Page 1 TNV DI Service Manual series SERVICE MANUAL 3TNV82A 3TNV84 • 3TNV84T • 3TNV88 4TNV84 • 4TNV84T • 4TNV88 4TNV94L 4TNV98 • 4TNV98T 4TNV106 • 4TNV106T P/N: 0BTNV0-U0000 INDUSTRIAL ENGINES...
Page 2 / or safely. Please contact an authorized Yanmar repair or service professional before working on your Yanmar product.
Page 3: Table Of Contents
Section 1 TABLE OF CONTENTS Page Table of Contents ................... iii Introduction ..................1-1 Yanmar Warranties................2-1 Safety....................3-1 General Service Information .............. 4-1 Engine ....................6-1 Periodic Maintenance ................. 5-1 Fuel System ..................7-1 Cooling System ................... 8-1 Lubrication System ................9-1 Turbocharger ..................
Page 4 TABLE OF CONTENTS This Page Intentionally Left Blank...
Page 5 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 Yanmar industrial engine dealer or distributor for answers to any questions relating to field modifications.
Page 6 INTRODUCTION This Page Intentionally Left Blank TNV DI Service Manual...
Page 7 What is Covered by this Warranty? .......... 2-3 How Long is the Warranty Period? ........... 2-3 What the Engine Owner Must Do: ..........2-3 To Locate an Authorized Yanmar Industrial Engine Dealer or Distributor: ................2-4 What Yanmar Will Do: ............... 2-4 What is Not Covered by this Warranty? ........
Page 8: Tnv Di Service Manual
YANMAR WARRANTIES This Page Intentionally Left Blank TNV DI Service Manual...
Page 9: Yanmar Limited Warranty
What the Engine Owner Must Do: If you believe your Yanmar engine has experienced a failure due to a defect in material and / or workmanship, you must contact an authorized Yanmar industrial engine dealer or distributor within thirty (30) days of discovering the failure.
Page 10: To Locate An Authorized Yanmar Industrial Engine Dealer Or Distributor
• “Click” on the desired country or Associate company to locate your nearest authorized Yanmar industrial engine dealer or distributor. • You may also contact Yanmar by clicking on “Inquiry” in the website heading and typing in your question or comment.
Page 11: Warranty Limitations
Failure to follow the requirements for submitting a claim under this Warranty may result in a waiver of all claims for damages and other relief. In no event shall Yanmar or any authorized industrial engine dealer or distributor be liable for incidental, special or consequential damages. Such consequential damages may include, but not be limited to, loss of revenue, loan payments, cost of rental of substitute equipment, insurance coverage, storage, lodging, transportation, fuel, mileage, and telephone costs.
Page 12: Emission System Warranty
The California Air Resources Board (CARB), the Environmental Protection Agency (EPA) and Yanmar Co., Ltd. hereafter referred to as Yanmar, are pleased to explain the emission control system warranty on your industrial compression-ignition engine. In California, model year 2000 or later off-road compression-ignition engines must be designed, built and equipped to meet the State’s stringent anti-smog standards.
Page 13: Warranty Coverage
Any part repaired or replaced under warranty shall be warranted for the remaining warranty period. During the warranty period, Yanmar is liable for damages to other engine components caused by the failure of any warranted part during the warranty period.
Page 14: Exclusions
You are responsible for initiating the warranty process. You must present your engine to a Yanmar dealer as soon as a problem exists. The warranty repairs should be completed by the dealer as expeditiously as possible.
Page 15: Safety
Section 3 TNV DI Service Manual SAFETY Page Safety Statements ................. 3-3 Safety Precautions ................3-4 TNV DI Service Manual...
Page 16 SAFETY This Page Intentionally Left Blank TNV DI Service Manual...
Page 17: Periodic Maintenance
Safety Statements SAFETY SAFETY STATEMENTS CAUTION Yanmar is concerned for your safety and your Caution (the word “CAUTION” is in black machine’s condition. Safety statements are one of letters with a yellow rectangle behind it) the primary ways to call your attention to the –...
Page 18: Fuel System
SAFETY Safety Precautions SAFETY PRECAUTIONS DANGER DANGER FIRE AND EXPLOSION HAZARD! • Diesel fuel is flammable and explosive under certain conditions. SCALD HAZARD! • When you remove any fuel system • NEVER remove the radiator cap if the component to perform maintenance engine is hot.
Page 19 Safety Precautions SAFETY DANGER DANGER FIRE AND EXPLOSION HAZARD! FIRE AND EXPLOSION HAZARD! • Diesel fuel is flammable and explosive • Diesel fuel is flammable and explosive under certain conditions. under certain conditions. • If the unit has an electric fuel pump, •...
Page 20 SAFETY Safety Precautions DANGER DANGER FIRE AND EXPLOSION HAZARD! CRUSH HAZARD! • Diesel fuel is extremely flammable and • When you need to transport an engine explosive under certain conditions. for repair, have a helper assist you to • Be sure to place the diesel fuel attach it to a hoist and load it on a container on the ground when truck.
Page 21 Safety Precautions SAFETY DANGER DANGER FIRE AND EXPLOSION HAZARD! EXPLOSION HAZARD! • Diesel fuel is flammable and explosive • NEVER check the remaining battery under certain conditions. charge by shorting out the terminals. • NEVER use diesel fuel as a cleaning This will result in a spark and may agent.
Page 22 SAFETY Safety Precautions WARNING WARNING SEVER HAZARD! EXHAUST HAZARD! • Keep hands and other body parts • NEVER operate the engine in an away from moving / rotating parts enclosed area such as a garage, such as the cooling fan, flywheel or tunnel, underground room, manhole or PTO shaft.
Page 23 Safety Precautions SAFETY WARNING WARNING BURN HAZARD! • If you must drain the engine oil while it EXPOSURE HAZARD! is still hot, stay clear of the hot engine • Wear personal protective equipment oil to avoid being burned. such as gloves, work shoes, eye and •...
Page 24 ALWAYS use a piece of wood is operating, remove all jewelry, tie or cardboard. Have your authorized back long hair, and keep your hands, Yanmar industrial engine dealer or other body parts and clothing away distributor repair the damage. from moving / rotating parts.
Page 25 Safety Precautions SAFETY WARNING WARNING SUDDEN MOVEMENT HAZARD! • Engaging the transmission or PTO at an elevated engine speed could result in unexpected movement of the equipment. FUME / BURN HAZARD! • Failure to comply could result in death • Always read and follow safety related or serious injury.
Page 26: Alternator
CAUTION 0000015en CAUTION • Only use diesel fuels recommended by Yanmar for the best engine performance, to prevent engine damage and to comply with EPA / ARB FLYING OBJECT HAZARD! warranty requirements. • ALWAYS wear eye protection when •...
Page 27: Starter Motor
• The standard range of ambient 0000010en temperatures for the normal operation of Yanmar engines is from +5°F (-15°C) CAUTION to +113°F (+45°C). Make sure the engine is installed on a • If the ambient temperature exceeds level surface.
Page 28 • Prevent dirt and debris from CAUTION contaminating the engine oil. Carefully For maximum engine life, Yanmar clean the oil cap / dipstick and the recommends that when shutting the surrounding area before you remove engine down, you allow the engine to the cap.
Page 29 • Failure to comply may impair the engine’s safety and performance characteristics and shorten the engine’s life. Any alterations to this engine may affect the warranty coverage of your engine. See Yanmar Limited Warranty in Warranty Section. 0000044enTNVDISM TNV DI Service Manual 3-15...
Page 30: General Service Information
NEVER attempt to adjust the low or high the warranty coverage on your engine. idle speed limit screw. This may impair See Yanmar Limited Warranty in the safety and performance of the Warranty Section. machine and shorten its life. If the idle...
Page 31 Safety Precautions SAFETY CAUTION CAUTION • When the engine is operated in dusty Do not loosen or remove the four bolts conditions, clean the air cleaner retaining the fuel injection pump drive element more frequently. gear to the fuel injection pump hub. Do not disassemble the fuel injection pump •...
Page 32 (boiling) crankshaft. Rotating the crankshaft will and charging malfunctions. Consult cause the fuel injection pump to become Yanmar before using the equipment in misaligned. such an environment or the warranty is voided. 0000048en...
Page 33: Electric Wiring
Safety Precautions SAFETY CAUTION CAUTION Make sure that the combined total Removing the battery cables or the resistance of the battery cable in both battery while the engine is operating directions between the starter motor may cause damage to the current limiter and the battery is within the value depending on the electrical equipment indicated on the wiring diagram.
Page 34 Any alterations to this in one position for any length of time. engine may void its warranty. Be sure Damage to the cylinder wall will occur. to use Yanmar genuine replacement Keep the tool in constant up-and-down parts. motion.
Page 35 • Tampering with or removing these devices may void the “Yanmar Limited Warranty.” 0000146en CAUTION Never use a steel wire brush to clean fuel injectors.
Page 36 SAFETY Safety Precautions This Page Intentionally Left Blank 3-22 TNV DI Service Manual...
Page 37: Cooling System
Section 4 TNV DI Service Manual GENERAL SERVICE INFORMATION Page Component Identification..............4-3 Location of Labels ................4-4 Engine Nameplate (Typical) ............4-4 Emission Control Regulations ............4-5 EPA / ARB Regulations - USA Only .......... 4-5 Emission Control Labels..............4-5 The 97/68/EC Directive Certified Engines........
Page 38 GENERAL SERVICE INFORMATION Specifications ................4-19 Description of Model Number..........4-19 Engine Speed Specifications........... 4-19 Engine General Specifications ..........4-20 Principal Engine Specifications ............. 4-22 3TNV82A................. 4-22 3TNV84 ................... 4-24 3TNV84T ................. 4-26 3TNV88 ................... 4-28 4TNV84 ................... 4-30 4TNV84T ................. 4-32 4TNV88 ...................
Page 39: Tnv Di Service Manual
Component Identification GENERAL SERVICE INFORMATION COMPONENT IDENTIFICATION Figure 4-2 shows where the major engine components are located. (20) (19) (18) (17) (16) (15) (21) (14) (25) (13) (24) (22) (23) 0000015B (12) (11) (10) 1 – Lifting Eye (Flywheel End) 14 –...
Page 40: Location Of Labels
GENERAL SERVICE INFORMATION Location of Labels LOCATION OF LABELS Figure 4-2 shows the location of regulatory and safety labels on Yanmar TNV series engines. 0000019A Figure 4-2 The typical location of the emission control Engine Nameplate (Typical) information label is shown for 4TNV84, 4TNV84T and 4TNV88 engines (Figure 4-2, (1)).
Page 41: Emission Control Regulations
EPA / ARB Regulations - USA Only regulations a particular engine complies with. We have listed several different types of labels you Yanmar TNV engines meet Environmental might find on your engine. Protection Agency (EPA) (U. S. Federal) emission control standards as well as the California Air EPA / ARB Labels Resources Board (ARB, California) regulations.
Page 42: The 97/68/Ec Directive Certified Engines
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: 1.33 Method of air aspiration Number of cylinders Engine speed specifications Displacement (liter) Non-road / Off-road engine Yanmar Diesel *2005 Model Year 5*: 2005 6 : 2006 7: 2007 TNV DI Service Manual...
Page 43: Function Of Major Engine Components
Air Cleaner engineer. It is not part of the basic engine package as shipped from the Yanmar factory. Periodic replacement of the air cleaner filter element is necessary. See the Periodic Maintenance Schedule on page 5-17 for the replacement frequency.
Page 44: Function Of Cooling System Components
The application specific items are not part of the basic engine package as shipped from the Yanmar factory. The engine cooling fan is driven by a V-belt which is powered by the crankshaft Engine Cooling Fan V-pulley.
Page 45: Diesel Fuel
• The fuel cetane number should be equal to 45 or diesel fuels. higher. Yanmar approves the use of bio-diesel fuels that do • The sulfur content must not exceed 0.5% by not exceed a blend of 5% (by volume) of FAME with volume.
Page 46: Filling The Fuel Tank
See • Failure to comply will result in death or Yanmar Limited Warranty on page 2-3. serious injury. 0000005en 4-10 TNV DI Service Manual...
Page 47 • Failure to comply will result in death or CAUTION serious injury. • Only use diesel fuels recommended by 0000014en Yanmar for the best engine performance, to prevent engine damage and to comply with EPA / ARB warranty requirements. • Only use clean diesel fuel.
Page 48: Priming The Fuel System
GENERAL SERVICE INFORMATION Engine Oil Note that a typical fuel tank is shown. The fuel tank 2. NEVER use the starter motor to crank the on your equipment may be different. engine in order to prime the fuel system. This may cause the starter motor to overheat and 1.
Page 49: Engine Oil Viscosity
See the SAE Service Grade Viscosity Chart 5. Fully reinsert the dipstick. (Figure 4-4). • Yanmar does not recommend the use of engine oil “additives.” Additional Technical Engine Oil Requirements: The engine oil must be changed when the Total Base Number (TBN) has been reduced to 2.0.
Page 50: Adding Engine Oil
5. Add more oil if necessary. 6. Reinstall the oil cap (Figure 4-5, (4)) and The following are the engine oil capacities for hand-tighten. Over-tightening may damage the various Yanmar TNV engines. cap. Dipstick Upper Engine Model Limit / Lower Limit 5.8 / 3.8 qt...
Page 51: Engine Coolant
