Yanmar 3TNV88F Service Manual

SERVICE MANUAL
SERVICE MANUAL
INDUSTRIAL ENGINES
3TNV88F
0BTN4-G00400
PRINTED IN JAPAN
INDUSTRIAL ENGINES
3TNV88F
California
Proposition 65 Warning
California
Proposition 65 Warning
Diesel engine exhaust and some of its
constituents are known to the state of
California to cause cancer, birth
defects, and other reproductive harm.
Battery posts, terminals, and related
accessories contain lead and lead
compounds, chemicals known to the
state of California to cause cancer and
reproductive harm.
Wash hands after handling.
Foreword:
This Service Manual has been developed for the exclusive use of service and repair
professionals such as YANMAR authorized distributors and YANMAR authorized dealers.
It is written with these professionals in mind and may not contain the necessary detail or
safety statements that may be required for a non-professional to perform the service or
repair properly and/or safely. Please contact an authorized YANMAR repair or service
professional before working on your YANMAR product.
Head Office:
YANMAR CO., LTD.
Umeda Gate Tower 1-9 Tsurunocho, kita-ku, Osaka, Japan
http://www.yanmar.co.jp
Yanmar America Corporation
101 International Parkway
Adairsville, GA 30103, U.S.A.
TEL: +1-770-877-9894 FAX: +1-770-877-9009
http://www.yanmar.com
Yanmar Europe B.V.
Brugplein11, 1332 BS Almere -de Vaart,
The Netherlands.
TEL: +31-36-5493200 FAX: +31-36-5493209
http://www.yanmar.nl
Yanmar Asia (Singapore) Corporation Pte. Ltd.
Disclaimers:
All information, illustrations and specifications in this manual are based on the latest
information available at the time of publishing. The illustrations used in this manual are
intended as representative reference views only. Moreover, because of our continuous
product improvement policy, we may modify information, illustrations and/or specifications
to explain and/or exemplify a product, service or maintenance improvement. We reserve
the right to make any change at any time without notice. YANMAR and
are
registered trademarks of YANMAR CO., LTD. in Japan, the United States and/or other
countries.
All Rights Reserved:
No part of this publication may be reproduced or used in any form by any means graphic, electronic, or mechanical, including photocopying, recording, taping, or information storage and retrieval systems - without the written permission of YANMAR CO., LTD.
4 Tuas Lane, Singapore 638613
TEL: +65-68615077 FAX: +65-68611509
http://www.yanmar.co.jp/yasc/
Yanmar Engine (Shanghai) Corporation Ltd.
10F, E-Block POLY PLAZA, No.18 Dongfang Road,
Pudong Shanghai, CHINA P.R.C 200120
TEL: +86-21-6880-5090 FAX: +86-21-6880-8682
http://www.yanmar-sha.com
Yanmar South America Industria De Maquinas Ltda.
Av. Presidente Vargas 1400, Indaiatuba, S.P., Brazil, CEP: 13338-901
TEL: +55-19-3801-9224 FAX: +55-19-3875-3899, 2241
http://www.yanmar.com.br
SERVICE MANUAL
3TNV88F
1st edition: June 2012
1st edition 1st rev. : December 2012
SERVICE MANUAL
Model
3TNV88F
Code No.
0BTN4-G00400
All Rights Reserved, Copyright
Issued by: YANMAR CO., LTD.
Edited by: YANMAR TECHNICAL SERVICE CO., LTD.
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TABLE OF
CONTENTS
TNV DI Service Manual
Page
Introduction ......................................................................................... 1-1
YANMAR Warranties ........................................................................... 2-1
Safety.................................................................................................... 3-1
General Service Information .............................................................. 4-1
Periodic Maintenance ......................................................................... 5-1
Engine .................................................................................................. 6-1
Fuel System ......................................................................................... 7-1
Cooling System ................................................................................... 8-1
Lubrication System ............................................................................. 9-1
Starter Motor...................................................................................... 10-1
Alternator ........................................................................................... 11-1
Electronic Control System ............................................................... 12-1
Electric Wiring ................................................................................... 13-1
Failure Diagnosis .............................................................................. 14-1
TNV DI Service Manual
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3TNV88F Service Manual
Section 1
INTRODUCTION
This Service Manual describes the service
procedures for the TNV series direct injection
engines. These engines are certified by the U.S.
EPA, California ARB 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.
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INTRODUCTION
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3TNV88F Service Manual
Section 2
YANMAR
WARRANTIES
Page
YANMAR Limited Warranty.............................................................
What is Covered by this Warranty? ..........................................
How Long is the Warranty Period? ...........................................
What the Engine Owner must Do: ............................................
To Locate an Authorized YANMAR Industrial Engine
Dealer or Distributor: .................................................................
What YANMAR will Do: .............................................................
What is not Covered by this Warranty? ....................................
Warranty Limitations: ................................................................
Warranty Modifications: ............................................................
Questions: .................................................................................
2-3
2-3
2-3
2-3
2-4
2-4
2-4
2-5
2-5
2-5
Emission System Warranty ............................................................. 2-6
YANMAR Co., Ltd. Limited Emission Control System
Warranty - USA Only.......................................................................
Your Warranty Rights and Obligations: .....................................
Manufacturer’s Warranty Period:...............................................
Warranty Coverage: ..................................................................
Warranted Parts: .......................................................................
Exclusions: ................................................................................
Owner’s Warranty Responsibilities:...........................................
3TNV88F Service Manual
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2-6
2-6
2-7
2-7
2-8
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YANMAR WARRANTIES
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YANMAR Limited Warranty
YANMAR WARRANTIES
YANMAR LIMITED WARRANTY
What is Covered by this Warranty?
YANMAR warrants to the original retail purchaser that a new YANMAR TNV series industrial engine will be
free from defects in material and/or workmanship for the duration of the warranty period.
Note: YANMAR engines may be equipped with external components including, but not limited to: wiring
harnesses, electrical devices, control panels, radiators, air filters, fuel filters, and/or exhaust systems
that are supplied and/or installed by manufacturers other than YANMAR. For warranty information on
such external components, please contact the machine or component manufacturer directly or see
your authorized YANMAR dealer or distributor.
This warranty is provided in lieu of all other warranties, express or implied. YANMAR specifically disclaims
any implied warranties of merchantability or fitness for a particular purpose, except where such disclaimer
is prohibited by law. If such disclaimer is prohibited by law, then implied warranties shall be limited in
duration to the life of the express warranty.
How Long is the Warranty Period?
The YANMAR standard limited warranty period runs for a period of twenty-four (24) months or twothousand (2000) engine operation hours, whichever occurs first. An extended limited warranty of thirtysix (36) months or three thousand (3000) engine operating hours, whichever occurs first, is provided for
these specific parts only: the cylinder block, cylinder head, crankshaft forging, connecting rods, flywheel,
flywheel housing, camshaft, timing gear, and gear case. The warranty period for both the standard limited
warranty and the extended limited warranty (by duration or operation hours) begins on the date of delivery
to the original retail purchaser and is valid only until the applicable warranted duration has passed or the
operation hours are exceeded, whichever comes first.
What the Engine Owner must Do:
If you believe your YANMAR engine has experienced a failure due to a defect in material and/or
workmanship, you must contact an authorized YANMAR industrial engine dealer or distributor within thirty
(30) days of discovering the failure. You must provide proof of ownership of the engine, proof of the date of
the engine purchase and delivery, and documentation of the engine operation hours. Acceptable forms of
proof of delivery date include, but are not limited to: the original warranty registration or sales receipts or
other documents maintained in the ordinary course of business by YANMAR dealers and/or distributors,
indicating the date of delivery of the YANMAR product to the original retail purchaser. This information is
necessary to establish whether the YANMAR product is still within the warranty period. Thus, YANMAR
strongly recommends you register your engine as soon as possible after purchase in order to facilitate any
future warranty matters.
You are responsible for the transportation of the engine to and from the repair location as designated by
YANMAR.
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YANMAR WARRANTIES
YANMAR Limited Warranty
YANMAR limited warranty - continued
To Locate an Authorized YANMAR Industrial Engine Dealer or Distributor:
You can locate your nearest authorized YANMAR industrial engine dealer or distributor by visiting the
YANMAR Co., Ltd. website at:
http://www.yanmar.co.jp (The Japanese language page will be displayed.) For English language “click” on
“English Page.”)
• “Click” on “Network” in the website heading to view the “Yanmar Worldwide Network.”
• Choose and “Click” on the desired product group.
• “Click” on the Icon closest to your region.
• “Click” on the desired country or associate company to locate your nearest authorized YANMAR
industrial engine dealer or distributor.
• You may also contact YANMAR by clicking on “Inquiry” in the website heading and typing in your question
or comment.
What YANMAR will Do:
YANMAR warrants to the original retail purchaser of a new YANMAR engine that YANMAR will make such
repairs and/or replacements at YANMAR’s option, of any part(s) of the YANMAR product covered by this
warranty found to be defective in material and/or workmanship. Such repairs and/or replacements will be
made at a location designated by YANMAR at no cost to the purchaser for parts or labor.
What is not Covered by this Warranty?
This warranty does not cover parts affected by or damaged by any reason other than defective materials or
workmanship including, but not limited to, accident, misuse, abuse, “Acts of God,” neglect, improper
installation, improper maintenance, improper storage, the use of unsuitable attachments or parts, the use
of contaminated fuels, the use of fuels, oils, lubricants, or fluids other than those recommended in your
YANMAR Operation Manual, unauthorized alterations or modifications, ordinary wear and tear, and rust or
corrosion. This warranty does not cover the cost of parts and/or labor required to perform
normal/scheduled maintenance on your YANMAR engine. This warranty does not cover consumable parts
such as, but not limited to, filters, belts, hoses, fuel injector nozzles, lubricants and cleaning fluids. This
warranty does not cover the cost of shipping the product to or from the Warranty repair facility.
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YANMAR Limited Warranty
YANMAR WARRANTIES
YANMAR limited warranty - continued
Warranty Limitations:
The foregoing is YANMAR’s only obligation to you and your exclusive remedy for breach of
warranty. Failure to follow the requirements for submitting a claim under this warranty may result in a
waiver of all claims for damages and other relief. In no event shall YANMAR or any authorized industrial
engine dealer or distributor be liable for incidental, special or consequential damages. Such
consequential damages may include, but not be limited to, loss of revenue, loan payments, cost of rental of
substitute equipment, insurance coverage, storage, lodging, transportation, fuel, mileage, and telephone
costs. The limitations in this warranty apply regardless of whether your claims are based on breach of
contract, tort (including negligence and strict liability) or any other theory. Any action arising hereunder
must be brought within one (1) year after the cause of action accrues or it shall be barred. Some states and
countries do not allow certain limitations on warranties or for breach of warranties. This warranty gives
you specific legal rights, and you may also have other rights which vary from state to state and
country to country. Limitations set forth in this paragraph shall not apply to the extent that they are
prohibited by law.
Warranty Modifications:
Except as modified in writing and signed by the parties, this warranty is and shall remain the complete and
exclusive agreement between the parties with respect to warranties, superseding all prior agreements,
written and oral, and all other communications between the parties relating to warranties. No person or
entity is authorized to give any other warranty or to assume any other obligation on behalf of
YANMAR, either orally or in writing.
Questions:
If you have any questions or concerns regarding this warranty, please call or write to the nearest authorized
YANMAR industrial engine dealer or distributor or other authorized facility.
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YANMAR WARRANTIES
Emission System Warranty
EMISSION SYSTEM WARRANTY
YANMAR CO., LTD. LIMITED EMISSION CONTROL SYSTEM
WARRANTY - USA ONLY
Your Warranty Rights and Obligations:
■ California
The California Air Resources Board (CARB), the Environmental Protection Agency (EPA) and YANMAR
Co., Ltd. hereafter referred to as YANMAR, are pleased to explain the emission control system warranty
on your industrial compression-ignition engine. In California, 2013 MY and subsequent model years offroad compression-ignition engines must be designed, built and equipped to meet the state’s stringent antismog standards. In all states, 1998 and later non-road compression-ignition engines must be designed,
built and equipped to meet the United States EPA emissions standards. YANMAR warrants the emission
control system on your engine for the periods of time listed below provided there has been no abuse,
neglect or improper maintenance of your engine.
Your emission control system may include parts such as the fuel injection system, Electronic Control Unit,
Exhaust Gas Recirculation (EGR) system and the air induction system. Also included may be hoses, belts,
connectors and other emission-related assemblies.
Where a warrantable condition exists, YANMAR will repair your non-road compression-ignition engine at no
charge to you including diagnosis, parts and labor.
Manufacturer’s Warranty Period:
The model year 1998 or later certified and labeled non-road compression-ignition engines are warranted
for the periods listed below. If any emission-related part on your engine is found to be defective during the
applicable warranty period, the part will be replaced by YANMAR.
If your engine is
certified as
And its maximum
power is
And its rated speed is
kW < 19
Any speed
1,500 hours or two (2) years whichever comes first.
In the absence of a device to measure the hours of use,
the engine has a warranty period of two (2) years.
Constant speed
19  kW < 37
3,000 rpm or higher
1,500 hours or two (2) years whichever comes first.
In the absence of a device to measure the hours of use,
the engine has a warranty period of two (2) years.
Constant speed
19  kW < 37
Less than 3,000 rpm
3,000 hours or five (5) years whichever comes first.
In the absence of a device to measure the hours of use, the
engine has a warranty period of five (5) years.
Variable speed
19  kW < 37
Any speed
3,000 hours or five (5) years whichever comes first.
In the absence of a device to measure the hours of use,
the engine has a warranty period of five (5) years.
kW  37
Any speed
3,000 hours or five (5) years whichever comes first.
In the absence of a device to measure the hours of use,
the engine has a warranty period of five (5) years.
Variable speed or
constant speed
Variable speed or
constant speed
2-6
Then its warranty period is
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Emission System Warranty
YANMAR WARRANTIES
Limited emission control system warranty - USA only - continued
Warranty Coverage:
This warranty is transferable to each subsequent purchaser for the duration of the warranty period. Repair
or replacement of any warranted part will be performed at an authorized YANMAR industrial engine dealer
or distributor.
Warranted parts not scheduled for replacement as required maintenance in the operation manual shall be
warranted for the warranty period. Warranted parts scheduled for replacement as required maintenance in
the operation manual are warranted for the period of time prior to the first scheduled replacement. Any part
repaired or replaced under warranty shall be warranted for the remaining warranty period.
During the warranty period, YANMAR is liable for damages to other engine components caused by the
failure of any warranted part during the warranty period.
Any replacement part which is functionally identical to the original equipment part in all respects may be
used in the maintenance or repair of your engine, and shall not reduce YANMAR’s warranty obligations.
Add-on or modified parts that are not exempted may not be used. The use of any non-exempted add-on or
modified parts shall be grounds for disallowing a warranty.
Warranted Parts:
This warranty covers engine components that are a part of the emission control system of the engine as
delivered by YANMAR to the original retail purchaser. Such components may include the following:
• Fuel injection system
• Electronic control system
• Cold start enrichment system
• Intake manifold
• Turbocharger systems
• Exhaust manifold
• EGR system
• Positive crankcase ventilation system
• Hoses, belts, connectors and assemblies associated with emission control systems
Since emissions-related parts may vary slightly between models, certain models may not contain all of
these parts and other models may contain the functional equivalents.
3TNV88F Service Manual
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YANMAR WARRANTIES
Emission System Warranty
Limited emission control system warranty - USA only - continued
Exclusions:
Failures other than those arising from defects in material and/or workmanship are not covered by this
warranty. The warranty does not extend to the following: malfunctions caused by abuse, misuse, improper
adjustment, modification, alteration, tampering, disconnection, improper or inadequate maintenance or use
of non-recommended fuels and lubricating oils; accident-caused damage, and replacement of expendable
items made in connection with scheduled maintenance. YANMAR disclaims any responsibility for
incidental or consequential damages such as loss of time, inconvenience, loss of use of equipment/engine
or commercial loss.
Owner’s Warranty Responsibilities:
As the engine owner, you are responsible for the performance of the required maintenance listed in
your owner’s manual. YANMAR recommends that you retain all documentation, including receipts,
covering maintenance on your non-road compression-ignition engine, but YANMAR cannot deny warranty
solely for the lack of receipts, or for your failure to ensure the performance of all scheduled maintenance.
YANMAR may deny your warranty coverage of your non-road compression-ignition engine if a part has
failed due to abuse, neglect, improper maintenance or unapproved modifications.
Your engine is designed to operate on diesel fuel only. Use of any other fuel may result in your engine no
longer operating in compliance with applicable emissions requirements.
You are responsible for initiating the warranty process. You must present your engine to a YANMAR dealer
as soon as a problem exists. The warranty repairs should be completed by the dealer as expeditiously as
possible. If you have any questions regarding your warranty rights and responsibilities, or would like
information on the nearest YANMAR dealer or authorized service center, you should contact YANMAR
America Corporation.
Website: www.yanmar.com
E-mail: CS [email protected]
Toll free telephone number: 1-800-872-2867, 1-855-416-7091
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Section 3
3TNV88F Service Manual
SAFETY
Page
Safety Statements ........................................................................... 3-3
Safety Precautions .......................................................................... 3-4
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SAFETY
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SAFETY
Safety Statements
SAFETY STATEMENTS
YANMAR is concerned for your safety and your
machine’s condition. Safety statements are one of
the primary ways to call your attention to the
potential hazards associated with YANMAR TNV
engine operation. Follow the precautions listed
throughout the manual before operation, during
operation and during periodic maintenance
procedures for your safety, the safety of others and
to protect the performance of your engine. Keep the
labels from becoming dirty or torn and replace
them if they are lost or damaged. Also, if you need
to replace a part that has a label attached to it,
make sure you order the new part and label at the
same time.
A
This safety alert symbol appears
with most safety statements. It
means attention, become alert,
your safety is involved! Please read
and abide by the message that
follows the safety alert symbol.
3TNV88F Service Manual
DANGER
DANGER indicates a hazardous situation
which, if not avoided, will result in death or
serious injury.
WARNING
WARNING indicates a hazardous situation
which, if not avoided, could result in death or
serious injury.
CAUTION
CAUTION indicates a hazardous situation
which, if not avoided, could result in minor or
moderate injury.
NOTICE
NOTICE indicates a situation which can cause
damage to the machine, personal property and/or
the environment or cause the equipment to operate
improperly.
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SAFETY
Safety Precautions
SAFETY PRECAUTIONS
DANGER
Scald Hazard!
• Never remove the radiator cap if
the engine is hot. Steam and hot
engine coolant will spurt out and
seriously burn you. Allow the
engine to cool down before you
attempt to remove the radiator
cap.
• Tighten the radiator cap securely after you
check the radiator. Steam can spurt out
during engine operation if the cap is loose.
• Always check the level of the engine coolant
by observing the reserve tank.
• Failure to comply will result in death or
serious injury.
DANGER
Fire and Explosion Hazard!
• Diesel fuel is flammable and
explosive under certain
conditions.
• When you remove any fuel system component
to perform maintenance (such as changing
the fuel filter) place an approved container
under the opening to catch the fuel.
• Never use a shop rag to catch the fuel. Vapors
from the rag are flammable and explosive.
• Wipe up any spills immediately.
• Wear eye protection. The fuel system is under
pressure and fuel could spray out when you
remove any fuel system component.
• Only use the key switch to start the engine.
DANGER
Explosion Hazard!
• Keep the area around the battery
well-ventilated. While the engine
is running or the battery is
charging, hydrogen gas is
produced which can be easily
ignited.
• Keep sparks, open flame and any other form
of ignition away while the engine is running or
battery is charging.
• Never check the remaining battery charge by
shorting out the terminals. This will result in a
spark and may cause an explosion or fire. Use
a hydrometer to check the remaining battery
charge.
• If the electrolyte is frozen, slowly warm the
battery before you recharge it.
• Failure to comply will result in death or
serious injury.
• Never jump-start the engine. Sparks caused
by shorting the battery to the starter terminals
may cause a fire or explosion.
• If the unit has an electric fuel pump, when you
prime the fuel system, turn the key switch to
the ON position for 10 to 15 seconds to allow
the electric fuel pump to prime the system.
• If the unit has a mechanical fuel pump, when
you prime the fuel system, operate the fuel
priming lever of the mechanical fuel pump
several times until the fuel filter cup is filled
with fuel.
• Only fill the fuel tank with diesel fuel. Filling
the fuel tank with gasoline may result in a fire
and will damage the engine.
• Never refuel with the engine running.
• Keep sparks, open flames or any other form of
ignition (match, cigarette, static electric
source) well away when refueling.
• Never overfill the fuel tank.
• Fill the fuel tank. Store any containers
containing fuel in a well-ventilated area, away
from any combustibles or sources of ignition.
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SAFETY
Safety Precautions
DANGER
(Continued)
• Be sure to place the diesel fuel container on
the ground when transferring the diesel fuel
from the pump to the container. Hold the hose
nozzle firmly against the side of the container
while filling it. This prevents static electricity
buildup which could cause sparks and ignite
fuel vapors.
• Never place diesel fuel or other flammable
material such as oil, hay or dried grass close
to the engine during engine operation or
shortly after shutdown.
• Before you operate the engine, check for fuel
leaks. Replace rubberized fuel hoses every
two years or every 2000 hours of engine
operation, whichever comes first, even if the
engine has been out of service. Rubberized
fuel lines tend to dry out and become brittle
after two years or 2000 hours of engine
operation, whichever comes first.
• Never remove the fuel cap with the engine
running.
• Never use diesel fuel as a cleaning agent.
• Place an approved container under the air
bleed port when you prime the fuel system.
Never use a shop rag to catch the fuel. Wipe
up any spills immediately. Always close the
air bleed port after you complete priming the
system.
• Wear eye protection. The fuel system is under
pressure and fuel could spray out when you
open the air bleed port.
• If the unit has an electric fuel pump, turn the
key switch to the ON position for 10 to 15
seconds, or until the fuel coming out of the air
bleed port is free of bubbles, to allow the
electric fuel pump to prime the system.
• If the unit has a mechanical fuel pump,
operate the fuel priming pump several times
until the fuel coming out of the air bleed port
is free of bubbles.
DANGER
Crush Hazard!
• When you need to transport an
engine for repair, have a helper
assist you to attach it to a hoist
and load it on a truck.
• Never stand under a hoisted engine. If the
hoist mechanism fails, the engine will fall on
you, causing death or serious injury.
• Failure to comply will result in death or
serious injury.
WARNING
Sever Hazard!
• Keep hands and other body parts
away from moving/rotating parts
such as the cooling fan, flywheel
or PTO shaft.
• Wear tight-fitting clothing and keep your hair
short or tie it back while the engine is
running.
• Remove all jewelry before you operate or
service the machine.
• Never start the engine in gear. Sudden
movement of the engine and/or machine
could cause death or serious personal injury.
• Never operate the engine without the guards
in place.
• Before you start the engine make sure that all
bystanders are clear of the area.
• Keep children and pets away while the engine
is operating.
• Check before starting the engine that any
tools or shop rags used during maintenance
have been removed from the area.
• Failure to comply could result in death or
serious injury.
• Failure to comply will result in death or
serious injury.
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SAFETY
Safety Precautions
WARNING
Exhaust Hazard!
• Never operate the engine in an
enclosed area such as a garage,
tunnel, underground room,
manhole or ship’s hold without
proper ventilation.
• Never block windows, vents, or other means
of ventilation if the engine is operating in an
enclosed area. All internal combustion
engines create carbon monoxide gas during
operation. Accumulation of this gas within an
enclosure could cause illness or even death.
• Make sure that all connections are tightened
to specifications after repair is made to the
exhaust system.
• Failure to comply could result in death or
serious injury.
WARNING
Alcohol and Drug Hazard!
• Never operate the engine while
you are under the influence of
alcohol or drugs.
• Never operate the engine when you are
feeling ill.
• Failure to comply could result in death or
serious injury.
WARNING
Exposure Hazard!
• Wear personal protective
equipment such as gloves, work
shoes, eye and hearing protection
as required by the task at hand.
• Never wear jewelry, unbuttoned cuffs, ties or
loose-fitting clothing when you are working
near moving/rotating parts such as the
cooling fan, flywheel or PTO shaft.
• Always tie back long hair when you are
working near moving/rotating parts such as a
cooling fan, flywheel, or PTO shaft.
• Never operate the engine while wearing a
headset to listen to music or radio because it
will be difficult to hear the alert signals.
• Failure to comply could result in death or
serious injury.
WARNING
Burn Hazard!
• If you must drain the engine oil
while it is still hot, stay clear of
the hot engine oil to avoid being
burned.
• Always wear eye protection.
• Wait until the engine cools before you drain
the engine coolant. Hot engine coolant may
splash and burn you.
• Keep your hands and other body parts away
from hot engine surfaces such as the muffler,
exhaust pipe, turbocharger (if equipped) and
engine block during operation and shortly
after you shut the engine down. These
surfaces are extremely hot while the engine is
operating and could seriously burn you.
• Failure to comply could result in death or
serious injury.
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SAFETY
Safety Precautions
WARNING
WARNING
Burn Hazard!
Shock Hazard!
• Batteries contain sulfuric acid.
Never allow battery fluid to come
in contact with clothing, skin or
eyes. Severe burns could result.
Always wear safety goggles and
protective clothing when
servicing the battery. If battery
fluid contacts the eyes and/or
skin, immediately flush the
affected area with a large amount
of clean water and obtain prompt
medical treatment.
• Failure to comply could result in death or
serious injury.
• Turn off the battery switch (if
equipped) or disconnect the
negative battery cable before
servicing the electrical system.
• Check the electrical harnesses for cracks,
abrasions, and damaged or corroded
connectors. Always keep the connectors and
terminals clean.
• Failure to comply could result in death or
serious injury.
WARNING
Entanglement Hazard!
WARNING
High-Pressure Hazard!
• Avoid skin contact with the
high-pressure diesel fuel spray
caused by a fuel system leak such
as a broken fuel injection line.
High-pressure fuel can penetrate
your skin and result in serious
injury. If you are exposed to highpressure fuel spray, obtain
prompt medical treatment.
• Never check for a fuel leak with your hands.
Always use a piece of wood or cardboard.
Have your authorized YANMAR industrial
engine dealer or distributor repair the
damage.
• Failure to comply could result in death or
serious injury.
• Stop the engine before you begin
to service it.
• Never leave the key in the key switch when
you are servicing the engine. Someone may
accidentally start the engine and not realize
you are servicing it. This could result in a
serious injury.
• If you must service the engine while it is
operating, remove all jewelry, tie back long
hair, and keep your hands, other body parts
and clothing away from moving/rotating parts.
• Failure to comply could result in death or
serious injury.
WARNING
Sudden Movement Hazard!
• Engaging the transmission or PTO at an
elevated engine speed could result in
unexpected movement of the equipment.
• Failure to comply could result in death or
serious injury.
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SAFETY
Safety Precautions
WARNING
To prevent possible eye injury,
always wear safety glasses while
servicing the engine.
WARNING
Fume/Burn Hazard!
• Always read and
follow safety related
precautions found on
containers of
hazardous substances
like parts cleaners,
primers, sealants and
sealant removers.
• Failure to comply could result in death or
serious injury.
WARNING
Never apply over 40 PSI (2.8 kgf/cm) to the
waste gate actuator.
WARNING
• Never inject fuel toward you. Since the fuel is
injected at high pressure from the nozzle, it
may penetrate the skin, resulting in injury.
• Never inject fuel toward a fire source.
Atomized fuel is highly flammable and may
cause a fire or burn skin.
WARNING
• Never use the E-ECU for other purposes than
intended or in other ways than specified by
YANMAR. Doing so could result in the
violation of emission control regulations and
will void the product warranty.
WARNING
• Be sure to use the E-ECU in conjunction with
the engines whose models or serial numbers
are specified by YANMAR.
Other E-ECU/engine combinations than
specified will void the engine warranty.
• Improper use or misuse of the E-ECU may
result in death or serious injury due to an
abrupt and unexpected increase in engine
speed.
WARNING
• Replacing the fuel injection pump involves
rewriting the fuel injection data in the E-ECU.
Be sure to contact your local YANMAR dealer
before replacing the fuel injection pump.
Failure to rewrite the fuel injection data before
replacing the fuel injection pump will void the
engine warranty.
• Improper use or misuse of the E-ECU may
result in death or serious injury due to an
abrupt and unexpected increase in engine
speed.
WARNING
• Replacing the E-ECU involves migrating the
fuel injection data to the existing E-ECU to the
new unit.
Be sure to contact your local YANMAR dealer
before replacing the E-ECU.
Failure to migrate the fuel injection data
before replacing the E-ECU will void the
engine warranty.
• Improper use or misuse of the E-ECU may
result in death or serious injury due to an
abrupt and unexpected increase in engine
speed.
• Improper use or misuse of the E-ECU may
result in death or serious injury due to an
abrupt and unexpected increase in engine
speed.
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SAFETY
Safety Precautions
CAUTION
Coolant Hazard!
• Wear eye protection
and rubber gloves
when you handle long
life or extended life
engine coolant. If
contact with the eyes
or skin should occur,
flush eyes and wash
immediately with
clean water.
• Failure to comply may result in minor or
moderate injury.
CAUTION
Flying Object Hazard!
• Always wear eye protection when
servicing the engine and when
using compressed air or highpressure water. Dust, flying
debris, compressed air,
pressurized water or steam may
injure your eyes.
• Failure to comply may result in minor or
moderate injury.
CAUTION
Be sure to secure the engine solidly to prevent
injury or damage to parts due to the engine
falling during work on the engine.
CAUTION
Pinch Hazard!
Carefully rotate the alternator
toward the cylinder block while
loosening the V-belt. Failure to
comply may result in minor or
moderate injury.
CAUTION
If any oil pump component clearance exceeds
its limit, the oil pump must be replaced as an
assembly.
CAUTION
To refuel the engine oil, refuel slowly after
removing the dipstick and both caps. If you
refuel rapidly, the oil intrusion to the intake
occurs through the PCV valve of the valve
cover. It will result in an oil hammer at engine
start, which may cause damage to the engine.
NOTICE
• Only use diesel fuels recommended by YANMAR
for the best engine performance, to prevent
engine damage and to comply with EPA/ARB
warranty requirements.
• Only use clean diesel fuel.
• Never remove the primary strainer (if equipped)
from the fuel tank filler port. If removed, dirt and
debris could get into the fuel system causing it to
clog.
NOTICE
Never attempt to adjust the low or high idle speed
limit screw. This may impair the safety and
performance of the machine and shorten its life. If
adjustment is ever required, contact your
authorized YANMAR industrial engine dealer or
distributor.
NOTICE
If any problem is noted during the visual check, the
necessary corrective action should be taken before
you operate the engine.
NOTICE
Never hold the key in the START position for longer
than 15 seconds or the starter motor will overheat.
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SAFETY
Safety Precautions
NOTICE
Make sure the engine is installed on a level surface.
If a continuously running engine is installed at an
angle greater than (IDI = 25°, DI = 30°) in any
direction or if an engine runs for short periods of
time (less than three minutes) at an angle greater
than (IDI = 30°, DI = 35°) in any direction, engine oil
may enter the combustion chamber causing
excessive engine speed and white exhaust smoke.
This may cause serious engine damage.
NOTICE
Observe the following environmental operating
conditions to maintain engine performance and
avoid premature engine wear:
• Avoid operating in extremely dusty conditions.
• Avoid operating in the presence of chemical
gases or fumes.
• Avoid operating in a corrosive atmosphere such
as salt water spray.
• Never install the engine in a floodplain unless
proper precautions are taken to avoid being
subject to a flood.
• Never expose the engine to the rain.
NOTICE
Observe the following environmental operating
conditions to maintain engine performance and
avoid premature engine wear:
• The standard range of ambient temperatures for
the normal operation of YANMAR engines is from
+5 °F (-15 °C) to +113 °F (+45 °C).
• If the ambient temperature exceeds +113 °F (+45
°C) the engine may overheat and cause the
engine oil to break down.
• If the ambient temperature is below +5 °F (-15 °C)
the engine will be hard to start and the engine oil
may not flow easily.
• Contact your authorized YANMAR industrial
engine dealer or distributor if the engine will be
operated outside of this standard temperature
range.
NOTICE
The illustrations and descriptions of optional
equipment in this manual, such as the operator’s
console, are for a typical engine installation. Refer
to the documentation supplied by the optional
equipment manufacturer for specific operation and
maintenance instructions.
NOTICE
If any indicator illuminates during engine operation,
stop the engine immediately. Determine the cause
and repair the problem before you continue to
operate the engine.
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SAFETY
Safety Precautions
NOTICE
• Only use the engine oil specified. Other engine
oils may affect warranty coverage, cause internal
engine components to seize and/or shorten
engine life.
• Prevent dirt and debris from contaminating the
engine oil. Carefully clean the oil cap/dipstick and
the surrounding area before you remove the cap.
• Never mix different types of engine oil. This may
adversely affect the lubricating properties of the
engine oil.
• Never overfill. Overfilling may result in white
exhaust smoke, engine overspeed or internal
damage.
NOTICE
• Only use the engine coolant specified. Other
engine coolants may affect warranty coverage,
cause an internal buildup of rust and scale and/or
shorten engine life.
• Prevent dirt and debris from contaminating the
engine coolant. Carefully clean the radiator cap
and the surrounding area before you remove the
cap.
• Never mix different types of engine coolants. This
may adversely affect the properties of the engine
coolant.
NOTICE
• Never overfill the engine with engine oil.
• Always keep the oil level between the upper and
lower lines on the oil cap/dipstick.
3TNV88F Service Manual
NOTICE
For maximum engine life, YANMAR recommends
that when shutting the engine down, you allow the
engine to idle, without load, for five minutes. This
will allow the engine components that operate at
high temperatures, such as the turbocharger (if
equipped) and exhaust system, to cool slightly
before the engine itself is shut down.
NOTICE
Never use an engine starting aid such as ether.
Engine damage will result.
NOTICE
• Always be environmentally
responsible.
• Follow the guidelines of the EPA or other
governmental agencies for the proper disposal of
hazardous materials such as engine oil, diesel
fuel and engine coolant. Consult the local
authorities or reclamation facility.
• Never dispose of hazardous materials
irresponsibly by dumping them into a sewer, on
the ground, or into ground water or waterways.
• Failure to follow these procedures may seriously
harm the environment.
NOTICE
Never engage the starter motor while the engine is
running. This may damage the starter motor pinion
and/or ring gear.
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SAFETY
Safety Precautions
NOTICE
New engine break-in:
• On the initial engine start-up, allow the engine to
idle for approximately 15 minutes while you check
for proper engine oil pressure, diesel fuel leaks,
engine oil leaks, coolant leaks, and for proper
operation of the indicators and/or gauges.
• During the first hour of operation, vary the engine
speed and the load on the engine. Short periods
of maximum engine speed and load are
desirable. Avoid prolonged operation at minimum
or maximum engine speeds and loads for the
next four to five hours.
• During the break-in period, carefully observe the
engine oil pressure and engine temperature.
• During the break-in period, check the engine oil
and coolant levels frequently.
NOTICE
• Never attempt to modify the engine’s design or
safety features such as defeating the engine
speed limit control or the fuel injection quantity
control.
• Failure to comply may impair the engine’s safety
and performance characteristics and shorten the
engine’s life. Any alterations to this engine may
affect the warranty coverage of your engine. See
YANMAR Limited Warranty in Warranty Section.
NOTICE
Protect the air cleaner, turbocharger (if equipped)
and electric components from damage when you
use steam or high-pressure water to clean the
engine.
NOTICE
Never use high-pressure water or compressed air
at greater than 28 PSI (193 kPa; 19686 mmAq) or a
wire brush to clean the radiator fins. Radiator fins
damage easily.
3-12
NOTICE
Never attempt to adjust the low or high idle speed
limit screw. This may impair the safety and
performance of the machine and shorten its life. If
the idle speed limit screws require adjustment, see
your authorized YANMAR industrial engine dealer
or distributor.
NOTICE
The tightening torque in the Standard Torque Chart
(see General Service Information section) should
be applied only to the bolts with a “7” head. (JIS
strength classification: 7T)
• Apply 60 % torque to bolts that are
not listed.
• Apply 80 % torque when tightened to
aluminum alloy.
NOTICE
If any indicator fails to illuminate when the key
switch is in the ON position, see your authorized
YANMAR industrial engine dealer or distributor for
service before operating the engine.
NOTICE
Establish a periodic maintenance plan according to
the engine application and make sure you perform
the required periodic maintenance at the intervals
indicated. Failure to follow these guidelines will
impair the engine’s safety and performance
characteristics, shorten the engine’s life and may
affect the warranty coverage on your engine.
See YANMAR Limited Warranty in Warranty
Section.
Consult your authorized YANMAR dealer or
distributor for assistance when checking items
marked with a .
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SAFETY
Safety Precautions
NOTICE
If the fuel filter/water separator is positioned higher
than the fuel level in the fuel tank, water may not
drip out when the fuel filter/water separator drain
cock is opened. If this happens, turn the air vent
screw on the top of the fuel filter/water separator 2 3 turns counterclockwise.
Be sure to tighten the air vent screw after the water
has drained out.
NOTICE
• When the engine is operated in dusty conditions,
clean the air cleaner element more frequently.
• Never operate the engine with the air cleaner
element(s) removed. This may allow foreign
material to enter the engine and damage it.
NOTICE
The maximum air intake restriction, in terms of
differential pressure measurement, must not
exceed 0.90 PSI (6.23 kPa; 635 mmAq). Clean or
replace the air cleaner element if the air intake
restriction exceeds the above mentioned value.
NOTICE
It is important to perform daily checks.
Periodic maintenance prevents unexpected
downtime, reduces the number of accidents due to
poor machine performance and helps extend the
life of the engine.
NOTICE
If the oil pump must be replaced, replace it as an
assembly only. Do not replace individual
components.
NOTICE
Do not loosen or remove the four bolts retaining the
fuel injection pump drive gear to the fuel injection
pump hub. Do not disassemble the fuel injection
pump drive gear from the hub. Correct fuel injection
timing will be very difficult or impossible to achieve.
NOTICE
The starter motor can be damaged if operated
continuously longer than 10 seconds while
performing the no-load test.
NOTICE
Do not short-circuit the charging system between
alternator terminals IG and L. Damage to the
alternator will result.
NOTICE
Do not connect a load between alternator terminals
L and E. Damage to the alternator will result.
NOTICE
Do not remove the positive (+) battery cable from
alternator terminal B while the engine is operating.
Damage to the alternator will result.
NOTICE
Do not turn the battery switch OFF while the engine
is operating. Damage to the alternator will result.
NOTICE
Do not operate the engine if the alternator is
producing unusual sounds. Damage to the
alternator will result.
NOTICE
If the engine coolant pump must be replaced,
replace the engine coolant pump as an assembly
only. Do not attempt to repair the engine coolant
pump or replace individual components.
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SAFETY
Safety Precautions
NOTICE
Use a new special O-ring between the engine
coolant pump and the joint. Be sure to use the
special O-ring for each engine model. Although the
O-ring dimensions are the same as a commercially
available O-ring, the material is different.
NOTICE
Remove or install the high-pressure fuel injection
lines as an assembly whenever possible.
Disassembling the high-pressure fuel injection lines
from the retainers or bending any of the fuel lines
will make it difficult to reinstall the fuel lines.
NOTICE
After marking the position of the pump drive gear,
do not rotate the engine crankshaft. Rotating the
crankshaft will cause the fuel injection pump to
become misaligned.
NOTICE
Do not use a high-pressure wash directly on the
alternator. Water will damage the alternator and
result in inadequate charging.
NOTICE
Do not reverse the positive (+) and negative (-)
ends of the battery cable. The alternator diode and
stator coil will be damaged.
NOTICE
When the battery indicator goes out, it should not
come on again. The battery indicator only comes
on during operation if the alternator fails. However,
if an LED is used in the battery indicator, the LED
will shine faintly during normal operation.
NOTICE
NOTICE
Agricultural or other chemicals, especially those
with a high sulfur content, can adhere to the IC
regulator. This will corrode the conductor and result
in battery over-charging (boiling) and charging
malfunctions. Consult YANMAR before using the
equipment in such an environment or the warranty
is voided.
NOTICE
Make sure that the combined total resistance of the
battery cable in both directions between the starter
motor and the battery is within the value indicated
on the wiring diagram. The starter motor will
malfunction or break down if the resistance is
higher than the specified value.
NOTICE
The starter motor is water-proofed according to JIS
D 0203, R2 which protects the motor from rain or
general cleaning. Do not use high-pressure wash
or submerse the starter motor in water.
NOTICE
Use a specialized battery charger to recharge a
battery with a voltage of 8 volts or less. Booster
starting a battery with a voltage of 8 volts or less
will generate an abnormally high voltage and
destroy electrical equipment.
NOTICE
Make sure that the combined total resistance of the
battery cable in both directions between the starter
motor and the battery is within the value indicated
in the Battery Cable Resistance chart in the Electric
Wiring Section of this manual. The starter motor will
malfunction and fail if the resistance is higher than
the specified value.
Using a non-specified V-belt will cause inadequate
charging and shorten the belt life. Use the specified
belt.
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SAFETY
Safety Precautions
NOTICE
Removing the battery cables or the battery while
the engine is operating may cause damage to the
current limiter depending on the electrical
equipment being used. This situation could cause
loss of control of output voltage. The continuous
high voltage of 23 - 24 volts (for 5000 min-1 (rpm)
dynamo) will damage the current limiter and other
electrical equipment.
NOTICE
Reversing the battery cable connections at the
battery or on the engine will destroy the SCR diode
in the current limiter. This will cause the charging
system to malfunction and may cause damage to
the electrical harnesses.
NOTICE
Avoid damage to the turbocharger or the engine.
Do not spray blower wash fluid or water too quickly.
Use short strokes from a spray bottle to inject
blower wash fluid or water into the turbocharger.
Spraying too much wash fluid or water, or spraying
too quickly will damage the turbocharger.
NOTICE
Do not allow any material to fall into the oil lines or
the oil inlet and outlet ports of the turbocharger.
NOTICE
If the waste valve does not meet specifications,
replace the turbocharger or have it repaired by a
qualified repair facility.
