Yanmar 3TNV82A to 4TNV106T Industrial Engine Service Manual

Description

• Model List:
  • 3TNV82A, 3TNV82A-B, 3TNV84, 3TNV84T, 3TNV84T-B, 3TNV88, 3TNV88-B, 3TNV88-U, 4TNV84, 4TNV84T, 4TNV84T-Z, 4TNV88, 4TNV88-B, 4TNV88-U, 4TNV94L, 4TNV98, 4TNV98-Z, 4TNV98-E, 4TNV98T, 4TNV98T-Z, 4TNV106, 4TNV106T

• 1. Table of Contents
• 2. Introduction
• 3. Yanmar Warranties
• 3.1. Yanmar Limited Warranty
• 3.1.1. What is Covered by this Warranty
• 3.1.2. How Long is the Warranty Period
• 3.1.3. What the Engine Owner Must Do
• 3.1.4. To Locate an Authorized Yanmar Industrial Engine Dealer or Distributor
• 3.1.5. What Yanmar Will Do
• 3.1.6. What is Not Covered by this Warranty
• 3.1.7. Warranty Limitations
• 3.1.8. Warranty Modifications
• 3.1.9. Questions
• 3.1.10. Retail Purchaser Registration
• 3.2. Emission System Warranty
• 3.3. Yanmar Co., Ltd. Limited Emission Control System Warranty – USA Only
• 3.3.1. Your Warranty Rights and Obligations
• 3.3.2. Manufacturers Warranty Period
• 3.3.3. Warranty Coverage
• 3.3.4. Warranted Parts
• 3.3.5. Exclusions
• 3.3.6. Owners Warranty Responsibilities
• 3.4. Safety Statements
• 3.5. Safety Precautions
• 4. General Service Information
• 4.1. Component Identification
• 4.2. Location of Labels
• 4.2.1. Engine Nameplate (Typical)
• 4.3. Emission Control Regulations
• 4.3.1. EPA / ARB Regulations – USA Only
• 4.4. Emission Control Labels
• 4.5. The 97/68/EC Directive Certified Engines
• 4.6. Engine Family
• 4.7. Function of Major Engine Components
• 4.8. MAIN ELECTRONIC CONTROL COMPONENTS AND FEATURES
• 4.9. Function of Cooling System Components
• 4.10. Diesel Fuel
• 4.10.1. Diesel Fuel Specifications
• 4.10.2. Filling The Fuel Tank
• 4.10.3. Priming the Fuel System
• 4.11. Engine Oil
• 4.11.1. Engine Oil Specifications
• 4.11.2. Engine Oil Viscosity
• 4.11.3. Checking Engine Oil
• 4.11.4. Adding Engine Oil
• 4.11.5. Engine Oil Capacity (Typical)
• 4.12. Engine Coolant
• 4.12.1. Engine Coolant Specifications
• 4.12.2. Filling Radiator with Engine Coolant
• 4.12.3. Engine Coolant Capacity (Typical)
• 4.13. Specifications
• 4.13.1. Description of Model Number
• 4.13.2. Engine Speed Specifications
• 4.14. Principal Engine Specifications
• 4.14.1. NV82A ( EPA Tier2)
• 4.15. Engine Service Standards
• 4.16. Tightening Torques for Standard Bolts and Nuts
• 4.17. Abbreviations and Symbols
• 4.17.1. Abbreviations
• 4.17.2. Symbols
• 4.18. Unit Conversions
• 4.18.1. Unit Prefixes
• 4.18.2. Units of Length
• 4.18.3. Units of Volume
• 4.18.4. Units of Mass
• 4.18.5. Units of Force
• 4.18.6. Units of Torque
• 4.18.7. Units of Pressure
• 4.18.8. Units of Power
• 4.18.9. Units of Temperature
• 5. Periodic Maintenance
• 5.1. Before You Begin Servicing
• 5.2. Introduction
• 5.2.1. The Importance of Periodic Maintenance
• 5.2.2. Performing Periodic Maintenance
• 5.2.3. Yanmar Replacement Parts
• 5.2.4. Required EPA / ARB Maintenance – USA Only
• 5.2.5. EPA / ARB Installation Requirements – USA Only
• 5.3. Periodic Maintenance Schedule
• 5.4. Periodic Maintenance Procedures
• 5.4.1. After Initial 50 Hours of Operation
• 5.4.2. Every 50 Hours of Operation
• 5.4.3. Every 250 Hours of Operation
• 5.4.4. Every 500 Hours of Operation
• 5.4.5. Every 1000 Hours of Operation
• 5.4.6. Every 1500 Hours of Operation
• 5.4.7. Every 2000 Hours of Operation
• 5.4.8. Every 3000 Hours of Operation
• 5.5. Before You Begin Servicing
• 5.6. Introduction
• 5.7. Cylinder Head Specifications
• 5.7.1. Adjustment Specifications
• 5.7.2. Cylinder Head
• 5.7.3. Intake / Exhaust Valve and Guide
• 5.7.4. Push Rod