Engine Coolant GENERAL SERVICE INFORMATION ENGINE COOLANT CAUTION DANGER COOLANT HAZARD! • Wear eye protection and rubber gloves SCALD HAZARD! when you handle long life or extended • NEVER remove the radiator cap if the life engine coolant. If contact with the engine is hot.
Page 52: Engine Coolant Specifications
(Figure 4-7, (1)) in the • Water quality is important to coolant cylinder block is closed or the oil coolant hoses performance. Yanmar recommends that soft, (Figure 4-8, (1)) are installed at the oil cooler. distilled, or demineralized water be used to mix with coolants.
Page 53: Engine Coolant Capacity (Typical)
Refer to the operation manual provided by the driven machine manufacturer for the actual engine coolant capacity on your machine. The following are the engine coolant capacities for various Yanmar TNV engines. Engine Coolant Engine Model Capacity 0001579B 3TNV82A 1.9 qt (1.8 L)
Page 54: Specifications
GENERAL SERVICE INFORMATION Specifications SPECIFICATIONS Description of Model Number TNV 84 0000 Customer Code Rated rpm Turbocharged (No symbol indicates naturally aspirated) Cylinder Bore (mm) Engine Series No. of Cylinders When ordering parts or making an inquiry about the engine you are working on, be sure to include the complete model and serial numbers as shown on the engine nameplate.
Page 55: Engine General Specifications
Hg), Relative humidity 30% • Fuel Temperature at Fuel Injector Pump Inlet: 104°F (40°C) • With Cooling Fan, Air Cleaner, Muffler: Yanmar Standard • After Engine Break-In Period; Output Allowable Deviation: ± 3% • 1 PS = 0.7355 kW •...
Page 56 GENERAL SERVICE INFORMATION Specifications This Page Intentionally Left Blank 4-20 TNV DI Service Manual...
Page 57: Principal Engine Specifications
Principal Engine Specifications GENERAL SERVICE INFORMATION PRINCIPAL ENGINE SPECIFICATIONS 3TNV82A Engine Model 3TNV82A Version Type Vertical In-line Diesel Engine Combustion System Direct Injection Aspiration Natural No. of Cylinders Bore × Stroke 3.228 x 3.307 in. (82 × 84 mm) Displacement 81.208 cu in.
Page 58 GENERAL SERVICE INFORMATION Principal Engine Specifications Engine Model 3TNV82A Version Engine Weight (Dry) 304.3 lb (138 kg) 282.2 lb (128 kg) with Flywheel Housing* Firing Order 1-3-2-1 (No. 1 Cylinder on the Flywheel End) Fuel Injection Timing See Checking and Adjusting Fuel Injection Timing on page 7-26.
Page 59: 3Tnv84
Principal Engine Specifications GENERAL SERVICE INFORMATION 3TNV84 Engine Model 3TNV84 Version Type Vertical In-line Diesel Engine Combustion System Direct Injection Aspiration Natural No. of Cylinders Bore × Stroke 3.307 x 3.543 in. (84 x 90 mm) Displacement 91.275 cu in. (1.496 L) 1500 1800 (min...
Page 60 GENERAL SERVICE INFORMATION Principal Engine Specifications Engine Model 3TNV84 Version Engine Weight (Dry) 355.0 lb (161 kg) 341.8 lb (155 kg) with Flywheel Housing* Firing Order 1-3-2-1 (No. 1 Cylinder on the Flywheel End) Fuel Injection Timing See Checking and Adjusting Fuel Injection Timing on page 7-26 PTO Position Flywheel End Direction of Rotation...
Page 61: 3Tnv84T
Principal Engine Specifications GENERAL SERVICE INFORMATION 3TNV84T Engine Model 3TNV84T Version Type Vertical In-line Diesel Engine Combustion System Direct Injection Aspiration Turbocharged No. of Cylinders Bore × Stroke 3.307 x 3.543 in. (84 x 90 mm) Displacement 91.275 cu in. (1.496 L) 1500 1800 (min...
Page 62 GENERAL SERVICE INFORMATION Principal Engine Specifications Engine Model 3TNV84T Version Engine Weight (Dry) 355.0 lb (161 kg) 341.8 lb (155 kg) with Flywheel Housing* Firing Order 1-3-2-1 (No. 1 Cylinder on the Flywheel End) Fuel Injection Timing See Checking and Adjusting Fuel Injection Timing on page 7-26 PTO Position Flywheel End Direction of Rotation...
Page 63: 3Tnv88
Principal Engine Specifications GENERAL SERVICE INFORMATION 3TNV88 Engine Model 3TNV88 Version Type Vertical In-line Diesel Engine Combustion System Direct Injection Aspiration Natural No. of Cylinders Bore × Stroke 3.465 x 3.543 in. (88 x 90 mm) Displacement 100.183 cu in. (1.642 L) 1500 1800 (min...
Page 64 GENERAL SERVICE INFORMATION Principal Engine Specifications Engine Model 3TNV88 Version Engine Weight (Dry) 355.0 lb (161 kg) 341.8 lb (155 kg) with Flywheel Housing* Firing Order 1-3-2-1 (No. 1 Cylinder on the Flywheel End) Fuel Injection Timing See Checking and Adjusting Fuel Injection Timing on page 7-26 PTO Position Flywheel End Direction of Rotation...
Page 65: 4Tnv84
Principal Engine Specifications GENERAL SERVICE INFORMATION 4TNV84 Engine Model 4TNV84 Version Type Vertical In-line Diesel Engine Combustion System Direct Injection Aspiration Natural No. of Cylinders Bore × Stroke 3.307 x 3.543 in. (84 x 90 mm) Displacement 121.721 cu in. (1.995 L) 1500 1800 (min...
Page 66 GENERAL SERVICE INFORMATION Principal Engine Specifications Engine Model 4TNV84 Version Engine Weight (Dry) 403.5 lb (183 kg) 374.9 lb (170 kg) with Flywheel Housing* Firing Order 1-3-4-2-1 (No. 1 Cylinder on the Flywheel End) Fuel Injection Timing See Checking and Adjusting Fuel Injection Timing on page 7-26 PTO Position Flywheel End Direction of Rotation...
Page 67: 4Tnv84T
Principal Engine Specifications GENERAL SERVICE INFORMATION 4TNV84T Engine Model 4TNV84T Version Type Vertical In-line Diesel Engine Combustion System Direct Injection Aspiration Turbocharged No. of Cylinders Bore × Stroke 3.307 x 3.543 in. (84 x 90 mm) Displacement 121.721 cu in. (1.995 L) 1500 1800 (min...
Page 68 GENERAL SERVICE INFORMATION Principal Engine Specifications Engine Model 4TNV84T Version Engine Weight (Dry) 403.5 lb (183 kg) 374.9 lb (170 kg) with Flywheel Housing* Firing Order 1-3-4-2-1 (No. 1 Cylinder on the Flywheel End) Fuel Injection Timing See Checking and Adjusting Fuel Injection Timing on page 7-26 PTO Position Flywheel End Direction of Rotation...
Page 69: 4Tnv88
Principal Engine Specifications GENERAL SERVICE INFORMATION 4TNV88 Engine Model 4TNV88 Version Type Vertical In-line Diesel Engine Combustion System Direct Injection Aspiration Natural No. of Cylinders Bore × Stroke 3.465 x 3.543 in. (88 x 90 mm) Displacement 133.618 cu in. (2.190 L) 1500 1800 (min...
Page 70 GENERAL SERVICE INFORMATION Principal Engine Specifications Engine Model 4TNV88 Version Engine Weight (Dry) 403.5 lb (183 kg) 374.9 lb (170 kg) with Flywheel Housing* Firing Order 1-3-4-2-1 (No. 1 Cylinder on the Flywheel End) Fuel Injection Timing See Checking and Adjusting Fuel Injection Timing on page 7-26 PTO Position Flywheel End Direction of Rotation...
Page 71: 4Tnv94L
Principal Engine Specifications GENERAL SERVICE INFORMATION 4TNV94L Engine Model 4TNV94L Version Type Vertical In-line Diesel Engine Combustion System Direct Injection Aspiration Natural No. of Cylinders Bore × Stroke 3.701 x 4.331 in (94 x 110 mm) Displacement 186.333 cu in (3.054 L) 1500 1800 (min...
Page 72 GENERAL SERVICE INFORMATION Principal Engine Specifications Engine Model 4TNV94L Version Engine Weight (Dry) 540.2 lb (245 kg) 518.2 lb (235 kg) with Flywheel Housing* PTO Position Flywheel End Firing Order 1-3-4-2-1 (No. 1 Cylinder on the Flywheel End) Fuel Injection Timing See Checking and Adjusting Fuel Injection Timing on page 7-26 Direction of Rotation Counterclockwise Viewed From the Flywheel End...
Page 73: 4Tnv98
Principal Engine Specifications GENERAL SERVICE INFORMATION 4TNV98 Engine Model 4TNV98 Version Type Vertical In-line Diesel Engine Combustion System Direct Injection Aspiration Natural No. of Cylinders Bore × Stroke 3.858 x 4.331 in. (98 x 110 mm) Displacement 202.502 cu in. (3.319 L) 1500 1800 (min...
Page 74 GENERAL SERVICE INFORMATION Principal Engine Specifications Engine Model 4TNV98 Version Engine Weight (Dry) 546.8 lb (248 kg) 518.2 lb (235 kg) with Flywheel Housing* PTO Position Flywheel End Firing Order 1-3-4-2-1 (No. 1 Cylinder on the Flywheel End) Fuel Injection Timing See Checking and Adjusting Fuel Injection Timing on page 7-26 Direction of Rotation Counterclockwise Viewed From the Flywheel End...
Page 75: 4Tnv98T
Principal Engine Specifications GENERAL SERVICE INFORMATION 4TNV98T Engine Model 4TNV98T Version Type Vertical In-line Diesel Engine Combustion System Direct Injection Aspiration Turbocharged No. of Cylinders Bore × Stroke 3.858 x 4.331 in. (98 x 110 mm) Displacement 202.502 cu in. (3.319 L) 1500 1800 (min...
Page 76 GENERAL SERVICE INFORMATION Principal Engine Specifications Engine Model 4TNV98T Version Engine Weight (Dry) 568.9 lb (258 kg) 540.2 lb (245 kg) with Flywheel Housing* PTO Position Flywheel End Firing Order 1-3-4-2-1 (No. 1 Cylinder on the Flywheel End) Fuel Injection Timing See Checking and Adjusting Fuel Injection Timing on page 7-26 Direction of Rotation Counterclockwise Viewed From the Flywheel End...
Page 77: 4Tnv106
Principal Engine Specifications GENERAL SERVICE INFORMATION 4TNV106 Engine Model 4TNV106 Version Type Vertical In-line Diesel Engine Combustion System Direct Injection Aspiration Natural No. of Cylinders Bore × Stroke 4.173 x 4.921 in. (106 x 125 mm) Displacement 269.189 cu in. (4.412 L) 1500 1800 (min...
Page 78 GENERAL SERVICE INFORMATION Principal Engine Specifications Engine Model 4TNV106 Version Engine Weight (Dry) 727.7 lb (330 kg) with Flywheel Housing* PTO Position Flywheel End Firing Order 1-3-4-2-1 (No. 1 Cylinder on the Flywheel End) Fuel Injection Timing See Checking and Adjusting Fuel Injection Timing on page 7-26 Direction of Rotation Counterclockwise Viewed From the Flywheel End Cooling System...
Page 79: 4Tnv106T
Principal Engine Specifications GENERAL SERVICE INFORMATION 4TNV106T Engine Model 4TNV106T Version Type Vertical In-line Diesel Engine Combustion System Direct Injection Aspiration Turbocharged No. of Cylinders Bore × Stroke 4.173 x 4.921 in. (106 x 125 mm) Displacement 269.189 cu in. (4.412 L) 1500 1800 (min...
Page 80 GENERAL SERVICE INFORMATION Principal Engine Specifications Engine Model 4TNV106T Version Engine Weight (dry) 749.7 lb (340 kg) with Flywheel Housing* PTO Position Flywheel End Firing Order 1-3-4-2-1 (No. 1 Cylinder on the Flywheel End) Fuel Injection Timing See Checking and Adjusting Fuel Injection Timing on page 7-26 Direction of Rotation Counter-clockwise Viewed From the Flywheel End Cooling System...
Page 81: Engine Service Standards
Fuel Injection See Test and Adjustment Specifications on page 7-8. Pressure 443 - 473 psi 340 - 370 psi 3TNV82A (3.06 - 3.26 MPa; (2.35 - 3.55 MPa; 30 - 32 kgf / cm²) 24 - 26 kgf / cm²)
Page 82: Tightening Torques For Standard Bolts And Nuts
GENERAL SERVICE INFORMATION Tightening Torques for Standard Bolts and Nuts TIGHTENING TORQUES FOR STANDARD BOLTS AND NUTS Use the correct amount of torque when you tighten CAUTION the fasteners on the machine. Applying excessive torque may damage the fastener or component and The tightening torque in the Standard not enough torque may cause a leak or component Torque Chart (see General Service...
Page 83 Tightening Torques for Standard Bolts and Nuts GENERAL SERVICE INFORMATION Nominal Thread Item x Pitch Tightening Torque Remarks Diameter 9 - 12 ft-lb (112 - 148 in.-lb, 12.7 - 16.7 N·m, 1.3 - 1.7 kgf·m) 14 - 19 ft-lb (173 - 225 in.-lb, 19.6 - 18.734 N·m, 2.0 - 3.5 kgf·m) Pipe Joint Bolt...
Page 84: Abbreviations And Symbols
GENERAL SERVICE INFORMATION Abbreviations and Symbols ABBREVIATIONS AND inHg inches Mercury in.-lb inch pound SYMBOLS joule JASO Japanese Automobile Abbreviations Standards Organization kelvin ampere kilogram alternating current kgf/cm² kilogram force per square ACEA Association des Constructeurs centimeter Européens d’Automobilies kgf/m kilogram force per meter ampere-hour kilometers...
Page 85: Unit Conversions
Unit Conversions GENERAL SERVICE INFORMATION UNIT CONVERSIONS plus minus ± plus or minus Unit Prefixes Ω µ Prefix Symbol Power micro mega x 1,000,000 percent kilo x 1,000 centi x 0.01 milli x 0.001 µ micro x 0.000001 Units of Length mile 1.6090 = km...
Page 86 GENERAL SERVICE INFORMATION Unit Conversions Units of Torque ft-lb 1.3558 = N·m ft-lb 0.1383 = kgf/m in.-lb 0.1130 = N·m in.-lb 0.0115 = kgf/m kgf/m 7.2330 = ft-lb kgf/m 86.8000 = in.-lb kgf/m 9.8070 = N·m N·m 0.7376 = ft-lb N·m 8.8510 = in.-lb...
Page 87 Introduction..................5-16 The Importance of Periodic Maintenance........ 5-16 Performing Periodic Maintenance ........... 5-16 Yanmar Replacement Parts ............ 5-16 Required EPA / ARB Maintenance -USA Only......5-16 EPA / ARB Installation Requirements - USA Only ....5-16 Periodic Maintenance Schedule............ 5-17 Periodic Maintenance Procedures ..........
Page 88: Tnv Di Service Manual
PERIODIC MAINTENANCE This Page Intentionally Left Blank TNV DI Service Manual...
Page 89: Before You Begin Servicing
Before You Begin Servicing PERIODIC MAINTENANCE BEFORE YOU BEGIN DANGER SERVICING DANGER SCALD HAZARD! • NEVER remove the radiator cap if the engine is hot. Steam and hot engine EXPLOSION HAZARD! coolant will spurt out and seriously • NEVER check the remaining battery burn you.
Page 90 PERIODIC MAINTENANCE Before You Begin Servicing DANGER DANGER FIRE AND EXPLOSION HAZARD! FIRE AND EXPLOSION HAZARD! • Diesel fuel is flammable and explosive • Diesel fuel is flammable and explosive under certain conditions. under certain conditions. • Before you operate the engine, check •...
Page 91 Before You Begin Servicing PERIODIC MAINTENANCE DANGER DANGER FIRE AND EXPLOSION HAZARD! CRUSH HAZARD! • Diesel fuel is extremely flammable and • When you need to transport an engine explosive under certain conditions. for repair, have a helper assist you to •...
Page 92 PERIODIC MAINTENANCE Before You Begin Servicing DANGER DANGER FIRE AND EXPLOSION HAZARD! FIRE AND EXPLOSION HAZARD! • Diesel fuel is flammable and explosive • Diesel fuel is extremely flammable and under certain conditions. explosive under certain conditions. • When you remove any fuel system •...
Page 93 Before You Begin Servicing PERIODIC MAINTENANCE WARNING WARNING EXHAUST HAZARD! SEVER HAZARD! • NEVER operate the engine in an • Keep hands and other body parts enclosed area such as a garage, away from moving / rotating parts tunnel, underground room, manhole or such as the cooling fan, flywheel or ship’s hold without proper ventilation.