NOTICE
• Never attempt to modify the engine’s design or
safety features such as defeating the engine
speed limit control or the diesel fuel injection
quantity control.
• Modifications may impair the engine’s safety and
performance characteristics and shorten the
engine’s life. Any alterations to this engine may
void its warranty. Be sure to use YANMAR
genuine replacement parts.
NOTICE
Identify all parts and their location using an
appropriate method. It is important that all parts are
returned to the same position during the
reassembly process.
NOTICE
Each pressure adjusting shim removed or added
changes the pressure threshold by approximately
275 PSI (1.9 MPa, 19 kgf/cm2). Adding adjusting
shims increases the threshold pressure. Removing
adjusting shims reduces the pressure threshold.
NOTICE
Do not rotate the crankshaft with the injection pump
removed.
NOTICE
Keep the piston pin parts, piston assemblies, and
connecting rod assemblies together to be returned
to the same position during the reassembly
process. Label the parts using an appropriate
method.
NOTICE
Do not allow the honing tool to operate in one
position for any length of time. Damage to the
cylinder wall will occur. Keep the tool in constant
up-and-down motion.
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SAFETY
Safety Precautions
NOTICE
Any part which is found defective as a result of
inspection or any part whose measured value does
not satisfy the standard or limit must be replaced.
NOTICE
Any part determined to not meet the service
standard or limit before the next service, as
determined from the state of current rate of wear,
should be replaced even though the part currently
meets the service standard limit.
NOTICE
• Never remove or attempt to remove the tamperproof devices from the full-load fuel adjusting
screw or the high-speed throttle limit screw on the
fuel injection pump and governor assembly.
These adjustments have been made at the
factory to meet all applicable emissions
regulations and then sealed.
• Never attempt to make any adjustments to these
sealed adjustment screws. If adjustments are
required, they can be made only by a qualified
fuel injection shop that will ensure the injection
pump continues to meet all applicable emissions
regulations and then replace the tamper-proof
seals.
• Tampering with or removing these devices may
void the “YANMAR Limited Warranty.”
NOTICE
NOTICE
Shut down the engine if the fault indicator comes
on.
Continuing running the engine with the fault
indicator being on may result in a serious
malfunction of or damage to the engine, and will
void the engine warranty.
NOTICE
Do not energize the starter for a period of longer
than 15 seconds.
Take a pause of at least 30 seconds between
energization of the starter.
Otherwise the starter could suffer damage.
NOTICE
• High-pressure washing not recommended.
• Avoid using high-pressure washing for electronic
or electric devices installed in, on or around the
engine, including the E-ECU, relays and harness
couplers.
Otherwise such devices may suffer malfunction due
to water ingress into them.
NOTICE
Always check the battery for proper charge.
Otherwise the electronically controlled engines may
fail to start.
Never use a steel wire brush to clean fuel injectors.
Damage to the nozzle and other components is
likely to result.
NOTICE
Allow the engine to warm-up for at least five
minutes and the idle speed of the engine to return
to normal before engaging the transmission or any
PTOs. Engaging the transmission or PTO at an
elevated engine speed could result in an
unexpected movement of the equipment.
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SAFETY
Safety Precautions
NOTICE
• Do not plug or unplug the E-ECU for a period of
at least 6 seconds after power to the unit has
been turned on or off.
• Do not touch connector pins of the E-ECU with
bare hands.
Doing so may result in corrosion of the connector
pins and/or damage to the internal circuits of the
E-ECU due to static electricity.
• Do not force a measuring probe into the female
coupler.
Doing so may cause contact failure of the
connector pins, resulting in malfunction of the EECU.
• Take care to prevent water from entering the
couplers when plugging or unplugging the
connector.
Water inside the couplers may cause corrosion,
resulting in malfunction of the E-ECU.
NOTICE
• Never permit anyone to operate the
engine or driven machine without
proper training.
• Read and understand this Operation Manual
before you operate or service the machine to
ensure that you follow safe operating practices
and maintenance procedures.
• Machine safety signs and labels are additional
reminders for safe operating and maintenance
techniques.
• See your authorized YANMAR industrial engine
dealer or distributor for additional training.
• Avoid plugging/unplugging the connector more
than approx. 10 times.
Frequent plugging/unplugging of the connector
may cause contact failure of the connector pins,
resulting in malfunction of the E-ECU.
• Do not use the E-ECU that has ever suffered drop
impact.
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SAFETY
Safety Precautions
This Page Intentionally Left Blank
3-18
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3TNV88F Service Manual
Section 4
GENERAL SERVICE
INFORMATION
Page
Component Identification................................................................. 4-3
Location of Labels ........................................................................... 4-4
Engine Nameplate (Typical) ...................................................... 4-4
Emission Control Regulations ......................................................... 4-5
EPA/ARB Regulations - USA Only ............................................ 4-5
Emission Control Labels.................................................................. 4-5
EPA/CARB Labels (Typical) ...................................................... 4-5
Engine Family.................................................................................. 4-6
Function of Major Engine Components ........................................... 4-7
Main Electronic Control Components and Features........................ 4-8
Function of Cooling System Components ..................................... 4-10
Diesel Fuel ....................................................................................
Diesel Fuel Specifications .......................................................
Filling The Fuel Tank ...............................................................
Priming the Fuel System .........................................................
4-11
4-11
4-15
4-16
Engine Oil......................................................................................
Engine Oil Specifications ........................................................
Engine Oil Viscosity.................................................................
Checking Engine Oil ................................................................
Adding Engine Oil....................................................................
Engine Oil Capacity (Typical) ..................................................
4-17
4-17
4-17
4-18
4-18
4-18
Engine Coolant..............................................................................
Engine Coolant Specifications.................................................
Filling Radiator with Engine Coolant........................................
Engine Coolant Capacity (Typical) ..........................................
4-19
4-20
4-20
4-21
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GENERAL SERVICE INFORMATION
Specifications ................................................................................. 4-22
Description of Model Number................................................... 4-22
Engine General Specifications ................................................. 4-22
Principal Engine Specifications ...................................................... 4-23
Engine Service Standards.............................................................. 4-24
Tightening Torques for Standard Bolts and Nuts ........................... 4-25
Abbreviations and Symbols............................................................ 4-27
Symbols.................................................................................... 4-27
Unit Conversions ............................................................................ 4-28
4-2
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GENERAL SERVICE INFORMATION
Component Identification
COMPONENT IDENTIFICATION
Figure 4-1 shows where the major engine components are located.
3TNV88F
1
2
3
16
17
18
15
14
13
12
11
10 9
8
7
6
5
4
22
21 20
19
045002-00X00
1 – Lifting eye (flywheel end)
2 – Lifting eye (engine cooling fan end)
3 – Engine coolant pump
4 – Engine cooling fan
5 – Crankshaft V-pulley
6 – V-belt
7 – Side filler port (engine oil)
8 – Engine oil cooler
9 – Fuel injection pump
10 – Engine oil filter
11 – Intake manifold
12 – Dipstick (engine oil)
13 – Fuel filter
14 – Fuel return to fuel tank
15 – Fuel inlet
16 – Top filler port (engine oil)
17 – Rocker arm cover
18 – EGR valve
19 – Flywheel
20 – Starter motor
21 – Exhaust manifold
22 – Alternator
Figure 4-1
*: Engine oil drain plug location may vary based on oil pan options.
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GENERAL SERVICE INFORMATION
Location of Labels
LOCATION OF LABELS
Figure 4-2 shows the location of regulatory and safety labels on YANMAR TNV series direct injection
model engine.
1
2
045044-00X01
Figure 4-2
■ Location of labels/nameplates on direct injection model engines
Model
Engine nameplate
EPA/ARB certification label
On the top of the locker arm cover (cooling On the top of the locker arm cover
fan end) Figure 4-2, (2)
(flywheel end) Figure 4-2, (1)
3TNV88F
Engine Nameplate (Typical)
MODEL
DISPLACEMENT
ENGINE NO.
MADE IN JAPAN
043923-00X00
Figure 4-3
4-4
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Emission Control Regulations
EMISSION CONTROL
REGULATIONS
EPA/ARB Regulations - USA Only
YANMAR TNV engines meet Environmental
Protection Agency (EPA) (U. S. Federal) emission
control standards as well as the California Air
Resources Board (ARB, California) regulations.
Only engines that conform to ARB regulations can
be sold in the State of California.
Refer to the specific EPA/ARB installation
(page 5-4) and maintenance (page 5-4) in the
Periodic Maintenance Schedule section of this
manual. Also refer to theEmission System Warranty
on page 2-6.
GENERAL SERVICE INFORMATION
EMISSION CONTROL LABELS
Since emission control regulations are being issued
on a global basis, it is necessary to identify which
regulations a particular engine complies with. We
have listed several different types of labels you
might find on your engine.
EPA/CARB Labels (Typical)
■ EPA
EMISSION CONTROL INFORMATION
THIS ENGINE COMPLIES WITH U.S. EPA REGULATIONS FOR
M. Y.
NONROAD AND STATIONARY DIESEL ENGINES.
ULTRA LOW SULFUR FUEL ONLY
PM : 0.30g / kWh
ENGINE FAMILY :
DISPLACEMENT :
LITERS
ENGINE MODEL :
E. C. S. :
FUEL RATE :
MM3/STROKE @
kW /
RPM
REFER TO OWNER'S MANUAL FOR MAINTENANCE SPECIFICATIONS AND
ADJUSTMENTS.
■ EPA and CARB
EMISSION CONTROL INFORMATION
THIS ENGINE COMPLIES WITH U. S. EPA AND CALIFORNIA REGULATIONS
FOR
M. Y. NONROAD AND STATIONARY / OFF-ROAD DIESEL ENGINES.
ULTRA LOW SULFUR FUEL ONLY
ENGINE FAMILY :
DISPLACEMENT :
LITERS
ENGINE MODEL :
E. C. S. :
FUEL RATE :
MM3/STROKE @
kW /
RPM
REFER TO OWNER'S MANUAL FOR MAINTENANCE SPECIFICATIONS AND
ADJUSTMENTS.
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GENERAL SERVICE INFORMATION
Engine Family
ENGINE FAMILY
The EPA/ARB labels have an Engine Family field.
The following is an explanation of the Engine Family designation:
C YDX L 1.64 M
3
N
Method of air aspiration
Number of cylinders
Engine speed specifications
Displacement (l)
Non-road/off-road engine
YANMAR diesel
Model year
C: 2012
D: 2013
E: 2014
F: 2015
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Function of Major Engine Components
GENERAL SERVICE INFORMATION
FUNCTION OF MAJOR ENGINE COMPONENTS
Components
Functions
Air cleaner
The air cleaner prevents airborne contaminants from entering the engine.
Since the air cleaner is application specific, it must be carefully selected by
an application engineer. It is not part of the basic engine package as shipped
from the YANMAR factory. Periodic replacement of the air cleaner filter
element is necessary. See the Periodic Maintenance Schedule on page 5-5
for the replacement frequency.
Alternator
The alternator is driven by a V-belt which is powered by the crankshaft Vpulley. The alternator supplies electricity to the engine systems and charges
the battery while the engine is running.
Dipstick (engine oil)
The engine oil dipstick is used to determine the amount of engine oil in the
crankcase.
Electric fuel pump
The electric fuel pump makes sure there is a constant supply of diesel fuel
to the fuel injection pump. The electric fuel pump is electro-magnetic and
runs on 12 V DC. It must be installed on every application. This is standard
equipment with every engine.
Engine oil filter
The engine oil filter removes contaminants and sediments from the engine
oil. Periodic replacement of the engine oil filter is necessary. See the
Periodic Maintenance Schedule on page 5-5 for the replacement frequency.
Engine oil cooler
(if equipped)
The engine oil cooler helps to keep the engine oil cool. Engine coolant from
the cooling system is circulated through an adapter at the base of the engine
oil filter assembly and then returned to the coolant pump inlet.
Fuel filter
The fuel filter removes contaminants and sediments from the diesel fuel.
Periodic replacement of the fuel filter is necessary. See the Periodic
Maintenance Schedule on page 5-5 for the replacement frequency.
Please note that the word “diesel” is implied throughout this manual
when the word “fuel” is used.
Fuel filter/water separator
The fuel filter/water separator removes contaminants, sediments and water
from the diesel fuel going to the fuel filter. This is a required component of
the fuel system. This is standard equipment with every engine. The
separator is installed between the fuel tank and the electric fuel pump.
Periodically drain the water from the fuel filter/water separator.
Fuel tank
The fuel tank is a reservoir that holds diesel fuel. When the fuel leaves the
fuel tank it goes to the fuel filter/water separator. Next the fuel is pumped to
the fuel filter by the electric fuel pump. Then the fuel goes to the fuel injection
pump. Since the fuel is used to keep the fuel injection pump cool and
lubricated, more fuel than necessary enters the injection pump. When the
injection pump pressure reaches a preset value, a relief valve allows the
excess fuel to be returned back to the fuel tank. The fuel tank is a required
engine component.
Side and top filler port (engine oil)
You can fill the crankcase with engine oil from either the side or the top filler
port depending upon which one is most convenient.
Starter motor
The starter motor is powered by the battery. When you turn the key switch
in the operator’s console to the START position, the starter motor engages
with the ring gear installed on the flywheel and starts the flywheel in motion.
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GENERAL SERVICE INFORMATION
Main Electronic Control Components and Features
MAIN ELECTRONIC CONTROL COMPONENTS AND FEATURES
Component/feature
Description
Engine controller (E-ECU)
Adjusts the rack position of the fuel injection pump depending
on the speed command signal from the accelerator sensor, thus
regulating the engine speed and power. The engine controller
also regulates the opening of the EGR valve depending on the
engine speed and power. It serves as the master station for the
following components/control features.
Electronic governor (Eco-governor)
Consists of the engine speed sensor, rack actuator, etc., and is
directly connected to the fuel injection pump in order to regulate
the rack position of the fuel injection pump depending on the
signals communicated with the E-ECU.
Fuel injection pump (for Eco-governor)
Is of single plunger type and equipped with a CSD solenoid
valve that allows the fuel injection timing to advance and the
injection quantity to increase, thereby improving the cold start
performance of the engine.
EGR valve
Controls the exhaust gas recirculation flow rate depending on
the engine speed/load signals from the E-ECU. It is installed on
the top of the exhaust manifold.
Accelerator sensor
Unlike mechanical governors, the Eco-governor has no
governor lever. The accelerator sensor serves as the governor
lever to provide the speed command signal (voltage signal) to
the E-ECU for engine speed control. It is installed in the
operator cabin of the driven machine. Constant speed engines
for e.g. generator use do not require accelerator sensors
because the engine speed can be shifted via a switch on the
operator's console.
Optional
CAN communication capability is available as an option.
Optional
Is installed on the operator’s console. If a fault occurs in the EECU or Eco-governor, the fault indicator flashes alerting the
operator to a fault. The number of flashes and/or the flashing
pattern vary depending on the type or source of the fault,
enabling quick-fix.
Fault indicator
Engine diagnosis tool
Allows the operator to troubleshoot the cause of a problem
based on detailed information regarding the problem occurring
in the E-ECU or Eco-governor. This tool can also be used for
data maintenance tasks including programming and mapping.
See Failure Diagnosis on page 14-1.
Option for service
Engine coolant temperature sensor
Allows the CSD to be controlled in engine cold-start conditions.
Glow plugs
When the key switch is turned to the ON position, the glow plugs
are energized for up to 15 seconds. The duration of
energization depends on the engine coolant temperature. The
HEAT indicator is on during energization. When the indicator
goes out, turn the key switch to the START position to start the
engine.
4-8
Optional
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Main Electronic Control Components and Features
Component/feature
GENERAL SERVICE INFORMATION
Description
Droop control
Standard with VM series
Reduces the engine speed by a certain percentage from no
load to full (rated) load in steady state operation. The same
percentage droop is maintained even when the load increases
at any no-load speed.
Isochronous control
Standard with CL series
Optional with VM series
Offers a constant engine speed from no load to full load. The
engine speed does not decrease even when the load increases
at any no-load speed.
Low-idling speed up
Increases the low-idling speed to up to 1000 min-1 (rpm)
depending on the engine coolant temperature. When the
coolant temperature reaches a predetermined value, this
feature returns the engine speed to the normal low idle setting,
thus reducing the warm-up time.
High-idling speed
down
Optional
Decreases the high-idling speed depending on the engine
coolant temperature. When the coolant temperature falls to a
predetermined value, this feature returns the engine speed to
the normal high idle setting, thus minimizing the emission of
white smoke at low temperatures.
Auto deceleration
Optional
Brings the running engine in low idle mode automatically when
the accelerator pedal is not operated for a predetermined period
of time. When the pedal is operated, i.e., the accelerator sensor
is activated, the low idle mode is cancelled.
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GENERAL SERVICE INFORMATION
Function of Cooling System Components
FUNCTION OF COOLING SYSTEM COMPONENTS
Components
Functions
Cooling system
The TNV engine is liquid-cooled by means of a cooling system. The cooling
system consists of a radiator, radiator cap, engine cooling fan, engine
coolant pump, thermostat, and reserve tank.
Note that all cooling system components are required for proper
engine operation. Since some of the components are application
specific, they must be carefully selected by an application engineer.
The application specific items are not part of the basic engine package
as shipped from the YANMAR factory.
• Engine cooling fan
The engine cooling fan is driven by a V-belt which is powered by the
crankshaft V-pulley. The purpose of the engine cooling fan is to circulate air
through the radiator.
• Engine coolant pump
The engine coolant pump circulates the engine coolant through the cylinder
block and the cylinder head and returns the engine coolant to the radiator.
• Radiator
The radiator acts as a heat exchanger. As the engine coolant circulates
through the cylinder block it absorbs heat. The heat in the engine coolant is
dissipated in the radiator. As the engine cooling fan circulates air through
the radiator, the heat is transferred to the air.
• Radiator cap
The radiator cap controls the cooling system pressure. The cooling system
is pressurized to raise the boiling point of the engine coolant. As the engine
coolant temperature rises, the system pressure and the coolant volume
increases. When the pressure reaches a preset value, the release valve in
the radiator cap opens and the excess engine coolant flows into the reserve
tank. As the engine coolant temperature is reduced, the system pressure
and volume is reduced and the vacuum valve in the radiator cap opens
allowing the engine coolant to flow from the reserve tank back into the
radiator.
• Reserve tank
The reserve tank contains the overflow of engine coolant from the radiator.
If you need to add engine coolant to the system, add it to the reserve tank;
not the radiator.
• Thermostat
A thermostat is placed in the cooling system to prevent the engine coolant
from circulating into the radiator until the engine coolant temperature
reaches a preset temperature. When the engine is cold, no engine coolant
flows through the radiator. Once the engine reaches its operating
temperature, the thermostat opens and allows the engine coolant to flow
through the radiator. By letting the engine warm up as quickly as possible,
the thermostat reduces engine wear, deposits and emissions.
4-10
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GENERAL SERVICE INFORMATION
Diesel Fuel
DIESEL FUEL
■ Additional technical fuel requirements
Diesel Fuel Specifications
• The fuel cetane number should be equal to 45 or
higher.
Diesel fuel should comply with the following
specifications. The table lists several worldwide
specifications for diesel fuels.
Diesel fuel specification
ASTM D975
No. 1D S15
No. 2D S15
EN590:96
ISO 8217 DMX
BS 2869-A1 or A2
JIS K2204 Grade No. 2
KSM-2610
GB252
Location
USA
European Union
International
United Kingdom
Japan
Korea
China
• The sulfur content must not exceed 0.5 % by
volume. Less than 0.05 % is preferred.
For electronically controlled engines 3TNV88F
(EGR system equipped engine), it is mandatory
to use fuel that does not contain 0.1 % or more
sulfur content.
In general, using a high sulfur fuel may
possible result in corrosion inside the
cylinder. Especially in U.S.A. and Canada,
Ultra Low Sulfur fuel must be used.
• Bio-Diesel fuels. See Bio-diesel fuels on
page 4-12.
• Never mix kerosene, used engine oil, or residual
fuels with the diesel fuel.
• The water and sediment in the fuel should not
exceed 0.05 % by volume.
• Keep the fuel tank and fuel-handling equipment
clean at all times.
• Poor quality fuel can reduce engine performance
and/or cause engine damage.
• Fuel additives are not recommended. Some fuel
additives may cause poor engine performance.
Consult your YANMAR representative for more
information.
• The ash content must not exceed 0.01 % by
volume.
• The carbon residue content must not exceed 0.35
% by volume. Less than 0.1 % is preferred.
• The total aromatics content should not exceed 35
% by volume. Less than 30 % is preferred.
• The PAH (Polycyclic Aromatic Hydrocarbons)
content should be below 10 % by volume.
• The metal content of Na, Mg, Si, and Al should be
equal to or lower than 1 mass ppm. (Test analysis
method JPI-5S-44-95)
• Lubricity: The wear mark of WS1.4 should be
Max. 0.018 in. (460 µm) at HFRR test.
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GENERAL SERVICE INFORMATION
■ Bio-diesel fuels
General description of biodiesel
1. Biodiesel is a renewable, oxygenated fuel made
from agricultural and renewable resources such
as soybeans or rapeseeds. Biodiesel is a fuel
comprised of methyl or ethyl ester-based
oxygenates of long chain fatty acids derived
from the transesterification of vegetable oils,
animal fats, and cooking oils. It contains no
petroleum-based diesel fuel but can be blended
at any level with petroleum-based diesel fuel. In
case it is not blended with petroleum-based
diesel fuel such biodiesel is referred to as
“B 100”, which means that it consists of 100 %
(pure) biodiesel. However, most common
biodiesel is blended with conventional
(petroleum-based) diesel fuel. The percentage
of the blend can be identified by its name. The
most common blends are “B 7” (consisting of 7
% bio- diesel and 93 % conventional petroleumbased diesel fuel) and “B 20” (a blend of 20 %
biodiesel and 80 % conventional diesel). Raw
pressed vegetable oils are not considered to be
biodiesel.
2. Advantages of biodiesel:
• Biodiesel produces less visible smoke and a
lower amount of particulate matter.
• Biodiesel is biodegradable and nontoxic.
• Biodiesel is safer than conventional diesel fuel
because of its higher flash point.
Following the increased interest in the reduction
of emissions and the reduction of the use of
petroleum distillate based fuels; many
governments and regulating bodies encourage
the use of biodiesel.
Diesel Fuel
• Biodiesel can accelerate the oxidation of
Aluminum, Brass, Bronze, Copper and Zinc.
• Biodiesel damages, and finally seeps through
certain seals, gaskets, hoses, glues and
plastics.
• Certain natural rubbers, nitride and butyl
rubbers will become harder and more brittle as
degradation proceeds when used with
biodiesel.
• Biodiesel typically creates deposits in the
engines.
• Due to its natural characteristic, biodiesel will
decrease the engine output by approximately 2
percent (in case of B 20) comparing to
conventional (petroleum-based) diesel fuel.
• The fuel consumption ratio will increase by
approximately 3 percent (in case of B 20)
comparing to conventional diesel fuel.
Approved engines
All of the following engine series of YANMAR can
be operated with biodiesel with concentrations up
to B 20. In case of using biodiesel fuel up to
B 7 concentrations, no special preparations etc.
have to be made and the original operating
conditions and service intervals as stated in the
operating manuals apply. In case of running below
indicated engines with biodiesel concentrations
above B 8 up to B 20, the required operating
conditions (see below Conditions for the operation
with biodiesel (B 8 through B 20)) have to be
observed.
Other than the following listed engines cannot be
run with biodiesel:
• 3TNV88F series
3. Disadvantages of biodiesel:
Concentrations that are higher than 7 % of
biodiesel (higher than B 7) can have an adverse
affect on the engine’s performance, its integrity
and/ or durability. The risk of problems occurring
in the engine increases as the level of biodiesel
blend increases. The following negative affects
are exemplary and typical for the usage of high
concentrated biodiesel blends:
4-12
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GENERAL SERVICE INFORMATION
Diesel Fuel
Approved fuel
In case of using biodiesel (only concentrations up
to B 20) such fuel should comply with the below
recommended standards. However, raw pressed
vegetable oils are not considered to be biodiesel
and are not acceptable for use as fuel in any
concentration in YANMAR engines.
1. EN14214 (European standard) and/or ASTM D6751 (American standard).
2. All applicable engines can be operated with
biodiesel fuel up to B 20 (20 % bio-fuel blend)
as a maximum concentration.
(For your information: In Japan, the legally
allowed maximum concentration for on-road
applications is B 5.)
Conditions for the operation with biodiesel
(B 8 through B 20)
When operating your applicable YANMAR engine
with biodiesel blends concentrated above B 5, we
seriously recommend observing the following
operation, service and maintenance conditions:
1. The original service interval of the below stated
services as indicated in the respective
YANMAR engine standard operation manual,
the application manual and the service manual
should be halved (please refer to your own
manuals for the each service interval):
4. Please use only biodiesel fuel that is
appropriate to the intended operation
environment of the engines. This especially
applies if the operating ambient temperature
falls below 0 degree centigrade.
5. Operation with biodiesel requires daily
maintenance as follows:
• Please daily check the engine oil level. If the oil
level rises above the oil level of the previous
day, the engine oil needs to be immediately
replaced.
• Please daily check the water level of the water
separator. If the water level rises above the
“max” indicator, an immediate drain of the
water separator is required.
6. Biodiesel blends up to B 20 can only be used
for a limited time of up to 3 months of the date
of biodiesel manufacture. Therefore biodiesel
needs to be used at latest within 2 months from
the time of filling the tank or within 3 months
from the time of production by the fuel supplier,
whichever comes first.
7. Before a long-term storage without operating
the engine, the biodiesel needs to be drained
out completely and the engine has to be run for
5 hours with conventional diesel fuel as
indicated in your operation manual.
• Replacement interval of engine oil filter, engine
oil and the fuel filter.
• Cleaning interval of the water separator
• Drain interval of the fuel tank.
2. It is required to inspect, clean and adjust the
fuel injector every 1000 operating hours.
3. Replacement of the following parts before using
the recommended biodiesel:
• Fuel hose
• If not already installed, a water separator
needs to be built in
• O-ring of fuel filter
• O-ring of water separator
Please refer to the attached list of exchange
parts for details.
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GENERAL SERVICE INFORMATION
Diesel Fuel
■ KIT parts list for B 20 (TNV DI engines)
No.
Length
Part No.
Part name
Number
No.
Length
Part No.
Part name
Number
No.
Length
Part No.
Part name
Number
No.
Length
Part No.
Part name
Number
Fuel oil tank / - Fuel oil tank
Fuel feed pump
- Fuel oil filter
Fuel oil filter
- Fuel injection pump
Fuel injection pump
- Fuel oil filter
Part No.
Cap, fuel injection nozzle
Part name
Number
No.
Length
Part No.
Part name
Number
No.
Length
Part No.
Part name
Number
Fuel injection nozzle
-Fuel injection nozzle
Fuel injection nozzle
- Fuel injection pump
Fuel oil filter
G75
P16
P7
G65
Water separator
KIT-V384BGS-BI
3TNV84(T),88
D29283-59260
(1)
2000
129946-59050
FO-T CMP
2
(4)
1000
129946-59040
FO-T CMP
1
(5)
220
129236-59000
FO-T CMP
1
(7)
300
129236-59010
FO-T CMP
1
119593-59581
124060-77680
CAP
CLIP
1
1
(13)
115
129486-59581
FO-T CMP
2
(17)
Formed pipe
129636-59561
FO-T CMP
1
No need
(Because of cartridge type)
Need to change only O-ring.
: 24326-000750 --> C
: 24316-000160 --> D
: 24316-000070 --> E
: 24326-000650 --> C (Need only for TAIYO-GIKEN)
D
C
E
033042-00X
4-14
C
24326-000750 (G75)
D
24316-000160 (P16)
E
24316-000070 (P7)
3TNV88F Service Manual
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GENERAL SERVICE INFORMATION
Diesel Fuel
Filling The Fuel Tank
DANGER
Fire and Explosion Hazard!
• Diesel fuel is flammable and
explosive under certain
conditions.
• Only fill the fuel tank with diesel fuel. Filling
the fuel tank with gasoline may result in a fire
and will damage the engine.
• Never refuel with the engine running.
NOTICE
• Only use diesel fuels recommended by YANMAR
for the best engine performance, to prevent
engine damage and to comply with EPA/ARB
warranty requirements.
• Only use clean diesel fuel.
• Never remove the primary strainer (if equipped)
from the fuel tank filler port. If removed, dirt and
debris could get into the fuel system causing it to
clog.
• Wipe up all spills immediately.
Note that a typical fuel tank is shown. The fuel tank
on your equipment may be different.
• Keep sparks, open flames or any other form of
ignition (match, cigarette, static electric
source) well away when refueling.
1. Clean the area around the fuel cap
(Figure 4-4, (1)).
• Never overfill the fuel tank.
• Fill the fuel tank. Store any containers
containing fuel in a well-ventilated area, away
from any combustibles or sources of ignition.
• Be sure to place the diesel fuel container on
the ground when transferring the diesel fuel
from the pump to the container. Hold the hose
nozzle firmly against the side of the container
while filling it. This prevents static electricity
buildup which could cause sparks and ignite
fuel vapors.
• Never place diesel fuel or other flammable
material such as oil, hay or dried grass close
to the engine during engine operation or
shortly after shutdown.
• Before you operate the engine, check for fuel
leaks. Replace rubberized fuel hoses every
two years or every 2000 hours of engine
operation, whichever comes first, even if the
engine has been out of service. Rubberized
fuel lines tend to dry out and become brittle
after two years or 2000 hours of engine
operation, whichever comes first.
2. Remove the fuel cap (Figure 4-4, (1)) from the
fuel tank (Figure 4-4, (2)).
3. Observe the fuel level sight gauge
(Figure 4-4, (3)) and stop fueling when the
gauge shows the fuel tank is full. Never overfill
the fuel tank.
4. Replace the fuel cap (Figure 4-4, (1)) and hand
tighten. Over-tightening the fuel cap will
damage it.
1
2
3
K0000002A
Figure 4-4
• Failure to comply will result in death or
serious injury.
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GENERAL SERVICE INFORMATION
Diesel Fuel
Priming the Fuel System
The fuel system needs to be primed under certain
conditions:
• Before starting the engine for the first time.
• After running out of fuel and fuel has been added
to the fuel tank.
• After fuel system maintenance such as changing
the fuel filter and draining the fuel filter/water
separator, or replacing a fuel system component.
To prime the fuel system:
1. Turn the key to the ON position for 10 - 15
seconds. This will allow the electric fuel pump
to prime the fuel system.
2. Never use the starter motor to crank the engine
in order to prime the fuel system. This may
cause the starter motor to overheat and
damage the coils, pinion and/or ring gear.
4-16
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GENERAL SERVICE INFORMATION
Engine Oil
ENGINE OIL
Note:
NOTICE
• Only use the engine oil specified. Other engine
oils may affect warranty coverage, cause internal
engine components to seize and/or shorten
engine life.
• Be sure the engine oil, engine oil storage
containers, and engine oil filling equipment are
free of sediment and water.
• Change the engine oil after the first 50 hours of
operation and then every 250 hours thereafter.
• Prevent dirt and debris from contaminating the
engine oil. Carefully clean the oil cap/dipstick and
the surrounding area before you remove the cap.
• Select the oil viscosity based on the ambient
temperature where the engine is being operated.
See the SAE service grade viscosity chart
(Figure 4-5).
• Never mix different types of engine oil. This may
adversely affect the lubricating properties of the
engine oil.
• YANMAR does not recommend the use of engine
oil “additives”.
• Never overfill. Overfilling may result in white
exhaust smoke, engine overspeed or internal
damage.
Engine Oil Specifications
Use an engine oil that meets or exceeds the
following guidelines and classifications:
■ Service categories
• API service categories CF, CF-4 and CI-4
■ Additional technical engine oil
requirements:
The engine oil must be changed when the Total
Base Number (TBN) has been reduced to 1.0
mgKOH/g test method; JIS K-201-5.2-2 (HCI),
ASTM D4739 (HCI).
Engine Oil Viscosity
Select the appropriate engine oil viscosity based on
the ambient temperature and use the SAE service
grade viscosity chart in Figure 4-5.
• ACEA service categories E-3, E-4, and E-5
• JASO service category DH-1
SAE 10W-30
SAE 5W-30
■ Definitions
SAE 15W-40
• API classification (American Petroleum Institute)
SAE 20
SAE 30
• ACEA classification (Association des
Constructeurs Européens d’Automobilies)
• JASO (Japanese Automobile Standards
Organization)
-30°C -20°C -10°C
0
10°C
20°C 30°C
40°C
K0000005A05
Figure 4-5
3TNV88F Service Manual
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GENERAL SERVICE INFORMATION
Engine Oil
Checking Engine Oil
Adding Engine Oil
1. Make sure the engine is level.
1. Make sure the engine is level.
2. Remove the dipstick (Figure 4-6, (1)) and wipe
it with clean cloth.
2. Remove the oil cap (Figure 4-6, (4)).
3. Fully reinsert the dipstick.
4. Remove the dipstick. The oil level should be
between the upper (Figure 4-6, (2)) and lower
(Figure 4-6, (3)) lines on the dipstick.
5. Fully reinsert the dipstick.
3. Add the indicated amount of engine oil at the
top or the side engine oil filler port
(Figure 4-6, (5)).
4. Wait three minutes and check the oil level.
5. Add more oil if necessary.
6. Reinstall the oil cap (Figure 4-6, (4)) and
hand-tighten. Over-tightening may damage the
cap.
4
Engine Oil Capacity (Typical)
4
Note: These are the engine oil capacities
associated with a “deep standard” oil pan.
The oil capacity will vary dependant upon
which optional oil pan is used. Refer to the
operation manual provided by the driven
machine manufacturer for the actual engine
oil capacity of your machine.
The following are the engine oil capacities for
various YANMAR TNV engines.
5
1
Engine model
3TNV88F
2
045046-00X02
4-18
7.1/4.1 qt (6.7/3.9 l)
CAUTION
3
Figure 4-6
Dipstick
upper limit/lower limit
To refuel the engine oil, refuel slowly after
removing the dipstick and both caps. If you
refuel rapidly, the oil intrusion to the intake
occurs through the PCV valve of the valve
cover. It will result in an oil hammer at engine
start, which may cause damage to the engine.
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GENERAL SERVICE INFORMATION
Engine Coolant
ENGINE COOLANT
DANGER
Scald Hazard!
• Never remove the radiator cap if
the engine is hot. Steam and hot
engine coolant will spurt out and
seriously burn you. Allow the
engine to cool down before you
attempt to remove the radiator
cap.
• Tighten the radiator cap securely after you
check the radiator. Steam can spurt out
during engine operation if the cap is loose.
NOTICE
• Only use the engine coolant specified. Other
engine coolants may affect warranty coverage,
cause an internal buildup of rust and scale and/or
shorten engine life.
• Prevent dirt and debris from contaminating the
engine coolant. Carefully clean the radiator cap
and the surrounding area before you remove the
cap.
• Never mix different types of engine coolants. This
may adversely affect the properties of the engine
coolant.
• Always check the level of the engine coolant
by observing the reserve tank.
• Failure to comply will result in death or
serious injury.
WARNING
Burn Hazard!
• Wait until the engine cools before
you drain the engine coolant. Hot
engine coolant may splash and
burn you.
• Failure to comply could result in death or
serious injury.
CAUTION
Coolant Hazard!
• Wear eye protection
and rubber gloves
when you handle long
life or extended life
engine coolant. If
contact with the eyes
or skin should occur,
flush eyes and wash
immediately with
clean water.
• Failure to comply may result in minor or
moderate injury.
3TNV88F Service Manual
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GENERAL SERVICE INFORMATION
Engine Coolant
Engine Coolant Specifications
Filling Radiator with Engine Coolant
Use a Long Life Coolant (LLC) or an Extended Life
Coolant (ELC) that meets or exceeds the following
guidelines and specifications:
Fill the radiator and reserve tank as follows. This
procedure is for filling the radiator for the first time
or refilling it after it is flushed. Note that a typical
radiator is illustrated (Figure 4-7).
■ Additional technical coolant
specifications:
2
• ASTM D6210, D4985 (US)
5
• JIS K-2234 (Japan)
• SAE J814C, J1941, J1034 or J2036
(International)
3
■ Alternative engine coolant
6
FULL
LOW
4
If an Extended or Long Life Coolant is not available,
alternatively, you may use an ethylene glycol or
propylene glycol based conventional coolant
(green).
1
K0000029A
Note:
• Always use a mix of coolant and water.
Never use water only.
• Mix the coolant and water per the mixing
instructions on the coolant container.
• Water quality is important to coolant
performance. YANMAR recommends that soft,
distilled, or demineralized water be used to mix
with coolants.
Figure 4-7
1. Check to be sure the radiator drain plug is
installed and tightened or the drain cock
(Figure 4-7, (1)) is closed. Also make sure the
coolant drain plug (Figure 4-8, (1)) in the
cylinder block is closed.
• Never mix extended or long life coolants and
conventional (green) coolants.
• Never mix different types and/or colors of
extended life coolants.
1
• Replace the coolant every 1000 engine hours or
once a year.
046370-00X00
Figure 4-8
2. Remove the radiator cap (Figure 4-7, (2)) by
turning it counter-clockwise about 1/3 of a turn.
4-20
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GENERAL SERVICE INFORMATION
Engine Coolant
3. Pour the engine coolant slowly into the radiator
until it is even with the lip of the engine coolant
filler port. Make sure that air bubbles do not
develop as you fill the radiator.
4. Reinstall the radiator cap (Figure 4-7, (2)).
Align the tabs on the back side of the radiator
cap with the notches on the engine coolant filler
port. Press down and turn the cap clockwise
about 1/3 of a turn.
Engine Coolant Capacity (Typical)
Note: The capacities listed are for the engine only
without a radiator. Refer to the operation
manual provided by the driven machine
manufacturer for the actual engine coolant
capacity on your machine.
The engine coolant capacity of 3TNV88F is
3TNV88F 2.1 qt (2.0 l) (engine only).
5. Remove the cap on the reserve tank
(Figure 4-7, (3)), and fill it to the LOW (COLD)
mark (Figure 4-7, (4)) with engine coolant.
Reinstall the cap.
6. Check the hose (Figure 4-7, (5)) that connects
the reserve tank (Figure 4-7, (3)) to the
radiator. Be sure it is securely connected and
there are no cracks or damage. If the hose is
damaged, the engine coolant will leak out
instead of going into the reserve tank.
7. Run the engine until it is at operating
temperature. Check the level of engine coolant
in the reserve tank. When the engine is running
and the engine coolant is at normal
temperature, the coolant level in the tank should
be at the FULL (HOT) mark (Figure 4-7, (6)). If
the engine coolant is not at the FULL (HOT)
mark (Figure 4-7, (6)), add additional engine
coolant to the reserve tank to bring the level to
the FULL (HOT) mark.
3TNV88F Service Manual
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GENERAL SERVICE INFORMATION
Specifications
SPECIFICATIONS
Description of Model Number
3
TNV
88
F
-
E
0
00
Customer code
Rated RPM
Electronic governor (Eco-governor)
EPA Tier 4 certified with Hot EGR
Cylinder bore (mm)
Engine series
No. of cylinders
Engine General Specifications
Type
Vertical in-line, water cooled, 4-cycle diesel engine
Combustion system
Direct injection
Starting system
Electric starting
Cooling system
Radiator
Lubricating system
Forced lubrication with trochoid pump
PTO position
Direction of rotation
Flywheel end
Counterclockwise viewed from flywheel end
Note:
• The information described in Principal Engine Specificationsis for a “standard” engine. To obtain the
information for the engine installed in your driven machine, please refer to the manual provided by the
driven machine manufacturer.
• Engine rating conditions are as follows (SAE J1349, ISO 3046/1):
• Atmospheric condition: Room temperature 77 °F (25 °C), atmospheric pressure 29.53 in. Hg (100 kPa,
750 mmHg), relative humidity 30 %
• Fuel temperature at fuel injector pump inlet: 104 °F (40 °C)
• Fuel feeding pressure: 20 ± 10 kPa (net) after engine break-in has been performed with the cooling fan,
air cleaner and muffler installed to the engine.
• With cooling fan, air cleaner, muffler: YANMAR standard
• After the engine break-in period. Output allowable deviation: ± 3 %
• 1 PS = 0.7355 kW
• 1 hp SAE (Society of Automotive Engineers) = 0.7457 kW
4-22
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Principal Engine Specifications
GENERAL SERVICE INFORMATION
PRINCIPAL ENGINE SPECIFICATIONS
Engine model
Version
Type
Combustion system
Aspiration
No. of cylinders
Bore × stroke
Displacement
Max. rated output (gross)
High idling
Engine weight (dry)
PTO position
Direction of rotation
Cooling system
Lubricating system
Normal oil pressure at rated engine speed
Normal oil pressure at low idle speed
Starting system
Dimensions (L × W × H)
Engine oil pan capacity
Engine coolant capacity
Standard cooling fan
Crank V-pulley dia./Fan V-pulley dia.
Top clearance
3TNV88F Service Manual
3TNV88F
VM
Vertical in-line diesel engine
Direct injection
Naturally aspiration
3
88 × 90 mm
1.642 l
2400 min-1
17.6 kW
23.9 PS
2550 ± 25 min-1
152 kg
Flywheel end
Counterclockwise viewed from flywheel end
Liquid-cooled with radiator
Forced lubrication with trochoid pump
0.34 - 0.54 MPa
0.06 MPa
Electric starting (starter motor: DC12 V - 1.7 kW)
Alternator (12 V - 40 A)
Recommended battery capacity: 12 V 413CCA
588 × 577 × 634 mm
6.7/3.9 l
Dipstick upper limit/lower Limit
2.0 l (Engine only)
ø335 Pusher
ø110/ø110 mm
0.73 ± 0.06 mm
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GENERAL SERVICE INFORMATION
Engine Service Standards
ENGINE SERVICE STANDARDS
Inspection item
Intake/exhaust valve clearance
Standard
Limit
Reference page
0.006 - 0.010 in.
(0.15 - 0.25 mm)
–
See Measuring and
Adjusting Valve
Clearance on page 6-30
Fuel injection timing
See Checking and Adjusting Fuel Injection Timing on page 7-20.
Fuel injection pressure
See Test and Adjustment Specifications on page 7-6.
483 - 513 PSI
(3.33 - 3.53 MPa;
34 - 36 kgf/cm²)
384 - 414 PSI
(2.65 - 2.85 MPa;
27 - 29 kgf/cm²)
See Troubleshooting By
Measuring Compression
Pressure on page 14-4
Deviation between cylinders
29 - 43 PSI
(0.2 - 0.3 MPa;
2 - 3 kgf/cm²)
–
–
Oil pressure switch operating
pressure
5.8 - 8.8 PSI
(0.04 - 0.06 MPa;
0.4 - 0.6 kgf/cm²)
–
–
Valve opening
temperature
Full opening lift
temperature
157 °F - 163 °F
(70 °C - 73 °C)
0.32 in. (8 mm)
or above
185 °F (85 °C)
176 °F - 183 °F
(80 °C - 84 °C)
0.39 in. (10 mm)
or above
203 °F (95 °C)
225 °F - 235 °F
(107 °C - 113 °C)
–
Compression pressure
at 250 min-1 (rpm)
Thermostat
Thermostat
Option
Coolant temperature switch
4-24
See Thermostat on
page 8-9
See Temperature switch
on page 8-8
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Tightening Torques for Standard Bolts and Nuts GENERAL SERVICE INFORMATION
TIGHTENING TORQUES FOR STANDARD BOLTS AND NUTS
Use the correct amount of torque when you tighten the fasteners on the machine. Applying excessive
torque may damage the fastener or component and not enough torque may cause a leak or component
failure.
NOTICE
The tightening torque in the Standard Torque Chart (see General Service Information section) should be
applied only to the bolts with a “7” head. (JIS strength classification: 7T)
• Apply 60 % torque to bolts that are not listed.
• Apply 80 % torque when tightened to aluminum alloy.
Item
Hexagon bolt (7T)
and nut
Nominal thread
diameter
× pitch
Tightening torque
M6 × 1.0 mm
7 - 9 ft-lb
(87 -104 in.-lb,
9.8 -11.8 N·m,
1.0 -1.2 kgf·m)
M8 × 1.25 mm
17 - 21 ft-lb
(200 - 251 in.-lb,
22.6 - 28.4 N·m,
2.3 - 2.9 kgf·m)
M10 × 1.5 mm
33 - 40 ft-lb
(44.1 - 53.9 N·m,
4.5 - 5.5 kgf·m)
M12 × 1.75 mm
58 - 72 ft-lb
(78.4 - 98.0 N·m,
8.0 - 10 kgf·m)
M14 × 1.5 mm
94 - 108 ft-lb
(127.5 - 147.1 N·m,
13 - 15 kgf·m)
M16 × 1.5 mm
159 - 174 ft-lb
(215.7- 235.4 N·m,
22 - 24 kgf·m)
1/8
7 ft-lb
(87 in.-lb, 9.8 N·m, 1.0 kgf·m)
1/4
14 ft-lb
(173 in.-lb, 19.6 N·m, 2.0 kgf·m)
3/8
22 ft-lb
(29.4 N·m, 3.0 kgf·m)
1/2
43 ft-lb
(58.8 N·m, 6.0 kgf·m)
PT plug
3TNV88F Service Manual
Remarks
Use 80 % of the value at
left when the tightening
part is aluminum.
Use 60 % of the value at
left for 4T bolts and lock
nuts.
–
4-25
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GENERAL SERVICE INFORMATION Tightening Torques for Standard Bolts and Nuts
Item
Nominal thread
diameter
× pitch
Tightening torque
M8
9 - 12 ft-lb
(112 - 148 in.-lb,
12.7 - 16.7 N·m,
1.3 - 1.7 kgf·m)
M10
14 - 19 ft-lb
(173 - 225 in.-lb,
19.6 - 18.734 N·m,
2.0 - 3.5 kgf·m)
M12
18 - 25 ft-lb
(24.5 - 34.3 N·m,
2.5 - 3.5 kgf·m)
M14
29 - 36 ft-lb
(39.2 - 49.0 N·m,
4.0 - 5.0 kgf·m)
M16
36 - 43 ft-lb
(49.0 - 58.8 N·m,
5.0 - 6.0 kgf·m)
Pipe joint bolt
Remarks
–
Note: Torque values shown in this manual are for clean, non-lubricated fasteners unless otherwise
specified.
4-26
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GENERAL SERVICE INFORMATION
Abbreviations and Symbols
ABBREVIATIONS AND SYMBOLS
■ Abbreviations
A
AC
ACEA
Ah
API
ARB
ATDC
BDC
BTDC
°C
CARB
CCA
cfm
cm
cm³
cm³/min
cu in.
D
DC
DI
DVA
EPA
ESG
°F
fl oz
fl oz/min
ft
ft-lb
ft-lbf/min
g
gal
gal/hr
gal/min
GL
hp
hr
I.D.
ID
IDI
in.
in.Aq
in.Hg
in.-lb
j
JASO
ampere
alternating current
Association des Constructeurs
Européens d’Automobilies
ampere-hour
American Petroleum Institute
Air Resources Board
after top dead center
bottom dead center
before top dead center
degree Celsius
California Air Resources Board
cold cranking amp
cubic feet per minute
centimeter
cubic centimeter
cubic centimeter per minute
cubic inch
diameter
direct current
direct injection
direct volt adapter
Environmental Protection Agency
electronic speed governor
degree Fahrenheit
fluid ounce (U.S.)
fluid ounce (U.S.) per minute
foot
foot pound
foot pound force per minute
gram
gallon (U.S.)
gallon (U.S.) per hour
gallon (U.S.) per minute
gear lubricant
horsepower (U.S.)
hour
inside diameter
identification
indirect injection
inch
inches Aqueous (water)
inches Mercury
inch pound
joule
Japanese Automobile Standards
Organization
3TNV88F Service Manual
k
kg
kgf/cm²
kgf/m
km
kPa
kW
L
L/hr
lb
lbf
m
ml
mm
mmAq
MPa
mV
N
N·m
No.
O.D.
oz
Pa
PS
PSI
qt
R
rpm
SAE
sec.
t
TBN
TDC
V
VAC
VDC
W
kelvin
kilogram
kilogram force per square
centimeter
kilogram force per meter
kilometers
kilopascal
kilowatt
liter
liter per hour
pound
pound force
meter
milliliter
millimeter
millimeter Aqueous (water)
megapascal
millivolt
newton
newton meter
number
outside diameter
ounce
pascal
horsepower (metric)
pound per square inch
quart (U.S.)
radius
revolutions per minute
Society of Automotive Engineers
second
short ton 2000 lb
total base number
top dead center
volt
volt alternating current
volt direct current
watt
■ Symbols
°
+
±


