applicable emissions regulations and then replace the tamper proof seals Tampering with or...

Page 246: ...tion 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 increases the threshold pressure Removing adjusting shims reduces the pressure threshold 0000081en CAUTION Shut down the engine if the fault indicator comes on Continuing running the engine with the fault indicator being...

Page 247: ...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 corrosion resulting in malfunction of the E ECU Avoid plugging unplugging the connector more than approx 10 times Frequent plugging unplugging of the connector may cause contact failure of the connector pins res...

Page 248: ...s 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 contains a governor and an internal camshaft The fuel is pressurized by the up and down motion of the camshaft driven single plunger It is then distributed to the proper fuel injector by the rotating distributor shaft Th...

Page 249: ...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 4TNV98T Z are designed so that when the key is turned on or off the corresponding signal is sent to the E ECU Thus the E ECU controls the rack actuator to provide a sufficient injection rate when the engine is starte...

Page 250: ... 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 required by the MP fuel injection pump The use of an electric fuel supply pump is required on all TNV model engines with the MP fuel injection pump Electronically controlled governor Electronically controlled engines 4...

Page 251: ...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 kgf m Not Applied Fuel Injection Pump Mounting Nuts 17 21 ft lb 23 28 N m 2 3 2 9 kgf m Not Applied Fuel Injector Nozzle Case Nut 30 33 ft lb 39 2 44 1 N m 4 4 5 kgf m Not Applied Fuel Injection Pump Plunger Plug...

Page 252: ...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 to the fuel injector by engine model and or engine speed Model Engine Class Injector ID mark Fuel Injector Pressure Fuel Injection Timing 3TNV82A 4TNV88 CL W 2843 2988 psi 19 6 20 6 MPa 200 210 kgf cm2 See Checkin...

Page 253: ...n 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 Adapter M14 TNV82 88 Yanmar Part No 158090 51831 Mount dial indicator to fuel injection pump M16 TNV94 106 Yanmar Part No 158090 51841 4 Plunger Adapter Clamp Yanmar Part No 23000 013000 Clamps stem of dial indicator in...

Page 254: ... 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 18 Mono Plunger 19 Distributor Shaft 20 Fuel Return Line 21 High Pressure Fuel Injection Lines 22 Fuel Injector Figure 7 4 0000034B 3 4 2 1 22 12 5 21 11 18 17 16 15 14 13 17 10 9 8 7 6 19 20 TNV_DI_SM_A4 book 14 ...

Page 255: ...M 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 ページ ２００７年１２月６日 木曜日 午前９時２３分 ...

Page 256: ...ar 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 Pump Insulator 11 Fuel Injection Pump 12 Rear Fuel Injection Pump Support 13 Fuel Filter Water Separator 14 Electric Fuel Supply Pump 15 Fuel Filter 16 Fuel Filter Housing 17 Stop Solenoid 18 Cold Start Device CSD ...

Page 257: ...UEL 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 ページ ２００７年１２月６日 木曜日 午前９時２３分 ...

Page 258: ... 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 17 Fuel Filter 18 Fuel Filter Housing 19 Stop Solenoid 20 Cold Start Device CSD 21 Trochoid Fuel Pump Not used for electronically controlled engines Electronically controlled engines are equipped with a solenoid ...

Page 259: ...n 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 from contamination by covering all open connections 8 Disconnect the coolant lines from the cold start device Figure 7 9 3 on the fuel injection pump Plug the open ends of the lines to minimize leakage and prevent...

Page 260: ...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 model Figure 7 11 14 Disconnect the lube oil line Figure 7 12 1 and the clamp Figure 7 12 2 from the pump IMPORTANT Take care to not damage or bend the oil line In some applications it may be preferable to remove...

Page 261: ... 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 reference marks on the fuel injection pump drive gear and on either the gear case cover or idler gear On TNV82 88 model engines the idler gear is not visible Make a reference mark on the fuel injection pump drive...

Page 262: ... 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 shaft 20 Remove the pump drive gear and hub as an assembly using an appropriate two bolt gear puller Figure 7 17 Figure 7 17 CAUTION Do not loosen or remove the four bolts retaining the fuel injection pump drive ...

Page 263: ...9 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 Figure 7 20 23 If required remove the intake manifold and fuel pump insulator to access the fuel injection pump mounting nuts Note The MP2 fuel injection pumps TNV82 88 model engines are fastened to the gear case w...

Page 264: ...egulations 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 that will ensure the injection pump continues to meet all applicable emissions regulations and then replace the tamper proof seals Tampering with or removing these devices may void the Yanmar Limited Warranty 0000146...

