Yanmar 4TNV88-U Manuals

Manuals and User Guides for Yanmar 4TNV88-U. We have 3 Yanmar 4TNV88-U manuals available for free PDF download: Service Manual, Troubleshooting Manual, Operation Manual

Yanmar 4TNV88-U Service Manual (394 pages)

Industrial

Brand: Yanmar | Category: Engine | Size: 29.06 MB

Table of Contents

5
- Proposition 65 Warning
  2
Yanmar Warranties

9
- Yanmar Warranties
  10
  - Yanmar Limited Warranty
    11
    
    How Long Is the Warranty Period
    11
    
    What Is Covered by this Warranty
    11
    
    What the Engine Owner Must Do
    11
    
    To Locate an Authorized Yanmar Industrial Engine Dealer or Distributor
    12
    
    What Is Not Covered by this Warranty
    12
    
    What Yanmar will Do
    12
    
    Questions
    13
    
    Retail Purchaser Registration
    13
    
    Warranty Limitations
    13
    
    Warranty Modifications
    13
- Dealer or Distributor
  12
  - Emission System Warranty
    14
  - Yanmar Co., Ltd. Limited Emission Control System Warranty - USA Only
    14
    
    Manufacturer's Warranty Period
    14
    
    Your Warranty Rights and Obligations
    14
    
    Warranted Parts
    15
    
    Warranty Coverage
    15
  - Turbocharger
    15
    
    Exclusions
    16
    
    Owner's Warranty Responsibilities
    16
  - Safety
    17
  - Periodic Maintenance
    19
  - Fuel System
    20
    
    Alternator
    29
    
    Starter Motor
    30
  - General Service Information
    33
  - Electric Wiring
    36
General Service Information

41
- Cooling System
  41
  - Component Identification
    43
  - Location of Labels
    45
    
    Engine Nameplate (Typical)
    46
  - Emission Control Regulations
    46
    
    EPA / ARB Regulations - USA Only
    46
  - Emission Control Labels
    46
  - The 97/68/EC Directive Certified Engines
    47
  - Engine Family
    47
  - Function of Major Engine Components
    48
  - Main Electronic Control Components and Features
    49
  - Function of Cooling System Components
    51
  - Diesel Fuel
    52
    
    Diesel Fuel Specifications
    52
    
    Filling the Fuel Tank
    53
    
    Priming the Fuel System
    55
  - Engine Oil
    55
    
    Engine Oil Specifications
    55
    
    Checking Engine Oil
    56
    
    Engine Oil Viscosity
    56
    
    Adding Engine Oil
    57
    
    Engine Oil Capacity (Typical)
    57
  - Engine Coolant
    58
    
    Engine Coolant Specifications
    59
    
    Filling Radiator with Engine Coolant
    59
    
    Engine Coolant Capacity (Typical)
    60
  - Specifications
    61
    
    Description of Model Number
    61
    
    Engine Speed Specifications
    61
    
    Engine General Specifications
    62
  - Principal Engine Specifications
    63
    
    3TNV82A (~ EPA Tier2)
    63
    
    3TNV84 (~ EPA Tier2)
    64
    
    3TNV84T (~ EPA Tier2)
    65
    
    3TNV88 (~ EPA Tier2)
    66
    
    4TNV84 (~ EPA Tier2)
    67
    
    4TNV84T (~ EPA Tier2)
    68
    
    4TNV88 (~ EPA Tier2)
    69
    
    4TNV94L (~ EPA Tier2)
    70
    
    4TNV98 (~ EPA Tier2)
    71
    
    4TNV98T (~ EPA Tier2)
    72
    
    4TNV106 (~ EPA Tier2)
    73
    
    4TNV106T (~ EPA Tier2)
    74
    
    3TNV82A-B (Complies with EPA Interim Tier4)
    75
    
    3TNV84T-B (Complies with EPA Interim Tier4)
    76
    
    3TNV88-U (Complies with EPA Interim Tier4)
    77
    
    3TNV88-B (Complies with EPA Interim Tier4)
    78
    
    4TNV84T-Z (Complies with EPA Interim Tier4)
    79
    
    4TNV88-U (Complies with EPA Interim Tier4)
    80
    
    4TNV88-B (Complies with EPA Interim Tier4)
    81
    
    4TNV98-E (Complies with EPA Interim Tier4)
    82
    
    4TNV98-Z (Complies with EPA Interim Tier4)
    83
    
    4TNV98T-Z (Complies with EPA Tier3)
    84
  - Engine Service Standards
    85
  - Tightening Torques for Standard Bolts and Nuts
    86
  - Abbreviations and Symbols
    88
    