%
degree
plus
minus
plus or minus
ohm
micro
percent
4-27
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GENERAL SERVICE INFORMATION
■ Units of torque
UNIT CONVERSIONS
■ Unit prefixes
Prefix
mega
kilo
centi
milli
micro
Symbol
M
k
c
m

Power
× 1,000,000
× 1,000
× 0.01
× 0.001
× 0.000001
■ Units of length
mile
ft
in.
in.
km
m
cm
mm
×
×
×
×
×
×
×
×
1.6090
0.3050
2.5400
25.4000
0.6210
3.2810
0.3940
0.0394
= km
=m
= cm
= mm
= mile
= ft
= in.
= in.
■ Units of volume
gal (U.S.)
qt (U.S.)
cu in.
cu in.
fl oz (U.S.)
fl oz (U.S.)
cm³
cm³
×
×
×
×
×
×
×
×
3.78540
0.94635
0.01639
16.38700
0.02957
29.57000
1.00000
0.03382
=l
=l
=l
= ml
=l
= ml
= ml
= fl oz (U.S.)
×
×
×
×
0.45360
28.35000
2.20500
0.03527
= kg
=g
= lb
= oz
4.4480
0.4536
0.2248
0.1020
2.2050
9.8070
=N
= kgf
= lbf
= kgf
= lbf
=N
■ Units of force
lbf
lbf
N
N
kgf
kgf
4-28
×
×
×
×
×
×
ft-lb
ft-lb
in.-lb
in.-lb
kgf/m
kgf/m
kgf/m
N·m
N·m
N·m
×
×
×
×
×
×
×
×
×
×
1.3558
0.1383
0.1130
0.0115
7.2330
86.8000
9.8070
0.7376
8.8510
0.1020
= N·m
= kgf/m
= N·m
= kgf/m
= ft-lb
= in.-lb
= N·m
= ft-lb
= in.-lb
= kgf/m
■ Units of pressure
PSI
PSI
PSI
bar
bar
bar
kPa
kPa
kPa
kg/cm²
kg/cm²
kg/cm²
in.Hg (60°)
in.Hg (60°)
in.Hg (60°)
mmAq
×
×
×
×
×
×
×
×
×
×
×
×
×
×
×
×
0.0689
6.8950
0.0703
14.5030
100.0000
29.5300
0.1450
0.0100
0.0102
98.0700
0.9807
14.2200
0.0333
3.3770
0.0344
0.0394
= bar
= kPa
= kg/cm²
= psi
= kPa
= inHg (60 °F)
= PSI
= bar
= kg/cm²
= psi
= bar
= kPa
= bar
= kPa
= kg/cm²
= in.Aq
■ Units of power
■ Units of mass
lb
oz
kg
g
Unit Conversions
hp (metric or
PS)
hp (metric or
PS)
hp SAE
hp SAE
kW
kW
×
0.9863201
= hp SAE
×
0.7354988
= kW
×
×
×
×
1.0138697
0.7456999
1.3596216
1.3410221
= hp (metric or PS)
= kW
= hp (metric or PS)
= hp SAE
■ Units of temperature
°F = (1.8 × °C) + 32
°C = 0.556 × (°F - 32)
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3TNV88F Service Manual
Section 5
PERIODIC
MAINTENANCE
Page
Before You Begin Servicing ............................................................ 5-3
Introduction......................................................................................
The Importance of Periodic Maintenance..................................
Performing Periodic Maintenance .............................................
YANMAR Replacement Parts....................................................
Required EPA/ARB Maintenance - USA Only...........................
EPA/ARB Installation Requirements - USA Only ......................
5-4
5-4
5-4
5-4
5-4
5-4
Periodic Maintenance Schedule...................................................... 5-5
Periodic Maintenance Procedures .................................................. 5-7
After Initial 50 Hours of Operation ............................................. 5-7
Every 50 Hours of Operation ................................................... 5-11
Every 250 Hours of Operation ................................................. 5-14
Every 500 Hours of Operation ................................................. 5-17
Every 1000 Hours of Operation ............................................... 5-20
Every 1500 Hours of Operation ............................................... 5-22
Every 2000 Hours of Operation ............................................... 5-23
Every 3000 Hours of Operation ............................................... 5-24
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PERIODIC MAINTENANCE
This Page Intentionally Left Blank
5-2
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Before You Begin Servicing
PERIODIC MAINTENANCE
BEFORE YOU BEGIN
SERVICING
Before performing any service procedures within
this section, read the following safety information
and review the Safety section on page 3-1.
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PERIODIC MAINTENANCE
Introduction
INTRODUCTION
YANMAR Replacement Parts
This section of the Service Manual describes the
procedures for proper care and maintenance of the
engine.
YANMAR recommends that you use genuine
YANMAR parts when replacement parts are
needed. Genuine replacement parts help ensure
long engine life.
The Importance of Periodic
Maintenance
Engine deterioration and wear occurs in proportion
to length of time the engine has been in service and
the conditions the engine is subject to during
operation. Periodic maintenance prevents
unexpected downtime, reduces the number of
accidents due to poor machine performance and
helps extend the life of the engine.
Performing Periodic Maintenance
WARNING
Exhaust Hazard!
• Never operate the engine in an
enclosed area such as a garage,
tunnel, underground room,
manhole or ship’s hold without
proper ventilation.
• Never block windows, vents, or other means
of ventilation if the engine is operating in an
enclosed area. All internal combustion
engines create carbon monoxide gas during
operation. Accumulation of this gas within an
enclosure could cause illness or even death.
Required EPA/ARB Maintenance USA Only
To maintain optimum engine performance and
compliance with the Environmental Protection
Agency (EPA) Regulations Non-road Engines and
the California Air Resources Board (ARB,
California), it is essential that you follow the
Periodic Maintenance Schedule on page 5-5 and
Periodic Maintenance Procedures on page 5-7.
EPA/ARB Installation Requirements USA Only
The following are the installation requirements for
the EPA/ARB. Unless these requirements are met,
the exhaust gas emissions will not be within the
limits specified by the EPA and ARB.
Maximum Exhaust Gas Restriction shall be:
• 1560 mmAq or less
Maximum air intake restriction shall be 0.90 PSI
(6.23 kPa; 635 mmAq) or less. Clean or replace the
air cleaner element if the air intake restriction
exceeds the above mentioned value.
• Make sure that all connections are tightened
to specifications after repair is made to the
exhaust system.
• Failure to comply could result in death or
serious injury.
Perform periodic maintenance procedures in an
open, level area free from traffic. If possible,
perform the procedures indoors to prevent
environmental conditions, such as rain, wind, or
snow, from damaging the machine.
5-4
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PERIODIC MAINTENANCE
Periodic Maintenance Schedule
PERIODIC MAINTENANCE SCHEDULE
Daily and periodic maintenance is important to keep the engine in good operating condition. The following
is a summary of maintenance items by periodic maintenance intervals. Periodic maintenance intervals vary
depending on engine application, loads, diesel fuel and engine oil used and are hard to establish
definitively. The following should be treated only as a general guideline.
NOTICE
Establish a periodic maintenance plan according to the engine application and make sure you perform the
required periodic maintenance at the intervals indicated. Failure to follow these guidelines will impair the
engine’s safety and performance characteristics, shorten the engine’s life and may affect the warranty
coverage on your engine.
See YANMAR Limited Warranty in Warranty Section.
Consult your authorized YANMAR dealer or distributor for assistance when checking items marked with a .
: Check : Replace : Contact your authorized YANMAR industrial engine dealer or distributor
Periodic maintenance interval
System
Check item
Check and refill engine coolant
Daily
Every
50
hours
Every
250
hours

1st
time
Cooling
system

Lap intake/exhaust valve seats
(if required)



Check battery
Drain and fill engine oil
Engine oil
Replace engine oil filter
3TNV88F Service Manual
Every
3000
hours
 or
every
1 year
whichever
comes
first
Adjust intake/exhaust valve clearance
Check engine oil level
Every
2000
hours

2nd
and
after
Drain, flush and refill cooling system with
new coolant
Check indicators
Every
1500
hours

Check and adjust cooling fan V-belt
Electrical
equipment
Every
1000
hours

Check and clean radiator fins
Cylinder
head
Every
500
hours


1st
time

2nd
and
after
5-5
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PERIODIC MAINTENANCE
Periodic Maintenance Schedule
: Check : Replace : Contact your authorized YANMAR industrial engine dealer or distributor
Periodic maintenance interval
System
Emission
control
warranty
Check item
Daily
Every
50
hours
Every
250
hours
Every
500
hours
Every
1000
hours
Every
1500
hours
Inspect, clean and test fuel injectors,
if necessary
Every
3000
hours

Inspect, clean and test EGR valve

Clean EGR lead valve


Inspect crankcase breather system
Check and refill fuel tank level


Drain fuel tank
Fuel
Every
2000
hours
Drain fuel filter/water separator

Check fuel filter/water separator

Clean fuel filter/water separator

Replace fuel filter

Hoses
Replace fuel system and cooling system
hoses
Intake and
exhaust
Clean or replace air cleaner element
Complete
engine
Overall visual check daily
 or
every 2
yrs.