Page 94 PERIODIC MAINTENANCE Before You Begin Servicing WARNING WARNING SUDDEN MOVEMENT HAZARD! • Engaging the transmission or PTO at an elevated engine speed could result in unexpected movement of the equipment. ALCOHOL AND DRUG HAZARD! • Failure to comply could result in death •...
Page 95 • NEVER check for a fuel leak with your hands. ALWAYS use a piece of wood or cardboard. Have your authorized Yanmar industrial engine dealer or distributor repair the damage. • Failure to comply could result in death or serious injury.
Page 96 PERIODIC MAINTENANCE Before You Begin Servicing WARNING WARNING BURN HAZARD! SHOCK HAZARD! • If you must drain the engine oil while it • Turn off the battery switch (if is still hot, stay clear of the hot engine equipped) or disconnect the negative oil to avoid being burned.
Page 97 Before You Begin Servicing PERIODIC MAINTENANCE CAUTION CAUTION • Only use diesel fuels recommended by Yanmar for the best engine performance, to prevent engine damage and to comply with EPA / ARB warranty requirements. • Only use clean diesel fuel.
Page 98 • The standard range of ambient engine’s life. Any alterations to this temperatures for the normal operation engine may void its warranty. Be sure of Yanmar engines is from +5°F (-15°C) to use Yanmar genuine replacement to +113°F (+45°C). parts.
Page 99 CAUTION engine oil leaks, coolant leaks, and for proper operation of the indicators For maximum engine life, Yanmar and / or gauges. recommends that when shutting the • During the first hour of operation, vary...
Page 100 Consult the machine and shorten its life. If the idle local authorities or reclamation facility. speed limit screws require adjustment, see your authorized Yanmar industrial • NEVER dispose of hazardous engine dealer or distributor. materials irresponsibly by dumping...
Page 101 Before You Begin Servicing PERIODIC MAINTENANCE CAUTION If the fuel filter / water separator is positioned higher than the fuel level in the fuel tank, water may not drip out when the fuel filter / water separator drain cock is opened. If this happens, turn the air vent screw on the top of the fuel filter / water separator 2-3 turns counterclockwise.
Page 102: Introduction
The Importance of Periodic Yanmar Replacement Parts Maintenance Yanmar recommends that you use genuine Yanmar parts when replacement parts are needed. Engine deterioration and wear occurs in proportion Genuine replacement parts help ensure long to length of time the engine has been in service and engine life.
Page 103: Periodic Maintenance Schedule
See Yanmar Limited Warranty in Warranty Section. Consult your authorized Yanmar dealer or distributor for assistance when checking items marked with a .
Page 104 PERIODIC MAINTENANCE Periodic Maintenance Schedule :Check :Replace : Contact your authorized Yanmar industrial engine dealer or distributor Periodic Maintenance Interval Every Every Every Every Every Every System Check Item Daily 1000 1500 2000 hours hours hours hours hours hours Check and Refill Engine Coolant...
Page 105: Periodic Maintenance Procedures
Periodic Maintenance Procedures PERIODIC MAINTENANCE PERIODIC MAINTENANCE CAUTION PROCEDURES • Only use the engine oil specified. Other engine oils may affect warranty After Initial 50 Hours of Operation coverage, cause internal engine components to seize and / or shorten engine life. Perform the following maintenance after the initial 50 hours of operation.
Page 106 (Figure 5-2, (4)) until it contacts the mounting surface. Tighten an additional 3/4 of a turn using the filter wrench. Applicable Engine Oil Filter Part No. 3TNV82A, 3TNV84, 3TNV84T, 3TNV88, 4TNV84, 4TNV84T, 129150-35152 4TNV88, 4TNV94L 0000084B...
Page 107 Periodic Maintenance Procedures PERIODIC MAINTENANCE 4. Add new engine oil to the engine as specified in 9. Reinstall the oil filler cap (Figure 5-3, (4)). If Adding Engine Oil on page 4-15. any engine oil is spilled, wipe it away with a clean cloth.
Page 108 PERIODIC MAINTENANCE Periodic Maintenance Procedures 2. If necessary, adjust the V-belt tension. Loosen 4. Check the V-belt for cracks, oil or wear. If any of the adjusting bolt (Figure 5-5, (1)) and move these conditions exist, replace the V-belt. the alternator (Figure 5-5, (2)) with a pry bar 5.
Page 109: Every 50 Hours Of Operation
Periodic Maintenance Procedures PERIODIC MAINTENANCE Every 50 Hours of Operation CAUTION If the fuel filter / water separator is After you complete the initial 50 hour maintenance positioned higher than the fuel level in procedures, perform the following procedures every the fuel tank, water may not drip out 50 hours thereafter.
Page 110 PERIODIC MAINTENANCE Periodic Maintenance Procedures The cup of the separator is made from semi- 5. Open the fuel cock (Figure 5-7, (3)). transparent material. In the cup is a red colored 6. Be sure to prime the diesel fuel system when float ring.
Page 111 CAUTION • If the engine still will not start after charging, have your authorized Yanmar industrial engine dealer or distributor check the battery and the engine’s starting system. • If operating the machine where the ambient temperature could drop to 5°F (-15°C) or less,...
Page 112: Every 250 Hours Of Operation
PERIODIC MAINTENANCE Periodic Maintenance Procedures Every 250 Hours of Operation CAUTION Perform the following maintenance every 250 hours of operation. • Drain Fuel Tank • Replace Engine Oil and Engine Oil Filter • ALWAYS be environmentally • Check and Clean Radiator Fins responsible.
Page 113 Periodic Maintenance Procedures PERIODIC MAINTENANCE 4. Drain the tank until clean diesel fuel with no CAUTION water and dirt flows out. Reinstall and tighten the drain plug firmly. 5. Reinstall the fuel cap. 6. Check for leaks. Replace Engine Oil and Engine Oil Filter •...
Page 114 PERIODIC MAINTENANCE Periodic Maintenance Procedures Check and Clean Radiator Fins CAUTION F U L L O W FLYING OBJECT HAZARD! • ALWAYS wear eye protection when 0000085A servicing the engine and when using Figure 5-10 compressed air or high-pressure water. Dust, flying debris, compressed Check and Adjust Cooling Fan V-Belt air, pressurized water or steam may Check and adjust the cooling fan V-belt every 250...
Page 115 If the idle air, pressurized water or steam may speed limit screws require adjustment, injure your eyes. see your authorized Yanmar industrial engine dealer or distributor. • Failure to comply may result in minor or moderate injury.
Page 116 PERIODIC MAINTENANCE Periodic Maintenance Procedures 3. Blow air (Figure 5-12, (3)) through the element 6. Replace the element with a new one if the from the inside out using 42 - 71 psi element is damaged, excessively dirty or oily. (0.29 - 0.49 MPa;...
Page 117: Every 500 Hours Of Operation
(Figure 5-13, (1)) if the engine lacks power or the CAUTION dust indicator actuates (if equipped). This is in addition to replacing the outer element. For maximum engine life, Yanmar recommends that when shutting the engine down, you allow the engine to idle, without load, for five minutes. This...
Page 118 PERIODIC MAINTENANCE Periodic Maintenance Procedures CAUTION • ALWAYS be environmentally responsible. • Follow the guidelines of the EPA or other governmental agencies for the proper disposal of hazardous 0000072A materials such as engine oil, diesel Figure 5-14 fuel and engine coolant. Consult the local authorities or reclamation facility.
Page 119 Periodic Maintenance Procedures PERIODIC MAINTENANCE Clean Fuel Filter / Water Separator CAUTION DANGER • ALWAYS be environmentally FIRE AND EXPLOSION HAZARD! responsible. • Diesel fuel is flammable and explosive • Follow the guidelines of the EPA or under certain conditions. other governmental agencies for the •...
Page 120 PERIODIC MAINTENANCE Periodic Maintenance Procedures Periodically clean the fuel filter / water separator 6. Remove the float ring (Figure 5-15, (8)) from element and inside cup. the cup. Pour the contaminants into the container and dispose of it properly. 1. Position an approved container under the cup 7.
Page 121: Every 1000 Hours Of Operation
Periodic Maintenance Procedures PERIODIC MAINTENANCE Every 1000 Hours of Operation WARNING Perform the following maintenance every 1000 hours of operation. • Drain, Flush and Refill Cooling System With New Coolant BURN HAZARD! • Adjust Intake / Exhaust Valve Clearance • Wait until the engine cools before you drain the engine coolant.
Page 122 PERIODIC MAINTENANCE Periodic Maintenance Procedures CAUTION F U L L O W • 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 0000074A fuel and engine coolant.
Page 123: Every 1500 Hours Of Operation
Adjust Intake / Exhaust Valve Clearance or cardboard. Have your authorized Proper adjustment is necessary to maintain the Yanmar industrial engine dealer or correct timing for opening and closing the valves. distributor repair the damage. Improper adjustment will cause the engine to run •...
Page 124 This procedure is considered normal maintenance To inspect the diaphragm and spring and is performed at the owner’s expense. This (Figure 5-19, (3)): procedure is not covered by the Yanmar Limited 1. Remove the bolts retaining the diaphragm Warranty. cover (Figure 5-19, (4)).
Page 125: Every 2000 Hours Of Operation
Periodic Maintenance Procedures PERIODIC MAINTENANCE Lap the Intake and Exhaust Valves Every 2000 Hours of Operation Adjustment is necessary to maintain proper contact of the valves and seats. See Inspection of Intake Perform the following maintenance every 2000 and Exhaust Valves on page 6-39. hours of operation.
Page 126 PERIODIC MAINTENANCE Periodic Maintenance Procedures This Page Intentionally Left Blank 5-40 TNV DI Service Manual...
Page 127 Section 6 TNV DI Service Manual ENGINE Page Before You Begin Servicing ............6-3 Introduction..................6-6 Cylinder Head Specifications ............6-6 Adjustment Specifications ............6-6 Cylinder Head................6-6 Intake / Exhaust Valve and Guide ..........6-7 Push Rod................... 6-8 Valve Spring ................6-9 Rocker Arm and Shaft ...............
Page 128 ENGINE 2-Valve Cylinder Head ..............6-32 2-Valve Cylinder Head Components ........6-32 Disassembly of 2-Valve Cylinder Head ........6-33 Cleaning of Cylinder Head Components ......... 6-37 Inspection of Cylinder Head Components....... 6-38 Reassembly of Cylinder Head..........6-42 4-Valve Cylinder Head ..............6-46 4-Valve Cylinder Head Components ........
Page 129: Before You Begin Servicing
Before You Begin Servicing ENGINE BEFORE YOU BEGIN WARNING SERVICING WARNING FUME / BURN HAZARD! • Always read and follow safety related precautions found on containers of hazardous substances like parts To prevent possible eye injury, always cleaners, primers, sealants and wear SAFETY GLASSES while servicing sealant removers.
Page 130 ENGINE Before You Begin Servicing CAUTION CAUTION • Only use the engine oil specified. Any part which is found defective as a Other engine oils may affect warranty result of inspection or any part whose coverage, cause internal engine measured value does not satisfy the components to seize and / or shorten standard or limit must be replaced.
Page 131 Before You Begin Servicing ENGINE 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 an appropriate method. 0000088en CAUTION Do not allow the honing tool to operate in one position for any length of time.
Page 132: Introduction
Combustion Surface Distortion (Flatness) (0.05 mm) or less (0.15 mm) 0.0138 - 0.0217 in. Intake 0.0315 in. (0.8 mm) (0.35 - 0.55 mm) 3TNV82A (2-Valve Head) 0.0118 - 0.0197 in. Exhaust 0.0315 in. (0.8 mm) (0.30 - 0.50 mm) 3TNV84, 3TNV84T, 0.0118 - 0.0197 in.
Page 133: Intake / Exhaust Valve And Guide
(6.945 - 9.960 mm) (6.90 mm) 0.0016 - 0.0028 in. 0.0071 in. Valve Stem Bend Inspection of (0.040 - 0.070 mm) (0.18 mm) 3TNV82A Valve Guides (2-Valve Head) 0.2756 - 0.2762 in. 0.2787 in. Guide Inside Diameter (7.000 - 7.015 mm) (7.08 mm) page 6-38.
Page 134: Push Rod
(6.90 mm) 0.0013 - 0.0024 in. 0.0071 in. Valve Stem Bend (0.033 - 0.060 mm) (0.18 mm) 0.4606 - 0.4724 in. 3TNV82A (11.70 - 12.00 mm) 3TNV84, 3TNV84T, 0.5791 -0.5905 in. 4TNV84, 4TNV88 (14.71 - 5.00 mm) Reassembly Valve Guide Projection From 0.3228 - 0.3346 in.
Page 135: Valve Spring
Cylinder Head Specifications ENGINE Valve Spring Reference Inspection Item Model Standard Limit Page 1.7480 in. 1.7283 in. 3TNV82A (2-Valve Head) (44.4 mm) (43.9 mm) 4TNV84, 3TNV84, 3TNV84T, 4TNV88 1.6535 in. 1.6339 in. (2-Valve Head) (42.0 mm) (41.5 mm) 1.4724 in. 1.4528 in.
Page 136: Camshaft And Timing Gear Train Specifications
(0.030 mm) page 6-71. 0 - 0.0008 in. 0.0020 in. Bend (1/2 the dial gauge reading) (0 - 0.02 mm) (0.05 mm) 3TNV82A, 3TNV84, 1.5197 - 1.5276 in. 1.5098 in. 3TNV84T, 3TNV88, 4TNV84, (38.600 - 38.800 mm) (38.350 mm) Inspection of...
Page 137 Camshaft and Timing Gear Train Specifications ENGINE (Camshaft Cont.) Reference Inspection Item Standard Limit Page 1.9681 - 1.9707 in. 1.9736 in. Bushing Inside Diameter (49.990 - 50.055 mm) (50.130 mm) 1.9655 - 1.9665 in. 1.7673 in. Gear End Camshaft Outside Diameter (49.925 - 49.950 mm) (49.890 mm) 0.0016 - 0.0051 in.
Page 138: Idler Gear Shaft And Bushing
(0.175 mm) Timing Gear Backlash Reference Model Inspection Item Standard Limit Page 3TNV82A 3TNV84, 3TNV84T, Crank Gear, Cam Gear, Idler Gear, 0.0028 - 0.0059 in. 0.0067 in. 3TNV88, 4TNV84, Fuel Injection Pump Gear and PTO (0.07 - 0.15 mm) (0.17 mm)
Page 139: Crankshaft And Piston Specifications
1.6891 in. Diameter (42.952 - 42.962 mm) (42.902 mm) Bearing Inside 1.6929 - 1.6946 in. Diameter (43.000 - 43.042 mm) 3TNV82A Bearing Insert 0.0585 -.0591 in. Thickness (1.487 - 1.500 mm) 0.0015 - 0.0035 in. 0.0059 in. Oil Clearance (0.038 - 0.090 mm) (0.150 mm)
Page 140: Thrust Bearing
