Yanmar 3TNV88C 3TNV86CT 4TNV88C 4TNV86CT 4TNV98C 4TNV98CT Industrial Engines Service Manual – PDF DOWNLOAD
IMAGES PREVIEW OF THE MANUAL:
VIDEO PREVIEW OF THE MANUAL:
DESCRIPTION:
Yanmar 3TNV88C 3TNV86CT 4TNV88C 4TNV86CT 4TNV98C 4TNV98CT Industrial Engines Service Manual – PDF DOWNLOAD
FOREWORD:
This Service Manual has been developed for the exclusive use of service and repair professionals such as YANMAR authorized distributors and YANMAR authorized dealers. It is written with these professionals in mind and may not contain the necessary detail or safety statements that may be required for a non-professional to perform the service or repair properly and/or safely. Please contact an authorized YANMAR repair or service professional before working on your YANMAR product.
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 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 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
PLEASE NOTE:
- This is the SAME manual used by the dealers to troubleshoot any faults in your vehicle. This can be yours in 2 minutes after the payment is made.
- Contact us at [email protected] should you have any queries before your purchase or that you need any other service / repair / parts operators manual.
S.V