Page 1 SERVICE MANUAL INDUSTRIAL ENGINES 3TNV88C 3TNV86CT 4TNV88C 4TNV86CT 4TNV98C 4TNV98CT 0BTN4-G00201 PRINTED IN JAPAN...
Page 2 Av. Presidente Vargas 1400, Indaiatuba, S.P., Brazil, CEP: 13338-901 graphic, electronic, or mechanical, including photocopying, recording, taping, or informa- TEL: +55-19-3801-9224 FAX: +55-19-3875-3899, 2241 tion storage and retrieval systems - without the written permission of YANMAR CO., LTD. http://www.yanmar.com.br/ SERVICE MANUAL 3TNV88C, 3TNV86CT, 4TNV88C,...
Page 3 TABLE OF TNV Tier 4 Service Manual CONTENTS Page Introduction ..................1-1 YANMAR Warranties ................2-1 Safety....................3-1 General Service Information .............. 4-1 Periodic Maintenance ................. 5-1 Engine ....................6-1 Fuel System ..................7-1 Cooling System ................... 8-1 Lubrication System ................9-1 Turbocharger ..................
Page 4 TABLE OF CONTENTS This Page Intentionally Left Blank TNV Tier 4 Service Manual...
Page 5 For the replacement of some parts and troubleshooting for the TNV series engines, the YANMAR Diagnostics Tool called SMARTASSIST- Direct is required. In addition, please read both Troubleshooting Manual and SMARTASSIST- Direct Operation Manual.
Page 6 INTRODUCTION This Page Intentionally Left Blank TNV Tier 4 Service Manual...
Page 7: Table Of Contents
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: Yanmar Warranties
YANMAR WARRANTIES This Page Intentionally Left Blank TNV Tier 4 Service Manual...
Page 9: Yanmar Limited Warranty
YANMAR LIMITED WARRANTY What is Covered by this Warranty? YANMAR warrants to the original retail purchaser that a new YANMAR TNV series industrial engine will be free from defects in material and/or workmanship for the duration of the warranty period.
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.
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...
Page 13: Warranty Coverage
Warranty Coverage: This warranty is transferable to each subsequent purchaser for the duration of the warranty period. Repair or replacement of any warranted part will be performed at an authorized YANMAR industrial engine dealer or distributor. Warranted parts not scheduled for replacement as required maintenance in the operation manual shall be warranted for 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 Section 3 TNV Tier 4 Service Manual SAFETY Page Safety Statements ................3-3 Safety Precautions ................3-4 During Operation and Maintenance........... 3-4 TNV Tier 4 Service Manual...
Page 16 SAFETY This Page Intentionally Left Blank TNV Tier 4 Service Manual...
Page 17: Safety Statements
Safety Statements SAFETY SAFETY STATEMENTS DANGER YANMAR is concerned for your safety and your DANGER indicates a hazardous situation machine’s condition. Safety statements are one of which, if not avoided, will result in death or the primary ways to call your attention to the serious injury.
Page 18: Safety Precautions
SAFETY Safety Precautions SAFETY PRECAUTIONS DANGER Explosion Hazard! During Operation and Maintenance • Keep the area around the battery DANGER well-ventilated. While the engine is running or the battery is High Pressure Hazard! charging, hydrogen gas is • This engine uses a high-pressure produced which can be easily common rail system.
Page 19 Safety Precautions SAFETY DANGER DANGER (Continued) Fire and Explosion Hazard! • Be sure to place the diesel fuel container on the ground when transferring the diesel fuel • Diesel fuel is flammable and from the pump to the container. Hold the hose explosive under certain nozzle firmly against the side of the container conditions.
Page 20 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 tunnel, underground room, or PTO shaft.
Page 21 • Always wear eye protection. Always use a piece of wood or cardboard. • Wait until the engine cools before you drain Have your authorized YANMAR industrial the engine coolant. Hot engine coolant may engine dealer or distributor repair the splash and burn you.
Page 22 • Never use the E-ECU for other purposes than intended or in other ways than specified by YANMAR. Doing so could result in the Sudden Movement Hazard! violation of emission control regulations and • Engaging the transmission or PTO at an will void the product warranty.
Page 23 • Failure to comply may result in minor or the injector trim data in the E-ECU. moderate injury. Be sure to contact your local YANMAR dealer before replacing the fuel injector. Failure to rewrite the injector trim data before Flying Object Hazard! replacing the fuel injector will void the engine •...
Page 24 SAFETY Safety Precautions NOTICE NOTICE • Only use diesel fuels recommended by YANMAR Observe the following environmental operating for the best engine performance, to prevent conditions to maintain engine performance and engine damage and to comply with EPA/ARB avoid premature engine wear: warranty requirements.
Page 25 SAFETY NOTICE NOTICE If any indicator illuminates during engine operation, For maximum engine life, YANMAR recommends stop the engine immediately. Determine the cause that when shutting the engine down, you allow the and repair the problem before you continue to engine to idle, without load, for five minutes.
Page 26 ON position, see your authorized next four to five hours. YANMAR industrial engine dealer or distributor for • During the break-in period, carefully observe the service before operating the engine.
Page 27 Safety Precautions SAFETY NOTICE NOTICE • When the engine is operated in dusty conditions, Do not turn the battery switch OFF while the engine clean the air cleaner element more frequently. is operating. Damage to the alternator will result. • Never operate the engine with the air cleaner element(s) removed.
Page 28 23 - 24 volts (for 5000 min (rpm) in battery over-charging (boiling) and charging dynamo) will damage the current limiter and other malfunctions. Consult YANMAR before using the electrical equipment. equipment in such an environment or the warranty is voided.
Page 29 Any alterations to this engine may Never use a steel wire brush to clean fuel injectors. void its warranty. Be sure to use YANMAR Damage to the nozzle and other components is genuine replacement parts.
Page 30 E-ECU due to static electricity. techniques. • Do not force a measuring probe into the female • See your authorized YANMAR industrial engine coupler. Doing so may cause contact failure of dealer or distributor for additional training.
Page 31 Section 4 TNV Tier 4 Service Manual GENERAL SERVICE INFORMATION Page Component Identification..............4-3 Location of Labels ................4-5 Engine Nameplate (Typical) ............4-6 Emission Control Regulations ............4-6 EPA/ARB Regulations - USA Only ..........4-6 Emission Control Labels..............4-6 EPA/CARB labels (Typical) ............
Page 32 GENERAL SERVICE INFORMATION Acceleration Sensor (YANMAR Standard)....... 4-21 Diesel Fuel ..................4-22 Diesel Fuel Specifications ............4-22 Filling The Fuel Tank..............4-23 Priming the Fuel System ............4-24 Engine Oil..................4-25 Engine Oil Specifications ............4-25 Engine Oil Viscosity..............4-25 Checking Engine Oil..............
Page 33: Component Identification
Component Identification GENERAL SERVICE INFORMATION COMPONENT IDENTIFICATION ■ 3TNV88C, 3TNV86CT, 4TNV88C, 4TNV86CT Figure 4-1 shows where the major engine components are located. 12 11 10 043922-00X01 1 – Fuel inlet 15 – Dipstick (engine oil) 2 – Fuel return to fuel tank 16 –...
Page 34 GENERAL SERVICE INFORMATION Component Identification ■ 4TNV98C, 4TNV98CT Figure 4-2 shows where the major engine components are located. 13 12 22 21 044738-01X00 1 – Lifting eye (flywheel end) 14 – Drain plug (cooling water) 2 – Lifting eye (engine cooling fan end) 15 –...
Page 35: Location Of Labels
Location of Labels GENERAL SERVICE INFORMATION LOCATION OF LABELS Figure 4-3 shows the location of regulatory and safety labels on YANMAR TNV series engines. 044740-00X00 044888-00X00 Figure 4-3 ■ Location of labels/nameplates on common rail system engine Model Engine nameplate...
Page 36: Engine Nameplate (Typical)
/ REFER TO OWNER'S MANUAL FOR MAINTENANCE SPECIFICATIONS AND EPA/ARB Regulations - USA Only ADJUSTMENTS. YANMAR TNV engines meet Environmental Protection Agency (EPA) (U. S. Federal) emission control standards as well as the California Air ■ EPA and CARB Resources Board (ARB, California) regulations.
Page 37: The 97/68/Ec Directive Certified Engines
The following is an explanation of the Engine Family designation: B YDX L 1.64 M Method of air aspiration Number of cylinders Engine speed specifications Displacement (l) Non-road/off-road engine YANMAR diesel Model year B: 2011 C: 2012 D: 2013 E: 2014 F: 2015...
Page 38: Function Of Major Engine Components
It is not part of the basic engine package as shipped from the factory. Periodic replacement of the air cleaner YANMAR filter element is necessary. See the Periodic Maintenance Schedule on page 5-5 for the replacement frequency.
Page 39: Function Of Cooling System Components
The application specific items are not part of the basic engine package as shipped from the factory. YANMAR • Engine cooling fan The engine cooling fan is driven by a V-belt which is powered by the crankshaft V-pulley. The purpose of the engine cooling fan is to circulate air through the radiator.
Page 40: Main Electronic Control Components And Features
GENERAL SERVICE INFORMATION Main Electronic Control Components and Features MAIN ELECTRONIC CONTROL COMPONENTS AND FEATURES Component/feature Description Controller By controlling the fuel injection timing, injection volume, injection pressure, and number of injection in accordance with the target speed indication entered from the accelerator sensor, the controller adjusts the engine speed and power.
Page 41 Main Electronic Control Components and Features GENERAL SERVICE INFORMATION Component/feature Description Engine diagnosis tool Allows the operator to troubleshoot the cause of a problem based on detailed information regarding the problem occurring in the ECU. This tool can also be used for data maintenance tasks including programming and mapping.
Page 42: Installation Position Of Sensors
GENERAL SERVICE INFORMATION Installation Position of Sensors INSTALLATION POSITION OF SENSORS Do not unnecessarily touch the sensor coupler portion with your bare hands. The sensor may be damaged due to static electricity. Injector DPF inlet exhaust temperature sensor Exhaust temperature sensor DPF inside exhaust temperature EGR valve sensor...
Page 43: Crank Rotation Sensor
Installation Position of Sensors GENERAL SERVICE INFORMATION Crank Rotation Sensor Vout A Vout B 037282-00X00 Figure 4-5 Part No. 129A00-21710 Sensor installation tightening torque 8 ± 2 N·m Cam Speed Sensor Vout 037283-00X00 Figure 4-6 Part No. 129A00-14710 Sensor installation tightening torque 8 ±...
Page 44: New Air Temperature Sensor
GENERAL SERVICE INFORMATION Installation Position of Sensors New Air Temperature Sensor Vout 037253-00X00 Figure 4-7 Part No. 129927-44900 With turbocharger 7.0 ± 1.4 N·m Sensor installation tightening torque Without turbocharger 3.5 ± 0.5 N·m EGR Temperature Sensor 044575-00X00 Figure 4-8 Part No.
Page 45: Fuel Temperature Sensor (Equipped On Supply Pump)
Installation Position of Sensors GENERAL SERVICE INFORMATION Fuel Temperature Sensor (equipped on supply pump) MPROP Fuel temperature sensor 037312-00E00 Figure 4-10 Part No. 129A00-51200 Sensor installation tightening torque 28 ± 2 N·m Cooling Water Temperature Sensor Vout M12x1.5 037249-00X00 Figure 4-11 Part No.
