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Yanmar Manuals
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4TNV88C
Service manual
Yanmar 4TNV88C Service Manual
Industrial
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Contents
Table of Contents
Troubleshooting
Bookmarks
Table of Contents
Table of Contents
Yanmar Warranties
YANMAR Limited Warranty
What Is Covered by this Warranty
How Long Is the Warranty Period
What the Engine Owner Must Do
To Locate an Authorized YANMAR Industrial Engine Dealer or Distributor
What YANMAR will Do
What Is Not Covered by this Warranty
Warranty Limitations
Warranty Modifications
Questions
Emission System Warranty
YANMAR Co., Ltd. Limited Emission Control System Warranty - USA Only
Your Warranty Rights and Obligations
Manufacturer's Warranty Period
Warranty Coverage
Warranted Parts
Exclusions
Owner's Warranty Responsibilities
Safety Statements
Safety Precautions
During Operation and Maintenance
Component Identification
General Service Information
Location of Labels
Engine Nameplate (Typical)
Emission Control Regulations
EPA/ARB Regulations - USA Only
Emission Control Labels
EPA/CARB Labels (Typical)
The 97/68/EC Directive Certified Engines
Engine Family
Function of Major Engine Components
Function of Cooling System Components
Main Electronic Control Components and Features
Installation Position of Sensors
Crank Rotation Sensor
Cam Speed Sensor
New Air Temperature Sensor
EGR Temperature Sensor
Intake Temperature Sensor
Fuel Temperature Sensor (Equipped on Supply Pump)
Cooling Water Temperature Sensor
Diesel Particulate Filter (DPF) Inside/Inlet, Exhaust Temperature Sensor
Rail Pressure Sensor
EGR Pressure Sensor
Diesel Particulate Filter (DPF) Differential Pressure Sensor
EGR Valve
Intake Air Throttles
Acceleration Sensor (YANMAR Standard)
Diesel Fuel
Diesel Fuel Specifications
Filling the Fuel Tank
Priming the Fuel System
Engine Oil
Engine Oil Specifications
Engine Oil Viscosity
Checking Engine Oil
Adding Engine Oil
Engine Oil Capacity (Typical)
Engine Coolant
Engine Coolant Specifications
Filling Radiator with Engine Coolant
Daily Check of the Cooling System
Engine Coolant Capacity (Typical)
Specifications
Description of Model Number
Engine General Specifications
Principal Engine Specifications
3Tnv88C
3Tnv86Ct
4Tnv88C
4Tnv86Ct
4Tnv98C
4Tnv98Ct
Set Output Listed by Rotation
Engine Service Standards
Tightening Torques for Standard Bolts and Nuts
Abbreviations and Symbols
Unit Conversions
Periodic Maintenance
Before You Begin Servicing
Introduction
The Importance of Periodic Maintenance
Performing Periodic Maintenance
YANMAR Replacement Parts
Ask Your Authorized YANMAR Industrial Engine Dealer or Distributor for Help
Required EPA/ARB Maintenance USA Only
EPA/ARB Installation Requirements USA Only
Periodic Maintenance Schedule
Periodic Maintenance Procedures
After Initial 50 Hours of Operation
Check and Adjust Cooling Fan V-Belt
Every 50 Hours of Operation
Every 250 Hours of Operation
Every 500 Hours of Operation
Replace Fuel Filter
Every 1000 Hours of Operation
Change Coolant
Adjust Intake/Exhaust Valve Clearance
Every 1500 Hours of Operation
Every 2000 Hours of Operation
Every 3000 Hours of Operation
Before You Begin Servicing
Introduction
Cylinder Head Specifications
Adjustment Specifications
Cylinder Head
Intake/Exhaust Valve and Guide
Push Rod
Rocker Arm and Shaft
Valve Spring
Camshaft and Timing Gear Train Specifications
Camshaft
Idler Gear Shaft and Bushing
Timing Gear Backlash
Crankshaft and Piston Specifications
Crankshaft
Thrust Bearing
Piston
Piston Ring
Connecting Rod
Tappet
Cylinder Block Specifications
Cylinder Block
Special Torque Chart
Torque for Bolts and Nuts
Special Service Tools
Measuring Instruments
Cylinder Head
Cylinder Head Components
Components of a Cylinder Head
Disassembly of Cylinder Head
Removing the Glow Plugs
Removal of Valve Cover
Removal of Rocker Arm Assembly
Removal of Cylinder Head
Disassembly of Rocker Arm Assembly
Removal of Intake/Exhaust Valves
Cleaning of Cylinder Head Components
Inspection of Cylinder Head Components
Inspection of Rocker Arm Assembly
Inspection of Cylinder Head
Reassembly of Cylinder Head
Reassembly of Rocker Arm Reassembly
Reassembly of the Valve Cover
Measuring and Adjusting Valve Clearance
Crankshaft and Camshaft Components
Disassembly of Engine
Disassembly of Camshaft and Timing Components
