Related Manuals for Yanmar 4TNV86CT
Summarization of Contents
YANMAR WARRANTIES
YANMAR Limited Warranty
Details the warranty coverage, period, and owner's responsibilities for YANMAR engines.
Emission System Warranty
Outlines the warranty coverage for engine emission control systems, including specific periods and parts.
SAFETY
Safety Statements
Explains the meaning of DANGER, WARNING, CAUTION, and NOTICE symbols for hazard identification.
Safety Precautions
Provides critical safety guidelines for operation and maintenance, covering hazards like pressure, scalds, and explosions.
GENERAL SERVICE INFORMATION
Component Identification
Illustrates and lists the location of major engine components for various models.
Function of Major Engine Components
Describes the function of key engine components such as the air cleaner, alternator, and fuel filter.
Main Electronic Control Components and Features
Details the components of the electronic control system, including the controller, sensors, and actuators.
Diesel Fuel
Covers diesel fuel specifications, technical requirements, and precautions for its use, including bio-diesel.
Engine Oil
Provides specifications for engine oil, viscosity selection, and additional technical requirements for optimal performance.
Engine Coolant
Details engine coolant specifications, handling precautions, and capacity requirements for the cooling system.
PERIODIC MAINTENANCE
Before You Begin Servicing
Advises on safety precautions and information review before commencing any service procedures.
Periodic Maintenance Schedule
Summarizes maintenance items and their intervals, serving as a guideline for regular upkeep.
Periodic Maintenance Procedures
Provides step-by-step instructions for performing periodic maintenance tasks at specified intervals.
ENGINE
Cylinder Head Specifications
Lists key dimensions and tolerances for cylinder head components like valves, guides, and seats.
Special Torque Chart
Details specific torque values for critical bolts and nuts used in engine assembly and disassembly.
Cylinder Head
Explains the components of the cylinder head and provides procedures for its disassembly and reassembly.
Crankshaft and Camshaft Components
Illustrates and lists components related to the crankshaft and camshaft, including their specifications.
EGR System
Describes the Exhaust Gas Recirculation (EGR) system, its components, and typical models.
FUEL SYSTEM
System Structure
Outlines the overall structure of the fuel system, including common rail, injectors, and ECU interaction.
Fuel System Specifications
Provides specifications for fuel system components, including torque charts for major bolts and nuts.
Fuel System Components
Details and illustrates the various components that make up the fuel system for the engine.
COOLING SYSTEM
Cooling System Diagram
Illustrates the flow of coolant through the engine, including the radiator, pump, and thermostat.
Engine Coolant Pump Components
Lists and illustrates the individual components of the engine coolant pump assembly.
Engine Coolant Pump
Covers the removal, disassembly, cleaning, and reassembly procedures for the engine coolant pump.
LUBRICATION SYSTEM
Oil Pump Service Information
Provides specifications for engine oil pressure, rotor clearances, and shaft clearances for the oil pump.
Lubrication System Diagram
Illustrates the flow of lubricating oil through the engine's lubrication system components.
Checking Engine Oil Pressure
Details the procedure for checking the engine oil pressure and troubleshooting low pressure indications.
Oil Pump Components
Lists and illustrates the components of the engine oil pump for various engine models.
TURBOCHARGER
Troubleshooting
Identifies common turbocharger problems, their causes, and recommended corrective actions.
Turbocharger Components
Illustrates and labels the various components that make up the turbocharger assembly.
Turbocharger Component Functions
Explains the function and theory of operation for key turbocharger components.
Washing Procedure
Provides instructions for cleaning the turbocharger's compressor impeller without disassembly.
Periodic Inspection
Outlines procedures for routine inspection of the turbocharger, including visual checks and rotor play.
STARTER MOTOR
STARTER MOTOR INFORMATION
Lists specifications for standard and optional starter motors used on different engine models.
STARTER MOTOR SPECIFICATIONS
Provides detailed technical specifications for the starter motor, including output, dimensions, and component tolerances.
Starter Motor Troubleshooting
Offers a diagnostic flowchart to identify and resolve common starter motor problems.
STARTER MOTOR COMPONENTS
Illustrates and labels the individual components of the starter motor assembly.
Disassembly of Starter Motor
Details the step-by-step process for removing the starter motor from the engine.
Cleaning and Inspection
Guides through the inspection of starter motor components like armature, brushes, and coils for wear or damage.
Installation of Starter Motor
Provides instructions for reinstalling the starter motor onto the engine after service or replacement.
ALTERNATOR
Alternator Troubleshooting
Presents a flowchart for diagnosing and troubleshooting common alternator issues based on indicator behavior.
Alternator Components
Illustrates and labels the various components that constitute the alternator assembly.
Alternator Wiring Diagram
Shows the electrical connections and layout for the alternator system, including key switch and battery.
Alternator Standard Output
Displays a graph illustrating the typical output current of the alternator at varying speeds and temperatures.
Removal of Alternator
Details the procedure for safely removing the alternator from the engine, including belt and wiring disconnection.
Disassembly of Alternator
Provides a step-by-step guide for dismantling the alternator into its constituent parts for inspection.
Reassembly of Alternator
Outlines the process for correctly reassembling the alternator after disassembly and inspection.
Installation of Alternator
Covers the steps for mounting the reassembled alternator onto the engine and connecting its wiring.
Dynamo Wiring Diagram
Depicts the electrical circuit connections for the dynamo, showing its relation to the battery and load.
Testing of Dynamo
Describes tests for stator coil continuity, short-to-ground, and regulated output to check dynamo functionality.
Removal of Dynamo
Details the procedure for removing the dynamo from the engine, similar to alternator removal.
ELECTRONIC CONTROL SYSTEM
System Structure
Explains the main systems managed by the ECU, including common rail, EGR, and DPF control.
Electronic Engine Speed Control
Details how the ECU controls engine speed through various schemes like droop and isochronous control.
Diesel Particulate Filter (DPF)
Describes the DPF system, its function, regeneration processes, and maintenance requirements.
Troubleshooting of Electronic Control System
Provides guidance on detecting and diagnosing faults within the electronic control system using a fault indicator.
SMARTASSIST DIRECT (SA-D)
Explains the use of the SA-D diagnosis tool for accessing ECU data, performing tests, and managing engine parameters.
Replacement of Components
Outlines the necessary procedures, including DPF regeneration, after replacing electronic control system components.
ELECTRIC WIRING
Electric Wiring Precautions
Lists crucial safety precautions to prevent electrical component failure and warranty voidance.
Electrical Wire Resistance
Provides a table of wire resistances based on AWG and metric sizes for calculating voltage drop.
Battery Cable Resistance
Specifies maximum allowable battery cable lengths and resistances for different starter motor ratings.
Electrical Wire Sizes - Voltage Drop
Offers a chart to determine appropriate wire sizes based on circuit current and length to minimize voltage drop.
FAILURE DIAGNOSIS
Special Service Tools
Lists special tools required for engine diagnostics, such as compression gauges.
Tier 4 (BOSCH) Compression Inspection Procedures
Details the step-by-step process for performing compression tests on Tier 4 Bosch systems.
Measured Value and Troubleshooting
Provides a table correlating measured values with potential causes and corrective actions for engine issues.
Quick Reference Table for Troubleshooting
Summarizes common engine trouble symptoms, their causes, and recommended corrective actions for quick diagnosis.
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