Page 46: Diesel Particulate Filter (Dpf) Inside/Inlet, Exhaust Temperature Sensor
GENERAL SERVICE INFORMATION Installation Position of Sensors Diesel Particulate Filter (DPF) Inside/Inlet, Exhaust Temperature Sensor Vout 037254-00X00 Figure 4-12 Exhaust temperature DPF inside exhaust DPF inlet exhaust sensor temperature sensor temperature sensor Part No. 129A00-13760 (Main) 129A00-13980 129A00-13990 Sensor installation 25 - 40 N·m 25 - 40 N·m 25 - 40 N·m...
Page 47: Egr Pressure Sensor
Installation Position of Sensors GENERAL SERVICE INFORMATION EGR Pressure Sensor PS-X429 **** ** Vout (Intake side) Vout (Exhaust side) BLANK BLANK Intake side ALLOWABLE ALLOWABLE MOUNTING ANGULAR MOUNTING ANGULAR Exhaust side 037257-00E00 Figure 4-14 Part No. 129A00-12700 Sensor installation tightening torque 7 ±...
Page 48: Diesel Particulate Filter (Dpf) Differential Pressure Sensor
GENERAL SERVICE INFORMATION Installation Position of Sensors Diesel Particulate Filter (DPF) Differential Pressure Sensor PS-X434 **** ** Vout (High pressure side) Vout (Differential pressure side) Vout (Low pressure side) BLANK ALLOWABLE High pressure side MOUNTING ANGULAR ALLOWABLE MOUNTING ANGULAR Low pressure side 037255-00E00 Figure 4-15 Part No.
Page 49: Egr Valve
Installation Position of Sensors GENERAL SERVICE INFORMATION EGR Valve CAN-L CAN-H 037280-00X00 Figure 4-16 3TNV88C, 3TNV86T 4TNV88C, 4TNV86CT 4TNV98C, 4TNV98CT Part No. 129A00-13901 129C00-13901 129E00-13901 TNV Tier 4 Service Manual 4-19...
Page 50: Intake Air Throttles
GENERAL SERVICE INFORMATION Installation Position of Sensors Intake Air Throttles Vout1 Motor terminal Sensor terminal Vout2 037319-00E00 Figure 4-17 Part No. 129A00-12900 Sensor installation tightening torque 9.0 ± 1.8 N·m Be sure to read the precautions before handling the Safety precaution intake throttle.
Page 51: Acceleration Sensor (Yanmar Standard)
Installation Position of Sensors GENERAL SERVICE INFORMATION Acceleration Sensor (YANMAR Standard) High idle (3.0 V) 57° Low idle (0.5 V) 73° Working range position (3.65 V - 4.35 V) Mating connector: 6189-0780 (Sumitomo Wiring Systems Ltd.) terminal: gold plate 032910-00E...
Page 52: Diesel Fuel
• Use the fuel that can be used where the diesel fuels. temperature is 12 °C (53.6 °F) lower than the YANMAR approves the use of bio-diesel fuels that expected lowest temperature to prevent the fuel do not exceed a blend of 7 % (by volume) of FAME from freezing.
Page 53: Filling The Fuel Tank
YANMAR Limited • Never place diesel fuel or other flammable Warranty on page 2-3. material such as oil, hay or dried grass close to the engine during engine operation or shortly after shutdown.
Page 54: Priming The Fuel System
Diesel Fuel Priming the Fuel System NOTICE DANGER • Only use diesel fuels recommended by YANMAR for the best engine performance, to prevent Fire and Explosion Hazard! engine damage and to comply with EPA/ARB • Diesel fuel is flammable and warranty requirements.
Page 55: Engine Oil
See the SAE service grade viscosity chart adversely affect the lubricating properties of the (Figure 4-20) engine oil. • YANMAR does not recommend the use of engine • Never overfill. Overfilling may result in white oil “additives.” exhaust smoke, engine overspeed or internal •...
Page 56: Checking Engine Oil
(Figure 4-21, (2)) and lower The following are the engine oil capacities for (Figure 4-21, (3)) lines on the dipstick. various YANMAR TNV engines. 5. Fully reinsert dipstick. Dipstick Adding Engine Oil Engine model upper limit/lower limit 1.
Page 57: Engine Coolant
Engine Coolant GENERAL SERVICE INFORMATION ENGINE COOLANT DANGER CAUTION Scald Hazard! Coolant Hazard! • Never remove the radiator cap if • Wear eye protection the engine is hot. Steam and hot and rubber gloves engine coolant will spurt out and when you handle long seriously burn you.
Page 58: Engine Coolant Specifications
• Mix coolant and water per the mixing instructions on the coolant container. • Water quality is important to coolant K0000029A performance. YANMAR recommends that soft, distilled or demineralized water be used to mix Figure 4-22 with coolants. • Never mix extended or long life coolants and conventional (green) coolants.
Page 59: Daily Check Of The Cooling System
7. Run the engine until it reaches operating The following are the engine coolant capacities for temperature. Check the level of engine coolant various YANMAR TNV engines. in the reserve tank When the engine is running and the engine coolant is at normal...
Page 60: Specifications
• Fuel feeding pressure: 20 ± 10 kPa (net) after engine break-in has been performed with the cooling fan, air cleaner and muffler installed to the engine. • With cooling fan, air cleaner, muffler: YANMAR standard • After the engine break-in period. Output allowable deviation: ± 3 % •...
Page 61: Principal Engine Specifications
Principal Engine Specifications GENERAL SERVICE INFORMATION PRINCIPAL ENGINE SPECIFICATIONS 3TNV88C Engine model 3TNV88C Version Type Vertical in-line diesel engine (Common rail system) Combustion system Direct injection Aspiration Naturally aspiration No. of cylinders Bore × stroke 88 × 90 mm 1.642 l...
Page 62: 3Tnv86Ct
GENERAL SERVICE INFORMATION Principal Engine Specifications 3TNV86CT Engine model 3TNV86CT Version Type Vertical in-line diesel engine (Common rail system) Combustion system Direct injection Aspiration Turbocharged No. of cylinders Bore × stroke 86 × 90 mm 1.568 l Displacement 3000 min Max.
Page 63: 4Tnv88C
Principal Engine Specifications GENERAL SERVICE INFORMATION 4TNV88C Engine model 4TNV88C Version Type Vertical in-line diesel engine (Common rail system) Combustion system Direct injection Aspiration Naturally aspiration No. of cylinders Bore × stroke 88 × 90 mm 2.189 l Displacement 3000 min Max.
Page 64: 4Tnv86Ct
GENERAL SERVICE INFORMATION Principal Engine Specifications 4TNV86CT Engine model 4TNV86CT Version Type Vertical in-line diesel engine (Common rail system) Combustion system Direct injection Aspiration Turbocharged No. of cylinders Bore × stroke 86 × 90 mm 2.090 l Displacement 3000 min Max.
Page 65: 4Tnv98C
Principal Engine Specifications GENERAL SERVICE INFORMATION 4TNV98C Engine model 4TNV98C Version Type Vertical in-line diesel engine (Common rail system) Combustion system Direct injection Aspiration Naturally aspiration No. of cylinders Bore × stroke 98 × 110 mm 3.319 l Displacement 2500 min Max.
Page 66: 4Tnv98Ct
GENERAL SERVICE INFORMATION Principal Engine Specifications 4TNV98CT Engine model 4TNV98CT Version Type Vertical in-line diesel engine (Common rail system) Combustion system Direct injection Aspiration Turbocharged No. of cylinders Bore × stroke 94 × 110 mm 3.053 l Displacement 2500 min Max.
Page 67: Set Output Listed By Rotation
Principal Engine Specifications GENERAL SERVICE INFORMATION Set Output Listed by Rotation Gross output (kW) Model Displacement 2000 2100 2200 2300 2400 2500 2600 2700 2800 3000 3TNV88C 1.642 – – – – 21.8 22.8 23.7 24.6 25.5 27.5 3TNV86CT 1.568 – –...
Page 68: Engine Service Standards
Valve (0.15 - 0.25 mm) Clearance on page 6-40 455 - 485 psi 355 - 385 psi 3TNV88C, 4TNV88C (3.14 - 3.34 MPa; (2.45 - 2.65 MPa; 32 - 34 kgf/cm²) 25 - 27 kgf/cm²) Compression 411 - 441 psi...
Page 69: Tightening Torques For Standard Bolts And Nuts
Tightening Torques for Standard Bolts and Nuts GENERAL SERVICE INFORMATION TIGHTENING TORQUES FOR STANDARD BOLTS AND NUTS Use the correct amount of torque when you tighten the fasteners on the machine. Applying excessive torque may damage the fastener or component and not enough torque may cause a leak or component failure.
Page 70: Abbreviations And Symbols
GENERAL SERVICE INFORMATION Abbreviations and Symbols ABBREVIATIONS AND SYMBOLS ■ Abbreviations kelvin kilogram ampere kilogram force per square kgf/cm² alternating current centimeter Association des Constructeurs kgf/m kilogram force per meter ACEA Européens d’Automobilies kilometers ampere-hour kilopascal American Petroleum Institute kilowatt Air Resources Board liter ATDC...
Page 71: Unit Conversions
Unit Conversions GENERAL SERVICE INFORMATION UNIT CONVERSIONS ■ Unit prefixes ■ Units of torque Prefix Symbol Power ft-lb × 1.3558 = N·m mega × 1,000,000 ft-lb × 0.1383 = kgf/m kilo × 1,000 in.-lb × 0.1130 = N·m centi × 0.01 in.-lb ×...
Page 72 GENERAL SERVICE INFORMATION Unit Conversions This Page Intentionally Left Blank 4-42 TNV Tier 4 Service Manual...
Page 73 The Importance of Periodic Maintenance........5-4 Performing Periodic Maintenance ..........5-4 YANMAR Replacement Parts............ 5-4 Ask Your Authorized YANMAR Industrial Engine Dealer or Distributor For Help ..............5-4 Required EPA/ARB Maintenance USA Only ......5-4 EPA/ARB Installation Requirements USA Only......5-4 Periodic Maintenance Schedule............
Page 74: Periodic Maintenance
PERIODIC MAINTENANCE This Page Intentionally Left Blank TNV Tier 4 Service Manual...
Page 75: Before You Begin Servicing
Before You Begin Servicing PERIODIC MAINTENANCE BEFORE YOU BEGIN SERVICING Before performing any service procedures within this section, read the following safety information and review the Safety section on page 3-1. TNV Tier 4 Service Manual...
Page 76: Introduction
PERIODIC MAINTENANCE Introduction INTRODUCTION YANMAR Replacement Parts YANMAR recommends that you use genuine This section of the Service Manual describes the YANMAR parts when replacement parts are procedures for proper care and maintenance of the needed. Genuine replacement parts help ensure engine.
Page 77: 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 ●. : Check : Replace ●: Contact your authorized YANMAR industrial engine dealer or distributor Periodic maintenance interval...
Page 78 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 Every System Check item Daily 1000 1500 2000 3000 hours hours hours...