Page 265: ...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 Yanmar industrial engine dealer or distributor for assistance Note Treat the timing index number as if it has a decimal point 68 6 8 Figure 7 22 1 Align the pump drive gear with the idler gear using the reference marks...

Page 266: ...mp 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 Figure 7 26 1 Do not lubricate the threads of the nut or shaft Hold the crankshaft pulley bolt with a socket wrench and tighten the drive gear nut to the specified torque See Special Torque Chart on page 7 11 Fig...

Page 267: ...nsate 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 must be advanced Figure 7 30 2 rotated away from the engine as compared to the standard mark Figure 7 30 1 by the calculated positive amount adjust the fuel injection pump to the calculated value If the differenc...

Page 268: ...on 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 rear bracket s Figure 7 32 1 to the fuel injection pump Tighten the rear support bolts Note Configuration of the fuel injection pump rear brackets may vary depending on the model Figure 7 32 7 Reconnect the throttle ...

Page 269: ...o 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 section of the governor housing 12 If equipped verify the fuel injection pump insulator Figure 7 34 2 is not damaged Reinstall the insulator and intake manifold if previously removed Figure 7 34 13 Reinstall the coo...

Page 270: ...r 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 complete engine model number The engine model number is located on the engine nameplate Figure 7 38 Figure 7 38 EXAMPLE The following example is for an engine model 3TNV82A DSA Find the engine model number in the ...

Page 271: ...r 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 for the MP2 fuel injection pumps TNV82 88 model engines or Yanmar part no 158090 51841 for the M16 adapter used on the MP4 fuel injection pumps TNV94 106 model engines and Yanmar part no 23000 013000 plunger adapt...

Page 272: ...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 15 BTDC 3 20 BTDC 4 Direction of Rotation 5 TDC Top Dead Center Figure 7 43 Note The TDC Top Dead Center mark can be identified by the cylinder numbers stamped near the TDC mark on the flywheel If you are uncerta...

Page 273: ... 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 7 30 Figure 7 44 Figure 7 45 10 Rotate the crankshaft counter clockwise until the dial indicator shows that the injection pump plunger is at the bottom of its stroke Rock the crankshaft back and forth sligh...

Page 274: ...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 0 098 in the fuel injection timing is advanced Figure 7 47 Note Some model engines require the intake manifold and fuel injection pump insulator be removed to access the inner fuel injection pump retaining nuts 4...

Page 275: ...n 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 the fuel injection pump 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 from contami...

Page 276: ...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 injectors 4 Valve Cylinder Head 1 Close any fuel valves in the fuel supply line 2 Remove the valve cover See Removal of Valve Cover on page 6 37 3 Remove the injector return line Figure 7 51 1 Be careful not to b...

Page 277: ...e 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 Repeat steps to remove the remaining fuel injectors 1 2 3 4 5 6 TNV_DI_SM_A4 book 37 ページ ２００７年１２月６日 木曜日 午前９時２３分 ...

Page 278: ...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 psi 5 MPa 51 kgf cm2 higher than one that has been operated for five hours or longer CAUTION Never use a steel wire brush to clean fuel injectors Damage to the nozzle and other components is likely to result 00001...

Page 279: ...gure 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 specified limits adjust the pressure See Adjusting Fuel Injector Pressure on page 7 41 Disassembly and Inspection of Fuel Injectors 1 Clean carbon from used injectors using clean diesel fuel Hardened deposits or va...

Page 280: ...d 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 area Figure 7 56 7 Perform a nozzle valve slide test a Wash nozzle body and valve in clean diesel fuel b While holding the nozzle body vertical pull the nozzle valve about 2 3 of the way out Figure 7 57 c Release th...

Page 281: ...uel 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 Testing of Fuel Injectors on page 7 38 If the injector cannot be adjusted to the appropriate pressure discard the fuel injector Reassembly of Fuel Injectors 1 Secure the injector in a soft jawed vise with the nozzl...

Page 282: ...tem 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 cylinder head for each injector 2 Reinstall a O ring on to each injector body 3 Reinsert each fuel injector Figure 7 60 4 into the cylinder head 4 Reinstall the fuel injector retainers Figure 7 60 3 and torque the reta...

Page 283: ...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 fuel injector assembly Figure 7 61 4TNV98 Z E 98T Z Identification groove two 4TNV94L 98 98T Identification groove none 4TNV84T Identification groove one 107 8 107 8 106 8 TNV_DI_SM_A4 book 43 ページ ２００７年１２月６日 木曜日 午前９時２３...

Page 284: ...FUEL SYSTEM 7 44 TNV DI Service Manual Fuel Injectors This Page Intentionally Left Blank TNV_DI_SM_A4 book 44 ページ ２００７年１２月６日 木曜日 午前９時２３分 ...

