Yanmar Engine 2TNV70 3TNV70 • 3TNV76 3TNV82A 3TNV84 • 3TNV84T • 3TNV88 4TNV84 • 4TNV84T • 4TNV88 4TNV94L 4TNV98 • 4TNV98T 4TNV106 • 4TNV106T TNV Series Operator Manual

Description

Yanmar Engine 2TNV70 3TNV70 • 3TNV76 3TNV82A 3TNV84 • 3TNV84T • 3TNV88 4TNV84 • 4TNV84T • 4TNV88 4TNV94L 4TNV98 •4TNV98T 4TNV106 • 4TNV106T TNV Series Operator Manual

DESCRIPTION:

Yanmar Engine 2TNV70 3TNV70 • 3TNV76 3TNV82A 3TNV84 • 3TNV84T • 3TNV88 4TNV84 • 4TNV84T • 4TNV88 4TNV94L 4TNV98 • 4TNV98T 4TNV106 • 4TNV106T TNV Series Operator Manual – PDF DOWNLOAD

INTRODUCTION
TNV Operation Manual
Welcome to the world of Yanmar Engines!
Yanmar has been the leader in industrial diesel
engines for over 90 years. We developed the
world’s first practical small-sized diesel engine in
1933. Our engineers are continuously developing
new technology to keep Yanmar on the leadingedge
of the industry. The TNV engine is only one
example of the new technology we have
developed. We are committed to maintaining our
environment, and are proud of our history of
innovation, quality and respect for operator safety.
To help you enjoy your Yanmar TNV engine for
many years to come, please follow these
recommendations:
• Read and understand this Operation Manual
before you operate the machine to ensure that
you follow safe operating practices and
maintenance procedures.
• Keep this Operation Manual in a convenient
place for easy access.
• If this Operation Manual is lost or damaged,
order a new one from your authorized Yanmar
industrial engine dealer or distributor.
• Make sure this manual is transferred to
subsequent owners. This manual should be
considered a permanent part of the engine and
remain with it.
• Constant efforts are made to improve the
quality and performance of Yanmar products, so
some details included in this Operation Manual
may differ slightly from your engine. If you have
any questions about these differences, please
contact your authorized Yanmar industrial
engine dealer or distributor.
• The specifications and components (instrument
panel, fuel tank, etc.) described in this manual
may differ from ones installed on your machine.
Please refer to the manual provided by the
manufacturer of these components.

TABLE OF CONTENTS:

Yanmar Engine 2TNV70 3TNV70 • 3TNV76 3TNV82A 3TNV84 • 3TNV84T • 3TNV88 4TNV84 • 4TNV84T • 4TNV88 4TNV94L 4TNV98 • 4TNV98T 4TNV106 • 4TNV106T TNV Series Operator Manual – PDF DOWNLOAD

