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HYDRAULIC EXCAVATOR

MAINTENANCE SPECIFICATIONS
SHOP SK35SR-5
MANUAL model

INDEX
1 SPECIFICATIONS SECTION

SYSTEM
2 MAINTENANCE SECTION
3 SYSTEM SECTION
4 DISASSEMBLY SECTION

DISASSEMBLING
5 TROUBLESHOOTING
6 ENGINE SECTION
E / G TROUBLESHOOTING

Book Code No.S5PX0015E01


0-1
EUR INDEX SK35SR-5
Book Code No. Index
Title
Distribution Year–Month No. 33 1
S5PA0105E01

MAINTENANCE SPECIFICATIONS
OUTLINE 1
2013-12
S5PX0215E01
SPECIFICATIONS 2
2013-12
S5PX0309E01
ATTACHMENT DIMENSIONS 3 2
2013-12 42 34
S5PW1131E03
TOOLS 11
2013-12
S5PW1237E01 STANDARD MAINTENANCE 12
2013-12 TIME SCHEDULE
S5PX1309E01 MAINTENANCE STANDARD 13
2013-12 AND TEST PROCEDURE
43 11 3
_ 51

S5PX2215E01
HYDRAULIC SYSTEM 22
2013-12
S5PW2337E01
SYSTEM
ELECTRIC SYSTEM 23
2013-12
S5PX2415E01
44 12
COMPONENTS SYSTEM 24
2013-12
_

S5PA3105E01 13
DISASSEMBLING
DISASSEMBLING

31
2013-12 & ASSEMBLING
S5PX3209E01
ATTACHMENT 32
2013-12
S5PX3315E01
UPPER STRUCTURE 33
2013-12
S5PX3409E01 22
TRAVEL SYSTEM 34
2013-12
_
E / G TROUBLESHOOTING

46
S5PW4231E02
HYDRAULIC SYSTEM 42
2013-12
S5PW4331E02
2013-12
ELECTRICAL SYSTEM 43 31 23
S5PW4431E02
ENGINE 44
2013-12
S5PW5131E02
2013-12
ENGINE 51
_
32 24
_

PX15-22809~ APPLICABLE MACHINES

0-5
[2. SPECIFICATIONS]


2. SPECIFICATIONS
TABLE OF CONTENTS

2.1 COMPONENTS NAME …………………………………………………………………………………………2-3


2.2 MACHINE DIMENSIONS ………………………………………………………………………………………2-4
2.3 SPECIFICATIONS AND PERFORMANCE ……………………………………………………………………2-5
2.4 MACHINE & COMPONENTS WEIGHT (DRY) ………………………………………………………………2-7
2.5 TRANSPORTATION………………………………………………………………………………………………2-9
2.6 TYPE OF CRAWLER SHOES …………………………………………………………………………………2-12
2.7 TYPE OF BUCKET ………………………………………………………………………………………………2-13
2.8 ENGINE SPECIFICATIONS ……………………………………………………………………………………2-14
2.8.1 SPECIFICATIONS …………………………………………………………………………………………2-14
2.8.2 ENGINE PERFORMANCE CURVE ………………………………………………………………………2-15

Book Code No. S5PX0215E01

2-1
[2. SPECIFICATIONS]

Issue Date of Issue Applicable Machines Remarks


S5PX0215E01
First Edition December, 2013 SK35SR-5 : PX15-22809~
(EUR)

2-2
[2. SPECIFICATIONS]

2.1 COMPONENTS NAME

2-3
[2. SPECIFICATIONS]

2.2 MACHINE DIMENSIONS

(1) SK35SR-5 (CANOPY)

(2) SK35SR-5 (CAB)

2-4
[2. SPECIFICATIONS]

2.3 SPECIFICATIONS AND PERFORMANCE

SPEED AND GRADEABILITY


Model SK35SR-5
Applicable Machines PX15-22809~
Shoe Type Rubber shoe Iron shoe (OPT)
-1


Slewing Speed min {rpm} 8.9 (8.9)
Low (1st) High (2nd) Low (1st) High (2nd)
Travel Speed km/h (mph)
2.5 4.5 2.5 4.4
Gradeability % (degree) 58(30)

ENGINE
Model (YANMAR) 3TNV88-BPYB
Type Water-cooled, 4-cycle type Swirl chamber type diesel engine
Number of cylinders-Bore X Stroke 3 - 88 dia. mm X 90 mm (3.46 in X 3.54 in)
Total Displacement L 1.642 (100.2 cu-in)
Output Rating kW/min-1 {PS/rpm} 21.2/2,400 (29/2,400)
-1
Maximum Torque N-m/min (lbf-ft/rpm) 98.0/1,440 (72.3/1,440)
Starting Motor V X kW 12 X 1.7
Generator V X A 12 X 55

HYDRAULIC COMPONENTS
Hydraulic Pump Variable displacement axial piston + gear pump
Hydraulic Motor Axial piston
Hydraulic Motor w/Reducer (Travel) 2-Axial piston, 2-Speed motor
Control Valve 10-spool multiple control valve
Cylinder (Boom, Arm, Swing, Bucket, Dozer) Double action cylinder
Return Filter Safety valve containing/Filter Type (30μ)

SIDE DIGGING & DOZER


Type Boom swing by hydraulic cylinder
Right 60 degrees
Boom Swing Angle
Left 70 degrees
Stroke of Dozer (above/below) mm (in) 540 / 440 (21.3/17.3)

2-5
[2. SPECIFICATIONS]

WEIGHT
Rubber shoe Iron shoe
Machine Weight kg (lb)
3,580 (7890) 3,700 (8160)
Upper slewing body kg (lb) 1,900 (4190) <--
Travel system kg (lb) 1,140 (2520) 1,260 (2780)
Attachment
kg (lb) 460 (1020)
(Boom+STD Arm+STD Bucket)
Oil & Water kg (lb) 80 (175)

This figure is calculated with Japanese standard bucket.

2-6
[13. MAINTENANCE STANDARD AND TEST PROCEDURE]

13. MAINTENANCE STANDARD AND


TEST PROCEDURE
TABLE OF CONTENTS

13.1 HOW TO USE MAINTENANCE STANDARDS AND PRECAUTIONS …………………………………13-3


13.2 PERFORMANCE INSPECTION STANDARD TABLE ……………………………………………………13-5
13.2.1 STANDARD VALUE TABLE ……………………………………………………………………………13-5
13.3 MEASURING ENGINE SPEED ………………………………………………………………………………13-7
13.3.1 ENGINE SPEED MEASUREMENT ……………………………………………………………………13-7
13.4 MEASURING HYDRAULIC OIL PRESSURE ………………………………………………………………13-9
13.4.1 STANDARD FOR HYDRAULIC OIL PRESSURE MEASUREMENT ……………………………13-9
13.4.2 PRESSURE MEASUREMENT AND ADJUSTMENT …………………………………………………13-9
13.5 MEASURING TRAVEL PERFORMANCES …………………………………………………………………13-13
13.5.1 TRAVEL ……………………………………………………………………………………………………13-13
13.5.2 TRAVEL DEVIATION ……………………………………………………………………………………13-13 13
13.5.3 MOVEMENT DRIFT DUE TO GRAVITY ………………………………………………………………13-14
13.5.4 DRAIN RATE OF TRAVEL MOTOR …………………………………………………………………13-14
13.6 MEASURING SLEW PERFORMANCES ……………………………………………………………………13-16
13.6.1 SLEW TIME…………………………………………………………………………………………………13-16
13.6.2 OVERRUN WHEN SLEWING STOPS …………………………………………………………………13-16
13.6.3 SLEW DRIFT DUE TO GRAVITY………………………………………………………………………13-16
13.6.4 DRAIN RATE OF TRAVEL MOTOR …………………………………………………………………13-17
13.7 MEASURING ATTACHMENT OPERATING PERFORMANCES …………………………………………13-18
13.7.1 CYLINDER SPEED ………………………………………………………………………………………13-18
13.7.2 GRAVITY DRIFT OF CYLINDERS ……………………………………………………………………13-19
13.8 MEASURING SLEW BEARING PERFORMANCES ………………………………………………………13-20
13.8.1 SLEW BEARING-BUCKET TIP PLAY …………………………………………………………………13-20
13.8.2 SLEW BEARING PLAY …………………………………………………………………………………13-20
13.9 MEASURING CRAWLER TENSION …………………………………………………………………………13-21
13.9.1 CRAWLER TENSION ……………………………………………………………………………………13-21

Book Code No. S5PX1309E01

13-1
[13. MAINTENANCE STANDARD AND TEST PROCEDURE]

Issue Date of Issue Applicable Machines Remarks


S5PX1309E01
First Edition September, 2013 SK35SR-5 : PX15-22809~
(NA)

December, 2013 SK35SR-5 : PX15-22809~


(EUR)

13-2
[13. MAINTENANCE STANDARD AND TEST PROCEDURE]

13.1 HOW TO USE MAINTENANCE STANDARDS AND


PRECAUTIONS
(1) Application
1. For New Machine;
This manual is to be used to check the actual performance and functions of the machine
compared with the PERFORMANCE STANDARDS.
2. At Specific Self-Inspection (as per LOCAL RULES);
The maintenance standards are used to make them as the criteria to determine the time for
reconditioning, adjustment and replacement.
3. At Deterioration of Performance;
This manual is of the criteria of safe and economical judgment whether the deterioration of
performance on the machine would be caused by any faults or normal deterioration due to
machine operation for a long period.
4. For Replacement of Major Components;
This manual is of the standard to determine the time for replacement to recover the performance
of major components such as pump, etc.

(2) Terminology
1. Standard Values :
These are of the standard values to assemble and regulate a new machine. Where special notes
are not given, these values are based on the machine with standard structure (the machine with
standard attachments and shoes).
2. Standard Values for Repair :
These are of the values at which the reconditioning is required.
In order to ensure the performance and safety, it is strictly prohibited to use the machine with the 13
parts and components being over the standard values.
3. Serviceability Limit :
This is of the service limit for each part and component at which the reconditioning is impossible
and they must be replaced to new ones.
All the parts and components which are estimated to exceed the serviceability limit up to the next
periodical inspection and maintenance, should be also replaced to new ones.
The machine operation with the parts and components which have exceeded the serviceability limit,
causes increase of troubles and down time of the machine, and also causes safety problems.

(3) Precautions for Judgment :


1. Evaluation for Measured Data :
It is inevitable some variation on the measured data due to differences between measuring
conditions, peculiar variability on a new machine, old and new versions of the machine and
measuring characteristics.
The judgment for the measured data should be comprehensively conducted based on the extent of
level of the measured data, instead of mere comparison with the standard values.
2. Determination for Reconditioning, Adjustment or Replacement :
There are two kinds of deterioration of machine performance; one is due to normal wear with
time elapsing of operation, and the other is recoverable to the standard values with the adjustment
for pressure, etc.
Therefore, the determination for reconditioning, adjustment or replacement should be conducted
taking various factors into consideration such as operating hours, working conditions and
maintenance conditions of the machine, so that the machine is able to be operated at the
optimum performance level.

