Yanmar 4TNV86CT Manuals

Manuals and User Guides for Yanmar 4TNV86CT. We have 1 Yanmar 4TNV86CT manual available for free PDF download: Service Manual

Yanmar 4TNV86CT Service Manual (304 pages)

INDUSTRIAL

Brand: Yanmar | Category: Engine | Size: 47 MB

Table of Contents
7
Yanmar Warranties
8
YANMAR Limited Warranty
9
What Is Covered by this Warranty
9
How Long Is the Warranty Period
9
What the Engine Owner Must Do
9
To Locate an Authorized YANMAR Industrial Engine Dealer or Distributor
10
What YANMAR will Do
10
What Is Not Covered by this Warranty
10
Warranty Limitations
11
Warranty Modifications
11
Questions
11
Emission System Warranty
12
YANMAR Co., Ltd. Limited Emission Control System Warranty - USA Only
12
Your Warranty Rights and Obligations
12
Manufacturer's Warranty Period
12
Warranty Coverage
13
Warranted Parts
13
Exclusions
14
Owner's Warranty Responsibilities
14
Safety Statements
17
Safety Precautions
18
During Operation and Maintenance
18
Component Identification
33
General Service Information
33
Location of Labels
35
Engine Nameplate (Typical)
36
Emission Control Regulations
36
EPA/ARB Regulations - USA Only
36
Emission Control Labels
36
EPA/CARB Labels (Typical)
36
The 97/68/EC Directive Certified Engines
37
Engine Family
37
Function of Major Engine Components
38
Function of Cooling System Components
39
Main Electronic Control Components and Features
40
Installation Position of Sensors
42
Crank Rotation Sensor
43
Cam Speed Sensor
43
New Air Temperature Sensor
44
EGR Temperature Sensor
44
Intake Temperature Sensor
44
Fuel Temperature Sensor (Equipped on Supply Pump)
45
Cooling Water Temperature Sensor
45
Diesel Particulate Filter (DPF) Inside/Inlet, Exhaust Temperature Sensor
46
Rail Pressure Sensor
46
EGR Pressure Sensor
47
Diesel Particulate Filter (DPF) Differential Pressure Sensor
48
EGR Valve
49
Intake Air Throttles
50
Acceleration Sensor (YANMAR Standard)
51
Diesel Fuel
52
Diesel Fuel Specifications
52
Filling the Fuel Tank
53
Priming the Fuel System
54
Engine Oil
55
Engine Oil Specifications
55
Engine Oil Viscosity
55
Checking Engine Oil
56
Adding Engine Oil
56
Engine Oil Capacity (Typical)
56
Engine Coolant
57
Engine Coolant Specifications
58
Filling Radiator with Engine Coolant
58
Daily Check of the Cooling System
59
Engine Coolant Capacity (Typical)
59
Specifications
60
Description of Model Number
60
Engine General Specifications
60
Principal Engine Specifications
61
3Tnv88C
61
3Tnv86Ct
62
4Tnv88C
63
4Tnv86Ct
64
4Tnv98C
65
4Tnv98Ct
66
Set Output Listed by Rotation
67
Engine Service Standards
68
Tightening Torques for Standard Bolts and Nuts
69
Abbreviations and Symbols
70
Unit Conversions
71
Periodic Maintenance
74
Before You Begin Servicing
75
Introduction
76
The Importance of Periodic Maintenance
76
Performing Periodic Maintenance
76
YANMAR Replacement Parts
76
Ask Your Authorized YANMAR Industrial Engine Dealer or Distributor for Help
76
Required EPA/ARB Maintenance USA Only
76
EPA/ARB Installation Requirements USA Only
76
Periodic Maintenance Schedule
77
Periodic Maintenance Procedures
79
After Initial 50 Hours of Operation
79
Check and Adjust Cooling Fan V-Belt
81
Every 50 Hours of Operation
82
Every 250 Hours of Operation
85
Every 500 Hours of Operation
88
Replace Fuel Filter
89
Every 1000 Hours of Operation
91
Change Coolant
92
Adjust Intake/Exhaust Valve Clearance
92
Every 1500 Hours of Operation
93
Every 2000 Hours of Operation
94