1.8465 in. Diameter (46.952 - 46.962 mm) (46.902 mm) Bearing Inside 1.8504 - 1.8516 in. Diameter (47.000 - 47.032 mm) 3TNV82A Bearing Insert 0.0782 - 0.0787 in. Thickness (1.987 - 2.000 mm) 0.0015 - 0.0031 in. 0.0059 in. Oil Clearance (0.038 - 0.080 mm)
Page 141: Piston
ENGINE Piston Reference Inspection Item Standard Limit Page 3.2264 - 3.2275 in. 3.2246 in. 3TNV82A (81.950 - 81.980 mm) (81.905 mm) 3TNV84, 3TNV84T, 3.3047 - 3.3059 in. 3.3029 in. 4TNV84, 4TNV84T (83.940 - 83.970 mm) (83.895 mm) 3.4622 - 3.4634 in.
Page 142 0.9055 - 0.9059 in. 0.9070 in. Hole Inside Diameter (23.000 - 23.009 mm) (23.039 mm) 0.9053 - 0.9055 in. 0.9041 in. 3TNV82A Pin Outside Diameter (22.995 - 23.000 mm) (22.965 mm) 0.0000 - 0.0006 in. 0.0029 in. Oil Clearance (0.000 - 0.014 mm) (0.074 mm)
Page 143: Piston Ring
End Gap (0.200 - 0.400 mm) (0.490 mm) 0.0801 - 0.0807 in. 0.0846 in. Ring Groove Width (2.035 - 2.050 mm) (2.150 mm) 3TNV82A, Inspection of 0.0776 - 0.0783 in. 0.0768 in. Ring Width 3TNV84, Pistons, (1.970 - 1.990 mm) (2.150 mm)
Page 144 ENGINE Crankshaft and Piston Specifications (Piston Ring Cont.) Reference Model Inspection Item Standard Limit Page 0.0811 - 0.0817 in. Ring Groove Width (2.060 - 2.075 mm) 0.0776 - 0.0783 in. 0.0768 in. Ring Width (1.970 - 1.990 mm) (1.950 mm) Top Ring 0.0028 - 0.0041 in.
Page 145 Crankshaft and Piston Specifications ENGINE (Piston Ring Cont.) Reference Model Inspection Item Standard Limit Page 0.0803 - 0.0811 in. Ring Groove Width (2.040 - 2.060 mm) 0.0764 - 0.0772 in. 0.0756 in. Ring Width (1.940 - 1.960 mm) (1.920 mm) Top Ring 0.0031 - 0.0047 in.
Page 146 ENGINE Crankshaft and Piston Specifications (Piston Ring Cont.) Reference Model Inspection Item Standard Limit Page 0.0992 - 0.1000 in. Ring Groove Width (2.520 - 2.540 mm) 0.0961 - 0.0969 in. 0.0953 in. Ring Width (2.440 - 2.460 mm) (2.420 mm) Top Ring 0.0024 - 0.0039 in.
Page 147: Connecting Rod
0.9065 - 0.9070 in. 0.9082 in. Inside Diameter (23.025 - 23.038 mm) (23.068 mm) Wrist Pin Outside 0.9053 - 0.9055 in. 0.9042 in. 3TNV82A Diameter (22.995 - 23.000 mm) (22.967 mm) 0.0010 - 0.0017 in. 0.0040 in. Oil Clearance (0.025 - 0.043 mm) (0.101 mm)
Page 148: Tappet
Page Tappet Bore (Block) Inside 0.4724 - 0.4734 in. 0.4742 in. Diameter (12.000 - 12.025 mm) (12.045 mm) 3TNV82A, 3TNV84, 3TNV84T, 3TNV88, 0.4715 - 0.4720 in. 0.4707 in. Tappet Stem Outside Diameter 4TNV84, 4TNV84T, (11.975 - 11.990 mm) (11.955 mm) 4TNV88 0.0004 - 0.0020 in.
Page 149: Special Torque Chart
Seat Surface) 46 - 49 ft·lb 3TNV82A M9 x 1.25 mm (61.7 - 65.7 N·m; 6.3 - 6.7 kgf·m) 3TNV82A, 3TNV84, 63 - 67 ft·lb 3TNV84T, 3TNV88, M10 x 1.25 mm (85.3 - 91.1 N·m; 4TNV84, 4TNV84T, 8.7 - 9.3 kgf·m)
Page 150 11.0 - 12.0 kgf·m) 137 - 152 ft·lb 4TNV106, 4TNV106T M14 x 1.5 mm (186.2 - 205.8 N·m; 19 - 21 kgf·m) 3TNV82A, 3TNV84, 83 - 91 ft·lb 3TNV84T, 3TNV88, M14 x 1.5 mm (112.7 - 122.7 N·m; 4TNV84, 4TNV84T, 11.5 - 12.5 kgf·m)
Page 151 Special Torque Chart ENGINE (Torque for Bolts and Nuts Cont.) Lubricating Oil Thread Diameter Application Component Model Torque and Pitch (Thread Portion and Seat Surface) 4TNV94L, 4TNV98, 70 - 86 in·lb Fuel Return Line 4TNV98T, 4TNV106, M6 x 1.0 mm (7.8 - 9.8 N·m;...
Page 152: Special Service Tools
(13 mm) (16 mm) 4TNV98T 4TNV106, 0.535 in. 2.559 in. 0.512 in. 0.630 in. 4TNV106T (13.6 mm) (65 mm) (13 mm) (16 mm) Locally Manufactured Fuel Injector Removal Tool Yanmar Part No. 129470-92305 (2-Valve Head) 6-26 TNV DI Service Manual...
Page 153 0.787 in. 3.937 in. 1.457 in. 1.575 in. 4TNV106T (20 mm) (100 mm) (37 mm) (40 mm) Locally Manufactured Valve Spring Compressor Yanmar Part No. (For Removal/ 129100-92630 Installation of 0000830 Valve Spring) Model 0.598 0.827 0.472 0.622 2.559 0.157 3TNV82A (15.2...
Page 154 (89 - 101 mm) 4TNV106, 3.740 - 4.252 in. 129400-92450 4TNV106T (95 - 108 mm) Piston Ring Yanmar Part No. 95550-002476 Compressor The Piston Insertion Tool is Applicable for (For Installing 2.362 - 4.921 in. (60 - 125 mm) Diameter Pistons Piston) 0000824...
Page 155 Special Service Tools ENGINE (Special Service Tools Cont.) Tool Name Applicable Model and Tool Size Illustration Locally Manufactured 0000826 Crankshaft Pulley (4TNV94L only) Installing Tool (Knurl knob (1)) 0002134 TNV DI Service Manual 6-29...
Page 156: Measuring Instruments
ENGINE Measuring Instruments MEASURING INSTRUMENTS Instrument Name Application Illustration Dial Indicator Locally Available Measure shaft bend and end play 0000831 Measurements of narrow or deep portions that Test Indicator Locally Available cannot be measured by dial gauge 0000832 Magnetic Stand Locally Available For holding the dial gauge when measuring 0000833...
Page 157 Measuring Instruments ENGINE Instrument Name Application Illustration V-Block Locally Available For measuring shaft bend 0000839 For tightening nuts and bolts to the specified Torque Wrench Locally Available torque 0000840 For measuring piston ring gaps, piston ring Feeler Gauge Locally Available clearance, and valve adjustment clearance 0000841 TNV DI Service Manual...
Page 158: 2-Valve Cylinder Head
ENGINE 2-Valve Cylinder Head 2-VALVE CYLINDER HEAD 2-Valve Cylinder Head Components (34) (32) (33) (10) (11) (12) (29) (13) (17) (14) (30) (18) (15) (28) (31) (19) (16) (20) (27) (21) (22) (23) (26) (24) (25) 0001919 Figure 6-1 6-32 TNV DI Service Manual...
Page 159: Disassembly Of 2-Valve Cylinder Head
2-Valve Cylinder Head ENGINE 1 – Valve Cover Nut CAUTION 2 – Valve Cover Nut O-Ring 3 – Crankcase Breather Cover Identify all parts and their location using 4 – Diaphragm Spring an appropriate method. It is important 5 – Diaphragm Plate that all parts are returned to the same 6 –...
Page 160 ENGINE 2-Valve Cylinder Head 3. Disconnect the coolant hoses from the cold 5. Remove the exhaust manifold bolts start device (Figure 6-3, (1)) on the fuel (Figure 6-4, (4)) and nuts (Figure 6-4, (5)). injection pump. Remove the exhaust manifold (Figure 6-4, (6)) and the exhaust manifold gasket (Figure 6-4, (7)).
Page 161 2-Valve Cylinder Head ENGINE Removal of Rocker Arm Assembly 1. Remove the bolts (Figure 6-6, (1)) that retain the rocker arm shaft supports. 2. Remove the rocker arm shaft assembly from the cylinder head. Note: Identify the push rods so they can be reinstalled in their original locations.
Page 162 ENGINE 2-Valve Cylinder Head 2. Remove the cylinder head bolts (Figure 6-9, (1)). 3. Lift the cylinder head away from the cylinder block. Discard the cylinder head gasket (Figure 6-9, (2)). Position the cylinder head on the work bench to prevent damage to the combustion surface.
Page 163: Cleaning Of Cylinder Head Components
2-Valve Cylinder Head ENGINE Removal of Valve Guides Thoroughly clean all components using a non- metallic brush and an appropriate solvent. Each Note: Removal of the valve guides should be part must be free of carbon, metal filings and other postponed until inspection and debris.
Page 164 ENGINE 2-Valve Cylinder Head 3. Use a feeler gauge to measure the gap Rocker Arm Shaft Outside Diameter (Figure 6-13). See Push Rod on page 6-8 for Use a micrometer to measure the rocker arm shaft the service limit. diameter. Measure at each rocker arm location in two directions 90°...
Page 165 2-Valve Cylinder Head ENGINE Inspection of Cylinder Head Valve Stem Bend Place the valve stem on a flat inspection block or Cylinder Head Distortion layout bed. Roll the valve until a gap can be Place the cylinder head flat and inverted observed between a portion of the valve stem and (combustion side up) on the bench.
Page 166 ENGINE 2-Valve Cylinder Head 0001755 Figure 6-21 Valve Face and Valve Seat Always check the clearance between the valve and 0001691B valve guide before grinding or lapping the valve Figure 6-22 seats. See Intake / Exhaust Valve and Guide on page 6-7 for the service limit.
Page 167: Reassembly Of Cylinder Head
2-Valve Cylinder Head ENGINE If the valve or seat require grinding, lap the valve after grinding. Lap the valve face to the valve seat using a mixture of valve lapping compound and engine oil. Be sure to thoroughly wash all parts to remove all grinding powder or compound.
Page 168 ENGINE 2-Valve Cylinder Head 2. Immediately after removing the valve guides Reassembly of Intake and Exhaust Valves from the freezer, insert the valve guides IMPORTANT (Figure 6-26, (1)) in their proper positions. Always install new valve stem seals. The exhaust seals can be identified by having yellow paint.
Page 169 2-Valve Cylinder Head ENGINE 3. Place the cylinder head assembly on its Reassembly of Cylinder Head exhaust port side. 1. Carefully clean both the combustion surface of 4. Place all the valves (Figure 6-30, (6)) in their the cylinder head and the top surface of the proper location in the cylinder head.
Page 170 ENGINE 2-Valve Cylinder Head 3. Lightly oil the threads of the cylinder head bolts 1. Lubricate the rocker arm shaft. Slide the rocker (Figure 6-31, (1)). Tighten the bolts to the arm supports (Figure 6-34, (5)), springs specified torque in two steps as shown in the (Figure 6-34, (1)) and rocker arms chart below.
Page 171 2-Valve Cylinder Head ENGINE 6. Tighten the rocker arm shaft alignment studs. 7. Adjust the valve clearance. See Measuring and Adjusting Valve Clearance on page 6-60. Reassembly of the Valve Cover 1. Lightly grease a new valve cover gasket (Figure 6-35, (4)). Place the gasket in the groove of the valve cover (Figure 6-35, (3)).
Page 172: 4-Valve Cylinder Head
ENGINE 4-Valve Cylinder Head 4-VALVE CYLINDER HEAD 4-Valve Cylinder Head Components (36) (35) (34) (12) (11) (10) (33) (14) (15) (13) (31) (30) (32) (29) (28) (27) (16) (26) (24) (25) (23) (17) (18) (22) (19) (21) (20) 0001861 Figure 6-36 6-46 TNV DI Service Manual...
Page 173: Disassembly Of 4-Valve Cylinder Head
4-Valve Cylinder Head ENGINE 1 – Crankcase Breather Cover CAUTION 2 – Diaphragm Spring 3 – Diaphragm Cup Identify all parts and their location using 4 – Crankcase Breather Diaphragm an appropriate method. It is important 5 – Oil Fill Cap that all parts are returned to the same 6 –...
Page 174 ENGINE 4-Valve Cylinder Head 5. Remove the turbocharger-to-intake manifold 2. Use a flat-blade screwdriver (Figure 6-39) to hose (Figure 6-38, (1)) (if equipped). remove the fuel injection line grommets (Figure 6-40, (1)) from the valve cover 6. Disconnect the electrical wire from the intake air (Figure 6-40, (3)) and fuel injectors heater (Figure 6-38, (12)).
Page 175 4-Valve Cylinder Head ENGINE 5. Remove the valve cover (Figure 6-40, (3)). Disassembly of Rocker Arm Assembly Discard the valve cover gasket Note: Identify the rocker arms so they can be (Figure 6-40, (6)). reinstalled with the original matching 6. Inspect and clean the crankcase breather valve and pushrod.
Page 176 ENGINE 4-Valve Cylinder Head Removal of Cylinder Head 1. Loosen the cylinder head bolts following the sequence shown in (Figure 6-43). 0001864 1 – Cooling Fan End 2 – Camshaft Side Figure 6-43 0001872 2. Remove the cylinder head bolts Figure 6-44 (Figure 6-44, (1)).
Page 177: Cleaning Of Cylinder Head Components
4-Valve Cylinder Head ENGINE Removal of Valve Guides 3. Remove the valve keepers (Figure 6-46, (1)). 4. Slowly release the tension on the valve spring. Note: Removal of the valve guides should be postponed until inspection and 5. Remove the spring retainer (Figure 6-46, (2)), measurement procedures have been valve spring (Figure 6-46, (3)).
Page 178: Inspection Of Cylinder Head Components
ENGINE 4-Valve Cylinder Head 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.
Page 179 4-Valve Cylinder Head ENGINE 0000192 Figure 6-52 If distortion exceeds the service limit, resurface or 0001952 replace the cylinder head. Remove only enough Figure 6-50 material to make the cylinder head flat, but do not remove more than 0.008 in (0.20 mm). Inspection of Valve Guides Inspection of Intake and Exhaust Valves Valve Guide Inside Diameter...
Page 180 ENGINE 4-Valve Cylinder Head Valve Stem Bend Place the valve stem on a flat inspection block or layout bed. Roll the valve until a gap can be observed between a portion of the valve stem and the surface of the block or bed. Use a feeler gauge to measure the gap (Figure 6-54).
Page 181 4-Valve Cylinder Head ENGINE Coat the valve seat with a thin coat of bluing Grind the valve face and/or valve seat as necessary compound. Install the valve and rotate to distribute to return them to serviceable condition. Grinding is bluing onto the valve face. The contact pattern needed if the valve and valve seat do not contact should be approximately centered on the valve face correctly.
Page 182: Reassembly Of Cylinder Head
ENGINE 4-Valve Cylinder Head Reassembly of Cylinder Head Free Length Use a caliper to measure the length of the spring Use new gaskets, O-rings, and seals on (Figure 6-60). See Valve Spring on page 6-9 for reassembly of the cylinder head. the service limit.
Page 183 4-Valve Cylinder Head ENGINE 3. Finish installing the valve guides 2. Measure the distance (Figure 6-65, (1)) from (Figure 6-63, (1)) into the cylinder head to the the cylinder head to the valve stem seal to proper height (Figure 6-63, (3)) using the valve ensure proper clearance (Figure 6-65, (2)) guide installation tool (Figure 6-63, (2)).
Page 184 ENGINE 4-Valve Cylinder Head 7. Insert the valve keepers (Figure 6-66, (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 head and the top surface of the cylinder block.
Page 185 4-Valve Cylinder Head ENGINE IMPORTANT Note: To properly align the rocker arm shaft with the rocker arm shaft supports, first The wave washers (Figure 6-70, (2)) must reinstall one of the end rocker arm be installed with the bow facing the rocker supports (Figure 6-72, (6)) with a hole arms (Figure 6-70, (1)).
Page 186: Measuring And Adjusting Valve Clearance
ENGINE Measuring and Adjusting Valve Clearance Reassembly of the Valve Cover 9. Reinstall the high pressure and fuel return lines. See Installation of the Fuel Injectors on 1. Lightly grease a new valve cover gasket page 7-37. (Figure 6-73, (6)). Place the gasket in the 10.