Page 285: ...stem 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 Cleaning and Inspection 8 10 Reassembly of Engine Coolant Pump 8 11 Installation of Engine Coolant Pump 8 12 TNV_DI_SM_A4 book 1 ページ ２００７年１２月６日 木曜日 午前９時２３分 ...

Page 286: ...COOLING SYSTEM 8 2 TNV DI Service Manual This Page Intentionally Left Blank TNV_DI_SM_A4 book 2 ページ ２００７年１２月６日 木曜日 午前９時２３分 ...

Page 287: ... 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 in the key switch when you are servicing the engine Someone may accidentally 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 op...

Page 288: ...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 Other engine coolants may affect warranty coverage 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...

Page 289: ... 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 available O ring the material is different 0000042en TNV_DI_SM_A4 book 5 ページ ２００７年１２月６日 木曜日 午前９時２３分 ...

Page 290: ...epresentative 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 Thermostat 3 Engine Coolant Pump 4 Radiator 5 Coolant Recovery Tank 6 Engine Oil Cooler 7 Cylinder Block Not standard on all models Figure 8 1 FULL LOW 0000573A 1 4 3 2 7 6 5 TNV_DI_SM_A4 book 6 ページ ２００７年１２月６日 木...

Page 291: ...tat 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 Coolant Fan 14 Water temperature sensor Electronically controlled engine Figure 8 2 1 2 3 4 6 9 10 11 12 13 5 14 7 8 0000031A 01 TNV_DI_SM_A4 book 7 ページ ２００７年１２月６日 木曜日 午前９時２３分 ...

Page 292: ...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 coolant Drain the coolant into a clean container if the coolant is to be reused Otherwise properly dispose of the coolant 2 Remove the radiator cap Figure 8 4 1 3 Remove the drain plug or open the drain cock Figure 8 4...

Page 293: ...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 switch lead wire from the engine coolant pump 8 Remove the engine coolant pump Figure 8 7 4 Discard the gasket A CAUTION PINCH HAZARD Carefully rotate the alternator toward the cylinder block while loosening the V belt...

Page 294: ...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 increase temperature of the fluid using an external heat source 4 The temperature switch is operating properly if the continuity light or ohmmeter indicates continuity when the fluid temperature reaches 225 F 235 F 107 ...

Page 295: ...ncrease 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 thermostat and fully opens as the temperature of the water is increased Radiator Cap 1 Check for proper operation of the radiator cap Install the radiator cap Figure 8 12 1 on a cooling system tester Figure 8 12 2 Apply...

Page 296: ...tion 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 the pulley groove replace the V belt Figure 8 15 6 Reinstall the V belt Tighten the V belt to the proper tension See Check and Adjust Cooling Fan V Belt on page 5 30 7 Reinstall and tighten the drain plug or clos...

Page 297: ...ternal 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 you remove the cap NEVER mix different types of engine coolants This may adversely affect the properties of the engine coolant 0000006en TNV_DI_SM_A4 book 13 ページ ２００７年１２月６日 木曜日 午前９時２３分 ...

Page 298: ...COOLING SYSTEM 8 14 TNV DI Service Manual Engine Coolant Pump This Page Intentionally Left Blank TNV_DI_SM_A4 book 14 ページ ２００７年１２月６日 木曜日 午前９時２３分 ...

Page 299: ...s 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 Pump Components 9 13 Disassembly of Oil Pump 9 14 Cleaning and inspection 9 14 Reassembly of Oil Pump 9 16 Trochoid Oil Pump 9 17 4TNV94L 98 106 Oil Pump Components 9 17 Disassembly of Oil Pump 9 17 Cleaning and Insp...

Page 300: ...LUBRICATION SYSTEM 9 2 TNV DI Service Manual This Page Intentionally Left Blank TNV_DI_SM_A4 book 2 ページ ２００７年１２月６日 木曜日 午前９時２３分 ...

Page 301: ...lure 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 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 operating and could seriously burn you Failure to comply c...

Page 302: ...ION 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 contaminating the engine oil Carefully clean the oil cap dipstick and the surrounding area before you remove the cap NEVER mix different types of engine oil This may adversely affect the lubricating properties of the ...

Page 303: ...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 0 29 0 44MPa 3 0 4 5kgf cm2 0 34 0 49MPa 3 5 5 0kgf cm2 0 39 0 54MPa 4 0 5 5kgf cm2 4TNV88 B 4TNV88 U 0 29 0 44MPa 3 0 4 5kgf cm2 0 32 0 47MPa 3 3 4 8kgf cm2 3TNV84T 3TNV84T Z 0 29 0 44MPa 3 0 4 5kgf cm2 0 34 0 4...

