Starting from:
$38
YANMAR 3TNV88C 3TNV86CT 4TNV88C 4TNV86CT 4TNV98C 4TNV98CT INDUSTRIAL ENGINES SERVICE MANUAL
YANMAR 3TNV88C 3TNV86CT 4TNV88C 4TNV86CT 4TNV98C 4TNV98CT INDUSTRIAL ENGINES SERVICE MANUAL – PDF DOWNLOAD
FILE DETAILS:
YANMAR 3TNV88C 3TNV86CT 4TNV88C 4TNV86CT 4TNV98C 4TNV98CT INDUSTRIAL ENGINES SERVICE MANUAL – PDF DOWNLOAD
Language : English
Pages : 316
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
YANMAR 3TNV88C 3TNV86CT 4TNV88C 4TNV86CT 4TNV98C 4TNV98CT INDUSTRIAL ENGINES SERVICE MANUAL – PDF DOWNLOAD
Cover............................................................................................... 1 Table of Contents................................................................................... 3 Introduction........................................................................................ 5 YANMAR Warranties................................................................................... 7 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 California.............................................................................. 12 Manufacturer’s Warranty Period:............................................................. 12 Warranty Coverage:.......................................................................... 13 Warranted Parts:............................................................................ 13 Exclusions:................................................................................. 14 Owner’s Warranty Responsibilities:.......................................................... 14 Safety.............................................................................................. 15 Safety Statements............................................................................... 17 Safety Precautions.............................................................................. 18 During Operation and Maintenance............................................................ 18 General Service Information......................................................................... 31 Component Identification........................................................................ 33 3TNV88C, 3TNV86CT, 4TNV88C, 4TNV86CT........................................................ 33 Location of Labels.............................................................................. 35 Location of labels/nameplates on common rail system engine.................................. 35 Engine Nameplate (Typical).................................................................. 36 Emission Control Regulations.................................................................... 36 EPA/ARB Regulations - USA Only.............................................................. 36 Emission Control Labels......................................................................... 36 EPA/CARB labels (Typical)................................................................... 36 EPA..................................................................................... 36 EPA and CARB............................................................................ 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 Cam Speed Sensor............................................................................ 43 New Air Temperature Sensor.................................................................. 44 EGR Temperature Sensor...................................................................... 44 Intake Temperature Sensor................................................................... 44 Cooling Water Temperature Sensor............................................................ 45 Diesel Particulate Filter (DPF) Inside/Inlet, Exhaust Temperature Sensor.................... 46 Rail Pressure Sensor........................................................................ 46 EGR Pressure Sensor......................................................................... 47 EGR Valve................................................................................... 49 Intake Air Throttles........................................................................ 50 Acceleration Sensor (YANMAR Standard)....................................................... 51 Diesel Fuel..................................................................................... 52 Diesel Fuel Specifications.................................................................. 52 Additional technical fuel requirements.................................................. 52 Precautions and concerns regarding the use of diesel fuel............................... 52 Bio-diesel fuels........................................................................ 52 Filling The Fuel Tank....................................................................... 53 Priming the Fuel System..................................................................... 54 Engine Oil...................................................................................... 55 Engine Oil Specifications................................................................... 55 Service categories...................................................................... 55 Definitions............................................................................. 55 Additional technical engine oil requirements:........................................... 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 Alternative engine coolant.............................................................. 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 Engine Service Standards........................................................................ 68 Tightening Torques for Standard Bolts and Nuts.................................................. 69 Abbreviations and Symbols....................................................................... 70 Abbreviations............................................................................... 70 Symbols..................................................................................... 70 Unit Conversions................................................................................ 71 Unit prefixes............................................................................... 71 Units of length............................................................................. 71 Units of volume............................................................................. 71 Units of mass............................................................................... 71 Units of force.............................................................................. 71 Units of torque............................................................................. 71 Units of pressure........................................................................... 71 Units of power.............................................................................. 71 Units of temperature........................................................................ 71 Periodic Maintenance................................................................................ 73 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 Maximum exhaust gas restriction shall be:............................................... 76 Periodic Maintenance Schedule................................................................... 77 Periodic Maintenance Procedures................................................................. 79 After Initial 50 Hours of Operation......................................................... 79 Replace engine oil and engine oil filter................................................ 79 Check and adjust cooling fan V-belt..................................................... 81 Every 50 Hours of Operation................................................................. 82 Drain water separator................................................................... 82 Check battery........................................................................... 84 Every 250 Hours of Operation................................................................ 85 Drain fuel tank......................................................................... 85 Replace engine oil and engine oil filter................................................ 86 Check and clean radiator fins........................................................... 87 Check and adjust cooling fan V-belt..................................................... 87 Clean air cleaner element............................................................... 87 Every 500 Hours of Operation................................................................ 88 Replace air cleaner element............................................................. 88 Replace fuel filter..................................................................... 