Yanmar Warranties……………………………………………………………………………. 7
Yanmar Limited Warranty…………………………………………………………………… 7
What is Covered by this Warranty?………………………………………………………. 7
How Long is the Warranty Period?……………………………………………………….. 7
What the Engine Owner Must Do:…………………………………………………………. 7
To Locate an Authorized Yanmar Industrial Engine…………………………………………. 8
Dealer or Distributor:………………………………………………………………… 8
What Yanmar Will Do:………………………………………………………………….. 8
What is Not Covered by this Warranty?…………………………………………………… 8
Warranty Limitations:…………………………………………………………………. 8
Warranty Modifications:……………………………………………………………….. 9
Questions:…………………………………………………………………………… 9
Customer Registration…………………………………………………………………. 9
Yanmar Co., Ltd. Limited Emission Control…………………………………………………… 10
System Warranty – USA Only………………………………………………………………… 10
Your Warranty Rights and Obligations:…………………………………………………… 10
California……………………………………………………………………….. 10
All States……………………………………………………………………….. 10
Manufacturer’s Warranty Period:………………………………………………………… 10
Warranty Coverage:……………………………………………………………………. 11
Warranted Systems / Parts Covered by this Warranty:………………………………………. 11
Exclusions:………………………………………………………………………….. 12
Owner’s Warranty Responsibilities:……………………………………………………… 12
Introduction………………………………………………………………………………… 13
Record of Ownership………………………………………………………………………. 14
Symbol Explanation……………………………………………………………………. 14
Table of Contents……………………………………………………………………………. 15
Safety……………………………………………………………………………………… 19
Safety Statements………………………………………………………………………… 19
Safety Precautions……………………………………………………………………….. 20
Before You Operate……………………………………………………………………. 20
During Operation and Maintenance……………………………………………………….. 20
Product Overview…………………………………………………………………………….. 33
Yanmar TNV Engine Features and Applications…………………………………………………. 33
Component Identification………………………………………………………………….. 34
Location of Labels……………………………………………………………………….. 36
EPA / ARB Emission Control Regulations – USA Only……………………………………………. 37
Emission Control Labels…………………………………………………………………… 37
EPA / ARB Labels……………………………………………………………………… 37
The 97/68/EC Directive Certified Engines……………………………………………………. 38
Engine Family……………………………………………………………………………. 38
Function of Major Engine Components………………………………………………………… 39
Function of Cooling System Components………………………………………………………. 41
Gauges and Indicators…………………………………………………………………….. 42
Gauges………………………………………………………………………………. 42
Indicators…………………………………………………………………………… 43
Controls………………………………………………………………………………… 44
Key Switch…………………………………………………………………………… 44
Glow Plugs…………………………………………………………………………… 45
Inlet Air Heater……………………………………………………………………… 45
Governor Lever……………………………………………………………………….. 46
Engine Stop Solenoid………………………………………………………………….. 46
Before You Operate…………………………………………………………………………… 47
Diesel Fuel……………………………………………………………………………… 51
Diesel Fuel Specifications…………………………………………………………….. 51
Additional Technical Fuel Requirements………………………………………………. 51
Bio-Diesel Fuels………………………………………………………………….. 51
Filling The Fuel Tank…………………………………………………………………. 52
Priming The Fuel System……………………………………………………………….. 54
Engine Oil………………………………………………………………………………. 56
Engine Oil Specifications……………………………………………………………… 56
Service Categories………………………………………………………………… 56
Definitions………………………………………………………………………. 56
Additional Technical Engine Oil Requirements:………………………………………… 56
Engine Oil Viscosity………………………………………………………………….. 56
Checking Engine Oil…………………………………………………………………… 56
Adding Engine Oil…………………………………………………………………….. 57
Engine Oil Capacity (Typical)………………………………………………………….. 57
Engine Coolant…………………………………………………………………………… 58
Engine Coolant Specifications………………………………………………………….. 59
Alternative Engine Coolant…………………………………………………………. 59
Additional Technical Coolant Specifications:…………………………………………. 59
Filling Radiator With Engine Coolant……………………………………………………. 60
Daily Check of the Cooling System………………………………………………………. 61
Engine Coolant Capacity (Typical)………………………………………………………. 61
Daily Checks…………………………………………………………………………….. 62
Visual Checks………………………………………………………………………… 62
Check Diesel Fuel, Engine Oil, and Engine Coolant Levels………………………………….. 62
Check Engine Speed Control…………………………………………………………….. 62
Check Operator’s Console………………………………………………………………. 63
Check Indicators……………………………………………………………………… 63
Engine Operation…………………………………………………………………………….. 65
Starting Engine………………………………………………………………………….. 71
Cold Start Device………………………………………………………………………… 73
Checking the Engine During Operation……………………………………………………….. 73
Adjust Engine Speed………………………………………………………………………. 75
Shutting Down the Engine………………………………………………………………….. 76
Periodic Maintenance…………………………………………………………………………. 77
Precautions……………………………………………………………………………… 89
The Importance of Periodic Maintenance………………………………………………….. 89
Performing Periodic Maintenance………………………………………………………… 89
The Importance of Daily Checks…………………………………………………………. 89
Keep a Log of Engine Hours and Daily Checks……………………………………………… 89
Yanmar Replacement Parts………………………………………………………………. 89
Tools Required……………………………………………………………………….. 89
Ask Your Authorized Yanmar Industrial Engine…………………………………………….. 89
Dealer or Distributor For Help…………………………………………………………. 89
Required EPA / ARB Maintenance – USA Only……………………………………………….. 90
EPA / ARB Installation Requirements – USA Only…………………………………………… 90
Tightening Fasteners………………………………………………………………….. 90
Standard Torque Chart…………………………………………………………………….. 90
Periodic Maintenance Schedule……………………………………………………………… 91
Periodic Maintenance Procedures……………………………………………………………. 93
After Initial 50 Hours of Operation…………………………………………………….. 93
Replace Engine Oil and Engine Oil Filter…………………………………………….. 93
Check and Adjust Cooling Fan V-belt…………………………………………………. 96
Every 50 Hours of Operation……………………………………………………………. 98
Drain Fuel Filter / Water Separator…………………………………………………. 98
Check Battery……………………………………………………………………..100
Every 250 Hours of Operation……………………………………………………………101
Drain Fuel Tank……………………………………………………………………101
Replace Engine Oil and Engine Oil Filter……………………………………………..102
Check and Clean Radiator Fins……………………………………………………….103
Check and Adjust Cooling Fan V-belt………………………………………………….104
Check and Adjust the Governor Lever and Engine Speed Control……………………………104
Clean Air Cleaner Element…………………………………………………………..105
Every 500 Hours of Operation……………………………………………………………106
Replace Air Cleaner Element…………………………………………………………106
Replace Fuel Filter………………………………………………………………..107
Clean Fuel Filter / Water Separator………………………………………………….109
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…………………………………………………………..114
Inspect, Clean and Test Fuel Injectors……………………………………………….114
Inspect Turbocharger (Blower Wash as Necessary) – 3TNV84T, 4TNV98T, 4TNV84T, and 4TNV106T….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……………………………………………………115
Troubleshooting………………………………………………………………………………117
Troubleshooting Chart……………………………………………………………………..117
Troubleshooting Information………………………………………………………………..120
Long Term Storage…………………………………………………………………………….121
Before You Place the Engine In Long Term Storage……………………………………………..121
Returning the Engine to Service…………………………………………………………….122
Specifications……………………………………………………………………………….123
General………………………………………………………………………………….123
Description of Model Number…………………………………………………………….123
Engine Speed Specifications…………………………………………………………….124
Engine General Specifications…………………………………………………………..124
Principal Engine Specifications…………………………………………………………….125
2TNV70……………………………………………………………………………….125
3TNV70……………………………………………………………………………….126
3TNV76……………………………………………………………………………….127
3TNV82A………………………………………………………………………………128
3TNV84……………………………………………………………………………….129
3TNV84T………………………………………………………………………………130
3TNV88……………………………………………………………………………….131
4TNV84……………………………………………………………………………….132
4TNV84T………………………………………………………………………………133
4TNV88……………………………………………………………………………….134
4TNV94L………………………………………………………………………………135
4TNV98……………………………………………………………………………….136
4TNV98T………………………………………………………………………………137
4TNV106………………………………………………………………………………138
4TNV106T……………………………………………………………………………..139

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