Yanmar Engines Electronic Control 3TNV82A-4TNV106T Service Manual 917172 04.2013 – PDF DOWNLOAD

Yanmar Engines Electronic Control 3TNV82A-4TNV106T Service Manual 917172 04.2013 – PDF DOWNLOAD

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Yanmar Engines Electronic Control 3TNV82A-4TNV106T Service Manual 917172 04.2013 – PDF DOWNLOAD

Language : English
Pages : 378
Downloadable : Yes
File Type : PDF
Size: 22.1 MB

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DESCRIPTION:

Yanmar Engines Electronic Control 3TNV82A-4TNV106T Service Manual 917172 04.2013 – PDF DOWNLOAD

3TNV82A 4TNV84T-B
3TNV82A-B 4TNV88
3TNV84 4TNV88-Z
3TNV84T 4TNV88-U
3TNV84T-Z 4TNV88-B
3TNV84T—B 4TNV94L
3TNV88 4TNV98
3TNV88-Z 4TNV98-Z
3TNV88-U 4TNV98-E
3TNV88-B 4TNV98T
4TNV84 4TNV98T-Z
4TNV84T 4TNV106
4TNV84T-Z 4TNV106T

INTRODUCTION:

This Service Manual describes the service procedures for the TNV series direct injection engines. 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. 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 Electronic Control 3TNV82A-4TNV106T Service Manual 917172 04.2013 – 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
Retail Purchaser Registration 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
General Service Information 33
Component Identification 35
Location of Labels 37
Engine Nameplate (Typical) 38
Emission Control Regulations 38
EPA / ARB Regulations – USA Only 38
Emission Control Labels 38
The 97/68/EC Directive Certified Engines 39
Engine Family 39
Function of Major Engine Components 40
MAIN ELECTRONIC CONTROL COMPONENTS AND FEATURES 41
Function of Cooling System Components 43
Diesel Fuel 44
Diesel Fuel Specifications 44
Additional Technical Fuel Requirements 44
Bio-Diesel Fuels 45
KIT PARTS LIST FOR B20 (TNV DI Engines) 47
Filling The Fuel Tank 49
Priming the Fuel System 50
Engine Oil 51
Engine Oil Specifications 51
Service Categories 51
Definitions 51
Additional Technical Engine Oil Requirements: 51
Engine Oil Viscosity 51
Checking Engine Oil 52
Adding Engine Oil 52
Engine Oil Capacity (Typical) 52
Engine Coolant 53
Engine Coolant Specifications 54
Additional Technical Coolant Specifications: 54
Alternative Engine Coolant 54
Filling Radiator with Engine Coolant 54
Engine Coolant Capacity (Typical) 55
Specifications 56
Description of Model Number 56
Engine Speed Specifications 56
Principal Engine Specifications 58
3TNV82A (~ EPA Tier2) 58
Engine Service Standards 83
Tightening Torques for Standard Bolts and Nuts 84
Abbreviations and Symbols 86
Abbreviations 86
Symbols 86
Unit Conversions 87
Unit Prefixes 87
Units of Length 87
Units of Volume 87
Units of Mass 87
Units of Force 87
Units of Torque 87
Units of Pressure 87
Units of Power 87
Units of Temperature 87
Periodic Maintenance 89
Before You Begin Servicing 91
Introduction 92
The Importance of Periodic Maintenance 92
Performing Periodic Maintenance 92
Yanmar Replacement Parts 92
Required EPA / ARB Maintenance – USA Only 92
EPA / ARB Installation Requirements – USA Only 92
Periodic Maintenance Schedule 93
Periodic Maintenance Procedures 96
After Initial 50 Hours of Operation 96
Replace Engine Oil and Engine Oil Filter 96
Check and Adjust Cooling Fan V-Belt 98
Every 50 Hours of Operation 100
Drain Fuel Filter / Water Separator 100
Check Battery 101
Every 250 Hours of Operation 103
Drain Fuel Tank 103
Replace Engine Oil and Engine Oil Filter 104
Check and Clean Radiator Fins 105
Check and Adjust Cooling Fan V-Belt 105
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 ) 105
Clean Air Cleaner Element 106
Every 500 Hours of Operation 108
