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Yanmar 3TNV & 4TNV Series Engine Technical Service Manual PDF
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YANMAR 3TNV82, 3TNV84, 3TNV88, 4TNV84, 4TNV88, 4TNV94, 4TNV98, 4TNV106 Engine Service Manual
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Description
YANMAR 3TNV82, 3TNV84, 3TNV88, 4TNV84, 4TNV88, 4TNV94, 4TNV98, 4TNV106 Engine Service Manual
FILE DETAILS:
YANMAR 3TNV82, 3TNV84, 3TNV88, 4TNV84, 4TNV88, 4TNV94, 4TNV98, 4TNV106 Engine Service Manual
Language : English
Pages : 378
Downloadable : Yes
File Type : PDF
Size: 25.5 MB
DESCRIPTION:
YANMAR 3TNV82, 3TNV84, 3TNV88, 4TNV84, 4TNV88, 4TNV94, 4TNV98, 4TNV106 Engine Service Manual
INTRODUCTION:
- This Service Manual describes the service procedures for the TNV series direct injection engines. These engines are certified by the US. 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 3TNV82, 3TNV84, 3TNV88, 4TNV84, 4TNV88, 4TNV94, 4TNV98, 4TNV106 Engine Service Manual
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 Back Cover...................................................................................................................................................................................378
YANMAR 3TNV82, 3TNV84, 3TNV88, 4TNV84, 4TNV88, 4TNV94, 4TNV98, 4TNV106 ENGINE SERVICE MANUAL – PDF DOWNLOAD:
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1 review for Yanmar 3TNV & 4TNV Series Engine Technical Service Manual PDF
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D Aden –
Just maybe a bit user friendlier! I was kinda confused initially before noticing ‘download’ window. Should be a bit more visible. I think. Otherwise everytning is great, I recommend!