13-3
[13. MAINTENANCE STANDARD AND TEST PROCEDURE]

(4) Other Precautions


1. Parts with Aging Effect :
The rubber products such as hydraulic hoses, O-rings, oil seals, etc. are deteriorated with the
aging effect. It is necessary to replace them to new ones at periodical intervals or at every
overhaul.
2. Parts required Periodical Replacement :
It is recommendable to designate the important hoses critical to secure the safety as Very
Important Parts (V.I.P.), and periodically replace with new ones.
3. Inspection & Replacement of Lubricants :
It is necessary for the user of the machine to fully familiarize himself with the procedures and
precautions to handle the machine in safe and carry out the maintenance, as well as the
procedures for inspection and lubrication. Refer to the OPERATION & MAINTENANCE MANUAL
as well.

13-4
[13. MAINTENANCE STANDARD AND TEST PROCEDURE]

13.2 PERFORMANCE INSPECTION STANDARD TABLE

13.2.1 STANDARD VALUE TABLE

13

*1. The pressure for slew is controlled by the relief valve attached to the slew motor.
*2. Reference value for checking of pressure
(tighten up the adjusting nut of main relief valve. Refer to item 13.4.2.1)

13-5
[13. MAINTENANCE STANDARD AND TEST PROCEDURE]

13-6
[13. MAINTENANCE STANDARD AND TEST PROCEDURE]

13.3 MEASURING ENGINE SPEED

13.3.1 ENGINE SPEED MEASUREMENT


(1) Measuring Instruments
1. Diesel Speedometer (Measuring engine
speed by means of applying a pick-up to
one of injection pipes)
2. Surface Thermometer (Measuring the
surface temperature getting contact of the
probe with the surface of hydraulic oil tank
and radiator)

Engine Speed measurement (The above figure


shows concept)

(2) Engine Warming up Operation


Start up the engine, and make the coolant
temperature within the range of 60 to 90C
degrees (140 to 194F degrees).
Check the coolant temperature with the coolant
thermometer on the monitor panel. The white 13
color zone shows approx. 67 to 105C degrees
(153 to 221F degrees) of temperature range.
Therefore, when the indicator is located at
around center of the white zone, it is suitable
for the engine operation.

(3) Engine Speed Measurement


1. Apply the pick up of speedometer to one of convenient injection pipes. (Refer to Fig. "Engine
Speed measurement")
2. Measure the engine speed at idling with no load, and compare it to the figure in the STANDARD
VALUE TABLE.

13-7
[13. MAINTENANCE STANDARD AND TEST PROCEDURE]

(4) Speed Adjustment


1. Low / High Idling Speed is low ;
The proper engine speed is obtained with
the length of accelerator wire as shown in
the right sketch. When the engine speed
is lower than the standard speed, adjust
the length of wire with loosening the
capscrew (9) of throttle lever side.

DETAIL Z [WITH DECEL]

Accelerator wire adjustment

However, if the proper high idling speed is not obtainable, consult it with the engine manufacturer.

13-8
[13. MAINTENANCE STANDARD AND TEST PROCEDURE]

13.4 MEASURING HYDRAULIC OIL PRESSURE

13.4.1 STANDARD FOR HYDRAULIC OIL PRESSURE MEASUREMENT


(1) Hydraulic Instruments
-6.86 MPa (1000 psi) pressure gauge : 1 set
-49 MPa (7100 psi) pressure gauge : 3 sets
-Surface Thermometer : 1 set
-Pressure Measuring Kit and Oil Analyzing
Equipment : 1 set
(2) Measuring cleanliness of hydraulic oil

After releasing air in the hydraulic oil tank, open the cover and sample oil in the hydraulic tank, and
measure with the instrument for analysis. If the measured value is over the standard value, replace the
return filter and/or change the hydraulic oil.

13.4.2 PRESSURE MEASUREMENT AND ADJUSTMENT


13.4.2.1 MAIN CIRCUIT PRESSURE
(1) Measuring Conditions
Engine speed : High idling
Hydraulic oil temperature : 50 to 60C degrees 13
(122 to 140F degrees)
Coolant temperature (on radiator surface) :
60 to 90C degrees (140 to 194F degrees)

13-9
[13. MAINTENANCE STANDARD AND TEST PROCEDURE]

(2) Pressure Measuring Procedures


1. After releasing pressure in the hydraulic oil
tank, and setting a 49 MPa (7100 psi)
pressure gauge to either of pressure
detecting ports (G1, G2 or G3, PF1/4 with
plug), operate the circuit to be measured to
measure the relief pressure.
2. When the main relief pressure is being
within the standard range, the measurement
for the overload relief pressure may be
omitted.
3. If the main relief pressure is lower than the
standard range, tighten up the main relief
valve by half turn [pressure increase by
12.2 MPa (1770 psi)], then measure the
Main hydraulic oil pressure measurement (1/2)
pressure at overload relief valve.
4. After adjustment for the overload relief
pressure, return back the main relief
pressure within the standard range.

Main hydraulic oil pressure measurement (2/2)

(3) Pressure Adjustment


1. Control Valve : Main Relief Valve and Overload Relief Valve
a. Loosen the lock nut (2), and adjust the
setting pressure turning the setscrew (1).
Roughly with one full turn :
Main relief valve & Overload relief valve :
Approx. 12.2 MPa (1770 psi)
CW turning : Increasing setting pressure
CCW turning : Decreasing setting pressure
b. After the adjustment, tighten up the lock
Relief valve
nut holding the setscrew not to turn around.
c. Again activate the relief valve to check the
stable setting pressure.
Tightening torque for nut (2) : 19.6 N-m
(14.5 lbf-ft)

13-10
[13. MAINTENANCE STANDARD AND TEST PROCEDURE]

2. Slewing Motor : Relief Valve


a. Loosen the lock nut (2). Then adjust the
setting pressure turning the setscrew (1).
Roughly with one full turn :
Approx. 9.8 MPa (1420 psi)
CW turning : Increasing setting pressure
CCW turning : Decreasing setting pressure
b. After the adjustment, tighten up the lock Relief valve (Slewing motor)
nut holding the setscrew not to turn around.
Tightening torque for nut (2) :
34.3 N-m (25.3 lbf-ft)

13.4.2.2 PILOT CIRCUIT PRESSURE


(1) Measuring Conditions
Engine : High idling
Hydraulic oil temp. : 50 to 60C degrees
(122 to 140F degrees)
Coolant temp. : 60 to 90C degrees
(140 to 194F degrees)
at radiator surface
(2) Measurement
Releasing pressure in the hydraulic oil
tank of hydraulic system, and setting a 6.86
MPa (1000 psi) pressure gauge to the
pressure detecting port (G4, PF 1/4 with
plug), measure the pilot relief pressure. 13

Pilot oil pressure measurement

Pressure Detecting Port


Relief Valve
Port Location Size
G4 PF1/4 PR1

13-11
[13. MAINTENANCE STANDARD AND TEST PROCEDURE]

(3) Pressure Adjustment


Adjust it with the relief valve attached to the solenoid valve.

1. Loosen the lock nut (2), then turn the


setscrew (1) to adjust the set pressure.
CW screwing : Set pressure is increased.
CCW screwing : Set pressure is decreased.
2. After the adjustment, lock the setscrew
with the lock nut holding the setscrew not
to allow its turning.
3. Again actuate the relief valve, and verify
that the set pressure is being stable.
Tightening Torque :
Lock Nut (2) : 7.8 N-m (5.8 lbf-ft)
Relief valve (PR1) : 44 N-m (32 lbf-ft) Relief valve
Capscrew (3) : 7.8N-m (5.8 lbf-ft)

13-12
[13. MAINTENANCE STANDARD AND TEST PROCEDURE]

13.5 MEASURING TRAVEL PERFORMANCES

TEST PROCEDURES
Measure 3-time each.
Apply average data of the above for judgement.

13.5.1 TRAVEL
(1) Travel Speed (5 Revolutions)
・ Engine : High Idle
・ Hydraulic Oil Temp. : 50 to 60C degrees
(122 to 140F degrees)
・ Measurement Posture : Machine Body is
raised using both hoe attachment and
dozer blade.
・ Set crawler shoes in motion. Starting after
one full revolution, measure the time
required for 5 revolutions. (To measure
speed after it has stabilized.)

(2) Travel Speed (10 m)


・ Engine : Rated r.p.m.
・ Hydraulic Oil Temp. : 50 to 60C degrees
(122 to 140F degrees) 13
・ Measurement Posture : Travel Posture
・ Set machine in motion. Starting after a
running of 5 meters, measure the time
required to travel 10 meters. Do this on
level and hard ground.
・ Travel Posture :
Fully extend the arm and bucket cylinders
and place the hoe attachment so that its
lowest part is even with the machine's
minimum ground clearance level. The hoe
attachment must be in a no-load and the
dozer blade must not touch the ground.

13.5.2 TRAVEL DEVIATION


・ Engine : Rated r.p.m.
・ Hydraulic Oil Temp. : 50 to 60C degrees
(122 to 140F degrees)
・ Measurement Posture : Travel Posture
・ Measure the deviation " X " at the point
of half of 10 m (32.8 ft) travel after 5 m
preliminary running. Measure on level and
hard ground.

13-13
[13. MAINTENANCE STANDARD AND TEST PROCEDURE]

13.5.3 MOVEMENT DRIFT DUE TO GRAVITY


Measure the movement distance of machine on a slope due to machine's own weight, holding the
machine for 5 minutes on the slope.

Measuring Conditions :

・ Engine : Stopped
・ Hydraulic Oil Temp. : 50 to 60C degrees
(122 to 140F degrees)
・ Gradient : 15° (Approx. 1/3.73)
・ Machine posture : Fully extending the
boom, arm and bucket cylinders, and fully
retracting the dozer cylinder.

13.5.4 DRAIN RATE OF TRAVEL MOTOR


(1) Preparation
1. Apply stopper pins for both travel
sprockets of left and right.
2. Stop the engine, and release air in the
hydraulic oil tank.
3. Connect a hose to the drain port of travel
motor, and receive the drained oil in a
container.
4. Apply a plug to the drain piping at tank
side.

Make sure of the rotating direction of travel motor referring to the figure. Otherwise, the rib "A" may be
broken by the stopper pin.

13-14
[13. MAINTENANCE STANDARD AND TEST PROCEDURE]

(2) Measurement :
・ Engine : At rated speed
・ Hydraulic oil temp. : 50 to 60C
degrees(122 to 140F degrees)
・ Machine posture : Locking the traveling,
and allowing relief on the travel motor
・ Measure the drained volume of oil for 30
seconds of relief.

13

13-15
[13. MAINTENANCE STANDARD AND TEST PROCEDURE]

13.6 MEASURING SLEW PERFORMANCES

TEST PROCEDURES
Measure 3-time each.
Apply average data of the above for judgement.