Replace Air Cleaner Element 108
Replace Fuel Filter 108
Clean Fuel Filter / Water Separator 110
Every 1000 Hours of Operation 111
Drain, Flush and Refill Cooling System With New Coolant 111
Adjust Intake / Exhaust Valve Clearance 113
Every 1500 Hours of Operation 113
Inspect, Clean and Test Fuel Injectors 113
Clean EGR Cooler 4TNV84T-Z, 4TNV98T-Z 114
Inspect Crankcase Breather System 114
Every 2000 Hours of Operation 115
Check and Replace Fuel Hoses and Engine Coolant Hoses 115
Lap the Intake and Exhaust Valves 116
Every 3000 Hours of Operation 116
Inspect Turbocharger (Blower Wash as Necessary) – 3TNV84T, 4TNV98T, 4TNV84T, and 4TNV106T, 3TNV84T-Z, 4TNV84T-Z, 4TNV98T-Z 116
Inspect, Clean and Test EGR Valve 4TNV84T-Z, 4TNV98T-E, 4TNV98-Z, 4TNV98T-Z 116
Inspect and Clean EGR Lead Valve 4TNV84T-Z, 4TNV98T-Z 116
Engine 117
Before You Begin Servicing 119
Introduction 120
Cylinder Head Specifications 120
Adjustment Specifications 120
Cylinder Head 120
Intake / Exhaust Valve and Guide 121
Push Rod 123
Rocker Arm and Shaft 123
Valve Spring 124
Camshaft and Timing Gear Train Specifications 125
Camshaft 125
Idler Gear Shaft and Bushing 127
Timing Gear Backlash 127
Crankshaft and Piston Specifications 128
Crankshaft 128
Thrust Bearing 129
Piston 130
Piston Ring 132
Connecting Rod 136
Connecting Rod Small End 136
Connecting Rod Big End 136
Tappet 137
Cylinder Block Specifications 138
Cylinder Block 138
Special Torque Chart 139
Torque for Bolts and Nuts 139
Special Service Tools 142
Measuring Instruments 146
2-Valve Cylinder Head 148
2-Valve Cylinder Head Components 148
Components of a two-valve cylinder head 149
Disassembly of 2-Valve Cylinder Head 150
Removing the glow plugs 151
Removal of Valve Cover 151
Removal of Rocker Arm Assembly 152
Disassembly of Rocker Arm Assembly 152
Removal of Cylinder Head 152
Removal of Intake / Exhaust Valves 153
Removal of Valve Guides 154
Cleaning of Cylinder Head Components 154
Inspection of Cylinder Head Components 154
Inspection of Push Rods 155
Inspection of Rocker Arm Assembly 155
Inspection of Valve Guides 155
Inspection of Cylinder Head 156
Inspection of Intake and Exhaust Valves 156
Inspection of Valve Springs 158
Reassembly of Cylinder Head 158
Reassembly of Valve Guides 158
Reassembly of Intake and Exhaust Valves 159
Reassembly of Cylinder Head 160
Reassembly of Rocker Arm Reassembly 161
Reassembly of the Valve Cover 162
4-Valve Cylinder Head 163
4-Valve Cylinder Head Components 163
Disassembly of 4-Valve Cylinder Head 164
Removal of Valve Cover 166
Removal of Rocker Arm Assembly 167
Disassembly of Rocker Arm Assembly 167
Removal of Cylinder Head 168
Removal of Intake and Exhaust Valves 168
Removal of Valve Guides 169
Cleaning of Cylinder Head Components 169
Inspection of Cylinder Head Components 170
Inspection of Push Rods 170
Inspection of Rocker Arm Assembly 170
Inspection of Valve Guides 171
Inspection of Cylinder Head 171
Inspection of Intake and Exhaust Valves 172
Inspection of Valve Springs 174
Inspection of Valve Bridges 174
Reassembly of Cylinder Head 175
Reassembly of Valve Guides 175
Reassembly of Intake and Exhaust Valves 175
Reassembly of Cylinder Head 176
Reassembly of Rocker Arm Assembly 177
Reassembly of the Valve Cover 179
Measuring and Adjusting Valve Clearance 180
2-Valve Cylinder Heads 181
4-Valve Cylinder Heads 182
Crankshaft and Camshaft Components 185
Disassembly of Engine 186
Disassembly of Camshaft and Timing Components 187
Removal of Timing Gear Case Cover 187
Checking Timing Gear Backlash 187
Measuring Idler Gear-to-Crankshaft Gear Backlash 188
Measuring Idler Gear-to-Camshaft Gear Backlash 188
