TT489
Date:
5 March 2009
Service Bulletin:
TT489
Subject:
Yanmar Tier 1 to Yanmar Tier 4i Engine Replacement
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This bulletin is available on SharePoint Info Central\ Bulletins\Service Bulletins
Summary
This bulletin provides information about replacing Yanmar Tier 1 engines with Yanmar Tier 4i engines in trailer
units.
Discussion/Background
CARB requirements make it necessary to replace a Yanmar EPA Tier 1 engine after a service life of 7 years, or
install a secondary pollution control device such as a DPF. This bulletin is meant to help service organizations
understand what is necessary to complete the engine replacement. Only the special preparations for specific
models are discussed here. The overall process of engine replacement is not addressed.
If you are attempting to replace an Izuzu engine with a Tier 4i Yanmar engine you will need Kit P/N 10-397 for SB
units or Kit P/N 10-398 for Super II units.
Required Parts
Alternator Mounting
NOTE: The alternator mounting information applies only to Model 30 units because the alternator is not mounted
on the engine on Model 50 units.
Some Tier 1 Yanmar installations include the current alternator mounting brackets and do not require a new one.
•
If the SB unit has an alternator bracket that resembles the assemblies shown in Figure 1 or Figure 2
below, it must be replaced. Order Kit P/N 90-403.
•
If the SB unit has an alternator bracket that resembles the assembly show in Figure 3, special care must
be taken.
•
o
If Item #1 in Figure 3 does not include a machined pocket on the back side of the left boss, it is an old
version and the Tier 4i water heater on the injection pump will interfere with it. Order a new bracket,
P/N 92-3870. Note that the part number was not changed when the pocket was added.
o
If Item #2 in Figure 3 is P/N 92-3866 the bottom edge is about 2 inches long and is the right one. If
Item #2 in Figure 3 is P/N 92-406, the bottom edge will be about 3.5 inches long and it will interfere
with the tubes coming off the water heater. Order P/N 92-3866 if necessary.
For Super II units order Kit P/N 90-404 (Figure 4).
Figure 1: Obsolete SB Alternator Bracket
Figure 2: Obsolete SB and Super II Alternator Bracket
2
1
2
1.
2.
Bracket P/N 92-3870
Bracket P/N 92-3866
Figure 3: Current SB Alternator Bracket
Figure 4: Current Super II Alternator Bracket
3
Throttle Solenoid
The throttle (speed) solenoid for the Tier 4i engine mounts differently and uses a different actuator rod assembly.
Order Thermo King Kit P/N 90-405 if you want to re-use the solenoid. Order Thermo King P/N 90-406 if you want
to replace the solenoid too. A photo of the mounting arrangement (Figure 5) appears in the Additional Photos and
Descriptions section on the following pages.
Engine Vibration Mounts:
Thermo King recommends replacement of the rubber vibration mounts when installing a new engine. For SB units
order Kit P/N 90-401. For Super II units order Kit P/N 90-402.
Battery Cables
Due to higher starting amperage, larger gauge battery cables are required for Tier 4i engines. Many different
battery cables were delivered with Yanmar Tier 1 engines so care must be taken when ordering cables for a
conversion. The following table will be helpful for most units. Some of the negative battery cables listed here
include the mid-cable mounting clip. If the unit has a negative battery cable without clips, you may need to find an
appropriate place in the frame to add an insert to connect the mid-cable clip. Also, be aware that the clip is a
ground connection for the cable.
Unit Type
SB Single Temp
SB Multi Temp
Super II
Single Temp
Super II
Multi Temp
Battery
Position
Internal
External
Battery Box
Internal
External
Battery Box
Internal
External
Battery Box
Internal
External
Battery Box
Positive
Battery Cable
for Post
P/N 41-6567
Negative
Battery Cable
for Post
P/N 41-6568
Positive Battery
Cable for
Threaded Stud
P/N 41-6565
Negative Battery
Cable for
Threaded Stud
P/N 41-6566
P/N 41-8506
P/N 41-8507
P/N 41-6563
P/N 41-6564
P/N 41-6567
P/N 41-6568
P/N 41-6565
P/N 41-6566
P/N 41-8506
P/N 41-8507
P/N 41-6563
P/N 41-6564
P/N 41-6571
P/N 41-6570
P/N 41-6616
P/N 41-6615
P/N 41-6612
P/N 41-6611
P/N 41-6614
P/N 41-6613
P/N 41-6738
P/N 41-6570
P/N 41-6741
P/N 41-6615
P/N 41-6739
P/N 41-6611
P/N 41-6740
P/N 41-6613
Software
The Tier 4i engine uses a different start sequence, which is controlled in the software for the microprocessor. The
update is particularly important for starting in cold weather. Contact TK customer service if you are not sure which
software upgrade is appropriate.
Wiring Brackets
Wiring brackets P/N 92-6727 and P/N 92-4990 will be needed to route wires in the engine compartment.
4
Additional Photos and Descriptions
The following photo shows the new throttle solenoid mounting bracket and actuator rod. Reuse the old solenoid if
it is working.
Also note the fuel line routing and the positive battery (starter) cable routing.
1
2
1.
Throttle Solenoid Mounting Bracket
2.
Actuator
NOTE: Reuse old solenoid if it is working.
Figure 5: New Throttle Solenoid Mounting Bracket and Actuator Rod
The following photo shows the fuel stop solenoid wire routing.
1
1.
Wiring Bracket P/N 92-4990
Figure 6: Fuel Stop Solenoid Wire Routing
5
The following photo shows wiring bracket P/N 92-6727, which attaches to the starter.
1
1.
Wiring Bracket P/N 92-6727
Figure 7: Wire Bracket Attached To Starter
The following photo shows the positive battery (starter) cable routing.
Figure 8: Positive Battery (Starter) Cable Routing
6
The following photo shows the negative battery cable routing. Make sure to coat the terminal with protectant after
attaching it to the engine.
1
1.
Negative Battery Cable Terminal Connection
Figure 9: Negative Battery Cable Routing
7
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