13.6.1 SLEW TIME


・ Engine : High Idle
・ Hydraulic Oil Temp. : 50 to 60C
degrees(122 to 140F degrees)
・ Measurement Posture :
Completely retract the arm cylinder, fully
extend the bucket cylinder and place so
that boom foot pin and bucket pin are at
matching height. Place the dozer blade on
the ground.
・ With the hoe attachment in a no-load, drive
1 rotation, then measure the time required
for the next 2 rotations.

13.6.2 OVERRUN WHEN SLEWING STOPS


・ Engine : High Idle
・ Hydraulic Oil Temp. : 50 to 60C degrees
(122 to 140F degrees)
・ Measurement Posture :
Same as that for measuring slew time.

・ Prior to measuring, draw matching marks on the outer race of the slew bearing and lower frame
at exactly 180 degrees slew from the starting point. Then with the hoe attachment in a no-load,
slew 180 degrees from starting point. At which point return the operating lever to neutral.
Measure the distance between the position marks and the point the hoe attachment stops.

13.6.3 SLEW DRIFT DUE TO GRAVITY


・ Engine : Stopped
・ Hydraulic Oil Temp. : 50 to 60C degrees
(122 to 140F degrees)
・ Gradient : 15° (Approx. 1/3.73)
・ Measurement Posture :
Same as that for measuring slew time.
・ Slew the upper slewing structure and stop
at right angle to the slope, then draw
matching marks on the slew bearing's outer
race and the lower frame. Then measure
the distance that develops between the
marks after 5 minutes. Measure for both
RH and LH directions.

13-16
[13. MAINTENANCE STANDARD AND TEST PROCEDURE]

13.6.4 DRAIN RATE OF TRAVEL MOTOR


(1) Preparation
1. Stop the engine, and release air inside the
hydraulic oil tank.
2. Disconnect the slew motor drain hose at
the return side to the hydraulic oil tank.
Then receive the drain oil to a container.
Install plug on bore of tank after removing
drain hose.

(2) Measurement :
・ Engine : At rated speed
・ Hydraulic oil temp. : 50 to 60C degrees
(122 to 140F degrees)
・ Machine posture :
Pushing a fixture with the side of bucket,
operating the engine.
・ Measure the drained volume of oil for 30
seconds relieving at full stroke of the
slewing operation.
13

13-17
[13. MAINTENANCE STANDARD AND TEST PROCEDURE]

13.7 MEASURING ATTACHMENT OPERATING PERFORMANCES

TEST PROCEDURES
Measure 3-time each.
Apply average data of the above for judgement.

13.7.1 CYLINDER SPEED


(1) Boom Cylinder Speed
・ Engine : High Idle
・ Hydraulic Oil Temp. : 50 to 60C degrees
(122 to 140F degrees)
・ Measurement Posture : Completely retract
the arm cylinder, fully extend the bucket
cylinder and place the dozer blade on the
ground.
・ Then measure the time required for the
bucket to reach its highest point (lowest
point) from its lowest point (highest point)
placing on the ground. (Do not include the
cushioning time.)

(2) Arm Cylinder Speed


・ Engine : High Idle
・ Hydraulic Oil Temp. : 50 to 60C
degrees(122 to 140F degrees)
・ Measurement Posture : Completely retract
the arm cylinder, fully extend the bucket
cylinder, position the arm horizontally and
place the dozer blade on the ground.
・ Then measure the time required for the
arm cylinder to completely retract (extend)
from a fully extended state (retracted state).

(3) Bucket Cylinder Speed


・ Engine : High Idle
・ Hydraulic Oil Temp. : 50 to 60C
degrees(122 to 140F degrees)
・ Measurement Posture : Completely retract
the arm cylinder, position the arm
horizontally and place the dozer blade on
the ground.
・ Then measure the time required for the
bucket cylinder to completely retract
(extend) from a fully extended state
(retracted state).

13-18
[13. MAINTENANCE STANDARD AND TEST PROCEDURE]

(4) Swing Cylinder Speed


・ Engine : High Idle
・ Hydraulic Oil Temp. : 50 to 60C
degrees(122 to 140F degrees)
・ Measurement Posture : Same as that for
measuring slew time.
・ While swinging the boom left (right) to
right (left), measure the time required for a
full stroke each way.

(5) Dozer Cylinder Speed


・ Engine : High Idle
・ Hydraulic Oil Temp. : 50 to 60C
degrees(122 to 140F degrees)
・ Measurement Posture : Using the hoe
attachment lift up the dozer blade side.
・ Then, up and down the dozer blade with
full stroke, measure the time required per
stroke in each direction.

13.7.2 GRAVITY DRIFT OF CYLINDERS


(1) Boom, Arm, Bucket, Dozer, Bucket Tip
・ Engine : Stopped 13
・ Hydraulic Oil Temp. : 50 to 60C
degrees(122 to 140F degrees)
・ Measurement Posture : Completely retract
the dozer and arm cylinders, fully extend
the bucket cylinder and position the bucket
pin to the same height as the boom foot
pin.
・ Maintain the position for 10 minutes then
measure the change of rod length and
distance of the bucket tip.

(2) Swing Cylinder


・ Engine : Stopped
・ Hydraulic Oil Temp. : 50 to 60C degrees
(122 to 140F degrees)
・ Gradient : 15° (Approx. 1/3.73)
・ Measurement Posture :
Same as that for measuring slew time.
・ Slew the upper slewing structure and stop
at right angle to the slope, then measure
the change in rod length after 5 minutes.

13-19
[13. MAINTENANCE STANDARD AND TEST PROCEDURE]

13.8 MEASURING SLEW BEARING PERFORMANCES

TEST PROCEDURES
Measure 3-time each.
Apply average data of the above for judgement.

13.8.1 SLEW BEARING-BUCKET TIP PLAY


・ Measurement Posture : Completely retract
the arm cylinder and fully extend the
bucket cylinder.
・ Move the tips of the bucket teeth from side
to side (left and right) and measure the
play.

13.8.2 SLEW BEARING PLAY


(1)
Attach a dial gauge to the bottom face of the
slew bearing's outer-race located in front of the
upper slewing structure.

(2)
Raise the crawler on one side off the ground
and set the dial gauge to zero.

(3)
Then raise the opposite crawler and read the
dial gauge.

13-20
[13. MAINTENANCE STANDARD AND TEST PROCEDURE]

13.9 MEASURING CRAWLER TENSION

13.9.1 CRAWLER TENSION


・ Raise the machine completely off the
ground using the hoe attachment and dozer
blade.
Then measure the distance (of sag)
between the center point on the crawler
frame and top of the crawler shoe.

In the case of rubber crawlers, measurements should be taken with setting the joint ("M" or "∞"
mark) in the top center position

13

13-21
[13. MAINTENANCE STANDARD AND TEST PROCEDURE]

13-22
[22. HYDRAULIC SYSTEM]

22. HYDRAULIC SYSTEM


TABLE OF CONTENTS

22.1 SUMMARY ………………………………………………………………………………………………………22-3


22.1.1 FUNCTION AND FEATURES OF HYDRAULIC CIRCUIT …………………………………………22-3
22.2 HYDRAULIC CIRCUITS AND COMPONENT MODELS …………………………………………………22-4
22.2.1 STANDARD SPECIFICATION……………………………………………………………………………22-5
22.2.2 ROTARY SPECIFICATION ………………………………………………………………………………22-6
22.3 HYDRAULIC CIRCUIT OPERATION ………………………………………………………………………22-8
22.3.1 COLOR CODING STANDARD FOR HYDRAULIC …………………………………………………22-8
22.3.2 NEUTRAL CIRCUIT ………………………………………………………………………………………22-8
22.3.3 TRAVEL CIRCUIT ………………………………………………………………………………………22-10
22.3.4 SLEW OPERATING CIRCUIT …………………………………………………………………………22-12
22.3.5 BUCKET OPERATING CIRCUIT ………………………………………………………………………22-14
22.3.6 BOOM OPERATING CIRCUIT …………………………………………………………………………22-16
22.3.7 ARM OPERATING CIRCUIT ……………………………………………………………………………22-18
22.3.8 SWING OPERATING CIRCUIT …………………………………………………………………………22-20
22.3.9 DOZER OPERATING CIRCUIT …………………………………………………………………………22-22
22.3.10 NIBBLER & BREAKER OPERATING CIRCUIT ……………………………………………………22-24
22.3.11 TRAVEL / DOZER COMBINED OPERATING CIRCUIT …………………………………………22-26 22
22.3.12 TRAVEL / BOOM COMBINED OPERATING CIRCUIT ……………………………………………22-28
22.4 SCHEMATIC PIPING FOR HYDRAULIC SYSTEM ………………………………………………………22-30

Book Code No. S5PX2215E01

22-1
[22. HYDRAULIC SYSTEM]

Issue Date of Issue Applicable Machines Remarks


S5PX2215E01
First Edition December, 2013 SK35SR-5 : PX15-22809~
(EUR)

22-2
[22. HYDRAULIC SYSTEM]

22.1 SUMMARY

22.1.1 FUNCTION AND FEATURES OF HYDRAULIC CIRCUIT


The hydraulic circuits are built up with the following functions and features in order to achieve easy
operation, safety and high working efficiency.

22

22-3
[22. HYDRAULIC SYSTEM]

22.2 HYDRAULIC CIRCUITS AND COMPONENT MODELS

STANDARD SPECIFICATION PX01Z00035P1E SK35SR-5


No. NAME PART No. MODEL No.
1 PUMP ASSY PX10V00013F1 AP2D18LV3RS7
2 CONTROL VALVE PX30V00041F4 BCV35-JAA10
3 SLEWING MOTOR PX15V00024F1 MSG-27P-16E-17
4 TRAVEL MOTOR PX15V00025F1 GM04VA
CANOPY PX01V00062F1 Ø80-Ø45-578
5 BOOM CYLINDER
CAB PX01V00066F1 Ø80-Ø45-555
6 ARM CYLINDER PX01V00063F2 Ø80-Ø45-560
7 BUCKET CYLINDER PX01V00064F1 Ø65-Ø40-497
8 SWING CYLINDER PX01V00042F2 Ø80-Ø45-488
9 DOZER CYLINDER PX01V00043F2 Ø100-Ø50-160
10 SWIVEL JOINT PW55V00015F2 YV-7200
11 PILOT VALVE (ATT) PX30V00043F1 PV48M2042
12 PILOT VALVE (TRAVEL) PX30V00082F1 PVD6P4062
13 SOLENOID VALVE PY35V00010F1 -
14 PILOT VALVE (DOZER) PB30V00002F2 PV6P1075
15 SHUTTLE VALVE PH26V00001F1
16 - -
17 RETURN FILTER (ELEMENT) PW52V01001F1
18 SUCTION STRAINER PW50V00015F1
19 INLINE FILTER YN50V00020F1 Y-457400
20 CHECK VALVE PW21V00003F1 Y-2389
YN25V00011F1(H)
23 STOP VALVE
YN25V00012F1(R)
24 SELECTOR VALVE PA30V00005F1
25 BREATHER ASSY YN57V00002F4 AB0210GA0018
26 HYDRAULIC OIL TANK -
52 RELIEF VALVE PM22V00005F3
53 SOLENOID VALVE PW35V00002F1

This is for reference only, because the model number might be changed due to improvement.