Note: These procedures are considered normal maintenance and are performed at the owner’s expense.
5-6
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Periodic Maintenance Procedures
PERIODIC MAINTENANCE
PROCEDURES
After Initial 50 Hours of Operation
Perform the following maintenance after the initial
50 hours of operation.
• Replace engine oil and engine oil filter
• Check and adjust cooling fan V-belt
■ Replace engine oil and engine oil filter
WARNING
Burn Hazard!
• If you must drain the engine oil
while it is still hot, stay clear of
the hot engine oil to avoid being
burned.
PERIODIC MAINTENANCE
NOTICE
• Only use the engine oil specified. Other engine
oils may affect warranty coverage, cause internal
engine components to seize and/or shorten
engine life.
• Prevent dirt and debris from contaminating the
engine oil. Carefully clean the oil cap/dipstick and
the surrounding area before you remove the cap.
• Never mix different types of engine oil. This may
adversely affect the lubricating properties of the
engine oil.
• Never overfill. Overfilling may result in white
exhaust smoke, engine overspeed or internal
damage.
NOTICE
• Always be environmentally
responsible.
• Always wear eye protection.
• Failure to comply could result in death or
serious injury.
WARNING
Sudden Movement Hazard!
• Engaging the transmission or PTO at an
elevated engine speed could result in
unexpected movement of the equipment.
• Failure to comply could result in death or
serious injury.
3TNV88F Service Manual
• Follow the guidelines of the EPA or other
governmental agencies for the proper disposal of
hazardous materials such as engine oil, diesel
fuel and engine coolant. Consult the local
authorities or reclamation facility.
• Never dispose of hazardous materials
irresponsibly by dumping them into a sewer, on
the ground, or into ground water or waterways.
• Failure to follow these procedures may seriously
harm the environment.
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PERIODIC MAINTENANCE
Periodic Maintenance Procedures
The engine oil in a new engine becomes
contaminated from the initial break-in of internal
parts. It is very important that the initial oil and filter
change is performed as scheduled.
Note: The oil drain plug may be in another location
if an optional oil pan is used.
6. Remove the oil drain plug (Figure 5-2, (1)) from
the engine oil pan. Allow oil to drain.
7. After all oil has been drained from the engine,
reinstall the oil drain plug (Figure 5-2, (1)) and
tighten to 139.8 - 47.0 ft·lb (53.9 - 63.7 N·m; 5.5
- 6.5 kgf·m).
8. Dispose of used oil properly.
Drain the engine oil as follows:
1. Make sure the engine is level.
2. Start the engine and bring it up to operating
temperature.
Remove the engine oil filter as follows:
1. Turn the engine oil filter (Figure 5-2, (2))
counterclockwise (Figure 5-2, (3)) using a filter
wrench.
3. Stop the engine.
4. Remove one of the oil filler caps
(Figure 5-1, (1)) to vent the engine crankcase
and allow the engine oil to drain more easily.
2
3
5. Position a container under the engine to collect
waste oil.
4
1
1
045049-00X00
Figure 5-2
2. Clean the engine oil filter mounting face.
046795-00X00
1
3. Lightly coat the gasket on the new oil filter with
engine oil. Install the new engine oil filter
manually by turning it clockwise
(Figure 5-2, (4)) until it contacts the mounting
surface. Tighten to 14 - 17 ft·lb (19.6 - 23.5 N·m;
2.0 - 2.4 kgf·m) or one additional turn using the
filter wrench.
Engine oil filter Part No.
Standard
Dust proof*
129150-35153
119005-35151
* Consult the operation manual for the driven
machine for applicability of the dust proof filter.
046796-00X00
Figure 5-1
5-8
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PERIODIC MAINTENANCE
Periodic Maintenance Procedures
4. Add new engine oil to the engine as specified in
Adding Engine Oil on page 4-18.
NOTICE
9. Reinstall the oil filler cap (Figure 5-3, (4)). If
any engine oil is spilled, wipe it away with a
clean cloth.
■ Check and adjust cooling fan V-belt
• Never overfill the engine with engine oil.
• Always keep the oil level between the upper
and lower lines on the oil cap/dipstick.
5. Warm up the engine by running it for five
minutes and check for any engine oil leaks.
6. After engine is warm, shut it off and let it sit for
10 minutes.
7. Recheck the engine oil level.
8. Add engine oil (Figure 5-3, (5)) as needed until
the level is between the upper (Figure 5-3, (2))
and lower lines (Figure 5-3, (3)) shown on the
dipstick (Figure 5-3, (1)).
4
The V-belt will slip if it does not have the proper
tension. This will prevent the alternator from
generating sufficient power. Also, the engine will
overheat due to the engine coolant pump pulley
slipping.
Check and adjust the V-belt tension (deflection) as
follows:
1. Press the V-belt down with your thumb with a
force of approximately 22 ft·lb (98 N·m; 10 kgf)
to check the deflection.
There are three positions to check for V-belt
tension (Figure 5-4, (A), (B) and (C)). You can
check the tension at whichever position is the
most accessible. The proper deflection of a used
V-belt at each position is:
Used V-belt tension
4
A
B
C
3/8 - 1/2 in.
(10 - 14 mm)
1/4 - 3/8 in.
(7 - 10 mm)
5/16 - 1/2 in.
(9 - 13 mm)
Note: A “Used V-Belt” refers to a V-belt which
has been used on a running engine for
five minutes or more.
B
5
1
2
A
C
3
K0000063B
045046-00X02
Figure 5-3
3TNV88F Service Manual
Figure 5-4
5-9
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PERIODIC MAINTENANCE
Periodic Maintenance Procedures
2. If necessary, adjust the V-belt tension. Loosen
the adjusting bolt (Figure 5-5, (1)) and the
other related bolts and/or nuts, then move the
alternator (Figure 5-5, (2)) with a pry bar
(Figure 5-5, (3)) to tighten the V-belt to the
desired tension. Then tighten the adjusting
bolts and/or nuts.
6. After adjusting, run the engine for 5 minutes or
more. Check the tension again using the
specifications for a used V-belt.
Used V-belt tension
A
B
C
3/8 - 1/2 in.
(10 - 14 mm)
1/4 - 3/8 in.
(7 - 10 mm)
5/16 - 1/2 in.
(9 - 13 mm)
3
1
2
K0000064B
Figure 5-5
3. Tighten the V-belt to the proper tension. There
must be clearance (Figure 5-6, (1)) between
the V-belt and the bottom of the pulley groove. If
there is no clearance (Figure 5-6, (2)) between
the V-belt and the bottom of the pulley groove,
replace the V-belt.
2
1
K0000584
Figure 5-6
4. Check the V-belt for cracks, oil or wear. If any of
these conditions exist, replace the V-belt.
5. Install the new V-belt. Refer to the table for
proper tension.
New V-belt tension
5-10
A
B
C
5/16 - 7/16 in.
(8 - 12 mm)
3/16 - 5/16 in.
(5 - 8 mm)
1/4 - 7/16 in.
(7 - 11 mm)
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Periodic Maintenance Procedures
Every 50 Hours of Operation
After you complete the initial 50 hour maintenance
procedures, perform the following procedures every
50 hours thereafter.
PERIODIC MAINTENANCE
NOTICE
• Always be environmentally
responsible.
• Drain fuel filter/water separator
• Check battery
■ Drain fuel filter/water separator
DANGER
Fire and Explosion Hazard!
• Diesel fuel is flammable and
explosive under certain
conditions.
• When you remove any fuel system component
to perform maintenance (such as changing
the fuel filter) place an approved container
under the opening to catch the fuel.
• Never use a shop rag to catch the fuel. Vapors
from the rag are flammable and explosive.
• Wipe up any spills immediately.
• Wear eye protection. The fuel system is under
pressure and fuel could spray out when you
remove any fuel system component.
• Failure to comply will result in death or
serious injury.
• Follow the guidelines of the EPA or other
governmental agencies for the proper disposal of
hazardous materials such as engine oil, diesel
fuel and engine coolant. Consult the local
authorities or reclamation facility.
• Never dispose of hazardous materials
irresponsibly by dumping them into a sewer, on
the ground, or into ground water or waterways.
• Failure to follow these procedures may seriously
harm the environment.
Drain the fuel filter/water separator whenever there
are contaminants, such as water, collected in the
bottom of the cup. Never wait until the scheduled
periodic maintenance if contaminants are
discovered.
The cup of the separator is made from semitransparent material. In the cup is a red colored
float ring. The float ring will rise to the surface of the
water to show how much needs to be drained. Also,
some optional fuel filter/water separators are
equipped with a sensor to detect the amount of
contaminants. This sensor sends a signal to an
indicator to alert the operator.
NOTICE
If the fuel filter/water separator is positioned higher
than the fuel level in the fuel tank, water may not
drip out when the fuel filter/water separator drain
cock is opened. If this happens, turn the air vent
screw on the top of the fuel filter/water separator 2 3 turns counterclockwise.
Be sure to tighten the air vent screw after the water
has drained out.
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PERIODIC MAINTENANCE
Periodic Maintenance Procedures
Drain the fuel filter/water separator as follows:
1. Position an approved container under the fuel
filter/water separator (Figure 5-7, (1)) to collect
the contaminants.
3
2
1
■ Check battery
DANGER
Explosion Hazard!
• Never check the remaining
battery charge by shorting out the
terminals. This will result in a
spark and may cause an
explosion or fire. Use a
hydrometer to check the
remaining battery charge.
• If the electrolyte is frozen, slowly warm the
battery before you recharge it.
• Failure to comply will result in death or
serious injury.
4
045099-00X00
Figure 5-7
2. Close (Figure 5-7, (2)) the fuel cock
(Figure 5-7, (3)).
3. Loosen the drain cock (Figure 5-7, (4)) at the
bottom of the fuel filter/water separator. Drain
any water collected inside.
4. Hand-tighten the drain cock. (tightening torque:
1.0 - 2.0 N·m (0.1 - 0.2 kgf·m))
NOTICE
If the fuel filter/water separator is positioned
higher than the fuel level in the fuel tank, water
may not drip out when the fuel filter/water
separator drain cock is opened. If this happens,
turn the air vent screw on the top of the fuel
filter/water separator 2 - 3 turns
counterclockwise.
WARNING
Burn Hazard!
• Batteries contain sulfuric acid.
Never allow battery fluid to come
in contact with clothing, skin or
eyes. Severe burns could result.
Always wear safety goggles and
protective clothing when
servicing the battery. If battery
fluid contacts the eyes and/or
skin, immediately flush the
affected area with a large amount
of clean water and obtain prompt
medical treatment.
• Failure to comply could result in death or
serious injury.
Be sure to tighten the air vent screw after the
water has drained out.
5. Open the fuel cock (Figure 5-7, (3)).
6. Be sure to prime the diesel fuel system when
you are finished. See Priming the Fuel System
on page 4-16.
7. Check for leaks.
5-12
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Periodic Maintenance Procedures
NOTICE
• Always be environmentally
responsible.
• Follow the guidelines of the EPA or other
governmental agencies for the proper disposal of
hazardous materials such as engine oil, diesel
fuel and engine coolant. Consult the local
authorities or reclamation facility.
PERIODIC MAINTENANCE
• If the engine still will not start after charging, have
your authorized YANMAR industrial engine dealer
or distributor check the battery and the engine’s
starting system.
• If operating the machine where the ambient
temperature could drop to 5 °F (-15 °C) or less,
remove the battery from the machine at the end
of the day. Store the battery in a warm place until
the next use. This will help start the engine easily
at low ambient temperatures.
• Never dispose of hazardous materials
irresponsibly by dumping them into a sewer, on
the ground, or into ground water or waterways.
• Failure to follow these procedures may seriously
harm the environment.
• When the amount of fluid nears the lower limit
(Figure 5-8, (3)), fill with distilled water
(Figure 5-8, (2)) so it is at the upper limit
(Figure 5-8, (1)). If operation continues with
insufficient battery fluid, the battery life is
shortened, and the battery may overheat and
explode. During the summer, check the fluid level
more often than specified.
2
1
3
031783-00X
Figure 5-8
• If the engine cranking speed is so slow that the
engine does not start, recharge the battery.
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PERIODIC MAINTENANCE
Periodic Maintenance Procedures
NOTICE
Every 250 Hours of Operation
Perform the following maintenance every 250 hours
of operation.
• Always be environmentally
responsible.
• Drain fuel tank
• Replace engine oil and engine oil filter
• Check and clean radiator fins
• Check and adjust cooling fan V-belt
• Clean air cleaner element
■ Drain fuel tank
DANGER
Fire and Explosion Hazard!
• Diesel fuel is flammable and
explosive under certain
conditions.
• When you remove any fuel system component
to perform maintenance (such as changing
the fuel filter) place an approved container
under the opening to catch the fuel.
• Never use a shop rag to catch the fuel. Vapors
from the rag are flammable and explosive.
• Follow the guidelines of the EPA or other
governmental agencies for the proper disposal of
hazardous materials such as engine oil, diesel
fuel and engine coolant. Consult the local
authorities or reclamation facility.
• Never dispose of hazardous materials
irresponsibly by dumping them into a sewer, on
the ground, or into ground water or waterways.
• Failure to follow these procedures may seriously
harm the environment.
Note that a typical fuel tank is illustrated.
1. Position an approved container under the diesel
fuel tank (Figure 5-9, (1)) to collect the
contaminates.
2. Remove the fuel cap (Figure 5-9, (3)).
3. Remove the drain plug (Figure 5-9, (2)) of the
fuel tank to drain the contaminates (water, dirt,
etc.) from the bottom of the tank.
• Wipe up any spills immediately.
3
• Wear eye protection. The fuel system is under
pressure and fuel could spray out when you
remove any fuel system component.
1
• Failure to comply will result in death or
serious injury.
2
K0000065A
Figure 5-9
4. Drain the tank until clean diesel fuel with no
water and dirt flows out. Reinstall and tighten
the drain plug firmly.
5. Reinstall the fuel cap.
6. Check for leaks.
5-14
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Periodic Maintenance Procedures
■ Replace engine oil and engine oil filter
PERIODIC MAINTENANCE
■ Check and clean radiator fins
NOTICE
• Only use the engine oil specified. Other engine
oils may affect warranty coverage, cause internal
engine components to seize and/or shorten
engine life.
• Prevent dirt and debris from contaminating the
engine oil. Carefully clean the oil cap/dipstick and
the surrounding area before you remove the cap.
• Never mix different types of engine oil. This may
adversely affect the lubricating properties of the
engine oil.
• Never overfill. Overfilling may result in white
exhaust smoke, engine overspeed or internal
damage.
NOTICE
• Always be environmentally
responsible.
• Follow the guidelines of the EPA or other
governmental agencies for the proper disposal of
hazardous materials such as engine oil, diesel
fuel and engine coolant. Consult the local
authorities or reclamation facility.
• Never dispose of hazardous materials
irresponsibly by dumping them into a sewer, on
the ground, or into ground water or waterways.
• Failure to follow these procedures may seriously
harm the environment.
Change the engine oil every 250 hours of operation
after the initial change at 50 hours. Replace the
engine oil filter at the same time. See Replace
engine oil and engine oil filter on page 5-7.
CAUTION
Flying Object Hazard!
• Always wear eye protection when
servicing the engine and when
using compressed air or highpressure water. Dust, flying
debris, compressed air,
pressurized water or steam may
injure your eyes.
• Failure to comply may result in minor or
moderate injury.
Dirt and dust adhering to the radiator fins reduce
the cooling performance, causing overheating.
Make it a rule to check the radiator fins daily and
clean as needed.
Note that a typical radiator is shown in Figure 5-10
for illustrative purposes only.
• Blow off dirt and dust from fins and radiator with
28 PSI (0.19 MPa; 2 kgf/cm2) or less of
compressed air (Figure 5-10, (1)). Be careful not
to damage the fins with the compressed air.
• If there is a large amount of contamination on the
fins, apply detergent, thoroughly clean and rinse
with tap water.
NOTICE
Never use high-pressure water or compressed air
at greater than 28 PSI (193 kPa; 19686 mmAq) or a
wire brush to clean the radiator fins. Radiator fins
damage easily.
1
FULL
LOW
K0000085A
Figure 5-10
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PERIODIC MAINTENANCE
Periodic Maintenance Procedures
■ Check and adjust cooling fan V-belt
Check and adjust the cooling fan V-belt every 250
hours of operation after the initial 50 hour V-belt
maintenance. See Check and adjust cooling fan Vbelt on page 5-9.
4. If the air cleaner is equipped with a double
element, only remove and replace the inner
element (Figure 5-12, (1)) if the engine lacks
power or the dust indicator actuates (if
equipped).
■ Clean air cleaner element
2
CAUTION
Flying Object Hazard!
• Always wear eye protection when
servicing the engine and when
using compressed air or highpressure water. Dust, flying
debris, compressed air,
pressurized water or steam may
injure your eyes.
• Failure to comply may result in minor or
moderate injury.
Note that a typical air cleaner is shown in
Figure 5-11 and Figure 5-12 for illustrative
purposes only.
1. Unlatch and remove the air cleaner cover
(Figure 5-11, (1)).
4
2
5
3
K0000071A-01X
Figure 5-12
5. The inner element should not be removed
when cleaning or replacing the outer element.
The inner element is used to prevent dust from
entering the engine while servicing the outer
element.
6. Replace the element with a new one if the
element is damaged, excessively dirty or oily.
The engine performance is adversely affected
when the air cleaner element is clogged with dust.
Be sure to clean the air filter element periodically.
6
1
1
7. Clean inside of the air cleaner cover.
8. Install the element into the air cleaner case
(Figure 5-11, (4)).
Note: If there is a red line (Figure 5-12, (2)) in
the outer element, reinsert the element
until the overlap position of red line and
end face of the air cleaner case.
9. Reinstall the air cleaner cover making sure you
match the arrow (Figure 5-11, (5)) on the cover
with the arrow on the case (Figure 5-11, (6)).
10. Latch the air cleaner cover to the case.
K0000070A
Figure 5-11
2. Remove the element (Figure 5-11, (2)) (outer
element if equipped with two elements).
3. Blow air (Figure 5-11, (3)) through the element
from the inside out using 42 - 71 PSI (0.29 0.49 MPa; 3.0 - 5.0 kgf/cm2) compressed air to
remove the particulates. Use the lowest
possible air pressure to remove the dust without
damaging the element.
5-16
NOTICE
• When the engine is operated in dusty
conditions, clean the air cleaner element
more frequently.
• Never operate the engine with the air cleaner
element(s) removed. This may allow foreign
material to enter the engine and damage it.
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Periodic Maintenance Procedures
Every 500 Hours of Operation
PERIODIC MAINTENANCE
■ Replace fuel filter
DANGER
Perform the following maintenance every 500 hours
of operation.
• Replace air cleaner element
• Replace fuel filter
Fire and Explosion Hazard!
• Diesel fuel is flammable and
explosive under certain
conditions.
• Clean fuel filter/water separator
■ Replace air cleaner element
NOTICE
The maximum air intake restriction, in terms of
differential pressure measurement, must not
exceed 0.90 PSI (6.23 kPa; 635 mmAq). Clean or
replace the air cleaner element if the air intake
restriction exceeds the above mentioned value.
Replace the air cleaner element (Figure 5-11, (2))
every 500 hours even if it is not damaged or dirty.
When replacing the element, clean the inside of the
air cleaner case (Figure 5-11, (4)).
If the air cleaner is equipped with a double element,
only remove and replace the inner element
(Figure 5-12, (1)) if the engine lacks power or the
dust indicator actuates (if equipped). This is in
addition to replacing the outer element.
• When you remove any fuel system component
to perform maintenance (such as changing
the fuel filter) place an approved container
under the opening to catch the fuel.
• Never use a shop rag to catch the fuel. Vapors
from the rag are flammable and explosive.
• Wipe up any spills immediately.
• Wear eye protection. The fuel system is under
pressure and fuel could spray out when you
remove any fuel system component.
• Failure to comply will result in death or
serious injury.
NOTICE
• Always be environmentally
responsible.
• Follow the guidelines of the EPA or other
governmental agencies for the proper disposal of
hazardous materials such as engine oil, diesel
fuel and engine coolant. Consult the local
authorities or reclamation facility.
• Never dispose of hazardous materials
irresponsibly by dumping them into a sewer, on
the ground, or into ground water or waterways.
• Failure to follow these procedures may seriously
harm the environment.
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PERIODIC MAINTENANCE
Periodic Maintenance Procedures
NOTICE
Applicable fuel filter Part No.
For maximum engine life, YANMAR recommends
that when shutting the engine down, you allow the
engine to idle, without load, for five minutes. This
will allow the engine components that operate at
high temperatures, such as the turbocharger (if
equipped) and exhaust system, to cool slightly
before the engine itself is shut down.
Replace the fuel filter at specified intervals to
prevent contaminants from adversely affecting the
diesel fuel flow.
1. Stop the engine and allow it to cool.
Standard
Dust proof*
119802-55801
129907-55801
* Consult the operation manual for the driven
machine for applicability of the dust proof filter.
6. Open the fuel cock of the fuel filter/water
separator.
7. Prime the fuel system. See Priming the Fuel
System on page 4-16.
8. Check for leaks.
■ Clean fuel filter/water separator
DANGER
2. Close the fuel cock of the fuel filter/water
separator.
3. Remove the fuel filter with a filter wrench,
turning it to the left (Figure 5-13, (1)). When
removing the fuel filter, carefully hold it to
prevent the fuel from spilling. Wipe up all spilled
fuel.
Fire and Explosion Hazard!
• Diesel fuel is flammable and
explosive under certain
conditions.
• Never use diesel fuel as a cleaning agent.
• When you remove any fuel system component
to perform maintenance (such as changing
the fuel filter) place an approved container
under the opening to catch the fuel.
• Never use a shop rag to catch the fuel. Vapors
from the rag are flammable and explosive.
• Wipe up any spills immediately.
2
1
K0000072A
Figure 5-13
• Wear eye protection. The fuel system is under
pressure and fuel could spray out when you
remove any fuel system component.
• Failure to comply will result in death or
serious injury.
4. Clean the filter mounting surface and apply a
small amount of diesel fuel to the gasket of the
new fuel filter.
5. Install the new fuel filter. Turn to the right
(Figure 5-13, (2)) and hand-tighten it only until
it comes in contact with the mounting surface.
Tighten to 14 - 17 ft·lb (19.6 - 23.5 N·m; 2.0 2.4 kgf·m) or one additional turn using the filter
wrench.
5-18
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Periodic Maintenance Procedures
NOTICE
• Always be environmentally
responsible.
• Follow the guidelines of the EPA or other
governmental agencies for the proper disposal of
hazardous materials such as engine oil, diesel
fuel and engine coolant. Consult the local
authorities or reclamation facility.
• Never dispose of hazardous materials
irresponsibly by dumping them into a sewer, on
the ground, or into ground water or waterways.
• Failure to follow these procedures may seriously
harm the environment.
Periodically clean the fuel filter/water separator
element and inside cup.
1. Position an approved container under the cup
(Figure 5-14, (1)) of the fuel filter/water
separator to collect the contaminants.
3
PERIODIC MAINTENANCE
4. Turn the cup (Figure 5-14, (1)) to the left
(Figure 5-14, (10)) and remove the cup
(Figure 5-14, (1)). If equipped, disconnect the
sensor wire from the cup before removing the
cup.
5. Carefully hold the cup to prevent fuel from
spilling. If you spill any fuel, clean up the spill
completely.
6. Remove the float ring (Figure 5-14, (8)) from
the cup. Pour the contaminants into the
container and dispose of it properly.
7. Clean the element (Figure 5-14, (9)) and inside
cup. Replace the element if it is damaged.
Applicable element Part No.
119802-55710
8. Install the element into the filter body.
9. Position the float ring in the cup.
10. Check the condition of the cup O-ring. Replace
if necessary.
11. Install the cup to the bracket by tightening the
cup to the right (Figure 5-14, (6)) to a torque of
18 - 22 N·m (1.8 - 2.2 kgf·m).
12. Close the drain cock. Reconnect the sensor
wire if equipped. (tightening torque: 1.0 - 2.0
N·m (0.1 - 0.2 kgf·m))
13. Open the fuel cock (Figure 5-14, (3)).
2
14. Prime the fuel system. See Priming the Fuel
System on page 4-16.
15. Check for leaks.
9
10
6
1
8
4
045100-00X00
Figure 5-14
2. Close (Figure 5-14, (2)) the fuel cock
(Figure 5-14, (3)).
3. Loosen the drain cock (Figure 5-14, (4)) and
drain the contaminants. See Drain fuel
filter/water separator on page 5-11.
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PERIODIC MAINTENANCE
Every 1000 Hours of Operation
Periodic Maintenance Procedures
CAUTION
Coolant Hazard!
Perform the following maintenance every 1000
hours of operation.
• Drain, flush and refill cooling system with new
coolant
• Adjust intake/exhaust valve clearance
■ Drain, flush and refill cooling system
with new coolant
DANGER
Scald Hazard!
• Never remove the radiator cap if
the engine is hot. Steam and hot
engine coolant will spurt out and
seriously burn you. Allow the
engine to cool down before you
attempt to remove the radiator
cap.
• Tighten the radiator cap securely after you
check the radiator. Steam can spurt out
during engine operation if the cap is loose.
• Always check the level of the engine coolant
by observing the reserve tank.
• Failure to comply will result in death or
serious injury.
WARNING
Burn Hazard!
• Wait until the engine cools before
you drain the engine coolant. Hot
engine coolant may splash and
burn you.
• Failure to comply could result in death or
serious injury.
• Wear eye protection
and rubber gloves
when you handle long
life or extended life
engine coolant. If
contact with the eyes
or skin should occur,
flush eyes and wash
immediately with
clean water.
• Failure to comply may result in minor or
moderate injury.
NOTICE
• Always be environmentally
responsible.
• Follow the guidelines of the EPA or other
governmental agencies for the proper disposal of
hazardous materials such as engine oil, diesel
fuel and engine coolant. Consult the local
authorities or reclamation facility.
• Never dispose of hazardous materials
irresponsibly by dumping them into a sewer, on
the ground, or into ground water or waterways.
• Failure to follow these procedures may seriously
harm the environment.
Engine coolant contaminated with rust or scale
reduces the cooling effect. Even when extended life
engine coolant is properly mixed, the engine
coolant gets contaminated as its ingredients
deteriorate. Drain, flush and refill the cooling
system with new coolant every 1000 hours or once
a year, whichever comes first.
1. Allow engine and coolant to cool.
2. Remove the radiator cap (Figure 5-15, (1)).
5-20
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PERIODIC MAINTENANCE
Periodic Maintenance Procedures
3. Remove the drain plug or open the drain cock
(Figure 5-15, (2)) at the lower portion of the
radiator and drain the engine coolant.
6. Fill radiator and engine with engine coolant.
See Filling Radiator with Engine Coolant on
page 4-20.
■ Adjust intake/exhaust valve clearance
1
Proper adjustment is necessary to maintain the
correct timing for opening and closing the valves.
Improper adjustment will cause the engine to run
noisily, resulting in poor engine performance and
engine damage. See Intake/Exhaust Valve and
Guide on page 6-4.
FULL
LOW
2
K0000074A
Figure 5-15
4. Drain the coolant from the engine block.
• On models not equipped with an oil cooler,
remove the coolant drain plug
(Figure 5-16, (1)) from the engine block.
1
046370-00X00
Figure 5-16
5. After draining the engine coolant, flush the
radiator and engine block to remove any rust,
scale and contaminants. Then reinstall and
tighten the drain plug or close the drain cock in
the radiator. Reinstall and tighten the cylinder
block drain plug.
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PERIODIC MAINTENANCE
Every 1500 Hours of Operation
Perform the following maintenance every 1500
hours of operation.
• Inspect, clean and test fuel injectors, if
necessary
• Inspect crankcase breather system
■ Inspect, clean and test fuel injectors
WARNING
High-pressure Hazard!
• Avoid skin contact with the
high-pressure diesel fuel spray
caused by a fuel system leak such
as a broken fuel injection line.
High-pressure fuel can penetrate
your skin and result in serious
injury. If you are exposed to highpressure fuel spray, obtain
prompt medical treatment.
• Never check for a fuel leak with your hands.
Always use a piece of wood or cardboard.
Have your authorized YANMAR industrial
engine dealer or distributor repair the
damage.
Periodic Maintenance Procedures
■ Inspect crankcase breather system
Proper operation of the crankcase breather system
is required to maintain the emission requirements
of the engine. The EPA/ARB requires that the
crankcase breather system is inspected every 1500
hours.
There are three different crankcase breather
systems used on the TNV engines. Only the nonturbo TNV engines crankcase breather system
requires periodic maintenance.
The non-turbo TNV engines use a crankcase
breather system that has a spring-backed
diaphragm (Figure 5-17, (1)) in the valve cover
(Figure 5-17, (2)). When the crankcase pressure
reaches a predetermined value, the diaphragm
opens a passage that allows crankcase fumes to
be routed to the intake manifold.
To inspect the diaphragm and spring
(Figure 5-17, (3)):
1. Remove the bolts retaining the diaphragm cover
(Figure 5-17, (4)).
4
3
5
1
• Failure to comply could result in death or
serious injury.
2
Proper operation of the fuel injectors is required to
obtain the optimum injection pattern for full engine
performance. The EPA/ARB requires that the fuel
injectors are inspected, cleaned and tested every
1500 hours. See Testing of Fuel Injectors on
page 7-27.
This procedure is considered normal maintenance
and is performed at the owner’s expense. This
procedure is not covered by the YANMAR Limited
Warranty.
K0002135
Figure 5-17
2. Remove the diaphragm cover, spring,
diaphragm plate (Figure 5-17, (5)) and
diaphragm.
3. Inspect the diaphragm for tears. Inspect the
spring for distortion. Replace components if
necessary.
5-22
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Periodic Maintenance Procedures
4. Reinstall the diaphragm, diaphragm plate,
spring and diaphragm cover. Tighten the
diaphragm bolts to specified torque.
Failure of the diaphragm and/or spring will cause
the loss of pressure control and allow an excessive
amount of crankcase fumes to be routed to the
intake manifold. This could result in excessive
deposits in the intake system, high engine exhaust
smoke levels, excessive engine oil consumption,
and/or engine run-on due to the burning of the
engine oil.
PERIODIC MAINTENANCE
Every 2000 Hours of Operation
Perform the following maintenance every 2000
hours of operation.
• Check and replace fuel hoses and engine
coolant hoses
• Lap the intake and exhaust valves.
If necessary
■ Check and replace fuel hoses and engine
coolant hoses
NOTICE
• Always be environmentally
responsible.
• Follow the guidelines of the EPA or other
governmental agencies for the proper disposal of
hazardous materials such as engine oil, diesel
fuel and engine coolant. Consult the local
authorities or reclamation facility.
• Never dispose of hazardous materials
irresponsibly by dumping them into a sewer, on
the ground, or into ground water or waterways.
• Failure to follow these procedures may seriously
harm the environment.
Regularly check the fuel system and engine coolant
system hoses. If they are cracked or degraded,
replace them. Replace the hoses at least every two
years.
■ Lap the intake and exhaust valves
Adjustment is necessary to maintain proper contact
of the valves and seats. See Inspection of intake
and exhaust valves on page 6-23.
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PERIODIC MAINTENANCE
Periodic Maintenance Procedures
Every 3000 Hours of Operation
Perform the following maintenance every 3000
hours of operation.
• Inspect, clean and test EGR valve
• Inspect and clean EGR lead valve
■ Inspect, clean and test EGR valve
The EGR valve is a key component for cleaning
exhaust gas.
To prevent the valve from deteriorating in exhaust
gas recirculation performance due to carbon
accumulation, inspect, clean and test the valve at
least every 3000 hours.
Consult your local YANMAR dealer for this service.
■ Inspect and clean EGR lead valve
The EGR lead valve is located in the passage of
recirculated gas.
To prevent carbon accumulation in or clogging of
the lead valve, inspect and clean the lead valve at
regular intervals.
Consult your local YANMAR dealer for this service.
EGR valve
EGR lead valve
046356-00EN00
Figure 5-18
5-24
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Section 6
3TNV88F Service Manual
ENGINE
Page
Before You Begin Servicing ............................................................ 6-3
Introduction...................................................................................... 6-4
Cylinder Head Specifications ..........................................................
Adjustment Specifications .........................................................
Cylinder Head............................................................................
Intake/Exhaust Valve and Guide ...............................................
Push Rod...................................................................................
Rocker Arm and Shaft ...............................................................
Valve Spring ..............................................................................
6-4
6-4
6-4
6-4
6-5
6-5
6-5
Camshaft and Timing Gear Train Specifications.............................
Camshaft ...................................................................................
Idler Gear Shaft and Bushing ....................................................
Timing Gear Backlash ...............................................................
6-6
6-6
6-6
6-6
Crankshaft and Piston Specifications..............................................
Crankshaft .................................................................................
Thrust Bearing ...........................................................................
Piston.........................................................................................
Piston Ring ................................................................................
Connecting Rod.........................................................................
Tappet .......................................................................................
6-7
6-7
6-7
6-7
6-8
6-8
6-9
Cylinder Block Specifications .......................................................... 6-9
Cylinder Block............................................................................ 6-9
Special Torque Chart .................................................................... 6-10
Torque for Bolts and Nuts........................................................ 6-10
Special Service Tools.................................................................... 6-11
Measuring Instruments.................................................................. 6-13
Cylinder Head................................................................................ 6-15
Cylinder Head Components .................................................... 6-15
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ENGINE
Components of a Cylinder Head .............................................. 6-16
Disassembly of Cylinder Head ................................................. 6-17
Cleaning of Cylinder Head Components .................................. 6-21
Inspection of Cylinder Head Components................................ 6-21
Reassembly of Cylinder Head.................................................. 6-26
Measuring and Adjusting Valve Clearance .................................... 6-30
Crankshaft and Camshaft Components ......................................... 6-32
Disassembly of Engine............................................................. 6-33
Disassembly of Camshaft and Timing Components ................ 6-34
Disassembly of Crankshaft and Piston Components ............... 6-37
Inspection of Crankshaft and Camshaft Components.............. 6-40
Honing and Boring.................................................................... 6-46
Reassembly of Crankshaft and Piston Components................ 6-47
Reassembly of Camshaft and Timing Components ................. 6-53
Final Reassembly of Engine..................................................... 6-56
EGR system ................................................................................... 6-57
EGR System............................................................................. 6-57
Inspecting/Cleaning EGR Related Components ...................... 6-60
6-2
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Before You Begin Servicing
ENGINE
BEFORE YOU BEGIN
SERVICING
Before performing any service procedures within
this section, read the following safety information
and review the Safety section on page 3-1.
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ENGINE
Introduction
INTRODUCTION
This section of the Service Manual describes servicing of the engine.
CYLINDER HEAD SPECIFICATIONS
Adjustment Specifications
Valve clearance
0.006 - 0.010 in. (0.15 - 0.25 mm)
Cylinder Head
Inspection item
Standard
Limit
0.0020 in.
(0.05 mm) or less
0.0059 in.
(0.15 mm)
Intake
0.0118 - 0.0197 in.
(0.30 - 0.50 mm)
0.0315 in.
(0.8 mm)
Exhaust
0.0118 - 0.0197 in.
(0.30 - 0.50 mm)
0.0315 in.
(0.8 mm)
Intake
120°
–
Exhaust
90°
–
40°, 150°
–
Standard
Limit
0.3154 - 0.3159 in.
(8.010 - 8.025 mm)
0.3189 in.
(8.10 mm)
0.3132 - 0.3140 in.
(7.955 - 7.975 mm)
0.3110 in.
(7.90 mm)
Valve stem bend
0.0014 - 0.0028 in.
(0.035 - 0.070 mm)
0.0071 in.
(0.18 mm)
Guide inside diameter
0.3156 - 0.3161 in.
(8.015 - 8.030 mm)
0.3189 in.
(8.10 mm)
0.3132 -.3134 in.
(7.955 - 7.960 mm)
0.3110 in.
(7.90 mm)
Valve stem bend
0.0018 - 0.0030 in.
(0.045 - 0.075 mm)
0.0071 in.
(0.18 mm)
Valve guide projection from cylinder head
0.5791 - 0.5905 in.
(14.71 - 15.00 mm)
–
Cold-fitted
–
0.736 - 0.748 in.
(18.7 - 19.0 mm)
–
Combustion surface distortion (flatness)
Valve recession
Seat angle
Valve seat
Seat correction angle
Reference page
See Valve recession on
page 6-24.
See Valve face and valve
seat on page 6-24.
Intake/Exhaust Valve and Guide
Inspection item
Guide inside diameter
Valve stem outside diameter
Valve stem outside diameter
Intake
Exhaust
Valve guide installation method
Valve stem seal projection from cylinder head
6-4
Reference page
See Inspection of valve
guides on page 6-23.
See Reassembly of valve
guides on page 6-26.
See Reassembly of intake
and exhaust valves on
page 6-26.
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ENGINE
Cylinder Head Specifications
Push Rod
Inspection item
Standard
Limit
Less than 0.0012 in.
(0.03 mm)
0.0012 in.
(0.03 mm)
Standard
Limit
Arm shaft hole diameter
0.6299 - 0.6307 in.
(16.000 - 16.020 mm)
0.6327 in.
(16.07 mm)
Shaft outside diameter
0.6286 - 0.6293 in.
(15.966 - 15.984 mm)
0.6276 in.
(15.94 mm)
0.0006 - 0.0021 in.
(0.016 - 0.054 mm)
0.0051 in.
(0.13 mm)
Standard
Limit
Free length
1.6535 in.
(42.0 mm)
1.6339 in.
(41.5 mm)
Squareness
–
0.0551 in.
(1.4 mm)
Push rod bend
Reference page
See Push rod bend on
page 6-22.
Rocker Arm and Shaft
Inspection item
Oil clearance
Reference page
See Inspection of rocker
arm assembly on
page 6-22.
Valve Spring
Inspection item
3TNV88F Service Manual
Reference page
See Inspection of valve
springs on page 6-25.
6-5
3TNV88F_SVM_A4.book
6 ページ
２０１２年７月２６日
木曜日
ENGINE
午後６時４分
Camshaft and Timing Gear Train Specifications
CAMSHAFT AND TIMING GEAR TRAIN SPECIFICATIONS
Camshaft
Inspection item
Standard
Limit
Reference page
0.0020 - 0.0079 in.
(0.05 - 0.20 mm)
0.0118 in.
(0.030 mm)
See Removal of camshaft
on page 6-36.
0 - 0.0008 in.
(0 - 0.02 mm)
0.0020 in.
(0.05 mm)
1.5197 - 1.5276 in.
(38.600 - 38.800 mm)
1.5098 in.
(38.350 mm)
Bushing
inside
diameter
1.7713 - 1.7738 in.
(44.990 - 45.055 mm)
1.7768 in.
(45.130 mm)
Camshaft
outside
diameter
1.7687 - 1.7697 in.
(44.925 - 44.950 mm)
1.7673 in.
(44.890 mm)
0.0016 - 0.0051 in.
(0.040 - 0.130 mm)
0.0094 in.
(0.240 mm)
Bore inside
diameter
1.7716 - 1.7726 in.
(45.000 - 45.025 mm)
1.7756 in.
(45.100 mm)
Camshaft
outside
diameter
1.7681 - 1.7691 in.
(44.910 - 44.935 mm)
1.7667 in.
(44.875 mm)
0.0026 - 0.0045 in.
(0.065 - 0.115 mm)
0.0089 in.
(0.225 mm)
Bore inside
diameter
1.7716 - 1.7726 in.
(45.000 - 45.025 mm)
1.7756 in.
(45.100 mm)
Camshaft
outside
diameter
1.7687 - 1.7697 in.
(44.925 - 44.950 mm)
1.7673 in.
(44.890 mm)
0.0020 - 0.0039 in.
(0.050 - 0.100 mm)
0.0083 in.
(0.210 mm)
Standard
Limit
Shaft outside diameter
1.8091 - 1.8100 in.
(45.950 - 45.975 mm)
1.8071 in.
(45.900 mm)
Bushing inside diameter
1.8110 - 4.8120 in.
(46.000 - 46.025 mm)
1.8140 in.
(46.075 mm)
0.0010 - 0.0030 in.
(0.025 - 0.075 mm)
0.0069 in.
(0.175 mm)
Inspection item
Standard
Limit
Reference page
Crank gear, cam gear, idler gear, fuel injection
pump gear and PTO gear
0.0028 - 0.0059 in.
(0.07 - 0.15 mm)
0.0067 in.
(0.17 mm)
See Checking timing gear
backlash on page 6-34.
End play
Bend (1/2 the dial gauge reading)
Cam lobe height
Gear end
Oil clearance
Shaft outside
diameter/bearing
inside diameter
Intermediate
Oil clearance
Flywheel
end
Oil clearance
See Inspection of camshaft
on page 6-45.
See Inspection of camshaft
on page 6-45.
Idler Gear Shaft and Bushing
Inspection item
Oil clearance
Reference page
See Inspection of idler gear
and shaft on page 6-46.
Timing Gear Backlash
6-6
3TNV88F Service Manual
3TNV88F_SVM_A4.book
7 ページ
２０１２年７月２６日
木曜日
午後６時４分
ENGINE
Crankshaft and Piston Specifications
CRANKSHAFT AND PISTON SPECIFICATIONS
Crankshaft
Note: Check appropriate parts catalog for various sizes of replacement main bearing inserts.
Inspection item
Standard
Limit
–
0.0008 in.
(0.02 mm)
Journal outside diameter
1.8879 - 1.8883 in.
(47.952 - 47.962 mm)
1.8859 in.
(47.902 mm)
Bearing inside diameter
1.8898 - 1.8909 in.
(48.000 - 48.026 mm)
–
Bearing insert thickness
0.0587 - 0.0591 in.
(1.492 - 1.500 mm)
–
Oil clearance
0.0015 - 0.0029 in.
(0.038 - 0.074 mm)
0.0059 in.
(0.150 mm)
Journal outside diameter
1.9666-1.9670 in.
(49.952-49.962 mm)
1.9646 in.
(49.902 mm)
Bearing inside diameter
1.9685 - 1.9693 in.
(50.000 - 50.020 mm)
–
Bearing insert thickness
0.0785 - 0.0791 in.
(1.995 - 2.010 mm)
–
Oil clearance
0.0015 - 0.0027 in.
(0.038 - 0.068 mm)
0.0059 in.
(0.150 mm)
Standard
Limit
Reference page
0.0051 - 0.0091 in.
(0.13 - 0.23 mm)
0.0110 in.
(0.28 mm)
See Removal of crankshaft
on page 6-39.
Standard
Limit
Reference page
3.4622 - 3.4634 in.
(87.940 - 87.970 mm)
3.4604 in.
(87.895 mm)
0.9449 in.
(24 mm)
–
Hole inside diameter
1.0236 - 1.0240 in.
(26.000 - 26.009 mm)
1.0252 in.
(26.039 mm)
Pin outside diameter
1.0234 - 1.0236 in.
(25.995 - 26.000 mm)
1.0222 in.
(25.965 mm)
0.0000 - 0.0006 in.
(0.000 - 0.014 mm)
0.0029 in.
(0.074 mm)
Bend (1/2 the dial gauge reading)
Connecting rod
journals
Main bearing
journal
Reference page
See Inspection of
crankshaft on page 6-44.
See Inspection of
crankshaft on page 6-44.
Thrust Bearing
Inspection item
Crankshaft end play
Piston
Inspection item
Piston outside diameter
(Measure at 90° to the piston pin.)
Piston diameter measure location
(Upward from the bottom of the piston.)
Piston pin
Oil clearance
3TNV88F Service Manual
See Inspection of pistons,
piston rings and wrist pin
on page 6-41.
See Inspection of pistons,
piston rings and wrist pin
on page 6-41.
6-7
3TNV88F_SVM_A4.book
8 ページ
２０１２年７月２６日
木曜日
午後６時４分
ENGINE
Crankshaft and Piston Specifications
Piston Ring
Inspection item
Standard
Limit
Ring groove
width
0.0811 - 0.0817 in.
(2.060 - 2.075 mm)
–
Ring width
0.0776 - 0.0783 in.
(1.970 - 1.990 mm)
0.0768 in.
(1.950 mm)
Side clearance
0.0028 - 0.0041 in.
(0.070 - 0.105 mm)
–
End gap
0.0079 - 0.157 in.
(0.200 -0.400 mm)
0.0193 in.
(0.490 mm)
Ring groove
Width
0.0797 - 0.0803 in.
(2.025 - 2.040 mm)
0.0843 in.
(2.140 mm)
Ring width
0.0776 - 0.0783 in.
(1.970 - 1.990 mm)
0.0768 in.
(1.950 mm)
Side clearance
0.0014 - 0.0028 in.
(0.035 - 0.070 mm)
0.0075 in.
(0.190 mm)
End gap
0.0079 - 0.0157 in.
(0.200 - 0.400 mm)
0.0193 in.
(0.490 mm)
Ring groove
width
0.1581 - 0.1587 in.
(4.015 - 4.030 mm)
0.1626 in.
(4.130 mm)
Ring width
0.1563 - 0.1571 in.
(3.970 - 3.990 mm)
0.1555 in.
(3.950 mm)
Side clearance
0.0010 - 0.0024 in.
(0.025 - 0.060 mm)
0.0071 in.
(0.180 mm)
End gap
0.0079 - 0.0157 in.
(0.200 - 0.400 mm)
0.0193 in.
(0.490 mm)
Standard
Limit
Wrist pin bushing inside diameter
1.0234 - 1.0251 in.
(26.025 - 26.038 mm)
1.0263 in.
(26.068 mm)
Wrist pin outside diameter
1.0234 - 1.0236 in.
(25.995 - 26.000 mm)
1.0223 in.
(25.967 mm)
0.0010 - 0.0017 in.
(0.025 - 0.043 mm)
0.0040 in.
(0.101 mm)
Standard
Limit
0.0079 - 0.0157 in.
(0.20 - 0.40 mm)
–
Top ring
Second ring
Oil ring
Reference page
See Inspection of pistons,
piston rings and wrist pin
on page 6-41.
Connecting Rod
■ Connecting rod small end
Inspection item
Oil clearance
Reference page
See Inspection of
connecting rod on
page 6-43.
■ Connecting rod big end
Inspection item
Side clearance
Reference page
See Inspection of
connecting rod on
page 6-43.
Note: See Special Torque Chart on page 6-10 for other specifications.
6-8
3TNV88F Service Manual
3TNV88F_SVM_A4.book
9 ページ
２０１２年７月２６日
木曜日
午後６時４分
ENGINE
Cylinder Block Specifications
Tappet
Inspection item
Standard
Limit
Tappet bore (block) inside diameter
0.4724 - 0.4734 in.
(12.000 - 12.025 mm)
0.4742 in.
(12.045 mm)
Tappet stem outside diameter
0.4715 - 0.4720 in.
(11.975 - 11.990 mm)
0.4707 in.
(11.955 mm)
0.0004 - 0.0020 in.
(0.010 - 0.050 mm)
0.0035 in.
(0.090 mm)
Oil clearance
Reference page
See Inspection of tappets
on page 6-44.
CYLINDER BLOCK SPECIFICATIONS
Cylinder Block
Inspection item
Cylinder inside diameter
Cylinder bore
Roundness
Taper
3TNV88F Service Manual
Standard
Limit
3.4646 - 3.4657 in.
(88.000 - 88.030 mm)
3.4724 in.
(88.200 mm)
0.0004 in. (0.01 mm)
or less
0.0012 in.
(0.03 mm)
Reference page
See Inspection of cylinder
block on page 6-41.
6-9
3TNV88F_SVM_A4.book
10 ページ
２０１２年７月２６日
木曜日
午後６時４分
ENGINE
Special Torque Chart
SPECIAL TORQUE CHART
Torque for Bolts and Nuts
Thread
diameter and
pitch
Torque
Lubricating oil
application
(thread portion and
seat surface)
M10 × 1.25 mm
63 - 67 ft·lb
(85.3 - 91.1 N·m;
8.7 - 9.3 kgf·m)
Applied
M9 × 1.0 mm
33 - 36 ft·lb
(44.1 - 49.0 N·m;
4.5 - 5.0 kgf·m)
Applied
Flywheel bolt
M10 × 1.25 mm
61 - 65 ft·lb
(83.3 - 88.2 N·m;
8.5 - 9.0 kgf·m)
Applied
Main bearing cap bolt
M12 × 1.5 mm
69 - 72 ft·lb
(93.2 - 98.1 N·m;
9.5 - 10.5 kgf·m)
Applied
Component
Cylinder head bolt
Connecting rod bolt
Cast metal (FC300)
62 - 69 ft·lb
(83.3 - 93.1 N·m;
8.5 - 9.5 kgf·m)
Applied
Crankshaft pulley bolt
M14 × 1.5 mm
Fuel injector bolt
M8 × 1.25 mm
18 - 21 ft·lb
(24.4 - 28.4 N·m;
2.5 - 2.9 kgf·m)
Not applied
Fuel pump drive gear nut
M14 × 1.5 mm
58 - 65 ft·lb
(78 - 88 N·m;
8 - 9 kgf·m)
Not applied
High-pressure fuel lines bolt
M12 × 1.5 mm
22 - 25 ft·lb
(29.4 - 34.3 N·m;
3.0 - 3.5 kgf·m)
Not applied
Glow plug
M10 × 1.25 mm
133 - 177 in·lb
(15 - 20 N·m
1.53 - 2.04 kgf·m)
Not applied
M4 × 0.7 mm
9 - 13 in·lb
(1 - 1.5 N·m)
Not applied
Glow connector nut
Steel metal (S45C)
83 - 91 ft·lb
(112.7 - 122.7 N·m;
11.5 - 12.5 kgf·m)
Note: See Tightening Torques for Standard Bolts and Nuts on page 4-25 for standard hardware torque
values.
6-10
3TNV88F Service Manual
3TNV88F_SVM_A4.book
11 ページ
２０１２年７月２６日
木曜日
午後６時４分
ENGINE
Special Service Tools
SPECIAL SERVICE TOOLS
No.
Tool name
Applicable model and tool size
Model
1
Valve guide tool
(for removing
valve guide)
3TNV88F
Illustration
L1
L2
d1
d2
0.787 in.
(20 mm)
2.953 in.
(75 mm)
0.295 in.
(7.5 mm)
0.433 in.
(11 mm)
L2
d2
L1
Locally manufactured
d1
010932-00X
Model
2
Valve guide tool
(for installing
valve guide)
3TNV88F
L1
L2
d1
d2
0.591 in.
(15 mm)
2.559 in.
(65 mm)
0.551 in.
(14 mm)
0.787 in.
(20 mm)
L2
L1
Locally manufactured
d1
d2
3
Fuel injector
removal tool
001421-00X
YANMAR Part No. 129470-92305
K0001618
4
Connecting rod
bushing
replacer
(for removal/
installation of
connecting rod
bushing)
Model
3TNV88F
L1
L2
d1
d2
0.787 in.
(20 mm)
3.937 in.
(100 mm)
1.024 in.
(26 mm)
1.142 in.
(29 mm)
L2
d2
L1
Locally manufactured
d1
010933-00X
5
Valve spring
compressor
(for removal/
installation of
valve spring)
YANMAR Part No. 129100-92630
010931-00X
Model
3TNV88F
d1
d2
d3
L1
L2
L3
0.638
in.
(16.2
mm)
0.866
in.
(22
mm)
0.531
in.
(13.5
mm)
0.740
in.
(18.8
mm)
2.559
in.
(65
mm)
0.157
in.
(4 mm)
Locally manufactured
6
L2
L1
d2
d1
001421-00X
Stem seal
installer (for
installing valve
stem seal)
L2
d3
L3
d1
d2
L1
001422-00X
3TNV88F Service Manual
6-11
3TNV88F_SVM_A4.book
12 ページ
２０１２年７月２６日
木曜日
午後６時４分
ENGINE
No.
Tool name
7
Filter wrench
(for removal/
installation of
engine oil filter)
Special Service Tools
Applicable model and tool size
Illustration
Available locally
002829-01X
Model
8
Camshaft
bushing tool
(for extracting
camshaft
bushing)
3TNV88F
9
L2
d1
d2
2.756 in.
(70 mm)
1.772 in.
(45 mm)
1.890 in.
(48 mm)
L2
L1
Allowance: d1 d2
Locally manufactured
Model
Flex-hone
(for preparation
of cylinder
walls)
L1
0.709 in.
(18 mm)
d2
YANMAR Part No.
Cylinder bore
129400-92430
3.268 - 3.740 in.
(83 - 95 mm)
3TNV88F
d1
001421-00X
010930-00X
10
Piston ring
compressor
(for installing
piston)
YANMAR Part No. 95550-002476
The piston insertion tool is applicable for
2.362 - 4.921 in. (60 - 125 mm) diameter pistons
007236-00X
11
Piston ring
expander
(for removal/
installation of
piston ring)
Available locally
001411-00X
6.3
0.05
A
0.1
(16)
20
5
0.
C
5
0.
16
M14 x 1.5
C
1
ø 35.4 -0.05
-0.15
ø6
12
Pulley installing
tool
A
36
C
1
C
A
3
52
Knurling
6-12
3TNV88F Service Manual
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13 ページ
２０１２年７月２６日
木曜日
午後６時４分
ENGINE
Measuring Instruments
MEASURING INSTRUMENTS
No.
1
Instrument name
Dial indicator
Locally available
Application
Illustration
Measure shaft bend and end play
001429-00X
2
Test indicator
Locally available
Measurements of narrow or deep portions that
cannot be measured by dial gauge
001430-00X
3
Magnetic stand
Locally available
For holding the dial gauge when measuring
001431-00X
4
Micrometer
Locally available
For measuring the outside diameters of
crankshaft, pistons, piston pins, etc.
001432-00X
5
Cylinder bore gauge Locally available
For measuring the inside diameters of cylinder
liners, bearing bores, etc.
001433-00X
6
Calipers
Locally available
For measuring outside diameters, depth,
thickness and width
001434-00X
7
Depth micrometer
Locally available
For measuring of valve recession
001435-00X
8
Square
Locally available
For measuring valve spring inclination and
straightness of parts
001436-00X
3TNV88F Service Manual
6-13
3TNV88F_SVM_A4.book
14 ページ
２０１２年７月２６日
木曜日
午後６時４分
ENGINE
No.
9
Measuring Instruments
Instrument name
V-block
Locally available
Application
Illustration
For measuring shaft bend
001437-00X
10
Torque wrench
Locally available
For tightening nuts and bolts to the specified
torque
001438-00X
11
Feeler gauge
Locally available
For measuring piston ring gaps, piston ring
clearance, and valve adjustment clearance
001426-00X
6-14
3TNV88F Service Manual
3TNV88F_SVM_A4.book
15 ページ
２０１２年７月２６日
木曜日
午後６時４分
ENGINE
Cylinder Head
CYLINDER HEAD
Cylinder Head Components
3
4
5
6
1
2
7
34
8
10
33
11
12
32
9
13
14
15
17
18
19
29
16
20
30
31
21
22
28
27
23
25
24
26
046614-00X00
Figure 6-1
3TNV88F Service Manual
6-15
3TNV88F_SVM_A4.book
16 ページ
２０１２年７月２６日
木曜日
午後６時４分
ENGINE
1
2
3
4
5
6
– Valve cover nut
– Valve cover nut O-ring
– Crankcase breather cover
– Diaphragm spring
– Diaphragm plate
– Crankcase breather diaphragm
(non-turbocharged engines only)
7 – Oil fill cap
8 – Valve cover gasket
9 – Rocker arm shaft spring
10 – Valve adjusting screw lock nut
11 – Valve adjusting screw
12 – Rocker arm
13 – Rocker arm shaft
14 – Rocker arm shaft aligning stud
15 – Support bolt
16 – Rocker arm shaft support
17 – Valve cap
18 – Valve keepers
19 – Spring retainer
20 – Valve spring
21 – Valve stem seal
22 – Valve guide
23 – Cylinder head
24 – Intake valve
25 – Exhaust valve
26 – Cylinder head gasket
27 – Fuel injector retainer
28 – Washer
29 – Fuel injector retainer bolt
30 – Fuel injector nozzle protector
31 – Fuel injector nozzle seat
32 – Push rod
33 – Crankcase breather components
34 – Valve cover
6-16
Cylinder Head
Components of a Cylinder Head
■ Cylinder head with glow plugs
3
2
1
046615-00X00
1 – Cylinder head
2 – Glow plug
3 – Harness, glow plug
Figure 6-2
3TNV88F Service Manual
3TNV88F_SVM_A4.book
17 ページ
２０１２年７月２６日
木曜日
午後６時４分
ENGINE
Cylinder Head
Disassembly of Cylinder Head
5
Prepare a clean, flat working surface on a
workbench large enough to accommodate the
cylinder head assembly. Discard all gaskets,
O-rings and seals. Use new gaskets, O-rings and
seals on reassembly of the cylinder head.
4
7
1. Drain the coolant from the engine into a suitable
container. See Drain, flush and refill cooling
system with new coolant on page 5-20.
6
3
NOTICE
2
Identify all parts and their location using an
appropriate method. It is important that all parts
are returned to the same position during the
reassembly process.
1
046616-00X00
Figure 6-4
3. Remove the exhaust manifold bolts
(Figure 6-4, (4)) and nuts (Figure 6-4, (5)).
Remove the exhaust manifold (Figure 6-4, (6))
and the exhaust manifold gasket
(Figure 6-4, (7)).
4. Remove the coolant pump. See Disassembly of
Engine Coolant Pump on page 8-8.
5. Remove the high-pressure lines and fuel
injectors from the cylinder head. See Removal
of Fuel Injectors on page 7-25.
046797-00X00
Figure 6-3
2. Remove the intake manifold bolts
(Figure 6-4, (1)). Remove the intake manifold
(Figure 6-4, (2)). Discard the intake manifold
gasket (Figure 6-4, (3)).
3TNV88F Service Manual
6-17
3TNV88F_SVM_A4.book
18 ページ
２０１２年７月２６日
木曜日
午後６時４分
ENGINE
Cylinder Head
■ Removing the glow plugs
■ Removal of valve cover
1. Remove the glow plug harness
(Figure 6-5, (2)) from each glow plug
(Figure 6-5, (1)).
1. Remove the valve cover nuts (Figure 6-6, (1)).
2. Remove the O-ring (Figure 6-6, (2)) on each
valve cover nut.
2. Remove the glow plug from the cylinder head.
1
2
2
1
3
4
046615-00X01
Figure 6-5
Note: Removing the cylinder head from the engine
requires that the glow plugs be removed in
advance.
Failure to remove the glow plugs in advance
could result in damages to the glow plugs
because their tips are protruding from the
cylinder head combustion chamber surface.
6-18
046620-00X00
Figure 6-6
3. Remove the valve cover (Figure 6-6, (3)) and
the valve cover gasket (Figure 6-6, (4)).
3TNV88F Service Manual
3TNV88F_SVM_A4.book
19 ページ
２０１２年７月２６日
木曜日
午後６時４分
ENGINE
Cylinder Head
■ Removal of rocker arm assembly
1. Remove the bolts (Figure 6-7, (1)) that retain
the rocker arm shaft supports.
7
6
1
2
2. Remove the rocker arm shaft assembly from
the cylinder head.
3
Note: Identify the push rods so they can be
reinstalled in their original locations.
4
3. Remove the push rods and identify for
installation.
5
K0001951
Figure 6-8
1
1
3. Remove the valve adjusting screw
(Figure 6-8, (6)) and the lock nut
(Figure 6-8, (7)) from the rocker arms.
■ Removal of cylinder head
1. Loosen the cylinder head bolts following the
sequence shown in Figure 6-9.
Cooling fan end
046617-00X00
Figure 6-7
■ Disassembly of rocker arm assembly
1. Remove the rocker arm shaft alignment stud
(Figure 6-8, (4)) from support (Figure 6-8, (5)).
8
14
5
2
12
9
3
4
10
11
1
Camshaft side
6
13
7
K0001864-02
Figure 6-9
Note: The rocker arm shaft fits tightly in the
rocker arm supports. Clamp the support
in a padded vise. Twist and pull out on
the rocker arm shaft to remove. Reverse
this process when you reinstall the
rocker arm shaft into the supports.
2. Slide the rocker arm shaft (Figure 6-8, (3)) out
of the rocker arm supports (Figure 6-8, (5)),
springs (Figure 6-8, (1)), and rocker arms
(Figure 6-8, (2)).
Note: Mark the rocker arms so they can be
reinstalled with the original matching
valve and pushrod.
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ENGINE
Cylinder Head
■ Removal of intake/exhaust valves
2. Remove the cylinder head bolts
(Figure 6-10, (1)).
3. Lift the cylinder head away from the cylinder
block. Discard the cylinder head gasket
(Figure 6-10, (2)). Position the cylinder head on
the work bench to prevent damage to the
combustion surface.
1. Place the cylinder head on the work bench with
the combustion side down.
2. Remove the valve cap (Figure 6-12, (1)) and
keep with the valve it was installed on.
3. Using the valve spring compressor tool,
compress one of the valve springs
(Figure 6-11).
1
K0000191
Figure 6-11
4. Remove the valve keepers (Figure 6-12, (2)).
5. Slowly release the tension on the valve spring.
6. Remove the spring retainer (Figure 6-12, (3))
and valve spring (Figure 6-12, (4)).
2
1
2
3
046618-00X00
Figure 6-10
4
5
6
046621-00X00
Figure 6-12
7. Repeat the procedure with all remaining valves.
6-20
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ENGINE
Cylinder Head
Note: If the valves are to be reused, identify
them so they can be installed in their
original location.
8. Turn the cylinder head so the exhaust port side
faces down. Remove the intake and exhaust
valves (Figure 6-12, (6)) from the cylinder
head.
9. Remove the valve stem seals
(Figure 6-12, (5)).
■ Removal of valve guides
Note: Removal of the valve guides should be
postponed until inspection and
measurement procedures have been
performed. See Inspection of valve guides
on page 6-23.
1. If the valve guides were not within
specifications, use a drift pin and hammer to
drive the valve guides (Figure 6-13, (1)) out of
the cylinder head.
1
Cleaning of Cylinder Head
Components
WARNING
Fume/Burn Hazard!
• Always read and
follow safety related
precautions found on
containers of
hazardous substances
like parts cleaners,
primers, sealants and
sealant removers.
• Failure to comply could result in death or
serious injury.
Thoroughly clean all components using a nonmetallic brush and an appropriate solvent. Each
part must be free of carbon, metal filings and other
debris.
Inspection of Cylinder Head
Components
Visually inspect the parts. Replace any parts that
are obviously discolored, heavily pitted or otherwise
damaged. Discard any parts that do not meet its
specified limit.
NOTICE
046619-00X00
Figure 6-13
Any part which is found defective as a result of
inspection or any part whose measured value does
not satisfy the standard or limit must be replaced.
NOTICE
Any part determined to not meet the service
standard or limit before the next service, as
determined from the state of current rate of wear,
should be replaced even though the part currently
meets the service standard limit.
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２０１２年７月２６日
木曜日
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ENGINE
Cylinder Head
■ Inspection of push rods
Push rod bend
Determine if the bend of the push rods are within
the specified limit.
1. Place the push rods on a flat inspection block or
layout bed.
1
1
2. Roll the push rods until a gap can be observed
between a portion of the push rod and the
surface of the block or layout bed.
3. Use a feeler gauge to measure the gap
(Figure 6-14). See Push Rod on page 6-5 for
the service limit.
K0001916
Figure 6-15
Rocker arm shaft outside diameter
Use a micrometer to measure the rocker arm shaft
diameter. Measure at each rocker arm location in
two directions 90° apart (Figure 6-16). See Rocker
Arm and Shaft on page 6-5 for the service limit.
K0000204
Figure 6-14
■ Inspection of rocker arm assembly
Rocker arm shaft hole diameter
1. Use a test indicator and micrometer to
determine if the inside diameter of all the rocker
arm support brackets and the rocker arms
(Figure 6-15) are within the specified limits.
See Rocker Arm and Shaft on page 6-5 for the
service limit.
K0001952
Figure 6-16
2. Inspect the contact areas (Figure 6-15, (1)) for
excessive wear or damage.
6-22
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２０１２年７月２６日
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ENGINE
Cylinder Head
■ Inspection of valve guides
■ Inspection of intake and exhaust valves
Visually inspect the valve guides for distortions,
scoring or other damage.
Visually inspect the intake and exhaust valves.
Replace any valves that are obviously discolored,
heavily pitted or otherwise damaged.
Note: Measure the valve guides while they are
installed in the cylinder head.
Use a telescoping gauge and micrometer to
measure the inside diameter at each end of the
valve guide. Measure in three places and 90° apart
(Figure 6-17). See Intake/Exhaust Valve and Guide
on page 6-4 for the service limit. Replace valve
guides if not within specification.
Valve stem diameter
Use a micrometer to measure the valve stem
diameter. Measure the valve stem near the
combustion end and near the opposite end
(Figure 6-19, (1)). See Intake/Exhaust Valve and
Guide on page 6-4 for the service limit.
1
K0000197
K0001869
Figure 6-19
Figure 6-17
■ Inspection of cylinder head
Cylinder head distortion
Place the cylinder head flat and inverted
(combustion side up) on the bench. Use a straight
edge and a feeler gauge to measure cylinder head
distortion (Figure 6-18). Measure diagonally and
along each side. See Cylinder Head on page 6-4
for the service limit.
Valve stem bend
Place the valve stem on a flat inspection block or
layout bed. Roll the valve until a gap can be
observed between a portion of the valve stem and
the surface of the block or bed. Use a feeler gauge
to measure the gap (Figure 6-20). See
Intake/Exhaust Valve and Guide on page 6-4 for
the service limit.
K0000199
Figure 6-20
K0000192
Figure 6-18
If distortion exceeds the service limit, resurface or
replace the cylinder head. Remove only enough
material to make the cylinder head flat, but do not
remove more than 0.008 in. (0.20 mm).
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２０１２年７月２６日
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ENGINE
Cylinder Head
Valve recession
Note: The valve guides must be installed to
perform this check.
Insert the valves into their original locations and
press them down until they are fully seated. Use a
depth micrometer (Figure 6-21) to measure the
difference between the cylinder head gasket
surface and the combustion surface of each
exhaust and intake valve (Figure 6-22). See
Cylinder Head on page 6-4 for the service limit.
Valve face and valve seat
Always check the clearance between the valve and
valve guide before grinding or lapping the valve
seats. See Intake/Exhaust Valve and Guide on
page 6-4 for the service limit. If the clearance
exceeds the limit, replace the valve and/or valve
guide to bring the clearance within the limit.
Roughness or burrs will cause poor seating of a
valve. Visually inspect the seating surfaces of each
valve and valve seat to determine if lapping or
grinding is needed.
Visually inspect all valve faces and valve seats for
pitting, distortion, cracking, or evidence of
overheating. Usually the valves and the valve seats
can be lapped or ground to return them to
serviceable condition. Severely worn or damaged
components will require replacement.
K0000193
Figure 6-21
Coat the valve seat with a thin coat of bluing
compound. Install the valve and rotate it to
distribute bluing onto the valve face. The contact
pattern should be approximately centered on the
valve face (Figure 6-23, (1)) and even in width.
1
K0001755
Figure 6-22
K0001691B
Figure 6-23
Also visually inspect the valve seat for even
contact.
Light cutting can be performed by the use of a
hand-operated cutter (Figure 6-24, (3)).
6-24
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ENGINE
Cylinder Head
150°
1
40°
2
3
Squareness
Use a flat surface and a square to check each
spring for squareness (Figure 6-25). See Valve
Spring on page 6-5 for the service limit.
K0001862
Figure 6-24
2
5
0
4
1
3
Free length
Use a caliper to measure the length of the spring
(Figure 6-26). See Valve Spring on page 6-5 for
the service limit.
6
9
If the valve or seat require grinding, lap the valve
after grinding. Lap the valve face to the valve seat
using a mixture of valve lapping compound and
engine oil.
Figure 6-25
8
Grind the valve face and/or valve seat only enough
to return them to serviceable condition. Grinding is
needed if the valve and the valve seat do not
contact correctly. Check the recession after
grinding.
K0000201
7
The valve seat diameter can be adjusted by topgrinding with a 150° stone to make the seat
diameter smaller, and bottom-grinding using a 40°
stone to make the seat diameter larger. Once the
seat location has been corrected, grind and lap the
seat angle (Figure 6-24, (1)) to specification. See
Cylinder Head on page 6-4 for specifications.
Be sure to thoroughly wash all parts to remove all
grinding powder or compound.
K0000200
■ Inspection of valve springs
Figure 6-26
Inspect the valve springs. If damage or corrosion is
seen, or if measurements exceed the specified
limits, replace the springs.
Fractures
Check for fractures on the inside and outside
portions of the springs. If the valve spring is
fractured, replace the valve spring.
Corrosion
Check for corrosion of the spring material caused
by oxidation.
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ENGINE
Cylinder Head
■ Reassembly of intake and exhaust valves
Reassembly of Cylinder Head
NOTICE
Use new gaskets, O-rings and seals for the
reassembly of the cylinder head.
Always install new valve stem seals.
NOTICE
Liberally oil all components during reassembly to
prevent premature wear or damage.
The exhaust valve stem seals are different than the
intake valve stem seals and can be identified by
either the paint marks on the outside of the seals or
by the color of the seal spring (Figure 6-29, (4)).
Ensure they are installed in the correct locations.
■ Reassembly of valve guides
1. The valve guides are installed into the cylinder
head with an extremely tight press fit. Before
installing the valve guides, place the valve
guides in a freezer for at least twenty minutes
This will cause the valve guides to contract,
making it easier to install the valve guides into
place.
2. Immediately after removing the valve guides
from the freezer, insert the valve guides
(Figure 6-27, (1)) in their proper positions.
Marking
Intake
Exhaust
None
Yellow
(Paint on outside of seal)
1. Oil the lip of the valve stem seal
(Figure 6-29, (2)). Using the valve stem seal
installation tool (Figure 6-29, (1)), install a new
valve stem seal on each of the valve guides
(Figure 6-29, (3)).
1
1
4
2
3
046619-00X00
K0001873B
Figure 6-27
Figure 6-29
3. Finish installing the valve guides
(Figure 6-28, (1)) into the cylinder head to the
proper height (Figure 6-28, (3)) using the valve
guide installation tool (Figure 6-28, (2)). See
Valve Guide Projection specification starting on
page 6-4.
2. Measure the distance (Figure 6-30, (1)) from
the cylinder head to valve stem seal to ensure
proper clearance (Figure 6-30, (2)) between
the guide and the seal. See Valve Stem Seal
Projection specification on page 6-5.
2
3
1
K0001756A
Figure 6-28
6-26
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２０１２年７月２６日
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ENGINE
Cylinder Head
■ Reassembly of cylinder head
1
1. Carefully clean both the combustion surface of
the cylinder head and the top surface of the
cylinder block. Then place a new cylinder head
gasket (Figure 6-32, (2)) on the cylinder block.
2
2. Position the cylinder head on the cylinder head
gasket.
1
K0001874
Figure 6-30
3. Place the cylinder head assembly on its
exhaust port side.
4. Place all the valves (Figure 6-31, (6)) in their
proper location in the cylinder head.
1
2
3
4
5
2
046618-00X00
Figure 6-32
6
046621-00X00
Figure 6-31
5. Place the cylinder head on the workbench with
the combustion side down to install the valve
springs. Install the valve spring
(Figure 6-31, (4)) and the spring retainer
(Figure 6-31, (5)).
6. Using the valve spring compressor tool,
compress the valve spring.
7. Insert the valve keepers (Figure 6-31, (2)) and
slowly release the tension on the valve spring.
Install the valve cap (Figure 6-31, (1)). Repeat
the steps on all the remaining valves.
3TNV88F Service Manual
3. Lightly oil the threads of the cylinder head bolts
(Figure 6-32, (1)). Tighten the bolts to the
specified torque in two steps as shown in the
chart below. Tighten in the sequence shown in
(Figure 6-33). See Special Torque Chart on
page 6-10 for specification.
First step
1/2 of final torque
Second step
Final torque
4. Insert the push rods in their respective
positions.
Camshaft Side
7
1
10
13
3
6
12
11
5
4
14
Fan End
9
2
8
K0001875X01
Figure 6-33
6-27
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ENGINE
Cylinder Head
■ Reassembly of rocker arm reassembly
Note: Ensure the lubrication holes
(Figure 6-34, (1)) in the rocker arm shaft are
oriented correctly with respect to the rocker
arms (Figure 6-34, (2)).
6
7
1
2
3
4
2
1
5
K0001951
Figure 6-35
1
K0001914
Figure 6-34
1. Lubricate the rocker arm shaft. Slide the rocker
arm supports (Figure 6-35, (5)), springs
(Figure 6-35, (1)) and rocker arms
(Figure 6-35, (2)) onto the shaft.
Note:
• The rocker arm shaft fits tightly in the rocker
arm supports. Clamp the support in a padded
vise. Twist and push on the rocker arm shaft to
reinstall.
• To properly align the rocker arm shaft with the
rocker arm shaft supports, first reinstall a
rocker arm support (Figure 6-35, (5)) having a
hole for the shaft alignment stud
(Figure 6-35, (4)). Align the hole in the rocker
arm shaft and the hole in the rocker arm
support. Reinstall the alignment stud.
6-28
Note: Figure 6-35 shows components for one
cylinder. Components for all remaining
cylinders are assembled in the same
order.
2. Place the rocker arm shaft assembly onto the
cylinder head.
3. If removed, reinstall the valve adjusting screws
(Figure 6-35, (6)) and the lock the nuts
(Figure 6-35, (7)).
4. Align the push rods with their respective rocker
arms.
5. Reinstall and tighten the rocker arm shaft
retaining bolts to the specified torque.
6. Tighten the rocker arm shaft alignment studs.
7. Adjust the valve clearance. See Measuring and
Adjusting Valve Clearance on page 6-30.
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２０１２年７月２６日
木曜日
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ENGINE
Cylinder Head
■ Reassembly of the valve cover
1. Lightly grease a new valve cover gasket
(Figure 6-36, (4)). Place the gasket in the
groove of the valve cover (Figure 6-36, (3)).
6. Install each glow plug (Figure 6-37, (1)), and
tighten it with the specified torque. Install each
electrical harness (Figure 6-37, (1)), and
tighten it with the specified torque.
2. Place the valve cover on the cylinder head.
3. Be sure new O-rings (Figure 6-36, (2)) are
installed on the valve cover nuts. Reinstall and
tighten the valve cover nuts (Figure 6-36, (1)).
2
1
4. Reinstall the exhaust manifold using a new
gasket. Tighten the bolts to the specified
torque.
1
2
046615-00X01
Figure 6-37
3
7. Reinstall the fuel injectors. See Installation of
the Fuel Injectors on page 7-31.
8. Reinstall the high pressure and the return fuel
injection lines. See Installation of the Fuel
Injectors on page 7-31
4
046620-00X00
Figure 6-36
5. Reinstall the intake manifold using a new
gasket. Tighten the bolts to the specified
torque.
3TNV88F Service Manual
9. Reinstall the engine coolant pump. See
Reassembly of Engine Coolant Pump on
page 8-10.
10. Reinstall the coolant hoses on the cold start
device on the fuel injection pump.
11. Reinstall the alternator. See Installation of
Alternator on page 11-14.
6-29
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ENGINE
Measuring and Adjusting Valve Clearance
MEASURING AND ADJUSTING VALVE CLEARANCE
Measure and adjust while the engine is cold.
Note:
• The No. 1 piston position is on the flywheel end of the engine, opposite the radiator. The firing order is 13-2 for 3-cylinder engines.
• 3-cylinder engines fire every 240° of crankshaft rotation.
• Valve clearance of both the intake and exhaust valves can be checked with the piston for that cylinder at
top dead center (TDC) of the compression stroke. When a piston is at TDC of the compression stroke,
both rocker arms will be loose and the cylinder TDC mark on the flywheel will be visible in the timing port
of the flywheel housing.
• If there is no valve clearance, and the cylinder is at TDC of the compression stroke, extreme wear, or
damage to the cylinder head or valves may be possible.
• If adjusting each cylinder individually, the cylinder to be adjusted first does not have to be the No. 1
cylinder. Select and adjust the cylinder where the piston is nearest to the top dead center after turning.
Make adjustment for the remaining cylinders in the order of firing by turning the crankshaft each time.
• To decrease the number of rotations required to check all cylinders, other cylinders can also be checked
as indicated in the chart below.
Example: On a 3-cylinder engine, with the No. 1 piston at TDC on the compression stroke (both valves
closed), the valves indicated on the top line of the chart can be adjusted without rotating the crankshaft. To
adjust the remaining two valves, rotate the crankshaft until the No. 1 piston is at TDC on the exhaust stroke
(exhaust valve only open).
■ 3-cylinder engines
Cylinder No.
Valve
No. 1 cylinder at TDC
compression
No. 1 cylinder at TDC
exhaust
6-30
1
2
Intake
Exhaust
Intake