Page 304: ... 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 Z 0 0020 0 0039 in 0 05 0 10 mm 0 0059 in 0 15 mm Check Outer Rotor Side Clearance on page 9 15 4TNV94L 4TNV98 4TNV98T 4TNV98 Z 4TNV98 E 4TNV98T Z 0 0020 0 0039 in 0 05 0 10 mm 0 0059 in 0 15 mm Check Outer Rotor...

Page 305: ... mm Model Inspection Item Standard Limit Reference Page 3TNV82A B 3TNV88 B 3TNV88 U 4TNV88 B 4TNV88 U 3TNV84T Z 4TNV84T Z ÉvÉåÅ ÉgéðéÛì åa 0 3937 0 3943 in 10 000 10 015 mm 0 3953 in 10 040 mm Check Rotor Shaft Clearance on page 9 15 Rotor Shaft O D 0 3919 0 3924 in 9 955 9 967 mm 0 3913 in 9 940 mm Rotor Clearance 0 0013 0 0024 in 0 033 0 060 mm 0 0039 in 0 100 mm 4TNV94L 4TNV98 4TNV98T 4TNV98 Z ...

Page 306: ...els 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 Face Oil Pressure Switch Oil Cooler Bypass Valve Oil Filter Crank Pin Crank Journal Fuel Injection Pump Turbocharger Oil Pan 0000042 TNV_DI_SM_A4 book 8 ページ ２００７年１２月６日 木曜日 午前９時２３分 ...

Page 307: ...ood 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 oil pressure troubleshoot the lubrication system to locate the cause of the low oil pressure See Failure Diagnosis Table on page 15 191 Repair as necessary TROCHOID OIL PUMP 3TNV82A TO 4TNV88 Oil Pump Components On ...

Page 308: ...crews 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 air tool to remove these screws Figure 9 5 4 Remove the oil pump cover Figure 9 5 1 from the gear case cover 5 Remove the outer rotor Figure 9 6 2 and inner rotor Figure 9 6 1 from the gear case cover Figure 9 6...

Page 309: ...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 cavity Figure 9 8 2 Record the measurement s and see Outer Rotor Outside Clearance on page 9 6 for the service limits Figure 9 8 Outer Rotor to Inner Rotor Tip Clearance Determine the outer rotor to inner rotor t...

Page 310: ... 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 oil Figure 9 12 2 Reinstall the outer rotor in the gear case The dot mark on the face of the outer rotor must face up toward the oil pump cover 3 Reinstall the inner rotor into the gear case cover with the dot m...

Page 311: ...er 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 pump on these model engines is located in the front gear case and is driven by the same gear train that drives the camshaft and fuel injection pump You must remove the front gear case cover to gain access to the o...

Page 312: ...ter 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 flaw Replace the parts with new ones as needed Check Outer Rotor Outside Clearance Inspect the outside diameter clearance of the outer rotor To inspect this insert a feeler gauge between the outer rotor Figure 9 17...

Page 313: ...earance 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 clearance use a straight edge and feeler gauge as shown in Figure 9 19 or a depth micrometer Figure 9 19 Record the measurement s and see Outer Rotor Outside Clearance on page 9 6 for the service limits Check Rotor Shaf...

Page 314: ...ver 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 For more information See Installation of Gear Case Cover on page 6 97 6 Install the crank shaft pulley 7 Install the cooling water pump V pulley Figure 9 21 1 spacer Figure 9 21 2 cooling water fan Figure 9 21 3 a...

Page 315: ...re 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 Figure 9 23 1 Remove the crankshaft pulley and the gear case cover See Removal of Timing Gear Case Cover on page 6 73 2 Remove the oil pump assembly bolts Remove the oil pump assembly Figure 9 24 1 from the gear ...

Page 316: ...r 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 Record the measurement s and see Outer Rotor to Inner Rotor Tip Clearance on page 9 11 for the service limits Check Outer Rotor Side Clearance Determine the side clearance of the outer rotor across the pump cavity ...

Page 317: ...e 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 pump assembly Figure 9 30 1 into the gear case housing Figure 9 30 2 Tighten the bolts to specified torque Figure 9 30 4 Reinstall the gear case cover and crankshaft pulley See Installation of Gear Case Cover on pa...

Page 318: ...LUBRICATION SYSTEM 9 20 TNV DI Service Manual Trochoid Oil Pump This Page Intentionally Left Blank TNV_DI_SM_A4 book 20 ページ ２００７年１２月６日 木曜日 午前９時２３分 ...