22-4
[22. HYDRAULIC SYSTEM]

22.2.1 STANDARD SPECIFICATION

22

22-5
[22. HYDRAULIC SYSTEM]

22.2.2 ROTARY SPECIFICATION

22-6
[22. HYDRAULIC SYSTEM]

22

22-7
[22. HYDRAULIC SYSTEM]

22.3 HYDRAULIC CIRCUIT the pilot secondary pressure is not generated.


By means of operating the operating lever, the
OPERATION
secondary pressure is generated in accordance
22.3.1 COLOR CODING STANDARD FOR with its motion and led to the control valve (2)
HYDRAULIC from the pilot valve to shift each spool of shifting
Blue : Feed, drain circuit,less than 0.34 MPa (50 psi) valve.
Green : Return, make-up circuit,0.34 to 0.59 MPa (50
to 86 psi) (2) Main Circuit
Purple : Secondary pilot pressure,0.59 to 3.5 MPa (85 1. Variable Pump Circuit
to 508 psi) The delivered oil from A1 and A2 ports on
Red : Primary pilot pressure,3.5 to 3.9 MPa (508 to variable pump enters into P1 and P2 ports on
566 psi) control valve (2) respectively.
Orange : Main pump drive pressure,4.9 to 23 MPa All the discharged oil from these two ports finally
(711 to 3340 psi) returns to the hydraulic oil tank (26), through each
valve of travel left, boom and bucket for the P1
Blue tone : At valve selection oil, and through each valve of travel right, swing,
Red valve : When proportional valve (reducing) is service and arm for the P2 oil.
operating 2. Third Pump Circuit
Red solenoid : In active and exciting The oil delivered from A3 port on 3rd pump
Displaying the flow circuit and standby circuit when enters into P3 port on control valve (2).
operating. The whole amount of oil discharged through the
Regarding the electrical symbols in this manual, refer port P3 returns to the hydraulic oil tank (26)
to the electric circuit diagram. through the selector valves for the dozer and
slewing and the independent travel and flow
22.3.2 NEUTRAL CIRCUIT conflux valves.
(1) Pilot Circuit
1. Pilot Primary Pressure Circuit
The oil delivered from the A4 port on pump assy
(1) enters into the solenoid valve (13) through the
line filter (19).
The pressurized oil from the port A2 of the
solenoid valve (13) with the safety lock lever
released (in the operating condition) is supplied to
the P ports of the pilot valves for attachment (11),
travel (12), dozer (14) and nibbler & breaker (53).
Since the operating circuit is fully closed in the
neutral position, the oil delivered by the pump
other than the oil supplied to the Pp1 port of the
control valve loses its flowing passage, and
returns to the hydraulic tank (26) through the
relief valve (set pressure : 3.5MPa [508 psi])
built in the solenoid valve (13).
The oil supplied to the Pp1 port is led to the
tank passage through the pilot passages
provided to the service spool and through the
pilot passages provided to the right and left travel
spools.
2. Pilot Secondary Pressure Circuit
While the pilot valves (11),(12), (14) and solenoid
valve for nibbler & breaker are being in neutral,

22-8
[22. HYDRAULIC SYSTEM]

22

Neutral circuit

22-9
[22. HYDRAULIC SYSTEM]

22.3.3 TRAVEL CIRCUIT valve [brake valve] (408) spool moves to the
Pilot oil hydraulic system with operating lever neutral position with the spring force.
As the results, the passage in return oil side is
22.3.3.1 2nd Speed Operating Circuit throttled, and the motor speed is suppressed by a
(Independent-forward travel) back-pressure, then the motor is controlled to the
(1) Pilot Circuit speed corresponding to the supplied oil volume
1. Shifting signal for 2nd speed travel of the pump.
When the "Rabbit and Turtle" mark (at the power c. The counterbalance valve spool is so designed
cut-off, it automatically takes back for 1st speed) that it is gradually shifted by a throttle effect to
on the nob of travel right lever is pushed down, it stop or start the motor absorbing shock at the
actuates the 1st and 2nd speed travel shifting start and stop of the machine.
valve of solenoid valve (13). d. When load increases during high speed travel, the
The pressurized oil signal for 2nd speed is speed automatically shifts to the 1st speed,
generated from the A1 port of solenoid valve(13), resulting in low speed and high torque.
and led to the P port on travel motor (4) through
swivel joint (10), and shifts the 2-speed shifting
valve (404).
2. Changing travel valve spool
The pilot secondary pressure is generated from
pilot valve (12) by the operation for travel forward.
The pressurized oil is led to the Pb7 and Pb6
ports on control valve (2) to shift the travel valve
spool.

(2) Main Circuit


1. Circuit up to Travel Motor (4)
The delivered oil from A1 and A2 ports on
variable pump enters into the P1 and P2 ports
of control valve (2), and led to the B7 and B6
ports through the travel valve.
Then it is led to the A and B ports on left and
right travel motors respectively through the swivel
joint (10).
2. Travel Motor

a. The pressurized oil supplied to the travel motor


shifts the spool of the counterbalance valve (brake
valve) (408), releases the parking brake (403),
opens the hydraulic circuit having closed by the
check valve (407) and rotates the travel motor.
It actuates the speed shifting valve (404) when
the 2nd speed signal is sent. The high pressure
oil pumped through the shuttle valve (406) passes
the speed change valve (404), actuates the
2-speed shifting piston (401) and provides the
motor with high speed and low torque.
b. When the motor reaches near to a self-running
condition (over-running) at going down a slope
and so on, the oil pressure of supply side gets
down to lower pressure, and the counter balance

22-10
[22. HYDRAULIC SYSTEM]

22

Travel circuit : Travel foward operation at travel 2nd speed

22-11
[22. HYDRAULIC SYSTEM]

22.3.4 SLEW OPERATING CIRCUIT mass.


Pilot oil hydraulic system with operating lever

22.3.4.1 Slew (left) Operating Circuit


(1) Pilot Circuit
1. Slew Valve Spool Shifting
With operation for slew (left), the pilot secondary
pressure oil is generated from the pilot valve (11),
and led to the Pb2 port of control valve (2) to
shift the slew valve spool.
2. Releasing Parking Brake
The pilot primary pressure is always led to PG
port on the timer valve (303).
With the slew operation, the operating pilot
secondary pressure is led to SH port on the timer
valve (303) through the shuttle valve (15) to shift
the spool.
It leads the pilot primary pressure 3.5 MPa (508
psi) to the parking brake to release it. (Similarly,
the arm in operation releases the slew brake.)
3. Activating Parking Brake
When the slew operating lever is returned to
neutral position to stop slewing, the pilot
secondary pressure disappears causing to shift
the timer valve (303), then the pressurized oil is
shut down.
The oil in the brake cylinder is discharged due
to spring force, and drained through the throttle in
the timer valve (303).
Thus the braking is activated with some time lag
for 2.5 to 5.0 seconds to smoothly absorb the
slewing inertia at its stop of motion.

(2) Main Circuit


1. Supply Circuit for Slewing Motor (3)
The oil delivered from the A3 port on hydraulic oil
pump (1) is supplied to the B port on slewing
motor (3) through the P3 port on control valve (2)
and slew valve to drive the slewing motor.
2. Slewing Motor (3)

a. The relief valve (304) relieves rapidly increased


pressure at start and stop of the machine to ease
shock.
b. The make-up valve (check valve) (305) has a
function to replenish oil from the return oil circuit
that is led to the tank [T2 port on control valve
(2)] to the slewing motor, to prevent the slewing
motor from the cavitation due to negative pressure
generated in it because of inertia on the slewing

22-12
[22. HYDRAULIC SYSTEM]

22

Slewing circuit : Slewing left operation

22-13
[22. HYDRAULIC SYSTEM]

22.3.5 BUCKET OPERATING CIRCUIT


Pilot oil hydraulic system with operating lever

22.3.5.1 Bucket Digging Operation Circuit


(1) Pilot Circuit
1. Bucket Spool Shifting
When the operating lever is put at bucket
digging position, the pilot secondary pressure oil
is generated from the pilot valve (11). The
pressurized oil entered into the Pb10 port on
control valve (2) shifts the bucket valve spool.

(2) Main Circuit


1. Supply Circuit for Cylinder (7)
The oil delivered from A1 port on variable pump
of pump assembly (1) enters into P1 port on
control valve (2). The pressurized oil from B10
port through bucket valve is supplied to the head
side of bucket cylinder (7) to activate the digging
work.
The return oil from the rod side of cylinder (7)
enters into A10 port on control valve (2) and
returns into the tank through bucket valve.

22.3.5.2 Bucket Dumping Operating Circuit


(1) Pilot Circuit
1. Bucket Spool Shifting
When the operating lever is moved to bucket
dumping position, the pilot secondary pressure oil
is supplied from pilot valve (11), and enters into
Pa10 port on control valve (2) to shift the bucket
valve spool.

(2) Main Circuit


1. Supply Circuit for Cylinder (7)
Similar to the case for bucket digging, the
pressurized oil delivered from A1 port on variable
pump enters into P1 port on control valve (2).
The oil supplied from A10 port through bucket
valve is entered into the rod side of bucket
cylinder (7) to activate the bucket dumping.

22-14
[22. HYDRAULIC SYSTEM]

22

Bucket circuit : Bucket digging operation

22-15
[22. HYDRAULIC SYSTEM]

22.3.6 BOOM OPERATING CIRCUIT the boom from lowering due to its own weight
Pilot oil hydraulic system with operating lever while the boom valve is being at neutral position.

22.3.6.1 Boom UP Operating Circuit


(1) Pilot Circuit
1. Boom Spool Shifting
When the operating lever is put at boom up
position, the pilot secondary pressure oil is
generated from pilot valve (11). The pressurized
oil entered into Pa8 port on control valve (2)
shifts the boom valve spool.

(2) Main Circuit


1. Supply Circuit for Cylinder (5)
The oil delivered from A1 port on variable pump
of pump assy (1) enters into P1 port on control
valve (2). The oil supplied from B9 port through
boom valve and lock valve is entered into the
head side of boom cylinder (5) to up the boom.

22.3.6.2 Boom Down Operating Circuit


(1) Pilot Circuit
1. Boom Spool Shifting
When the operating lever is put at boom down
position, the pilot secondary pressure oil is
generated from pilot valve (11), and enters into
Pb8 port on control valve (2) to shift the boom
valve spool.
At the same time, the pilot secondary pressure
is led to the boom lock valve (206) to push up
the check valve and open the oil path from
closed condition.