3
Exhaust
Intake
Exhaust



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２０１２年７月２６日
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ENGINE
Measuring and Adjusting Valve Clearance
1. Remove the valve cover. See Removal of valve
cover on page 6-18.
2
Note: If adjusting each cylinder individually, the
cylinder to be adjusted first does not
have to be the No. 1 cylinder. Select and
adjust the cylinder where the piston is
nearest to the top dead center after
turning, and make adjustment for other
cylinders in the order of firing by turning
the crankshaft.
2. Rotate the crankshaft clockwise as seen from
the coolant pump end, to bring No. 1 piston to
TDC on the compression stroke while watching
the rocker arm motion and timing grid on the
flywheel. (Position where both the intake and
exhaust valves are closed.)
3. Insert a feeler gauge (Figure 6-38, (1))
between the rocker arm and valve cap, and
record the measured valve clearance. (Use the
data for estimating the wear.)
1
1
K0001783A
Figure 6-39
6. Insert a feeler gauge of the correct thickness
(Figure 6-40, (1)) (see Adjustment
Specifications on page 6-4) between the rocker
arm and valve cap. Turn the valve adjustment
screw to adjust the valve clearance so there is a
slight “drag” on the feeler gauge when sliding it
between the rocker arm and the valve cap. Hold
the adjusting screw while tightening the valve
adjusting screw lock nut (Figure 6-39, (1)).
Recheck the clearance.
Note: There is a tendency for the clearance to
decrease slightly when the lock nut is
tightened. It is suggested that you make
the initial clearance adjustment slightly
on the “loose” side before tightening the
lock nut.
1
K0001782A
Figure 6-38
4. If adjustment is required, proceed to the next
step.
5. Loosen the valve adjusting screw lock nut
(Figure 6-39, (1)) and valve adjusting screw
(Figure 6-39, (2)) on the rocker arm and check
the valve for inclination of the valve cap,
entrance of dirt, or wear.
K0001782A
Figure 6-40
7. Apply oil to the contact surface between the
adjusting screw and push rod.
8. Rotate the crankshaft. Measure and adjust the
valves on the next cylinder. Continue until all
the valves have been measured and adjusted.
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ENGINE
Crankshaft and Camshaft Components
CRANKSHAFT AND CAMSHAFT COMPONENTS
40
1
2
39
5
6
38
37
36
4
34
35
3
33
7
8
32
9
15
30
29
11
16
12
14
17 13
18
28
27
10
19
20
26
21
22
23
24
25
046622-00X00
Figure 6-41
6-32
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ENGINE
Crankshaft and Camshaft Components
1 – Cylinder block
2 – Camshaft bushing
3 – Dowel (2 used)
4 – O-ring
5 – Front plate
6 – Gear case cover
7 – Front crankshaft seal
8 – Tappets
9 – Camshaft
10 – Camshaft gear key
11 – Camshaft end plate
12 – Camshaft gear
13 – Idler gear shaft
14 – Idler gear bushing
15 – Idler gear
16 – Oil pickup gasket
17 – Oil pickup
18 – Crankshaft
19 – Crankshaft gear key
20 – Crankshaft gear
21 – Crankshaft pulley
22 – Main bearing inserts
23 – Main bearing cap
24 – Oil pan spacer
25 – Oil pan
26 – Thrust bearings
27 – Ring gear
28 – Flywheel
29 – Connecting rod cap
30 – Connecting rod bearing inserts
31 – Connecting rod
32 – Wrist pin bushing
33 – Circlip
34 – Wrist pin
35 – Piston
36 – Oil ring
37 – Second compression ring
38 – Top compression ring
39 – Crankshaft rear seal housing
40 – Crankshaft rear seal
Disassembly of Engine
Prepare a clean, flat working surface on a
workbench large enough to accommodate the
engine components. Discard all used gaskets,
O-rings and seals. Use new gaskets, O-rings and
seals on reassembly of engine.
NOTICE
Identify all parts and their location using an
appropriate method. It is important that all parts are
returned to the same position during the
reassembly process.
If the engine will be completely disassembled, the
following preliminary steps should be performed:
1. Disconnect the battery cables at the battery.
Always disconnect the negative (-) cable first.
2. Remove the throttle cable, electrical
connections, intake and exhaust system
connections, and fuel supply lines from the
engine.
3. Remove the alternator. See Removal of
Alternator on page 11-10.
4. Drain the engine coolant from the radiator and
cylinder block. See Drain, flush and refill cooling
system with new coolant on page 5-20.
Remove the cooling system components from
the engine.
5. Remove the engine from the machine. Mount
the engine to a suitable engine repair stand
having adequate weight capacity.
NOTICE
Be sure to secure the engine solidly to prevent
injury or damage to parts due to the engine falling
during work on the engine.
6. Clean the engine by washing with solvent, air or
steam cleaning. Carefully operate so as to
prevent any foreign matter or fluids from
entering the engine or any fuel system or
electrical components remaining on the engine.
7. Drain the engine oil into a suitable container.
Remove the oil filter.
8. Remove the cylinder head. See Cylinder Head
on page 6-15.
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ENGINE
Crankshaft and Camshaft Components
9. Remove the fuel injection pump from the gear
case/front plate only if it must be sent out for
repair, or will interfere with other procedures
such as “hot tank” cleaning. If the fuel injection
pump does not need to be repaired, leaving it
mounted to the timing gear case or plate will
eliminate the need to re-time it during
reassembly. See Fuel Injection Pump on
page 7-11.
10. Remove the starter motor. See Removal of
Starter Motor on page 10-8.
■ Checking timing gear backlash
Prior to removing the timing gears, measure the
gear backlash and determine the gear wear.
Check the backlash between each pair of mating
gears (Figure 6-43). If not within specification,
replace both mating gears. See Timing Gear
Backlash on page 6-6 for service limits.
Note: Do not allow the gear being checked to move
axially as excess end play could cause a
false reading.
Disassembly of Camshaft and Timing
Components
1
Discard all gaskets, O-rings and seals. Use new
gaskets, O-rings and seals on reassembly of the
camshaft and timing components.
B
7
■ Removal of timing gear case cover
1. Remove the bolt and washer retaining the
crankshaft pulley.
NOTICE
Use care not to damage the threads in the end of
the crankshaft when removing the crankshaft
pulley.
2. Remove the crankshaft pulley using a gear
puller.
3. Remove the bolts that retain the gear case
cover to the cylinder block and oil pan.
4. Remove the gear case cover (Figure 6-42, (1)).
2
B
C C
A
A
3
4
6
5
1
2
3
4
5
6
7
K0001709A
– Fuel injection pump drive gear
– Camshaft drive gear
– Auxiliary drive gear (optional)
– Crankshaft drive gear
– Direction of rotation
– Oil pump drive gear
– Idler gear
Figure 6-43
■ Measuring idler gear-to-crankshaft gear
backlash
1. Install a dial indicator as shown in Figure 6-44.
K0002086
1
Figure 6-44
K0001641A
Figure 6-42
6-34
2. Rotate the idler gear back and forth to check
the idler gear-to-crankshaft gear backlash. The
total indicator reading is the backlash. Record
the measurement.
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ENGINE
Crankshaft and Camshaft Components
■ Measuring idler gear-to-camshaft gear
backlash
1. Drive a small wooden wedge between the
crankshaft gear and idler gear to prevent the
idler gear from rotating.
■ Removal of oil pan
1. Invert the engine (oil pan up) on the engine
stand.
2. Remove the oil pan (Figure 6-46, (1)).
2. Install the dial indicator to read the camshaft
gear backlash. Rotate the camshaft drive gear
against the idler gear to measure the backlash.
Record the measurement.
3. Check the idler gear-to-fuel injection pump
drive gear backlash in the same manner as the
camshaft drive gear. Record the measurement.
■ Removal of timing gears
1. Remove the bolts from the idler gear shaft
(Figure 6-45, (1)). Remove the idler gear shaft,
idler gear (Figure 6-45, (2)) and bushing
(Figure 6-45, (3)).
1
046357-00X00
Figure 6-46
2
3. Remove the oil pickup tube (Figure 6-47, (1))
and O-ring (Figure 6-47, (2)).
3
1
K0001728A
Figure 6-45
2. Do not remove the crankshaft gear unless it is
damaged and requires replacement. If the gear
must be removed, remove it using a gear puller.
3. Removal of the camshaft gear requires the
camshaft be removed and placed in a press. Do
not remove the camshaft gear unless it or the
camshaft is damaged and requires
replacement. See Removal of camshaft on
page 6-36.
2
1
046358-00X00
Figure 6-47
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ENGINE
Crankshaft and Camshaft Components
■ Removal of camshaft
1. Before removing the camshaft, check the
camshaft end play.
2. Remove the two bolts (Figure 6-50, (3))
retaining the camshaft thrust plate
(Figure 6-50, (1)).
• Method A: Install a dial indicator
(Figure 6-48, (1)) on the cylinder block. Move
the camshaft (Figure 6-48, (2)) back and forth
to measure the end play. Record the
measurement. See Camshaft on page 6-6 for
the service limit.
2
5
1
3 4
2
K0001966
Figure 6-50
60
70
50
40
80
30
90
1
3. Rotate the engine in the engine stand so that
gravity causes the tappets (Figure 6-50, (5)) to
drop away from the camshaft lobes.
0
10
20
Note: Rotate the camshaft at least two turns to
“bump” any sticking tappets away from
the camshaft.
K0002085A
Figure 6-48
• Method B: Use a feeler gauge to measure the
clearance between the thrust plate
(Figure 6-49, (1)) and front camshaft bearing
(Figure 6-49, (2)). See Thrust Bearing on
page 6-7 for the service limit.
1
2
4. Slowly pull the camshaft (Figure 6-50, (2))
assembly out of the engine being careful not to
damage the front camshaft bushing.
Note:
• If the engine is not installed on an engine repair
fixture, stand the engine upright on the flywheel
end mounting flange. Rotate the camshaft at
least two turns to bump the tappets out of the
way to prevent the tappets from interfering with
the removal of the camshaft.
• The tappets are “mushroom” shaped and must
be removed from inside the engine crankcase.
5. Remove the tappets. Mark the tappets so they
can be reinstalled in the same location.
K0001710B
Figure 6-49
6-36
6. Remove the camshaft drive gear
(Figure 6-50, (4)) only if the gear or camshaft
require replacement. Use a knife-edge puller
and a press to remove the gear. The gear is a
shrink-fit and will need to be heated to 356 392 °F (180 - 200 °C) to remove.
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ENGINE
Crankshaft and Camshaft Components
■ Removal of gear case or front plate
Note: The camshaft must be removed before the
gear case/front plate can be removed. See
Inspection of camshaft on page 6-45.
1. Remove the oil pump.
Note: It is not necessary to remove the fuel
injection pump from the gear case/front
plate to remove the gear case/front plate.
If the fuel injection pump does not need
to be repaired, leaving it mounted to the
timing gear case/front plate will eliminate
the need to re-time it during assembly.
See Fuel Injection Pump on page 7-11.
2. Remove the bolts.
3. Remove the gear case or front plate from the
cylinder block. Thoroughly clean all old sealant
from the mating surfaces.
4. Inspect and measure the camshaft bushing.
See Camshaft on page 6-6 for the service limit.
If damaged or worn beyond service limits,
remove the camshaft bushing.
5. Remove two O-rings.
6. Remove the O-ring (Figure 6-51, (2)) and
dowels (Figure 6-51, (5)).
Disassembly of Crankshaft and
Piston Components
■ Removal of pistons
NOTICE
Keep the piston pin parts, piston assemblies, and
connecting rod assemblies together to be returned
to the same position during the reassembly
process. Label the parts using an appropriate
method.
NOTICE
Engines with high operating hours may have a
ridge near the top of the cylinders that will catch the
piston rings and make it impossible to remove the
pistons. Use a suitable ridge reamer to remove
ridges and carbon prior to removing the pistons.
Note: Pistons can fall from cylinder block if the
engine is inverted. Rotate the engine so the
connecting rods are horizontal before
removing the connecting rod caps.
1. Using a feeler gauge, measure the connecting
rod side clearance as shown (Figure 6-52).
See Connecting Rod on page 6-8 for the
standard limit. If the measurement is out of
specification, replace the crankshaft,
connecting rod, or both.
3
1
2
4
5
K0002016
Figure 6-51
K0000219
Figure 6-52
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ENGINE
Crankshaft and Camshaft Components
2. Measure bearing oil clearance prior to removing
the pistons and connecting rods to determine
extent of wear. Record the measurements.
1
NOTICE
Mark the connecting rod caps and connecting
rods so the caps and connecting rods stay
together.
K0001899
Figure 6-54
1- Remove the bearing cap. Do not remove the
bearing inserts at this time.
2- Wipe oil from the bearing insert and
crankshaft journal surfaces.
3- Place a piece of PLASTIGAGE®
(Figure 6-53, (1)) along the full width of the
bearing insert.
7- Repeat with remaining connecting rods.
NOTICE
Do not allow the connecting rod to contact the
crankshaft journal during piston removal.
Damage to the bearing journal may result.
3. Use a wooden dowel against the connecting
rod and tap the piston/connecting rod assembly
out of the cylinder.
1
4. Mark the cylinder number on the piston and
connecting rod.
5. Remove the bearing inserts (Figure 6-55, (2)).
K0001898
Figure 6-53
NOTICE
6. Remove the compression rings
(Figure 6-55, (3)) from the piston using a piston
ring expander.
7. Remove the oil ring (Figure 6-55, (4)) from the
piston using a piston ring expander.
Do not rotate the crankshaft when using
PLASTIGAGE. A false reading may result.
3
4
4- Reinstall bearing cap and tighten to
specification. See Special Torque Chart on
page 6-10.
5
9
6
5
5- Remove bearing cap.
6- Compare the width of the flattened
PLASTIGAGE to the graduation marks on
the package (Figure 6-54, (1)). The mark
that most closely matches the width of the
flattened PLASTIGAGE will indicate the
bearing oil clearance.
8
7
2
1
K0001960
Figure 6-55
6-38
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ENGINE
Crankshaft and Camshaft Components
8. Remove the circlips (Figure 6-55, (5)) from the
wrist pin.
9. Remove the wrist pin (Figure 6-55, (6)) and
connecting rod (Figure 6-55, (8)) from the
piston (Figure 6-55, (9)).
10. Repeat the steps until all pistons are removed
and dissembled.
• Method B: Use a feeler gauge to measure the
clearance (Figure 6-58, (3)) between the
thrust bearing (Figure 6-58, (1)) and
crankshaft (Figure 6-58, (2)). Record the
measurement. See Thrust Bearing on
page 6-7 for the service limit.
■ Removal of crankshaft
1. Remove the flywheel (Figure 6-56, (1)) from
the crankshaft.
1
2. Remove the bolts from the rear oil seal
assembly (Figure 6-56, (2-3)). Remove the
assembly from the engine.
2
3
2
K0001962
3
Figure 6-58
1
4. Remove the main bearing caps
(Figure 6-59, (3)). Be sure to note the markings
on the main bearing caps, or mark them
yourself, so they can be reinstalled in the same
order as they were removed. Do not remove the
bearing inserts at this time.
K0001707A
Figure 6-56
Note: The “arrows” on the main bearing caps
point to the flywheel end of the engine.
3. Before removing the main bearing caps,
measure the crankshaft end play. Use either of
the following two methods.
• Method A: Install a dial gauge
(Figure 6-57, (1)) on the cylinder block. Move
the crankshaft (Figure 6-57, (2)) in and out to
measure the end play. Record the
measurement.
2
1
1
3
046359-00X00
2
K0001961
Figure 6-59
Figure 6-57
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ENGINE
Crankshaft and Camshaft Components
5. Measure bearing oil clearance prior to removing
the crankshaft to determine extent of wear.
Record the measurements.
1- Wipe oil from the bearing insert and
crankshaft journal surfaces.
2- Place a piece of PLASTIGAGE
(Figure 6-60, (1)) along the full width of
each bearing insert.
1
7. Remove the bearing inserts (Figure 6-59, (1))
and thrust bearings (Figure 6-59, (2)).
Note: Do not remove the crankshaft gear
unless the gear or crankshaft are
damaged and require replacement.
8. If necessary, remove the crankshaft gear
(Figure 6-62, (1)), parallel pin
(Figure 6-62, (2)) and key (Figure 6-62, (3)). If
using a gear puller, be careful not to damage
the threads in the end of the crankshaft.
2
3
1
K0001898
Figure 6-60
K0001731A
NOTICE
Figure 6-62
Do not rotate the crankshaft when using
PLASTIGAGE. A false reading may result.
3- Reinstall bearing caps and tighten to
specification. See Special Torque Chart on
page 6-10.
4- Remove bearing caps.
5- Compare the width of the flattened
PLASTIGAGE to the graduation marks on
the package (Figure 6-61, (1)). The mark
that most closely matches the width of the
flattened PLASTIGAGE will indicate the
bearing oil clearance.
Inspection of Crankshaft and
Camshaft Components
WARNING
Fume/Burn Hazard!
• Always read and
follow safety related
precautions found on
containers of
hazardous substances
like parts cleaners,
primers, sealants and
sealant removers.
• Failure to comply could result in death or
serious injury.
1
Thoroughly clean all components using a brush
and appropriate solvent. Each part must be free of
carbon, gasket material, metal filings and other
debris.
K0001899
Figure 6-61
6. Remove the crankshaft from the engine.
6-40
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ENGINE
Crankshaft and Camshaft Components
■ Replacement of crankshaft oil seals
■ Measure crankshaft bearing oil clearance
1. Remove the seal (Figure 6-63, (2)) from the
cover (Figure 6-63, (1)).
Oil clearance should be checked during
disassembly to determine the extent of wear, and
during assembly to ensure long engine life. The
same procedure is done for both connecting rods
and main bearings.
2. Apply a continuous bead of ThreeBond Liquid
Gasket No. 1207F, YANMAR Part No. 9777701207F to the outside diameter of a new oil seal
(Figure 6-63, (2)), and install in the gear case
cover. Apply lithium grease to the lip of the seal.
■ Inspection of cylinder block
1. Ensure that oil passages are clear and
unobstructed.
2. Check for discoloration or evidence of cracks. If
a fracture is suspected, use the color check
method or the Magnaflux method to determine
if the cylinder block is fractured.
1
2
046360-00X00
Figure 6-63
3. Inspect cylinders for roundness, taper, or
evidence of scoring. Collect and record the
measurements. Consider honing, reboring or
replacing the cylinder block if the
measurements are not within specification.
• Take measurements at three places
(Figure 6-65) (a, b, c), and in two directions (d
and e) in each cylinder.
3. Remove the rear oil seal (Figure 6-64, (3)) from
the seal housing (Figure 6-64, (2)).
a
4. Apply a continuous bead of ThreeBond Liquid
Gasket No. 1207F, YANMAR Part No. 9777701207F to the outside diameter of a new oil seal
(Figure 6-64, (2)), and install in the housing.
Apply lithium grease to the lip of the seal.
b
20 mm
(0.75 in.)
d
e
c
20 mm
(0.75 in.)
K0000230B
Figure 6-65
■ Inspection of pistons, piston rings and
wrist pin
2
3
Note:
1
• On an engine with low hours, the pistons, piston
rings may be reused if they are found to be within
specifications. The pistons and piston rings must
be reinstalled in the same cylinders from which
they were originally removed.
K0001707A
Figure 6-64
3TNV88F Service Manual
• On an engine with high hours, the pistons rings
should be replaced and the cylinder honed (See
Honing and Boring on page 6-46) or replaced.
The piston should be replaced as necessary.
6-41
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ENGINE
Crankshaft and Camshaft Components
1. Clean piston ring grooves using a piston ring
groove cleaning tool. Follow manufacturer’s
instructions for correct operation.
2. Wash the pistons in an appropriate solvent
using a soft brush.
3. Visually inspect each piston for cracks. Pay
particular attention to the ring lands between
the piston ring grooves.
4. Measure the diameter of the piston skirt at 90°
to the wrist pin bore as shown (Figure 6-66).
Measurements must be taken at a specified
distance (Figure 6-66, (1)) from the bottom of
the piston, based on engine model. Record the
measurements. See Piston on page 6-7 for
specifications.
K0000237
Figure 6-67
7. Measure the outside diameter of the wrist pin in
three places and at 90° (Figure 6-68). See
Piston on page 6-7 for specifications. Record
the measurements.
1
K0001889
Figure 6-68
K0000235
Figure 6-66
5. Subtract the piston measurement from the
greatest measurement acquired during cylinder
inspection (see Inspection of cylinder block on
page 6-41) to obtain piston-to-cylinder
clearance. Record the measurements. See
Piston on page 6-7 for specifications.
6. Measure the diameter of the wrist pin bore on
both sides of the piston (Figure 6-67). See
Piston on page 6-7 for specifications. Record
the measurements.
8. Using a micrometer, measure the thickness of
each piston ring. See Piston on page 6-7 for
specifications. Record the measurements.
Note:
• On an engine with low hours, the pistons,
piston rings and cylinders may be reused if they
are found to be within specifications.
• On an engine with high hours, the pistons rings
should be replaced and the cylinder honed
(see Honing and Boring on page 6-46) or
replaced. The piston should be replaced as
necessary.
9. Place each compression piston ring in the
groove as shown (Figure 6-69). Use a feeler
gauge to measure the clearance between the
piston ring and the piston ring land. Record the
measurements. See Piston Ring on page 6-8
for specifications. Replace the piston if not
within specification.
6-42
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ENGINE
Crankshaft and Camshaft Components
Note: Always check the piston ring end gap
when installing new piston rings. See
Piston Ring on page 6-8 for
specifications. Use a piston ring end gap
filing tool to adjust the piston ring end
gap on new piston rings.
11. Repeat the above steps for each cylinder and
piston assembly.
■ Inspection of connecting rod
K0001892
Figure 6-69
10. To measure piston ring end gap, insert each
compression piston ring (Figure 6-70, (1)), one
at a time, into the cylinder. Use a piston with the
piston rings removed to slide the ring into the
cylinder bore until it is approximately 1.18 in.
(30 mm) (Figure 6-70, (2)) from the bottom of
the bore. Remove the piston. Measure the end
gap (Figure 6-70, (3)) of each piston ring.
Record the measurements. See Piston Ring on
page 6-8 for specifications.
1. Measure the wrist pin bushing bore using a
bore gauge (Figure 6-71, (1)). Replace the
bushing if not within specifications. If the
bushing has been removed, measure the inside
diameter of the connecting rod small end
(Figure 6-71, (2)). See Connecting Rod on
page 6-8 for specifications.
1
2
K0001724A
Figure 6-71
2. Place the connecting rod bearing inserts into
the connecting rod and connecting rod cap.
Install the rod cap and tighten the bolts to the
specified torque.
1
2
3
3. Measure the inside diameter. See Crankshaft
on page 6-7 for specifications.
K0001964
Figure 6-70
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ENGINE
Crankshaft and Camshaft Components
■ Inspection of tappets
■ Inspection of crankshaft
1. Inspect the tappet contact surfaces for
abnormal wear (Figure 6-72, (1)). Normal wear
will be even as shown in (Figure 6-72, (2)).
Slight surface defects can be corrected using
an oilstone.
1. Place the crankshaft end journals
(Figure 6-74, (4)) on V-blocks.
2. Place a dial indicator (Figure 6-74, (3)) on a
center main bearing surface.
1
2
1
2
3
K0001725
Figure 6-72
2. Measure the outside diameter of the tappet
stem (Figure 6-73, (1)). See Tappet on
page 6-9 for the service limit.
4
4
K0000232A
Figure 6-74
3. Rotate the crankshaft and observe runout. See
Crankshaft on page 6-7 for specifications.
4. Use the color check method or Magnaflux® to
inspect the crankshaft for cracks. Replace the
crankshaft if evidence of fractures are found.
1
K0001726A
Figure 6-73
3. Measure the tappet bores in the cylinder block.
See Tappet on page 6-9 for the service limit.
6-44
5. Measure the outside diameter of each crankpin
(Figure 6-75, (2)) and main bearing journal
(Figure 6-75, (1)). See Crankshaft on page 6-7
for specifications. Take measurements at
several places around each bearing surface. If
not within specification, grind the journals and
install undersize bearings, or replace the
crankshaft.
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ENGINE
Crankshaft and Camshaft Components
■ Inspection of camshaft
1. Use V-blocks and a dial indicator to check
camshaft bend (Figure 6-76). Place the
indicator on the center bearing journal.
K0001711
Figure 6-76
R
2. Rotate the camshaft and observe the runout.
See Camshaft on page 6-6 for specifications.
R
3. Measure the height of each lobe
(Figure 6-77, (1)). See Camshaft on page 6-6
for specifications.
1
2
K0001733A
Figure 6-75
1
K0001712A
Figure 6-77
4. Measure the diameter of the gear end
(Figure 6-78, (1)), intermediate
(Figure 6-78, (2)), and flywheel end
(Figure 6-78, (3)) bearing journals. See
Camshaft on page 6-6 for specifications.
3
2
1
K0001713A
Figure 6-78
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ENGINE
Crankshaft and Camshaft Components
■ Inspection of camshaft bushing and
bores
1. Measure the I.D. of the front bushing and the
remaining bores in the cylinder block. See
Camshaft on page 6-6 for specifications.
2. If the camshaft bushing is not within
specification, replace it using the appropriate
service tool. If the remaining bores are not
within specification, the cylinder block will
require replacement as there are no bearing
inserts used.
■ Inspection of idler gear and shaft
1. Measure the outside diameter
(Figure 6-79, (1)) of the idler gear shaft
(Figure 6-79, (2)). See Idler Gear Shaft and
Bushing on page 6-6 for specifications.
2. Measure the inside diameter (Figure 6-79, (3))
of the idler gear bushing (Figure 6-79, (4)). See
Idler Gear Shaft and Bushing on page 6-6 for
specifications.
4
1
3
2
K0001714A
Figure 6-79
Honing and Boring
Pistons must move freely in the cylinders while
maintaining adequate compression and oil sealing.
If the cylinder walls are scuffed, scored,
out-of-round, or tapered beyond specifications,
rebore and hone to restore cylinders to usable
condition. Slight imperfections can be corrected by
honing alone.
1. Boring - Significant cylinder damage may be
corrected by boring the cylinder to an oversize
dimension. Refer to the appropriate parts
catalog for available oversize pistons and piston
rings.
• Boring a cylinder should always be done in a
properly equipped machine shop.
• A bored cylinder should always be finished with
a hone to properly prepare the cylinder surface
so the new piston rings will seat properly.
• After the cylinder has been bored and honed,
install the appropriate oversize pistons and
piston rings.
2. Honing - Minor cylinder imperfections may be
corrected by using a rigid cylinder hone
(Figure 6-81, (1)). Be sure not to exceed the
maximum cylinder bore specification.
Deglazing - A used cylinder that did not require
boring or honing, should always be deglazed with
a ball hone (Figure 6-81, (2)) before installing
new piston rings. This will properly prepare the
cylinder surface to allow new piston rings to seat
properly.
Note: When honing a cylinder, with either a
ridged hone or a ball hone
(Figure 6-80, (1)), move the rotating
hone up and down in the cylinder bore to
accomplish a 30° to 40° crosshatch
pattern (Figure 6-80). This will provide
the ideal surface for the proper seating of
new piston rings.
6-46
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ENGINE
Crankshaft and Camshaft Components
NOTICE
Do not allow the honing tool to operate in one
position for any length of time. Damage to the
cylinder wall will occur. Keep the tool in constant
up-and-down motion.
1
• When honing is completed, wash the cylinder
block with hot water and soap. The cylinder wall
is adequately cleaned when a white rag wiped
in cylinder comes out clean. Use brushes to
clean all passages and crevices. Rinse with hot
water and dry with compressed air. Apply clean
engine oil to all steel surfaces to prevent
rusting.
Reassembly of Crankshaft and
Piston Components
Note:
• Proceed slowly. Make no forced assemblies
unless a pressing operation is called for. All parts
must be perfectly clean and lightly lubricated
when assembled.
• Use new gaskets, seals and O-rings during
assembly.
K0000248A
• Liberally apply clean engine oil to all internal
parts during assembly.
Figure 6-80
• Use a 50:50 mixture of diesel fuel and engine
oil as a honing fluid.
• Use a 300-grit hone at 300 - 1200 min-1 (rpm)
(Figure 6-81).
1
2
• All fasteners should be tightened to a given
torque. If a special torque is not provided in the
Special Torque Chart on page 6-10, tighten to
standard torque specifications. See Tightening
Torques for Standard Bolts and Nuts on
page 4-25.
■ Reassembly of pistons
1. Select the parts needed to reassemble the
piston and connecting rod for one cylinder.
K0000249B
Figure 6-81
2. If removed, install a new wrist pin bushing
(Figure 6-82, (7)) using a press and the
appropriate service tool. Be sure to align the oil
holes.
NOTICE
Solvents will not adequately remove honing
residue, resulting in premature piston and ring
wear. Always wash cylinders using hot, soapy
water.
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ENGINE
Crankshaft and Camshaft Components
3
4
9
ML V88
5
6
5
1
8
7
2
046623-00X00
1
2
K0001960
Figure 6-82
V84
3. Reinstall one circlip (Figure 6-82, (5)) into the
piston. Ensure the circlip is securely seated in
the groove.
R
046646-00X00
NOTICE
The piston and connecting rod must be
assembled together in the correct orientation.
The orientation of the piston and connecting rod
are different depending on engine model.
3
80
80
K0002089
Piston to connecting rod orientation - by model
Orient the piston identification mark stamped on top of the
piston on the same side as the rod and cap match marks
stamped on the connecting rod.
1 – Piston identification mark
2 – Embossed mark on connecting rod
3 – Rod and cap match marks
Figure 6-83
Note: The actual appearance of the match
marks on the piston and connecting rod
may vary, but they will always be in the
same locations.
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ENGINE
Crankshaft and Camshaft Components
Piston assembly
3
When correctly assembled, the piston
identification mark (Figure 6-84, (2)) stamped
into the top of the piston will be on the same side
of the connecting rod as the match marks
(Figure 6-84, (4)) stamped into the connecting
rod and connecting rod cap.
4
5
9
6
5
When installed in the cylinder, the piston
identification mark (Figure 6-84, (2)) stamped
on the top of the piston must face the fuel
injection pump side (Figure 6-84, (1)) of the
engine and the embossed mark on the
connecting rod (Figure 6-84, (3)) must face the
flywheel end (Figure 6-84, (5)) of the engine.
8
7
2
1
K0001960
6
1
Figure 6-85
Note:
2
5
3
4
K0001967
1
2
3
4
5
6
– Fuel injection pump side of engine
– Piston identification mark
– Embossed mark on connecting rod
– Rod and cap match marks
– Flywheel end of engine
– Camshaft side of engine
Figure 6-84
• If installing new piston rings the end gap must
be checked and adjusted as necessary. See
Inspection of pistons, piston rings and wrist pin
on page 6-41 for specifications. Use a piston
ring end gap filing tool to adjust the piston ring
end gap on new piston rings.
• Reinstall the top and second piston rings with
the stamped “makers mark” (Figure 6-86 (1))
facing the top of the piston. The “makers mark”
may vary in appearance but will always be
located on the top surface of the piston ring
adjacent to the piston ring gap. The oil ring and
oil ring expander can be installed either side
up.
1
4. Lubricate and reinstall the wrist pin
(Figure 6-85, (3)) through the piston and
connecting rod.
K0000225A
5. Reinstall the second circlip (Figure 6-85, (4))
and ensure it is securely seated in the groove.
Figure 6-86
NOTICE
Always use a piston ring installation tool
(expander) when installing piston rings. Never
attempt to install piston rings by hand.
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ENGINE
Crankshaft and Camshaft Components
6. Reinstall the oil ring expander
(Figure 6-87, (4)). Reinstall the oil ring
(Figure 6-87, (3)) with the end gap at 180° from
the expander end gap.
7. Reinstall the second compression ring
(Figure 6-87, (2)). This ring is identified by its
dark color and tapered face profile.
1
2
3
8. Reinstall the top compression ring
(Figure 6-87, (1)). This ring is identified by its
silver color and barrel-shaped face profile.
NOTICE
The oil ring expander (Figure 6-87, (4)) end gap
must be located 180° from the oil ring
(Figure 6-87, (3)) end gap.
1
K0001968
1 – Top compression ring end gap
2 – Second compression ring end gap
3 – Oil ring end gap
Figure 6-88
2
3
4
K0001722B
Figure 6-87
9. Stagger the piston ring end gaps at 120°
intervals (Figure 6-88, (1, 2, 3)). Do not
position the top piston ring end gap in line with
the wrist pin.
■ Installation of crankshaft
1. If removed, reinstall the keys and timing gear on
the crankshaft.
2. Reinstall new bearing inserts (Figure 6-89, (1))
and thrust bearing (Figure 6-89, (2)) in the
cylinder block and main bearing caps. Apply a
liberal coat of clean engine oil to the bearings
and crankshaft journals.
3. Place the crankshaft into the engine.
NOTICE
The main bearing caps are numbered and have
arrows for proper positioning. The No. 1 cap is at
the flywheel end. The arrows point toward the
flywheel end of the engine.
4. Reinstall the main bearing caps
(Figure 6-89, (3)).
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ENGINE
Crankshaft and Camshaft Components
5. Apply a light coat of clean engine oil to the
bearing cap bolts and tighten the bolts to the
specified torque in two stages (1/2 then full
torque). See Special Torque Chart on
page 6-10 for specifications.
■ Installation of pistons
NOTICE
Do not allow the connecting rod to contact the
crankshaft journal during piston installation.
Damage to the crankshaft bearing journal may
result.
1. Lubricate the piston, piston rings, and cylinder
with clean engine oil or assembly lubricant.
2
2. Rotate the crankshaft so the crankpin for the
piston being installed is near bottom dead
center.
NOTICE
1
Ensure the piston ring gaps are located correctly
(Figure 6-91).
3
K0001752A
1
Figure 6-89
6. Rotate the crankshaft to assure it turns freely.
7. Apply ThreeBond Liquid Gasket No. 1207F,
YANMAR Part No. 977770-1207F to the
mounting flange of the seal housing
(Figure 6-90, (2)).
2
3
8. Align the seal housing with the two dowel pins.
9. Reinstall seal housing and seal assembly.
10. Reinstall the flywheel (Figure 6-90, (1)) and
tighten the bolts to the specified torque. See
Special Torque Chart on page 6-10 for
specifications.
1 – Top compression ring end gap
2 – Second compression ring end gap
3 – Oil ring end gap
Figure 6-91
3. Using a piston ring compressor, compress the
piston rings.
NOTICE
2
The piston and connecting rod must be installed
in the correct orientation. The orientation of the
piston to the cylinder is different depending on
engine model.
3
1
Piston orientation to cylinder - by model
Orient the piston identification mark stamped on top of the
piston on the fuel injection pump side of the engine
K0001707A
Figure 6-90
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ENGINE
Crankshaft and Camshaft Components
Piston installation
When correctly assembled, the piston
identification mark (Figure 6-92, (2)) stamped
into the top of the piston will be on the same side
of the connecting rod as the match marks
(Figure 6-92, (4)) stamped into the connecting
rod and connecting rod cap.
When installed in the cylinder, the piston
identification mark (Figure 6-92, (2)) stamped
on the top of the piston must face the fuel
injection pump side (Figure 6-92, (1)) of the
engine and the embossed mark on the
connecting rod (Figure 6-92, (3)) must face the
flywheel end (Figure 6-92, (5)) of the engine.
6
4. Reinstall the bearing inserts (Figure 6-93, (1))
in the connecting rod and cap.
5. Apply a liberal coat of clean engine oil to the
bearing inserts and crankshaft journal.
6. Apply a light coat of clean engine oil to the rod
cap bolts. Reinstall the connecting rod cap
(Figure 6-93, (2)). Tighten the connecting rod
bolts to the specified torque in two stages (1/2
then full torque). See Special Torque Chart on
page 6-10 for specifications.
1
1
2
2
5
3
K0001965
4
Figure 6-93
K0001967
1
2
3
4
5
6
– Fuel injection pump side of engine
– Piston identification mark
– Embossed mark on connecting rod
– Rod and cap match marks
– Flywheel end of engine
– Camshaft side of engine
7. Reinstall the remaining pistons in their
respective cylinders.
Figure 6-92
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ENGINE
Crankshaft and Camshaft Components
Reassembly of Camshaft and Timing
Components
■ Installation of gear case or front plate
1. If removed, install a new camshaft bushing
(Figure 6-94, (3)) using the appropriate service
tool.
2. Apply a continuous bead of ThreeBond Liquid
Gasket No. 1207F, YANMAR Part No. 9777701207F to the mounting area of the gear case or
front plate. Be sure to circle each bolt hole.
3
■ Installation of camshaft
Note: The gear housing or front plate must be
reinstalled prior to installing the camshaft.
See Installation of gear case or front plate on
page 6-53.
1. If removed, reinstall the camshaft end plate
(Figure 6-96, (1)), key, and timing gear
(Figure 6-96, (4)) onto the camshaft using a
press.
Note: Heat the gear to 356 - 392 °F (180 - 200
°C) and press onto the end of the
camshaft.
2. Rotate the cylinder block so that gravity will
keep the tappets (Figure 6-96, (5)) in place and
out of the way of the camshaft lobes when the
camshaft is being reinstalled.
1
4
Note:
• If the engine is not installed on an engine repair
fixture, stand the engine upright on the flywheel
end mounting flange.
2
• The tappets are “mushroom” shaped and must
be installed from inside the engine crankcase.
046374-00X00
Figure 6-94
3. Reinstall the dowels (Figure 6-95, (5)) and a
new O-ring (Figure 6-95, (2)).
4. Lubricate the camshaft (Figure 6-96, (2)) with
clean engine oil or assembly lube. Slowly insert
the camshaft through the front of the engine.
3
1
2
3. Lubricate the tappets with clean oil or assembly
lube. Reinstall the tappets in their respective
locations in the cylinder block. Push the tappets
fully into the tappet bores so they will not
interfere with the installation of the camshaft.
4
5. Reinstall and tighten the cap screws
(Figure 6-96, (3)).
2
5
5
1
K0002016
3 4
Figure 6-95
4. Reinstall the gear case (Figure 6-94, (1)) or
front plate (Figure 6-95, (1)). Tighten the bolts
to the specified torque.
K0001966
Figure 6-96
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ENGINE
Crankshaft and Camshaft Components
6. If removed, reinstall the fuel injection pump.
Adjust the fuel injection timing the engine after
installation. See Adjusting Fuel Injection Timing
on page 7-24.
■ Installation of timing gears
1. Set the No. 1 piston to top dead center.
2. Rotate the camshaft until the mark
(Figure 6-97, (C)) is approximately at the
9 o’clock position.
1
B
7
2
B
7. When all gears are properly aligned, tighten the
idler gear retaining bolts to specified torque.
See Special Torque Chart on page 6-10 for
specifications.
■ Installation of gear case cover
1. Apply a continuous bead of ThreeBond Liquid
Gasket No. 1207F, YANMAR Part No. 9777701207F to the mounting area of the gear case
cover (Figure 6-99, (1)). Be sure to circle the
bolt holes.
NOTICE
C C
Be sure to align the flats on the oil pump with the
flats on the crankshaft gear when installing the
gear case cover.
A
A
3
4
6
5
1
2
3
4
5
6
7
6. Ensure all three timing marks (Figure 6-97, (A,
B, C)) are aligned.
K0001709A
2. Reinstall and tighten the gear case cover bolts.
– Fuel injection pump gear
– Camshaft gear
– Optional accessory drive gear
– Crankshaft gear
– Direction of rotation
– Oil pump gear
– Idler gear
Figure 6-97
3. Lubricate the idler gear (Figure 6-98, (2)),
bushing (Figure 6-98, (3)) and idler gear shaft
(Figure 6-98, (1)) with clean engine oil.
1
K0001641A
Figure 6-99
2
3. Reinstall the crankshaft pulley.
3
1
K0001728A
Figure 6-98
NOTICE
Use the crankshaft pulley installation tool
(Figure 6-100, (3)) when reinstalling the pulley
(Figure 6-100, (1)). The tool will guide the pulley
hub and protect the front seal (Figure 6-100, (2))
from damage.
4. Align the timing gears as shown in
(Figure 6-97).
5. Reinstall the idler gear and idler gear shaft. Be
sure the oil hole in the bushing is facing toward
the top of the engine.
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ENGINE
Crankshaft and Camshaft Components
■ Installation of oil pan
1
2
1. Reinstall the oil pickup tube (Figure 6-101, (1))
using a new O-ring (Figure 6-101, (2)).
2
1
3
K0001696A
K0002133
Figure 6-100
4. Reinstall the washer and bolt. Tighten the bolt
to the specified torque. See Special Torque
Chart on page 6-10 for specifications.
Figure 6-101
2. Apply a continuous bead of ThreeBond Liquid
Gasket No. 1207F, YANMAR Part No.
977770-1207F to the mounting surface of the
oil pan (Figure 6-102, (1)). Be sure to circle
each bolt hole.
3. Reinstall the oil pan and tighten the bolts
securely.
1
K0001695A
Figure 6-102
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ENGINE
Crankshaft and Camshaft Components
Final Reassembly of Engine
1. Reinstall the starter motor.
2. Reinstall the cylinder head. See Reassembly of
cylinder head on page 6-27.
3. Reinstall the engine in the machine.
4. Reconnect the fuel and coolant lines.
5. Reinstall the alternator.
6. Reconnect and adjust the throttle cable.
7. Reconnect all electrical connections.
8. Fill the engine with oil and coolant.
9. Reconnect the battery cables, negative (-) cable
last.
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ENGINE
EGR system
EGR SYSTEM
EGR System
3
1
4
2
5
6
046361-00X00
1 – EGR pipe
2 – Exhaust manifold
3 – Cooling water hose, EGR valve inlet
4 – Cooling water hose, EGR valve outlet
5 – Intake manifold
6 – EGR valve
Figure 6-103
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ENGINE
EGR system
DANGER
Scald Hazard!
• Never remove the radiator cap if
the engine is hot. Steam and hot
engine coolant will spurt out and
seriously burn you. Allow the
engine to cool down before you
attempt to remove the radiator
cap.
• Tighten the radiator cap securely after you
check the radiator. Steam can spurt out
during engine operation if the cap is loose.
• Always check the level of the engine coolant
by observing the reserve tank.
• Failure to comply will result in death or
serious injury.
WARNING
Burn Hazard!
• Keep your hands and other body
parts away from hot engine
surfaces such as the muffler,
exhaust pipe, turbocharger (if
equipped) and engine block
during operation and shortly after
you shut the engine down. These
surfaces are extremely hot while
the engine is operating and could
seriously burn you.
• Failure to comply could result in death or
serious injury.
6-58
WARNING
Entanglement Hazard!
• Stop the engine before you begin
to service it.
• Never leave the key in the key switch when
you are servicing the engine. Someone may
accidentally start the engine and not realize
you are servicing it. This could result in a
serious injury.
• If you must service the engine while it is
operating, remove all jewelry, tie back long
hair, and keep your hands, other body parts
and clothing away from moving / rotating
parts.
• Failure to comply could result in death or
serious injury.
WARNING
Fume/Burn Hazard!
• Always read and
follow safety related
precautions found on
containers of
hazardous substances
like parts cleaners,
primers, sealants and
sealant removers.
• Failure to comply could result in death or
serious injury.
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ENGINE
EGR system
CAUTION
Flying Object Hazard!
• Always wear eye protection when
servicing the engine and when
using compressed air or highpressure water. Dust, flying
debris, compressed air,
pressurized water or steam may
injure your eyes.
• Failure to comply may result in minor or
moderate injury.
CAUTION
Coolant Hazard!
• Wear eye protection
and rubber gloves
when you handle long
life or extended life
engine coolant. If
contact with the eyes
or skin should occur,
flush eyes and wash
immediately with
clean water.
1. Drain the engine cooling water.
2. Remove the battery cable from the battery’s
minus (-) terminal.
3. If there is any additional equipment (such as an
air cleaner) installed above the EGR valves,
remove it in advance.
4. Remove the EGR valve connectors.
5. Disconnect the cooling water inlet and outlet
hoses from each EGR valve by loosening the
hose clips. When loosening the clips, put waste
cloth or the like beneath the hose joints in case
water leaks.
6. Loosen the nuts in the coupling flanges of the
exhaust manifold and the EGR pipe.
7. Loosen the bolts in the coupling flanges of the
EGR pipe and EGR valve, and remove the EGR
pipe.
• Failure to comply may result in minor or
moderate injury.
NOTICE
When it is necessary to replace an EGR valve, be
sure to replace the entire EGR valve assembly.
Neither attempt to disassemble and repair the EGR
valve, nor replace its individual components.
NOTICE
1
046362-00X00
1 – EGR pipe
Figure 6-104
8. Remove the EGR valve.
The EGR system uses steel gaskets at the joints
between its components/parts. These steel gaskets
are specific to the respective joints. When you
remove the system’s components/parts and
reinstall them, replace the steel gaskets between
them with new correct ones.
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ENGINE
EGR system
Inspecting/Cleaning EGR Related
Components
■ EGR valve
Each EGR valve has four built-in coils. The power
to each of the four coil is either ON or OFF at any
given time. Depending on which coil is ON and
which coil is OFF, the step motor rotates to
determine the valve lift. The power to each coil is
turned ON/OFF by the E-ECU based on the engine
speed and fuel injection rate. The resistances of
these coils should be as specified below when
measured between each pair of pins shown. If any
of the actually measured values is beyond the
standard range, replace the entire EGR valve
assembly.
■ EGR valve operation checks
1. After removing each EGR valve from the
engine, connect the valve with the connector.
2. Connect the valve to the battery’s minus (-)
terminal.
3. Turn on the key switch.(Note that turning on the
key switch causes the E-ECU to check whether
the valve functions properly by opening and
shutting it.)
4. From the exhaust gas inlet, visually check
whether the valve operates correctly.
Note:
• If the EGR valve fails to smoothly operate,
replace the entire valve assembly with new
one.
• If the EGR valve does not respond at all, check
whether there exists a voltage (EGR valve
signal) between the connector pins. If the
voltage is within the standard range, then
replace the entire valve assembly with new
one.
1
NOTICE
Alternatively, you can remove the EGR pipe from
the engine and check the valve operation
through the gas inlet window, instead of
removing the EGR valve from the engine.
1 – EGR valve connectors
Figure 6-105
Standard value
Terminal
Resistance ()
-
-
-
15 ± 2
at 20 °C
-
Note: The higher the temperature, the higher the
coil resistance. Therefore, wait for the EGR
valve to return to normal state before
measuring the resistances.
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ENGINE
EGR system
■ Cleaning the EGR valves
WARNING
Fume/Burn Hazard!
• Always read and
follow safety related
precautions found on
containers of
hazardous substances
like parts cleaners,
primers, sealants and
sealant removers.
■ Lead valves
Similarly to the EGR valves, the lead valves must
be periodically cleaned every 3000 hours because,
as exhaust gas circulates through them for a
prolonged time, carbon is deposited on their inner
surfaces, possibly deteriorating the EGR ratio.
To remove carbon deposited inside the lead valves,
disassemble and clean them.
• Failure to comply could result in death or
serious injury.
1
2
CAUTION
Flying Object Hazard!
• Always wear eye protection when
servicing the engine and when
using compressed air or highpressure water. Dust, flying
debris, compressed air,
pressurized water or steam may
injure your eyes.
• Failure to comply may result in minor or
moderate injury.
The EGR valves must be periodically cleaned every
3000 hours because, as exhaust gas circulates
through them for a prolonged time, carbon is
deposited on their inner surfaces, possibly
deteriorating the EGR ratio.
To remove deposited carbon, use compressed air
(0.19 MPa (2 kg/cm2) or lower). If the valves are
heavily fouled, use carbon cleaner, kerosene, or
some other liquid capable of removing carbon as
well as a soft brush to clean the valves, taking care
not to damage their parts.
When cleaning the valves, take extreme care to
prevent water, solvent, cleaner, and other liquid
from entering into the motor and coupler terminals;
otherwise, failure may result.
3TNV88F Service Manual
3
1
2
3
4
4
– Case
– Stopper
– Valve
– Machine screw
Figure 6-106
To remove deposited carbon, use carbon cleaner,
kerosene, or some other liquid capable of removing
carbon as well as a soft brush or cloth to clean the
valves, taking care not to damage their parts.
Upon completion of carbon removal, wipe off water
and liquid, make sure that the case, valve, and
stopper are free of foreign matter, and then reinstall
the valve and related parts.
Stopper chamfer
Exhaust gas
passage hole
17.5
Assemble without
misalignment.
20
Valve plate
Figure 6-107
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ENGINE
■ Precautions for installation
1. The valve and stopper must be installed in their
specific orientations. As shown in the figure
above, install the valve and stopper so that they
are located on the left-hand side of the lead
valve.
2. Install the valve by tightening the machine
screw while ensuring that it is evenly positioned
inside the case window.
3. The machine screw must be tightened with
torque of 1.37 ± 0.2 N·m (14 ± 2 kgf·cm).
4. After tightening the machine screw, mark it with
a marker to indicate that it has already been
tightened.
■ EGR pipe and other connecting elbows
The exhaust gas passage is subject to carbon
deposition when used over time. To remove
deposited carbon from the gas passage, use
compressed air (0.19 MPa (2 kg/cm2) or lower). If
the exhaust gas passage is heavily fouled, clean it
by dipping it in carbon cleaner, kerosene, or some
other liquid capable of removing carbon.
EGR system
NOTICE
• Always be environmentally
responsible.
• Follow the guidelines of the EPA or other
governmental agencies for the proper disposal of
hazardous materials such as engine oil, diesel
fuel and engine coolant. Consult the local
authorities or reclamation facility.
• Never dispose of hazardous materials
irresponsibly by dumping them into a sewer, on
the ground, or into ground water or waterways.
• Failure to follow these procedures may seriously
harm the environment.
■ Installing EGR related components/parts
To install these components/parts, reverse the
disassembly procedure described above: thus
install the lead valve, spacer, EGR valve, EGR pipe,
elbow, exactly in this order.
The EGR system uses steel gaskets at the joints
between its components/parts. When you remove
the system’s components/parts and reinstall them,
replace the steel gaskets between them with new
correct ones.
6-62
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3TNV88F Service Manual
Section 7
FUEL SYSTEM
Page
Before You Begin Servicing ............................................................ 7-3
Trochoid Fuel Pump .................................................................. 7-4
Electronically Controlled Governor ............................................ 7-4
Fuel System Specifications ............................................................. 7-5
Special Torque Chart................................................................. 7-5
Special Service Tools...................................................................... 7-7
Measuring Instruments.................................................................... 7-7
Fuel System Diagram...................................................................... 7-8
Fuel System Components ............................................................... 7-9
Fuel Injection Pump....................................................................... 7-11
Removal of Fuel Injection Pump.............................................. 7-11
Installation of Fuel Injection Pump........................................... 7-15
Checking and Adjusting Fuel Injection Timing ..............................
Determining the Fuel Injection Timing Specification................
Checking Fuel Injection Timing ...............................................
Adjusting Fuel Injection Timing................................................
7-20
7-20
7-21
7-24
Fuel Injectors.................................................................................
Removal of Fuel Injectors........................................................
Testing of Fuel Injectors ..........................................................
Disassembly and Inspection of Fuel Injectors .........................
Adjusting Fuel Injector Pressure..............................................
Reassembly of Fuel Injectors ..................................................
Installation of the Fuel Injectors...............................................
7-25
7-25
7-27
7-28
7-30
7-30
7-31
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FUEL SYSTEM
This Page Intentionally Left Blank
7-2
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Before You Begin Servicing
FUEL SYSTEM
BEFORE YOU BEGIN
SERVICING
Before performing any service procedures within
this section, read the following safety information
and review the Safety section on page 3-1.
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FUEL SYSTEM
Before You Begin Servicing
• When the cold start device is activated, you may
notice a slight increase in the exhaust smoke of
the engine during engine warm-up.
Electronically controlled engines use a Cold Start
Device (CSD) that consists of a fuel injection
pump complete with a solenoid valve
(Figure 7-1, (1)).
2
1
4
Trochoid Fuel Pump
Note: The trochoid fuel pump located on the side
of the MP fuel injection pump is not a “fuel
supply” pump. The function of this pump is to
raise the pressure of the fuel supplied by the
electric fuel supply pump to the internal fuel
pressure required by the MP fuel injection
pump.
The use of an electric fuel supply pump is required
on all TNV model engines with the MP fuel injection
pump.
Electronically Controlled Governor
3
Electronically controlled engines are quipped with
an electronically controlled governor called “Eco
Governor”. Combined with the rack actuator
(Figure 7-1, (3)), engine speed sensor