Page 187 Measuring and Adjusting Valve Clearance ENGINE • If adjusting each cylinder individually, the Example: On a 3-cylinder engine, with the No. 1 cylinder to be adjusted first does not have to be piston at TDC on the compression stroke (both the No.
Page 188: 2-Valve Cylinder Heads
ENGINE Measuring and Adjusting Valve Clearance 2-Valve Cylinder Heads 1. Remove the valve cover. See Removal of Valve Cover on page 6-48. Note: If adjusting each cylinder individually, the cylinder to be adjusted first does not have to be the No. 1 cylinder. Select and adjust the cylinder where the piston is nearest to the top dead center after turning, and make adjustment for other...
Page 189: 4-Valve Cylinder Heads
Measuring and Adjusting Valve Clearance ENGINE 4-Valve Cylinder Heads IMPORTANT Do not loosen or tighten the valve adjusting The 4-valve cylinder head operates two valves with screw lock nut without holding the valve a single rocker arm by employing a valve bridge bridge.
Page 190 ENGINE Measuring and Adjusting Valve Clearance 7. Tighten the lock nut (Figure 6-80, (1)), while holding the valve bridge (Figure 6-80, (3)) with a wrench (Figure 6-80, (2)). Verify that the valve clearance (Figure 6-81, (2) is zero “0”. 0001917A Figure 6-80 0003566 Figure 6-82...
Page 191 Measuring and Adjusting Valve Clearance ENGINE 0001918 Figure 6-83 12. Hold the adjusting screw (Figure 6-83, (4)) while tightening the valve adjusting screw lock nut (Figure 6-83, (5)). Recheck the clearance. 13. Apply oil to the contact surface between the adjusting screw and push rod.
Page 192: Crankshaft And Camshaft Components
ENGINE Crankshaft and Camshaft Components CRANKSHAFT AND CAMSHAFT COMPONENTS 0001963 Figure 6-84 6-66 TNV DI Service Manual...
Page 193: Disassembly Of Engine
Crankshaft and Camshaft Components ENGINE 1 – Cylinder Block CAUTION 2 – Camshaft Bushing 3 – Gear Case (3TNV94 - 4TNV106) Identify all parts and their location using 4 – Dowel (2 used) an appropriate method. It is important 5 – O-Ring that all parts are returned to the same 6 –...
Page 194: Disassembly Of Camshaft And Timing Components
ENGINE Crankshaft and Camshaft Components 9. Remove the fuel injection pump from the gear case / front plate only if it must be sent out for repair, or will interfere with other procedures such as “hot tank” cleaning. If the fuel injection pump does not need to be repaired, leaving it mounted to the timing gear case or plate will eliminate the need to re-time it during...
Page 195 Crankshaft and Camshaft Components ENGINE Note: 3TNV82A - 4TNV88: The oil pump is driven directly by flats on the crankshaft drive gear hub. Measuring Idler Gear-to-Crankshaft Gear Backlash 1. Install a dial indicator as shown in Figure 6-87. 0001728A Figure 6-88 2.
Page 196 ENGINE Crankshaft and Camshaft Components 0000162A Figure 6-89 Removal of Oil Pan 1. Invert the engine (oil pan up) on the engine stand. 2. Remove the oil pan (Figure 6-90, (1)). 0001695A Figure 6-90 6-70 TNV DI Service Manual...
Page 197 Crankshaft and Camshaft Components ENGINE 3. Remove the oil pickup tube (Figure 6-91, (1)) and O-ring (Figure 6-91, (2)). 0002085A Figure 6-92 • Method B: Use a feeler gauge to measure the clearance between the thrust plate (Figure 6-93, (1)) and front camshaft bearing (Figure 6-93, (2)).
Page 198 ENGINE Crankshaft and Camshaft Components 2. Remove the two bolts (Figure 6-94, (3)) Removal of Gear Case or Front Plate retaining the camshaft thrust plate Note: The camshaft must be removed before (Figure 6-94, (1)). the gear case / front plate can be removed.
Page 199: Disassembly Of Crankshaft And Piston Components
Crankshaft and Camshaft Components ENGINE 6. TNV84 - TNV88: Remove the O-ring 1. Using a feeler gauge, measure the connecting (Figure 6-96, (2)) and dowels rod side clearance as shown (Figure 6-97). (Figure 6-96, (5)). See Connecting Rod on page 6-21 for the standard limit.
Page 200 ENGINE Crankshaft and Camshaft Components IMPORTANT (g) Repeat with remaining connecting rods. Mark the connecting rod caps and IMPORTANT connecting rods so the caps and connecting Do not allow the connecting rod to contact rods stay together. the crankshaft journal during piston (a) Remove the bearing cap.
Page 201 Crankshaft and Camshaft Components ENGINE Removal of Crankshaft • Method B: Use a feeler gauge to measure the clearance (Figure 6-103, (3)) between the 1. Remove the flywheel (Figure 6-101, (1)) from thrust bearing (Figure 6-103, (1)) and the crankshaft. crankshaft (Figure 6-103, (2)).
Page 202 ENGINE Crankshaft and Camshaft Components 4. Remove the main bearing caps (Figure 6-104, (3)). Be sure to note the markings on the main bearing caps, or mark them yourself, so they can be reinstalled in the same order as they were removed. Do not remove the bearing inserts at this time.
Page 203: Inspection Of Crankshaft And Camshaft Components
8. If necessary, remove the crankshaft gear 2. Apply a continuous bead of ThreeBond Liquid (Figure 6-107, (1)), parallel pin Gasket No. 1212, Yanmar Part No. 977770- (Figure 6-107, (2)) and key (Figure 6-107, (3)). 01212 to the outside diameter of a new oil seal...
Page 204 ENGINE Crankshaft and Camshaft Components Measure Crankshaft Bearing Oil Clearance Inspection of Pistons, Piston Rings and Wrist Pin Oil clearance should be checked during disassembly to determine the extent of wear, and Notes: during assembly to ensure long engine life. The •...
Page 205 Crankshaft and Camshaft Components ENGINE 5. Subtract the piston measurement from the • On an engine with high hours, the pistons rings greatest measurement acquired during cylinder should be replaced and the cylinder honed inspection (see Inspection of Cylinder Block on (see Honing and Boring on page 6-83) or page 6-78) to obtain piston-to-cylinder replaced.
Page 206 ENGINE Crankshaft and Camshaft Components 10. To measure piston ring end gap, insert each compression piston ring (Figure 6-115, (1)), one at a time, into the cylinder. Use a piston with the piston rings removed to slide the ring into the cylinder bore until it is approximately 1.18 in.
Page 207 Crankshaft and Camshaft Components ENGINE 2. Measure the outside diameter of the tappet 4. Use the color check method or Magnaflux® to stem (Figure 6-118, (1)). See Tappet on inspect the crankshaft for cracks. Replace the page 6-22 for the service limit. crankshaft if evidence of fractures are found.
Page 208 ENGINE Crankshaft and Camshaft Components Inspection of Camshaft 1. Use V-blocks and a dial indicator to check camshaft bend (Figure 6-121). Place the indicator on the center bearing journal. 0001713A Figure 6-123 0001711 Inspection of Camshaft Bushing and Bores 1. Measure the I.D. of the front bushing and the Figure 6-121 remaining bores in the cylinder block.
Page 209: Honing And Boring
Crankshaft and Camshaft Components ENGINE Honing and Boring CAUTION Pistons must move freely in the cylinders while Do not allow the honing tool to operate maintaining adequate compression and oil sealing. in one position for any length of time. If the cylinder walls are scuffed, scored, Damage to the cylinder wall will occur.
Page 210: Reassembly Of Crankshaft And Piston Components
ENGINE Crankshaft and Camshaft Components • When honing is completed, wash the cylinder block with hot water and soap. The cylinder wall is adequately cleaned when a white rag wiped in cylinder comes out clean. Use brushes to clean all passages and crevices. Rinse with hot water and dry with compressed air.
Page 211 Crankshaft and Camshaft Components ENGINE 0001967 1 – Fuel Injection Pump Side of Engine 0002090 2 – Piston Identification Mark 3 – Embossed Mark on Connecting Rod 4 – Rod and Cap Match Marks 5 – Flywheel End of Engine 6 –...
Page 212 ENGINE Crankshaft and Camshaft Components 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 6-78 for specifications. Use a piston ring end gap filing tool to adjust the piston ring end gap on new piston rings.
Page 213 6. Rotate the crankshaft to assure it turns freely. 1. If removed, reinstall the keys and timing gear on 7. Apply ThreeBond Liquid Gasket No. 1212, Yanmar Part No. 977770-01212 to the mounting the crankshaft. flange of the seal housing (Figure 6-135, (2)).
Page 214 ENGINE Crankshaft and Camshaft Components 2. Rotate the crankshaft so the crankpin for the 4. Carefully reinstall the piston and rod assembly. piston being installed is near bottom dead Be sure the match marks (Figure 6-137, (4)) center. stamped into the connecting rod and cap, and the identification mark (Figure 6-137, (2)) IMPORTANT stamped into the piston top are facing the fuel...
Page 215: Reassembly Of Camshaft And Timing Components
Installation of Camshaft 2. Apply a continuous bead of ThreeBond Liquid Gasket No. 1212, Yanmar Part No. 977770- Note: The gear housing or front plate must be 01212 to the mounting area of the gear case or reinstalled prior to installing the front plate.
Page 216 ENGINE Crankshaft and Camshaft Components 1. If removed, reinstall the camshaft end plate Installation of Timing Gears (Figure 6-141, (1)), key, and timing gear 1. Set the No. 1 piston to top dead center. (Figure 6-141, (4)) onto the camshaft using a 2.
Page 217 Installation of Gear Case Cover 1. Apply a continuous bead of ThreeBond Liquid Gasket No. 1212, Yanmar Part No. 977770- 01212 to the mounting area of the gear case cover (Figure 6-144, (1)). Be sure to circle the bolt holes.
Page 218: Final Reassembly Of Engine
0001696A Figure 6-146 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 6-147, (1)). Be sure to circle each bolt hole. 3. Reinstall the oil pan and tighten the bolts securely.
Page 219 Section 7 TNV DI Service Manual FUEL SYSTEM Page Before You Begin Servicing ............7-3 Introduction..................7-5 Fuel Injection Pump..............7-5 Stop Solenoid ................7-6 Cold Start Device............... 7-7 Trochoid Fuel Pump ..............7-7 Fuel System Specifications ............. 7-8 Special Torque Chart..............7-8 Test and Adjustment Specifications ..........
Page 220 FUEL SYSTEM Removal of Fuel Injectors ..............7-31 Testing of Fuel Injectors..............7-33 Disassembly and Inspection of Fuel Injectors........7-35 Adjusting Fuel Injector Pressure ............7-36 Reassembly of Fuel Injectors.............. 7-37 Installation of the Fuel Injectors ............7-37 TNV DI Service Manual...
Page 221: Before You Begin Servicing
Before You Begin Servicing FUEL SYSTEM BEFORE YOU BEGIN WARNING SERVICING • Never inject fuel toward you. Since the fuel is injected at high pressure from WARNING 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.
Page 222 0000003en tamper-proof seals. CAUTION • Tampering with or removing these devices may void the “Yanmar Limited Warranty.” 0000146en CAUTION Never use a steel wire brush to clean PINCH HAZARD! fuel injectors. Damage to the nozzle and Carefully rotate the alternator toward the other components is likely to result.
Page 223: Introduction
Do not rotate the crankshaft with the regulations and then replace the injection pump removed. tamper-proof seals. 0000083en • Tampering with or removing these devices may void the “Yanmar Limited CAUTION Warranty.” Each pressure adjusting shim removed 0000146en or added changes the pressure threshold by approximately 275 psi (1.9 MPa, 19 kgf/cm...
Page 224: Stop Solenoid
OFF position. Use a multimeter or continuity light to Injection Pump. The smaller of the two pumps, the check for 12V at the stop solenoid connector in the MP2 pump, is used on the 3TNV82A - 4TNV88 correct sequence. model engines. The larger pump, the MP4 pump,...
Page 225: Cold Start Device
Introduction FUEL SYSTEM Cold Start Device Trochoid Fuel Pump The Yanmar TNV model engines are equipped with Note: The trochoid fuel pump located on the a cold start device (CSD). side of the MP fuel injection pump is not a “fuel supply” pump. The function of this...
Page 226: Fuel System Specifications
Model Fuel Injector Pressure Fuel Injection Timing Class mark* 3133 - 3278 psi 3TNV82A - 4TNV88 (21.6 - 22.6 MPa; 220 - 230 kgf/cm See Checking and Adjusting Fuel Injection Timing on page 7-26 3TNV82A - 4TNV88 2843 - 2988 psi (19.6 - 20.6 MPa;...
Page 227: Special Service Tools
* These special service tools may also be available as an “MP Fuel Injection Pump Special Tool Set”, under a different part number, in territories serviced by Yanmar America and Yanmar Europe. Contact your authorized Yanmar dealer or distributor for details.
Page 228: Fuel System Diagram
FUEL SYSTEM Fuel System Diagram FUEL SYSTEM DIAGRAM (20) (21) (18) (17) (19) (16) (22) (15) (17) (14) (13) (11) (12) (10) 0000034B 1 – Diesel Fuel Tank 12 – Engine Crankcase 2 – Fuel Filter / Water Separator 13 – Tappet 3 –...
Page 229 Fuel System Diagram FUEL SYSTEM This Page Intentionally Left Blank TNV DI Service Manual 7-11...
Page 230: Fuel System Components
FUEL SYSTEM Fuel System Components FUEL SYSTEM COMPONENTS 2-Valve Cylinder Head (16 ) (15 ) (14 ) (13) (18) (10) (12) (17) (11) (19) 0002128 Figure 7-3 7-12 TNV DI Service Manual...
Page 231 Fuel System Components FUEL SYSTEM 1 – High-Pressure Fuel Injection Lines 9 – Coolant Lines for Cold Start Device 2 – Fuel Return Line 10 – Fuel Injection Pump Insulator 3 – Fuel Injector 11 – Fuel Injection Pump 4 – Front Plate or Timing Gear Case 12 –...
Page 232: 4-Valve Cylinder Head
FUEL SYSTEM Fuel System Components 4-Valve Cylinder Head (18) (17) (16) (15) (12) (20) (14) (19) (11) (10) (13) (21) 0002017 Figure 7-4 7-14 TNV DI Service Manual...
Page 233 Fuel System Components FUEL SYSTEM 1 – High-Pressure Fuel Injection Lines 11 – Coolant Lines for Cold Start Device 2 – Fuel Return Line 12 – Fuel Injection Pump Insulator 3 – Return Line-to-Cylinder Head Bolt 13 – Diesel Fuel Injection Pump 4 –...
Page 234: Fuel Injection Pump