Page 79: Periodic Maintenance Procedures
Periodic Maintenance Procedures PERIODIC MAINTENANCE PERIODIC MAINTENANCE PROCEDURES NOTICE After Initial 50 Hours of Operation • Only use the engine oil specified. Other engine Perform the following maintenance after the initial oils may affect warranty coverage, cause internal 50 hours of operation. engine components to seize and/or shorten engine life.
Page 80 PERIODIC MAINTENANCE Periodic Maintenance Procedures The engine oil on a new engine becomes Remove the engine oil filter as follows: contaminated from the initial break-in of internal 1. Turn the engine oil filter (Figure 5-2, (2)) parts. It is very important that the initial oil and oil counterclockwise (Figure 5-2, (3)) using a filter filter change is performed every 50 hours of wrench.
Page 81: Check And Adjust Cooling Fan V-Belt
Periodic Maintenance Procedures PERIODIC MAINTENANCE 5. Warm up the engine by running it for five There are three positions to check for V-belt minutes and check for any engine oil leaks. tension (Figure 5-4, (A), (B) and (C)). You can check the tension at whichever position is the 6.
Page 82: Every 50 Hours Of Operation
PERIODIC MAINTENANCE Periodic Maintenance Procedures 3. Tighten the V-belt to the proper tension. There Every 50 Hours of Operation must be clearance (Figure 5-6, (1)) between the V-belt and the bottom of the pulley groove. If there is no clearance (Figure 5-6, (2)) After you complete the initial 50 hour maintenance between the V-belt and the bottom of the pulley procedures, perform the following procedures...
Page 83 Periodic Maintenance Procedures PERIODIC MAINTENANCE 1. Position an approved container under the water NOTICE separator (Figure 5-7, (1)) to collect the contaminants. • Be sure to perform periodic maintenance in a clean environment 2. Close (Figure 5-7, (2)) the fuel cock free from dust.
Page 84 PERIODIC MAINTENANCE Periodic Maintenance Procedures ■ Check battery NOTICE DANGER • Always be environmentally responsible. Explosion Hazard! • Never check the remaining battery charge by shorting out the terminals. This will result in a • Follow the guidelines of the EPA or other spark and may cause an governmental agencies for the proper disposal of explosion or fire.
Page 85: Every 250 Hours Of Operation
• If the engine still will not start after charging, have Perform the following maintenance every 250 your authorized YANMAR industrial engine hours of operation. dealer or distributor check the battery and the engine’s starting system.
Page 86 PERIODIC MAINTENANCE Periodic Maintenance Procedures ■ Replace engine oil and engine oil filter NOTICE NOTICE • Always be environmentally responsible. • Only use the engine oil specified. Other engine oils may affect warranty coverage, cause internal engine components to seize and/or shorten engine life.
Page 87 Periodic Maintenance Procedures PERIODIC MAINTENANCE ■ Check and clean radiator fins ■ Check and adjust cooling fan V-belt Check and adjust the cooling fan V-belt every 250 CAUTION hours of operation after the initial 50 hour V-belt maintenance. See Check and adjust cooling fan V- Flying Object Hazard! belt on page 5-9.
Page 88: Every 500 Hours Of Operation
PERIODIC MAINTENANCE Periodic Maintenance Procedures 4. If the air cleaner is equipped with a double Every 500 Hours of Operation element, only remove and replace the inner element (Figure 5-12, (1)) if the engine lacks power or the dust indicator actuates (if Perform the following maintenance every 500 equipped).
Page 89: Replace Fuel Filter
8. Check for leaks. NOTICE NOTICE For maximum engine life, YANMAR recommends Be sure to perform priming the engine before that when shutting the engine down, you allow the starting. If air is mixed to the fuel, seizure to the engine to idle, without load, for five minutes.
Page 90 PERIODIC MAINTENANCE Periodic Maintenance Procedures ■ Replace water separator element Replace the water separator element every 500 hours of operation. DANGER 1. Position an approved container under the cup Fire and Explosion Hazard! (Figure 5-14, (1)) of the water separator to collect the contaminants.
Page 91: Every 1000 Hours Of Operation
Periodic Maintenance Procedures PERIODIC MAINTENANCE 13. Open the fuel cock (Figure 5-14, (3)). Every 1000 Hours of Operation 14. Prime the fuel system. See Priming the Fuel System on page 4-24. Perform the following maintenance every 1000 NOTICE hours of operation. •...
Page 92: Change Coolant
PERIODIC MAINTENANCE Periodic Maintenance Procedures CAUTION Coolant Hazard! • Wear eye protection and rubber gloves when you handle long life or extended life engine coolant. If contact with the eyes or skin should occur, flush eyes and wash immediately with clean water.
Page 93: Every 1500 Hours Of Operation
To prevent such a problem, clean the cooler at be routed to the intake manifold. least every 1500 hours. To inspect the diaphragm and spring Consult your local YANMAR dealer for this service. (Figure 5-18, (3)): 1. Remove the bolts retaining the diaphragm EGR valve EGR lead valve cover (Figure 5-18, (4)).
Page 94: Every 2000 Hours Of Operation
■ Lap the intake and exhaust valves Adjustment is necessary to maintain proper contact of the valves and seats. See your authorized YANMAR industrial engine dealer or distributor to lap the valve seats. 5-22 TNV Tier 4 Service Manual...
Page 95: Every 3000 Hours Of Operation
• Inspect turbocharger (blower wash as regular intervals. necessary) Consult your local YANMAR dealer for this service. 3TNV86CT, 4TNV86CT, 4TNV98CT • Inspect, clean and test EGR valve EGR valve EGR lead valve •...
Page 96 PERIODIC MAINTENANCE Periodic Maintenance Procedures This Page Intentionally Left Blank 5-24 TNV Tier 4 Service Manual...
Page 97 Section 6 TNV Tier 4 Service Manual ENGINE Page Before You Begin Servicing ............6-3 Introduction..................6-4 Cylinder Head Specifications ............6-4 Adjustment Specifications ............6-4 Cylinder Head................6-4 Intake/Exhaust Valve and Guide ..........6-5 Push Rod................... 6-6 Rocker Arm and Shaft ............... 6-6 Valve Spring ................
Page 98 ENGINE Components of a Cylinder Head ..........6-26 Disassembly of Cylinder Head ..........6-27 Cleaning of Cylinder Head Components ........6-31 Inspection of Cylinder Head Components........ 6-31 Reassembly of Cylinder Head..........6-36 Measuring and Adjusting Valve Clearance ........6-40 Crankshaft and Camshaft Components ......... 6-42 Disassembly of Engine.............
Page 99: Before You Begin Servicing
Before You Begin Servicing ENGINE BEFORE YOU BEGIN SERVICING Before performing any service procedures within this section, read the following safety information and review the Safety section on page 3-1. TNV Tier 4 Service Manual...
Page 100: Introduction
Combustion surface distortion (flatness) (0.05 mm) or less (0.15 mm) 0.0118 - 0.0197 in. 0.0315 in. Intake (0.30 - 0.50 mm) (0.8 mm) 3TNV88C, 3TNV86CT, See Valve 4TNV88C, 4TNV86CT 0.0118 - 0.0197 in. 0.0315 in. Exhaust recession on (0.30 - 0.50 mm) (0.8 mm)
Page 101: Intake/Exhaust Valve And Guide
(6.940 - 6.955 mm) (6.90 mm) 0.0018 - 0.0030 in. 0.0067 in. Valve stem bend (0.045 - 0.075 mm) (0.17 mm) 3TNV88C, 3TNV86CT, Valve guide projection from 0.5791 - 0.5905 in. 4TNV88C, 4TNV86CT, – Reassembly of cylinder head (14.71 - 15.00 mm)
Page 102: Push Rod
0.0051 in. Oil clearance (0.010 - 0.050 mm) (0.13 mm) Valve Spring Reference Inspection item Model Standard Limit page 3TNV88C, 3TNV86CT, 4TNV88C, 1.6535 in. 1.6339 in. 4TNV86CT (42.0 mm) (41.5 mm) Free length 1.8701 in. 1.8504 in. 4TNV98C, 4TNV98CT See Inspection (47.5 mm)
Page 103: Camshaft And Timing Gear Train Specifications
6-46. 0 - 0.0008 in. 0.0020 in. Bend (1/2 the dial gauge reading) (0 - 0.02 mm) (0.05 mm) See Inspection 3TNV88C, 3TNV86CT, 1.5197 - 1.5276 in. 1.5098 in. of camshaft on 4TNV88C, 4TNV86CT (38.600 - 38.800 mm) (38.350 mm) page 6-56.
Page 104: Idler Gear Shaft And Bushing
1.8110 - 1.8120 in. 1.8140 in. Idler gear A Bushing inside diameter (46.000 - 46.025 mm) (46.075 mm) 0.0010 - 0.0030 in. 0.0068 in. 3TNV88C, Oil clearance (0.025 - 0.075 mm) (0.175 mm) 3TNV86CT, 4TNV88C, 1.6909 - 1.6919 in. 1.6890 in.
Page 105: Crankshaft And Piston Specifications
– (0.02 mm) 1.8879 - 1.8883 in. 1.8859 in. Journal outside diameter (47.952 - 47.962 mm) (47.902 mm) 1.8898 - 1.8909 in. 3TNV88C, Bearing inside diameter – (48.000 - 48.026 mm) 3TNV86CT, 4TNV88C, 0.0587 - 0.0591 in. Bearing insert thickness –...
Page 106: Thrust Bearing
Piston Reference Inspection item Standard Limit page 3.4622 - 3.4634 in. 3.4604 in. 3TNV88C, 4TNV88C (87.940 - 87.970 mm) (87.895 mm) Piston outside diameter 3.3835 - 3.3846 in. 3.3817 in. 3TNV86CT, 4TNV86CT See Inspection (Measure at 90° to the piston pin) (85.940 - 85.970 mm)
Page 107: Piston Ring
Crankshaft and Piston Specifications ENGINE Piston Ring Reference Model Inspection item Standard Limit page 0.0813 - 0.0819 in. Ring groove width – (2.065 - 2.080 mm) 0.0776 - 0.0783 in. 0.0768 in. Ring width (1.970 - 1.990 mm) (1.950 mm) Top ring 0.0030 - 0.0043 in.
Page 108 (2.140 mm) See Inspection 0.0776 - 0.0783 in. 0.0768 in. Ring width of pistons, (1.970 - 1.990 mm) (1.950 mm) 3TNV88C, Second ring piston rings and 4TNV88C 0.0014 - 0.0028 in. 0.0075 in. wrist pin on Side clearance (0.035 - 0.070 mm) (0.190 mm)
Page 109 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 110: Connecting Rod
Standard Limit page 1.0234 - 1.0251 in. 1.0263 in. Wrist pin bushing inside diameter (26.025 - 26.038 mm) (26.068 mm) 3TNV88C, 3TNV86CT, 1.0234 - 1.0236 in. 1.0223 in. Wrist pin outside diameter 4TNV88C, (25.995 - 26.000 mm) (25.967 mm) 4TNV86CT 0.0010 - 0.0017 in.