(2) Main Circuit


1. Supply Circuit for Cylinder (5) and Return Oil
Circuit
The pressurized oil delivered from A1 port on
variable pump is led to boom valve provided on
control valve (2), and supplied to the rod side of
boom cylinder (5) to down the boom.
The oil returned from the head side of cylinder
(5) enters into B9 port on control valve (2), and
returns to the tank through the boom lock valve
(206) and boom valve.
Its flow rate is restricted by the throttle effect in
boom valve, accordingly the boom is lowered at a
stable speed.

a. Boom lock valve (206)


This is of a check valve mechanism to prevent

22-16
[22. HYDRAULIC SYSTEM]

22

Boom circuit : Boom up operation

22-17
[22. HYDRAULIC SYSTEM]

22.3.7 ARM OPERATING CIRCUIT of the arm cylinder to perform arm out work.
Pilot oil system with operating lever
With oil flow conflux function for the third pump.

22.3.7.1 Arm In Operating Circuit


(1) Pilot Circuit
1. Shift for Arm Spool
At the arm in operation, the pilot secondary
pressure generated from the pilot valve (11) is led
to the Pa3 port on control valve (2) to shift the
arm valve spool.
Furthermore, the pilot secondary pressure acts to
the SH port on timer valve (303) through the
shuttle valve (15) to release the parking brake.
Since the spool of the arm valve shifts to close
the pilot passage, the pressure of pilot oil thru the
Pp1 port equals to the supply pressure.
Thus the pressure overcomes the spring forces
of the independent travel and flow conflux valves
to shift the valve spool.

(2) Main Circuit


1. Supply Circuit for Cylinder (6)
The oil delivered from the A2 port on variable
pump enters into P2 port on control valve (2).
The pressurized oil from the P3 port joins with
the oil from the P2 port through the independent
travel and flow conflux valves. The joined oil flows
out from the A3 port through the arm valve and
is supplied to the head side of the arm cylinder
(6) to perform arm in work.
2. Return Line from Cylinder (6)
The return oil from the rod side of arm cylinder
enters into the B3 port on control valve(2), and
is led to the return line from the T1 port through
arm valve, then return to the tank.

22.3.7.2 Operating Circuit for Arm Out


(1) Pilot Circuit
At the operation for arm out, the pilot secondary
pressure is generated from the pilot valve (11),
and led to the Pb3 port on control valve (2) to
shift the arm valve spool.
The independent travel and flow conflux valves
are actuated as in the excavating operation.
(2) Main Circuit
As in the case of excavating operation, the oil
having flown into the control valve (2) joins with
the pressurized oil from P2 and P3, flows out
from the B3 port and is supplied to the rod side

22-18
[22. HYDRAULIC SYSTEM]

22

Arm circuit : Arm in operation

22-19
[22. HYDRAULIC SYSTEM]

22.3.8 SWING OPERATING CIRCUIT


Cable driving system with operating pedal

22.3.8.1 Swing (left) Operating Circuit


(1) Swing Operation
When depress the left side of swing pedal, the swing
valve spool in control valve (2) is shifted by the
cabling mechanism. Since the pilot oil pressure is not
utilized for it is activated regardless to the safety lock
lever.

(2) Main Circuit


1. Supply Circuit for Cylinder (8)
The delivered oil from A2 port on variable pump
enters into P2 port on control valve (2), and
comes out from A5 port through swing valve,
and is supplied to the head side of cylinder (8) to
activate the swing (left).

a. At activation of the swing valve spool for both left


and right swing motions, a part of appropriate
volume of oil is returned to the tank through the
P2 bypass circuit due to the throttle effect on
the spool.
Then supplying volume of oil to the cylinder is
restricted to ensure the slow and stable swing
motions for both leftward and rightward.

22-20
[22. HYDRAULIC SYSTEM]

22

Swing circuit : Boom swing left operation

22-21
[22. HYDRAULIC SYSTEM]

22.3.9 DOZER OPERATING CIRCUIT


Pilot oil system with operating lever

22.3.9.1 Dozer Down Operating Circuit


(1) Dozer Operation
When the operating lever is pushed forward, the pilot
secondary pressure is generated from the pilot valve
(14) to shift the dozer valve spool through the Pb1
port of the control valve (2).

(2) Main Circuit


1. Supply Circuit for Cylinder (9)
The oil delivered from A3 port of the hydraulic
pump (1) enters into P3 port on control valve
(2), and is led to B1 port through dozer valve.
The pressurized oil passed through swivel joint
(10) is supplied to the head side of dozer cylinder
(9) to activate dozer down motion.

22-22
[22. HYDRAULIC SYSTEM]

22

Dozer circuit : Dozer down operation

22-23
[22. HYDRAULIC SYSTEM]

22.3.10 NIBBLER & BREAKER operation.


OPERATING CIRCUIT
Pilot oil hydraulic system with operating pedal, and (2) Main Circuit
with 3rd. pump conflux function The pressurized oil is flowed in the control valve (2)
together, and it is same operation as closing circuit.
22.3.10.1 Nibbler Close Operating Circuit The confluent oil flows from B4 port, enters into R
(1) Pilot Circuit side of Nibbler cylinder, and opens the Nibbler.
1. Service Spool Shifting
Slide the slide switch on the grip of right control 22.3.10.3 Breaker Blow Operating Circuit
lever to the left, and secondary pilot pressure Change the valve position of selector valve (24) to the
flows out from A1 port of solenoid valve (53). position for Breaker.
The secondary pressure of pilot valve is varied
according to the sliding distance. (1) Pilot Circuit
The pressurized oil which entered into Pa4 port of 1. Service spool shifting
control valve (2) switches the spool for Press the button on the grip of right control lever,
Nibbler/Breaker. and secondary pilot pressure flows out from A1
Consequently the service spool shifts to close port of solenoid valve (53).
the pilot passage, the pressure of pilot oil thru The pressurized oil which entered into Pa4 port of
Pp1 port equals to the supply pressure. control valve (2) switches the spool for
Thus the pressure overcomes the spring forces Nibbler/Breaker.
of the travel independent and flow conflux valves By this shift of service spool, the independent and
to shift the valve spool. flow conflux valves are actuated like the
Nibbler-close operation.
(2) Main Circuit
1. Supply Circuit for Nibbler Cylinder (2) Main Circuit
Delivery oil from A2 port on the variable 1. Supply Circuit for Breaker
displacement pump enters into P2 port on control Both P2 and P3 pump oil flow together in the
valve (2). And the pressurized oil from P3 port control valve, and this is same operation as
flows together the oil from P2 port thru travel closing Nibbler.
independent/conflux valve. The conflux oil is delivered from A4 port through
The confluent oil flows from A4 port thru service the service valve, and is supplied into Breaker,
valve, enters into H side of Nibbler cylinder, and and makes the blow work of Breaker.
closes the Nibbler. 2. Return Line from Breaker
2. Return Line from Nibbler Cylinder The return oil of Breaker flows through the
The return oil from Nibbler cylinder enters into selector valve (24), and the oil returns directly to
B4 port on control valve (2), and flows into hydraulic tank.
return path thru the service valve, and then
returns from T1 port to the hydraulic tank.

22.3.10.2 Nibbler Open Operating Circuit


(1) Pilot Circuit
Slide the slide switch on the grip of right control
lever to the right, and secondary pilot pressure flows
out from A2 port of solenoid valve (53).
The secondary pressure of pilot valve is varied
according to the sliding distance.
The pressurized oil which entered into Pb4 port of
control valve (2) switches the spool for Nibbler/Breaker.
By this shift of service spool, the independent and
flow conflux valves are actuated like the Nibbler-close

22-24
[22. HYDRAULIC SYSTEM]

22

Nibbler & breaker circuit : Nibbler close operation

22-25
[22. HYDRAULIC SYSTEM]

22.3.11 TRAVEL / DOZER COMBINED


OPERATING CIRCUIT
At the combined operation of travel and dozer at the
same time, the straight traveling is secured with this
function.

22.3.11.1 Travel (1st speed forwarding) / Dozer


Down Operating Circuit
(1) Pilot Circuit
Both the travel and dozer are operated by the lever
using the pilot oil system.
The operation of each lever directly shifts the travel
valve spool and dozer valve spool in the control
valve (2) respectively.

(2) Main Circuit


The oil delivered from A1 and A2 ports on the
variable pump (1) enters into P1 and P2 ports on
control valve (2), and each flow of left and right is led
to swivel joint (10) and travel motor (4) respectively
through each travel valve of left and right.
The oil delivered from A3 port on the third pump
enters into P3 port on control valve (2), then it is led
to the dozer cylinder (9) through dozer valve and
swivel joint (10).

1. The dozer is operated by the pressurized oil


supplied by the third pump which has no relation
with travel circuit. Then there is no variation on
the supply volume of pressurized oil for both
travel motors of left and right even though the
dozer is operated during traveling.
Thus the straight traveling is secured.
(The slewing is operated in the same way as the
dozer.)
2. As the above mentioned, the traveling speed is
not changed from the single operation for traveling
securing the straight traveling.

22-26
[22. HYDRAULIC SYSTEM]

22

Combined operation circuit : Travel (forward) 1st speed / Dozer down operation

22-27
[22. HYDRAULIC SYSTEM]

22.3.12 TRAVEL / BOOM COMBINED


OPERATING CIRCUIT
At the combined operation of travel and boom at the
same time, the straight traveling is secured with this
function.

22.3.12.1 Travel (1st speed forward) / Boom Up


Operating Circuit
(1) Pilot Circuit
The traveling/boom up is of the pilot oil hydraulic
system with lever operation.
By means of pushing forward of travel operating
lever and pulling this side of boom up operating lever,
the pilot secondary pressure shifts the travel valve
spool and/or boom spool in the control valve (2).
Thus the pilot passage of the boom valve is closed to
make the pressure of the oil from the Pp1 port equal
to the supply pressure. Therefore the hydraulic
pressure overcomes the spring force of the
independent travel and flow conflux valves to shift
the valve spool.

(2) Main Circuit


The oil delivered from A1 and A2 ports on the
variable pump enters into P1 and P2 ports on the
control valve (2).
The whole amount of oil from the P1 and P2 ports
is supplied to the travel motor in the same way as
operating the independent travel. The oil flows from
the travel valve through the B7 and B6 ports and the
swivel joint (10) to the right and left travel motor (4).
The oil delivered from the port A3 of the hydraulic
pump (1) is supplied to the boom cylinder. The oil
through the P3 port of the control valve (2) flows
through the dozer and slewing valves and through
the shifted independent travel and flow conflux valves
to the boom valve.
The oil from the B9 port through the boom and block
valves is supplied to the head side of the boom
cylinder (5).

1. When the travel and other attachments (boom,


arm, bucket, swing, and service (for N & B) are
operated in combination, the independent travel
and flow conflux valves are actuated. Thus the
attachments are actuated only by oil supplied from
the P3 port. Therefore the oil of the P1 and P2
ports is utilized only by the travel to secure stable
travel in the combined operation.