Page 319: ...charger 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 Gate Modulation 10 11 Washing Procedure 10 12 Periodic Inspection 10 13 Visual Inspection 10 13 Inspection of Rotor Rotation 10 13 Inspection of Rotor Play 10 13 Removal of Turbocharger 10 13 Checking Rotor Play 10...

Page 320: ...TURBOCHARGER 10 2 TNV DI Service Manual This Page Intentionally Left Blank TNV_DI_SM_A4 book 2 ページ ２００７年１２月６日 木曜日 午前９時２３分 ...

Page 321: ...f 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 kgf cm to the waste gate actuator 0000026en A CAUTION FLYING OBJECT HAZARD ALWAYS wear eye protection when servicing the engine and when using compressed air or high pressure water Dust flying debris compressed ai...

Page 322: ... 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 lines or the oil inlet and outlet ports of the turbocharger 0000064en CAUTION If the waste valve does not meet specifications replace the turbocharger or have it repaired by a qualified repair facility 0000078en TNV...

Page 323: ...ication 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 Compressor Type Centrifugal Lubrication External lubrication Maximum Continuous Allowable Speed 250 000 180 000 Maximum Continuous Allowable Gas Inlet Temperature 750 F 399 C Weight Dry 5 4 lb 24 N 2 4 kgf 9 2 l...

Page 324: ...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 to a qualified repair facility 3d Improper operation of the machine Refer to the Operation Manual 4 Contact or breakdown of turbine wheel or blower vane 4a Excessive revolution 4b Excessive exhaust temperature ris...

Page 325: ...r 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 turbocharger Send to a qualified repair facility Incomplete combustion Correct the condition Cause Corrective action Excessively narrowed gas path due to clogged nozzle in the turbine wheel chamber or reverse flow of...

Page 326: ...al 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 Figure 10 1 12 9 8 7 22 23 15 14 13 5 4 3 2 11 21 32 18 26 1 6 17 13 14 24 19 20 10 29 27 29 28 30 16 31 25 0000078A TNV_DI_SM_A4 book 8 ページ ２００７年１２月６日 木曜日 午前９時２３分 ...

Page 327: ...e 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 22 Bolt 23 Lock Washer 24 Heat Protector 25 Liquid Gasket 26 Waste Gate Actuator 27 Hose 28 Adapter 29 Clip 30 Retaining Ring 31 Waste Gate Valve 32 Link Plate TNV_DI_SM_A4 book 9 ページ ２００７年１２月６日 木曜日 午前９時２３分 ...

Page 328: ...ing 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 Compressor Wheel 19 Shaft End Nut 20 Heat Protector A Exhaust Gas Inlet B Exhaust Gas Outlet C Air Inlet D Air Outlet E Oil Inlet F Oil Outlet Figure 10 2 0000077A 19 18 2 7 4 6 5 3 20 1 11 13 14 12 15 8 9 10 17 16 B A F...

Page 329: ...late 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 turbine shaft during engine operation A thrust bearing prevents the shaft from moving laterally under this thrust force Radial Bearing A floating radial bearing moves with the turbine shaft as oil films form on t...

Page 330: ... 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 90 cc of clean water over a period of ten to fifteen seconds into the air inlet 5 Continue to operate the engine under the same load for at least ten minutes to completely dry the air intake system and turbocharger...

Page 331: ...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 reinstalling Removal of Turbocharger 1 Shut down the engine and allow the turbocharger to cool Remove the exhaust outlet connection from the turbocharger housing 2 Remove the air inlet connection from the turbocharger ho...

Page 332: ...rements 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 operation will adversely affect the engine performance Rotor Play Standard Dimension Wear Limit RHF5 RHB31 RHB51 RHF5 RHB31 RHB51 End Play 0 0011 0 0024 in 0 03 0 06 mm 0 0009 0 0021 in 0 022 0 053 mm 0 0012 0 0024 ...

Page 333: ...ss 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 oz 60 cc of clean engine oil in the oil inlet port at the top of the turbocharger Rotate the compressor wheel to ensure the shaft bearings are lubricated 2 Flush the oil lines to ensure that they are free of conta...

Page 334: ...TURBOCHARGER 10 16 TNV DI Service Manual Periodic Inspection This Page Intentionally Left Blank TNV_DI_SM_A4 book 16 ページ ２００７年１２月６日 木曜日 午前９時２３分 ...

Page 335: ...onal 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 11 10 Cleaning and Inspection 11 12 Reassembly of Starter Motor 11 17 Check Pinion Projection Length 11 18 No Load Test 11 19 Installation of Starter Motor 11 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 ...