• 5.7.5. Rocker Arm and Shaft
• 5.7.6. Valve Spring
• 5.8. Camshaft and Timing Gear Train Specifications
• 5.8.1. Camshaft
• 5.8.2. Idler Gear Shaft and Bushing
• 5.8.3. Timing Gear Backlash
• 5.9. Crankshaft and Piston Specifications
• 5.9.1. Crankshaft
• 5.9.2. Thrust Bearing
• 5.9.3. Piston Ring
• 5.9.4. Connecting Rod
• 5.10. Cylinder Block Specifications
• 5.10.1. Cylinder Block
• 5.11. Special Torque Chart
• 5.11.1. Torque for Bolts and Nuts
• 5.12. Special Service Tools
• 5.13. Measuring Instruments
• 5.14. Valve Cylinder Head
• 5.14.1. Valve Cylinder Head Components
• 5.14.2. Components of a two-valve cylinder head
• 5.14.3. Disassembly of 2-Valve Cylinder Head
• 5.14.4. Cleaning of Cylinder Head Components
• 5.14.5. Inspection of Cylinder Head Components
• 5.14.6. Reassembly of Cylinder Head
• 5.15. Valve Cylinder Head
• 5.15.1. Valve Cylinder Head Components
• 5.15.2. Disassembly of 4-Valve Cylinder Head
• 5.15.3. Cleaning of Cylinder Head Components
• 5.15.4. Inspection of Cylinder Head Components
• 5.15.5. Reassembly of Cylinder Head
• 5.16. Measuring and Adjusting Valve Clearance
• 5.16.1. Valve Cylinder Heads
• 5.16.2. Valve Cylinder Heads
• 5.17. Crankshaft and Camshaft Components
• 5.17.1. Disassembly of Engine
• 5.17.2. Disassembly of Camshaft and Timing Components
• 5.17.3. Disassembly of Crankshaft and Piston Components
• 5.17.4. Inspection of Crankshaft and Camshaft Components
• 5.17.5. Honing and Boring
• 5.17.6. Reassembly of Crankshaft and Piston Components
• 5.17.7. Reassembly of Camshaft and Timing Components
• 5.17.8. Final Reassembly of Engine
• 5.18. EGR system
• 5.18.1. EGR system
• 5.18.2. EGR system
• 5.18.3. Inspecting/cleaning EGR related components
• 6. Fuel System
• 6.1. Before You Begin Servicing
• 6.2. Introduction
• 6.2.1. Fuel Injection Pump
• 6.2.2. Stop Solenoid
• 6.2.3. Cold Start Device
• 6.2.4. Trochoid Fuel Pump
• 6.2.5. Electronically controlled governor
• 6.3. Fuel System Specifications
• 6.3.1. Special Torque Chart
• 6.3.2. Test and Adjustment Specifications
• 6.4. Special Service Tools
• 6.5. Measuring Instruments
• 6.6. Fuel System Diagram
• 6.7. Fuel System Components
• 6.7.1. Valve Cylinder Head
• 6.7.2. Valve Cylinder Head
• 6.8. Fuel Injection Pump
• 6.8.1. Removal of Fuel Injection Pump
• 6.8.2. Installation of Fuel Injection Pump
• 6.9. Idle Sub Spring Adjustment
• 6.10. Checking and Adjusting Fuel Injection Timing
• 6.10.1. Determining the Fuel Injection Timing Specification
• 6.10.2. Checking Fuel Injection Timing
• 6.10.3. Adjusting Fuel Injection Timing
• 6.11. Fuel Injectors
• 6.11.1. Removal of Fuel Injectors
• 6.11.2. Testing of Fuel Injectors
• 6.11.3. Disassembly and Inspection of Fuel Injectors
• 6.11.4. Adjusting Fuel Injector Pressure
• 6.11.5. Reassembly of Fuel Injectors
• 6.11.6. Installation of the Fuel Injectors
• 7. Cooling System
• 7.1. Before You Begin Servicing
• 7.2. Introduction
• 7.3. Cooling System Diagram
• 7.4. Engine Coolant Pump Components
• 7.5. Engine Coolant System Check
• 7.6. Engine Coolant Pump
• 7.6.1. Removal of Engine Coolant Pump
• 7.6.2. Disassembly of Engine Coolant Pump
• 7.6.3. Cleaning and Inspection
• 7.6.4. Reassembly of Engine Coolant Pump
• 7.6.5. Installation of Engine Coolant Pump
• 8. Lubrication System
• 8.1. Before You Begin Servicing
• 8.2. Introduction
• 8.3. Oil Pump Service Information
• 8.4. Lubrication System Diagram
• 8.5. Checking Engine Oil Pressure
• 8.6. Trochoid Oil Pump
• 8.6.1. NV82A to 4TNV88 Oil Pump Components
• 8.6.2. Disassembly of Oil Pump
• 8.6.3. Cleaning and Inspection