22-28
[22. HYDRAULIC SYSTEM]

22

Combined operation circuit : Travel (forward) 1st speed / Boom up operation

22-29
[22. HYDRAULIC SYSTEM]

22.4 SCHEMATIC PIPING FOR


HYDRAULIC SYSTEM

22-30
[23. ELECTRICAL SYSTEM]

23. ELECTRICAL SYSTEM


TABLE OF CONTENTS

23.1 HOW TO READ CIRCUIT DIAGRAM AND HARNESS CONNECTION ………………………………23-3


23.1.1 ELECTRIC CIRCUIT DIAGRAM …………………………………………………………………………23-3
23.1.2 HARNESS CONNECTION ………………………………………………………………………………23-3
23.2 ELECTRICAL EQUIPMENT & HARNESS …………………………………………………………………23-4
23.2.1 ELECTRICAL EQUIPMENT LIST ………………………………………………………………………23-4
23.2.2 HARNESS & CABLE LIST ………………………………………………………………………………23-6
23.2.3 ELECTRIC CIRCUIT DIAGRAM …………………………………………………………………………23-7
23.2.4 ARRANGEMENT DRAWING FOR COMPONENTS & HARNESS ………………………………23-11
23.2.5 DETAIL OF HARNESS & CABLE………………………………………………………………………23-24

23

Book Code No. S5PW2337E01

23-1
[23. ELECTRICAL SYSTEM]

Issue Date of Issue Applicable Machines Remarks


S5PW2337E01
First Edition December, 2013 SK30SR-5 : PW14-46519~
(EUR)

SK35SR-5 : PX15-22809~
(EUR)

23-2
[23. ELECTRICAL SYSTEM]

23.1 HOW TO READ CIRCUIT DIAGRAM AND HARNESS


CONNECTION

23.1.1 ELECTRIC CIRCUIT DIAGRAM


(1) In the diagram, the number, size and color of wires are shown on the wiring line.
The size of the wire is to be 0.75 sq (square mm = mm2) unless otherwise specified.

23.1.2 HARNESS CONNECTION


(1) Indication for Connector

1. The figure for the connector pin arrangement is shown by putting the lock (nail) to upper portion,
and looking from the fitting face.
2. The numbers in the connector show the wire No., and alphabetical letters show the wire color.
3. On the side face of connector, the connector name and serial number of the connector No. are
indicated.
4. At the place indicated as "DOUBLE SPLICE", Two wires are connected to one place.

(2) The connector is to be connected with engaging the male (M) and female (F) connectors of the
same number.
Example : CN-101M and CN-101F
23
Where : M means for Male, and F for Female.
(3) +<-- mark means the connector with diode. The direction for diode is shown by the arrow.
(4) The AVSS wires are to be used for the size between 0.75 sq and 2 sq. AVS wires between 3 sq
and 5 sq and others are AV wires, unless otherwise specified.
(5) The wire size is 0.75 sq, unless otherwise specified.
(6) The treatment for the harness end is to be as follows :

(7) The length for the above (6)-3) is to be 20 to 40 mm. (0.8 to 1.6 in), and the length includes in
the total length of wire shown in the diagram.

23-3
[23. ELECTRICAL SYSTEM]

23.2 ELECTRICAL EQUIPMENT & HARNESS

23.2.1 ELECTRICAL EQUIPMENT LIST

Group Code Part Name Part No.


D-1 DIODE YN02D01001P1
D-2 DIODE
D-3 DIODE
D-4 DIODE
Diode
D-12 DIODE
D-14 DIODE
D-18 DIODE
D-20 DIODE
E-1 FUSE BOX PW73E00003F1
E-2 GENERATOR (ALTERNATOR) E/G accessory (119626-77210)
E-3 HORN PY53S00002P1
E-4 FUSIBLE LINK PH73S00001P1
E-6 GAUGE CLUSTER PH59S00005F1
E-7 POWER SOCKET PF81S01001P1
E-8 GLOW PLUG E/G accessory (129008-77800)

Electical E-9 FUSE PW13E01080P1


Fittings E-10 RADIO (OPT) Cab accessory (PW54S00002P1)
E-11 OVER LOAD BUZZER YJ53S01001D3
E-12 HEATER (OPT) PM21M00005F1
E-13 BATTERY PW72S00004P1
E-14 SEQUENCE BOX PA24S00002P3
E-20 TRAVEL ALARM (OPT) PW53S00002F1
E-26 HOUR METER YT58S00006P1
E-32 FUSE 2479R655S10
L-1 ROOM LAMP PM80S00006P1
Light L-2 BOOM WORKING LIGHT PM80S00008F1
L-5 CANOPY WORKING LIGHT PW80S00003F1
M-1 STARTER MOTOR E/G accessory (129242-77010)
M-2 WIPER MOTOR (CAB) Cab accessory (PM76S00001F1)
Cab accessory
Motor M-3 WASHER MOTOR (CAB)
(PE54C00002S002)
M-4 DECELERATION MOTOR PW20S00012F1
M-6 FUEL PUMP PW22P00001P1
R-1 BATTERY RELAY PH24S00001P1
R-2 SAFETY RELAY PX24S00001P1
Relay R-3 DECELERATION RELAY PA24E01001P1
R-6 TIMER UNIT PH25S00002P1
R-7 E/G STOP RELAY PX24S00003P1

23-4
[23. ELECTRICAL SYSTEM]

Group Code Part Name Part No.


R-8 CHARGE INDICATOR RELAY PA24E01001P1
Relay
R-9 CAB / CANOPY WORKING LIGHT RELAY
SE-1 FUEL SENSOR PX52S00006F1
Sensor
SE-2 COOLANT THERMO SENSOR PA24S00003P1
SV-1 LEVER LOCK SOL.
PX35V00003F1
SV-2 2-SPEED SELECT SOL.
Solenoid
SV-3 E/G STOP SOL. E/G accessory (119233-77932)
SV-5 POWER SHIFT SOL. (Cooler Spec) YJ35V00004F2
PSV-D NIBBLER OPEN PROPORTIONAL SOL.
PW35V00002F1
Proportional PSV-E NIBBLER CLOSE PROPORTIONAL SOL.
Solenoid Valve PSV-F REVOLUTION LEFT(A1) PROPORTIONAL SOL. (OPT) Pending
PSV-G REVOLUTION RIGHT(A2) PROPORTIONAL SOL. (OPT)

SW-1 KEY SWITCH PW50S00005S001


SW-2 WORKING LIGHT SW. PV24E01001P2
SW-3 2-SPEED SELECT SW. YN03M01286S002
SW-4 WIPER WASHER SW. PY50S00004P2
SW-5 E/G COOLANT TEMP. SW. PM50S00006P1
SW-6 E/G OIL PRESSURE SW. E/G accessory (114250-39450)
SW-7 HORN SW. YN50E01001P2
SW-9 LEVER LOCK SW. PA50S00001P1
SW-10 HEATER SW. (OPT) PY50S00003P2
SW-11 DECELERATION SW. PM50S00005P1
SW-17 TILT ANGLE SELECT SW. PW03M01350F1
Switch SW-23 TRAVEL ALARM SELECT SW. 2479U1190F16
SW-24 TRAVEL RIGHT(FORWARD) PRESSURE SW. (OPT) GB50S00049F2
SW-25 TRAVEL RIGHT(REVERSE) PRESSURE SW. (OPT)

SW-26 TRAVEL LEFT(FORWARD) PRESSURE SW. (OPT)

SW-27 TRAVEL LEFT(REVERSE) PRESSURE SW. (OPT)

SW-30 SLEWING LEVER PRESSURE SW. (LEFT)


SW-31 SLEWING LEVER PRESSURE SW. (RIGHT)
SW-35 NIBBLER OPEN-CLOSE SW. PW03M01958F1
SW-37 (A1, A2) REVOLUTION SW. (OPT) PW03M01959F1 23
SW-39 OVER LOAD PRESS. SW. 72117480 (DIN 43650)
SW-40 OVER LOAD SW. 2479U1190F33
SW-46 BATTERY DISCONNECT SW. LP50S00003P1

The part number may be changed owing to modification, use them only for reference.

23-5
[23. ELECTRICAL SYSTEM]

23.2.2 HARNESS & CABLE LIST

Code Name Part No. Remarks


H-1 Inst - Main Harness PW14E01064P2
H-2 Proportional N&B Harness PH14E01041P2
H-3 Engine Harness PW16E01024P2
H-4 Starter Cable (+) PW13E01090P1
H-5-1 Battery Ground Cable (-) PX13E01008P1
H-5-2 Battery Ground Cable (-) PX13E01009P1
H-6 Engine Ground Cable PH13E01047D1
H-7 Boom Harness PW15E01007P1
H-8 Key Switch Harness PW50E01002P1
H-9 Canopy Work Light Harness PW11E01026D3
H-10 Boom Work Light Extension Harness PW14E01038D1
H-11 Connection Harness with Cab PW14E01065P1 (OPT.)
H-12 - -
H-13 Travel Alarm Harness PW13E01069P1 (OPT.)
H-14 Alarm Extension Harness PH13E01078P1 (OPT.)
H-15 Heater Harness PW13E01068P1 (OPT.)
H-16 Cooler Harness PH11E01031P2 (OPT.)

The part number may be changed owing to modification, use them only for reference.

23-6
[23. ELECTRICAL SYSTEM]

23.2.3 ELECTRIC CIRCUIT DIAGRAM

23

23-7
[23. ELECTRICAL SYSTEM]

23-8
[23. ELECTRICAL SYSTEM]

23

23-9
[24. COMPONENTS SYSTEM]

24. COMPONENTS SYSTEM


TABLE OF CONTENTS

24.1 HYDRAULIC COMPONENTS …………………………………………………………………………………24-3


24.1.1 HYDRAULIC PUMP ………………………………………………………………………………………24-3
24.1.2 PILOT VALVE (ATT)………………………………………………………………………………………24-15
24.1.3 PILOT VALVE (TRAVEL)…………………………………………………………………………………24-19
24.1.4 CONTROL VALVE …………………………………………………………………………………………24-25
24.1.5 SLEWING MOTOR ………………………………………………………………………………………24-41
24.1.6 TRAVEL MOTOR …………………………………………………………………………………………24-52
24.1.7 SWIVEL JOINT ……………………………………………………………………………………………24-63
24.1.8 CYLINDER …………………………………………………………………………………………………24-66
24.2 ELECTRICAL EQUIPMENT ……………………………………………………………………………………24-75
24.2.1 ELECTRICAL EQUIPMENT LIST ………………………………………………………………………24-75
24.2.2 SPECIFICATIONS ELECTRICAL EQUIPMENT ………………………………………………………24-77

24

Book Code No. S5PX2415E01

24-1
[24. COMPONENTS SYSTEM]

Issue Date of Issue Applicable Machines Remarks


S5PX2415E01
First Edition December, 2013 SK35SR-5 : PX15-22809~
(EUR)

24-2
[24. COMPONENTS SYSTEM]

24.1 HYDRAULIC COMPONENTS

24.1.1 HYDRAULIC PUMP


24.1.1.1 SUMMARY
(1) GENERAL VIEW

General view of hydraulic pump

(2) SPECIFICATIONS

24

24-3
[24. COMPONENTS SYSTEM]

24.1.1.2 CONSTRUCTION - FUNCTION

(1) Piston pump


・ This pump is a variable displacement double piston pump which delivers two equal flows with
one cylinder block., and has only one inlet port, but the flow is separated into two flows by the
control plate on the cover and is led to two delivery ports provided on the cover.
・ The hydraulic pressure produced by the delivery oil acts on the hanger, resists the spring force,
and tilts the hanger. As the piston stroke is changed by the tilting of the hanger, the flow rate
varies.
・ The 3rd pump or pilot pump is installed on the same shaft with a coupling.