Page 336: ...STARTER MOTOR 11 2 TNV DI Service Manual This Page Intentionally Left Blank TNV_DI_SM_A4 book 2 ページ ２００７年１２月６日 木曜日 午前９時２３分 ...

Page 337: ...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 before servicing the electrical 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 ...

Page 338: ... 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 the resistance is higher than the specified value 0000054en CAUTION The starter motor is water proofed according to JIS D 0203 R2 which protects the motor from rain or general cleaning Do not use high pressure was...

Page 339: ...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 3732 DC12V 1 9 hp 1 4 kW 11 5 90A MAX 3000 8 5 350 Max 117 in lb 13 2 N m 1 4 kgf m 1000 129608 77010 Hitachi S114 817A DC12V 1 9 hp 1 4 kW 11 90A MAX 2700 8 4 250 Max 74 in lb 8 3 N m 0 9 kgf m 1000 129242 77010...

Page 340: ... 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 3 5 kW 23 90A MAX 3100 20 2 250 Max 130 in lb 14 7 N m 1 5 kgf m 1300 129900 77030 Hitachi S24 14 DC24V 4 8 hp 3 5 kW Wet 23 90A MAX 3100 20 2 250 Max 130 in lb 14 7 N m 1 5 kgf m 1300 129910 77022 Hitachi S13 205...

Page 341: ... 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 Resistance 0 27 W at 68 F 20 C Shunt Coil Resistance 0 60 W at 68 F 20 C Commutator Outside Diameter Standard 1 437 in 36 5 mm Limit 1 398 in 35 mm Run Out Standard 0 001 in 0 03 mm Limit 0 008 in 0 2 mm Insulation D...

Page 342: ...spect 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 starter motor Solenoid switch assembly contact defective Repair or replace Repair or replace key switch starting motor relay or magnetic switch assembly If a problem occurs Immediately disconnect battery negative te...

Page 343: ...ng 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 Brushes 19 Negative Brushes 20 Brush Holder Assembly 21 Rear Cover 22 M5 Through Bolts 2 used 23 M4 Bolts 2 used Figure 11 1 1 3 2 4 5 6 7 8 9 10 11 12 13 14 15 23 18 22 21 20 19 17 16 0000103A TNV_DI_SM_A4 book ...

Page 344: ...g 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 two M4 bolts Figure 11 4 1 securing the rear cover Figure 11 4 2 to the brush holder assembly Figure 11 4 3 A WARNING SHOCK HAZARD Turn off the battery switch if equipped or disconnect the negative battery cable ...

Page 345: ...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 the field coil assembly Figure 11 6 2 7 Remove the two M6 bolts Figure 11 7 1 retaining the magnetic switch assembly Figure 11 7 2 to the gear housing Remove the magnetic switch assembly dust cover s Figure 11 7...

Page 346: ...haft 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 11 Cleaning and Inspection Armature Commutator Surface Inspection If the commutator surface is rough polish the surface with a 500 to 600 emery cloth Figure 11 12 Figure 11 12 Measure Commutator Outside Diameter M...

Page 347: ... 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 commutator segments using a multimeter Figure 11 15 The multimeter should indicate continuity Figure 11 15 If the multimeter does not indicate continuity replace the armature Armature Coil Insulation Test Check for...

Page 348: ...8 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 between the field coil terminal and the yoke using a multimeter Figure 11 19 The multimeter should not indicate continuity If the multimeter indicates continuity replace the field coil assembly Figure 11 19 Measure B...

Page 349: ...ultimeter 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 and M terminals using a multimeter Figure 11 22 The multimeter should indicate continuity If the multimeter does not indicate continuity replace the magnetic switch Figure 11 22 Coil Resistance Test See Starter M...

Page 350: ...on 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 should slide smoothly on the shaft Figure 11 25 Rust too much grease or damage could prevent the pinion clutch from sliding smoothly If the pinion clutch assembly does not slide smoothly clean the shaft and pinion clu...

Page 351: ...r 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 portions of the shift lever Figure 11 28 1 Reassemble the torsion spring Figure 11 28 2 shift lever and dust cover s Figure 11 28 3 plunger Figure 11 28 4 and magnetic switch assembly Figure 11 28 5 Figure 11 28 5 Reasse...

Page 352: ...sh 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 Tighten the M8 nut Reinstall the cover over the connection Figure 11 32 Check Pinion Projection Length 1 Connect the positive lead from a battery to the S terminal 2 Connect the negative lead to the M terminal 3 L...

Page 353: ...ire 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 terminal Figure 11 35 5 and the main positive battery terminal Figure 11 35 3 on the starter motor 5 Install a switch Figure 11 35 6 in a circuit between the battery positive terminal Figure 11 35 2 and the starter magn...