Every 3000 Hours of Operation
95
Before You Begin Servicing
99
Introduction
100
Cylinder Head Specifications
100
Adjustment Specifications
100
Cylinder Head
100
Intake/Exhaust Valve and Guide
101
Push Rod
102
Rocker Arm and Shaft
102
Valve Spring
102
Camshaft and Timing Gear Train Specifications
103
Camshaft
103
Idler Gear Shaft and Bushing
104
Timing Gear Backlash
104
Crankshaft and Piston Specifications
105
Crankshaft
105
Thrust Bearing
106
Piston
106
Piston Ring
107
Connecting Rod
110
Tappet
110
Cylinder Block Specifications
111
Cylinder Block
111
Special Torque Chart
112
Torque for Bolts and Nuts
112
Special Service Tools
115
Measuring Instruments
119
Cylinder Head
121
Cylinder Head Components
121
Components of a Cylinder Head
122
Disassembly of Cylinder Head
123
Removing the Glow Plugs
124
Removal of Valve Cover
124
Removal of Rocker Arm Assembly
125
Removal of Cylinder Head
125
Disassembly of Rocker Arm Assembly
125
Removal of Intake/Exhaust Valves
126
Cleaning of Cylinder Head Components
127
Inspection of Cylinder Head Components
127
Inspection of Rocker Arm Assembly
128
Inspection of Cylinder Head
129
Reassembly of Cylinder Head
132
Reassembly of Rocker Arm Reassembly
134
Reassembly of the Valve Cover
135
Measuring and Adjusting Valve Clearance
136
Crankshaft and Camshaft Components
138
Disassembly of Engine
139
Disassembly of Camshaft and Timing Components
140
Removal of Timing Gear Case Cover
140
Checking Timing Gear Backlash
140
Removal of Timing Gears
141
Removal of Camshaft
142
Disassembly of Crankshaft and Piston Components
144
Removal of Crankshaft
146
Inspection of Crankshaft and Camshaft Components
147
Replacement of Crankshaft Oil Seals
148
Measure Crankshaft Bearing Oil Clearance
148
Inspection of Cylinder Block
148
Inspection of Connecting Rod
150
Inspection of Tappets
151
Inspection of Crankshaft
151
Inspection of Camshaft
152
Inspection of Idler Gear and Shaft
153
Honing and Boring
153
Reassembly of Crankshaft and Piston Components
154
Installation of Crankshaft
157
Reassembly of Camshaft and Timing Components
160
Installation of Gear Case
160
Installation of Camshaft
160
Installation of Timing Gears
161
Installation of Gear Case Cover
161
Installation of Oil Pan
162
Final Reassembly of Engine
163
EGR System
164
EGR System (Typical Model)
164
Typical Model for Turbocharger Model
165
Disassembly of Supply Pump
166
Cleaning the EGR Valves
169
Lead Valves
170
Precautions for Installation
170
EGR Cooler
170
EGR Pipe and Other Connecting Elbows
171
Installing EGR Related Components/Parts
171
Intake Throttle
172
Precautions for Handling the Intake Throttle
172
Fuel System
173
Before You Begin Servicing
175
System Structure
176
Fuel System Specifications
178
Torque Chart for Major Bolts and Nuts
178
Fuel System Diagram
179
Fuel System Components
180
Removal of Common Rail
181
Reassembly of Common Rail
182
Removal of Injector
183
Reassembly of Injector
184
Removal of Supply Pump
185
Reassembly of Supply Pump
186
Cooling System
189
Before You Begin Servicing
191
Introduction
192
Cooling System Diagram
192
Engine Coolant Pump Components
193
Engine Coolant System Check
194
Engine Coolant Pump
194
Removal of Engine Coolant Pump
194
Disassembly of Engine Coolant Pump
195
Cleaning and Inspection
196
Temperature Switch
196
Water Temperature Sensor
196
Radiator Cap
197
Reassembly of Engine Coolant Pump
197
Installation of Engine Coolant Pump
198
Lubrication System
199