24-4
[24. COMPONENTS SYSTEM]

(2) Operation
1. Pump operation

a. The cylinder block is fitted on the spline and rotates with the drive shaft.
b. The piston fitted on the cylinder block follows the sliding surface of the hanger and moves to and
fro.
c. The piston moves to increase the capacity from the bottom dead point to the top dead point, the
pressure oil flows from the inlet port into cylinder block through the control plate. (Suction stroke)
d. But as the piston moves to decrease the capacity from the top dead point to the bottom dead
point, the pressure oil is sent out to the delivery port. (Delivery stroke)
e. By changing the tilting angle of the hanger (sliding surface), the displacement varies.
f. The oil sucked from the inside port of the cylinder block is delivered from the delivery port inside
of the control valve.
g. The oil sucked from the outside port of the cylinder block is delivered from the delivery port
outside of the control plate.
24

24-5
[24. COMPONENTS SYSTEM]

2. Control

a. The piston sliding on the surface of the hanger acts on the hanger through the hydraulic
pressure due to the delivery oil pressure P1 and P2.
b. The spring is located in the position which is in opposition to the delivery oil pressure.
c. When the hydraulic pressure acting on the hanger through the piston goes below the setting load
of the spring, the hanger is fixed at the maximum tilt angle.
d. When the hydraulic pressure acting on the hanger through the position exceeds the setting load of
the spring, the hanger is tilted and held tilting at the position where the hydraulic pressure
balances the spring pressure. (Control line, Area A)
e. The control line is shifted after the hydraulic pressure P3 acts on the shift piston.

24-6
[24. COMPONENTS SYSTEM]

3. Adjusting procedure of set torque

a. Adjusting procedure
1. Loosen the hexagon nut.
2. Set the power line by tightening or loosening the adjusting screw.

24

24-7
[24. COMPONENTS SYSTEM]

24.1.1.3 INNER CONSTRUCTION


Refer to Fig. 24.1.1.2 regarding the whole pump

(1) Drive shaft

No. NAME Q'TY No. NAME Q'TY


1 Shaft 1 6 Key 1
4 Ring 1 7 Shim 1
5 Snap ring (for Shaft) 1 8 Shim 1

(2) Swash plate (Hanger)

No. NAME Q'TY No. NAME Q'TY


1 Hanger 1 4 Guide (Delivery) 1
2 Guide (Suction) 1 5 Bushing (Delivery) 1
3 Bushing (Suction) 1

24-8
[24. COMPONENTS SYSTEM]

(3) Rotary group

No. NAME Q'TY No. NAME Q'TY


1 Piston 10 5 Spring 1
2 Cylinder block 1 6 Parallel pin 3
3 Retainer 1 7 Spring seat 1
4 Guide 1 8 Snap ring (for hole) 1

(4) Control spring

No. NAME Q'TY No. NAME Q'TY


1 Spring seat 1 8 Capscrew (M8X30) 2
2 Spring seat 1 9 Nut 1
3 Cover 1 10 Spring 1
4 Setscrew 1 34 Shim 2 24
5 Spring 1 44 Shim 2
6 Spring 1 54 Shim 2
7 O-ring 1

24-9
[24. COMPONENTS SYSTEM]

(5) Cover

No. NAME Q'TY No. NAME Q'TY


1 Cover 1 7 Bearing 1
2 Control plate 1 8 Plug 2
3 Parallel pin 1 9 Capscrew (M12X55) 1
4 Capscrew (M12X40) 3 10 Plug 3
5 Packing 1 12 Orifice 1
6 Plug 3

24-10
[24. COMPONENTS SYSTEM]

(6) Gear pump

No. NAME Q'TY No. NAME Q'TY No. NAME Q'TY


3 Housing 1 10 Plate 2 16 Square ring 1
4 Cover 1 11 Guide 2 17 Square ring 2
5 Gear 1 12 Coupling 1 18 O-ring (1B P6) 1
6 Gear 1 14 O-ring 2 19 Capscrew (M12X25) 2
7 Side plate assy 2 15 O-ring 1 21 Capscrew (M10X20) 4

24

24-11
[24. COMPONENTS SYSTEM]

(7) Housing

No. NAME Q'TY No. NAME Q'TY No. NAME Q'TY


1 Housing 1 8 O-ring (1B P9) 1 22 Distance piece 1
2 Oil seal 1 9 Distance piece 1 23 Snap ring 1
3 Bearing 1 12 Guide 1 30 Shim 1
4 Piston 1 16 Sleeve 1 31 Shim 1
5 Parallel pin 1 18 Shim 1 32 Shim 1
6 Disk spring 5 19 Shim 1
7 O-ring (1B P15) 1 20 Shim 1

24-12
[24. COMPONENTS SYSTEM]

(8) Trochoid pump

No. NAME Q'TY No. NAME Q'TY


1 Gear 1 6 Capscrew 3
2 Casing 1 7 Side plate (B) 1
3 Side plate (A) 1 8 Spring pin 1
4 O-ring 1 9 Plate 1
5 Spring pin 1

24

24-13
[24. COMPONENTS SYSTEM]

This page is blank for editing convenience.

24-14
[24. COMPONENTS SYSTEM]

24.1.2 PILOT VALVE (ATT)


24.1.2.1 SUMMARY
(1) General view

24

24-15
[24. COMPONENTS SYSTEM]

24.1.2.2 CONSTRUCTION

Pilot valve-Sectional view

No. NAME Q'TY No. NAME Q'TY No. NAME Q'TY


101 Casing 1 213 Seal 4 241-1 Spring 2
151 Plate 1 214 O-ring; 1B P20 4 241-2 Spring 2
201 Spool 4 216-1 Spring seat 2 301 Joint; M14 1
211 Plug 4 216-2 Spring seat 2 302 Disk 1
212-1 Push rod 2 217 Washer 2 4 312 Adjusting nut; M14 1
212-2 Push rod 2 221 Spring 4 501 Bellows 1

24-16
[24. COMPONENTS SYSTEM]

24.1.2.3 OPERATION
(1) Lever in neutral position
In this case, the force of the secondary
pressure setting spring (241) that determines
the output pressure of the pilot valve is not
transmitted to the spool (201). Accordingly, the
spool (201) is pushed up by the return spring
(221) and spring seat (216) permitting the
output port 2, 4 to connect with the tank port
T. This makes the output pressure equal to
the tank pressure.

Lever in neutral position

(2) When the Lever is tilted


When the lever is tilted, the push rod (212)
strokes. The spool (201) and spring seat (216)
moves downward to make the port P to
connect with the port 2, 4. With the result that
the oil of the pilot pump flow out to the port
2, 4, to produce a pressure.

When Lever is tilted

(3) The Lever being held


When the lever is tilted till the pressure of the
port 2, 4 rises to an oil pressure
corresponding to the set spring force, the
hydraulic pressure is balanced with the spring
(241) force. And when the pressure of the port
2, 4 rises above a set pressure, the port P
are closed and the port T are opened. When
the pressure of the port 2, 4 falls below a set
pressure, the port P are caused to open and 24
the port T are caused to close, thus holding
the second pressure constant.

Lever being held

24-17
[24. COMPONENTS SYSTEM]

This page is blank for editing convenience.

24-18
[24. COMPONENTS SYSTEM]

24.1.3 PILOT VALVE (TRAVEL)


24.1.3.1 SUMMARY
(1) General view

(2) Specifications
ITEM SPECIFICATIONS
Model (Type) PVD6P4062
Max. primary pressure 6.9MPa (1000 psi)
Rated flow 10 L/min (2.6 gal/min)
Weight 3.9 kg (8.6 lb)

(3) Performance Characteristics

24

24-19
[24. COMPONENTS SYSTEM]

24.1.3.2 CONSTRUCTION

Pilot valve-Sectional view

Torque Torque
No. NAME Q'TY No. NAME Q'TY
N-m (lbf-ft) N-m (lbf-ft)
101 Casing 1 6.9 (5.1) 252 Plug 2
102 Casing (Damper) 1 261 O-ring 3
201 Cover 2 8.8 (6.5) 271 Capscrew 4
202 Plug 4 301 Spool 4
203 Grease cup 4 311 Spring seat 4
210 Packing 4 313 Washer 4
211 O-ring 4 324 Spring 4
212 O-ring 4 335 Spring 4
213 O-ring 2 336 Spring 4
214 Push rod 4 413 Cam shaft 2
217 Shim 4 414 Bushing 4
218 Spring seat 4 420 Cam 2
224 Piston 4 471 Steel ball 4
225 Steel ball 12 6.9 (5.1) 472 Set screw 2
29.4 (21.7) 251 RO Plug 3 501 Boots (Bellows) 2

24-20
[24. COMPONENTS SYSTEM]

24.1.3.3 OPERATION
1. Reducing valve
(1) When the lever is at neutral position
The spool is pushed up by the return
spring (335) through spring seat (311), and
is positioned at the neutral position in the
right figure. Therefore, the pressure at
delivery ports 1 and 2 is equivalent to that
of port T because the delivery port is
connected to only port T following the
switched spool condition.

(2) In case where the lever is tilted


By rotating cam (420) in clockwise, push
rod (214) on the port 1 side is pushed
down, and the spool moves down by way
of spring seat (311), spring (324) for setting
the secondary pressure, shim (217) and
washer (313) and consequently the port P
is connected to the port 1 and the supplied
oil from the pilot pump flows into port 1
and generates pressure.
When the pressure at port 1 rises to the
pressure equivalent to the spring pressure
for the secondary pressure setting set by
tilting the control section, the hydraulic
pressure applied to the spool balances the
spring force, and maintains port 1 at a
constant delivery pressure.
The spool on the port 2 side is held at
neutral position, and the return oil from the
control valve is discharged through port T.

24

24-21
[24. COMPONENTS SYSTEM]

2. Damping mechanism
(1) In case of neutral position,
Push rod (214) is pushed up by damping spring (336) through piston (224), and holds at the
position shown in Fig. "Pilot valve-Sectional view".
(2) Where the control section is inclined from the neutral position,
By rotating the cam clockwise, the push rod on the port 1 side is pushed down, and the piston
also moves down.
Then, the oil in the damping piston chamber is discharged through the orifice, and the
simultaneously generated pressure produces damping force.
On the other hand, the push rod on the port 2 side moves up by the damping spring through the
piston.
Then, oil is sucked from the tank into the damping piston chamber through three ball check
valves. The oil outside of the piston chamber flows out through the passage leading to port T on
the casing top end.