(Figure 7-1, (5)), and other parts, the electronically
controlled governor communicates with the engine
controller (E-ECU), whereby the engine speed and
fuel injection rate are controlled.
6
5
Figure 7-1
• When the engine is started with the cooling water
sensor detecting a low water temperature of 10
°C or lower and the E-ECU receives the
corresponding signal, then the E-ECU causes the
CSD’s solenoid valve to increase the injection
rate and advance the injection timing.
• Because of this, the engine speed increases by
approximately 75 min-1 while the CSD is
operating. When the water temperature becomes
10 °C or higher, the CSD is turned off and the
engine returns to the normal speed.
7-4
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FUEL SYSTEM
Fuel System Specifications
FUEL SYSTEM SPECIFICATIONS
Special Torque Chart
Tightening torque
Lubricating oil application
(Thread portion and seat surface)
Fuel injector retainer bolt
29 ft·lb
(39.2 N·m; 4 kgf·m)
Not applied
Fuel pump drive gear nut
58 - 65 ft·lb
(78 - 88 N·m; 8 - 9 kgf·m)
Not applied
High-pressure fuel injection line nuts
22 - 25 ft·lb
(29 - 34 N·m;
3.0 - 3.5 kgf·m)
Not applied
Fuel return line bolts
69 - 87 in·lb
(7.8 - 9.8 N·m;
0.8 - 1.0 kgf·m)
Not applied
Fuel injection pump mounting nuts
17 - 21 ft·lb
(23 - 28 N·m;
2.3 - 2.9 kgf·m)
Not applied
30 - 33 ft·lb
(39.2 - 44.1 N·m;
4 - 4.5 kgf·m)
Not applied
22 - 26 ft·lb
(30 - 35 N·m;
3.1 - 3.6 kgf·m)
Not applied
Component
Fuel injector nozzle case nut
Fuel injection pump plunger plug
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FUEL SYSTEM
Fuel System Specifications
Test and Adjustment Specifications
Injector ID mark*
Fuel injector pressure
W
2843 - 2988 PSI
(19.6 - 20.6 MPa, 200 - 210 kgf/cm2)
V
3133 - 3278 PSI
(21.6 - 22.6 MPa, 220 - 230 kgf/cm2)
S
2702 - 2845 PSI
(18.6 - 19.6 MPa, 190 - 200 kgf/cm2)
R
3058 - 3200 PSI
(21.1 - 22.1 MPa, 215 - 225 kgf/cm2)
Fuel injection timing
See Checking and Adjusting Fuel Injection Timing
on page 7-20
Note:
• Fuel injection pressure of a new fuel injector is reduced approximately 72.5 PSI (0.5 MPa; 5.0 kgf/cm2)
after about 5 hours of operation due to the initial break in of the engine. When adjusting a new fuel
injector or after it has been disassembled for service, adjust the fuel injector 72.5 PSI (0.5 MPa; 5.0
kgf/cm2) higher than the above standard.
• All fuel injectors have a three character identification mark (Figure 7-2 (1)). The first character starts with
“V”, “W”, “R” or “S”.
1
K0004105
Figure 7-2
Note: Fuel injector identification is critical as each engine has a unique fuel injection pressure. The fuel
nozzle is specifically matched to the fuel injector by engine model and/or engine speed.
7-6
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FUEL SYSTEM
Special Service Tools
SPECIAL SERVICE TOOLS
No.
1
Tool name
Torque wrench
Locally available
Application
Illustration
For tightening nuts and bolts to the specified
torque
001438-00X
2
Fuel injector
removal tool
YANMAR Part No.
129470-92305
Used in conjunction with a slide hammer to
remove the fuel injectors
K0001618
MEASURING INSTRUMENTS
No.
1
Instrument name
Fuel injector tester
Locally available
Application
For observing injection spray pattern of fuel
injection nozzle and measuring injection
pressure
Illustration
OFF
P-
OFF
ON
E-
AG
-G
K0000581
Mituotoyo 2050SB
- Locally available
Dial indicator*
2
Check and adjust fuel injection timing
001429-00X
Mituotoyo 303613 locally available
Extension rod*
(M14) TNV82-88 YANMAR Part No.
158090-51831
3
Fuel injection pump
plunger adapter*
(M16) TNV94-106 YANMAR Part No.
158090-51841
Mount dial indicator to fuel injection pump
K0002690
4
Plunger adapter
clamp
YANMAR Part No.
23000-013000
Clamps stem of dial indicator in plunger adapter.
K0002691
* These special service tools may also be available as an “MP Fuel Injection Pump Special Tool Set”, under a different part
number, in territories serviced by YANMAR America and YANMAR Europe. Contact your authorized YANMAR dealer or
distributor for details.
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FUEL SYSTEM
Fuel System Diagram
FUEL SYSTEM DIAGRAM
5
20
21
4
18
17
19
3
16
22
15
2
17
14
13
11
1
12
10
6
9
7
8
K0000034B
1 – Diesel fuel tank
2 – Fuel filter/water separator
3 – Electric fuel pump
4 – Fuel filter
5 – Air bleed orifice
6 – Fuel supply line
7 – Low pressure gallery
8 – Pressure control valve
9 – Trochoid pump
10 – Oil seal
11 – Fuel injection pump cam
12 – Engine crankcase
13 – Tappet
14 – High pressure gallery
15 – Overflow orifice
16 – Accumulator
17 – Timer piston
18 – Mono-plunger
19 – Distributor shaft
20 – Fuel return line
21 – High-pressure fuel injection lines
22 – Fuel injector
Figure 7-3
7-8
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FUEL SYSTEM
Fuel System Components
FUEL SYSTEM COMPONENTS
16
1
15
2
3
14
4
13
12
10
17
5
9
11
18
8
7
6
046798-00X00
Figure 7-4
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FUEL SYSTEM
1
2
3
4
5
6
7
8
– High-pressure fuel injection lines
– Fuel return line
– Fuel injector
– Front plate or timing gear case
– Gear case cover
– Fuel injection pump drive gear nut
– Lock washer
– Fuel injection pump drive gear assembly
(Do not remove or loosen the four bolts that
fasten the injection pump drive gear to the
injection pump drive gear hub!)
9 – Cold start device (CSD)*
10 – Fuel injection pump insulator
11 – Fuel injection pump
12 – Rear fuel injection pump support
13 – Fuel filter/water separator
14 – Electric fuel supply pump
15 – Fuel filter
16 – Fuel filter housing
17 – Stop solenoid
18 – Trochoid fuel pump
Fuel System Components
*: Electronically controlled engines are equipped with a
solenoid valve. As shown in the following figure,
electronically controlled engines use an electronically
controlled governor combined with a solenoid valve (CSD),
rack actuator, engine speed sensor, and other parts.
2
4
3
6
5
Figure 7-5
7-10
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FUEL SYSTEM
Fuel Injection Pump
FUEL INJECTION PUMP
NOTICE
Removal of Fuel Injection Pump
1. Loosen the cooling fan V-belt.
2. Remove the engine coolant fan guard (if
equipped), engine coolant fan (Figure 7-6, (2)),
spacer (Figure 7-6, (3)) if equipped, V-pulley
(Figure 7-6, (4)) and cooling fan V-belt
(Figure 7-6, (1)).
3
2
Remove or install the high-pressure fuel injection
lines as an assembly whenever possible.
Disassembling the high-pressure fuel injection
lines from the retainers or bending any of the fuel
lines will make it difficult to reinstall the fuel lines.
7. Finish loosening all the fuel line nuts and
remove the high-pressure fuel lines as an
assembly being careful not to bend any of the
fuel lines. Be sure to protect the fuel system
from contamination by covering all open
connections.
8. Disconnect the fuel return lines from the fuel
return fitting (Figure 7-7, (2)). Plug the open
ends of the lines to minimize leakage and
prevent contamination.
1
4
K0000163A
Figure 7-6
1
3. Close any fuel valves in the fuel supply line.
4. Place a drain pan under the fuel injection pump
to catch any spillage.
3
5. Remove the high-pressure fuel injection lines
as an assembly (Figure 7-7, (1)).
2
Note: To prevent “rounding” the fuel line nuts
always use a “line” or “flare nut” wrench.
When loosening the fuel line nuts,
always hold the fuel injection pump
delivery valves with a “back up” wrench
to prevent loosening of the delivery
valves.
6. First loosen the fuel line nuts at the fuel
injectors and then at the fuel injection pump.
3TNV88F Service Manual
046799-00X00
Figure 7-7
7-11
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FUEL SYSTEM
Fuel Injection Pump
9. Remove the fuel supply line (Figure 7-7, (3)).
Plug the open end of the line to minimize
leakage and prevent contamination.
1
2
4
1
3
2
6
K0000593B
Figure 7-9
5
Figure 7-8
10. Remove the solenoid valve connector
(Figure 7-8, (2)), rack actuator connector
(Figure 7-8, (4)), and engine speed sensor
connector (Figure 7-8, (6)).
11. Remove the rear fuel injection pump bracket(s)
from the fuel injection pump.
13. Remove the fuel injection pump drive gear
cover (Figure 7-10, (1)) from the gear case
cover (Figure 7-10, (2)).
Note: The fuel injection pump drive gear cover
is secured with an adhesive sealant. Use
a gasket scraper to separate the fuel
injection pump cover from the gear case
cover.
Note: Configuration of the fuel injection pump
rear brackets may vary depending upon
engine model.
2
12. Disconnect the lube oil line (Figure 7-9, (1))
and the clamp (Figure 7-9, (2)) from the pump.
NOTICE
Take care to not damage or bend the oil line. In
some applications, it may be preferable to
remove the complete oil line assembly from the
engine before proceeding.
1
046373-00X00
Figure 7-10
7-12
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FUEL SYSTEM
Fuel Injection Pump
14. To position the fuel injection pump for easier
removal and installation, install a dial indicator
(see Checking and Adjusting Fuel Injection
Timing on page 7-20) into the injection pump
plunger opening. Using a wrench on the
crankshaft pulley bolt, rotate the crankshaft until
the dial indicator shows that injection pump
plunger is at the bottom of it’s stroke.
15. To aid in reassembly, make reference marks on
the fuel injection pump drive gear, and on either
the gear case cover or idler gear.
NOTICE
After marking the position of the pump drive gear,
do not rotate the engine crankshaft. Rotating the
crankshaft will cause the fuel injection pump to
become misaligned.
NOTICE
Do not loosen or remove the four bolts retaining
the fuel injection pump drive gear to the fuel
injection pump hub. Do not disassemble the fuel
injection pump drive gear from the hub. Correct
fuel injection timing will be very difficult or
impossible to achieve.
16. Do not loosen or remove the four bolts
(Figure 7-12, (3)) retaining the pump drive gear
to the hub. Only remove the single drive gear
nut (Figure 7-12, (1)) and washer
(Figure 7-12, (2)), leaving the hub attached to
the gear.
• On 3TNV88F engine the idler gear is not
visible. Make a reference mark on the fuel
injection pump drive gear (Figure 7-11, (1))
and a matching mark on the bore of the gear
case opening (Figure 7-11, (2)).
3
1
2
046363-00X01
2
Figure 7-12
1
17. Hold the gear train using a large socket wrench
on the crankshaft pulley nut. Loosen the fuel
injection pump drive gear retaining nut
(Figure 7-12, (1)) and turn it out to the end of
the fuel injection pump shaft.
K0000575A
Figure 7-11
3TNV88F Service Manual
18. Remove the pump drive gear and hub as an
assembly using an appropriate two-bolt gear
puller (Figure 7-13).
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FUEL SYSTEM
Fuel Injection Pump
20. Locate the mark stamped into the upper outside
mounting boss of the fuel injection pump.
Highlight this mark and make a corresponding
mark on the gear case or front plate
(Figure 7-15, (1)).
K0000574
Figure 7-13
Note: The injection pump drive gear will remain
“captured” in the gear case.
19. Once the fuel injection pump drive gear and
hub assembly has “popped” loose from the
tapered fuel injection pump drive shaft, carefully
remove the drive gear nut (Figure 7-14, (1))
and lock washer (Figure 7-14, (2)).
1
K0000593A
Figure 7-15
Note: Some model engines may require the
intake manifold and fuel injection pump
insulator (Figure 7-16, (2)) be removed
to access the inner fuel injection pump
(Figure 7-16, (1)) retaining nuts.
1
2
1
2
046363-00X02
Figure 7-14
046372-00X00
Figure 7-16
7-14
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FUEL SYSTEM
Fuel Injection Pump
21. If required, remove the intake manifold and fuel
pump insulator to access the fuel injection
pump mounting nuts.
Note: The MP2 fuel injection pump is fastened
to the gear case with three (3) studs and
nuts.
22. Remove the fuel injection pump
(Figure 7-16, (1)). For purposes of future
injection timing purposes, record the fuel
injection pump timing index number located on
the boss on the engine side (back) of the of the
fuel injection pump (Figure 7-17, (1)).
Installation of Fuel Injection Pump
For electronically controlled engine
WARNING
• Replacing the fuel injection pump involves
rewriting the fuel injection data in the E-ECU.
Be sure to contact your local YANMAR dealer
before replacing the fuel injection pump.
Failure to rewrite the fuel injection data before
replacing the fuel injection pump will void the
engine warranty.
• Improper use or misuse of the E-ECU may
result in death or serious injury due to an
abrupt and unexpected increase in engine
speed.
1
NOTICE
K0002047
If installing a new or recalibrated fuel injection
pump, locate and record the timing index number
located on the pump housing boss on the engine
side of the new or recalibrated fuel injection pump
(Figure 7-18, (1)). This number will be used to
calculate and adjust the final fuel injection timing.
Figure 7-17
NOTICE
Do not rotate the crankshaft with the injection
pump removed.
23. If the fuel injection pump requires servicing, it
must be sent to an authorized YANMAR FIE
repair facility for repair and calibration, or
replaced with a new fuel injection pump.
Note: If either or both of the fuel injection pumps
do not have a timing index number, note the
injection pump ID (example: XK42) on the
injection pump ID label.
To locate the timing index number for the engine
being serviced use the Timing Index Chart under
“FIE Specs” on the YANMAR Distributor Website
(http://distributor.yanmar.co.jp).
If additional assistance is needed in locating the
engine timing index number See To Locate an
Authorized YANMAR Industrial Engine Dealer or
Distributor: on page 2-4 and follow the instructions
to locate an authorized YANMAR industrial engine
dealer or distributor for assistance.
Note: Treat the timing index number as if it has a
decimal point (68 = 6.8).
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FUEL SYSTEM
Fuel Injection Pump
1
1
B
7
2
B
C C
A
A
3
4
6
5
K0002047
Figure 7-18
1. Align the pump drive gear with the idler gear
using the reference marks made earlier.
(Figure 7-19, (1))
1
2
3
4
5
6
7
K0001709A
– Fuel injection pump drive gear
– Camshaft drive gear
– Auxiliary drive gear (optional)
– Crankshaft drive gear
– Direction of rotation
– Oil pump drive gear
– Idler gear
Figure 7-20
3. Install a new O-ring on the pump mounting
flange. Apply grease to the O-ring to hold it in
place during installation of the injection pump.
1
K0000575B
Figure 7-19
2. If installing the fuel injection pump on an engine
with the front gear case cover removed, the fuel
injection pump drive gear can be aligned with
the idler gear by aligning the stamped marks
(A, B, C) on the fuel injection pump drive gear,
idler gear, and crankshaft drive gear. Ensure all
three timing marks (Figure 7-20, (A, B, C)) are
aligned.
7-16
Note: Ensure the tapered surface of the fuel
injection pump shaft is clean and dry.
4. Align the key on the fuel injection pump shaft
with the keyway in the fuel injection pump drive
gear hub. Reinstall the fuel injection pump into
the fuel injection pump drive gear and gear
housing. Reinstall the pump retaining nuts
finger tight.
5. Reinstall the fuel injection pump drive gear lock
washer (Figure 7-21, (2)) and nut
(Figure 7-21, (1)). Do not lubricate the threads
of the nut or shaft. Hold the crankshaft pulley
bolt with a socket wrench and tighten the drive
gear nut to the specified torque. See Special
Torque Chart on page 7-5.
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FUEL SYSTEM
Fuel Injection Pump
If installing a new fuel injection pump:
• Reinstall the timing grid sticker, provided with
the new fuel injection pump, onto the back of
the gear case/front plate (Figure 7-23). Align
the “standard mark” (Figure 7-23, (1)) with the
reference mark (Figure 7-23, (2)) made on the
gear case during disassembly.
1
2
046363-00X00
Figure 7-21
If reinstalling the original fuel injection pump:
• Align the reference marks (Figure 7-22, (1))
previously made on both the fuel injection
pump mounting flange and gear case or front
plate.
2
1
1
K0000593A
Figure 7-22
• Tighten the fuel injection pump retaining nuts
to specification. See Special Torque Chart on
page 7-5.
K0002139
Figure 7-23
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FUEL SYSTEM
Fuel Injection Pump
• Calculate the difference between the timing
index numbers (Figure 7-24, (1)) of the fuel
injection pump that you removed and the
replacement fuel injection pump. See
Calculation example below.
The above calculated difference indicates that
the replacement fuel injection pump is to be
installed at +0.5° (advanced) from the “Standard
Mark” (Figure 7-25, (1)) on the timing sticker.
1
3
1
+0.5°
K0002047
Figure 7-24
+1.0°
2
Adjusting the fuel injection timing to
compensate for the difference in pump timing
index numbers:
Calculation example
Timing index number
Original injection pump = 6.8
Replacement injection pump = 7.3
Difference = +0.5
K0002124A
Figure 7-25
In this case, rotate the top of the fuel injection
pump away from the cylinder block until the mark
on the outside upper mounting boss
(Figure 7-26, (1)) of the fuel injection pump
aligns with the +0.5° mark on the timing sticker.
• If the difference between the timing index
numbers is a positive number, the fuel injection
pump mounting position must be advanced
(Figure 7-25, (2)) (rotated away from the
engine) as compared to the “standard mark”
(Figure 7-25, (1)) by the calculated positive
amount, adjust the fuel injection pump to the
calculated value.
• If the difference between the timing index
numbers is a negative number, the
replacement injection pump must be retarded
(Figure 7-25, (3)) (rotated toward the engine)
by the calculated negative amount.
• Each mark on the timing sticker represents
0.5° timing change.
1
Figure 7-26
7-18
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FUEL SYSTEM
Fuel Injection Pump
Tighten the fuel injection pump mounting nuts to
specification. See Special Torque Chart on
page 7-5.
6. Reinstall the rear bracket(s) (Figure 7-27, (1))
to the fuel injection pump. Tighten the rear
support bolts.
Note: Configuration of the fuel injection pump
rear brackets may vary depending on the
model.
8. Apply ThreeBond Liquid Gasket No. 1207F,
YANMAR Part No. 977770-1207F, or equivalent
sealant to the sealing surface of the pump
cover. Install the pump cover and tighten the
cover bolts.
9. Reconnect the fuel return lines, fuel supply line
and coolant lines to the fuel injection pump.
10. Reinstall the fuel injection high-pressure lines.
Tighten the nuts to specification. See Special
Torque Chart on page 7-5.
NOTICE
1
When reinstalling a new or repaired fuel injection
pump, it is important to add engine oil to the fuel
injection pump to provide lubrication for initial
start-up. Add 5 - 7 oz (150 - 200 cc) of clean
engine oil to the fuel injection pump at the fill plug
located in the upper outside section of the
governor housing.
11. If equipped, verify the fuel injection pump
insulator (Figure 7-29, (2)) is not damaged.
Reinstall the insulator and intake manifold if
previously removed.
046364-00X00
Figure 7-27
2
7. Reconnect the lube oil line (Figure 7-28, (1))
and clamp (Figure 7-28, (2)).
1
1
046372-00X00
Figure 7-29
12. Reinstall the coolant pump V-pulley
(Figure 7-30, (4)), spacer (Figure 7-30, (3)) (if
equipped) and engine coolant fan
(Figure 7-30, (2)).
2
K0000593B
Figure 7-28
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FUEL SYSTEM
Checking and Adjusting Fuel Injection Timing
CHECKING AND ADJUSTING
FUEL INJECTION TIMING
3
2
Determining the Fuel Injection Timing
Specification
1. Locate and record the fuel injection pump
timing index number (Figure 7-32, (1)) stamped
into the boss on the engine side of the fuel
injection pump housing (Figure 7-31, (1)). Treat
this number as though there is a decimal point
between the two digits. i.e. 68 = 6.8
1
4
K0000163A
1
Figure 7-30
13. Reinstall the cooling fan V-belt
(Figure 7-30, (1)). Adjust it as described in
Check and adjust cooling fan V-belt on
page 5-9.
14. Reinstall the cooling fan guard (if equipped).
15. Prime the fuel system. See Priming the Fuel
System on page 4-16.
K0000040B
16. Operate the engine and check for fuel and
coolant leaks.
Figure 7-31
1
K0002047
Figure 7-32
2. Using the FIR number for the engine being
serviced use the Fuel Injection Reference (FIR)
Chart under “FIE Specs” on the YANMAR
Distributor Website
(http://distributor.yanmar.co.jp).
7-20
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Checking and Adjusting Fuel Injection Timing
The FIR number is determined by the complete
engine model number. The engine model
number is located on the engine nameplate
(Figure 7-33).
FUEL SYSTEM
Checking Fuel Injection Timing
Note: Some fuel may drain from the fuel injection
pump during this process. Make provisions
to contain any such spillage.
1. Turn off the fuel valve in the fuel supply hose
and the fuel return hose.
MODEL
2. Clamp shut the fuel injection pump fuel return
hose leading to fuel filter (Figure 7-34, (1)).
DISPLACEMENT
1
ENGINE NO.
2
MADE IN JAPAN
043923-00X00
Figure 7-33
• Find the engine model number in the FIR chart.
Locate and record the FIR number (For
example the FIR number is 4).
• Insert the numbers you have recorded into the
following equation:
(Fuel injection pump timing index number × 2) +
FIR number = FIT° (Fuel injection timing in
degrees)
■ (6.8 × 2) = 13.6 + 4 = 17.6° fuel injection
timing
• Record the calculated fuel injection timing
specification.
046365-00X00
Figure 7-34
NOTICE
Clean the top of the fuel injection pump to prevent
any contamination when the fuel injection pump
plunger plug is removed.
3. Remove the forward fuel injection pump plunger
plug (Figure 7-34, (2)) on the top of the fuel
injection pump.
4. Install a dial indicator adapter and clamp into
the pump plunger opening.
Note: Use the YANMAR Part No. 15809051831 M14 adapter for the MP2 fuel
injection pumps and YANMAR Part No.
23000-013000 plunger adapter clamp
(Figure 7-35, (1)).
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FUEL SYSTEM
Checking and Adjusting Fuel Injection Timing
6. Using a wrench on the crankshaft pulley bolt,
rotate the crankshaft in a clockwise direction
while looking through the flywheel inspection
port (Figure 7-37, (1)). Rotate the crankshaft
until the injection timing marks on the flywheel
are visible.
1
K0002068A
1
Figure 7-35
5. Install a dial indicator (Figure 7-36, (1)),
Mitutoyo No. 2050SB or equivalent, with a 30
mm extension, YANMAR Part No.
158090-51870 or Mitutoyo No. 303613, into the
adapter. Secure with the YANMAR Part No.
23000-013000 plunger adapter clamp
(Figure 7-35, (1)) at approximately the midpoint of its travel.
Figure 7-37
7. Typical flywheel markings are as shown in
(Figure 7-38, (1)).
Note: A typical flywheel will have multiple
timing grids depending on the number of
cylinders. Any grid can be used to check
the fuel injection timing.
The flywheel shown in Figure 7-38 is for a
YANMAR “Standard Specification” DI engine.
Flywheels used on some “OEM Specific” DI
engines may be marked differently. You should
contact that specific OEM for information on the
identification of the timing marks.
1
K0002069
Figure 7-36
Note: The following references to the directionof-rotation are facing the coolant pump
end of the engine and are adjusted by
turning the crankshaft pulley.
7-22
K0002070
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FUEL SYSTEM
Checking and Adjusting Fuel Injection Timing
3
2
4
14
1
5
K0002071
1
2
3
4
5
– 10° BTDC (Before Top Dead Center)
– 15° BTDC
– 20° BTDC
– Direction of rotation
– TDC (Top Dead Center)
Figure 7-38
Note: The TDC (Top Dead Center) mark can
be identified by the cylinder numbers
stamped near the TDC mark on the
flywheel.
If you are uncertain as to the timing degree
designation of the timing marks on the flywheel
timing grid, you can determine the timing degree
designation by measuring the timing grid.
8. Highlight the timing reference mark
(Figure 7-39, (2)) on the flywheel housing or
engine back plate (Figure 7-40, (2)). Highlight
the TDC (Top Dead Center) mark
(Figure 7-39, (1)) on the flywheel.
9. Highlight the target timing mark
(Figure 7-40, (1)) on the flywheel as calculated
in Determining the Fuel Injection Timing
Specification on page 7-20.
1
2
1 4
• First measure the distance between two of the
“longer” marks on the timing grid. (They are 5°
apart.) Then measure the distance from the
TDC mark to the first “longer” mark on the
timing grid. Divide that measurement by the
distance between the two “longer” marks. The
resulting answer will tell you how many
degrees there are between the TDC mark and
the first “longer” mark.
• EXAMPLE: If the distance between the two
“longer” marks is approximately 2.0 cm and the
distance from the TDC mark is approximately
4.0 cm, the answer is approximately 2. This
indicates there is 10° (2 × 5°) between the TDC
mark and the first “longer” mark on the timing
grid. That means the first “longer” mark on the
timing grid indicates 10° BTDC, the second
“longer” mark indicates 15° BTDC and the third
timing mark indicates 20° BTDC. If the answer
is 3, that indicates there is 15° (3 × 15°)
between the TDC mark and the first “longer”
mark and that the first “longer” mark indicates
15° BTDC with the second and third “longer”
marks indicating 20° BTDC and 25° BTDC
respectively.
K0002065
Figure 7-39
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FUEL SYSTEM
Checking and Adjusting Fuel Injection Timing
13. If the injection timing is correct, remove the dial
indicator and adapter. Replace the pump
plunger plug and its copper gasket and tighten
to specifications. Replace the flywheel
inspection port cover. Open the fuel supply
valve and remove the clamp from the fuel
supply hose and the fuel return hose.
1
2
14. Prime the fuel system. Operate the engine and
check for leaks.
Adjusting Fuel Injection Timing
K0002066
2
1
If the timing marks did not align when performing
the Checking Fuel Injection Timing on page 7-21,
the following steps must be performed to properly
time the engine.
1. Leave the dial indicator installed in the fuel
injection pump. Do not disturb the reading on
the dial indicator.
2. Rotate the flywheel until the target timing mark
(Figure 7-41, (1)) and the timing reference
mark (Figure 7-41, (2)) on the flywheel housing
or back plate are aligned.
NOTICE
K0002142
Figure 7-40
10. Rotate the crankshaft counter-clockwise until
the dial indicator shows that the injection pump
plunger is at the bottom of its stroke. Rock the
crankshaft back and forth slightly to confirm a
point where the dial indicator shows no
movement. Zero the dial indicator.
Do not rotate the crankshaft during the
remainder of this procedure.
1
2
11. Slowly rotate the crankshaft clockwise until the
dial indicator shows a pump plunger lift of 2.5
mm (0.098 in.).
12. Check the position of the flywheel target timing
mark (previously determined) (Figure 7-40, (1))
in relation to the timing reference mark
(Figure 7-40, (2)) on the flywheel housing or
engine back plate. If the two marks are aligned,
the fuel injection timing is correct. If the marks
do not align, the fuel injection timing must be
adjusted. See Adjusting Fuel Injection Timing
on page 7-24.
7-24
K0002066
Figure 7-41
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FUEL SYSTEM
Fuel Injectors
3. Note the reading on the dial indicator
(Figure 7-42, (1)). If the reading is less than
2.5 mm (0.098 in.), the fuel injection timing is
“retarded”. If the dial indicator reading is greater
than 2.5 mm (0.098 in.), the fuel injection timing
is “advanced.”
1
9. Tighten the fuel injection pump mounting nuts
and rear bracket(s).
10. Remove the dial indicator and adapter. Replace
the plug in the pump plunger opening and
tighten it to specification. If removed, install the
intake manifold and pump insulator. Tighten the
high-pressure injection line nuts to
specification. Open the fuel supply valve,
remove the clamp from the fuel return line and
prime the fuel system. Operate the engine and
check it for leaks.
FUEL INJECTORS
Removal of Fuel Injectors
1. Close any fuel valves in the fuel supply line.
2. Remove the high-pressure fuel injection lines
as an assembly (Figure 7-43, (1)).
K0002069
Figure 7-42
Note: Some model engines require the intake
manifold and fuel injection pump
insulator be removed to access the inner
fuel injection pump retaining nuts.
1
4. Loosen the nuts fastening the fuel injection
pump to the gear case or front plate. Loosen
the rear bracket(s) on the fuel injection pump.
Note: Loosening the high-pressure injection
line nuts on the fuel injection pump may
make rotating the pump easier.
5. Rotate the fuel injection pump until the dial
indicator reads 2.5 mm (0.098 in.).
6. To “advance” the injection timing, rotate the top
of the fuel injection pump away from the engine.
7. To “retard” the injection timing, rotate the top of
the fuel injection pump toward the engine.
8. When the dial indicator reads 2.5 mm (0.098
in.) of pump plunger lift and the target timing
mark on the flywheel aligns with the reference
mark on the flywheel housing or engine back
plate, the injection timing is correct.
3TNV88F Service Manual
046369-00X00
Figure 7-43
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FUEL SYSTEM
Fuel Injectors
NOTICE
Enclose the removed high-pressure injection line
with a clean vinyl bag to protect it from the dust.
1
3
4
Note: To prevent “rounding” the fuel line nuts
always use a “line” or “flare nut” wrench.
When loosening the fuel line nuts,
always hold the fuel injection pump
delivery valves with a “back up” wrench
to prevent loosening.
2
• Loosen the fuel line nuts at the fuel injectors
and then at the fuel injection pump.
NOTICE
Remove or install the high-pressure fuel injection
lines as an assembly whenever possible.
Disassembling the high-pressure fuel injection
lines from the retainers or bending any of the fuel
lines will make it difficult to reinstall the fuel lines.
• Finish loosening all the fuel line nuts and
remove the high-pressure fuel lines as an
assembly being careful not to bend any of the
fuel lines. Be sure to protect the fuel system
from contamination by covering all open
connections.
046647-00X00
Figure 7-44
6. Remove the fuel injector.
Note: The fuel injectors can usually be
removed by manually pulling them out of
the fuel injector wells. If the fuel injectors
cannot be manually removed, use the
fuel injector removal tool, YANMAR Part
No. 129470-92305, and a slide-hammer
puller (Figure 7-45).
• Attach a slide-hammer puller to the fuel injector
removal tool using a 3/8-16 puller rod.
3. Remove the return fuel hoses (Figure 7-44, (1))
from one side of each fuel injector.
4. Remove the bolts and washers that secure the
fuel injector retainers (Figure 7-44, (2)) to the
cylinder head.
5. Remove the fuel injector retainer.
7-26
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FUEL SYSTEM
Fuel Injectors
Testing of Fuel Injectors
WARNING
• Never inject fuel toward you. Since the fuel is
injected at high pressure from the nozzle, it
may penetrate the skin, resulting in injury.
• Never inject fuel toward a fire source.
Atomized fuel is highly flammable and may
cause a fire or burn skin.
CAUTION
Flying Object Hazard!
• Always wear eye protection when
servicing the engine and when
using compressed air or highpressure water. Dust, flying
debris, compressed air,
pressurized water or steam may
injure your eyes.
K0000815
Figure 7-45
• Tap the fuel injector out of the cylinder head
using the slide hammer.
NOTICE
To distinguish the cylinder number of the
removed nozzle, mark the number on the nozzle
body in advance.
7. Remove the injector nozzle protector
(Figure 7-44, (3)) and seat (Figure 7-44, (4))
from the cylinder head.
8. Repeat the steps to remove the remaining fuel
injectors.
• Failure to comply may result in minor or
moderate injury.
NOTICE
Never use a steel wire brush to clean fuel injectors.
Damage to the nozzle and other components is
likely to result.
1. Thoroughly clean the fuel injector nozzle using
clean diesel fuel and a brass wire brush.
2. Visually inspect the fuel injectors and nozzle
protectors for deposits or damage. Clean, repair
or replace as necessary.
Note: For testing the fuel injector using an
injection nozzle tester. Operate the tester
following the information provided by the
tester manufacturer. Use clean, filtered
fuel or FIE calibration fluid for the test.
3. Using the correct adapter, connect a fuel
injector to a nozzle tester. Aim the fuel injector
into a suitable container to catch the fuel spray.
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FUEL SYSTEM
Fuel Injectors
OFF
P-
OFF
ON
-
E
AG
-G
K0000581
K0001336A
Figure 7-46
Figure 7-47
4. Pump the operating lever of the tester slowly,
observing the pressure reading at the point
where the fuel injector begins spraying fuel
(Figure 7-46).
See Figure 7-49 for injector ID location.
See Test and Adjustment Specifications on
page 7-6 for correct pressure readings.
K0001337A
Note: The opening pressure of a new fuel
injector will be approximately 0.5 MPa (5
kgf/cm2, 72.5 PSI) higher than one that
has been operated for five hours or
longer.
5. Pump the operating lever slowly to hold the
pressure steady at a point just below the
opening pressure and hold it for 5 seconds.
Observe the injector to see that it is sealing
properly and is not “dripping”. If fuel leaks from
the return line fitting, check that the nozzle case
nut is tight. Service or replace the injector if fuel
continues to leak from either the return line
fitting or nozzle.
6. Pump the operating lever more rapidly to
repeatedly “pop” the injector and observe the
spray pattern. The pattern should be a very fine
uniform spray (Figure 7-47). If a dripping or an
uneven pattern is seen (Figure 7-48), service
or replace the injector.
7-28
Figure 7-48
If the fuel injector fails any of these tests, it should
be serviced or replaced as necessary. If the
pressure is outside specified limits, adjust the
pressure. See Adjusting Fuel Injector Pressure
on page 7-30.
Disassembly and Inspection of Fuel
Injectors
NOTICE
Never use a steel wire brush to clean fuel injectors.
Damage to the nozzle and other components is
likely to result.
1. Clean carbon from used injectors using clean
diesel fuel. Hardened deposits or varnish can
be cleaned using a brass wire brush.
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FUEL SYSTEM
Fuel Injectors
1
2
3
6. Inspect the sealing surfaces (Figure 7-50, (2))
between the valve stop spacer and nozzle body
for nicks or scratches. Check the contact area
between the valve stop spacer and the nozzle
valve (Figure 7-50, (1)) for scoring, or pitting.
Use a magnifier glass to inspect the area.
1
4
2
5
6
7
8
9
K0001333A
Figure 7-50
10
K0002093X01
1 – Fuel return passage
2 – Injector ID location
3 – Injector body
4 – Pressure adjusting shims
5 – Spring
6 – Spring seat
7 – Valve stop spacer
8 – Nozzle valve
9 – Nozzle body
10 – Nozzle case nut
7. Perform a nozzle valve slide test:
1- Wash nozzle body and valve in clean diesel
fuel.
2- While holding the nozzle body vertical, pull
the nozzle valve about 2/3 of the way out
(Figure 7-51).
3- Release the valve. It should fall smoothly to
its seat by it’s own weight.
Figure 7-49
2. Place the fuel injector in a soft-jawed vise with
the nozzle pointing up.
3. Remove the nozzle case nut.
4. Carefully remove the injector from the vise.
5. Turn the injector over and remove the nozzle
body, nozzle valve, valve stop spacer, nozzle
spring seat, nozzle spring, and shims.
K0001332A
Figure 7-51
8. Replace the fuel injector assembly if it fails any
inspection.
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FUEL SYSTEM
Fuel Injectors
Adjusting Fuel Injector Pressure
The fuel injectors open when pressure reaches a
predetermined pressure threshold. They close
when the pressure is reduced below that threshold.
The pressure threshold can be adjusted by adding
or removing shims (Figure 7-52, (3)).
1
2
3
See the parts catalog for available shims.
NOTICE
Each pressure adjusting shim removed or added
changes the pressure threshold by approximately
275 PSI (1.9 MPa, 19 kgf/cm2). Adding adjusting
shims increases the threshold pressure. Removing
adjusting shims reduces the pressure threshold.
1. Disassemble the fuel injector assembly. See
Disassembly and Inspection of Fuel Injectors
on page 7-28.
2. Remove or add adjusting shims as needed.
4
5
6
7
3. Reassemble the fuel injector assembly. See
Reassembly of Fuel Injectors on page 7-30.
4. Retest the fuel injector. See Testing of Fuel
Injectors on page 7-27. If the injector cannot be
adjusted to the appropriate pressure, discard
the fuel injector.
Reassembly of Fuel Injectors
8
1. Secure the injector in a soft-jawed vise with the
nozzle end up.
9
2. Reinstall the shims, nozzle spring, nozzle
spring seat, valve stop spacer, nozzle valve,
and nozzle body.
10
3. Reinstall the nozzle case nut. Tighten it to
specification. See Special Torque Chart on
page 7-5.
K0002093X01
1 – Fuel return passage
2 – Injector ID location
3 – Injector body
4 – Pressure adjusting shims
5 – Spring
6 – Spring seat
7 – Valve stop spacer
8 – Nozzle valve
9 – Nozzle body
10 – Nozzle case nut
Figure 7-52
The injection pressure will change by
approximately 275 PSI (1.9 MPa; 19 kgf/cm2) for
every 0.1 mm (0.004 in.) in shim thickness.
7-30
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FUEL SYSTEM
Fuel Injectors
Installation of the Fuel Injectors
1. Reinsert a new nozzle seat (Figure 7-53, (4))
and nozzle protector (Figure 7-53, (3)) in the
cylinder head for each injector.
2. Reinstall a O-ring on to each injector body.
3. Reinsert each fuel injector into the cylinder
head. Reinstall the injector to the original
cylinder.
4. Reinstall the fuel injector retainers
(Figure 7-53, (2)) and torque the retaining bolts
to specification.
5. Reinstall the fuel return hoses
(Figure 7-53, (1)), one on each side of each
injector.
6. Reinstall the fuel high-pressure fuel line
assembly and tighten the nuts using a “line” or
“flare nut” wrench.
1
3
4
2
046647-00X00
Figure 7-53
7. Prime the fuel system. See Priming the Fuel
System on page 4-16.
8. Operate the engine and check for fuel and
coolant leaks.
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FUEL SYSTEM
Fuel Injectors
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3TNV88F Service Manual
Section 8
COOLING SYSTEM
Page
Before You Begin Servicing ............................................................ 8-3
Introduction...................................................................................... 8-4
Cooling System Diagram................................................................. 8-4
Engine Coolant Pump Components ................................................ 8-5
Engine Coolant System Check........................................................ 8-6
Engine Coolant Pump ..................................................................... 8-6
Removal of Engine Coolant Pump ............................................ 8-6
Disassembly of Engine Coolant Pump ...................................... 8-8
Cleaning and Inspection ............................................................ 8-8
Reassembly of Engine Coolant Pump..................................... 8-10
Installation of Engine Coolant Pump ....................................... 8-10
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COOLING SYSTEM
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Before You Begin Servicing
COOLING SYSTEM
BEFORE YOU BEGIN
SERVICING
Before performing any service procedures within
this section, read the following safety information
and review the Safety section on page 3-1.
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COOLING SYSTEM
Introduction
INTRODUCTION
This section of the Service Manual describes the procedures necessary to service the 3TNV88F engine
coolant pump. This engine coolant pump is representative of the coolant pumps used on other TNV model
engines. For specific part detail, see the parts catalog for the engine you are working on.
COOLING SYSTEM DIAGRAM
1
2
4
3
6
5
046371-00X00
1 – Cylinder head
2 – Thermostat
3 – Engine coolant pump
4 – Radiator
5 – Coolant recovery tank
6 – Cylinder block
Figure 8-1
8-4
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COOLING SYSTEM
Engine Coolant Pump Components
ENGINE COOLANT PUMP COMPONENTS
1
2
3
5
4
7
14
8
6
9
12
10
11
13
K0000031A-01X
1
2
3
4
5
6
7
– Thermostat cover
– Thermostat cover gasket
– Thermostat
– Thermostat O-ring
– Special O-ring
– Engine coolant pump
– Temperature switch
8 – Gasket
9 – Engine coolant pump gasket
10 – V-belt
11 – Engine coolant pump V-pulley
12 – Spacer
13 – Engine coolant fan
14 – Water temperature sensor
(electronically controlled engine)
Figure 8-2
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COOLING SYSTEM
Engine Coolant System Check
ENGINE COOLANT SYSTEM
CHECK
ENGINE COOLANT PUMP
Removal of Engine Coolant Pump
Check the engine coolant system for leakage.
1. With the radiator properly filled, install a cooling
system tester (Figure 8-3, (1)).
CAUTION
Pinch Hazard!
Carefully rotate the alternator
toward the cylinder block while
loosening the V-belt. Failure to
comply may result in minor or
moderate injury.
1
K0000577AX
Figure 8-3
2. Apply 10.8 - 14.8 PSI (75 - 105 kPa; 0.75 - 1.05
kgf/cm²) to the cooling system. If the pressure
reading drops, the engine coolant system is
leaking. Identify the source of the leak and
repair it.
Verify the condition of the engine coolant pump
before disassembling it from the engine. Check the
engine coolant pump shaft bearing for abnormal
noise, sticking, excessive play and water leakage.
Replace the coolant pump if any of these conditions
are present.
NOTICE
If the engine coolant pump must be replaced,
replace the engine coolant pump as an assembly
only. Do not attempt to repair the engine coolant
pump or replace individual components.
NOTICE
Make sure the engine and engine coolant are not
hot.
1. Before removing the engine coolant pump or
thermostat, it will be necessary to drain the
engine coolant. Drain the coolant into a clean
container if the coolant is to be reused.
Otherwise, properly dispose of the coolant.
2. Remove the radiator cap (Figure 8-4, (1)).
3. Remove the drain plug or open the drain cock
(Figure 8-4, (1)) at the lower portion of the
radiator and drain the coolant.
8-6
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COOLING SYSTEM
Engine Coolant Pump
1
1
2
FULL
LOW
4
2
3
K0000074A
K0000163B
Figure 8-4
Figure 8-6
4. Drain the coolant from the engine block.
• Remove the coolant drain plug
(Figure 8-5, (1)) from the engine block.
7. Disconnect the coolant hoses and the
temperature switch lead wire from the engine
coolant pump.
8. Remove the engine coolant pump
(Figure 8-6, (4)). Discard the gasket.
1
046370-00X00
Figure 8-5
5. Loosen the alternator mounting bolts. Loosen
and remove the V-belt and rotate the alternator
away from the engine and out of the way.
6. Remove the engine coolant fan guard (if
equipped), engine coolant fan (Figure 8-6, (1)),
spacer (Figure 8-6, (2)) and engine coolant
pump V-pulley (Figure 8-6, (3)).
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COOLING SYSTEM
Engine Coolant Pump
Disassembly of Engine Coolant
Pump
1. Remove the thermostat cover (Figure 8-7, (1)).
Discard the gasket.
1
3
Cleaning and Inspection
■ Temperature switch
1. Check for proper operation of the temperature
switch. Connect a continuity light or ohmmeter
to the temperature switch. Connect one lead to
the terminal of the switch (Figure 8-8, (1)) and
the other lead to the metal portion of the switch
(Figure 8-8, (2)).
3
4
2
1
2
K0000576AX
Figure 8-8
K0000267AX
Figure 8-7
2. Remove the thermostat (Figure 8-7, (2)).
Discard the O-ring. Remove the temperature
switch (Figure 8-7, (3)) and gasket
(Figure 8-7, (4)). Discard the gasket.
8-8
2. Place the temperature switch and an accurate
thermometer (Figure 8-8, (3)) in engine
coolant.
3. Slowly increase temperature of the fluid using
an external heat source.
4. The temperature switch is operating properly if
the continuity light or ohmmeter indicates
continuity when the fluid temperature reaches
225 °F - 235 °F (107 °C - 113 °C).
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COOLING SYSTEM
Engine Coolant Pump
■ Water temperature sensor
■ Thermostat
1. Inspect the water temperature sensor to make
sure that it is properly operating. As shown in
the following figure, connect an electric resistor
to the coupler of the water temperature sensor
(Figure 8-9, (1)).
1. Check for proper operation of the thermostat.
Place the thermostat (Figure 8-10, (1)) and an
accurate thermometer (Figure 8-10, (2)) in
warm water.
2
1
2
1
K0000578A
Figure 8-10
2. Slowly increase the temperature of the water
using an external heat source.
Figure 8-9
2. Dip the water temperature sensor and an
accurate thermometer (Figure 8-9, (2)) into the
cooling water.
3. Measure the electric resistance value while
slowly raising the cooling water temperature
using an external heat source.
4. The resistance value at each of the following
temperatures is within the permissible range
specified, the water temperature sensor is
correctly operating.
Cooling water
temperature (°C)
Resistance (k)
20
2.45 +0.14
-0.13
80
0.318 ± 0.008
100
(0.1836)
3. The thermostat is operating properly if it starts
to open at the temperature value stamped on
the flange of the thermostat, and fully opens as
the temperature of the water is increased.
■ Radiator cap
1. Check for proper operation of the radiator cap.
Install the radiator cap (Figure 8-11, (1)) on a
cooling system tester.
1
K0000579A
Figure 8-11
2. Apply 10.8 - 14.8 PSI (75 - 105 kPa; 0.75 - 1.05
kgf/cm²) to the radiator cap. The radiator cap
relief valve must open within the specified
range.
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COOLING SYSTEM
Engine Coolant Pump
Reassembly of Engine Coolant Pump
Installation of Engine Coolant Pump
1. Reinstall the thermostat (Figure 8-12, (1)) and
a new O-ring.
1. Position the engine coolant pump on the engine
and install a new gasket. Install a new special
O-ring (Figure 8-12, (5)) on assembly between
the engine coolant pump and the joint.
NOTICE
2
5
3
1
Use a new special O-ring between the engine
coolant pump and the joint. Be sure to use the
special O-ring. Although the O-ring dimensions
are the same as a commercially available O-ring,
the material is different.
4
2. Reinstall the engine coolant pump bolts.
Tighten the bolts.
3. Inspect and reinstall the coolant hoses and the
temperature switch lead wire.
4. Reinstall the engine coolant pump V-pulley
(Figure 8-13, (1)), spacer (Figure 8-13, (2))
engine coolant fan (Figure 8-13, (3)) and
engine coolant fan guard (if equipped).
K0001623AX
Figure 8-12
2. Reinstall the thermostat cover
(Figure 8-12, (2)) and a new gasket. Tighten
the thermostat cover bolts.
2
3
3. Reinstall the temperature switch
(Figure 8-12, (3)) and a new gasket
(Figure 8-12, (4)).
1
K0000163C
Figure 8-13
5. Inspect the condition of the V-belt. There must
be clearance (Figure 8-14, (1)) between the
V-belt and the bottom of the pulley groove. If
there is no clearance (Figure 8-14, (2))
between the V-belt and the bottom of the pulley
groove, replace the V-belt.
8-10
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COOLING SYSTEM
Engine Coolant Pump
2
1
K0000584
Figure 8-14
6. Reinstall the V-belt. Tighten the V-belt to the
proper tension. See Check and adjust cooling
fan V-belt on page 5-16.
7. Reinstall and tighten the drain plug or close the
drain cock in the radiator. Reinstall and tighten
the engine block drain plug or reconnect the
coolant hose at the oil cooler.
8. Fill the radiator and engine with engine coolant.
See Drain, flush and refill cooling system with
new coolant on page 5-20.
NOTICE
• Only use the engine coolant specified. Other
engine coolants may affect warranty
coverage, cause an internal buildup of rust
and scale and/or shorten engine life.
• Prevent dirt and debris from contaminating
the engine coolant. Carefully clean the
radiator cap and the surrounding area before
you remove the cap.
• Never mix different types of engine coolants.
This may adversely affect the properties of
the engine coolant.
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COOLING SYSTEM
Engine Coolant Pump
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3TNV88F Service Manual
Section 9
LUBRICATION
SYSTEM
Page
Before You Begin Servicing ............................................................ 9-3
Introduction...................................................................................... 9-4
Oil Pump Service Information.......................................................... 9-4
Lubrication System Diagram ........................................................... 9-5
Checking Engine Oil Pressure ........................................................ 9-6
Trochoid Oil Pump...........................................................................
Oil Pump Components ..............................................................
Disassembly of Oil Pump ..........................................................
Cleaning and Inspection ............................................................
Reassembly of Oil Pump ...........................................................
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9-6
9-7
9-7
9-9
9-1
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LUBRICATION SYSTEM
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Before You Begin Servicing
LUBRICATION SYSTEM
BEFORE YOU BEGIN
SERVICING
Before performing any service procedures within
this section, read the following safety information
and review the Safety section on page 3-1.
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LUBRICATION SYSTEM
Introduction
INTRODUCTION
This section of the Service Manual describes the procedures necessary to service the trochoid oil pumps.
See Replace engine oil and engine oil filter on page 5-15 for engine oil and engine oil filter replacement
procedures.
OIL PUMP SERVICE INFORMATION
■ Engine oil pressure
At rated engine RPM
1500 - 1800
min-1
2000 - 2500
min-1
0.29 - 0.44 MPa
(3.0 - 4.5 kgf/cm2)
2600
min-1
2700
min-1
0.34 - 0.49 MPa
(3.5 - 5.0 kgf/cm2)
2800
min-1
2900 - 3000
min-1
0.39 - 0.54 MPa
(4.0 - 5.5 kgf/cm2)
At low idle
speed
0.06 MPa
(0.6 kgf/cm2)
or greater
■ Rotor shaft clearance
Inspection item
Standard
Limit
Plate bearing inside diameter
0.3937 - 0.3943 in.
(10.000 - 10.015 mm)
0.3953 in.
(10.040 mm)
Rotor shaft outside diameter
0.3919 - 0.3924 in.
(9.955 - 9.967 mm)
0.3913 in.
(9.940 mm)
Rotor clearance
0.0013 - 0.0024 in.
(0.033 - 0.060 mm)
0.0039 in.
(0.100 mm)
9-4
Reference page
See Check rotor shaft
clearance on page 9-8
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LUBRICATION SYSTEM
Lubrication System Diagram
LUBRICATION SYSTEM DIAGRAM
Oil filter
Bypass valve
Oil pressure
switch
Fuel
injection pump
Cylinder body - main gallery
Pressure
regulator valve
Oil pump
Oil suction pipe
strainer
Idle gear
shaft
Piston cooling
nozzles
Camshaft
bearing
Crank
journal
Rocker arm
bearing
Crank pin
Rocker arm
Tappet
cam face
Oil pan
046648-00EN00
Figure 9-1
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LUBRICATION SYSTEM
Checking Engine Oil Pressure
CHECKING ENGINE OIL
PRESSURE
TROCHOID OIL PUMP
Oil Pump Components
Perform an engine oil pressure check if there is any
indication of low oil pressure such as the oil
pressure indicator is on or the oil pressure gauge
indicates low oil pressure. See Engine oil pressure
on page 9-4.
The oil pump is located in the front gear case and is
driven by the same gear train that drives the
camshaft and fuel injection pump. You must remove
the front gear case cover to gain access to the oil
pump.
1. Disconnect the wire lead from the oil pressure
switch or sending unit (Figure 9-2, (1)).
3
7
1
5
4
046805-00X00
Figure 9-2
2. Remove the oil pressure switch.
3. Install a mechanical oil pressure gauge in the
oil pressure switch port.
4. Start the engine:
• If the mechanical oil pressure test gauge
indicates good oil pressure, replace the faulty
oil pressure switch or sending unit, or faulty
machine oil pressure gauge in instrument
panel.
1
2
3
4
5
6
7
– Body
– Shaft
– Inner rotor
– Outer rotor
– Cover
– Drive gear
– Pressure regulator valve
Figure 9-3
• If the mechanical oil pressure test gauge
indicates low oil pressure, troubleshoot the
lubrication system to locate the cause of the
low oil pressure. See Failure Diagnostic List on
page 14-9. Repair as necessary.
9-6
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LUBRICATION SYSTEM
Trochoid Oil Pump
Disassembly of Oil Pump
NOTICE
If the oil pump must be replaced, replace it as an
assembly only. Do not replace individual
components.
Remove the cooling water fan guard (if equipped),
cooling fan (Figure 9-4, (3)), spacer
(Figure 9-4, (2)), cooling water pump V-pulley
(Figure 9-4, (1)), and V-belt.
1
2
3
2
Figure 9-5
Cleaning and Inspection
1
K0000163C
Figure 9-4
1. Remove the crank shaft pulley and gear case
cover. SeeRemoval of timing gear case cover
on page 6-34.
2. Remove the lubricating oil pump assembly
mounting bolts. Remove the lubricating oil
pump assembly (Figure 9-5, (1)) from the gear
case flange (Figure 9-5, (2)).
3. You can remove by hand the lubricating oil
pump cover (Figure 9-3, (5)) and outer rotor
(Figure 9-3, (4)).
3TNV88F Service Manual
Clean the lubricating oil pump, pressure regulator
valve (Figure 9-3, (7)), and rotor inserting portion.
Check the parts for wear or flaw. Replace the parts
with new ones as needed.
NOTICE
• Never overfill the engine with engine oil.
• Always keep the oil level between the upper and
lower lines on the oil cap/dipstick.
■ Check outer rotor outside clearance
Inspect the outside diameter clearance of the outer
rotor. To inspect this, insert a feeler gauge between
the outer rotor (Figure 9-6, (1)) and the lubricating
oil pump body (Figure 9-6, (2)).
9-7
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LUBRICATION SYSTEM
Trochoid Oil Pump
■ Check outer rotor side clearance
Inspect the side clearance between the lubricating
oil pump body and the outer rotor. To measure the
side clearance, use a straight edge and feeler
gauge (as shown in Figure 9-8) or a depth
micrometer.
1
2
Figure 9-6
Record the measurement(s) and see Rotor shaft
clearance on page 9-4 for the service limits.
■ Outer rotor to inner rotor tip clearance
Inspect the tip clearance between the outer and
inner rotors. To inspect this, insert a feeler gauge
between the inner rotor tooth tip (Figure 9-7, (1))
and the outer rotor tooth tip (Figure 9-7, (2)), and
measure the clearance.
Figure 9-8
Record the measurement(s) and see Rotor shaft
clearance on page 9-4 for the service limits.
■ Check rotor shaft clearance
Inspect the rotor shaft clearance. Measure the
outside diameter of the rotor shaft (Figure 9-9, (1))
and the inside diameter of the cover.
1
Determine the clearance by subtracting the outside
diameter of the rotor from the inside diameter of the
cover.
1
2
Figure 9-7
Record the measurement(s) and see Rotor shaft