FUEL SYSTEM Fuel Injection Pump FUEL INJECTION PUMP CAUTION Remove or install the high-pressure fuel Removal of Fuel Injection Pump injection lines as an assembly whenever 1. Loosen the cooling fan V-belt. possible. Disassembling the 2. Remove the engine coolant fan guard (if high-pressure fuel injection lines from equipped), engine coolant fan (Figure 7-5, (2)), the retainers or bending any of the fuel...
Page 235 Fuel Injection Pump FUEL SYSTEM 10. Remove the fuel supply line (Figure 7-6, (4)). Plug the open end of the line to minimize leakage and prevent contamination. 11. Remove the throttle cable from the fuel injection pump. 12. Separate the stop solenoid wiring connector (Figure 7-7, (2)).
Page 236 FUEL SYSTEM Fuel Injection Pump 16. To position the fuel injection pump for easier • On TNV94 - 106 model engines, the idler gear removal and installation, install a dial indicator is visible. Make a reference mark (see Checking and Adjusting Fuel Injection (Figure 7-11, (1)) across both the fuel injection Timing on page 7-26) into the injection pump pump drive gear and the idler gear.
Page 237 Fuel Injection Pump FUEL SYSTEM Note: On TNV82 - 88 models the injection pump drive gear will remain “captured” in the gear case. On TNV94 - 106 models, the injection pump drive gear can be removed through the gear case cover opening.
Page 238 0000083en 25. If the fuel injection pump requires servicing, it Figure 7-16 must be sent to an authorized Yanmar FIE repair facility for repair and calibration, or 23. If required, remove the intake manifold and fuel replaced with a new fuel injection pump.
Page 239: Installation Of Fuel Injection Pump
• NEVER remove or attempt to remove Distributor: on page 2-4 and follow the instructions the tamper-proof devices from the to locate an authorized Yanmar industrial engine full-load fuel adjusting screw or the dealer or distributor for assistance. high-speed throttle limit screw on the...
Page 240 FUEL SYSTEM Fuel Injection Pump Note: Ensure the tapered surface of the fuel injection pump shaft is clean and dry. 4. Align the key on the fuel injection pump shaft with the keyway in the fuel injection pump drive gear hub. Reinstall the fuel injection pump into the fuel injection pump drive gear and gear housing.
Page 241 Fuel Injection Pump FUEL SYSTEM If installing a new fuel injection pump: • Reinstall the timing grid sticker, provided with the new fuel injection pump, onto the back of the gear case / front plate (Figure 7-24). Align the “standard mark” (Figure 7-24, (1)) with the reference mark (Figure 7-24, (2)) made on the gear case during disassembly.
Page 242 FUEL SYSTEM Fuel Injection Pump • Calculate the difference between the timing The above calculated difference indicates that index numbers (Figure 7-25, (1)) of the fuel the replacement fuel injection pump is to be injection pump that you removed and the installed at +0.5°...
Page 243 0000593B Figure 7-29 9. Apply ThreeBond Liquid Gasket No. 1212, Yanmar Part No. 977770-01212, or equivalent sealant to the sealing surface of the pump cover. Install the pump cover and tighten the cover bolts. 10. Reconnect the fuel return lines, fuel supply line 0000153A and coolant lines to the fuel injection pump.
Page 244: Checking And Adjusting Fuel Injection Timing
FUEL SYSTEM Checking and Adjusting Fuel Injection Timing 12. If equipped, verify the fuel injection pump 16. Prime the fuel system. See Priming the Fuel insulator (Figure 7-30, (2)) is not damaged. System on page 4-12. Reinstall the insulator and intake manifold if 17.
Page 245: Checking Fuel Injection Timing
2. Using the FIR number for the engine being serviced use the Fuel Injection Reference (FIR) Note: Some fuel may drain from the fuel Chart under “FIE Specs” on the Yanmar injection pump during this process. Make Distributor Website provisions to contain any such spillage.
Page 246 FUEL SYSTEM Checking and Adjusting Fuel Injection Timing 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.
Page 247 FUEL SYSTEM The flywheel shown in Figure 7-39 is for a • EXAMPLE: If the distance between the two Yanmar “Standard Specification” DI engine. “longer” marks is approximately 2.0 cm and the Flywheels used on some “OEM Specific” DI distance from the TDC mark is approximately engines may be marked differently.
Page 248: Adjusting Fuel Injection Timing
FUEL SYSTEM Checking and Adjusting Fuel Injection Timing 13. If the injection timing is correct, remove the dial indicator and adapter. Replace the pump plunger plug and its copper gasket and tighten to specifications. Replace the flywheel inspection port cover. Open the fuel supply valve and remove the clamp from the fuel supply hose and the fuel return hose.
Page 249: Removal Of Fuel Injectors
Fuel Injectors FUEL SYSTEM 3. Note the reading on the dial indicator 9. Tighten the fuel injection pump mounting nuts (Figure 7-43, (1)). If the reading is less than and rear bracket(s). 2.5 mm (0.098 in.), the fuel injection timing is 10.
Page 250 If the fuel injectors connections. cannot be manually removed, use the fuel injector removal tool, Yanmar Part 3. Remove the return fuel hoses (Figure 7-45, (1)) No. 129470-92305, and a slide-hammer from one side of each fuel injector.
Page 251: Testing Of Fuel Injectors
Fuel Injectors FUEL SYSTEM 0000815 Figure 7-46 • Tap the fuel injector out of the cylinder head using the slide hammer. Figure 7-47 7. Remove the injector nozzle protector Note: The fuel injectors can be removed by (Figure 7-45, (3)) and seat (Figure 7-45, (4)) manually pulling them out of the fuel from the cylinder head.
Page 252 FUEL SYSTEM Fuel Injectors 2. Visually inspect the fuel injectors and nozzle protectors for deposits or damage. Clean, repair or replace as necessary. Note: Test the fuel injector using an injection nozzle tester. Operate the tester following the information provided by the tester manufacturer.
Page 253: Disassembly And Inspection Of Fuel Injectors
Fuel Injectors FUEL SYSTEM 6. Pump the operating lever more rapidly to repeatedly “pop” the injector and observe the spray pattern. The pattern should be a very fine uniform spray (Figure 7-49). If a dripping or an uneven pattern is seen (Figure 7-50), service or replace the injector.
Page 254: Adjusting Fuel Injector Pressure
FUEL SYSTEM Fuel Injectors Adjusting Fuel Injector Pressure 6. Inspect the sealing surfaces (Figure 7-52, (2)) between the valve stop spacer and nozzle body The fuel injectors open when pressure reaches a for nicks or scratches. Check the contact area predetermined pressure threshold.
Page 255: Reassembly Of Fuel Injectors
Fuel Injectors FUEL SYSTEM Installation of the Fuel Injectors CAUTION 2-Valve Cylinder Head Each pressure adjusting shim removed or added changes the pressure 1. Reinsert a new nozzle seat (Figure 7-55, (4)) threshold by approximately 275 psi and nozzle protector (Figure 7-55, (3)) in the (1.9 MPa, 19 kgf/cm ).
Page 256 FUEL SYSTEM Fuel Injectors 4-Valve Cylinder Head 8. Operate the engine and check for fuel and coolant leaks. 1. Reinsert a new nozzle seat (Figure 7-56, (6)) and nozzle protector (Figure 7-56, (5)) in the cylinder head for each injector. 2.
Page 257 Section 8 TNV DI Service Manual COOLING SYSTEM Page Before You Begin Servicing ............8-3 Introduction..................8-6 Cooling System Diagram..............8-6 Engine Coolant Pump Components ..........8-7 Engine Coolant System Check............8-8 Engine Coolant Pump ..............8-8 Removal of Engine Coolant Pump ..........8-8 Disassembly of Engine Coolant Pump ........
Page 258 COOLING SYSTEM This Page Intentionally Left Blank TNV DI Service Manual...
Page 259: Before You Begin Servicing
Before You Begin Servicing COOLING SYSTEM BEFORE YOU BEGIN WARNING SERVICING DANGER ENTANGLEMENT HAZARD! • Stop the engine before you begin to service it. • NEVER leave the key in the key switch SCALD HAZARD! when you are servicing the engine. •...
Page 260 COOLING SYSTEM Before You Begin Servicing WARNING CAUTION BURN HAZARD! PINCH HAZARD! • If you must drain the engine oil while it Carefully rotate the alternator toward the is still hot, stay clear of the hot engine cylinder block while loosening the oil to avoid being burned.
Page 261 Before You Begin Servicing COOLING SYSTEM CAUTION Use a new special O-ring between the engine coolant pump and the joint. Be sure to use the special O-ring for each engine model. Although the O-ring dimensions are the same as a commercially available O-ring, the material is different.
Page 262: Introduction
COOLING SYSTEM Introduction INTRODUCTION This section of the Service Manual describes the procedures necessary to service the 4TNV84 engine coolant pump. This engine coolant pump is representative of the coolant pumps used on other TNV model engines. For specific part detail, see the parts catalog for the engine you are working on. COOLING SYSTEM DIAGRAM F U L L O W...
Page 263: Engine Coolant Pump Components
Engine Coolant Pump Components COOLING SYSTEM ENGINE COOLANT PUMP COMPONENTS (12) (10) (11) (13) 0000031A 1 – Thermostat Cover 8 – Gasket 2 – Thermostat Cover Gasket 9 – Engine Coolant Pump Gasket 3 – Thermostat 10 – V-Belt 4 – Thermostat O-Ring 11 –...
Page 264: Engine Coolant System Check
COOLING SYSTEM Engine Coolant System Check ENGINE COOLANT SYSTEM 1. Before removing the engine coolant pump or thermostat, it will be necessary to drain the CHECK engine coolant. Drain the coolant into a clean container if the coolant is to be reused. Check the engine coolant system for leakage.
Page 265 Engine Coolant Pump COOLING SYSTEM • On models not equipped with an oil cooler, remove the coolant drain plug (Figure 8-6, (1)) from the engine block. 0000163B 0000027B Figure 8-7 Figure 8-6 7. Disconnect the coolant hoses and the 5. Loosen the alternator mounting bolts. Loosen temperature switch lead wire from the engine and remove the V-belt and rotate the alternator coolant pump.
Page 266: Disassembly Of Engine Coolant Pump
COOLING SYSTEM Engine Coolant Pump Disassembly of Engine Coolant Pump 1. Remove the thermostat cover (Figure 8-8, (1)). Discard the gasket. 0000577A 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.
Page 267: Reassembly Of Engine Coolant Pump
Engine Coolant Pump COOLING SYSTEM 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.
Page 268 COOLING SYSTEM Engine Coolant Pump 2. Reinstall the engine coolant pump bolts. 6. Reinstall the V-belt. Tighten the V-belt to the Tighten the bolts. proper tension. See Check and Adjust Cooling Fan V-Belt on page 5-28. 3. Inspect and reinstall the coolant hoses and the temperature switch lead wire.
Page 269: Lubrication System
Introduction..................9-5 Oil Pump Service Information............9-5 Lubrication System Diagram ............9-8 Checking Engine Oil Pressure ............9-9 3TNV82A To 4TNV88 Trochoid Oil Pump........9-9 Oil Pump Components .............. 9-9 Disassembly of Oil Pump ............9-10 Cleaning and Inspection ............9-11 Reassembly of Oil Pump ............
Page 270: Tnv Di Service Manual
LUBRICATION SYSTEM This Page Intentionally Left Blank TNV DI Service Manual...
Page 271: Before You Begin Servicing
Before You Begin Servicing LUBRICATION SYSTEM BEFORE YOU BEGIN WARNING SERVICING WARNING BURN HAZARD! • Keep your hands and other body parts away from hot engine surfaces such ENTANGLEMENT HAZARD! as the muffler, exhaust pipe, turbocharger (if equipped) and engine •...
Page 272 LUBRICATION SYSTEM Before You Begin Servicing CAUTION CAUTION • Only use the engine oil specified. Other engine oils may affect warranty coverage, cause internal engine components to seize and / or shorten engine life. • Prevent dirt and debris from FLYING OBJECT HAZARD! contaminating the engine oil.
Page 273: Introduction
LUBRICATION SYSTEM INTRODUCTION This section of the Service Manual describes the procedures necessary to service the 3TNV82A to 4TNV88, and 4TNV94L/98/106 Trochoid oil pumps. See Replace Engine Oil and Engine Oil Filter on page 5-27 for engine oil and engine oil filter replacement procedures.
Page 274 4TNV94L, 4TNV98, 4TNV98T – (0.16 mm) Inner Rotor Tip Clearance on 0.0063 in. 4TNV106, 4TNV106T – page 9-11 (0.16 mm) Inner Rotor and Gear Boss Clearance - 3TNV82A to 88 Standard Standard Standard Reference Item Parts Clearance Dimension Clearance Page Limit 2.0886 - 2.0925 in.
Page 275 Oil Pump Service Information LUBRICATION SYSTEM Rotor Shaft Clearance - 4TNV94L to 4TNV106T Reference Model Inspection Item Standard Limit Page 0.5110 - 0.5126 in. 0.5138 in. Gear Case Bearing I.D. (12.980 - 13.020 mm) (13.05 mm) 4TNV94L, 4TNV98, 0.5100 - 0.5108 in. 0.5096 in.
Page 276: Lubrication System Diagram
LUBRICATION SYSTEM Lubrication System Diagram LUBRICATION SYSTEM DIAGRAM Oil Filter Turbocharger* Bypass Valve Oil Cooler * Fuel Injection Pump Oil Pressure Switch Cylinder Body - Main Gallery Pressure Regulator Valve Camshaft Crank Idle Gear Oil Pump Shaft Bearing Journal Piston Cooling Rocker Arm Crank Pin Oil Suction Pipe...
Page 277: Checking Engine Oil Pressure
Checking Engine Oil Pressure LUBRICATION SYSTEM CHECKING ENGINE OIL TROCHOID OIL PUMP PRESSURE 3TNV82A TO 4TNV88 Oil Pump Perform an engine oil pressure check if there is any Components indication of low oil pressure such as the oil pressure indicator is on or the oil pressure gauge On these model engines, the oil pump is located indicates low oil pressure.
Page 278: Disassembly Of Oil Pump
LUBRICATION SYSTEM Trochoid Oil Pump Disassembly of Oil Pump CAUTION If the oil pump must be replaced, replace it as an assembly only. Do not replace individual components. 0000030en 1. Remove the engine cooling fan guard (if equipped), engine cooling fan (Figure 9-4, (3)), spacer (Figure 9-4, (2)), engine coolant pump V-pulley (Figure 9-4, (1)) and V-belt.
Page 279: Cleaning And Inspection
Trochoid Oil Pump LUBRICATION SYSTEM 6. Remove the oil pressure regulator valve Record the measurement(s) and see Outer (Figure 9-7, (1)) from the oil pump cover Rotor Outside Clearance - All Models on (Figure 9-7, (2)). page 9-5 for the service limits. 0001151A Figure 9-8 0001642...
