Yanmar TNV Series Direct Injection Engines Repair Service Manual

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This Workshop Service Repair manual PDF download for the Yanmar TNV Series Direct Injection Industrial Engines has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to fully at every opportunity.


APPLICABLE MODELS :

3TNV82A, 3TNV84, 3TNV84T, 3TNV88
3TNV82A-B, 3TNV88-B, 3TNV88-U
3TNV84T-B

4TNV84, 4TNV88, 4TNV84T
4TNV88-B, 4TNV88-U, 4TNV84T-Z

4TNV94L, 4TNV98, 4TNV98T
4TNV106, 4TNV106T
4TNV98-Z, 4TNV98-E, 4TNV98T-Z


TABLE OF CONTENTS :

Introduction
Yanmar Warranties
Safety
General Service Information
Periodic Maintenance
Engine
Fuel System
Cooling System
Lubrication System
Turbocharger
Starter Motor
Alternator
Electronic Control System
Electric Wiring


MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
Part Number : 0BTNV-U00102
Total Pages : 378


This Service / Repair / Workshop Manual PDF Download contains specs, diagrams, actual real photo illustrations, and schemes. In addition to space savings, nice thing about having completly searcheble PDF files instead of a hard-printed manual is that you can use the Search feature in your PDF reader software (Adobe Acrobat) to find just what your looking for and just print out the exact pages you need or all manual easily. This is the same manual your local dealer will use when doing a repair. This is a must for the Do-It-Yourselfer! Saving Yourself $$$$$$ In Service Repair And Maintenance Costs !!!!