Page 354: ...ts 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 assembly solenoid Be sure to place the cover over the battery positive cable connection 4 Reconnect the battery cables at the battery 1 0002126 TNV_DI_SM_A4 book 20 ページ ２００７年１２月６日 木曜日 午前９時２３分 ...

Page 355: ...ubleshooting 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 St...

Page 356: ...TERNATOR 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 ページ ２００７年１２月６日 木曜日 午前９時２３分 ...

Page 357: ...ry 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 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 0000009en A WARNING BURN HAZARD Keep your hands and ...

Page 358: ...ON 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 permit anyone to operate the engine or driven machine without proper training Read and understand this Operation Manual before you operate or service the machine to ensure that you follow safe operating practices and m...

Page 359: ... 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 in the battery indicator the LED will shine faintly during normal operation 0000051en CAUTION Using a non specified V belt will cause inadequate charging and shorten the belt life Use the specified belt 0000052en C...

Page 360: ...re 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 Number Specification 171301 77201 Kokusan GP8138 DC12V 15A 119910 77200 Kokusan GP9191 DC12V 20A YANMAR Part Number Mfg Mfg Part Number Specification 119620 77201 Denso 100211 4531 DC12V 40A 129423 77200 Denso 101211...

Page 361: ... 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 kg Revolution Direction As Viewed From Pulley Clockwise Rating Continuous Battery Voltage 12 Volts Rated Revolution 3500 rpm Operating Range 1400 6600 rpm Grounding Characteristics Negative Side of Circuit Regulat...

Page 362: ...lso 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 available from driven machine manufacturer Battery indicator flashes Battery voltage is between 13 and 15 volts Battery voltage greater than 15 5 volts Battery voltage minus L terminal voltage is greater than 0 5...

Page 363: ... 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 15 Nut 2 used 16 Nut 17 Insulation Bushing 18 Spring 2 used 19 Brush Holder 20 Rear Frame Housing 21 Bolt 2 used 22 Holder 23 IC Regulator Assembly 24 Bolt 2 used 25 Bolt 26 Brush 2 used 27 Bolt 28 Rear Cover 29 ...

Page 364: ...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 alternator terminals L and E Damage to the alternator will result 0000036en CAUTION Do not remove the positive battery cable from alternator terminal B while the engine is operating Damage to the alternator will result 0...

Page 365: ...rnator 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 4 5 6 7 8 TNV_DI_SM_A4 book 11 ページ ２００７年１２月６日 木曜日 午前９時２３分 ...

Page 366: ...lley 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 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 0000009en A CAUTION PINCH HAZARD C...

Page 367: ...he 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 bushing 7 Remove the two bolts Figure 12 8 1 and two nuts Figure 12 8 2 securing the rear frame housing to the front frame housing Figure 12 8 8 Using a press remove the rotor assembly Figure 12 9 1 from the fron...

Page 368: ...earing 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 thrust washers Figure 12 11 3 Figure 12 11 Reassembly of Alternator 1 If removed reinstall the two trust washers Figure 12 12 3 and bearing cover Figure 12 12 2 in the rear frame housing Lubricate the outside diamete...

Page 369: ...icate 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 front frame housing with the rear frame housing Reinstall the two bolts Figure 12 15 1 and two nuts Figure 12 15 2 Figure 12 15 6 Reinstall the insulation bushing Figure 12 16 4 and nut Figure 12 16 3 Figure 12 16 7...

Page 370: ...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 kgf m 3 Reinstall the V belt Tighten the V belt to the proper tension as described in Check and Adjust Cooling Fan V Belt on page 5 22 4 Start the engine Listen for any unusual sounds from the alternator 5 Verify...

Page 371: ...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 Spacer 9 Stator Assembly 10 Front Bearing 2 used 11 Flat Washer 12 Flywheel Assembly 13 Pulley Half 14 Through Bolt Figure 12 20 0002140 1 2 3 6 4 5 7 8 9 10 11 12 13 14 TNV_DI_SM_A4 book 17 ページ ２００７年１２月６日 木曜日 午前...

Page 372: ...f 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 output is an AC alternating current signal The AC is converted to DC direct current by the current limiter The current limiter outputs charging DC current to the battery 0002137 1 2 3 4 5 6 TNV_DI_SM_A4 book 18 ページ...

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 ページ ２００７年１２月６日 木曜日 午前９時２３分 ...

Page 374: ...ted 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 running Results The meter reading with the engine running must be higher than with the engine not running If results are not correct test the stator for continuity and shorts to the ground Check the charging system ...