    Abbreviations
    88
    
    Symbols
    88
  - Unit Conversions
    89
    
    Unit Prefixes
    89
    
    Units of Force
    89
    
    Units of Length
    89
    
    Units of Mass
    89
    
    Units of Power
    89
    
    Units of Pressure
    89
    
    Units of Temperature
    89
    
    Units of Torque
    89
    
    Units of Volume
    89
Periodic Maintenance

91
- Before You Begin Servicing
  93
- Introduction
  106
- Periodic Maintenance Schedule
  107
- Periodic Maintenance Procedures
  110
  - After Initial 50 Hours of Operation
    110
  - Every 50 Hours of Operation
    114
  - Every 250 Hours of Operation
    117
  - Every 500 Hours of Operation
    122
  - Every 1000 Hours of Operation
    126
  - Every 1500 Hours of Operation
    129
  - Every 2000 Hours of Operation
    132
Engine

133
- Before You Begin Servicing
  135
- Cylinder Head Specifications
  138
  - Adjustment Specifications
    138
  - Cylinder Head
    138
  - Intake / Exhaust Valve and Guide
    139
  - Push Rod
    141
  - Rocker Arm and Shaft
    141
  - Valve Spring
    142
- Introduction
  138
- Camshaft and Timing Gear Train Specifications
  143
  - Camshaft
    143
  - Idler Gear Shaft and Bushing
    145
  - Timing Gear Backlash
    145
- Crankshaft and Piston Specifications
  146
  - Crankshaft
    146
  - Thrust Bearing
    147
  - Piston
    148
  - Piston Ring
    150
  - Connecting Rod
    154
  - Tappet
    155
- Cylinder Block Specifications
  156
  - Cylinder Block
    156
- Special Torque Chart
  157
  - Torque for Bolts and Nuts
    157
- Special Service Tools
  160
- Measuring Instruments
  164
- 2-Valve Cylinder Head
  166
- 4-Valve Cylinder Head
  181
- Measuring and Adjusting Valve Clearance
  198
  - 2-Valve Cylinder Heads
    199
  - 4-Valve Cylinder Heads
    200
- Crankshaft and Camshaft Components
  203
- EGR System
  232
  - Inspecting/Cleaning EGR Related Components
    237
Fuel System

241
- Before You Begin Servicing
  243
- Introduction
  248
  - Fuel Injection Pump
    248
  - Cold Start Device
    249
  - Stop Solenoid
    249
  - Electronically Controlled Governor
    250
  - Trochoid Fuel Pump
    250
- Fuel System Specifications
  251
  - Special Torque Chart
    251
  - Test and Adjustment Specifications
    252
- Measuring Instruments
  253
- Special Service Tools
  253
- Fuel System Diagram
  254
- 2 Valve Cylinder Head
  
  255
  - Fuel System Components
    255
- 4 Valve Cylinder Head
  
  257
  - Fuel Injection Pump
    259
    
    Removal of Fuel Injection Pump
    259
    
    Installation of Fuel Injection Pump
    264
  - Checking and Adjusting Fuel Injection Timing
    270
    
    Determining the Fuel Injection Timing Specification
    270
    
    Checking Fuel Injection Timing
    271
    
    Adjusting Fuel Injection Timing
    274
  - Fuel Injectors
    275
  - Removal of Fuel Injectors
    275
  - Testing of Fuel Injectors
    278
  - Disassembly and Inspection of Fuel Injectors
    279
  - Adjusting Fuel Injector Pressure
    281
  - Reassembly of Fuel Injectors
    281
  - Installation of the Fuel Injectors
    282
Cooling System

285
- Before You Begin Servicing
  287
- Cooling System Diagram
  290
- Introduction
  290
- Engine Coolant Pump Components
  291
- Engine Coolant Pump
  292
  - Removal of Engine Coolant Pump
    292
  - Disassembly of Engine Coolant Pump
    294
  - Cleaning and Inspection
    294
  - Reassembly of Engine Coolant Pump
    295
  - Installation of Engine Coolant Pump
    296
- Engine Coolant System Check
  292
Lubrication System