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Cover
Table of Contents
Introduction
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:
Retail Purchaser Registration
Emission System Warranty
Yanmar Co., Ltd. Limited Emission Control System Warranty - USA Only
Your Warranty Rights and Obligations:
California
Manufacturer’s Warranty Period:
Warranty Coverage:
Warranted Parts:
Exclusions:
Owner’s Warranty Responsibilities:
Safety
Safety Statements
Safety Precautions
General Service Information
Component Identification
Location of Labels
Engine Nameplate (Typical)
Emission Control Regulations
EPA / ARB Regulations - USA Only
Emission Control Labels
The 97/68/EC Directive Certified Engines
Engine Family
Function of Major Engine Components
MAIN ELECTRONIC CONTROL COMPONENTS AND FEATURES
Function of Cooling System Components
Diesel Fuel
Diesel Fuel Specifications
Additional Technical Fuel Requirements
Bio-Diesel Fuels
KIT PARTS LIST FOR B20 (TNV DI Engines)
Filling The Fuel Tank
Priming the Fuel System
Engine Oil
Engine Oil Specifications
Service Categories
Definitions
Additional Technical Engine Oil Requirements:
Engine Oil Viscosity
Checking Engine Oil
Adding Engine Oil
Engine Oil Capacity (Typical)
Engine Coolant
Engine Coolant Specifications
Additional Technical Coolant Specifications:
Alternative Engine Coolant
Filling Radiator with Engine Coolant
Engine Coolant Capacity (Typical)
Specifications
Description of Model Number
Engine Speed Specifications
Principal Engine Specifications
3TNV82A (~ EPA Tier2)
Engine Service Standards
Tightening Torques for Standard Bolts and Nuts
Abbreviations and Symbols
Abbreviations
Symbols
Unit Conversions
Unit Prefixes
Units of Length
Units of Volume
Units of Mass
Units of Force
Units of Torque
Units of Pressure
Units of Power
Units of Temperature
Periodic Maintenance
Before You Begin Servicing
Introduction
The Importance of Periodic Maintenance
Performing Periodic Maintenance
Yanmar Replacement Parts
Required EPA / ARB Maintenance - USA Only
EPA / ARB Installation Requirements - USA Only
Periodic Maintenance Schedule
Periodic Maintenance Procedures
After Initial 50 Hours of Operation
Replace Engine Oil and Engine Oil Filter
Check and Adjust Cooling Fan V-Belt
Every 50 Hours of Operation
Drain Fuel Filter / Water Separator
Check Battery
Every 250 Hours of Operation
Drain Fuel Tank
Replace Engine Oil and Engine Oil Filter
Check and Clean Radiator Fins
Check and Adjust Cooling Fan V-Belt
Check and Adjust the Governor Lever and Engine Speed Control (This does not apply to the following electronically controlled engines: 4TNV84T-Z, 4TNV98-E, Z, and 4TNV98T-Z.)
Clean Air Cleaner Element
Every 500 Hours of Operation
Replace Air Cleaner Element
Replace Fuel Filter
Clean Fuel Filter / Water Separator
Every 1000 Hours of Operation
Drain, Flush and Refill Cooling System With New Coolant
Adjust Intake / Exhaust Valve Clearance
Every 1500 Hours of Operation
Inspect, Clean and Test Fuel Injectors
Clean EGR Cooler 4TNV84T-Z, 4TNV98T-Z
Inspect Crankcase Breather System
Every 2000 Hours of Operation
Check and Replace Fuel Hoses and Engine Coolant Hoses
Lap the Intake and Exhaust Valves
Every 3000 Hours of Operation
Inspect Turbocharger (Blower Wash as Necessary) - 3TNV84T, 4TNV98T, 4TNV84T, and 4TNV106T, 3TNV84T-Z, 4TNV84T-Z, 4TNV98T-Z
Inspect, Clean and Test EGR Valve 4TNV84T-Z, 4TNV98T-E, 4TNV98-Z, 4TNV98T-Z
Inspect and Clean EGR Lead Valve 4TNV84T-Z, 4TNV98T-Z
Engine
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
Connecting Rod Small End
Connecting Rod Big End
Tappet
Cylinder Block Specifications
Cylinder Block
Special Torque Chart
Torque for Bolts and Nuts
Special Service Tools
Measuring Instruments
2-Valve Cylinder Head
2-Valve Cylinder Head Components
Components of a two-valve cylinder head
Disassembly of 2-Valve Cylinder Head
Removing the glow plugs
Removal of Valve Cover
Removal of Rocker Arm Assembly
Disassembly of Rocker Arm Assembly
Removal of Cylinder Head
Removal of Intake / Exhaust Valves
Removal of Valve Guides
Cleaning of Cylinder Head Components
Inspection of Cylinder Head Components
Inspection of Push Rods
Inspection of Rocker Arm Assembly
Inspection of Valve Guides
Inspection of Cylinder Head
Inspection of Intake and Exhaust Valves
Inspection of Valve Springs
Reassembly of Cylinder Head
Reassembly of Valve Guides
Reassembly of Intake and Exhaust Valves
Reassembly of Cylinder Head
Reassembly of Rocker Arm Reassembly
Reassembly of the Valve Cover
4-Valve Cylinder Head
4-Valve Cylinder Head Components
Disassembly of 4-Valve Cylinder Head
Removal of Valve Cover
Removal of Rocker Arm Assembly
Disassembly of Rocker Arm Assembly
Removal of Cylinder Head
Removal of Intake and Exhaust Valves
Removal of Valve Guides
Cleaning of Cylinder Head Components
Inspection of Cylinder Head Components
Inspection of Push Rods
Inspection of Rocker Arm Assembly
Inspection of Valve Guides
Inspection of Cylinder Head
Inspection of Intake and Exhaust Valves
Inspection of Valve Springs
Inspection of Valve Bridges
Reassembly of Cylinder Head
Reassembly of Valve Guides
Reassembly of Intake and Exhaust Valves
Reassembly of Cylinder Head
Reassembly of Rocker Arm Assembly
Reassembly of the Valve Cover
Measuring and Adjusting Valve Clearance
2-Valve Cylinder Heads
