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4 TNV Series
Yanmar 4 TNV Series User Manual
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4TNV106
4TNV106T
4TNV94L
4TNV98
4TNV98T
3TNV82A
3TNV84(T)
・
4TNV84(T)
3TNV88
・
4TNV88
2
Table of Contents
Default Chapter
11
Table of Contents
11
1 General
16
Engine Nomenclature
16
Specifications
16
Fuel Oil, Lubricating Oil and Cooling Water
29
Fuel Oil
29
Lubricating Oil
30
Cooling Water
30
Engine External Views
31
Structural Description
32
Exhaust Gas Emission Regulation
33
The Emission Standard in USA
33
Engine Identification
34
Guarantee Conditions for the EPA Emission Standard
35
2 Inspection and Adjustment
37
Periodic Maintenance Schedule
37
Periodic Inspection and Maintenance Procedure
38
Check before Daily Operation
38
Inspection after Initial 50 Hours Operation
40
Inspection Every 50 Hours
43
Inspection Every 250 Hours or 3 Months
47
Inspection Every 500 Hours or 6 Months
50
Inspection Every 1,000 Hours or One Year
52
Inspection Every 2000 Hours or 2 Years
61
Adjusting the No-Load Maximum or Minimum Speed
64
Sensor Inspection
65
Oil Pressure Switch
65
Thermo Switch
65
Water Leak Check in Cooling Water System
65
Radiator Cap Inspection
66
Thermostat Inspection
66
Adjusting Operation
67
Long Storage
67
3 Troubleshooting
68
Preparation before Troubleshooting
68
Quick Reference Table for Troubleshooting
69
Troubleshooting by Measuring Compression Pressure
72
4 Disassembly, Inspection and Reassembly of Engines
74
Complete Disassembly and Reassembly
74
Introduction
74
Special Service Tools
75
Complete Disassembly
80
Precautions before and During Reassembly
84
Adjusting Operation
84
Cylinder Head: Disassembly, Inspection and Reassembly
85
Components (2-Valve Cylinder Head)
85
Disassembly Procedure
85
Reassembly Procedure
86
Servicing Points
87
Parts Inspection and Measurement
91
Valve Seat Correction
95
Valve Guide Replacement
96
Valve Stem Seal Replacement
97
Gear Train and Camshaft
98
Components
98
Disassembly Procedure
98
Reassembly Procedure
98
Servicing Points
99
Parts Inspection and Measurement
102
Oil Seal Replacement (Gear Case Side)
104
Camshaft Bushing Replacement
104
Cylinder Block
105
Components
105
Disassembly Procedure
105
Reassembly Procedure
105
Servicing Points
106
Parts Inspection and Measurement
110
Cylinder Bore Correction
121
Piston Pin Bushing Replacement
122
Oil Seal Replacement (Flywheel Housing Side)
122
5 Lubrication System
123
Lubrication System Diagram
123
Trochoid Pump Components
124
Disassembly(Reverse the Procedure below for Assembly)
124
Servicing Points
124
Parts Inspection and Measurement
125
Trochoid Pump Inspection and Measurement
125
6 Cooling System
127
Cooling Water System
127
Cooling Water Pump Components
127
Disassembly (Reverse the Procedure below for Assembly)
128
Servicing Points
128
7 Fuel Injection Pump/Governor
129
Introduction
129
Fuel Injection Pump
129
Fuel System Diagram
129
External View and Components
130
Disassembly Procedure
130
Assembly Procedure
131
Servicing Points
131
8 TURBOCHAGER: Disassembly, Inspection and Reassembly
133
Structure and Functions
133
Main Specifications
133
Construction
133
Structural and Functional Outline
134
Components
135
Service Standards and Tightening Torque
136
Service Standards
136
Tightening Torque
137
Periodic Inspection Procedure
138
Periodic Inspection Intervals
138
Inspection Procedure
139
Waste Gate Valve Adjustment Procedure
140
Disassembly Procedure
142
Preparation for Disassembly
142
Inspection before Disassembly
143
Disassembly
143
Washing and Inspection Procedure
145
Washing
145
Inspection Procedure
146
Reassembly Procedure
149
Preparation for Reassembly
149
Reassembly
149
Handling after Disassembly and Reassembly
152
Instructions for Turbocharger Installation
152
Troubleshooting
153
Excessively Exhaust Smoke
153
White Smoke Generation
153
Sudden Oil Decrease
154
Decrease in Output
154
Poor (Slow) Response (Starting) of Turbocharger
154
Abnormal Sound or Vibration
154
9 Starting Motor
155
For 4TNV94L/ 98
155
Specifications
155
Components
156
Troubleshooting
157
Names of Parts and Disassembly Procedure
158
Inspection and Maintenance
162
Service Standards
167
Assembly
168
Characteristic Test
170
For 4TNV106(T)
171
Specifications
171
Congiguration Drawing
171
Troubleshooting
172
Component Names and Disassembly Procedure
173
Disassembly Procedure
174
Inspection and Maintenance
182
Assembly
188
Adjustment
189
Service Standards
190
10 Alternator
191
The 40A Alternator for 3TNV84 and Other Models
191
Components
191
Specifications
192
Wiring Diagram
192
Standard Output Characteristics
193
Inspection
193
Troubleshooting
194
11 Electric Wiring
195
Electric Wiring Diagram
195
Precaution on Electric Wiring
196
Alternator
196
Starter
197
Current Limiter
198
Section Area and Resistance of Electric Wire
199
12 Service Standards
200
Engine Tuning
200
Engine Body
201
Cylinder Head
201
Gear Train and Camshaft
204
Cylinder Block
205
Lubricating Oil System (Trochoid Pump)
210
Outside Clearance of Outer Rotor
210
Side Clearance of Outer Rotor
210
Inside Clearance of Inner Rotor
210
Rotor Shaft Clearance
210
13 TIGHTENING TORQUE for BOLTS and NUTS
211
Tightening Torques for Main Bolts and Nuts
211
Tightening Torques for Standard Bolts and Nuts
212
4
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Yanmar 4 TNV Series Specifications
General
Engine Type
Diesel
Number of Cylinders
4
Fuel System
Direct injection
Cooling System
Liquid-cooled
Engine Model
4TNV
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