Before You Begin Servicing
201
Introduction
201
Oil Pump Service Information
202
Lubrication System Diagram
204
Checking Engine Oil Pressure
205
Oil Pump Components
205
3Tnv88C, 3Tnv86Ct, 4Tnv88C, 4Tnv86Ct
205
Disassembly of Oil Pump
205
Cleaning and Inspection
206
Check Outer Rotor Outside Clearance
206
Outer Rotor to Inner Rotor Tip Clearance
206
Check Outer Rotor Side Clearance
207
Reassembly of Oil Pump
207
4TNV98C, 4TNV98CT (Trochoid Oil Pump)
208
Disassembly of Oil Pump
208
Cleaning and Inspection
209
Check Rotor Shaft Clearance
210
Reassembly of Oil Pump
210
Before You Begin Servicing
213
Introduction
214
Specifications
214
Turbocharger Service Information
214
Troubleshooting
215
Turbocharger Components
217
Turbocharger Component Functions
218
Theory of Operation
219
Compressor Side Sealing Mechanism
219
Waste Gate Modulation
219
Washing Procedure
220
Periodic Inspection
221
Visual Inspection
221
Inspection of Rotor Rotation
221
Inspection of Rotor Play
221
Removal of Turbocharger
221
Checking Rotor Play
222
To Check Rotor Run-Out
222
Waste Gate Valve Test
223
Waste Gate Actuator Leak Test
223
Installation of Turbocharger
223
Starter Motor
226
Before You Begin Servicing
227
Introduction
228
Starter Motor Information
228
3TNV88C to 4TNV86CT - Standard and Optional
228
4TNV98C and 4TNV98CT - Standard and Optional
228
Starter Motor Specifications
229
Starter Motor Troubleshooting
230
Starter Motor Components
231
Starter Motor
232
Removal of Starter Motor
232
Disassembly of Starter Motor
232
Cleaning and Inspection
234
Reassembly of Starter Motor
238
Check Pinion Projection Length
239
No-Load Test
240
Installation of Starter Motor
241
Before You Begin Servicing
245
Introduction
246
Dynamo and Alternator Information
246
3TNV88C to 4TNV98CT - Standard and Optional Dynamos
246
3TNV88C to 4TNV98CT - Standard and Optional Alternators
246
Alternator Specifications
247
Dynamo Specifications
247
Alternator Troubleshooting
248
Alternator Components
249
Alternator Wiring Diagram
250
Alternator Standard Output
251
Alternator
252
Removal of Alternator
252
Disassembly of Alternator
252
Reassembly of Alternator
254
Installation of Alternator
256
Dynamo Component Location
257
Dynamo Wiring Diagram
258
Operation of Dynamo
258
Dynamo Standard Output
259
Testing of Dynamo
260
Testing Stator Coil Continuity
260
Testing Stator Coil Short-To-Ground
260
Testing Dynamo Regulated Output
260
Dynamo
260
Removal of Dynamo
260
Disassembly of Dynamo
261
Reassembly of Dynamo
261
Installation of Dynamo
262
Electronic Control System
263
Before You Begin Servicing
265
System Structure
266
Electronic Engine Speed Control
267
Diesel Particulate Filter (DPF)
269
Troubleshooting of Electronic Control System
273
Fault Detection Capability
273
Smartassist Direct (Sa-D)
275
Replacement of Components
276
Electronic Control Harness Connections
280
Electronic Control Harness Connections
285
Electric Wiring
287
Electric Wiring Precautions
289
Electrical Wire Resistance
290
Battery Cable Resistance
291
Electrical Wire Sizes - Voltage Drop
292
Conversion of AWG to European Standards
293
Failure Diagnosis
295
Special Service Tools
297
Tier 4 (BOSCH) Compression Inspection Procedures
298
Measured Value and Troubleshooting
300
Quick Reference Table for Troubleshooting
300

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Yanmar 4TNV86CT Service Manual (304 pages)

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