Removal of Timing Gears 188
Removal of Oil Pan 189
Removal of Camshaft 190
Removal of Gear Case or Front Plate 191
Disassembly of Crankshaft and Piston Components 192
Removal of Pistons 192
Removal of Crankshaft 194
Inspection of Crankshaft and Camshaft Components 196
Replacement of Crankshaft Oil Seals 196
Measure Crankshaft Bearing Oil Clearance 196
Inspection of Cylinder Block 197
Inspection of Pistons, Piston Rings and Wrist Pin 197
Inspection of Connecting Rod 199
Inspection of Tappets 199
Inspection of Crankshaft 200
Inspection of Camshaft 201
Inspection of Camshaft Bushing and Bores 201
Inspection of Idler Gear and Shaft 201
Honing and Boring 202
Reassembly of Crankshaft and Piston Components 203
Reassembly of Pistons 203
Installation of Crankshaft 206
Installation of Pistons 207
Reassembly of Camshaft and Timing Components 209
Installation of Gear Case or Front Plate 209
Installation of Camshaft 210
Installation of Timing Gears 211
Installation of Gear Case Cover 211
Installation of Oil Pan 212
Final Reassembly of Engine 213
EGR system 214
EGR system 214
EGR system 216
4TNV98-E, 4TNV98-Z 218
4TNV84T-Z, 4TNV98T-Z 218
Inspecting/cleaning EGR related components 219
EGR Valve 219
EGR valve operation checks 219
Cleaning the EGR valves 220
Lead valves 220
Precautions for installation 221
EGR cooler 221
EGR pipe and other connecting elbows 221
Installing EGR related components/parts 222
Fuel System 223
Before You Begin Servicing 225
Introduction 226
Fuel Injection Pump 226
Stop Solenoid 227
Cold Start Device 227
Trochoid Fuel Pump 228
Electronically controlled governor 228
Fuel System Specifications 229
Special Torque Chart 229
Test and Adjustment Specifications 230
Special Service Tools 231
Measuring Instruments 231
Fuel System Diagram 232
Fuel System Components 233
2-Valve Cylinder Head 233
4-Valve Cylinder Head 235
Fuel Injection Pump 237
Removal of Fuel Injection Pump 237
Installation of Fuel Injection Pump 242
Idle Sub Spring Adjustment 248
Checking and Adjusting Fuel Injection Timing 249
Determining the Fuel Injection Timing Specification 249
(6 8 X 2) = 13 6 + 4 = 17 6 Fuel injection Timing 249
Checking Fuel Injection Timing 250
Adjusting Fuel Injection Timing 253
Fuel Injectors 254
Removal of Fuel Injectors 254
2-Valve Cylinder Head 254
4-Valve Cylinder Head 255
Testing of Fuel Injectors 257
Disassembly and Inspection of Fuel Injectors 258
Adjusting Fuel Injector Pressure 259
Reassembly of Fuel Injectors 260
Installation of the Fuel Injectors 260
2-Valve Cylinder Head 260
4-Valve Cylinder Head 261
Fuel injection system (for a four-valve cylinder head) 261
Cooling System 263
Before You Begin Servicing 265
Introduction 266
Cooling System Diagram 266
Engine Coolant Pump Components 267
Engine Coolant System Check 268
Engine Coolant Pump 268
Removal of Engine Coolant Pump 268
Disassembly of Engine Coolant Pump 270
Cleaning and Inspection 270
Temperature Switch 270
Water temperature sensor 270
Thermostat 271
Radiator Cap 271
Reassembly of Engine Coolant Pump 271
Installation of Engine Coolant Pump 272
Lubrication System 275
Before You Begin Servicing 277
Introduction 278
Oil Pump Service Information 278
Lubrication System Diagram 281
Checking Engine Oil Pressure 282
Trochoid Oil Pump 282
3TNV82A to 4TNV88 Oil Pump Components 282
Disassembly of Oil Pump 283
Cleaning and Inspection 284
Check Outer Rotor Outside Clearance 284
Outer Rotor to Inner Rotor Tip Clearance 284
Check Outer Rotor Side Clearance 285
Check Inner Rotor and Gear Boss Clearance 285
Reassembly of Oil Pump 285
Trochoid Oil Pump 286