89 Replace water separator element......................................................... 90 Every 1000 Hours of Operation............................................................... 91 Change coolant.......................................................................... 92 Adjust intake/exhaust valve clearance................................................... 92 Every 1500 Hours of Operation............................................................... 93 Inspect crankcase breather system....................................................... 93 Every 2000 Hours of Operation............................................................... 94 Check and replace fuel hoses and engine coolant hoses................................... 94 Lap the intake and exhaust valves....................................................... 94 Every 3000 Hours of Operation............................................................... 94 Inspect turbocharger (blower wash as necessary)......................................... 94 Inspect, clean and test EGR valve....................................................... 94 Inspect and clean EGR lead valve........................................................ 95 Check and clean of DPF soot filter...................................................... 95 Check and clean injector................................................................ 95 Inspect and test intake throttle valve.................................................. 95 Clean EGR cooler........................................................................ 95 Engine.............................................................................................. 97 Before You Begin Servicing...................................................................... 99 Introduction....................................................................................100 Cylinder Head Specifications....................................................................100 Adjustment Specifications...................................................................100 Cylinder Head...............................................................................100 Rocker Arm and Shaft........................................................................102 Valve Spring................................................................................102 Camshaft and Timing Gear Train Specifications...................................................103 Camshaft....................................................................................103 Timing Gear Backlash........................................................................104 Crankshaft and Piston Specifications............................................................105 Crankshaft..................................................................................105 Piston......................................................................................106 Connecting rod small end................................................................110 Connecting rod big end..................................................................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 Disassembly of rocker arm assembly......................................................125 Removal of cylinder head................................................................125 Removal of intake/exhaust valves........................................................126 Removal of valve guides.................................................................127 Cleaning of Cylinder Head Components........................................................127 Inspection of Cylinder Head Components......................................................127 Inspection of push rods.................................................................128 Inspection of rocker arm assembly.......................................................128 Inspection of valve guides..............................................................129 Inspection of cylinder head.............................................................129 Inspection of intake and exhaust valves.................................................129 Inspection of valve springs.............................................................131 Reassembly of Cylinder Head.................................................................132 Reassembly of valve guides..............................................................132 Reassembly of intake and exhaust valves.................................................132 Reassembly of cylinder head.............................................................133 Reassembly of rocker arm reassembly.....................................................134 Reassembly of the valve cover...........................................................135 Measuring and Adjusting Valve Clearance.........................................................136 3-cylinder engines..........................................................................136 4-cylinder engines..........................................................................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 Measuring idler gear-to-crankshaft gear backlash........................................141 Measuring idler gear-to-camshaft gear backlash..........................................141 Removal of timing gears.................................................................141 Removal of oil pan......................................................................142 Removal of camshaft.....................................................................142 Removal of gear case or front plate.....................................................143 Disassembly of Crankshaft and Piston Components.............................................144 Removal of pistons......................................................................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 pistons, piston rings and wrist pin.......................................148 Inspection of connecting rod............................................................150 Inspection of tappets...................................................................151 Inspection of crankshaft................................................................151 Inspection of camshaft..................................................................152 Inspection of camshaft bushing and bores................................................153 Inspection of idler gear and shaft......................................................153 Honing and Boring...........................................................................153 Reassembly of Crankshaft and Piston Components..............................................154 Reassembly of pistons...................................................................154 Installation of crankshaft..............................................................157 Installation of pistons.................................................................158 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 Disassembly of Supply Pump..................................................................166 Engine without turbocharger (3TNV88C, 4TNV88C, 4TNV98C).................................168 Engine with turbocharger (3TNV86CT, 4TNV86CT, 4TNV98CT).................................168 EGR active control......................................................................168 Cleaning the EGR Valves.....................................................................169 Exit the EGR active control.............................................................169 Precautions for cleaning................................................................169 Clean Lead Valves...........................................................................170 Precautions for Installation................................................................170 Clean 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 Supply pump.................................................................................176 Rail........................................................................................176 Injector....................................................................................176 ECU.........................................................................................177 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 Thermostat..............................................................................197 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 Engine oil pressure.........................................................................202 Outer rotor outside clearance...............................................................202 Outer rotor side