4-Valve Cylinder Heads
Crankshaft and Camshaft Components
Disassembly of Engine
Disassembly of Camshaft and Timing Components
Removal of Timing Gear Case Cover
Checking Timing Gear Backlash
Measuring Idler Gear-to-Crankshaft Gear Backlash
Measuring Idler Gear-to-Camshaft Gear Backlash
Removal of Timing Gears
Removal of Oil Pan
Removal of Camshaft
Removal of Gear Case or Front Plate
Disassembly of Crankshaft and Piston Components
Removal of Pistons
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 Pistons, Piston Rings and Wrist Pin
Inspection of Connecting Rod
Inspection of Tappets
Inspection of Crankshaft
Inspection of Camshaft
Inspection of Camshaft Bushing and Bores
Inspection of Idler Gear and Shaft
Honing and Boring
Reassembly of Crankshaft and Piston Components
Reassembly of Pistons
Installation of Crankshaft
Installation of Pistons
Reassembly of Camshaft and Timing Components
Installation of Gear Case or Front Plate
Installation of Camshaft
Installation of Timing Gears
Installation of Gear Case Cover
Installation of Oil Pan
Final Reassembly of Engine
EGR system
EGR system
EGR system
4TNV98-E, 4TNV98-Z
4TNV84T-Z, 4TNV98T-Z
Inspecting/cleaning EGR related components
EGR Valve
EGR valve operation checks
Cleaning the EGR valves
Lead valves
Precautions for installation
EGR cooler
EGR pipe and other connecting elbows
Installing EGR related components/parts
Fuel System
Before You Begin Servicing
Introduction
Fuel Injection Pump
Stop Solenoid
Cold Start Device
Trochoid Fuel Pump
Electronically controlled governor
Fuel System Specifications
Special Torque Chart
Test and Adjustment Specifications
Special Service Tools
Measuring Instruments
Fuel System Diagram
Fuel System Components
2-Valve Cylinder Head
4-Valve Cylinder Head
Fuel Injection Pump
Removal of Fuel Injection Pump
Installation of Fuel Injection Pump
Idle Sub Spring Adjustment
Checking and Adjusting Fuel Injection Timing
Determining the Fuel Injection Timing Specification
(6.8 X 2) = 13.6 + 4 = 17.6˚ Fuel injection Timing
Checking Fuel Injection Timing
Adjusting Fuel Injection Timing
Fuel Injectors
Removal of Fuel Injectors
2-Valve Cylinder Head
4-Valve Cylinder Head
Testing of Fuel Injectors
Disassembly and Inspection of Fuel Injectors
Adjusting Fuel Injector Pressure
Reassembly of Fuel Injectors
Installation of the Fuel Injectors
2-Valve Cylinder Head
4-Valve Cylinder Head
Fuel injection system (for a four-valve cylinder head)
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
Thermostat
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
Trochoid Oil Pump
3TNV82A to 4TNV88 Oil Pump Components
Disassembly of Oil Pump
Cleaning and Inspection
Check Outer Rotor Outside Clearance
Outer Rotor to Inner Rotor Tip Clearance
Check Outer Rotor Side Clearance
Check Inner Rotor and Gear Boss Clearance
Reassembly of Oil Pump
Trochoid Oil Pump
3TNV82A-B, 3TNV88-B, 3TNV88- U, 4TNV88-B4TNV88-U, 3TNV84T-Z, 4TNV84T-Z Oil Pump Components
Disassembly of Oil Pump
Cleaning and inspection
Check Outer Rotor Outside Clearance
Outer Rotor to Inner Rotor Tip Clearance
Check Outer Rotor Side Clearance
Check Rotor Shaft Clearance
Reassembly of Oil Pump
Trochoid Oil Pump
4TNV94L/98/106 Oil Pump Components
Disassembly of Oil Pump
Cleaning and Inspection
Check Outer Rotor Outside Clearance
Outer Rotor to Inner Rotor Tip Clearance
Check Outer Rotor Side Clearance
Check Rotor Shaft Clearance
Reassembly of Oil Pump
Turbocharger
Before You Begin Servicing
Introduction
Specifications
Turbocharger Service Information
Troubleshooting
Excessive Exhaust Smoke
Generates White Smoke
Sudden Oil Decrease
Decrease in Output
Poor (Slow) Response (Starting) of Turbocharger
Abnormal Sound or Vibration
Turbocharger Components
Turbocharger Component Functions
Theory of Operation
Turbine
Compressor
Bearings
Compressor Side Sealing Mechanism
Waste Gate Modulation
Waste Gate Control
Washing Procedure
Periodic Inspection
Visual Inspection
Inspection of Rotor Rotation
Inspection of Rotor Play
Removal of Turbocharger
Checking Rotor Play
To Check Rotor End 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
3TNV82A to 4TNV88 - 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
Armature
Field Coil
Magnetic Switch
Pinion Clutch Assembly
Reassembly of Starter Motor
Check Pinion Projection Length
No-Load Test
Installation of Starter Motor
Alternator
Before You Begin Servicing
Introduction
Dynamo and Alternator Information
3TNV82A to 4TNV106T - Standard and Optional Dynamos
3TNV82A to 4TNV106T - 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
Reassembly of Dynamo
Installation of Dynamo
ELECTRONIC CONTROL SYSTEM
Engines available with the electronic control system
Before You Begin Servicing
Introduction
ELECTRONIC CONTROL SYSTEM
Electronic control harness connections
Electric Wiring
Electric Wiring Precautions
Electrical Wire Resistance
Battery Cable Resistance
Electrical Wire Sizes - Voltage Drop
Conversion of AWG to European Standards
Failure Diagnosis
Special Service Tools
Troubleshooting By Measuring Compression Pressure
Compression Pressure Measurement Method
Measured Value and Troubleshooting
Quick Reference Table For Troubleshooting
Failure Diagnostic List
Electrical Wiring
Back Cover

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