Page 280: Reassembly Of Oil Pump
Trochoid Oil Pump Check Outer Rotor Side Clearance Record the measurement(s) and see Inner Rotor and Gear Boss Clearance - 3TNV82A to 88 on Determine the side clearance of the outer rotor page 9-6 for the service limits. across the pump cavity. While pressing down on...
Page 281: Oil Pump Components
Trochoid Oil Pump LUBRICATION SYSTEM TROCHOID OIL PUMP 6. Reinstall the gear case cover and crankshaft pulley. See Installation of Gear Case Cover on page 6-91. 4TNV94L/98/106 Oil Pump 7. Reinstall the engine coolant pump V-pulley Components (Figure 9-13, (1)), spacer (Figure 9-13, (2)), The oil pump on these model engines is located in engine cooling fan (Figure 9-13, (3)) and the front gear case and is driven by the same gear...
Page 282: Disassembly Of Oil Pump
LUBRICATION SYSTEM Trochoid Oil Pump Disassembly of Oil Pump CAUTION If the oil pump must be replaced, replace it as an assembly only. Do not replace individual components. 0000030en Remove the engine cooling fan guard (if equipped), engine cooling fan (Figure 9-15, (3)), spacer (Figure 9-15, (2)), engine coolant pump V-pulley 0000049D (Figure 9-15, (1)) and V-belt.
Page 283: Reassembly Of Oil Pump
Trochoid Oil Pump LUBRICATION SYSTEM Outer Rotor to Inner Rotor Tip Clearance Check Rotor Shaft Clearance Determine the outer rotor to inner rotor tip Determine the rotor shaft clearance. Measure the clearance. Insert a feeler gauge between the top of outside diameter of the rotor shaft an inner rotor tooth (Figure 9-18, (1)) and the top (Figure 9-20, (1)) and the bore diameter in the gear...
Page 284 LUBRICATION SYSTEM Trochoid Oil Pump 3. Reinstall the oil pump assembly (Figure 9-22, (1)) into the gear case housing (Figure 9-22, 2). Tighten the bolts to specified torque. 0000049D Figure 9-22 4. Reinstall the gear case cover and crankshaft pulley. See Installation of Gear Case Cover on page 6-91.
Page 285 Section 10 TNV DI Service Manual TURBOCHARGER Page Before You Begin Servicing ............10-3 Introduction..................10-5 Specifications ................10-5 Turbocharger Service Information ........... 10-5 Troubleshooting................10-6 Excessive Exhaust Smoke ............10-6 Generates White Smoke ............10-7 Sudden Oil Decrease .............. 10-7 Decrease in Output..............
Page 286 TURBOCHARGER This Page Intentionally Left Blank 10-2 TNV DI Service Manual...
Page 287: Before You Begin Servicing
/ rotating parts. 0000003en • Failure to comply could result in death CAUTION or serious injury. For maximum engine life, Yanmar 0000010en recommends that when shutting the engine down, you allow the engine to WARNING idle, without load, for five minutes. This...
Page 288 TURBOCHARGER Before You Begin Servicing CAUTION Avoid damage to the turbocharger or the engine. Do not spray blower wash fluid or water too quickly. Use short strokes from a spray bottle to inject blower wash fluid or water into the turbocharger.
Page 289: Introduction
Introduction TURBOCHARGER INTRODUCTION This section of the Service Manual describes the servicing of the RHF5, RHB31 and RHB51 model turbochargers. SPECIFICATIONS Turbocharger Service Information 3TNV84T (CL, 4TNV106T Applicable Engine Model (application) 3TNV84T (VM) 4TNV98T (CL, VM) 4TNV84T (CL) Turbocharger Model RHB31 RHB51 RHF5...
Page 290: Troubleshooting
TURBOCHARGER Troubleshooting TROUBLESHOOTING The following troubleshooting procedures apply to problems identified as turbocharger related. Consider all other troubleshooting possibilities before cleaning or removing the turbocharger. Excessive Exhaust Smoke Cause Corrective action Clogged air cleaner element Clean or replace the air cleaner element Blocked air intake port Correct the condition Leak from a joint in intake line...
Page 291: Generates White Smoke
Troubleshooting TURBOCHARGER Generates White Smoke Cause Corrective action Correct the condition Clogged or deformed oil return pipe causing oil flow to the blower on the turbine side Excessive bearing wear causing abnormal wear or damage of the seal ring Repair the turbocharger. Send to a qualified repair facility. Sudden Oil Decrease Cause Corrective action...
Page 292: Turbocharger Components
Turbocharger Components TURBOCHARGER COMPONENTS Note: The following illustration is provided for informational purposes only. Yanmar does not offer individual service parts for turbochargers. If the turbocharger is worn or damaged, it should be replaced or repaired by a qualified repair facility.
Page 293 Turbocharger Components TURBOCHARGER 1 – Turbine Shaft 17 – Bolt 2 – Thrust Bearing 18 – Lock Plate 3 – Oil Thrower 19 – Bearing Housing 4 – Seal Ring 20 – Retaining Ring 5 – Seal Ring 21 – Bolt 6 –...
Page 294: Turbocharger Component Functions
TURBOCHARGER Turbocharger Component Functions TURBOCHARGER COMPONENT FUNCTIONS (13) (14) (12) (15) (8) (9) (10) (17) (19) (18) (11) (20) (16) 0000077A 1 – Turbine Shaft 11 – Turbine Housing 2 – Oil Thrower 12 – M6 Hex Bolt 3 – Turbine Side Seal Ring 13 –...
Page 295: Theory Of Operation
Turbocharger Component Functions TURBOCHARGER Theory of Operation Bearings Normally aspirated engines produce horsepower Thrust Bearing that is limited by the atmospheric pressure of the A thrust force is continuously imposed on the induction air. The turbocharger is an exhaust gas turbine shaft during engine operation.
Page 296: Washing Procedure
TURBOCHARGER Washing Procedure WASHING PROCEDURE Note: Inspection, cleaning and repair of the internal turbocharger components must be performed by a qualified repair facility. The washing procedure described in this section is intended to clean the impeller on the compressor only if the engine loses rpm, seems sluggish or has insufficient boost pressure.
Page 297: Periodic Inspection
Periodic Inspection TURBOCHARGER PERIODIC INSPECTION Inspect the turbocharger at regularly scheduled intervals. Inspection interval Application 200 hours 400 hours 500 hours 800 hours 1000 hours 2000 hours First 6 First 12 Every 24 Construction Equipment months months months or 500 hrs or 1000 hrs or 2000 hrs First 6...
Page 298: Checking Rotor Play
TURBOCHARGER Periodic Inspection Checking Rotor Play Note: If rotor play measurements are not within specification, replace the turbocharger assembly or have it repaired by a qualified facility. Standard Dimension Wear Limit Rotor Play RHF5 RHB31 RHB51 RHF5 RHB31 RHB51 0.0011 - 0.0024 in. 0.0009 - 0.0021 in.
Page 299: Waste Gate Actuator Leak Test
Periodic Inspection TURBOCHARGER 1. Connect a hand-operated air pump to the waste • If the pressure reading is equal to or greater gate actuator pipe (Figure 10-6, (1)). The pump than 15.9 psi (0.11 MPa; 1.1 kgf/cm ), the should be equipped with a 30 psi (0.21 MPa; waste gate actuator is not leaking and is operating properly.
Page 300 TURBOCHARGER Periodic Inspection This Page Intentionally Left Blank 10-16 TNV DI Service Manual...
Page 301 Page Before You Begin Servicing ............11-3 Introduction..................11-5 Starter Motor Information .............. 11-5 3TNV82A to 4TNV88 - Standard and Optional......11-5 Starter Motor Specifications ............11-7 Starter Motor Troubleshooting............11-8 Starter Motor Components ............11-9 Starter Motor ................11-10 Removal of Starter Motor ............
Page 302 STARTER MOTOR This Page Intentionally Left Blank 11-2 TNV DI Service Manual...
Page 303: Before You Begin Servicing
Before You Begin Servicing STARTER MOTOR BEFORE YOU BEGIN WARNING SERVICING WARNING SHOCK HAZARD! • Turn off the battery switch (if equipped) or disconnect the negative ENTANGLEMENT HAZARD! battery cable before servicing the • Stop the engine before you begin to electrical system.
Page 304 STARTER MOTOR Before You Begin Servicing CAUTION 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 wash or submerse the starter motor in water. FLYING OBJECT HAZARD! 0000055en •...
Page 305: Introduction
STARTER MOTOR INTRODUCTION This section of the Service Manual covers the servicing of the starter motor. Yanmar Part No. 129900-77010 is standard equipment on 4TNV94-98 model engines and is used in this section to show the service procedures for a representative starter motor. For specific part detail, see the Yanmar Parts Catalog for the engine you are working on.
Page 306 STARTER MOTOR Starter Motor Information 4TNV94L to 4TNV106T - Standard and Optional No Load Loaded YANMAR Mfg. Part Mfg. Part Specification Terminal Amperag Terminal Amperag Torque Number Number Voltage e Draw Voltage e Draw 97 in.-lb 129900- DC12V-3.1 hp 140A...
Page 307: Starter Motor Specifications
Starter Motor Specifications STARTER MOTOR STARTER MOTOR SPECIFICATIONS Yanmar Part Number 129900-77010 Nominal Output 3.0 hp (2.3 kW) 12.1 lb Weight (5.5 kg) Revolution Direction (As Viewed From Pinion) Clockwise Engagement System Magnetic Shift Terminal Voltage / Current 11 V / 140 A max...
Page 308: Starter Motor Troubleshooting
STARTER MOTOR Starter Motor Troubleshooting STARTER MOTOR TROUBLESHOOTING 0000102 11-8 TNV DI Service Manual...
Page 309: Starter Motor Components
Starter Motor Components STARTER MOTOR STARTER MOTOR COMPONENTS (13) (14) (12) (11) (10) (23) (15) (18) (22) (21) (19) (20) (17) (16) 0000103A 1 – Pinion Shaft 13 – Magnetic Switch Assembly (Solenoid) 2 – M4 Bolts (3 used) 14 – Cover 3 –...
Page 310: Removal Of Starter Motor
STARTER MOTOR Starter Motor STARTER MOTOR WARNING SHOCK HAZARD! • Turn off the battery switch (if equipped) or disconnect the negative 0002126 battery cable before servicing the Figure 11-2 electrical system. Disassembly of Starter Motor • Check the electrical harnesses for cracks, abrasions, and damaged or 1.
Page 311 Starter Motor STARTER MOTOR Figure 11-6 6. Pull the armature assembly (Figure 11-6, (3)) 0000105A out from the field coil assembly Figure 11-4 (Figure 11-6, (2)). 7. Remove the two M6 bolts (Figure 11-7, (1)) 3. Remove the two M5 through bolts retaining the magnetic switch assembly (Figure 11-4, (4)).
Page 312: Cleaning And Inspection
STARTER MOTOR Starter Motor 9. Remove the three M4 bolts (Figure 11-9, (1)) securing the bearing retainer assembly (Figure 11-9, (2)) to the gear housing. Remove the bearing retainer assembly from the gear housing. 0000112A Figure 11-11 Cleaning and Inspection Armature Commutator Surface Inspection If the commutator surface is rough, polish the...
Page 313 Starter Motor STARTER MOTOR Armature Coil Continuity Test Check for continuity between the commutator segments using a multimeter (Figure 11-15). The multimeter should indicate continuity. 0000113 Figure 11-13 See Starter Motor Specifications on page 11-7 for the service limit. 0000114 Measure Commutator Insulation Depth Figure 11-15 Measure the depth of the insulating material...
Page 314 STARTER MOTOR Starter Motor Measure Armature and Commutator Run-Outs Field Coil Insulation Test Measure the armature core run-out and the Check for continuity between the field coil terminal commutator run-out using a dial indicator and the yoke using a multimeter (Figure 11-19). (Figure 11-17).
Page 315 Starter Motor STARTER MOTOR Magnetic Switch Series Coil Continuity Test Check for continuity between the “S” and “M” If the starter motor becomes wet, replace the terminals using a multimeter (Figure 11-22). The magnetic switch even if the magnetic switch multimeter should indicate continuity.
Page 316 STARTER MOTOR Starter Motor Contact Continuity Test Slide the pinion clutch assembly on the shaft. It should slide smoothly on the shaft (Figure 11-25). Depress the plunger at the bottom of the magnetic Rust, too much grease or damage could prevent switch.
Page 317: Reassembly Of Starter Motor
Starter Motor STARTER MOTOR Reassembly of Starter Motor 1. Apply NPC-FC6A grease to the pinion shaft. Reassemble the pinion shaft (Figure 11-27, (5)), pinion clutch assembly (Figure 11-27, (1)), return spring (Figure 11-27, (4)) and pinion stop (Figure 11-27, (3)). Reinstall the retaining ring (Figure 11-27, (2)) in the groove in the pinion shaft.
Page 318: Check Pinion Projection Length
STARTER MOTOR Starter Motor 7. Carefully install the armature assembly 12. Reinstall the two M4 through bolts (Figure 11-30, (1)) into the field coil assembly (Figure 11-32). Securely tighten the through (Figure 11-30, (2)). bolts. Reconnect the wire to the magnetic switch assembly.
Page 319: No-Load Test
7. Turn the switch to the ON position. Monitor the 0000034en rpm, amperage draw and voltage. For test specifications, see 3TNV82A to 4TNV88 - 1. Secure the starting motor in a vise or other Standard and Optional and 4TNV94L to suitable fixture.
Page 320: Installation Of Starter Motor
STARTER MOTOR Starter Motor Installation of Starter Motor 1. Reinstall the starter motor to the flywheel housing. 2. Reinstall the starter mounting bolts (Figure 11-36, (1)). Tighten the bolts to specification. See Tightening Torques for Standard Bolts and Nuts on page 4-47. 0002126 Figure 11-36 3.
Page 321 TNV DI Service Manual ALTERNATOR Page Before You Begin Servicing ............12-3 Introduction..................12-6 Dynamo and Alternator Information ..........12-6 3TNV82A Thru 4TNV106T - Standard and Optional Dynamos ..............12-6 Optional Alternators..............12-6 Alternator Specifications..............12-7 Dynamo Specifications..............12-7 Alternator Troubleshooting ............12-8 Alternator Components ..............
Page 322 ALTERNATOR Dynamo ..................12-20 Removal of Dynamo.............. 12-20 Disassembly of Dynamo............12-21 Reassembly of Dynamo ............12-21 Installation of Dynamo............12-22 12-2 TNV DI Service Manual...
Page 323: Before You Begin Servicing
