Yanmar Engines 3TNV88C, 3TNV86CT, 4TNV88C, 4TNV86CT, 4TNV98C, 4TNV98CT Service Manual 50950137B PDF

Yanmar Engines 3TNV88C, 3TNV86CT, 4TNV88C, 4TNV86CT, 4TNV98C, 4TNV98CT Service Manual 50950137B – PDF DOWNLOAD

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Yanmar Engines 3TNV88C, 3TNV86CT, 4TNV88C, 4TNV86CT, 4TNV98C, 4TNV98CT Service Manual 50950137B – PDF DOWNLOAD

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Yanmar Engines 3TNV88C, 3TNV86CT, 4TNV88C, 4TNV86CT, 4TNV98C, 4TNV98CT Service Manual 50950137B – PDF DOWNLOAD

INTRODUCTION:

This Service Manual describes the service procedures for the TNV series engines have common rail injection system. These engines are certified by the U.S. EPA, California ARB and/or the 97/68/EC Directive for industrial use. Please use this manual for accurate, quick and safe servicing of the engine. Since the directions in this manual are for a typical engine, some specifications and components may be different from your engine.

• Refer to the documentation supplied by the optional equipment manufacturer for specific service instructions. For the replacement of some parts and troubleshooting for the TNV series engines, the YANMAR Diagnostics Tool called SMARTASSISTDirect is required.
• In addition, please read both Troubleshooting Manual and SMARTASSISTDirect Operation Manual. YANMAR products are continuously undergoing improvement. This Service Manual might not address possible field modifications to the equipment. Contact an authorized YANMAR industrial engine dealer or distributor for answers to any questions relating to field modifications.

TABLE OF CONTENTS:

Yanmar Engines 3TNV88C, 3TNV86CT, 4TNV88C, 4TNV86CT, 4TNV98C, 4TNV98CT Service Manual 50950137B – PDF DOWNLOAD

Cover………………………………………………………………………………….. 0
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
Clean EGR cooler……………………………………………………………… 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……………………………………………………… 95
Inspect turbocharger (blower wash as necessary)………………………………….. 95
Inspect, clean and test EGR valve………………………………………………. 95
Inspect and clean EGR lead valve……………………………………………….. 95
Inspect and clean soot filter of Diesel Particulate Filter (DPF)…………………… 95
Check and clean injector………………………………………………………. 95
Check and test Intake throttle valve operation…………………………………… 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
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
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
Troubleshooting of Electronic Control System…………………………………………….273
Fault Detection Capability…………………………………………………………273
SMARTASSIST DIRECT (SA-D)………………………………………………………….275
About SA-D use………………………………………………………………..275
Replacement of Components……………………………………………………………..276
Processing the DPF regeneration after the parts replacement……………………………276
Processing after the ECU replacement (when it is impossible to inherit from the old ECU)….277
Electronic Control Harness Connections………………………………………………….280
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
Engine speed and compression pressure (use for reference)……………………………..299
Measured Value and Troubleshooting……………………………………………………..300
Quick Reference Table for Troubleshooting……………………………………………….300
Failure Diagnostic List……………………………………………………………301