clearance on page 9-4 for the service limits.
2
Figure 9-9
Record the measurement(s) and see Rotor shaft
clearance on page 9-4 for the service limits.
9-8
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LUBRICATION SYSTEM
Trochoid Oil Pump
Reassembly of Oil Pump
1. Apply clean lubricating oil to the lubricating oil
pump body and inner rotor assembly as well as
to the outer rotor.
2. Insert the outer rotor into the lubricating oil
pump body and inner rotor assembly and install
the cover.
3. Replace the packing with new one.
4. Install the lubricating oil pump assembly to the
gear case flange by tightening the bolts with the
specified torque.
5. Install the gear case cover. For more
information, See Installation of gear case cover
on page 6-54.
6. Install the crank shaft pulley.
7. Install the cooling water pump V-pulley
(Figure 9-10, (1)), spacer (Figure 9-10, (2)),
cooling water fan (Figure 9-10, (3)), and fan
guard (if equipped).
2
3
1
K0000163C
Figure 9-10
8. Install the V-belt. Adjust the belt to uniform
tensile strength in accordance with the
instructions given in Check and adjust cooling
fan V-belt on page 5-9.
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LUBRICATION SYSTEM
Trochoid Oil Pump
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3TNV88F Service Manual
Section 10
STARTER MOTOR
Page
Before You Begin Servicing .......................................................... 10-3
Introduction.................................................................................... 10-4
Starter Motor Information .............................................................. 10-4
Standard and Optional............................................................. 10-4
Starter Motor Specifications .......................................................... 10-5
Starter Motor Troubleshooting....................................................... 10-6
Starter Motor Components ............................................................ 10-7
Starter Motor ................................................................................. 10-8
Removal of Starter Motor ........................................................ 10-8
Disassembly of Starter Motor .................................................. 10-8
Inspection and Maintenance.................................................. 10-11
No-load Test .......................................................................... 10-18
Installation of Starter Motor ................................................... 10-18
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STARTER MOTOR
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Before You Begin Servicing
STARTER MOTOR
BEFORE YOU BEGIN
SERVICING
Before performing any service procedures within
this section, read the following safety information
and review the Safety section on page 3-1.
3TNV88F Service Manual
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STARTER MOTOR
Introduction
INTRODUCTION
This section of the Service Manual covers the servicing of the starter motor. YANMAR Part No. 12924277010 is standard equipment on 3TNV88F model engines and is used in this section to show the service
procedures for a representative starter motor. For specific part detail, see the YANMAR Parts Catalog for
the engine you are working on.
STARTER MOTOR INFORMATION
Standard and Optional
YANMAR
Part No.
Mfg.
Mfg.
Part No.
No load
Specification
Loaded
-1
Terminal Amperage
Terminal Amperage min
(rpm) voltage
draw
voltage
draw
Torque
min-1
(rpm)
12912977010
Denso
2280000251
DC 12 V-1.6
hp (1.2 kW)
11.5
90 A MAX
3000
8
280 Max
87 in.-lb
(9.81 N·m;
1.0 kgf·m)
900
12940777010
Denso
2280003732
DC 12 V-1.9
hp (1.4 kW)
11.5
90 A MAX
3000
8.5
350 Max
117 in.-lb
(13.2 N·m;
1.4 kgf·m)
1000
12960877010
Hitachi
S114-817A
DC 12 V-1.9
hp (1.4 kW)
11
90 A MAX
2700
8.4
250 Max
74 in.-lb
(8.3 N·m;
0.9 kgf·m)
1000
12924277010
Hitachi
S114-883
DC 12 V-2.3
hp (1.7 kW)
11
90 A MAX
2300
8
370 Max
134 in.-lb
(15.1 N·m;
1.5 kgf·m)
880
12913677011
Hitachi
S13-332
DC 12 V-3.1
hp (2.3 kW)
11
140 A MAX
4100
7.7
400 Max
97 in.-lb
(11.0 N·m;
1.1 kgf·m)
1400
12961277011
Hitachi
S25-166A
DC 24 V-5.3
hp (4.0 kW)
24
100 A MAX
3500
18
400 Max
269 in.-lb
(30.4 N·m;
3.1 kgf·m)
1000
10-4
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STARTER MOTOR
Starter Motor Specifications
STARTER MOTOR SPECIFICATIONS
YANMAR Part No.
129242-77010
Nominal output
2.3 hp (1.7 kW)
Weight
3.4 kg
Revolution direction (viewed from pinion)
Clockwise
Engagement system
No-load
Loaded
Magnetic shift
Terminal voltage/current
11 V/940 A max.
2300 min-1 min.
Revolution
Terminal voltage/current
8 V/370 A max.
Torque
15.1 N·m (1.5 kgf·m)
Clutch system
Overrunning
Pinion projection voltage at 100 °C (212 °F)
8.0 V max.
Pinion DP (number of teeth)
10/12 (11)
Difference (o-ring, oil seal)
Dry (none)
Application
Standard
Spring force
Brush
Magnetic
switch
Height
17 mm (0.67 in.)
Limit
12 mm (0.47 in.)
0.37 
Shunt coil resistance
0.62 
Run-out
Insulation depth
Armature
Standard
Series coil resistance
Outside diameter
Commutator
14.5 - 18.0 N (1.5 - 1.8 kgf)
Run-out
Pinion projection length (length L)
3TNV88F Service Manual
Standard
ø29.0 mm (1.14 in.)
Limit
ø28.0 mm (1.10 in.)
Standard
0.05 mm (0.002 in.)
Limit
0.1 mm (0.004 in.)
Standard
0.5 - 0.8 mm (0.02 - 0.03 in.)
Limit
0.2 mm (0.008 in.)
Standard
0.05 mm (0.002 in.)
Limit
0.1 mm (0.004 in.)
0.3 - 1.5 mm (0.01 - 0.06 in.)
10-5
10-6
Inspect fuel system.
3TNV88F Service Manual
Inspect condition of engine.
YES
YES
NO
Repair or replace
starter motor.
Replace engine oil.
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‡,IEUXVKHVDUHQRWZRUQUHSODFHDUPDWXUH
assembly.
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‡,QVSHFWVKLIWOHYHUIRUGHIRUPDWLRQ
return spring for fatigue and pinion
for sliding.
‡5HSDLUPHVKLQJEHWZHHQSLQLRQDQG
ring gear or replace as needed.
Inspect wiring up to solenoid switch
and repair if necessary.
‡.H\VZLWFK
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‡&KDUJHRUUHSODFHEDWWHU\
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motor relay or magnetic switch assembly.
Engine does not stop
even when key switch is
turned OFF.
If a problem occurs:
Immediately disconnect battery negative terminal.
,IVWDUWHUPRWRUEHFRPHVZHWUHSODFHVROHQRLGVZLWFK
assembly even if function is normal.
NO
‡&KDUJHRUUHSODFHEDWWHU\
‡&OHDQWHUPLQDOV
Solenoid switch assembly
contact defective. Repair
or replace.
YES
&RQQHFW0WHUPLQDORIVWDUWHU
motor directly to battery.
Does starter motor operate?
NO
Slow Revolution
Does engine turn when
starter motor is replaced?
YES
Is the engine oil
viscosity correct?
YES
Is battery fully charged
and terminals clean?
NO
NO
NO
NO
STARTER MOTOR
YES
Is revolution normal?
Pinion roller clutch or
reduction gear damaged.
Inspect and replace.
YES
Pinion and ring gear
meshing normal?
YES
Is starter motor operating?
Is starter motor solenoid
switch actuating sound
heard?
YES
Is battery fully charged
and terminals clean?
木曜日
NO
(slow revolution)
NO
Move shift lever to
NEUTRAL position.
２０１２年７月２６日
YES
Does engine crank?
NO
6 ページ
YES
Engine does not start?
Is the shift lever at
NEUTRAL position?
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Starter Motor Troubleshooting
STARTER MOTOR TROUBLESHOOTING
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STARTER MOTOR
Starter Motor Components
STARTER MOTOR COMPONENTS
13
14
12
11
10
9
8
5
6
7
4
23
3
2
15
1
18
22
21
19
20
17
16
1 – Pinion shaft
2 – M4 bolts (3 used)
3 – Bearing retainer
4 – Pinion clutch assembly
5 – Return spring
6 – Pinion stop
7 – Retaining ring
8 – Gear housing
9 – Shift lever
10 – Torsion spring
11 – Plunger
12 – Dust covers (shims)
K0000103A
13 – Magnetic switch assembly (solenoid)
14 – Cover
15 – M6 bolts (2 used)
16 – Armature assembly
17 – Field coil assembly
18 – Positive (+) brushes
19 – Negative (-) brushes
20 – Brush holder assembly
21 – Rear cover
22 – M5 through bolts (2 used)
23 – M4 bolts (2 used)
Figure 10-1
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STARTER MOTOR
Starter Motor
STARTER MOTOR
Disassembly of Starter Motor
1. M8 nut
WARNING
Shock Hazard!
• Turn off the battery switch (if
equipped) or disconnect the
negative battery cable before
servicing the electrical system.
Remove the M8 nut (12 mm) of the magnetic
switch M terminal, and remove the motor lead
wire.
1
• Check the electrical harnesses for cracks,
abrasions, and damaged or corroded
connectors. Always keep the connectors and
terminals clean.
• Failure to comply could result in death or
serious injury.
Motor lead wire
046413-00EN00
Figure 10-3
Note: While starter motor design varies between
models, the basic repair procedures are the
same. The following procedures are typical
and may differ from the stater being
serviced.
2. M6 bolt (2)
3. Magnetic switch
If you remove the M6 bolts (10 mm), the magnetic
switch will be removed.
Removal of Starter Motor
1. Disconnect the battery cables at the battery,
negative (-) cable first.
2. Remove the electrical wires from the magnetic
switch assembly.
2
3
3. Remove the starter mounting bolts
(Figure 10-2, (1)). Remove the starter motor
from the flywheel housing.
1
046414-00X00
Figure 10-4
K0002126
Figure 10-2
10-8
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STARTER MOTOR
Starter Motor
8. Brush holder
4. M4 screw (2)
5. M5 through bolt (2)
6. Rear cover
If you remove the M4 screws and the M5 through
bolts, the rear cover will be removed.
Pull out the brush holder from the outer
commutator while caring not to damage the
brush.
5
Brush
6
Commutator
4
046453-00EN00
Figure 10-7
046415-00X00
9. Yoke
10. Armature
Figure 10-5
11. Center bracket A
7. Thrust washer A
Remove the thrust washer A from the groove of
the shaft by using a screw driver.
The permanent magnet is installed in the inner
yoke. Pull out the armature quietly not to damage
the magnet for disassembly.
Motor lead wire
9
10
11
Screw driver
7
046416-00EN00
Figure 10-6
046417-00X00
Figure 10-8
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STARTER MOTOR
Starter Motor
12. Gear case
17. Pinion stopper clip
13. Dust cover
14. Shift lever
Remove the dust rubber from the gear case, and
remove the shift lever.
Pull out the center bracket P, and the pinion
clutch assembly from the gear case.
Move the pinion stopper to the pinion side, and
pull out the pinion stopper clip from the groove of
the pinion shaft by using a screw driver.
Care must be taken not to damage the pinion
shaft surface while removing the clip.
14
13
12
17
Pinion shaft
Pinion stopper
046419-00EN00
Figure 10-11
046418-00X00
Figure 10-9
18. Pinion stopper
19. Pinion clutch
15. Internal gear
16. Planet gear (3)
Pull out the internal gear and the planet gears
from the center bracket P and the pinion clutch
assembly.
15
If you remove the pinion stopper clip from the
pinion shaft, the pinion stopper and the pinion
clutch are removed from the pinion shaft.
19
18
16
046420-00X00
Figure 10-12
046472-00X00
Figure 10-10
10-10
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STARTER MOTOR
Starter Motor
Inspection and Maintenance
20. E-ring
Use a special tool and hit with a hammer to pull
out the E-ring from the pinion shaft groove.
1. Armature
1- Outer diameter of commutator
Measure the outer diameter of the
commutator. If it is below the limit, replace it
with a non-defective.
Standard
Limit
ø29 mm
ø28 mm
Special tools
Pinion shaft
20
046421-00EN00
Figure 10-13
046452-00X00
Figure 10-15
21. Washer (2)
2- Conduction test for armature coil
22. Center bracket P
23. Pinion shaft
Remove the E-ring, and then pull out the center
bracket P and the washers from the pinion shaft.
Check between the commutator bars with a
tester.
If there is conduction, it is a non-defective.
No conduction
(Coil burnout)
23
21
Replace the armature
22
21
046422-00X00
Figure 10-14
046470-00X00
Figure 10-16
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STARTER MOTOR
Starter Motor
3- Insulation test for armature coil
Check between the commutator and the
shaft (or the armature core) with a tester.
If there is no conduction, it is a non-defective.
Armature core
Commutator
Conduction
(Coil short-circuit)
Replace the armature
046451-00EN00
Figure 10-18
5- Inspection of commutator outer diameter
surface
046471-00X00
Figure 10-17
If the outer diameter surface of the
commutator is rough, polish it with a No. 500
- 600 sandpaper.
4- Vibration of armature core and commutator
Measure the vibration of the armature core
outer diameter and the commutator outer
diameter by placing the dial gauge in the
shaft center.
If it is above the limit, correct or replace it with
a non-defective.
Armature
Commutator
Standard
Limit
0.05 mm or less
0.05 mm or less
0.1 mm
0.1 mm
046450-00X00
Figure 10-19
10-12
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STARTER MOTOR
Starter Motor
6- Depth of insulation between commutator
bars
Measure the depth of the insulator between
the commutator bars. If it is below the limit,
correct or replace it with a non-defective.
Standard
Limit
0.5 - 0.8 mm
0.2 mm
3. Brush holder
1- Insulation test for brush holder
Check the conduction between the brush
holder (positive side) and the base (negative)
side with a tester.
If there is no conduction, it is a non-defective.
Conduction
(Insulation failure)
Replace the brush holder
Hacksaw
Commutator
Commutator
Insulator
piece
Chamfer
0.5~0.8mm
046447-00X00
Defective
Non-defective
Figure 10-22
046449-00EN00
Figure 10-20
2- Inspection of brush spring
2. Brush
1- Inspection of brush height
Measure the height of the brush. If it is below
the limit, its life is ending. Replace it with a
non-defective.
Standard
Limit
17 mm
12 mm
Measure the brush spring load after aligning
the brush position to the commutator outer
diameter.
If it is out of range, replace the brush spring.
Load
14.5 - 18.0 N
046446-00X00
Figure 10-23
Brush
046448-00EN00
Figure 10-21
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14 ページ
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STARTER MOTOR
Starter Motor
3- Conduction test for contact
4. Magnetic switch
Note: When the starter is flooded, be sure to
replace the magnetic switch with a new
one even if it does not have any
operational malfunction.
1- Conduction test for shunt coil
Check the conduction between the S
terminal and the switch body.
If there is conduction, it is a non-defective.
No conduction
(Coil burnout)
Place the plunger on the lower side and push
down the magnetic switch fully until the end.
At this time, check the conduction between
the B terminal and the M terminal.
If there is conduction, it is a non-defective.
No conduction
(Contact conduction
failure)
Replace the magnetic
switch
Replace the magnetic
switch
046443-00X00
Figure 10-26
046445-00X00
Figure 10-24
2- Conduction test for sheath coil
Check the conduction between the S
terminal and the M terminal.
If there is conduction, it is a non-defective.
No conduction
(Coil burnout)
5. Pinion clutch
1- Hold the clutch outer diameter and turn the
pinion by hand.
Inspect that the pinion turns smoothly when
turned in the drive direction, and the pinion
locks when turned in the anti-drive direction.
If there is any malfunction, replace it.
Replace the magnetic
switch
046442-00X00
Figure 10-27
046444-00X00
Figure 10-25
10-14
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STARTER MOTOR
Starter Motor
2- Rear cover bearing
6. Yoke
1- Inspect the permanent magnet in the inner
yoke. If it is damaged or slipped out, replace
and correct the yoke assembly.
Permanent magnet
Measure the inner diameter of the rear cover
bearing. If it exceeds the wear limit, replace it.
Standard
Wear limit
12.0 - 12.018 mm
12.1 mm
046441-00EN00
Figure 10-28
12 +0.018
0
046377-00X00
7. Bearing
Figure 10-30
1- Gear case bearing
Measure the inner diameter of the gear case
bearing. If it exceeds the wear limit, replace it.
Standard
Wear limit
12.5 - 12.527 mm
12.6 mm
3- Center bracket P bearing
Measure the inner diameter of the center
bracket P bearing. If it exceeds the wear limit,
replace it.
Standard
Wear limit
18.035 - 18.060 mm
18.13 mm
+0.035
18 +0.060
12.5 +0.027
0
046440-00X00
Figure 10-29
046378-00X00
Figure 10-31
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STARTER MOTOR
Starter Motor
4- Pinion shaft bearing
Measure the inner diameter of the pinion
shaft bearing. If it exceeds the wear limit,
replace it.
Standard
Wear limit
6.735 - 6.740 mm
6.83 mm
ø6.7 +0.040
+0.035
046439-00X00
Figure 10-32
10-16
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STARTER MOTOR
Starter Motor
Reassembly
Perform assembly in the reverse order of disassembly. The following precautions must be taken.
1. Tightening torque for nuts, bolts, and screws
Tighten the torque for the nuts, bolts, and screws with the component part No. shown on Figure 10-6 at the
time of disassembly.
1
Switch M8 nut
7.4 - 8.9 N·m
2
M6 bolt
5.4 - 8.3 N·m
3
M4 screw
1.7 - 2.3 N·m
4
M5 through bolt
4.9 - 6.3 N·m
2. Grease application part
Depending on the part, grease brand differs. Apply grease as follows:
Part
Shift lever connection
(Support between the
plunger and the gear case)
Switch plunger outer
circumference part
Pinion sliding shaft outer
circumference part, helical
spline part, planet gear part
Grease brand
Shell Alvania S2
NPC FG-6A
Multemp ET-R
3. Dimensions during pinion operation
2- Adjustment method
1- Measurement method
Connect the positive side of battery to the S
terminal and the negative side of battery to the M
terminal. Then, close the switch and operate the
pinion.
After operation, push the pinion to the direction of
arrow and measure the gap with the stopper: L.
If the gap: 1 is except for the L standard value,
make adjustment by either inserting the dust
cover (packing) or removing it.
Standard value ratio
Dust cover
Large
Insert
Small
Remove
Standard value
L
0.3 - 1.5 mm
Note: Perform the measurement within 10 seconds.
Dust cover
Switch
S
Magnetic switch
M
Gear case
Battery
Pinion
L
046376-00EN00
046375-00EN00
Figure 10-33
3TNV88F Service Manual
Figure 10-34
10-17
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STARTER MOTOR
Starter Motor
No-load Test
Test the characteristics of the starter motor by
performing a no-load test.
NOTICE
The starter motor can be damaged if operated
continuously longer than 10 seconds while
performing the no-load test.
1. Secure the starting motor in a vise or other
suitable fixture.
2. Connect an ammeter (Figure 10-35, (1)) in
series between the battery positive (+) terminal
(Figure 10-35, (2)) and the main positive (+)
terminal (Figure 10-35, (3)) on the starter
motor.
Note: The ammeter and all wire leads used in
this test must have a capacity equal to or
greater than the amperage draw
specification for the starter motor being
tested.
5. Install a switch (Figure 10-35, (6)) in a circuit
between the battery positive (+) terminal
(Figure 10-35, (2)) and the starter magnetic
switch (solenoid) terminal (Figure 10-35, (8))
on the starter motor.
6. Use a suitable tachometer to monitor the rpm of
the starter.
7. Turn the switch to the ON position. Monitor the
rpm, amperage draw and voltage. For test
specifications, see Standard and Optional on
page 10-4 for the appropriate starter motor.
Installation of Starter Motor
1. Reinstall the starter motor to the flywheel
housing.
2. Reinstall the starter mounting bolts
(Figure 10-36, (1)). Tighten the bolts to
specification. See Tightening Torques for
Standard Bolts and Nuts on page 4-25.
1
3
6
M
1
8
2
7
K0002126
5
4
K0002127A
Figure 10-35
3. Connect a wire lead between the mounting
base of the starter motor (Figure 10-35, (4))
and the battery negative terminal
(Figure 10-35, (5)).
Figure 10-36
3. Reconnect the electrical wires to the magnetic
switch assembly (solenoid). Be sure to place
the cover over the battery positive (+) cable
connection.
4.
Reconnect the battery cables at the battery.
4. Connect a voltmeter (Figure 10-35, (7)) to the
battery negative (-) terminal (Figure 10-35, (5))
and the main positive (+) battery terminal
(Figure 10-35, (3)) on the starter motor.
10-18
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3TNV88F Service Manual
Section 11
ALTERNATOR
Page
Before You Begin Servicing .......................................................... 11-3
Introduction.................................................................................... 11-4
Dynamo and Alternator Information .............................................. 11-4
Standard and Optional Dynamos ............................................ 11-4
Standard and Optional Alternators .......................................... 11-4
Alternator Specifications................................................................ 11-5
Dynamo Specifications.................................................................. 11-5
Alternator Troubleshooting ............................................................ 11-6
Alternator Components ................................................................. 11-7
Alternator Wiring Diagram ............................................................. 11-8
Alternator Standard Output .......................................................... 11-9
Alternator ....................................................................................
Removal of Alternator............................................................
Disassembly of Alternator......................................................
Reassembly of Alternator ......................................................
Installation of Alternator.........................................................
11-10
11-10
11-10
11-12
11-14
Dynamo Component Location..................................................... 11-15
Dynamo Wiring Diagram ............................................................. 11-16
Operation of Dynamo .................................................................. 11-16
Dynamo Standard Output ........................................................... 11-17
Testing of Dynamo ......................................................................
Testing Stator Coil Continuity ................................................
Testing Stator Coil Short-to-Ground ......................................
Testing Dynamo Regulated Output .......................................
11-18
11-18
11-18
11-18
Dynamo ....................................................................................... 11-18
Removal of Dynamo .............................................................. 11-18
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ALTERNATOR
Disassembly of Dynamo......................................................... 11-19
Reassembly of Dynamo ......................................................... 11-19
Installation of Dynamo............................................................ 11-20
11-2
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２０１２年７月２６日
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Before You Begin Servicing
ALTERNATOR
BEFORE YOU BEGIN
SERVICING
Before performing any service procedures within
this section, read the following safety information
and review the Safety section on page 3-1.
3TNV88F Service Manual
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２０１２年７月２６日
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ALTERNATOR
Introduction
INTRODUCTION
This section of the Service Manual describes the servicing of the dynamos and alternators. YANMAR Part
No. 129423-77200 alternator is used in this section to show the service procedures for the representative
alternator. YANMAR Part No. 171301-77201 dynamo is used in this section to show the service procedures
for the representative dynamo. For specific part detail, see the Parts Catalog for the engine you are working
on.
DYNAMO AND ALTERNATOR INFORMATION
Standard and Optional Dynamos
YANMAR Part No.
Mfg.
Mfg. Part No.
Specification
171301-77201
Kokusan
GP8138
DC 12 V-15 A
119910-77200
Kokusan
GP9191
DC 12 V-20 A
Standard and Optional Alternators
11-4
YANMAR Part No.
Mfg.
Mfg. Part No.
Specification
119620-77201
Denso
100211-4531
DC 12 V-40 A
129423-77200
Denso
101211-1170
DC 12 V-40 A with pulse
129961-77200
Denso
101211-2591
DC 12 V-55 A
119626-77210
Denso
101211-2951
DC 12 V-55 A with pulse
129612-77290
Hitachi
LR180-772
DC 12 V-80 A with pulse
129900-77240
Hitachi
LR235-705
DC 24 V-35 A with pulse
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ALTERNATOR
Alternator Specifications
ALTERNATOR SPECIFICATIONS
YANMAR Part No.
129423-77200
Nominal output (13.5 V heat)
40 A
Weight
6.17 lb (2.8 kg)
Revolution direction (as viewed from pulley)
Clockwise
Rating
Continuous
Battery voltage
12 V
Rated revolution
5000 min-1 (rpm)
Operating range
1350 - 18000 min-1 (rpm)
Grounding characteristics
Negative (-) side of circuit
Integrated regulator
IC regulator
Outside diameter of pulley
2.724 in. (69.2 mm)
Belt shape
Type A
DYNAMO SPECIFICATIONS
YANMAR Part No.
119910-77200
Nominal output
20 A
Weight
3.97 lb (1.8 kg)
Revolution direction (as viewed from pulley)
Clockwise
Rating
Continuous
Battery voltage
12 V
Rated revolution
3500 min-1 (rpm)
Operating range
1400 - 6600 min-1 (rpm)
Grounding characteristics
Negative (-) side of circuit
Current limiter
(YANMAR Part No. 119653-77710)
Regulator
Outside diameter of pulley
Belt shape
A-belt
2.56 in. (65 mm)
Special M-belt
2.28 in. (58 mm)
Type A or type special M
3TNV88F Service Manual
11-5
11-6
3TNV88F Service Manual
1. Use a fully charged battery
2. DC voltmeter: 0 to 30 V, 0.5 class
3. The check method is also applicable to the bench test
Notes:
OFF
Not abnormal.
Inspect auxiliary diode.
ON
Check condition of L terminal.
Inspect diode negative (-) side.
Battery voltage
is between 13
and 15 volts.
Does battery indicator
come ON?
Battery voltage minus
L terminal voltage is
less than 0.5 volt.
Replace regulator.
With engine idling,
turn light switch ON.
With engine idling,
measure voltage at L
terminal and at battery.
Excessive voltage drop between
BAT and batt ( + side) terminal.
Inspect diode positive (+) side.
Inspect or replace V-belt.
Inspect alternator.
Inspect rotor assembly and
brushes.
Replace the battery indicator.
Battery indicator is available from
driven machine manufacturer.
Battery voltage greater
than 15.5 volts.
Battery indicator
is dim.
Battery voltage minus
L terminal voltage is
greater than 0.5 volt.
OFF
ALTERNATOR
With engine running at 1500
rpm, measure voltage at
battery.
OFF
Does battery indicator
come ON?
Increase engine speed to
1500 rpm. Turn light switch ON.
Battery indicator
is dim.
ON
Ground drive machine side
L terminal. Does battery
indicator turn on?
木曜日
OFF
Battery indicator flashes.
Battery indicator ON.
Disconnect harness L terminal
and IG terminal at alternator
２０１２年７月２６日
At idle, does battery
indicator turn OFF?
Start Engine.
OFF
6 ページ
ON
Turn key switch ON.
Does battery indicator
turn ON?
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Alternator Troubleshooting
ALTERNATOR TROUBLESHOOTING
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ALTERNATOR
Alternator Components
ALTERNATOR COMPONENTS
YANMAR Part No. 129423-77200 alternator is used in this section to show the service procedures for the
representative alternator. For specific part detail, see the Parts Catalog for the engine you are working on.
11
10
8
6
12 13
14
9
5
29
4
2
7
3
19
16
17
1
18
25
15
28
27
26
24
23
22
21
20
1 – Nut
2 – Pulley
3 – Collar
4 – Front frame housing
5 – Stator assembly
6 – Stud (2 used)
7 – Front frame housing bearing
8 – Bearing cover
9 – Bearing cover bolt (4 used)
10 – Rotor assembly
11 – Rear frame housing bearing
12 – Bearing cover
13 – Thrust washer
14 – Thrust washer
15 – Nut (2 used)
K0000255
16 – Nut
17 – Insulation bushing
18 – Spring (2 used)
19 – Brush holder
20 – Rear frame housing
21 – Bolt (2 used)
22 – Holder
23 – IC regulator assembly
24 – Bolt (2 used)
25 – Bolt
26 – Brush (2 used)
27 – Bolt
28 – Rear cover
29 – Bolt (3 used)
Figure 11-1
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ALTERNATOR
Alternator Wiring Diagram
ALTERNATOR WIRING DIAGRAM
B
1
IG
P
IG
B
PI
P
L
2
F
L
3
3
0.5PF
IC
B
4A
T
E
E
5
6
1 – Key switch
2 – Charge lamp (3.4 W max.)
3 – Load
4 – Battery
5 – Alternator assembly
6 – IC Regulator assembly
Figure 11-2
NOTICE
Do not short-circuit the charging system between
alternator terminals IG and L. Damage to the
alternator will result.
NOTICE
Do not remove the positive (+) battery cable from
alternator terminal B while the engine is operating.
Damage to the alternator will result.
NOTICE
Do not connect a load between alternator terminals
L and E. Damage to the alternator will result.
11-8
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ALTERNATOR
Alternator Standard Output
ALTERNATOR STANDARD OUTPUT
Output current
60
Cold
13.5 V, constant ambient
temperature at 77 °F (25 °C)
50
Hot
40
30
20
10
0
1
2
3
4
5
6
7
8
-1
Alternator speed (× 10³ min )
Figure 11-3
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ALTERNATOR
Alternator
ALTERNATOR
4. Remove the nut (Figure 11-4, (2)) from the
gear case stud. Remove the alternator.
WARNING
Shock Hazard!
• Turn off the battery switch (if
equipped) or disconnect the
negative battery cable before
servicing the electrical system.
• Check the electrical harnesses for cracks,
abrasions, and damaged or corroded
connectors. Always keep the connectors and
terminals clean.
• Failure to comply could result in death or
serious injury.
2
1
K0000264
Figure 11-4
Disassembly of Alternator
1. Remove the nut (Figure 11-5, (1)) from the
shaft of the rotor assembly. Remove the pulley
(Figure 11-5, (2)).
Removal of Alternator
1. Disconnect the electrical wires from the
alternator.
2. Loosen the V-belt.
CAUTION
Pinch Hazard!
Carefully rotate the alternator
toward the cylinder block while
loosening the V-belt. Failure to
comply may result in minor or
moderate injury.
1
2
Figure 11-5
3. Remove the V-belt adjuster from the alternator
bolt (Figure 11-4, (1)).
11-10
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ALTERNATOR
Alternator
2. Remove the three bolts (Figure 11-6, (1))
retaining the rear cover (Figure 11-6, (2)) to the
rear frame assembly.
6. Remove the nut (Figure 11-7, (3)) retaining the
insulation bushing (Figure 11-7, (4)). Remove
the insulation bushing.
7. Remove the two bolts (Figure 11-8, (1)) and
two nuts (Figure 11-8, (2)) securing the rear
frame housing to the front frame housing.
1
3
2
2
4
5
1
K0000257A
Figure 11-6
K0000265A
3. Remove the brush holder (Figure 11-6, (3)).
Remove the brush springs (Figure 11-6, (4))
and brushes (Figure 11-6, (5)).
4. Remove the bolt retaining the regulator
assembly (Figure 11-7, (1)) to the holder
(Figure 11-7, (2)).
Figure 11-8
8. Using a press, remove the rotor assembly
(Figure 11-9, (1)) from the front frame housing
(Figure 11-9, (2)) and rear frame housing
(Figure 11-9, (1)).
3
3
1
4
1
2
2
K100266A
Figure 11-9
K0000258A
Figure 11-7
5. Remove the bolts retaining the holder
(Figure 11-7, (2)) to the rear frame housing.
Remove the holder.
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ALTERNATOR
Alternator
9. Remove the stator assembly
(Figure 11-10, (1)) from the front frame
housing.
4
3
3
1
2
2
K0000260A
1
Figure 11-11
Reassembly of Alternator
K0000259A
Figure 11-10
10. If it is necessary to replace the bearing
(Figure 11-10, (2)) in the front frame housing,
remove the four bolts (Figure 11-10, (3))
securing the plate (Figure 11-10, (4)) to the
front frame housing. Remove the plate. Use a
puller to remove the bearing. Discard the
bearing.
11. If it is necessary to replace the bearing
(Figure 11-11, (1)) in the rear frame housing,
use a puller to remove. Discard the bearing.
Remove the bearing cover (Figure 11-11, (2))
and two thrust washers (Figure 11-11, (3)).
1. If removed, reinstall the two trust washers
(Figure 11-12, (3)) and bearing cover
(Figure 11-12, (2)) in the rear frame housing.
Lubricate the outside diameter of a new bearing
(Figure 11-12, (1)). Press the bearing into the
rear frame housing.
3
1
2
K0000260A
Figure 11-12
11-12
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ALTERNATOR
Alternator
2. If removed, lubricate the outside diameter of a
new front frame housing bearing. Press the
bearing (Figure 11-13, (2)) into the front frame
housing. Reinstall the plate (Figure 11-13, (4))
to the front housing. Tighten the four bolts
(Figure 11-13, (3)).
5. Align the front frame housing with the rear
frame housing. Reinstall the two bolts
(Figure 11-15, (1)) and two nuts
(Figure 11-15, (2)).
2
4
1
3
2
K0000265A
1
Figure 11-15
6. Reinstall the insulation bushing
(Figure 11-16, (4)) and nut (Figure 11-16, (3)).
K0000259A
Figure 11-13
3
3. Position the stator assembly (Figure 11-13, (1))
on the front frame housing studs.
4
1
4. Lubricate the shaft of the rotor assembly
(Figure 11-14, (1)). Press the rotor assembly
into the front frame housing (Figure 11-14, (2))
and rear frame housing (Figure 11-14, (3)).
3
2
1
2
K0000258A
Figure 11-16
7. Reassemble the regulator assembly
(Figure 11-16, (1)) to the holder
(Figure 11-16, (2)).
K100266A
Figure 11-14
3TNV88F Service Manual
8. Reinstall the brush holder (Figure 11-17, (3)),
springs (Figure 11-17, (4)) and brushes
(Figure 11-17, (5)).
11-13
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ALTERNATOR
Alternator
9. Reattach the regulator assembly and holder to
the rear frame housing.
1
3
4
5
Installation of Alternator
1. Position the alternator on the gear case.
Loosely reinstall the nut (Figure 11-19, (2)) on
the gear case stud and the V-belt adjuster bolt
(Figure 11-19, (1)).
2
2
1
K0000264
K0000257A
Figure 11-17
10. Reinstall the rear cover (Figure 11-17, (2)) to
the rear frame housing with three bolts
(Figure 11-17, (1)).
11. Reassemble the pulley (Figure 11-18, (2)) and
nut (Figure 11-18, (1)) to the shaft of the rotor
assembly. Tighten the nut.
Figure 11-19
2. Reconnect the electrical wires to the alternator.
Tighten the nuts to 15 - 20 in.-lb (1.7 - 2.3 N·m;
17 - 23 kgf·m).
3. Reinstall the V-belt. Tighten the V-belt to the
proper tension as described in Check and
adjust cooling fan V-belt on page 5-9.
4. Start the engine. Listen for any unusual sounds
from the alternator.
NOTICE
Do not operate the engine if the alternator is
producing unusual sounds. Damage to the
alternator will result.
5. Verify that the charge indicator is ON while the
engine is operating. If the charge indicator is
not ON, repair the problem before operating the
engine.
1
2
K0000256
Figure 11-18
11-14
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ALTERNATOR
Dynamo Component Location
DYNAMO COMPONENT LOCATION
YANMAR Part No. 171301-77201 dynamo is used in this section to show the service procedures for the
representative dynamo. For specific part detail, see the Parts Catalog for the engine you are working on.
1
2
3
4
7
5
8
9
10
6
11
12
13
14
K0002140X
1
2
3
4
5
6
7
– Rear cover
– Nut
– Lock washer
– Flat washer
– Rear bearing
– Output wire and connector
– Plate
8 – Spacer
9 – Stator assembly
10 – Front bearing (2 used)
11 – Flat washer
12 – Flywheel assembly
13 – Pulley half
14 – Through bolt
Figure 11-20
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ALTERNATOR
Dynamo Wiring Diagram
DYNAMO WIRING DIAGRAM
3
6
5
4
2
1
K0002137X
1 – Dynamo
2 – Current limiter
3 – Key switch
4 – Charge lamp (3.4 W max.)
5 – Battery
6 – Load
Figure 11-21
OPERATION OF DYNAMO
The dynamo consists of a series of permanent magnets that rotate around a stationary stator coil. The
magnets are attached to the flywheel which is rotated via the engine cooling fan drive belt. The resultant
output is an AC (alternating current) signal. The AC is converted to DC (direct current) by the current limiter.
The current limiter outputs charging DC current to the battery.
11-16
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ALTERNATOR
Dynamo Standard Output
DYNAMO STANDARD OUTPUT
Standard characteristics (12 V)
25
Output current (A)
20
15
10
5
0
1
2
3
4
Alternator speed (min-1)
5
6
7 × 103
K0002138E
Figure 11-22
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ALTERNATOR
Testing of Dynamo
TESTING OF DYNAMO
DYNAMO
Use a circuit tester or multimeter to perform the
following tests.
Removal of Dynamo
Testing Stator Coil Continuity
1. Disconnect the dynamo output wire connector.
2. Connect one meter lead to each of the stator
wire terminals and read the meter.
Results: The meter reading should indicate
continuity. If continuity is not indicated, the windings
are open and the stator must be replaced.
Testing Stator Coil Short-to-Ground
1. Disconnect the dynamo output wire connector.
2. Test continuity between each stator wire
terminal and engine ground.
Results: The meter reading should infinity. If the
meter reading indicates continuity, the windings are
shorted to ground and the stator must be replaced.
CAUTION
Pinch Hazard!
Carefully rotate the alternator
toward the cylinder block while
loosening the V-belt. Failure to
comply may result in minor or
moderate injury.
1. Disconnect the output wire connector from the
dynamo.
2. Loosen the V-belt.
3. Remove the V-belt adjuster from the dynamo
bolt (Figure 11-23, (1)).
4. Remove the nut (Figure 11-23, (2)) from the
gear case stud. Remove the dynamo.
Testing Dynamo Regulated Output
1. Test and record the battery voltage with the
engine not running.
2. Start the engine and operate it at normal
operating rpm.
3. Again, check the battery voltage with the engine
running.
Results: The meter reading with the engine
running must be higher than with the engine not
running.
2
Figure 11-23
• If results are not correct, test the stator for
continuity and shorts to the ground.
• Check the charging system wiring.
• If no problems are found in previous checks,
replace the IC regulator.
11-18
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ALTERNATOR
Dynamo
Disassembly of Dynamo
4. Remove the screws (Figure 11-26, (1)) and the
stator assembly (Figure 11-26, (2)).
1. Remove the rear cover (Figure 11-24, (1)).
2. Remove the nut (Figure 11-24, (2)), lock
washer (Figure 11-24, (3)), and flat washer
(Figure 11-24, (4)).
5. Remove the rear bearing (Figure 11-26, (3)).
3
1
2
3
4
2
1
K0002145X
Figure 11-26
Reassembly of Dynamo
K0002143X
1. Reinstall the rear bearing (Figure 11-27, (3)).
Figure 11-24
3. Remove the through bolt (Figure 11-25, (1)),
pulley half (Figure 11-25, (2)), flywheel
(Figure 11-25, (3)), flat washer
(Figure 11-25, (4)), bearings
(Figure 11-25, (5)), and spacer
(Figure 11-25, (6)).
2. Reinstall the stator (Figure 11-27, (2)) and
screws.
3
2
6
1
5
4
3
2
K0002145X
1
Figure 11-27
K0002144X
Figure 11-25
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ALTERNATOR
Dynamo
3. Reinstall the front bearings (Figure 11-28, (5))
and spacer (Figure 11-28, (6)).
4. Reinstall the flat washer (Figure 11-28, (4)),
flywheel (Figure 11-28, (3)), pulley half
(Figure 11-28, (2), and through bolt
(Figure 11-28, (1)).
Installation of Dynamo
1. Position the dynamo on the gear case. Loosely
reinstall the nut (Figure 11-30, (2)) on the gear
case stud and the V-belt adjuster bolt
(Figure 11-30, (1)).
6
5
4
3
2
1
2
1
K0002141X
Figure 11-30
2. Reconnect the dynamo output wire connector.
K0002144X
Figure 11-28
5. Reinstall the flat washer (Figure 11-29, (4)),
lock washer (Figure 11-29, (3)), and nut
(Figure 11-29, (2)). Tighten the nut to the
specified torque.
6. Reinstall the rear cap (Figure 11-29, (1)).
1
2
3
3. Reinstall the V-belt. Tighten the V-belt to the
proper tension as described in Check and
adjust cooling fan V-belt on page 5-9.
4. Start the engine. Listen for any unusual sounds
from the alternator.
NOTICE
Do not operate the engine if the alternator is
producing unusual sounds. Damage to the
alternator will result.
4
5. Verify that the charge indicator is ON while the
engine is operating. If the charge indicator is
not ON, repair the problem before operating the
engine.
K0002143X
Figure 11-29
11-20
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3TNV88F Service Manual
Section 12
ELECTRONIC
CONTROL SYSTEM
Page
Before You Begin Servicing .......................................................... 12-3
Introduction.................................................................................... 12-4
Electronic Control System ............................................................. 12-4
Electronic control harness connections......................................... 12-5
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ELECTRONIC CONTROL SYSTEM
This Page Intentionally Left Blank
12-2
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Before You Begin Servicing
木曜日
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ELECTRONIC CONTROL SYSTEM
BEFORE YOU BEGIN
SERVICING
Before performing any service procedures within
this section, read the following safety information
and review the Safety section on page 3-1.
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ELECTRONIC CONTROL SYSTEM
Introduction
INTRODUCTION
None of the components of the electronic control
system can be individually repaired. When any
component is faulty and needs repair, the entire
assembly must be replaced.
Features of the electronic engine control system
include:
• Engine speed control schemes
Droop control/Low-idling speed up/Auto
deceleration/High-idling speed down/Black
smoke suppression
• Starting aid
Auto preheating/After heating
ELECTRONIC CONTROL
SYSTEM
• Engine failure detection
Model 3TNV88F engine come with the Exhaust
Gas Recirculation (EGR) system to conform to the
engine emission regulations (EPA 2013 rules). The
EGR system and an electronic governor (Ecogovernor) constitute an electronic engine control
system.
The electronic engine control system regulates the
exhaust gas recirculation flow rate and the fuel
injection volume depending on the engine load and
speed signals from the engine controller (E-ECU),
so that the exhaust gas is kept clean according to
the emission control regulations. Figure 12-1
illustrates the electronic engine control system.
• CAN communication with the control system of
the driven machine
Although these features are described in section 47, whether they are available as options differs
among machines/vehicles; for more information,
see the instruction manuals for the respective
machines/vehicles.
Eco-governor
Fuel injection pump
Actuator
Intake
Exhaust
EGR-Valve
CAN
OFF
E-ECU
Inj.Nozzle
Re-circulation
Rack position
sensor
Engine speed
sensor
CSD
ON
START
Key switch
Liner
Piston
EGR
Stop switch
Starting aid
Operator's console
Coolant temperature
sensor
Starter
Engine
Accelerator sensor
Figure 12-1
12-4
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Electronic control harness connections
ELECTRONIC CONTROL SYSTEM
ELECTRONIC CONTROL HARNESS CONNECTIONS
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ELECTRONIC CONTROL SYSTEM
12-6
Electronic control harness connections
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3TNV88F Service Manual
Section 13
ELECTRIC WIRING
Page
Electric Wiring Precautions .......................................................... 13-3
Electrical Wire Resistance ............................................................ 13-4
Battery Cable Resistance.............................................................. 13-5
Electrical Wire Sizes - Voltage Drop ............................................. 13-6
Conversion of AWG to European Standards................................. 13-7
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ELECTRIC WIRING
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Electric Wiring Precautions
ELECTRIC WIRING
PRECAUTIONS
Failure to follow these precautions may result in the
failure of an electrical component and the loss of
warranty coverage on that item as well as related
items. Make sure that all users read and
understand these precautions.
ELECTRIC WIRING
NOTICE
Reversing the battery cable connections at the
battery or on the engine will destroy the SCR diode
in the current limiter. This will cause the charging
system to malfunction and may cause damage to
the electrical harnesses.
NOTICE
Do not reverse the positive (+) and negative (-)
ends of the battery cable. The alternator diode and
stator coil will be damaged.
NOTICE
When the battery indicator goes out, it should not
come on again. The battery indicator only comes
on during operation if the alternator fails. However,
if an LED is used in the battery indicator, the LED
will shine faintly during normal operation.
NOTICE
Make sure that the combined total resistance of the
battery cable in both directions between the starter
motor and the battery is within the value indicated
in the Battery Cable Resistance chart in the Electric
Wiring Section of this manual. The starter motor will
malfunction and fail if the resistance is higher than
the specified value.
NOTICE
Removing the battery cables or the battery while
the engine is operating may cause damage to the
current limiter depending on the electrical
equipment being used. This situation could cause
loss of control of output voltage. The continuous
high voltage of 23 - 24 volts (for 5000 min-1 (rpm)
dynamo) will damage the current limiter and other
electrical equipment.
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ELECTRIC WIRING
Electrical Wire Resistance
ELECTRICAL WIRE RESISTANCE
AWG
Metric nominal mm²
Ohms/foot resistance
20
0.5
0.009967
18
0.8
0.006340
16
1.25
0.004359
14
2
0.002685
12
3
0.001704
10
5
0.001073
8
8
0.000707
6
15
0.000421
4
20
0.000270
2
30
0.000158
1
40
0.000130
0 (1/0)
50
0.000103
00 (2/0)
60
0.000087
000 (3/0)
85
0.000066
0000 (4/0)
100
0.000051
Wiring voltage drop should not exceed 5 % [0.05] × 12 Volts = 0.6 Volts.
Voltage drop = Current [Amps] × Length of wire [Feet] × Resistance per Foot 
Example:
Current draw of 100 Amps × 3 feet of 4 AWG wire
100 Amps × 3 Feet × 0.000270 = 0.08 Volts [Voltage drop]
13-4
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ELECTRIC WIRING
Battery Cable Resistance
BATTERY CABLE RESISTANCE
AWG
Maximum total battery cable length
(positive cable + negative cable + a*)
12 V starter motor output
mm²
Less than 2.68 HP (2 kW)
Greater than 2.68 HP (2 kW)
m
ft
m
ft
6
15
1.5
4.75
N/A
N/A
4
20
2.3
7.4
N/A
N/A
2
30
3.8
12.6
2.3
7.5
1
40
4.6
15.3
2.8
9.2
0 (1/0)
50
5.9
19.5
3.5
11.6
00 (2/0)
60
7.0
22.8
4.2
13.7
000(3/0)
85
9.3
30.5
5.6
18.3
0000 (4/0)
100
11.9
39.0
7.1
23.4
00000 (5/0)
125
N/A
N/A
8.3
27.3
000000 (6/0)
150
N/A
N/A
10.1
33.3
Note:
• Total allowable resistance of the complete battery cable circuit (positive cable + negative cable + a*)
(a*: Resistance () of a battery switch or other electrical equipment having high resistance).
• For starter motors of less than 2.68 HP (2 kW): the total resistance must be less than 0.002 .
For starter motors of greater than 2.68 HP (2 kW): the total resistance must be less than 0.0012 .
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ELECTRIC WIRING
Electrical Wire Sizes - Voltage Drop
ELECTRICAL WIRE SIZES - VOLTAGE DROP
Total
current
on circuit
in amps
12 Volts
Length of conductor from source of current to device and back to source (in feet)
10
15
20
25
30
40
50
60
70
80
90
100
110
120
130
140
150
160
170
Wire size (AWG)
5
18
16
14
12
12
10
10
10
8
8
8
6
6
6
6
6
6
6
6
10
14
12
10
10
10
8
6
6
6
6
4
4
4
4
2
2
2
2
2
15
12
10
10
8
8
6
6
6
4
4
2
2
2
2
2
1
1
1
1
20
10
10
8
6
6
6
4
4
2
2
2
2
1
1
1
0
0
0
2/0
25
10
8
6
6
6
4
4
2
2
2
1
1
0
0
0
2/0
2/0
2/0
3/0
30
10
8
6
6
4
4
2
2
1
1
0
0
0
2/0
2/0
3/0
3/0
3/0
3/0
4/0
4/0
4/0
4/0
40
8
6
6
4
4
2
2
1
0
0
2/0
2/0
3/0
3/0
3/0
50
6
6
4
4
2
2
1
0
2/0
2/0
3/0
3/0
4/0
4/0
4/0
60
6
4
4
2
2
1
0
2/0
3/0
3/0
4/0
4/0
4/0
70
6
4
2
2
1
0
2/0
3/0
3/0
4/0
4/0
80
6
4
2
2
1
0
3/0
3/0
4/0
4/0
90
4
2
2
1
0
2/0
3/0
4/0
4/0
100
4
2
2
1
0
2/0
3/0
4/0
24 Volts
5
18
18
18
16
16
14
12
12
12
10
10
10
10
10
8
8
8
8
8
10
18
16
14
12
12
10
10
10
8
8
8
6
6
6
6
6
6
6
6
15
16
14
12
12
10
10
8
8
6
6
6
6
6
4
4
4
4
4
2
20
14
12
10
10
10
8
6
6
6
6
4
4
4
4
2
2
2
2
2
25
12
12
10
10
8
6
6
6
4
4
4
4
2
2
2
2
2
2
1
30
12
10
10
8
8
6
6
4
4
4
2
2
2
2
2
1
1
1
1
40
10
10
8
6
6
6
4
4
2
2
2
2
1
1
1
0
0
0
2/0
50
10
8
6
6
6
4
4
2
2
2
1
1
0
0
0
2/0
2/0
2/0
3/0
60
10
8
6
6
4
4
2
2
1
1
0
0
0
2/0
2/0
3/0
3/0
3/0
3/0
70
8
6
6
4
4
2
2
1
1
0
0
2/0
2/0
3/0
3/0
3/0
3/0
4/0
4/0
80
8
6
6
4
4
2
2
1
0
0
2/0
2/0
3/0
3/0
3/0
4/0
4/0
4/0
4/0
90
8
6
4
4
2
2
1
0
0
2/0
2/0
3/0
3/0
4/0
4/0
4/0
4/0
4/0
100
6
6
4
4
2
2
1
0
2/0
2/0
3/0
3/0
4/0
4/0
4/0
13-6
3TNV88F Service Manual
3TNV88F_SVM_A4.book
7 ページ
２０１２年７月２６日
木曜日
午後６時４分
Conversion of AWG to European Standards
ELECTRIC WIRING
CONVERSION OF AWG TO EUROPEAN STANDARDS
Conductor size
(AWG)
Conductor diameter
(mm)
Conductor cross-sectional area
(mm2)
25
0.455
0.163
24
0.511
0.205
23
0.573
0.259
22
0.644
0.325
21
0.723
0.412
20
0.812
0.519
19
0.992
0.653
18
1.024
0.823
17
1.15
1.04
16
1.29
1.31
15
1.45
1.65
14
1.63
2.08
13
1.83
2.63
12
2.05
3.31
11
2.30
4.15
10
2.59
5.27
9
2.91
6.62
8
3.26
8.35
7
3.67
10.6
6
4.11
13.3
5
4.62
16.8
4
5.19
21.2
3
5.83
26.7
2
6.54
33.6
1
7.35
42.4
0 (1/0)
8.25
53.4
00 (2/0)
9.27
67.5
000(3/0)
10.40
85.0
0000 (4/0)
11.68
107.2
00000 (5/0)
13.12
135.1
000000 (6/0)
14.73
170.3
1.1 circular mil (CM) @ 0.0005067 mm2
3TNV88F Service Manual
13-7
3TNV88F_SVM_A4.book
8 ページ
２０１２年７月２６日
ELECTRIC WIRING
木曜日
午後６時４分
Conversion of AWG to European Standards
This Page Intentionally Left Blank
13-8
3TNV88F Service Manual
3TNV88F_SVM_A4.book
1 ページ
２０１２年７月２６日
木曜日
午後６時４分
3TNV88F Service Manual
Section 14
FAILURE DIAGNOSIS
Page
Special Service Tools.................................................................... 14-3
Troubleshooting By Measuring Compression Pressure ................ 14-4
Compression Pressure Measurement Method ........................ 14-4
Quick Reference Table For Troubleshooting ................................ 14-7
3TNV88F Service Manual
14-1
3TNV88F_SVM_A4.book
2 ページ
２０１２年７月２６日
木曜日
午後６時４分
FAILURE DIAGNOSIS
This Page Intentionally Left Blank
14-2
3TNV88F Service Manual
3TNV88F_SVM_A4.book
3 ページ
２０１２年７月２６日
木曜日
午後６時４分
Special Service Tools
FAILURE DIAGNOSIS
SPECIAL SERVICE TOOLS
For measuring compression pressure
YANMAR Gauge Set Part No. TOL-97190080
Compression
gauge kit
K0000849
Adapter for direct injection 2-valve cylinder head
YANMAR Adapter Part No. 119802-92950
130
K0000850
3TNV88F Service Manual
14-3
3TNV88F_SVM_A4.book
4 ページ
２０１２年７月２６日
FAILURE DIAGNOSIS
木曜日
午後６時４分
Troubleshooting By Measuring Compression Pressure
TROUBLESHOOTING BY
MEASURING COMPRESSION
PRESSURE
Compression pressure drop is one of the major
causes of increasing blow-by gas (engine oil
contamination or increased engine oil consumption
as a resultant phenomenon) or starting failure. The
compression pressure is affected by the following
factors:
1. Degree of clearance between the piston and
cylinder
4. Turn off the fuel supply valve in the fuel supply
line. Disconnect the fuel injection pump stop
solenoid at the connector. This prevents the fuel
injection pump from injecting fuel during
compression testing.
5. Before installing the compression gauge
((Figure 14-1, (1)) 2 valve engine,
(Figure 14-2, (1)) 4 valve engine) adapter,
crank the engine with the stop solenoid
disconnected for a few seconds to clear the
cylinder of any residual fuel.
2. Degree of clearance at the intake/exhaust valve
seat
6. Install a nozzle seat at the tip end of the
compression gauge adapter. Install the
compression gauge and the compression
gauge adapter at the cylinder to be measured.
3. Gas leak from the nozzle gasket or cylinder
head gasket
7. Crank the engine until the compression gauge
reading is stabilized.
The pressure will drop due to increased parts wear.
Pressure drop reduces the durability of the engine.
1
A pressure drop may also be caused by a
scratched cylinder or piston, dust entrance from the
dirty air cleaner element or a worn or broken piston
ring. Measure the compression pressure to
determine the condition of the engine.
Compression Pressure Measurement
Method
1. Warm up the engine.
2. Stop the engine. Remove the high-pressure fuel
injection lines as an assembly from the engine.
Figure 14-1
3. Remove the fuel injector from the cylinder to be
measured. See Removal of Fuel Injectors on
page 7-25.
NOTICE
Remove or install the high-pressure fuel injection
lines as an assembly whenever possible.
Disassembling the high-pressure fuel injection
lines from the retainers or bending any of the fuel
lines will make it difficult to reinstall the fuel lines.
14-4
3TNV88F Service Manual
3TNV88F_SVM_A4.book
5 ページ
２０１２年７月２６日
木曜日
午後６時４分
Troubleshooting By Measuring Compression Pressure
FAILURE DIAGNOSIS
1
Figure 14-2
8. After performing the compression check
remove the compression gauge and
compression gauge adapter from the cylinder.
9. Reinstall the fuel injector, high-pressure fuel
injection lines, and reconnect the stop solenoid.
See Reassembly of Fuel Injectors on
page 7-30.
10. Turn on the fuel supply valve and reconnect the
injection pump stop solenoid.
11. Prime the fuel system. Check for leaks. Test the
engine.
3TNV88F Service Manual
14-5
3TNV88F_SVM_A4.book
6 ページ
２０１２年７月２６日
FAILURE DIAGNOSIS
木曜日
午後６時４分
Troubleshooting By Measuring Compression Pressure
■ Standard compression pressure (reference value)
Compression pressure at 250 min-1 (rpm)
Deviation between cylinders
Standard
Limit
483 - 513 PSI
(3.33 - 3.53 MPa; 34 - 36 kgf/cm²)
384 - 414 PSI
(2.65 - 2.85 MPa; 27 - 29 kgf/cm²)
29 - 43 PSI
(0.2 - 0.3 MPa; 2 - 3 kgf/cm²)
■ Engine speed and compression pressure (use for reference)
569 psi
(40 Kgf/cm2)
(4 MPa)
498 psi
(35 Kgf/cm2)
427 psi
(30 Kgf/cm2)
(3 MPa)
356 psi
(25 Kgf/cm2)
284 psi
(20 Kgf/cm2)
(2 MPa)
200
250
300
350
400
Engine speed (min-1)
Figure 14-3
14-6
3TNV88F Service Manual
K0000802E01
3TNV88F_SVM_A4.book
7 ページ
２０１２年７月２６日
木曜日
午後６時４分
Quick Reference Table For Troubleshooting
FAILURE DIAGNOSIS
■ Measured value and troubleshooting
When the measured compression pressure is below the limit value, inspect each part by referring to the
table below.
No.
Item
Cause
Clogged element
1
Air cleaner element
Broken element
Defect at element seal portion
Corrective action
Clean the element.
Replace the element.
2
Valve clearance
Excessive or no clearance
Adjust the valve clearance.
3
Valve timing
Incorrect valve clearance
Adjust the valve clearance.
4
Cylinder head gasket
Gas leak from gasket
Retighten the cylinder head bolts to the
specified torque.
Intake/exhaust valve
Sticking valve
Replace the intake/exhaust valve.
Valve seat
Gas leak due to worn valve seat
Lap the valve seat.
or foreign matter trapped in valve
Replace the gasket.
5
Piston
6
Piston ring
Gas leak due to scratching or
wear
Perform honing and use an oversized part.
Cylinder
QUICK REFERENCE TABLE FOR TROUBLESHOOTING
The following table summarizes the general trouble symptoms and their causes. If any trouble symptom
occurs, take corrective action before it becomes a serious problem so as not to shorten the engine service
life.
3TNV88F Service Manual
14-7
3TNV88F_SVM_A4.book
8 ページ
２０１２年７月２６日
FAILURE DIAGNOSIS
木曜日
午後６時４分
Quick Reference Table For Troubleshooting
This Page Intentionally Left Blank
14-8
3TNV88F Service Manual
Engine not start (stall after serial combustion)
Engine not start (not even initial combustion)
ECU indicator lamp on just after key-on (2 seconds)
ECU indicator lamp not on just after key-on
3TNV88F Service Manual
Engine vibration isolating support
loose, damage