Page 111: Cylinder Block Specifications
Cylinder Block Reference Inspection item Model Standard Limit page 3.4646 - 3.4657 in. 3.4724 in. 3TNV88C - 4TNV88C (88.000 - 88.030 mm) (88.200 mm) 3.3858 - 3.3870 in. 3.3937 in. Cylinder inside diameter 3TNV86CT, 4TNV86CT See Inspection (86.000 - 86.030 mm) (86.200 mm)
Page 112: Special Torque Chart
Component Model Torque and pitch (Thread portion and seat surface) 68 - 72 ft·lb 3TNV88C, 3TNV86CT, M10 × 1.25 mm (92.0 - 98.0 N·m; 4TNV88C, 4TNV86CT 9.4 - 10.0 kgf·m) Cylinder head bolt Applied 76 - 83 ft·lb 4TNV98C, 4TNV98CT M11 ×...
Page 113 5.5 - 6.3 ft·lb Cam speed sensor All models M6 × 1.0 mm (7.5 - 8.5 N·m; Not applied 0.75 - 0.85 kgf·m) 3TNV88C, 14.0 - 18.2 ft·lb 3TNV86CT, M8 × 1.25 mm (18.9 - 24.7 N·m; Not applied 4TNV88C, 1.9 - 2.5 kgf·m)
Page 114 ENGINE Special Torque Chart (Torque for bolts and nuts cont.) Lubricating oil Thread diameter application Component Model Torque and pitch (Thread portion and seat surface) 18.4 - 29.5 ft·lb DPF temperature All models M12 × 1.25 mm (25.0 - 40.0 N·m; Not applied sensor 2.5 - 4.1 kgf·m)
Page 115: Special Service Tools
1.181 in. 1.299 in. bushing) 4TNV98CT (20 mm) (100 mm) (30 mm) (33 mm) 010933-00X Locally manufactured Valve spring compressor (for removal/ YANMAR Part No. 129100-92630 installation of valve spring) 010931-00X Model 0.638 0.866 0.531 0.740 2.559 0.157 All models (16.2 (13.5...
Page 116 4TNV98C, 3.504 - 3.976 in. 129400-92440 4TNV98CT (89 - 101 mm) 010930-00X 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) 007236-00X...
Page 117 039125-00E00 ローレットノブ Crankshaft m0.3 pulley installing Locally manufactured tool (4TNV98C, 4TNV98CT M14×1.5 (for straight series) pilot) 0.2 A ø0.03 A 039126-00J00 0.05 (16) M14 x 1.5 Pulley installing 3TNV88C, 3TNV86CT, tool 4TNV88C, 4TNV86CT Knurling TNV Tier 4 Service Manual 6-21...
Page 118 ENGINE Special Service Tools Tool name Applicable model and tool size Illustration 16mmx18/1inch (Whitworth screw thread) ø 13 Compression gauge adapter (129A00- 92950) (ø16) ø17 ø7.2 -0.1 043931-00E00 6-22 TNV Tier 4 Service Manual...
Page 119: Measuring Instruments
Measuring Instruments ENGINE MEASURING INSTRUMENTS Instrument name Application Illustration Dial Indicator Locally available Measure shaft bend and end play. 001429-00X Measurements of narrow or deep portions that Test indicator Locally available cannot be measured by dial gauge. 001430-00X Magnetic stand Locally available For holding the dial gauge when measuring.
Page 120 ENGINE Measuring Instruments Instrument name Application Illustration V-block Locally available For measuring shaft bend. 001437-00X For tightening nuts and bolts to the specified Torque wrench Locally available torque. 001438-00X For measuring piston ring gaps, piston ring Feeler gauge Locally available clearance, and valve adjustment clearance.
Page 121: Cylinder Head
Cylinder Head ENGINE CYLINDER HEAD Cylinder Head Components K0001919 Figure 6-1 TNV Tier 4 Service Manual 6-25...
Page 122: Components Of A Cylinder Head
ENGINE Cylinder Head Components of a Cylinder Head 1 – Valve cover nut 2 – Valve cover nut O-ring Cylinder head with glow plugs applicable to all 3 – Crankcase breather cover models. 4 – Diaphragm spring 5 – Diaphragm plate 6 –...
Page 123: Disassembly Of Cylinder Head
Cylinder Head ENGINE Disassembly of Cylinder Head Prepare a clean, flat working surface on a workbench large enough to accommodate the cylinder head assembly. Discard all gaskets, O-rings and seals. Use new gaskets, O-rings and seals on reassembly of the cylinder head. 1.
Page 124: Removing The Glow Plugs
ENGINE Cylinder Head ■ Removing the glow plugs ■ Removal of valve cover 1. Remove the glow plug harness 1. Disconnect the electrical wire from sensors on (Figure 6-5, (2)) from each glow plug the valve cover. (Figure 6-5, (1)). 2.
Page 125: Removal Of Rocker Arm Assembly
Cylinder Head ENGINE ■ Removal of rocker arm assembly Note: Mark the rocker arms so they can be reinstalled with the original matching 1. Remove the bolts (Figure 6-7, (1)) that retain valve and pushrod. the rocker arm shaft supports. 2.
Page 126: Removal Of Intake/Exhaust Valves
ENGINE Cylinder Head ■ Removal of intake/exhaust valves 2. Remove the cylinder head bolts (Figure 6-10, (1)). 1. Place the cylinder head on the work bench with 3. Lift the cylinder head away from the cylinder the combustion side down. block.
Page 127: Cleaning Of Cylinder Head Components
Cylinder Head ENGINE Note: If the valves are to be reused, identify Cleaning of Cylinder Head them so they can be installed in their Components original location. WARNING 8. Turn the cylinder head so the exhaust port side faces down. Remove the intake and exhaust Fume/Burn Hazard! valves (Figure 6-12, (6)) from the cylinder •...
Page 128: Inspection Of Rocker Arm Assembly
ENGINE Cylinder Head ■ Inspection of push rods Push rod bend Determine if the bend of the push rods are within the specified limit. 1. Place the push rods on a flat inspection block or layout bed. 2. Roll the push rods until a gap can be observed between a portion of the push rod and the surface of the block or layout bed.
Page 129: Inspection Of Cylinder Head
Cylinder Head ENGINE ■ Inspection of valve guides ■ Inspection of intake and exhaust valves Visually inspect the valve guides for distortions, Visually inspect the intake and exhaust valves. scoring or other damage. Replace any valves that are obviously discolored, heavily pitted or otherwise damaged.
Page 130 ENGINE Cylinder Head Valve recession Valve face and valve seat Note: The valve guides must be installed to Always check the clearance between the valve and valve guide before grinding or lapping the valve perform this check. seats. See Intake/Exhaust Valve and Guide on Insert the valves into their original locations and page 6-5 for the service limit.
Page 131 Cylinder Head ENGINE Squareness Use a flat surface and a square to check each 150° spring for squareness (Figure 6-25). See Valve 40° Spring on page 6-6 for the service limit. K0001862 Figure 6-24 The valve seat diameter can be adjusted by top- grinding with a 150°...
Page 132: Reassembly Of Cylinder Head
ENGINE Cylinder Head ■ Reassembly of intake and exhaust valves Reassembly of Cylinder Head NOTICE Use new gaskets, O-rings and seals for the reassembly of the cylinder head. Always install new valve stem seals. NOTICE The exhaust valve stem seals are different than the intake valve stem seals and can be identified by Liberally oil all components during reassembly to either the paint marks on the outside of the seals or...
Page 133 Cylinder Head ENGINE 7. Insert the valve keepers (Figure 6-31, (2)) and slowly release the tension on the valve spring. Install the valve cap (Figure 6-31, (1)). Repeat the steps on all the remaining valves. ■ Reassembly of cylinder head 1.
Page 134: Reassembly Of Rocker Arm Reassembly
ENGINE Cylinder Head 3. Lightly oil the threads of the cylinder head bolts 1. Lubricate the rocker arm shaft. Slide the rocker (Figure 6-32, (1)). Tighten the bolts to the arm supports (Figure 6-35, (5)), springs specified torque in two steps as shown in the (Figure 6-35, (1)) and rocker arms chart below.
Page 135: Reassembly Of The Valve Cover
Cylinder Head ENGINE ■ Reassembly of the valve cover 1. Lightly grease a new valve cover gasket (Figure 6-36, (4)). Place the gasket in the groove of the valve cover (Figure 6-36, (3)). 2. Place the valve cover on the cylinder head. 3.
Page 136: Measuring And Adjusting Valve Clearance
ENGINE Measuring and Adjusting Valve Clearance MEASURING AND ADJUSTING • If there is no valve clearance, and the cylinder is at TDC of the compression stroke, extreme wear, VALVE CLEARANCE or damage to the cylinder head or valves may be possible.
Page 137 Measuring and Adjusting Valve Clearance ENGINE 1. Remove the valve cover. See Removal of valve cover on page 6-28. 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 138: Crankshaft And Camshaft Components
ENGINE Crankshaft and Camshaft Components CRANKSHAFT AND CAMSHAFT COMPONENTS 043952-00X00 Figure 6-41 6-42 TNV Tier 4 Service Manual...
Page 139: Disassembly Of Engine
Crankshaft and Camshaft Components ENGINE Disassembly of Engine 1 – Cylinder block 2 – Camshaft bushing Prepare a clean, flat working surface on a 3 – Gear case workbench large enough to accommodate the 4 – Gear case cover engine components. Discard all used gaskets, 5 –...
Page 140: Disassembly Of Camshaft And Timing Components
ENGINE Crankshaft and Camshaft Components ■ Checking timing gear backlash 7. Drain the engine oil into a suitable container. Remove the oil filter. Prior to removing the timing gears, measure the 8. Remove the cylinder head. See Cylinder Head gear backlash and determine the gear wear. on page 6-25.
Page 141: Removal Of Timing Gears
Crankshaft and Camshaft Components ENGINE ■ Measuring idler gear-to-crankshaft gear ■ Removal of timing gears backlash 1. Remove the bolts from the idler gear shaft (Figure 6-45, (1)). Remove the idler gear shaft, 1. Install a dial indicator as shown in Figure 6-44. idler gear (Figure 6-45, (2)) and bushing (Figure 6-45, (3)).
Page 142: Removal Of Camshaft
ENGINE Crankshaft and Camshaft Components ■ Removal of oil pan ■ Removal of camshaft 1. Invert the engine (oil pan up) on the engine 1. Before removing the camshaft, check the stand. camshaft end play. 2. Remove the oil pan (Figure 6-47, (1)). •...
Page 143 Crankshaft and Camshaft Components ENGINE ■ Removal of gear case or front plate 2. Remove the two bolts (Figure 6-51, (3)) retaining the camshaft thrust plate Note: The camshaft must be removed before the (Figure 6-51, (1)). gear case can be removed. See Inspection of camshaft on page 6-56.
Page 144: Disassembly Of Crankshaft And Piston Components
ENGINE Crankshaft and Camshaft Components 6. 3TNV88C - 4TNV86CT: Remove the O-ring 1. Using a feeler gauge, measure the connecting (Figure 6-53, (2)) and dowels rod side clearance as shown (Figure 6-54). (Figure 6-53, (5)). See Connecting Rod on page 6-14 for the standard limit.
Page 145 Crankshaft and Camshaft Components ENGINE 3. Use a wooden dowel against the connecting rod and tap the piston/connecting rod assembly out of the cylinder. 4. Mark the cylinder number on the piston and connecting rod. 5. Remove the bearing inserts (Figure 6-57, (2)). 6.