299
- Before You Begin Servicing
  301
- Introduction
  303
- Oil Pump Service Information
  304
- Lubrication System Diagram
  306
- Checking Engine Oil Pressure
  307
- Trochoid Oil Pump
  307
  - 3TNV82A to 4TNV88 Oil Pump Components
    307
  - Disassembly of Oil Pump
    308
  - Cleaning and Inspection
    309
  - Reassembly of Oil Pump
    310
- Trochoid Oil Pump
  311
  - 3Tnv82A-B, 3Tnv88-B, 3Tnv88-U, 4Tnv88-B4Tnv88-U
    311
  - 3TNV84T-Z, 4TNV84T-Z Oil Pump Components
    311
  - Disassembly of Oil Pump
    312
  - Cleaning and Inspection
    312
  - Reassembly of Oil Pump
    314
- 4 TNV94L/98/106 Oil Pump Components
  315
- Trochoid Oil Pump
  315
  - Disassembly of Oil Pump
    315
  - Cleaning and Inspection
    316
  - Reassembly of Oil Pump
    317
Turbocharger

319
- Before You Begin Servicing
  321
- Introduction
  323
- Specifications
  323
  - Turbocharger Service Information
    323
- Troubleshooting
  324
  - Excessive Exhaust Smoke
    324
  - Generates White Smoke
    325
  - Sudden Oil Decrease
    325
  - Decrease in Output
    325
  - Poor (Slow) Response (Starting) of Turbocharger
    325
  - Abnormal Sound or Vibration
    325
- Turbocharger Components
  326
- Turbocharger Component Functions
  328
  - Theory of Operation
    329
  - Compressor Side Sealing Mechanism
    329
  - Waste Gate Modulation
    329
- Washing Procedure
  330
- Periodic Inspection
  331
  - Visual Inspection
    331
  - Inspection of Rotor Rotation
    331
  - Inspection of Rotor Play
    331
  - Removal of Turbocharger
    331
  - Checking Rotor Play
    332
  - Waste Gate Valve Test
    332
  - Waste Gate Actuator Leak Test
    333
  - Installation of Turbocharger
    333
Starter Motor

335
- Before You Begin Servicing
  337
- Introduction
  339
- Starter Motor Information
  339
  - 3TNV82A to 4TNV88 - Standard and Optional
    339
- Starter Motor Specifications
  341
- Starter Motor Troubleshooting
  342
- Starter Motor Components
  343
- Starter Motor
  344
  - Removal of Starter Motor
    344
  - Disassembly of Starter Motor
    344
  - Cleaning and Inspection
    346
  - Reassembly of Starter Motor
    351
  - Check Pinion Projection Length
    352
  - No-Load Test
    353
  - Installation of Starter Motor
    354
Alternator

355
- Before You Begin Servicing
  357
- Dynamo and Alternator Information
  360
  - 3TNV82A to 4TNV106T - Standard and Optional Dynamos
    360
  - 3TNV82A to 4TNV106T - Standard and Optional Alternators
    360
- Introduction
  360
- Alternator Specifications
  361
- Dynamo Specifications
  361
- Alternator Troubleshooting
  362
- Alternator Components
  363
- Alternator Wiring Diagram
  364
- Alternator Standard Output
  365
- Alternator
  366
  - Removal of Alternator
    366
  - Disassembly of Alternator
    366
  - Reassembly of Alternator
    368
  - Installation of Alternator
    370
- Dynamo Component Location
  371
- Dynamo Wiring Diagram
  372
- Operation of Dynamo
  372
- Dynamo Standard Output
  373
- Testing of Dynamo
  374
  - Testing Stator Coil Continuity
    374
  - Testing Stator Coil Short-To-Ground
    374
  - Testing Dynamo Regulated Output
    374
  - Engines Available with the Electronic Control System
    379
  - Before You Begin Servicing
    379
  - Introduction
    381
  - Electronic Control System
    381
  - Electronic Control Harness Connections
    382
  - Electric Wiring Precautions
    387
  - Electrical Wire Resistance
    388
  - Battery Cable Resistance
    389
  - Electrical Wire Sizes - Voltage Drop
    390
  - Conversion of AWG to European Standards
    391

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Yanmar Warranties

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Cooling System

Lubrication System

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