Page 375: ...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 5 Remove the rear bearing Figure 12 26 3 Figure 12 26 Reassembly of Dynamo 1 Reinstall the rear bearing Figure 12 27 3 2 Reinstall the stator Figure 12 27 2 and screws Figure 12 27 1 2 3 4 0002143 6 5 4 3 2 1 000...

Page 376: ...ll 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 belt to the proper tension as described in Check and Adjust Cooling Fan V Belt on page 5 22 4 Start the engine Listen for any unusual sounds from the alternator 5 Verify that the charge indicator is ON while the e...

Page 377: ... 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 control harness connections 13 5 TNV_DI_SM_A4 book 1 ページ ２００７年１２月６日 木曜日 午前９時２３分 ...

Page 378: ...ELECTRONIC CONTROL SYSTEM 13 2 TNV DI Service Manual This Page Intentionally Left Blank TNV_DI_SM_A4 book 2 ページ ２００７年１２月６日 木曜日 午前９時２３分 ...

Page 379: ...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 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 result in death or serious injury due ...

Page 380: ...he 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 into the female coupler Doing so may cause contact 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 connec...

Page 381: ...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 schemes Droop control Low idling speed up Auto deceleration High idling speed down Black smoke suppression Starting aid Auto preheating After heating Engine failure detection CAN communication with the control syste...

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 ページ ２００７年１２月６日 木曜日 午前９時２３分 ...

Page 383: ...ELECTRONIC CONTROL SYSTEM TNV DI Service Manual 13 7 Electronic control harness connections TNV_DI_SM_A4 book 7 ページ ２００７年１２月６日 木曜日 午前９時２３分 ...

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 ページ ２００７年１２月６日 木曜日 午前９時２３分 ...

Page 385: ...ion 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 European Standards 14 7 TNV_DI_SM_A4 book 1 ページ ２００７年１２月６日 木曜日 午前９時２３分 ...

Page 386: ...ELECTRIC WIRING 14 2 TNV DI Service Manual This Page Intentionally Left Blank TNV_DI_SM_A4 book 2 ページ ２００７年１２月６日 木曜日 午前９時２３分 ...

Page 387: ...esistance 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 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 while the engine is operating may ca...

Page 388: ...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 25 0 004359 14 2 0 002685 12 3 0 001704 10 5 0 001073 8 8 0 000707 6 15 0 000421 4 20 0 000270 2 30 0 000158 1 40 0 000130 0 1 0 50 0 000103 00 2 0 60 0 000087 000 3 0 85 0 000066 0000 4 0 100 0 000051 TNV_DI_SM...

Page 389: ... 002 Ω For starter motors of greater than 2 68 HP 2 kW the total resistance must be less than 0 0012 Ω AWG mm Maximum Total Battery Cable Length Positive Cable Negative Cable a 12V Starter Motor Output Less Than 2 68 HP 2 kW Greater Than 2 68 HP 2 kW m ft m ft 6 15 1 5 4 75 N A N A 4 20 2 3 7 4 N A N A 2 30 3 8 12 6 2 3 7 5 1 40 4 6 15 3 2 8 9 2 0 1 0 50 5 9 19 5 3 5 11 6 00 2 0 60 7 0 22 8 4 2 13...

Page 390: ...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 Volts 5 18 18 18 16 16 14 12 12 12 10 10 10 10 10 8 8 8 8 8 10 18 16 14 12 12 10 10 10 8 8 8 6 6 6 6 6 6 6 6 15 16 14 12 12 10 10 8 8 6 6 6 6 6 4 4 4 4 4 2 20 14 12 10 10 10 8 6 6 6 6 4 4 4 4 2 2 2 2 2 25 12 12 10 10 ...

Page 391: ...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 67 10 6 6 4 11 13 3 5 4 62 16 8 4 5 19 21 2 3 5 83 26 7 2 6 54 33 6 1 7 35 42 4 0 1 0 8 25 53 4 00 2 0 9 27 67 5 000 3 0 10 40 85 0 0000 4 0 11 68 107 2 00000 5 0 13 12 135 1 000000 6 0 14 73 170 3 1 1 circular mi...

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 ページ ２００７年１２月６日 木曜日 午前９時２３分 ...

Page 393: ...cancer 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 Buffalo Grove IL 60089 4508 U S A TEL 1 847 541 1900 FAX 1 847 541 2161 http www yanmar com Yanmar Europe B V Brugplein11 1332 BS Almere de Vaart The Netherlands TEL 31 36 5493200 FAX 31 36 5493209 h...

Page 394: ...N 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 4TNV98T Z 4TNV106 4TNV106T ...

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