Page 146: Removal Of Crankshaft
ENGINE Crankshaft and Camshaft Components ■ Removal of crankshaft • Method B: Use a feeler gauge to measure the clearance (Figure 6-60, (3)) between the 1. Remove the flywheel (Figure 6-58, (1)) from thrust bearing (Figure 6-60, (1)) and the crankshaft. crankshaft (Figure 6-60, (2)).
Page 147: Inspection Of Crankshaft And Camshaft Components
Crankshaft and Camshaft Components ENGINE 5. Measure bearing oil clearance prior to removing 6. Remove the crankshaft from the engine. the crankshaft to determine extent of wear. 7. Remove the bearing inserts (Figure 6-61, (1)) Record the measurements. and thrust bearings (Figure 6-61, (2)). 1- Wipe oil from the bearing insert and Note: Do not remove the crankshaft gear crankshaft journal surfaces.
Page 148: Replacement Of Crankshaft Oil Seals
The 2. Apply a continuous bead of ThreeBond Liquid same procedure is done for both connecting rods Gasket No. 1207F, YANMAR Part No. 977770- and main bearings. 1207F to the outside diameter of a new oil seal (Figure 6-65, (2)), and install in the gear case ■...
Page 149 Crankshaft and Camshaft Components ENGINE 1. Clean piston ring grooves using a piston ring groove cleaning tool. Follow manufacturer’s instructions for correct operation. 2. Wash the pistons in an appropriate solvent using a soft brush. 3. Visually inspect each piston for cracks. Pay particular attention to the ring lands between the piston ring grooves.
Page 150: Inspection Of Connecting Rod
ENGINE Crankshaft and Camshaft Components Note: Always check the piston ring end gap when installing new piston rings. See Piston Ring on page 6-11 for specifications. Use a piston ring end gap filing tool to adjust the piston ring end gap on new piston rings.
Page 151: Inspection Of Tappets
Crankshaft and Camshaft Components ENGINE ■ Inspection of tappets ■ Inspection of crankshaft 1. Inspect the tappet contact surfaces for 1. Place the crankshaft end journals abnormal wear (Figure 6-74, (1)). Normal wear (Figure 6-76, (4)) on V-blocks. will be even as shown in (Figure 6-74, (2)). 2.
Page 152: Inspection Of Camshaft
ENGINE Crankshaft and Camshaft Components ■ Inspection of camshaft 1. Use V-blocks and a dial indicator to check camshaft bend (Figure 6-78). Place the indicator on the center bearing journal. K0001711 Figure 6-78 2. Rotate the camshaft and observe the runout. See Camshaft on page 6-7 for specifications.
Page 153: Inspection Of Idler Gear And Shaft
Crankshaft and Camshaft Components ENGINE ■ Inspection of camshaft bushing and Honing and Boring bores Pistons must move freely in the cylinders while 1. Measure the I.D. of the front bushing and the maintaining adequate compression and oil sealing. remaining bores in the cylinder block. See If the cylinder walls are scuffed, scored, Camshaft on page 6-7 for specifications.
Page 154: Reassembly Of Crankshaft And Piston Components
ENGINE Crankshaft and Camshaft Components • When honing is completed, wash the cylinder NOTICE block with hot water and soap. The cylinder wall is adequately cleaned when a white rag Do not allow the honing tool to operate in one wiped in cylinder comes out clean.
Page 155 Crankshaft and Camshaft Components ENGINE K0002091 K0001960 Figure 6-84 3. Reinstall one circlip (Figure 6-84, (5)) into the piston. Ensure the circlip is securely seated in K0002090 the groove. NOTICE The piston and connecting rod must be assembled together in the correct orientation. The orientation of the piston and connecting rod are different depending on engine model.
Page 156 ENGINE Crankshaft and Camshaft Components Piston assembly - all TNV models When correctly assembled, the piston identification mark (Figure 6-86, (2)) stamped into the top of the piston will be on the same side of the connecting rod as the match marks (Figure 6-86, (4)) stamped into the connecting rod and connecting rod cap.
Page 157: Installation Of Crankshaft
Crankshaft and Camshaft Components ENGINE NOTICE Always use a piston ring installation tool (expander) when installing piston rings. Never attempt to install piston rings by hand. 6. Reinstall the oil ring expander (Figure 6-90, (4)). Reinstall the oil ring (Figure 6-90, (3)) with the end gap at 180° from the expander end gap.
Page 158 Figure 6-91 6. Rotate the crankshaft to assure it turns freely. 7. Apply ThreeBond Liquid Gasket No. 1207F, YANMAR Part No. 977770-1207F to the mounting flange of the seal housing (Figure 6-92, (2)). 8. Align the seal housing with the two dowel pins.
Page 159 Crankshaft and Camshaft Components ENGINE Piston installation - all TNV models 4. Reinstall the bearing inserts (Figure 6-95, (1)) in the connecting rod and cap. When correctly assembled, the piston 5. Apply a liberal coat of clean engine oil to the identification mark (Figure 6-95, (2)) stamped bearing inserts and crankshaft journal.
Page 160: Reassembly Of Camshaft And Timing Components
4. Lubricate the camshaft (Figure 6-98, (2)) with Figure 6-96 clean engine oil or assembly lube. Slowly insert 4. 3TNV88C - 4TNV86CT: Reinstall the dowels the camshaft through the front of the engine. (Figure 6-97, (5)) and a new O-ring 5.
Page 161: Installation Of Timing Gears
■ Installation of gear case cover 1. Apply a continuous bead of ThreeBond Liquid Gasket No. 1207F, YANMAR Part No. 977770- 1207F to the mounting area of the gear case 043953-00X00 cover (Figure 6-101, (1)). Be sure to circle the 1 –...
Page 162: Installation Of Oil Pan
Chart on page 6-16 for specifications. K0001696A Figure 6-103 2. Apply a continuous bead of ThreeBond Liquid Gasket No. 1207F, YANMAR Part No. 977770-1207F to the mounting surface of the oil pan (Figure 6-104, (1)). Be sure to circle each bolt hole.
Page 163: Final Reassembly Of Engine
Crankshaft and Camshaft Components ENGINE Final Reassembly of Engine 1. Reinstall the starter motor. 2. Reinstall the cylinder head. See Reassembly of cylinder head on page 6-37. 3. Reinstall the engine in the machine. 4. Reconnect the fuel and coolant lines. 5.
Page 164: Egr System
ENGINE EGR System EGR SYSTEM EGR System (Typical Model) 043960-01X00 1 – Exhaust manifold 3 – EGR valve 2 – EGR pipe 4 – Intake manifold Figure 6-105 6-68 TNV Tier 4 Service Manual...
Page 165: Typical Model For Turbocharger Model
EGR System ENGINE Typical Model for Turbocharger Model 043962-00X00 1 – Exhaust manifold 7 – Spacer, EGR lead valve 2 – Elbow, EGR cooler inlet 8 – Lead valve, EGR 3 – EGR cooler 9 – Turbocharger 4 – Intake throttle valve 10 –...
Page 166: Disassembly Of Supply Pump
ENGINE EGR System Disassembly of Supply Pump WARNING DANGER Entanglement Hazard! • Stop the engine before you begin Scald Hazard! to service it. • Never remove the radiator cap if the engine is hot. Steam and hot engine coolant will spurt out and seriously burn you.
Page 167 EGR System ENGINE NOTICE CAUTION Flying Object Hazard! When it is necessary to replace an EGR valve, be sure to replace the entire EGR valve assembly. • Always wear eye protection when Neither attempt to disassemble and repair the EGR servicing the engine and when valve, nor replace its individual components.
Page 168 ENGINE EGR System ■ Engine without turbocharger (3TNV88C, 4TNV88C, 4TNV98C) 1. Loosen the nuts in the coupling flanges of the exhaust manifold and the EGR pipe. 2. Loosen the bolts in the coupling flanges of the EGR pipe and EGR valve, and remove the EGR pipe.
Page 169: Cleaning The Egr Valves
EGR System ENGINE Remove the remaining carbon deposits by blowing NOTICE the compressed air. (Figure 6-110) Do not end the SA-D while cleaning the EGR. For details on how to operate the EGR Active Control, refer to the SMARTASSIST DIRECT (SA- D) Operation Manual.
Page 170: Lead Valves
ENGINE EGR System Lead Valves Precautions for Installation Similarly to the EGR valves, the lead valves must 1. The valve and stopper must be installed in their be periodically cleaned every 3000 hours because, specific orientations. As shown in the figure as exhaust gas circulates through them for a above, install the valve and stopper so that they prolonged time, carbon is deposited on their inner...
Page 171: Egr Pipe And Other Connecting Elbows
EGR System ENGINE EGR Pipe and Other Connecting Elbows The exhaust gas passage is subject to carbon deposition when used over time. To remove deposited carbon from the gas passage, use compressed air (0.19 MPa (2 kg/cm ) or lower). If the exhaust gas passage is heavily fouled, clean it by dipping it in carbon cleaner, kerosene, or some other liquid capable of removing carbon.
Page 172: Intake Throttle
ENGINE Intake Throttle INTAKE THROTTLE The intake throttle is a device that controls the Characteristics of the intake throttle amount of the engine air intake. The TNV series engines use it for the combustion of soot collected Fully closed angle flow rate before adjustment inside the DPF.
Page 173: Fuel System
Section 7 TNV Tier 4 Service Manual FUEL SYSTEM Page Before You Begin Servicing ............7-3 System Structure................7-4 Fuel System Specifications ............. 7-6 Torque Chart for Major Bolts and Nuts........7-6 Fuel System Diagram..............7-7 Fuel System Components ............... 7-8 Removal of Common Rail............
Page 174 FUEL SYSTEM This Page Intentionally Left Blank TNV Tier 4 Service Manual...
Page 175: Before You Begin Servicing
Before You Begin Servicing FUEL SYSTEM BEFORE YOU BEGIN SERVICING Before performing any service procedures within this section, read the following safety information and review the Safety section on page 3-1. TNV Tier 4 Service Manual...
Page 176: System Structure
FUEL SYSTEM System Structure SYSTEM STRUCTURE Fuel feed pump Rail pressure sensor Rail Relief valve (mechanical) Main filter Supply pump Intake metering valve Fuel feed pump (electromagnetic) Fuel cooler Pre-filter Injector Crank speed sensor Gear speed sensor Fuel tank Accelerator sensor Flow of intake Flow of injection fuel Flow of electrical signal...
Page 177 System Structure FUEL SYSTEM ■ Crank rotation sensor and gear speed sensor The crank rotation sensor is equipped on the flywheel side and the gear speed sensor is equipped on the gear side. Based on these 2 sensor outputs, the ECU recognizes the engine speed and each piston position.
Page 178: Fuel System Specifications
FUEL SYSTEM Fuel System Specifications FUEL SYSTEM SPECIFICATIONS Torque Chart for Major Bolts and Nuts Thread diameter and Lubricating oil application Component Tightening torque pitch (Thread portion and seat surface) 18.0 - 20.9 ft·lb Fuel injector retainer bolt M8 × 1.25 mm (24.4 - 28.4 N·m;...
