Yanmar 4 TNV Series Manuals

Manuals and User Guides for Yanmar 4 TNV Series. We have 1 Yanmar 4 TNV Series manual available for free PDF download: Service Manual

Yanmar 4 TNV Series Service Manual

Yanmar 4 TNV Series Service Manual (213 pages)

Industrial Diesel Engine. Direct Injection System

Brand: Yanmar | Category: Engine | Size: 31.76 MB

Table of Contents

Table of Contents
11
1 General

16
- Engine Nomenclature
  16
- Specifications
  16
- Fuel Oil, Lubricating Oil and Cooling Water
  29
  - Fuel Oil
    29
  - Lubricating Oil
    30
  - Cooling Water
    30
- Engine External Views
  31
- Structural Description
  32
- Exhaust Gas Emission Regulation
  33
2 Inspection and Adjustment

37
3 Troubleshooting

68
4 Disassembly, Inspection and Reassembly of Engines

74
- Complete Disassembly and Reassembly
  74
  - Introduction
    74
  - Special Service Tools
    75
  - Complete Disassembly
    80
  - Precautions before and During Reassembly
    84
  - Adjusting Operation
    84
- Cylinder Head: Disassembly, Inspection and Reassembly
  85
  - Components (2-Valve Cylinder Head)
    85
  - Disassembly Procedure
    85
  - Reassembly Procedure
    86
  - Servicing Points
    87
  - Parts Inspection and Measurement
    91
  - Valve Seat Correction
    95
  - Valve Guide Replacement
    96
  - Valve Stem Seal Replacement
    97
- Gear Train and Camshaft
  98
  - Components
    98
  - Disassembly Procedure
    98
  - Reassembly Procedure
    98
  - Servicing Points
    99
  - Parts Inspection and Measurement
    102
  - Oil Seal Replacement (Gear Case Side)
    104
  - Camshaft Bushing Replacement
    104
- Cylinder Block
  105
  - Components
    105
  - Disassembly Procedure
    105
  - Reassembly Procedure
    105
  - Servicing Points
    106
  - Parts Inspection and Measurement
    110
  - Cylinder Bore Correction
    121
  - Piston Pin Bushing Replacement
    122
  - Oil Seal Replacement (Flywheel Housing Side)
    122
5 Lubrication System

123
- Lubrication System Diagram
  123
- Trochoid Pump Components
  124
- Disassembly(Reverse the Procedure below for Assembly)
  124
- Servicing Points
  124
- Parts Inspection and Measurement
  125
  - Trochoid Pump Inspection and Measurement
    125
6 Cooling System

127
- Cooling Water System
  127
- Cooling Water Pump Components
  127
- Disassembly (Reverse the Procedure below for Assembly)
  128
- Servicing Points
  128
7 Fuel Injection Pump/Governor

129
- Introduction
  129
- Fuel Injection Pump
  129
  - Fuel System Diagram
    129
  - External View and Components
    130
  - Disassembly Procedure
    130
  - Assembly Procedure
    131
  - Servicing Points
    131
8 TURBOCHAGER: Disassembly, Inspection and Reassembly

133
- Structure and Functions
  133
  - Main Specifications
    133
  - Construction
    133
  - Structural and Functional Outline
    134
  - Components
    135
- Service Standards and Tightening Torque
  136
  - Service Standards
    136
  - Tightening Torque
    137
- Periodic Inspection Procedure
  138
  - Periodic Inspection Intervals
    138
  - Inspection Procedure
    139
  - Waste Gate Valve Adjustment Procedure
    140
- Disassembly Procedure
  142
  - Preparation for Disassembly
    142
  - Inspection before Disassembly
    143
  - Disassembly
    143
- Washing and Inspection Procedure
  145
  - Washing
    145
  - Inspection Procedure
    146
- Reassembly Procedure
  149
  - Preparation for Reassembly
    149
  - Reassembly
    149
- Handling after Disassembly and Reassembly
  152
  - Instructions for Turbocharger Installation
    152
- Troubleshooting
  153
  - Excessively Exhaust Smoke
    153
  - White Smoke Generation
    153
  - Sudden Oil Decrease
    154
  - Decrease in Output
    154
  - Poor (Slow) Response (Starting) of Turbocharger
    154
  - Abnormal Sound or Vibration
    154
9 Starting Motor

155
- For 4TNV94L/ 98
  155
  - Specifications
    155
  - Components
    156
  - Troubleshooting
    157
  - Names of Parts and Disassembly Procedure
    158
  - Inspection and Maintenance
    162
  - Service Standards
    167
  - Assembly
    168
  - Characteristic Test
    170
- For 4TNV106(T)
  171
  - Specifications
    171
  - Congiguration Drawing
    171
  - Troubleshooting
    172
  - Component Names and Disassembly Procedure
    173
  - Disassembly Procedure
    174
  - Inspection and Maintenance
    182
  - Assembly
    188
  - Adjustment
    189
  - Service Standards
    190
10 Alternator

191
- The 40A Alternator for 3TNV84 and Other Models
  191
  - Components
    191
  - Specifications
    192
  - Wiring Diagram
    192
  - Standard Output Characteristics
    193
  - Inspection
    193
- Troubleshooting
  194
11 Electric Wiring

195
- Electric Wiring Diagram
  195
- Precaution on Electric Wiring
  196
  - Alternator
    196
  - Starter
    197
  - Current Limiter
    198
  - Section Area and Resistance of Electric Wire
    199
12 Service Standards

200
- Engine Tuning
  200
- Engine Body
  201
  - Cylinder Head
    201
  - Gear Train and Camshaft
    204
  - Cylinder Block
    205
- Lubricating Oil System (Trochoid Pump)
  210
  - Outside Clearance of Outer Rotor
    210
  - Side Clearance of Outer Rotor
    210
  - Inside Clearance of Inner Rotor
    210
  - Rotor Shaft Clearance
    210
13 TIGHTENING TORQUE for BOLTS and NUTS

211
- Tightening Torques for Main Bolts and Nuts
  211
- Tightening Torques for Standard Bolts and Nuts
  212

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