3TNV82A-B, 3TNV88-B, 3TNV88- U, 4TNV88-B4TNV88-U, 3TNV84T-Z, 4TNV84T-Z Oil Pump Components 286
Disassembly of Oil Pump 287
Cleaning and inspection 287
Check Outer Rotor Outside Clearance 287
Outer Rotor to Inner Rotor Tip Clearance 288
Check Outer Rotor Side Clearance 288
Check Rotor Shaft Clearance 288
Reassembly of Oil Pump 289
Trochoid Oil Pump 290
4TNV94L/98/106 Oil Pump Components 290
Disassembly of Oil Pump 290
Cleaning and Inspection 291
Check Outer Rotor Outside Clearance 291
Outer Rotor to Inner Rotor Tip Clearance 291
Check Outer Rotor Side Clearance 291
Check Rotor Shaft Clearance 292
Reassembly of Oil Pump 292
Turbocharger 293
Before You Begin Servicing 295
Introduction 296
Specifications 296
Turbocharger Service Information 296
Troubleshooting 297
Excessive Exhaust Smoke 297
Generates White Smoke 298
Sudden Oil Decrease 298
Decrease in Output 298
Poor (Slow) Response (Starting) of Turbocharger 298
Abnormal Sound or Vibration 298
Turbocharger Components 299
Turbocharger Component Functions 301
Theory of Operation 302
Turbine 302
Compressor 302
Bearings 302
Compressor Side Sealing Mechanism 302
Waste Gate Modulation 302
Waste Gate Control 302
Washing Procedure 303
Periodic Inspection 304
Visual Inspection 304
Inspection of Rotor Rotation 304
Inspection of Rotor Play 304
Removal of Turbocharger 304
Checking Rotor Play 305
To Check Rotor End Play: 305
To Check Rotor Run-out: 305
Waste Gate Valve Test 305
Waste Gate Actuator Leak Test 306
Installation of Turbocharger 306
Starter Motor 307
Before You Begin Servicing 309
Introduction 310
Starter Motor Information 310
3TNV82A to 4TNV88 – Standard and Optional 310
Starter Motor Specifications 312
Starter Motor Troubleshooting 313
Starter Motor Components 314
Starter Motor 315
Removal of Starter Motor 315
Disassembly of Starter Motor 315
Cleaning and Inspection 317
Armature 317
Field Coil 319
Magnetic Switch 320
Pinion Clutch Assembly 321
Reassembly of Starter Motor 322
Check Pinion Projection Length 323
No-Load Test 324
Installation of Starter Motor 325
Alternator 327
Before You Begin Servicing 329
Introduction 330
Dynamo and Alternator Information 330
3TNV82A to 4TNV106T – Standard and Optional Dynamos 330
3TNV82A to 4TNV106T – Standard and Optional Alternators 330
Alternator Specifications 331
Dynamo Specifications 331
Alternator Troubleshooting 332
Alternator Components 333
Alternator Wiring Diagram 334
Alternator Standard Output 335
Alternator 336
Removal of Alternator 336
Disassembly of Alternator 336
Reassembly of Alternator 338
Installation of Alternator 340
Dynamo Component Location 341
Dynamo Wiring Diagram 342
Operation of Dynamo 342
Dynamo Standard Output 343
Testing of Dynamo 344
Testing Stator Coil Continuity 344
Testing Stator Coil Short-to-Ground 344
Testing Dynamo Regulated Output 344
Dynamo 344
Removal of Dynamo 344
Disassembly of Dynamo 345
Reassembly of Dynamo 345
Installation of Dynamo 346
ELECTRONIC CONTROL SYSTEM 347
Engines available with the electronic control system 349
Before You Begin Servicing 349
Introduction 350
ELECTRONIC CONTROL SYSTEM 350
Electronic control harness connections 351
Electric Wiring 353
Electric Wiring Precautions 355
Electrical Wire Resistance 356
Battery Cable Resistance 357
Electrical Wire Sizes – Voltage Drop 358
Conversion of AWG to European Standards 359
Failure Diagnosis 361
Special Service Tools 363
Troubleshooting By Measuring Compression Pressure 364
Compression Pressure Measurement Method 364
Measured Value and Troubleshooting 367
Quick Reference Table For Troubleshooting 367
Failure Diagnostic List 369
Electrical Wiring 375