Page 179: Fuel System Diagram
Fuel System Diagram FUEL SYSTEM FUEL SYSTEM DIAGRAM Pressure sensor Rail Pressure control valve Supplier pump Fuel filter Fuel feed pump Injectors Various sensors Fuel filter/water separator Fuel tank Engine Engine Accelerator Turbocharger Intake Cooling speed speed pedal temperature boost water (crank) (cam)
Page 180: Fuel System Components
FUEL SYSTEM Fuel System Components FUEL SYSTEM COMPONENTS 043937-00X00 1 – High-pressure fuel injection lines 7 – Fuel supply pump drive gear 2 – Fuel return line 8 – Supply pump 3 – Fuel injector 9 – Fuel filter 4 – Gear case 10 –...
Page 181: Removal Of Common Rail
Fuel System Components FUEL SYSTEM Removal of Common Rail 4. Remove the fuel return hose from the injector. Pull out the fuel return hose connector (back 1. Remove the wiring of the injector coupler on the leak rail connector) (Figure 7-7, (2)) vertically injector.
Page 182: Reassembly Of Common Rail
FUEL SYSTEM Fuel System Components Reassembly of Common Rail 1. Reassembly of common rail body Temporarily tighten the 2 pieces of M8 bolts by hand while securely holding the common rail body by hand. Then, tighten the bolts to specification. 16.7 - 20.9 ft·lb Tightening torque (22.6 - 28.4 N·m;...
Page 183: Removal Of Injector
Fuel System Components FUEL SYSTEM 4. Be sure the new O-rings are installed on the valve cover nuts. Reinstall and tighten the valve cover nuts. 5. Press in the connector vertically from above while fully pressing the retaining ring of the injector in the direction of the arrow A.
Page 184: Reassembly Of Injector
• If rewriting is not correctly done, the engine SMARTASSIST DIRECT(SA-D). performance cannot be guaranteed. • The correction value is written on the injector. • Rewrite the correction value using Yanmar Diagnostic Tool, SMARTASSIST DIRECT (SA-D). 2. Reassembly of injector fixture retainer 1- Reinstall the injector fixture retainer.
Page 185: Removal Of Supply Pump
Fuel System Components FUEL SYSTEM Removal of Supply Pump 1- Clean around the cap nuts on both the pump and rail sides, using a brush or aspirator. 1. Remove the wiring coupler of the fuel pressure 2- Press the pipe against the bearing surface sensor.
Page 186: Reassembly Of Supply Pump
FUEL SYSTEM Fuel System Components Reassembly of Supply Pump 2- Temporarily tighten the cap nuts (both the pump and rail sides) while pressing and 1. Reassembly of supply pump body fixing the seat portions. Align the position of the supply pump drive shaft 3- Tighten the cap nuts to specification.
Page 187 Fuel System Components FUEL SYSTEM 055192-00X00 Figure 7-13 TNV Tier 4 Service Manual 7-15...
Page 188 FUEL SYSTEM Fuel System Components This Page Intentionally Left Blank 7-16 TNV Tier 4 Service Manual...
Page 189: Cooling System
Section 8 TNV Tier 4 Service Manual COOLING SYSTEM Page Before You Begin Servicing ............8-3 Introduction..................8-4 Cooling System Diagram..............8-4 Engine Coolant Pump Components ..........8-5 Engine Coolant System Check............8-6 Engine Coolant Pump ..............8-6 Removal of Engine Coolant Pump ..........8-6 Disassembly of Engine Coolant Pump ........
Page 190 COOLING SYSTEM This Page Intentionally Left Blank TNV Tier 4 Service Manual...
Page 191: Before You Begin Servicing
Before You Begin Servicing COOLING SYSTEM BEFORE YOU BEGIN SERVICING Before performing any service procedures within this section, read the following safety information and review the Safety section on page 3-1. TNV Tier 4 Service Manual...
Page 192: Introduction
COOLING SYSTEM Introduction INTRODUCTION This section of the Service Manual describes the procedures necessary to service the TNV 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 193: Engine Coolant Pump Components
Engine Coolant Pump Components COOLING SYSTEM ENGINE COOLANT PUMP COMPONENTS K0000031A-01X 1 – Thermostat cover 8 – Gasket 2 – Thermostat cover gasket 9 – Engine coolant pump gasket 3 – Thermostat 10 – V-belt 4 – Thermostat O-ring 11 – Engine coolant pump V-pulley 5 –...
Page 194: Engine Coolant System Check
COOLING SYSTEM Engine Coolant System Check ENGINE COOLANT SYSTEM CHECK Check the engine coolant system for leakage. 1. With the radiator properly filled, install a cooling system tester (Figure 8-3, (1)). 2. Apply 10.8 - 14.8 psi (75 - 105 kPa; 0.75 - 1.05 kgf/cm²) to the cooling system.
Page 195: Disassembly Of Engine Coolant Pump
Engine Coolant Pump COOLING SYSTEM 4. Drain the coolant from the engine block. • On models equipped with an oil cooler, remove the coolant hose (Figure 8-5, (1)) at the oil cooler. K0000163B Figure 8-7 7. Disconnect the coolant hoses and the 043935-00X00 temperature switch lead wire from the engine coolant pump.
Page 196: Cleaning And Inspection
COOLING SYSTEM Engine Coolant Pump ■ Water temperature sensor Cleaning and Inspection 1. Inspect the water temperature sensor to make ■ Temperature switch sure that it is properly operating. As shown in the following figure, connect an electric resistor 1. Check for proper operation of the temperature to the coupler of the water temperature sensor switch.
Page 197: Radiator Cap
Engine Coolant Pump COOLING SYSTEM ■ Thermostat Reassembly of Engine Coolant Pump 1. Check for proper operation of the thermostat. 1. Reinstall the thermostat (Figure 8-13, (1)) and Place the thermostat (Figure 8-11, (1)) and an a new O-ring. accurate thermometer (Figure 8-11, (2)) in warm water.
Page 198: Installation Of Engine Coolant Pump
COOLING SYSTEM Engine Coolant Pump Installation of Engine Coolant Pump 1. Position the engine coolant pump on the engine and install a new gasket. Install a new special O-ring (Figure 8-13, (5)) on assembly between the engine coolant pump and the joint. NOTICE Use a new special O-ring between the engine K0000584...
Page 199: Lubrication System
Oil Pump Service Information............9-4 Lubrication System Diagram ............9-6 Checking Engine Oil Pressure ............9-7 Oil Pump Components ..............9-7 3TNV88C, 3TNV86CT, 4TNV88C, 4TNV86CT ......9-7 Disassembly of Oil Pump ............9-7 Cleaning and Inspection ............9-8 Reassembly of Oil Pump ............9-9 4TNV98C, 4TNV98CT (Trochoid Oil Pump)......
Page 200 LUBRICATION SYSTEM This Page Intentionally Left Blank TNV Tier 4 Service Manual...
Page 201: Before You Begin Servicing
Safety section on page 3-1. INTRODUCTION This section of the Service Manual describes the procedures necessary to service the 3TNV88C to 4TNV86CT and 4TNV98C/4TNV98CT Trochoid oil pumps. See Replace engine oil and engine oil filter on page 5-14 for engine oil and engine oil filter replacement procedures.
Page 202: Oil Pump Service Information
4TNV98CT (3.0 - 4.0 kgf/cm ■ Outer rotor outside clearance Reference Model Standard Limit page Check outer 3TNV88C, 3TNV86CT, 0.0035 - 0.0059 in. 0.0098 in. rotor outside 4TNV88C, 4TNV86CT (0.09 - 0.15 mm) (0.25 mm) clearance on page 9-8 Check outer 0.0039 - 0.0061 in.
Page 203 Inspection item Standard Limit page 0.3945 - 0.3952 in. 0.3962 in. Plate bearing I.D. (10.020 - 10.038 mm) (10.063 mm) 3TNV88C, Check rotor 3TNV86CT, 0.3928 - 0.3932 in. 0.3922 in. shaft Rotor shaft O.D. 4TNV88C, (9.978 - 9.987 mm) (9.963 mm)
Page 204: 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 Idle gear Camshaft Crank Oil pump bearing journal shaft Piston cooling Rocker arm Crank pin Oil suction pipe...
Page 205: Checking Engine Oil Pressure
LUBRICATION SYSTEM CHECKING ENGINE OIL OIL PUMP COMPONENTS PRESSURE 3TNV88C, 3TNV86CT, 4TNV88C, Perform an engine oil pressure check if there is any 4TNV86CT indication of low oil pressure such as the oil The oil pump on these model engines is located in...
Page 206: Cleaning And Inspection
LUBRICATION SYSTEM Oil Pump Components Cleaning and Inspection Clean the lubricating oil pump, pressure regulator valve (Figure 9-3, (7)), and rotor inserting portion. Check the parts for wear or flaw. Replace the parts with new ones as needed. NOTICE • Never overfill the engine with engine oil. •...
Page 207: Check Outer Rotor Side Clearance
Oil Pump Components LUBRICATION SYSTEM ■ Check rotor shaft clearance Inspect the rotor shaft clearance. Measure the outside diameter of the rotor shaft (Figure 9-9, (1)) and the inside diameter of the cover. Determine the clearance by subtracting the outside diameter of the rotor from the inside diameter of the cover.
Page 208: 4Tnv98C, 4Tnv98Ct (Trochoid Oil Pump)
LUBRICATION SYSTEM Oil Pump Components Disassembly of Oil Pump NOTICE If the oil pump must be replaced, replace it as an assembly only. Do not replace individual components. Remove the engine cooling fan guard (if equipped), engine cooling fan (Figure 9-12, (3)), spacer (Figure 9-12, (2)), engine coolant pump V-pulley (Figure 9-12, (1)) and V-belt.
Page 209: Cleaning And Inspection
Oil Pump Components LUBRICATION SYSTEM Cleaning and Inspection Wash the oil pump, oil pressure regulator and oil pump cavity. Inspect for wear or damage. Replace as necessary. NOTICE If any oil pump component clearance exceeds its limit, the oil pump must be replaced as an assembly.
Page 210: Check Rotor Shaft Clearance
LUBRICATION SYSTEM Oil Pump Components ■ Check rotor shaft clearance Determine the rotor shaft clearance. Measure the outside diameter of the rotor shaft (Figure 9-17, (1)) and the bore diameter in the gear case housing (Figure 9-17, (2)). Calculate the difference between the two measurements to determine the clearance.
Page 211 Section 10 TNV Tier 4 Service Manual TURBOCHARGER Page Before You Begin Servicing ............10-3 Introduction..................10-4 Specifications ................10-4 Turbocharger Service Information ........... 10-4 Troubleshooting................10-5 Turbocharger Components ............10-7 Turbocharger Component Functions..........10-8 Theory of Operation..............10-9 Compressor Side Sealing Mechanism ........10-9 Waste Gate Modulation ............
Page 212 TURBOCHARGER This Page Intentionally Left Blank 10-2 TNV Tier 4 Service Manual...
Page 213: Before You Begin Servicing
Before You Begin Servicing TURBOCHARGER BEFORE YOU BEGIN SERVICING Before performing any service procedures within this section, read the following safety information and review the Safety section on page 3-1. TNV Tier 4 Service Manual 10-3...