• 8.6.4. Reassembly of Oil Pump
• 8.7. Trochoid Oil Pump
• 8.7.1. NV82A-B, 3TNV88-B, 3TNV88- U, 4TNV88-B4TNV88-U, 3TNV84T-Z, 4TNV84T-Z Oil Pump Components
• 8.7.2. Disassembly of Oil Pump
• 8.7.3. Cleaning and inspection
• 8.7.4. Reassembly of Oil Pump
• 8.8. Trochoid Oil Pump
• 8.8.1. NV94L/98/106 Oil Pump Components
• 8.8.2. Disassembly of Oil Pump
• 8.8.3. Cleaning and Inspection
• 8.8.4. Reassembly of Oil Pump
• 9. Turbocharger
• 9.1. Before You Begin Servicing
• 9.2. Introduction
• 9.3. Specifications
• 9.3.1. Turbocharger Service Information
• 9.4. Troubleshooting
• 9.4.1. Excessive Exhaust Smoke
• 9.4.2. Generates White Smoke
• 9.4.3. Sudden Oil Decrease
• 9.4.4. Decrease in Output
• 9.4.5. Poor (Slow) Response (Starting) of Turbocharger
• 9.4.6. Abnormal Sound or Vibration
• 9.5. Turbocharger Components
• 9.6. Turbocharger Component Functions
• 9.6.1. Theory of Operation
• 9.6.2. Compressor Side Sealing Mechanism
• 9.6.3. Waste Gate Modulation
• 9.7. Washing Procedure
• 9.8. Periodic Inspection
• 9.8.1. Visual Inspection
• 9.8.2. Inspection of Rotor Rotation
• 9.8.3. Inspection of Rotor Play
• 9.8.4. Removal of Turbocharger
• 9.8.5. Checking Rotor Play
• 9.8.6. Waste Gate Valve Test
• 9.8.7. Waste Gate Actuator Leak Test
• 9.8.8. Installation of Turbocharger
• 10. Starter Motor
• 10.1. Before You Begin Servicing
• 10.2. Introduction
• 10.3. Starter Motor Information
• 10.3.1. NV82A to 4TNV88 – Standard and Optional
• 10.4. Starter Motor Specifications
• 10.5. Starter Motor Troubleshooting
• 10.6. Starter Motor Components
• 10.7. Starter Motor
• 10.7.1. Removal of Starter Motor
• 10.7.2. Disassembly of Starter Motor
• 10.7.3. Cleaning and Inspection
• 10.7.4. Reassembly of Starter Motor
• 10.7.5. Check Pinion Projection Length
• 10.7.6. No-Load Test
• 10.7.7. Installation of Starter Motor
• 11. Alternator
• 11.1. Before You Begin Servicing
• 11.2. Introduction
• 11.3. Dynamo and Alternator Information
• 11.3.1. NV82A to 4TNV106T – Standard and Optional Dynamos
• 11.3.2. NV82A to 4TNV106T – Standard and Optional Alternators
• 11.4. Alternator Specifications
• 11.5. Dynamo Specifications
• 11.6. Alternator Troubleshooting
• 11.7. Alternator Components
• 11.8. Alternator Wiring Diagram
• 11.9. Alternator Standard Output
• 11.10. Alternator
• 11.10.1. Removal of Alternator
• 11.10.2. Disassembly of Alternator
• 11.10.3. Reassembly of Alternator
• 11.10.4. Installation of Alternator
• 11.11. Dynamo Component Location
• 11.12. Dynamo Wiring Diagram
• 11.13. Operation of Dynamo
• 11.14. Dynamo Standard Output
• 11.15. Testing of Dynamo
• 11.15.1. Testing Stator Coil Continuity
• 11.15.2. Testing Stator Coil Short-to-Ground
• 11.15.3. Testing Dynamo Regulated Output
• 11.15.4. Removal of Dynamo
• 11.15.5. Disassembly of Dynamo
• 11.15.6. Reassembly of Dynamo
• 11.15.7. Installation of Dynamo
• 12. ELECTRONIC CONTROL SYSTEM
• 12.1. Engines available with the electronic control system
• 12.2. Before You Begin Servicing
• 12.3. Introduction
• 12.4. ELECTRONIC CONTROL SYSTEM
• 12.5. Electronic control harness connections
• 13. Electric Wiring
• 13.1. Electric Wiring Precautions
• 13.2. Electrical Wire Resistance
• 13.3. Battery Cable Resistance
• 13.4. Electrical Wire Sizes – Voltage Drop
• 13.5. Conversion of AWG to European Standards
• 14. Failure Diagnosis
• 14.1. Special Service Tools
• 14.2. Troubleshooting By Measuring Compression Pressure
• 14.2.1. Compression Pressure Measurement Method
• 14.3. Quick Reference Table For Troubleshooting
• 14.3.1. Failure Diagnostic List
• 14.4. Electrical Wiring
• 15. Back Cover