clearance..................................................................202 Outer rotor to inner rotor tip clearance....................................................202 Rotor shaft clearance.......................................................................203 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 Check rotor shaft clearance.............................................................207 Reassembly of Oil Pump......................................................................207 4TNV98C, 4TNV98CT (Trochoid Oil Pump).......................................................208 Disassembly of Oil Pump.....................................................................208 Cleaning and Inspection.....................................................................209 Check outer rotor outside clearance.....................................................209 Outer rotor to inner rotor tip clearance................................................209 Check outer rotor side clearance........................................................209 Check rotor shaft clearance.............................................................210 Reassembly of Oil Pump......................................................................210 Turbocharger........................................................................................211 Before You Begin Servicing......................................................................213 Introduction....................................................................................214 Specifications..................................................................................214 Turbocharger Service Information............................................................214 Troubleshooting.................................................................................215 Excessive exhaust smoke.....................................................................215 Sudden oil decrease.........................................................................216 Decrease in output..........................................................................216 Poor (slow) response (starting) of turbocharger.............................................216 Abnormal sound or vibration.................................................................216 Turbocharger Components.........................................................................217 Turbocharger Component Functions................................................................218 Theory of Operation.........................................................................219 Turbine.................................................................................219 Compressor..............................................................................219 Bearings................................................................................219 Compressor Side Sealing Mechanism...........................................................219 Waste Gate Modulation.......................................................................219 Waste gate control......................................................................219 Washing Procedure...............................................................................220 Periodic Inspection.............................................................................221 Visual Inspection...........................................................................221 Inspection of Rotor Rotation................................................................221 Inspection of Rotor Play....................................................................221 Removal of Turbocharger.....................................................................221 To check rotor end 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.......................................................................................225 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 Armature................................................................................234 Field coil..............................................................................236 Magnetic switch.........................................................................236 Pinion clutch assembly..................................................................237 Reassembly of Starter Motor.................................................................238 Check Pinion Projection Length..............................................................239 No-Load Test................................................................................240 Installation of Starter Motor...............................................................241 Alternator..........................................................................................243 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 Speed control...........................................................................267 Engine speed curves.....................................................................267 Other engine speed control..............................................................267 Overview of Diesel Particulate Filter (DPF) regeneration control........................270 Self-regeneration.......................................................................270 Assisted regeneration...................................................................270 Reset regeneration......................................................................270 Stationary regeneration.................................................................270 Precautions for stationary regeneration.................................................271 Recovery regeneration (optional)........................................................271 Precautions for recovery regeneration...................................................271 DPF service.............................................................................272 Procedures for servicing the Diesel Particulate Filter (DPF)............................272 How to Remove and Reattach the Diesel Particulate Filter (DPF)..................................273 How to remove the soot filter (SF)..........................................................273 How to reattach the soot filter (SF)........................................................276 How to remove the DPF unit..................................................................277 How to reattach the DPF.....................................................................279 SF and DPF Maintenance Kit......................................................................282 Troubleshooting of Electronic Control System....................................................284 Fault Detection Capability..................................................................284 SMARTASSIST DIRECT (SA-D)...................................................................286 About SA-D use..........................................................................286 Replacement of Components.......................................................................287 Processing the DPF regeneration after the parts replacement.................................287 Processing after the ECU replacement (when it is impossible to inherit from the old ECU)....288 Required processing at the CR-related parts replacement.....................................289 Electronic Control Harness Connections..........................................................290 Electric Wiring.....................................................................................297 Electric Wiring Precautions.....................................................................299 Electrical Wire Resistance......................................................................300 Battery Cable Resistance........................................................................301 Electrical Wire Sizes - Voltage Drop............................................................302 Conversion of AWG to European Standards.........................................................303 Failure Diagnosis...................................................................................305 Special Service Tools...........................................................................307 Tier 4 (BOSCH) Compression Inspection Procedures................................................308 Engine speed and compression pressure (use for reference)...................................309 Measured Value and Troubleshooting..............................................................310 Quick Reference Table for Troubleshooting.......................................................310 Failure Diagnostic List.....................................................................311
More products