Page 214: Introduction
TURBOCHARGER Introduction INTRODUCTION This section of the Service Manual describes the servicing of the RHF3, RHF4 and RHF5 model turbochargers. SPECIFICATIONS Turbocharger Service Information Applicable engine model (application) 3TNV86CT 4TNV86CT 4TNV98CT Turbocharger model RHF3 RHF4 RHF5 Turbocharger specification Standard (w/waste gate) Turbine type Radial flow Blower (compressor) type...
Page 215: Troubleshooting
Troubleshooting TURBOCHARGER 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 216 TURBOCHARGER Troubleshooting ■ Generates white smoke Cause Corrective action Clogged or deformed oil return pipe causing oil flow to the Correct the condition blower on the turbine side Excessive bearing wear causing abnormal wear or Repair the turbocharger. Send to a qualified repair damage of the seal ring facility.
Page 217: Turbocharger Components
TURBOCHARGER 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 218: Turbocharger Component Functions
TURBOCHARGER Turbocharger Component Functions TURBOCHARGER COMPONENT FUNCTIONS 20 19 18 17 16 15 14 13 12 10 9 037891-00X00 1 – Turbine side clamp 11 – Oil thrower 2 – Lock washer 12 – Compressor housing 3 – M6 hex bolt 13 –...
Page 219: Theory Of Operation
Turbocharger Component Functions TURBOCHARGER ■ Bearings Theory of Operation 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 220: 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 221: Periodic Inspection
Periodic Inspection TURBOCHARGER PERIODIC INSPECTION Inspect the turbocharger at regularly scheduled Inspection of Rotor Play intervals (for reference). To inspect the rotor, the turbocharger must be removed. Inspect for maximum rotor end play and Visual Inspection run-out limits before reinstalling. 1.
Page 222: 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. in. (mm) Standard dimension Wear limit Rotor play RHF4 RHF5 RHF4 RHF5 0.0010 - 0.0033 0.0011 - 0.0024 0.0035 0.0035...
Page 223: Waste Gate Valve Test
Periodic Inspection TURBOCHARGER Waste Gate Valve Test Waste Gate Actuator Leak Test Before reinstalling the turbocharger, verify the Allow the pressure, 17 psi (0.12 MPa; 1.2 kgf/cm operation of the waste gate valve. Poor waste gate to remain in the circuit for one minute. After one operation will adversely affect the engine minute, observe the pressure reading.
Page 224 TURBOCHARGER Periodic Inspection This Page Intentionally Left Blank 10-14 TNV Tier 4 Service Manual...
Page 225 Page Before You Begin Servicing ............11-3 Introduction..................11-4 Starter Motor Information .............. 11-4 3TNV88C to 4TNV86CT - Standard and Optional....11-4 4TNV98C and 4TNV98CT - Standard and Optional....11-4 Starter Motor Specifications ............11-5 Starter Motor Troubleshooting............11-6 Starter Motor Components ............11-7 Starter Motor .................
Page 226: Starter Motor
STARTER MOTOR This Page Intentionally Left Blank 11-2 TNV Tier 4 Service Manual...
Page 227: Before You Begin Servicing
Before You Begin Servicing STARTER MOTOR BEFORE YOU BEGIN SERVICING Before performing any service procedures within this section, read the following safety information and review the Safety section on page 3-1. TNV Tier 4 Service Manual 11-3...
Page 228: Introduction
Introduction INTRODUCTION This section of the Service Manual covers the servicing of the starter motor. YANMAR Part No. 129900- 77010 is typical equipment on 4TNV98C 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 229: Starter Motor Specifications
Starter Motor Specifications STARTER MOTOR STARTER MOTOR SPECIFICATIONS YANMAR Part No. 129900-77010 Nominal output 3.0 HP (2.3 kW) Weight 12.1 lb (5.5 kg) Revolution direction (as viewed from pinion) Clockwise Engagement system Magnetic shift Terminal voltage/current 11 V/140 A max...
Page 230: Starter Motor Troubleshooting
STARTER MOTOR Starter Motor Troubleshooting STARTER MOTOR TROUBLESHOOTING 11-6 TNV Tier 4 Service Manual...
Page 231: Starter Motor Components
Starter Motor Components STARTER MOTOR STARTER MOTOR COMPONENTS K0000103A 1 – Pinion shaft 13 – Magnetic switch assembly (solenoid) 2 – M4 bolts (3 used) 14 – Cover 3 – Bearing retainer 15 – M6 bolts (2 used) 4 – Pinion clutch assembly 16 –...
Page 232: Starter Motor
STARTER MOTOR Starter Motor STARTER MOTOR Disassembly of Starter Motor 1. Loosen the M8 nut from the magnetic switch WARNING (solenoid) assembly (Figure 11-3). Disconnect the wire from the magnetic switch. Shock Hazard! • Turn off the battery switch (if equipped) or disconnect the negative battery cable before servicing the electrical system.
Page 233 Starter Motor STARTER MOTOR 4. Pull the brush springs up using a brush spring puller. On the negative (-) side, bring the brush spring into contact with the side of the brush for lifting from the commutator surface. On the positive (+) side, remove the brush from the brush holder assembly (Figure 11-5, (1)).
Page 234: Cleaning And Inspection
STARTER MOTOR Starter Motor 10. Remove the pinion clutch assembly Cleaning and Inspection (Figure 11-9, (3)) from the bearing retainer ■ Armature assembly. 11. Using a flat-blade screwdriver, remove the Commutator surface inspection retaining ring (Figure 11-10, (1)) from the shaft If the commutator surface is rough, polish the of the pinion.
Page 235 Starter Motor STARTER MOTOR Measure commutator insulation depth Armature coil insulation test Measure the depth of the insulating material Check for continuity between a commutator (Figure 11-14, (1)) between commutator segments segment and the shaft or armature using a (Figure 11-14, (2)). If the depth measures less multimeter (Figure 11-16).
Page 236 STARTER MOTOR Starter Motor ■ Field coil Measure brush length Measure the length of the brush (Figure 11-20). Field coil continuity test Replace the brush if the length is less than the limit. Check for continuity between the field coil terminals using a multimeter (Figure 11-18).
Page 237 Starter Motor STARTER MOTOR ■ Pinion clutch assembly Series coil continuity test Check for continuity between the “S” and “M” Pinion clutch assembly inspection terminals using a multimeter (Figure 11-22). The Manually rotate the pinion clutch assembly in the multimeter should indicate continuity. drive direction (Figure 11-24).
Page 238: Reassembly Of Starter Motor
STARTER MOTOR Starter Motor 4. Apply a small amount of high temperature lithium grease (obtain locally) to the sliding portions of the shift lever (Figure 11-28, (1)). Reassemble the torsion spring (Figure 11-28, (2)), shift lever and dust cover(s) (Figure 11-28, (3)), plunger (Figure 11-28, 4) and magnetic switch assembly (Figure 11-28, (5)).
Page 239: 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 240: No-Load Test
7. Turn the switch to the ON position. Monitor the rpm, amperage draw and voltage. For test 1. Secure the starting motor in a vise or other specifications, see 3TNV88C to 4TNV86CT - suitable fixture. Standard and Optional and 4TNV98C and 2.
Page 241: 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 4-39. K0002126 Figure 11-36 3.
Page 242 STARTER MOTOR Starter Motor This Page Intentionally Left Blank 11-18 TNV Tier 4 Service Manual...
Page 243 Before You Begin Servicing ............12-3 Introduction..................12-4 Dynamo and Alternator Information ..........12-4 3TNV88C to 4TNV98CT - Standard and Optional Dynamos ..12-4 3TNV88C to 4TNV98CT - Standard and Optional Alternators ..12-4 Alternator Specifications..............12-5 Dynamo Specifications..............12-5 Alternator Troubleshooting ............
Page 244 ALTERNATOR Disassembly of Dynamo............12-19 Reassembly of Dynamo ............12-19 Installation of Dynamo............12-20 12-2 TNV Tier 4 Service Manual...
Page 245: Before You Begin Servicing
Before You Begin Servicing ALTERNATOR BEFORE YOU BEGIN SERVICING Before performing any service procedures within this section, read the following safety information and review the Safety section on page 3-1. TNV Tier 4 Service Manual 12-3...
Page 246: 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 247: Alternator Specifications
Operating range 1400 - 6600 min (rpm) Grounding characteristics Negative (-) side of circuit Current limiter Regulator (YANMAR Part No. 119653-77710) A-belt 2.56 in. (65 mm) Outside diameter of pulley Special M-belt 2.28 in. (58 mm) Belt shape Type A or type special M...
Page 248: Alternator Troubleshooting
ALTERNATOR Alternator Troubleshooting ALTERNATOR TROUBLESHOOTING 12-6 TNV Tier 4 Service Manual...
Page 249: 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. K0000255 1 –...
Page 250: Alternator Wiring Diagram
ALTERNATOR Alternator Wiring Diagram ALTERNATOR WIRING DIAGRAM 1 – Key switch 4 – Battery 2 – Charge lamp (3.4 watts maximum) 5 – Alternator assembly 3 – Load 6 – IC regulator assembly Figure 12-2 NOTICE NOTICE Do not short-circuit the charging system between Do not remove the positive (+) battery cable from alternator terminals IG and L.
Page 251: Alternator Standard Output
Alternator Standard Output ALTERNATOR ALTERNATOR STANDARD OUTPUT Output current Cold Alternator speed (× 10³ min Figure 12-3 TNV Tier 4 Service Manual 12-9...
Page 252: 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 equipped) or disconnect the negative battery cable before servicing the electrical system. •...
Page 253 Alternator ALTERNATOR 2. Remove the three bolts (Figure 12-6, (1)) 6. Remove the nut (Figure 12-7, (3)) retaining the retaining the rear cover (Figure 12-6, (2)) to the insulation bushing (Figure 12-7, (4)). Remove rear frame assembly. the insulation bushing. 7.
Page 254: Reassembly Of Alternator
ALTERNATOR Alternator 9. Remove the stator assembly (Figure 12-10, (1)) from the front frame housing. K0000260A Figure 12-11 Reassembly of Alternator K0000259A 1. If removed, reinstall the two trust washers Figure 12-10 (Figure 12-12, (3)) and bearing cover (Figure 12-12, (2)) in the rear frame housing. 10.
Page 255 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 256: Installation Of Alternator
ALTERNATOR Alternator 8. Reinstall the brush holder (Figure 12-17, (3)), Installation of Alternator 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 257: Dynamo Component Location
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. K0002140X 1 –...
Page 258: Dynamo Wiring Diagram
ALTERNATOR Dynamo Wiring Diagram DYNAMO WIRING DIAGRAM K0002137X 1 – Dynamo 4 – Charge lamp (3.4 watts maximum) 2 – Current limiter 5 – Battery 3 – Key switch 6 – Load Figure 12-21 OPERATION OF DYNAMO The dynamo consists of a series of permanent magnets that rotate around a stationary stator coil. The magnets are attached to the flywheel which is rotated via the engine cooling fan drive belt.
Page 259: Dynamo Standard Output
Dynamo Standard Output ALTERNATOR DYNAMO STANDARD OUTPUT Standard characteristics (12 V) 7 × 10 Alternator speed (min K0002138E Figure 12-22 TNV Tier 4 Service Manual 12-17...