Open/close timing failure of
intake/exhaust valve


Wear of intake/exhaust valve guide
Gear backlash too big






Foreign material entered into
combustion chamber













Knocking noise at combustion too high






Lubricant consumption too much





Combustion noise uneven
Connecting rod bolt loose




Noise other than combustion from engine





Exhaust color
Engine vibration too big

Wear of crank pin metal and journal
metal
Reverse assembling of piston ring


Seizure of crank pin metal or bearing
parts
Closed gap position fault of piston ring


Wear of piston ring, piston or cylinder



Piston ring sticking or breakage
Cylinder head gasket blow-out

At work

Engine starts later then ever

Little
Intake/exhaust valve seizure
Much

Speed change by accelerator not available (constant speed)

Specified speed setting not available
Compression failure at valve seat
None

Poor acceleration

Return to low speed not smooth
Intake/exhaust valve clearance
incorrect
Cause
Hunting
Without load
Hunting
Exhaust
fume
Normal
Starter
rotates
White
Starter not
rotate
Black
Noise/vibration
Lubricant
Lubricant diluted with fuel



Lubricant mixed with water

Oil pressure too low (oil pressure lamp on)


Cooling
water


Overheated (water temperature lamp on)
Insufficient
engine output
Water temperature too low
Defective rotation control
Intake



Pressure down (air cleaner lamp on)
Engine stall
after start
Pressure up
Defective start
Exhaust
At work




White exhaust color
Symptoms and conditions of failures



Black exhaust color
Failure Diagnostic List
Engine system









Blow-by too much
Exhaust temperature up



Fuel consumption too much

Fuel
Electrics/electronics
See Valve face and valve seat on
page 6-24.
See Removal of intake/exhaust valves on
page 6-20.
See Removal of cylinder head on
page 6-19.
See Reassembly of pistons on
page 6-47.
Valve seat facing
Correction or replacement of
intake/exhaust valve
Gasket replacement
Piston ring replacement
Repair or replacement of faulty parts
14-9
See Inspection of valve guides on
page 6-23.
Measurement and replacement
See Measuring and Adjusting Valve
Clearance on page 6-30.
See Checking timing gear backlash on
page 6-34.
Gear mesh adjustment
Valve clearance adjustment
See Disassembly of Engine on
page 6-33.
See Torque for Bolts and Nuts on
page 6-10.
Tightening at specified torque
Disassembling and repair
See Inspection of crankshaft on
page 6-44.
See Reassembly of pistons on
page 6-47.
Correction of assembling
Measurement and replacement
See Reassembly of pistons on
page 6-47.
See Inspection of crankshaft on
page 6-44.
Correction of closed gap position
Repair or replacement
Honing work and usage of over-sized parts See Honing and Boring on page 6-46.
See Measuring and Adjusting Valve
Clearance on page 6-30
Referenced page number
FAILURE DIAGNOSTIC LIST
Valve clearance adjustment
Action
FAILURE DIAGNOSTIC LIST
Fuel mixed with water (oil-water separator lamp on)
3TNV88F Service Manual
Fuel filter contaminated too early
Failure Diagnostic List
Battery charge defect (charge lamp on)
午後６時４分
ECU indicator lamp flashing
２０１２年７月２６日 木曜日
ECU indicator lamp not on just after key-on (2 seconds)
9 ページ
Prescribed ECU control function not operate
3TNV88F_SVM_A4.book
Fuse meltdown, disconnection (repeated)
Engine not start (not even initial combustion)

None


Engine vibration too big
Noise other than combustion from engine
Combustion noise uneven
Knocking noise at combustion too high
Speed change by accelerator not available (constant speed)
Much
Little
Engine starts later then ever
Engine not start (stall after serial combustion)
ECU indicator lamp on just after key-on (2 seconds)
ECU indicator lamp not on just after key-on


Cooling
water
14-10
Excess filling into crankcase




Regulator valve fault


Lubricant filter clogged
Insufficient lubricant quantity



Insufficient discharge rate of trochoid
pump
Lubricant system leakage




Thermostat fault
Incorrect lubricant



Fan belt elongation
Water jacket cracks

Lubricant consumption too much

Lubricant diluted with fuel
Insufficient cooling water quantity
Specified speed setting not available
Exhaust color
Lubricant mixed with water

Poor acceleration
At work
Oil pressure too low (oil pressure lamp on)

Return to low speed not smooth
Lubricant
Overheated (water temperature lamp on)
Insufficient radiator cooling
Radiator super cooled
Hunting
Without load
Hunting
Exhaust
fume
Normal
Starter
rotates
White
Starter not
rotate
Black
Noise/vibration


Water temperature too low
Insufficient
engine output
Intake
Pressure down (air cleaner lamp on)
Defective rotation control
Pressure up
Engine stall
after start
Exhaust
At work



White exhaust color
Defective start
Black exhaust color
Symptoms and conditions of failures
Cause
Cooling water system
Lubricant system


Blow-by too much
FAILURE DIAGNOSTIC LIST
Exhaust temperature up



Fuel consumption too much

Fuel
Fuel mixed with water (oil-water separator lamp on)
午後６時４分
Electrics/electronics
Battery charge defect (charge lamp on)
木曜日
ECU indicator lamp flashing
２０１２年７月２６日
ECU indicator lamp not on just after key-on (2 seconds)
10 ページ
Prescribed ECU control function not operate
3TNV88F_SVM_A4.book
Fuse meltdown, disconnection (repeated)
Fuel filter contaminated too early
See Engine Oil Specifications on
page 4-17.
See Disassembly of Oil Pump on
page 9-7.
Usage of correct lubricant
Repair
Engine oil check
See Adding Engine Oil on page 4-18.
See Adding Engine Oil on page 4-18.
3TNV88F Service Manual
Replenishment of correct lubricant
See Disassembly of Oil Pump on
page 9-7.
See Disassembly of Engine Coolant
Pump on page 8-8.
Inspection or replacement
Cleaning, adjustment or replacement
See Check and adjust cooling fan V-belt
on page 5-9.
Adjustment of belt tension
See Replace engine oil and engine oil
filter on page 5-7.
See Disassembly of Engine Coolant
Pump on page 8-8.
Repair or replacement
Cleaning or replacement
See Engine Coolant System Check on
page 8-6.
Water leak inspection of cooling water
system
See Disassembly of Oil Pump on
page 9-7.
See Disassembly of Engine Coolant
Pump on page 8-8 or Check and adjust
cooling fan V-belt on page 5-9.
Thermostat replacement
or check for fan belt loose
Inspection and repair
See Disassembly of Engine Coolant
Pump on page 8-8.
Referenced page number
Thermostat replacement
Action
Failure Diagnostic List


Fuel pipe clogged, cracked
Insufficient fuel feeding to fuel injection
pump
Exhaust pipe clogged
3TNV88F Service Manual
Engine operation at high temperature
or high land
Air filter clogged
Sealing defect of fuel tank
Operation defect of CSD valve
Strainer at feed pump inlet clogged
Priming not available
Defective spray of fuel injection nozzle
Fuel injection quantity too much



Air entered into fuel system
Uneven injection quantity of fuel
injection pimp

ECU indicator lamp not on just after key-on
Fuel filter clogged
ECU indicator lamp on just after key-on (2 seconds)

Engine not start (not even initial combustion)
Water entered into fuel system
Incorrect fuel
Fuel injection pump with injection
timing excessively retarded
Fuel injection pump with injection
timing excessively advanced
Cause
Engine not start (stall after serial combustion)



Engine starts later then ever



None




Little

Much


Poor acceleration









Hunting
Return to low speed not smooth
Specified speed setting not available
Without load
At work




Hunting
Exhaust
fume
Exhaust color






Normal
Starter
rotates





White
Starter not
rotate







Black
Noise/vibration
Knocking noise at combustion too high


Combustion noise uneven






Engine vibration too big



Lubricant consumption too much


Lubricant
Cooling
water
Overheated (water temperature lamp on)


Water temperature too low
Lubricant mixed with water
Lubricant diluted with fuel
Noise other than combustion from engine
Insufficient
engine output
Intake


Pressure down (air cleaner lamp on)
Defective rotation control

Pressure up
Engine stall
after start
Exhaust
At work






White exhaust color
Defective start









Black exhaust color
Symptoms and conditions of failures

Blow-by too much
Failure Diagnostic List
Fuel system
Intake
Exhaust temperature up





Fuel consumption too much




Fuel



Fuel mixed with water (oil-water separator lamp on)
午後６時４分
Fuel filter contaminated too early


Electrics/electronics
Battery charge defect (charge lamp on)
木曜日
ECU indicator lamp flashing
２０１２年７月２６日
ECU indicator lamp not on just after key-on (2 seconds)
11 ページ
Prescribed ECU control function not operate
3TNV88F_SVM_A4.book
Fuse meltdown, disconnection (repeated)
Oil pressure too low (oil pressure lamp on)
Speed change by accelerator not available (constant speed)
See Drain fuel filter/water separator on
page 5-11.
See Clean fuel filter/water separator on
page 5-18.
See Priming the Fuel System on
page 4-16.
Drainage of fuel filter
Cleaning or replacement
Bleeding
See Testing of Fuel Injectors on
page 7-27.
See Fuel System Components on
page 7-9.
Inspection and adjustment
Valve in priming pump pinched dust
(disassembled cleaning)
Cleaning of exhaust pipe
Consideration of matching output
reduction with load
Cleaning of air filter
Check of fuel tank and cap, as well as
installation of
genuine parts
Replacing the pump
Replacement of CSD valve
See Clean air cleaner element on
page 5-16.
See Testing of Fuel Injectors on
page 7-27.
Inspection and adjustment
Cleaning of strainer
See Testing of Fuel Injectors on
page 7-27.
Inspection and adjustment
Check of fuel tank cock, fuel filter, fuel
pipe, fuel feed pump
14-11
See Diesel Fuel Specifications on
page 4-11.
Usage of correct fuel
Cleaning or replacement
See Checking and Adjusting Fuel
Injection Timing on page 7-20.
See Checking and Adjusting Fuel
Injection Timing on page 7-20.
Referenced page number
Inspection and adjustment
Inspection and adjustment
Action
FAILURE DIAGNOSTIC LIST
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None
Specified speed setting not available
Little
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At work
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Exhaust color
Knocking noise at combustion too high
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Combustion noise uneven
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Overheated (water temperature lamp on)
Oil pressure too low (oil pressure lamp on)
Lubricant mixed with water
Lubricant diluted with fuel
Lubricant consumption too much
Engine vibration too big
Noise other than combustion from engine
Speed change by accelerator not available (constant speed)
At work
Exhaust

Fuel
Electrics/electronics
-







14-12

Much
Intake
Exhaust temperature up
ECU faulty (ECU self diagnosis failure)

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Poor acceleration
Cooling
water
Fuel consumption too much

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


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
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Return to low speed not smooth
Lubricant
Fuel filter contaminated too early
ECU failure lamp disconnected
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Operation defect of rack actuator
(Level that ECU can’t detect)
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Engine not start (stall after serial combustion)
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Engine not start (not even initial combustion)

Engine starts later then ever
Rack position sensor signal error
(Level that ECU can’t detect)
Speed sensor signal error
(Cause of noise etc. that ECU can’t
detect)
Water temperature sensor signal error
(Error at which level ECU can’t detect)
Accelerator sensor signal error
(Error at which level ECU can’t detect)
The start assist relay may be faulty.
(Error of contact that ECU can’t detect)
Actuator relay fault
(Error of contact that ECU can’t detect)
Main relay fault
(Error other than contact sticking that
ECU can’t detect)
Failure, disconnection, short-circuit of
starter relay
Instantaneous interruption of key
switch
Key switch fault, disconnection
Battery voltage descent

Wiring short-circuit (insulator broken),
electric power load of added device too
big
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
ECU indicator lamp not on just after key-on

ECU indicator lamp on just after key-on (2 seconds)
Wiring disconnection
Alternator fault
Starter fault
Fuse meltdown, disconnection
Cause
Hunting
Without load
Hunting
Exhaust
fume
Normal
Starter
rotates
White
Starter not
rotate
Black
Noise/vibration
Water temperature too low
Insufficient
engine output
Pressure down (air cleaner lamp on)
Defective rotation control
Pressure up
Engine stall
after start
White exhaust color
Defective start
Black exhaust color
Symptoms and conditions of failures
Blow-by too much
FAILURE DIAGNOSTIC LIST
Fuel mixed with water (oil-water separator lamp on)
午後６時４分
Battery charge defect (charge lamp on)
木曜日
ECU indicator lamp flashing
２０１２年７月２６日
ECU indicator lamp not on just after key-on (2 seconds)
12 ページ


Prescribed ECU control function not operate
3TNV88F_SVM_A4.book
Electric system


Fuse meltdown, disconnection (repeated)
See Removal of Alternator on
page 11-10.
Monitor the accelerator sensor by the
diagnosis tool.
For harness inspection method, See
Failure Diagnosis on page 14-1.
Replace the ECU.
Check the movement of rack actuator by
the diagnosis tool.
Monitor the rack position sensor signal by
the diagnosis tool.
Monitor the engine rotational speed by
the diagnosis tool.
3TNV88F Service Manual
Replace the lamp.
Repair or replace the harness.
Repair or replacement of fuel injection
pump
Repair or replacement of fuel injection
pump
Cleaning or replacement of speed sensor
Repair or replacement of fuel injection
pump
Replacement of water temperature sensor Monitor the cooling water temperature by
the diagnosis tool.
Repair or replacement of accelerator
sensor
Replacement of start assist relay
Replacement of actuator relay
Repair or replacement of harness
Replacement of main relay
Repair or replacement of harness
Replacement of starter relay
For harness inspection method, See
Failure Diagnosis on page 14-1.
For harness inspection method, See
Failure Diagnosis on page 14-1.
Repair or replacement of harness
Key switch replacement
Key switch replacement
See Check battery on page 5-12.
Inspection and charging of battery
Inspection, repair or replacement of
harnesses
Review of added devices
Repair or replacement of harness
disconnection
See Starter Motor on page 10-8.
Repair or replacement of alternator
For harness inspection method, See
Failure Diagnosis on page 14-1.
Referenced page number
Repair or replacement of starter
Inspection and replacement of fuse
Repair or replacement of harness
Action
Failure Diagnostic List
ECU indicator lamp on just after key-on (2 seconds)
Engine not start (stall after serial combustion)
Engine starts later then ever

Engine vibration too big
Noise other than combustion from engine
Combustion noise uneven
Knocking noise at combustion too high
At work
Exhaust

Fuel
Electrics/electronics





3TNV88F Service Manual









Lubricant consumption too much
Malfunction by ECU self-diagnosis


Lubricant diluted with fuel




Lubricant mixed with water



Exhaust color
Oil pressure too low (oil pressure lamp on)

Little
At work
Overheated (water temperature lamp on)

Much
Intake
Exhaust temperature up



None


Specified speed setting not available

Poor acceleration
Cooling
water
Fuel consumption too much


Speed change by accelerator not available (constant speed)

Return to low speed not smooth
Lubricant
Fuel filter contaminated too early
Disconnection/short-circuit of rack
actuator relay
Main relay “OFF” not available

Disconnection/short-circuit of start
assist relay
ECU indicator lamp not on just after key-on



Engine not start (not even initial combustion)
Disconnection/short-circuit of CSD
solenoid valve
Disconnection/short-circuit of EGR
valve motor
CAN communication error
Engine over speed
Operation defect of rack actuator
Rack position sensor signal error
Speed sensor signal error
Disconnection/short-circuit of
accelerator sensor
Disconnection/short-circuit of water
temperature sensor
ECU control function operating
Cause
Hunting
Without load
Hunting
Exhaust
fume
Normal
Starter
rotates
White
Starter not
rotate
Black
Noise/vibration
Water temperature too low
Insufficient
engine output
Pressure down (air cleaner lamp on)
Defective rotation control
Pressure up
Engine stall
after start
White exhaust color
Defective start
Black exhaust color
Symptoms and conditions of failures
Blow-by too much
午後６時４分
Fuel mixed with water (oil-water separator lamp on)
木曜日
Battery charge defect (charge lamp on)
Failure Diagnostic List
Engine stop or operation limits by ECU failure diagnosis function
ECU indicator lamp flashing
２０１２年７月２６日
ECU indicator lamp not on just after key-on (2 seconds)
13 ページ

Prescribed ECU control function not operate
3TNV88F_SVM_A4.book
Fuse meltdown, disconnection (repeated)
Check the causes of engine stop or
starter restraint by a diagnosis tool.
Referenced page number
For harness inspection method, See
Failure Diagnosis on page 14-1.
For harness inspection method, See
Failure Diagnosis on page 14-1.
Repair or replacement of harness
Repair or replacement of fuel injection
pump
Repair or replacement of harness
Repair or replacement of fuel injection
pump
ECU Replacement
Repair or replacement of harness
Relay replacement
Relay replacement
Repair or replacement of harness
Relay replacement
Repair or replacement of harness
Replacement of CSD valve solenoid
Repair or replacement of harness
Replacement of EGR valve
Repair or replacement of harness
ECU Replacement
14-13
For harness inspection method, See
Failure Diagnosis on page 14-1.
For harness inspection method, See
Failure Diagnosis on page 14-1.
For harness inspection method, See
Failure Diagnosis on page 14-1.
For harness inspection method, See
Failure Diagnosis on page 14-1.
For harness inspection method, See
Failure Diagnosis on page 14-1.
For harness inspection method, See
Failure Diagnosis on page 14-1.
Repair or replacement of harness
Repair or replacement of fuel injection
pump
Check operating machine’s driving.
Check speed sensor signal.
For harness inspection method, See
Failure Diagnosis on page 14-1.
Repair or replacement of harness
Replacement of accelerator sensor
Repair or replacement of harness
For harness inspection method, See
Replacement of water temperature sensor Failure Diagnosis on page 14-1.
Not failure
Implement regular usage
Action
FAILURE DIAGNOSTIC LIST
14 ページ
２０１２年７月２６日
14-14
FAILURE DIAGNOSTIC LIST
3TNV88F_SVM_A4.book
木曜日
午後６時４分
This Page Intentionally Left Blank
3TNV88F Service Manual
Failure Diagnostic List
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