Before You Begin Servicing ALTERNATOR BEFORE YOU BEGIN WARNING SERVICING WARNING SHOCK HAZARD! • Turn off the battery switch (if equipped) or disconnect the negative ENTANGLEMENT HAZARD! battery cable before servicing the • Stop the engine before you begin to electrical system.
Page 324 • Failure to comply may result in minor • See your authorized Yanmar industrial or moderate injury. engine dealer or distributor for 0000003en additional training.
Page 325 This will corrode the conductor and result in battery over-charging (boiling) 0000037en and charging malfunctions. Consult Yanmar before using the equipment in CAUTION such an environment or the warranty is Do not turn the battery switch OFF while voided.
Page 326: Introduction
Introduction INTRODUCTION This section of the Service Manual describes the servicing of the dynamos and alternators. Yanmar Part No. 129423-77200 alternator is used in this section to show the service procedures for the representative alternator. Yanmar Part No. 171301-77201 dynamo is used in this section to show the service procedures for the representative dynamo.
Page 327: Alternator Specifications
Alternator Specifications ALTERNATOR ALTERNATOR SPECIFICATIONS Yanmar Part Number 129423-77200 Nominal Output (13.5 Volts Heat) 40 Amps Weight 6.17 lb (2.8 kg) Revolution Direction (As Viewed From Pulley) Clockwise Rating Continuous Battery Voltage 12 Volts Rated Revolution 5000 rpm (min Operating Range...
Page 328: Alternator Troubleshooting
ALTERNATOR Alternator Troubleshooting ALTERNATOR TROUBLESHOOTING 12-8 TNV DI Service Manual...
Page 329: Alternator Components
Alternator Components ALTERNATOR ALTERNATOR COMPONENTS Yanmar Part No. 129423-77200 alternator is used in this section to show the service procedures for the representative alternator. For specific part detail, see the Parts Catalog for the engine you are working on. 0000255 1 –...
Page 330: Alternator Wiring Diagram
ALTERNATOR Alternator Wiring Diagram ALTERNATOR WIRING DIAGRAM 1 – Key Switch 4 – Battery 2 – Charge Lamp (3.4 Watts Max.) 5 – Alternator Assembly 3 – Load 6 – IC Regulator Assembly Figure 12-2 CAUTION CAUTION Do not short-circuit the charging system Do not remove the positive (+) battery between alternator terminals IG and L.
Page 331: Alternator Standard Output
Alternator Standard Output ALTERNATOR ALTERNATOR STANDARD OUTPUT Output Current Cold Alternator RPM (x10³ min¯¹) Figure 12-3 TNV DI Service Manual 12-11...
Page 332: Alternator
ALTERNATOR Alternator ALTERNATOR 4. Remove the nut (Figure 12-4, (2)) from the gear case stud. Remove the alternator. WARNING SHOCK HAZARD! • Turn off the battery switch (if 0000264 equipped) or disconnect the negative Figure 12-4 battery cable before servicing the electrical system.
Page 333 Alternator ALTERNATOR 2. Remove the three bolts (Figure 12-6, (1)) 5. Remove the bolts retaining the holder retaining the rear cover (Figure 12-6, (2)) to the (Figure 12-7, (2)) to the rear frame housing. rear frame assembly. Remove the holder. 6.
Page 334: Reassembly Of Alternator
ALTERNATOR Alternator 9. Remove the stator assembly (Figure 12-10, (1)) from the front frame housing. 0000260A Figure 12-11 Reassembly of Alternator 0000259A 1. If removed, reinstall the two trust washers (Figure 12-12, (3)) and bearing cover Figure 12-10 (Figure 12-12, (2)) in the rear frame housing. Lubricate the outside diameter of a new bearing 10.
Page 335 Alternator ALTERNATOR 2. If removed, lubricate the outside diameter of a 5. Align the front frame housing with the rear new front frame housing bearing. Press the frame housing. Reinstall the two bolts bearing (Figure 12-13, (2)) into the front frame (Figure 12-15, (1)) and two nuts housing.
Page 336: Installation Of Alternator
ALTERNATOR Alternator Installation of Alternator 8. Reinstall the brush holder (Figure 12-17, (3)), springs (Figure 12-17, (4)) and brushes 1. Position the alternator on the gear case. (Figure 12-17, (5)). Loosely reinstall the nut (Figure 12-19, (2)) on 9. Reattach the regulator assembly and holder to the gear case stud and the V-belt adjuster bolt the rear frame housing.
Page 337: Dynamo Component Location
ALTERNATOR DYNAMO COMPONENT LOCATION Yanmar Part No. 171301-77201 dynamo is used in this section to show the service procedures for the representative dynamo. For specific part detail, see the Parts Catalog for the engine you are working on. (10) (11)
Page 338: Dynamo Wiring Diagram
ALTERNATOR Dynamo Wiring Diagram DYNAMO WIRING DIAGRAM 0002137 1 – Dynamo 2 – IC Regulator Assembly 3 – Key Switch 4 – Charge Lamp (3.4 Watts Max.) 5 – Battery 6 – Load Figure 12-21 OPERATION OF DYNAMO The dynamo consists of a series of permanent magnets that rotate around a stationary stator coil.
Page 339: Dynamo Standard Output
Dynamo Standard Output ALTERNATOR DYNAMO STANDARD OUTPUT 0002138 Figure 12-22 TNV DI Service Manual 12-19...
Page 340: Testing Of Dynamo
ALTERNATOR Testing of Dynamo TESTING OF DYNAMO DYNAMO Use a circuit tester or multimeter to perform the Removal of Dynamo following tests. 1. Disconnect the output wire connector from the Testing Stator Coil Continuity dynamo. 1. Disconnect the dynamo output wire connector. 2.
Page 341 Dynamo ALTERNATOR Disassembly of Dynamo 4. Remove the screws (Figure 12-26, (1)) and the stator assembly (Figure 12-26, (2)). 1. Remove the rear cover (Figure 12-24, (1)). 5. Remove the rear bearing (Figure 12-26, (3)). 2. Remove the nut (Figure 12-24, (2)), lock washer (Figure 12-24, (3)), and flat washer (Figure 12-24, (4)).
Page 342 ALTERNATOR Dynamo Installation of Dynamo 3. Reinstall the front bearings (Figure 12-28, (5)) and spacer (Figure 12-28, (6)). 1. Position the dynamo on the gear case. Loosely 4. Reinstall the flat washer (Figure 12-28, (4)), reinstall the nut (Figure 12-30, (2)) on the gear flywheel (Figure 12-28, (3)), pulley half case stud and the V-belt adjuster bolt (Figure 12-28, (2), and through bolt...
Page 343 Section 13 TNV DI Service Manual ELECTRIC WIRING Page Electric Wiring Precautions ............13-3 Electrical Wire Resistance ............13-4 Battery Cable Resistance.............. 13-5 Electrical Wire Sizes - Voltage Drop ..........13-6 Conversion of AWG to European Standards......... 13-7 TNV DI Service Manual 13-1...
Page 344 ELECTRIC WIRING This Page Intentionally Left Blank 13-2 TNV DI Service Manual...
Page 345: Electric Wiring Precautions
Electric Wiring Precautions ELECTRIC WIRING ELECTRIC WIRING CAUTION PRECAUTIONS Removing the battery cables or the battery while the engine is operating Failure to follow these precautions may result in the may cause damage to the current limiter failure of an electrical component and the loss of depending on the electrical equipment warranty coverage on that item as well as related being used.
Page 346: Electrical Wire Resistance
ELECTRIC WIRING Electrical Wire Resistance ELECTRICAL WIRE RESISTANCE Metric Ohms / Foot Nominal mm² Resistance 0.009967 0.006340 1.25 0.004359 0.002685 0.001704 0.001073 0.000707 0.000421 0.000270 0.000158 0.000130 0 (1/0) 0.000103 00 (2/0) 0.000087 000 (3/0) 0.000066 0000 (4/0) 0.000051 Wiring voltage drop should not exceed 5% [0.05] x 12 Volts = 0.6 Volts. Voltage Drop = Current [Amps] x Length of Wire [Feet] x Resistance per Foot Ω...
Page 347: Battery Cable Resistance
Battery Cable Resistance ELECTRIC WIRING BATTERY CABLE RESISTANCE Maximum Total Battery Cable Length (Positive Cable + Negative Cable + a*) 12V Starter Motor Output mm² Less Than 2.68 HP (2 kW) Greater Than 2.68 HP (2 kW) 4.75 12.6 15.3 0 (1/0) 19.5 11.6...
Page 348: Electrical Wire Sizes - Voltage Drop
ELECTRIC WIRING Electrical Wire Sizes - Voltage Drop ELECTRICAL WIRE SIZES - VOLTAGE DROP Total Length of conductor from source of current to device and back to source (in feet) current on circuit in 100 110 120 130 140 150 160 170 amps 12 Volts Wire Size (AWG)
Page 349: Conversion Of Awg To European Standards
Conversion of AWG to European Standards ELECTRIC WIRING CONVERSION OF AWG TO EUROPEAN STANDARDS Conductor Size Conductor Diameter Conductor Cross-sectional Area (AWG) (mm) 0.455 0.163 0.511 0.205 0.573 0.259 0.644 0.325 0.723 0.412 0.812 0.519 0.992 0.653 1.024 0.823 1.15 1.04 1.29 1.31...
Page 350 ELECTRIC WIRING Conversion of AWG to European Standards This Page Intentionally Left Blank 13-8 TNV DI Service Manual...
Page 351 Section 14 TNV DI Service Manual TROUBLESHOOTING Page Special Service Tools..............14-3 Troubleshooting By Measuring Compression Pressure ....14-4 Compression Pressure Measurement Method ......14-4 Quick Reference Table For Troubleshooting ........ 14-6 Troubleshooting Charts ..............14-7 Wiring Diagram................14-19 TNV DI Service Manual 14-1...
Page 352 TROUBLESHOOTING This Page Intentionally Left Blank 14-2 TNV DI Service Manual...
Page 353: Special Service Tools
Special Service Tools TROUBLESHOOTING SPECIAL SERVICE TOOLS For measuring compression pressure Yanmar Gauge Set Part No. TOL-97190080 0000849 Adapter for direct injection 2-valve cylinder head Yanmar Adapter Part No. 119802-92950 Compression Gauge Kit 0000850 Adapter for direct injection 4-valve cylinder head for 4TNV94L/98/98T Yanmar Adapter Part No.
Page 354: Troubleshooting By Measuring Compression Pressure
TROUBLESHOOTING Troubleshooting By Measuring Compression Pressure TROUBLESHOOTING BY 3. Turn off the fuel supply valve in the fuel supply line. Disconnect the fuel injection pump stop MEASURING COMPRESSION solenoid at the connector. This prevents the fuel PRESSURE injection pump from injecting fuel during compression testing.
Page 355 Engine Model Deviation Between Cylinders Standard Limit 443 - 473 psi 340 - 370 psi 3TNV82A (3.06 - 3.26 MPa; 30 - 32 kgf/cm²) (2.35 - 2.55 MPa; 24 - 26 kgf/cm²) 3TNV84 455 - 485 psi 355 - 385 psi 4TNV84 (3.14 - 3.34 MPa;...
Page 356: Quick Reference Table For Troubleshooting
TROUBLESHOOTING Quick Reference Table For Troubleshooting Measured Value and Troubleshooting When the measured compression pressure is below the limit value, inspect each part by referring to the table below. Item Cause Corrective Action Clogged element Clean the element. Air Cleaner Element Broken element Replace the element.
Page 357: Troubleshooting Charts
Troubleshooting Charts TROUBLESHOOTING TNV DI Service Manual TROUBLESHOOTING CHARTS Poor Insufficient Engine Engine Trouble Symptom Starting Problem Exhaust Engine Oil Air Intake Engine Output Surging Coolant Color Engine Starts During But Stops Exhaust Color Work Soon. Exhaust Smoke Corrective Action Reference Page Cause See Measuring and Adjusting Valve...
Page 358 TROUBLESHOOTING Troubleshooting Charts This Page Intentionally Left Blank 14-8 TNV DI Service Manual...
Page 359 Troubleshooting Charts TROUBLESHOOTING Poor Insufficient Engine Engine Trouble Symptom Starting Problem Exhaust Engine Oil Air Intake Engine Output Surging Coolant Color Engine Starts During But Stops Exhaust Color Work Soon. Exhaust Smoke Corrective Action Reference Page Cause See Reassembly of Pistons on Reverse Assembly of Piston Rings Reassemble Correctly.
Page 360 TROUBLESHOOTING Troubleshooting Charts This Page Intentionally Left Blank 14-10 TNV DI Service Manual...
Page 361 Troubleshooting Charts TROUBLESHOOTING Poor Insufficient Engine Engine Trouble Symptom Starting Problem Exhaust Engine Oil Air Intake Engine Output Surging Coolant Color Engine Starts During But Stops Exhaust Color Work Soon. Exhaust Smoke Corrective Action Reference Page Cause See Washing Procedure on page 10-12. Fouled Blower Wash the Blower.
Page 362 TROUBLESHOOTING Troubleshooting Charts This Page Intentionally Left Blank 14-12 TNV DI Service Manual...
Page 363 Troubleshooting Charts TROUBLESHOOTING Poor Insufficient Engine Engine Trouble Symptom Starting Problem Exhaust Engine Oil Air Intake Engine Output Surging Coolant Color Engine Starts During But Stops Exhaust Color Work Soon. Exhaust Smoke Corrective Action Reference Page Cause See Engine Oil Specifications on Incorrect Engine Oil Use Correct Engine Oil.
Page 364 TROUBLESHOOTING Troubleshooting Charts This Page Intentionally Left Blank 14-14 TNV DI Service Manual...
Page 365 Troubleshooting Charts TROUBLESHOOTING Poor Insufficient Engine Engine Trouble Symptom Starting Problem Exhaust Engine Oil Air Intake Engine Output Surging Coolant Color Engine Starts During But Stops Exhaust Color Work Soon. Exhaust Smoke Corrective Action Reference Page Cause See Stop Solenoid on page 7-6. Stop Solenoid Failure Check and Replace See Checking and Adjusting Fuel...
Page 366 TROUBLESHOOTING Troubleshooting Charts This Page Intentionally Left Blank 14-16 TNV DI Service Manual...
Page 367 Troubleshooting Charts TROUBLESHOOTING Poor Insufficient Engine Engine Trouble Symptom Starting Problem Exhaust Engine Oil Air Intake Engine Output Surging Coolant Color Engine Starts During But Stops Exhaust Color Work Soon. Exhaust Smoke Corrective Action Reference Page Cause See Clean Air Cleaner Element on Clogged Air Filter Clean Air Filter.
Page 368 TROUBLESHOOTING Troubleshooting Charts This Page Intentionally Left Blank 14-18 TNV DI Service Manual...
Page 369: Wiring Diagram
TNV DI Service Manual ELECTRICAL WIRING Note: The following wiring diagram is “representative” of a common installation using a Yanmar engine. The actual installation may be equipped with a variety of electrical components and wiring harnesses. Contact the machine manufacturer for specific information.
Page 370 WIRING DIAGRAM Electrical Wiring This Page Intentionally Left Blank 14-20 TNV DI Service Manual...

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Yanmar 3TNV82A Service Manual

Section 1

Section 2

Section 4

Specifications

Principal Engine Specifications

Engine Service Standards

Tightening Torques for Standard Bolts and Nuts

Abbreviations and Symbols

Section 5

Engine

Fuel System

2 Valve Cylinder Head

4 Valve Cylinder Head

Cooling System

Section 9

Turbocharger

Starter Motor

Alternator

Quick Links

Chapters

Troubleshooting

Related Manuals for Yanmar 3TNV82A

Summary of Contents for Yanmar 3TNV82A