Page 260: 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. CAUTION Testing Stator Coil Continuity Pinch Hazard! 1. Disconnect the dynamo output wire connector. Carefully rotate the alternator 2.
Page 261: Disassembly Of Dynamo
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 262: Installation Of Dynamo
ALTERNATOR Dynamo 3. Reinstall the front bearings (Figure 12-28, (5)) Installation of Dynamo 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 263: Electronic Control System
Section 13 TNV Tier 4 Service Manual ELECTRONIC CONTROL SYSTEM Page Before You Begin Servicing ............13-3 System Structure................13-4 Electronic Engine Speed Control..........13-5 Diesel Particulate Filter (DPF) ..........13-7 Troubleshooting of Electronic Control System ......13-11 Fault Detection Capability............13-11 SMARTASSIST DIRECT (SA-D)...........
Page 264 ELECTRONIC CONTROL SYSTEM This Page Intentionally Left Blank 13-2 TNV Tier 4 Service Manual...
Page 265: Before You Begin Servicing
Before You Begin Servicing ELECTRONIC CONTROL SYSTEM BEFORE YOU BEGIN SERVICING Before performing any service procedures within this section, read the following safety information and review the Safety section on page 3-1. TNV Tier 4 Service Manual 13-3...
Page 266: System Structure
ELECTRONIC CONTROL SYSTEM System Structure SYSTEM STRUCTURE YANMAR TNV engines come with the following • Engine speed control schemes systems: Droop control/Isochronous control/Low-idling speed up/High-idling speed down/Auto • Common rail system as shown in the Figure 7-1 deceleration on page 7-4.
Page 267: Electronic Engine Speed Control
System Structure ELECTRONIC CONTROL SYSTEM Electronic Engine Speed Control Isochronous control The CL series consists of isochronous design ■ Speed control engines, the speed of which is kept constant from no load to full rated load. See curves (2) in The electronically controlled engines have no Figure 13-4 below.
Page 268 ELECTRONIC CONTROL SYSTEM System Structure Auto deceleration (optional) This feature brings the running engine in low idle mode automatically when the accelerator pedal is not operated for a predetermined period of time. When the pedal is operated, i.e., the accelerator sensor is activated, the low idle mode is cancelled.
Page 269: Diesel Particulate Filter (Dpf)
DOC and collecting the PM with the SF. the SF with the accumulated ash from the DPF. The PM clogs the SF if left there and the engine Yanmar recommends to do this maintenance once performance decreases, so a means of every 3,000 operating hours.
Page 270 The ECU • Through this genuine YANMAR regeneration also controls the regeneration by performing after- method, the dilution of the lubricating oil with injection to increase the exhaust temperature.
Page 271 System Structure ELECTRONIC CONTROL SYSTEM If the DPF regeneration request lamp is lit, • Turn the DPF regeneration prohibition switch immediately conduct the stationary to “Regeneration Prohibited”. regeneration by performing the following • Raise the accelerator lever above the lowest operation.
Page 272 Replacement only, every 9000 hrs of operation. Silencer Case,DPF Maintenance is required parts Perform the cleaning every 3000 hrs of operation. Contact authorized YANMAR industrial engine dealer or distributor for the detailed information about cleaning the DPF. 044159-00EN00 Figure 13-7 Periodic maintenance interval Item...
Page 273: Troubleshooting Of Electronic Control System
• When replacing the ECU, the correction value of the old ECU need to be written to the new ECU. Be sure to contact your local YANMAR 1 – Fault indicator dealer. If the correction value is not correctly...
Page 274 Figure 13-10 NOTICE If the fault indicator lamp comes on, stop the engine immediately and contact your local YANMAR dealer. As shown in Figure 13-10, SMARTASSIST DIRECT (SA-D), Yanmar genuine diagnosis tool, is required to connect to your engine for fault diagnosis.
Page 275: Smartassist Direct (Sa-D)
DPF or sensors that affects the electronic control system. A connector is provided at an end of the harness of the driven machine so that the YANMAR genuine SMMARTASSIST DIRECT (SA-D) can be loaded with data from the ECU. See Figure 13-11 and Communication Figure 13-12.
Page 276: Replacement Of Components
ELECTRONIC CONTROL SYSTEM Replacement of Components REPLACEMENT OF COMPONENTS If any part for the electronic control system must be repaired or replaced as a result of periodic maintenance or the failure diagnosis conducted using the SMARTASSIST DIRECT, do not attempt to repair the individual device of the electronic control system.
Page 277 Replacement of Components ELECTRONIC CONTROL SYSTEM Calculation of PM sediment amount in DPF ECU calculate the PM sediment amount that is accumulated in soot filter (SF) by following 2 methods: • Method C calculates the difference between the estimated PM sediment amount that is discharged from the engine and the estimated PM sediment amount that is burned inside the SF.
Page 278 ELECTRONIC CONTROL SYSTEM Replacement of Components ■ Required processing at the CR-related parts replacement SA-D operation Bosch DENSO Replacement parts Processing DPF Processing DPF ECU rewrite ECU rewrite regeneration regeneration  *  *     Injector  ...
Page 279 Replacement of Components ELECTRONIC CONTROL SYSTEM This Page Intentionally Left Blank TNV Tier 4 Service Manual 13-17...
Page 280: Electronic Control Harness Connections
E02 0.5 REOP1 3-1.Unspecified load not to be applied on alternator l and p terminal. E22 0.5 REOP2 Not acceptable that unspecified load is applied without yanmar approval. E43 0.5 E03 0.5 TDPFI REOP3 3-2.While alternetor turns, battery terminal and b terminal not to be disconnected.
Page 281 Operations and predictable wrong operations. 7-8.Confirm that instantaneous break(more than 1ms) do not occure Under nomal operations and predictable wrong operations. 7-9.Devices with parts code are able to be supplied by yanmar. 7-10.※ marked are option. 042405-00E00 TNV Tier 4 Service Manual...
Page 282 ELECTRONIC CONTROL SYSTEM Electronic Control Harness Connections Kind Cross Wire Circuit Circuit Circuit Kind Cross Wire Circuit Circuit Circuit mark Terminal Terminal Remarks mark Terminal Terminal Remarks of wire section color mark mating tip of wire section color mark mating tip AVSS Gold AVSS...
Page 283 Electronic Control Harness Connections ELECTRONIC CONTROL SYSTEM Kind Cross Wire Circuit Circuit Circuit mark Terminal Terminal Remarks of wire section color mark mating tip AVSSX V36A AVSSX V36 twisted pair AVSSX V16A AVSSX 1.25 B00B B00B AVSSX Gold AVSSX Gold AVSSX Gold AVSSX...
Page 284 ELECTRONIC CONTROL SYSTEM Electronic Control Harness Connections Common rail system ecu Common rail system ecu Engine side Vehicle side Connector: 34566-1903 Connector: 34566-0803 Cover : 34565-0003 Cover : 34565-0003 (Molex) (Molex) V13B SEALING SEALING SEALING E20 E19 E18 E14 E13 SEALING SEALING SEALING...
Page 285: Electronic Control Harness Connections
Electronic Control Harness Connections ELECTRONIC CONTROL SYSTEM Accelerator sensor3 J1939 6195-0021 Analog reserve Dtm06-06s-e007(deutsch) Dt04-3p-e008(deutsch) (Sumitomo) 174357-2(amp) V37A M00E V17A V46A V71A V65A V51A SEALING PLUG M00D SEALING SEALING SEALING PLUG PLUG PLUG B00C Alternator b Alternator b La308 La306 Terminal cover: Accelerator sensor1 Accelerator sensor2...
Page 286 ELECTRONIC CONTROL SYSTEM Electronic Control Harness Connections This Page Intentionally Left Blank 13-24 TNV Tier 4 Service Manual...
Page 287: Electric Wiring
Section 14 TNV Tier 4 Service Manual ELECTRIC WIRING Page Electric Wiring Precautions ............14-3 Electrical Wire Resistance ............14-4 Battery Cable Resistance.............. 14-5 Electrical Wire Sizes - Voltage Drop ..........14-6 Conversion of AWG to European Standards......... 14-7 TNV Tier 4 Service Manual 14-1...
Page 288 ELECTRIC WIRING This Page Intentionally Left Blank 14-2 TNV Tier 4 Service Manual...
Page 289: Electric Wiring Precautions
Electric Wiring Precautions ELECTRIC WIRING ELECTRIC WIRING PRECAUTIONS Failure to follow these precautions may result in the failure of an electrical component and the loss of warranty coverage on that item as well as related items. Make sure that all users read and understand these precautions.
Page 290: Electrical Wire Resistance
ELECTRIC WIRING Electrical Wire Resistance ELECTRICAL WIRE RESISTANCE Metric nominal mm² Ohms/foot 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] × 12 volts = 0.6 volts. Voltage drop = Current [Amps] ×...
Page 291: Battery Cable Resistance
Battery Cable Resistance ELECTRIC WIRING BATTERY CABLE RESISTANCE Maximum total battery cable length (positive cable + negative cable + a*) 12 V 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...
Page 292: 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 amps 12 v Wire size (AWG) 24 v 14-6 TNV Tier 4 Service Manual...
Page 293: 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 294 ELECTRIC WIRING Conversion of AWG to European Standards This Page Intentionally Left Blank 14-8 TNV Tier 4 Service Manual...
Page 295: Failure Diagnosis
Section 15 TNV Tier 4 Service Manual FAILURE DIAGNOSIS Page Special Service Tools..............15-3 Tier 4 (BOSCH) Compression Inspection Procedures ....15-4 Measured Value and Troubleshooting .......... 15-6 Quick Reference Table for Troubleshooting........15-6 TNV Tier 4 Service Manual 15-1...
Page 296 FAILURE DIAGNOSIS This Page Intentionally Left Blank 15-2 TNV Tier 4 Service Manual...
Page 297: Special Service Tools
Special Service Tools FAILURE DIAGNOSIS SPECIAL SERVICE TOOLS 16mmx18/1inch (Whitworth screw thread) ø 13 For measuring compression pressure YANMAR Part No.129978-92950 Compression gauge For detailed dimensions, refer to Compression gauge adapter (129A00-92950) on page 6-22. (ø16) ø17 ø7.2 -0.1 043931-00E00...
Page 298: Tier 4 (Bosch) Compression Inspection Procedures
FAILURE DIAGNOSIS Tier 4 (BOSCH) Compression Inspection Procedures TIER 4 (BOSCH) COMPRESSION INSPECTION PROCEDURES 1. Warm up the engine. 2. Stop the engine. 3. Remove the high-pressure fuel line assembly. 4. Remove the injector harnesses (couplers) of all cylinders. 5. Remove the injector fuel return hose assembly of all cylinders. 6.
Page 299 FAILURE DIAGNOSIS ■ Standard compression pressure (reference value) Compression pressure at 250 min Deviation between Engine model cylinders Standard Limit 3TNV88C 3TNV86CT 4TNV88C 3.14 - 3.34 MPa 2.45 - 2.65 MPa 0.2 - 0.3 MPa 4TNV86CT (32 - 34 kgf/cm...
Page 300: Measured Value And Troubleshooting
FAILURE DIAGNOSIS Measured Value and 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.

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