Removal of Timing Gear Case Cover
Checking Timing Gear Backlash
Removal of Timing Gears
Removal of Camshaft
Disassembly of Crankshaft and Piston Components
Removal of Crankshaft
Inspection of Crankshaft and Camshaft Components
Replacement of Crankshaft Oil Seals
Measure Crankshaft Bearing Oil Clearance
Inspection of Cylinder Block
Inspection of Connecting Rod
Inspection of Tappets
Inspection of Crankshaft
Inspection of Camshaft
Inspection of Idler Gear and Shaft
Honing and Boring
Reassembly of Crankshaft and Piston Components
Installation of Crankshaft
Reassembly of Camshaft and Timing Components
Installation of Gear Case
Installation of Camshaft
Installation of Timing Gears
Installation of Gear Case Cover
Installation of Oil Pan
Final Reassembly of Engine
EGR System
EGR System (Typical Model)
Typical Model for Turbocharger Model
Disassembly of Supply Pump
Cleaning the EGR Valves
Lead Valves
Precautions for Installation
EGR Cooler
EGR Pipe and Other Connecting Elbows
Installing EGR Related Components/Parts
Intake Throttle
Precautions for Handling the Intake Throttle
Fuel System
Before You Begin Servicing
System Structure
Fuel System Specifications
Torque Chart for Major Bolts and Nuts
Fuel System Diagram
Fuel System Components
Removal of Common Rail
Reassembly of Common Rail
Removal of Injector
Reassembly of Injector
Removal of Supply Pump
Reassembly of Supply Pump
Cooling System
Before You Begin Servicing
Introduction
Cooling System Diagram
Engine Coolant Pump Components
Engine Coolant System Check
Engine Coolant Pump
Removal of Engine Coolant Pump
Disassembly of Engine Coolant Pump
Cleaning and Inspection
Temperature Switch
Water Temperature Sensor
Radiator Cap
Reassembly of Engine Coolant Pump
Installation of Engine Coolant Pump
Lubrication System
Before You Begin Servicing
Introduction
Oil Pump Service Information
Lubrication System Diagram
Checking Engine Oil Pressure
Oil Pump Components
3Tnv88C, 3Tnv86Ct, 4Tnv88C, 4Tnv86Ct
Disassembly of Oil Pump
Cleaning and Inspection
Check Outer Rotor Outside Clearance
Outer Rotor to Inner Rotor Tip Clearance
Check Outer Rotor Side Clearance
Reassembly of Oil Pump
4TNV98C, 4TNV98CT (Trochoid Oil Pump)
Disassembly of Oil Pump
Cleaning and Inspection
Check Rotor Shaft Clearance
Reassembly of Oil Pump
Before You Begin Servicing
Introduction
Specifications
Turbocharger Service Information
Troubleshooting
Turbocharger Components
Turbocharger Component Functions
Theory of Operation
Compressor Side Sealing Mechanism
Waste Gate Modulation
Washing Procedure
Periodic Inspection
Visual Inspection
Inspection of Rotor Rotation
Inspection of Rotor Play
Removal of Turbocharger
Checking Rotor Play
To Check Rotor Run-Out
Waste Gate Valve Test
Waste Gate Actuator Leak Test
Installation of Turbocharger
Starter Motor
Before You Begin Servicing
Introduction
Starter Motor Information
3TNV88C to 4TNV86CT - Standard and Optional
4TNV98C and 4TNV98CT - Standard and Optional
Starter Motor Specifications
Starter Motor Troubleshooting
Starter Motor Components
Starter Motor
Removal of Starter Motor
Disassembly of Starter Motor
Cleaning and Inspection
Reassembly of Starter Motor
Check Pinion Projection Length
No-Load Test
Installation of Starter Motor
Before You Begin Servicing
Introduction
Dynamo and Alternator Information
3TNV88C to 4TNV98CT - Standard and Optional Dynamos
3TNV88C to 4TNV98CT - Standard and Optional Alternators
Alternator Specifications
Dynamo Specifications
Alternator Troubleshooting
Alternator Components
Alternator Wiring Diagram
Alternator Standard Output
Alternator
Removal of Alternator
Disassembly of Alternator
Reassembly of Alternator
Installation of Alternator
Dynamo Component Location
Dynamo Wiring Diagram
Operation of Dynamo
Dynamo Standard Output
Testing of Dynamo
Testing Stator Coil Continuity
Testing Stator Coil Short-To-Ground
Testing Dynamo Regulated Output
Dynamo
Removal of Dynamo
Disassembly of Dynamo
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0BTN4-G00201
PRINTED IN JAPAN
SERVICE MANUAL
INDUSTRIAL ENGINES
3TNV88C
3TNV86CT
4TNV88C
4TNV86CT
4TNV98C
4TNV98CT
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Table of Contents
Troubleshooting
Troubleshooting
215
Starter Motor Troubleshooting
230
Alternator Troubleshooting
248
Troubleshooting of Electronic Control System
273
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