Operation when the lever is stroked from the neutral position

24-22
[24. COMPONENTS SYSTEM]

(3) Where the control section is inclined in the opposite direction from the full tilting
After tilting the cam clockwise fully, if it is rotated counterclockwise, the push rod on the port 2
side is pushed down and the piston moves down.
Then, the same as above, the oil in the damping piston chamber is discharged through restriction
of piston, and the simultaneously generated pressure produces damping force.
On the other hand, the push rod on the port 1 side is moved up by the force of the return
spring and damping spring.
Similarly oil is sucked from the tank into the damping piston chamber through three ball check
valves.
And the oil in the piston chamber flows out through the passage leading from the casing top end
to the tank port.

That is, either tilting operation from the neutral position to the full tilting position or the full tilting
position to the neutral position is designed to produce the damping force.

24

Operation when the lever is stroked or operated in reverse

24-23
[24. COMPONENTS SYSTEM]

This page is blank for editing convenience.

24-24
[24. COMPONENTS SYSTEM]

24.1.4 CONTROL VALVE


24.1.4.1 GENERAL VIEW AND HYDRAULIC PORTS NO.

24.1.4.2 SPECIFICATIONS

24

24-25
[24. COMPONENTS SYSTEM]

24.1.4.3 CONSTRUCTION
(1) Control Valve: Overall composition

No. NAME Q'TY No. NAME Q'TY No. NAME Q'TY


1 Dozer section 1 7 Travel (right) section 1 14 P3 Main relief valve 1
2 Slewing section 1 8 P1, P2 inlet straight 1 15 Over load relief valve 6

P3 inlet, independent 9 Travel (left) section 1 16 Over load relief valve 2


3 1
travel & conflux section 10 Boom section 1 17 Anti cavitation valve 1
4 Arm section 1 11 Boom lock section 1 18 Tie bolt 4
5 Service section 1 12 Bucket section 1 19 Nut 4
6 Swing section 1 13 P1, P2 Main relief valve 2

24-26
[24. COMPONENTS SYSTEM]

(2) Component Parts


The control valve is roughly classified into the following three sections.

-Manual operation section : Swing


-Pilot operation section : Travel right and left, boom, arm, bucket, slewing, independent travel and
conflux, dozer blade, service (nibbler & breaker)
-Accessory section : P1 and P2 inlets, and P3 inlet (common with independent travel and conflux)
-Accessory section (valve) : P1, P2, P3 main relief, overload relief, anti cavitation, boom lock

* For respective operation section, only typical example is described.


1. Manual operation: Swing (No.6)

2. Pilot operation: Slewing (No.2)

24

24-27
[24. COMPONENTS SYSTEM]

3. Main relief valve (P1, P2, P3) and overload relief valve

4. Anti cavitation valve

24-28
[24. COMPONENTS SYSTEM]

24.1.4.4 HYDRAULIC CIRCUIT

24

24-29
[24. COMPONENTS SYSTEM]

24.1.4.5 EXPLANATION OF OPERATION


(1) Neutral position

P1:
The oil delivered from the hydraulic pump flows from the P1 port of the control valve (hereafter called
a C/V) into the left travel spool section through the passage of the supply section.
At the spool neutral position, the entered oil passes through the by-pass of the spool leading from
the left travel to the boom because the spool does not cut off the by-pass and flows out to the tank
circuit through the by-pass of the spool for the bucket and the by-pass leading to the tank.
P2:
The oil delivered from the hydraulic pump flows from the P2 port of C/V into the right travel spool
section through the passage of the supply section.
At the spool neutral position, the entered oil passes through the by-pass of the spools for the right
travel, boom swing and service, and flows out to the tank circuit through the by-pass circuit leading
from the by-pass of the spool for service.
P3:
The delivery from the hydraulic pump flows from the (C/V) P3 port into the parallel circuit of swing and
dozer operation.
Since the spool does not shut off the by-pass passage in the neutral spool condition, the oil having
flown into the parallel passage flows out to the tank passage through the by-pass passages of the
spools for the dozer and slewing and through the by-pass passage of the P3 supply section.

As the flow from the pump is fed into each line (P1, P2, P3), the switching sections of respective
line shown below are in operable condition. Therefore, don't operate them except when working.
- P1 line: Left travel, Boom, Bucket
- P2 line: Right travel, Boom Swing, Service and Arm
- P3 line: Dozer, slewing [Service and Arm]

Pp1:
The delivery oil from the gear pump flows from the (C/V) Pp1 port into the pilot circuit through the
orifice provided on P3 supply section. (Two systems for shifting independent travel and for shifting
arm and service flow conflux)
In the neutral spool condition, the oil of the independent travel shifting side flows out to the tank
passage through the passages provided to the right and left travel spool and the swing spool.
Therefore the pilot circuit pressure becomes equal to the tank pressure, the received pressure of the
independent travel valve is equal to the tank pressure, and consequently the independent travel spool
does not switch.
Moreover, the oil of the flow conflux shifting side flows out to the tank passage through the passage
provided to the service spool. Since the pilot passage pressure equals to the tank pressure and the
receiving pressure of the flow conflux piston equals to the tank pressure, the flow conflux spool is not
shifted.

24-30
[24. COMPONENTS SYSTEM]

When the engine is stopped (when each hydraulic pump is stopped), the actuator does not function
even when being loaded by the self weight, because the pilot pressure does not act on the pilot
control spool (except for the condition where the accumulator, etc. is attached and the pressure
remains due to the pipe volume). On the spool of boom swing which directly actuates the spool, the
port on the loaded side is led to the tank circuit with the operating direction making it unable to hold
the load, consequently the actuator may be actuated causing danger. Therefore, even if the engine is
stopped, when there are people around the machine or it may be in contact with implements, don't
use the control lever.

24

Operation at neutral position

24-31
[24. COMPONENTS SYSTEM]

(2) Pilot operating section


1. Operating boom raise
With the boom raise operation, the pilot secondary pressure enters into the Pa8 port, and moves the
spool for the boom operation. And with the movement of the spool, as the by-pass circuit is cut at the
boom switching section, the oil received through the P1 port flows from the parallel circuit through the
check valve installed on the upper part of the spool by-pass circuit for the travel operation into the
parallel circuit on the boom switching section.
With the movement of the spool, as the circuit from the passage leading to the boom lock section to
the bridge passage is opened, the oil entered in the parallel circuit passes through the load check
valve on the boom switching section and flows into the boom lock section through the bridge
passage. The oil entered in boom section opens the lock valve and is fed into the boom cylinder head
side.
On the other hand, the return oil from the boom cylinder rod side flows into the B8 port, and with
the movement of the spool the oil flows out into the tank circuit that is connected by the notch of the
spool. Consequently, the boom cylinder extends and raises the boom.
The oil from the Pp1 port passes through the orifice provided on the P3 supply section and flows into
the pilot circuit.
The oil entered into the pilot circuit flows from the travel switching section to the tank circuit, and the
pilot circuit pressure becomes equal to the tank pressure, consequently the independent travel spool
is not switched.

Operation at boom raising

24-32
[24. COMPONENTS SYSTEM]

(3) Manual operation section


1. Left swing operation
With the left swing operation, the swing spool moves to the push-in direction.
With the movement of the spool, as the by-pass circuit is cut off at the swing switching section, (a
portion of the oil flows out to the by-pass (tank) circuit through the notch provided on the swing
spool.), the oil entered through the P2 port flows into the parallel circuit through the check valve
provided on the upper part of the travel spool by-pass circuit.
With the movement of the spool, as the circuit from the A5 port to the bridge passage is open, the oil
entered in the parallel circuit passes though the load check valve, flows into the A5 port through the
bridge passage, and is fed into the swing cylinder head side.
On the other hand, the return oil from the swing cylinder rod side flows into through the B5 port, and
with the movement of the spool the return oil flows out to the tank circuit that is connected by the
notch of the spool.
Consequently, the swing cylinder extends, and the boom swings leftward.
The oil entered through Pp1 port passes through the orifice provided on the P3 supply section, and
flows into the pilot circuit.
As the oil entered in the pilot circuit flows out from the travel switching section into the tank circuit,
the pilot circuit pressure becomes equal to the tank pressure, and consequently the independent travel
spool is not switched.

24
Operation of swing

24-33
[24. COMPONENTS SYSTEM]

(4) Flow conflux function


This valve actuates the arm and service using joined flow amount of P2 and P3.
The flow conflux circuit is used only for actuating the arm and service as explained below. (The
explanation shown below for the service shifting is also applicable to the arm.)
The operation for the service shifts the spool for the service by the secondary pressure from the
remote control valve.
Since the spool shifting results in shutoff of the pilot and tank passages for flow conflux, the pressure
in the flow conflux pilot passage equals to the Pp1 port supply pressure, which acts on the flow
conflux piston to move it to the position where the piston collar contacts with the inner shoulder the
valve.
At the same time, the flow conflux piston moves the flow conflux and independent travel spools.
Once the spool is shifted, the pressurized oil supplied from P3 flows into the second by-pass passage
of P2 side through the parallel and by-pass passages of the slewing and dozer shifting and through
the check valve provided to the P3 supply section, which is connected to the by-pass passage of the
P2 side at the upstream (between boom swing and service) of the service shifting section, and also
connected to the by-pass passage of the P2 side through the check valve at the P3 supply section.
Therefore the flow of oil supplied from P3 joins in the parallel passage of the P2 side in proportion to
an operating amount of the arm or the service.
(The drawing below shows service operation.)

Actuation of flow conflux circuit in service operation

24-34
[24. COMPONENTS SYSTEM]

(5) Independent travel function


When both right and left travels is shifted, and one of boom, bucket and boom swing is shifted, the oil
flows from the Pp1 port through the throttle into the pilot passage, in which pressure equals to the
Pp1 port supply pressure because the pilot passage is shut off from the tank passage.
Then the Pp1 port supply pressure acts on the independent travel spool, and the spool moves until it
contacts with the pilot cap overcoming the spring force.
Once the spool is shifted, the pressurized oil supplied from P3 passes through the parallel and
by-pass passages of the slewing and dozer shifting sections, and passes through the spool of the P3
supply section and the land of main unit to flow into the second parallel passage of the P1 side and
the parallel passage of the P2 side.
After these shifting, the pressurized oil supplied to P1 and P2 actuates the right and left travel, and
the pressurized oil supplied to P3 actuates the other attachments.
Therefore even if the travel and other attachment are simultaneously operated, the travel is correctly
performed without deviating.
The arm or service operated in the flow conflux position without relating to the independent travel
function can be simultaneously performed with the travel in the same operability as the independent
travel function.

24

Independent travel actuation

24-35
[24. COMPONENTS SYSTEM]

(6) Function of Lock Valve


1. Piston Holding
When the boom spool is at neutral position, the pilot piston chamber (a) is connected to the drain
passage through the pilot port (Pb8') for releasing lock valve. And the piston chamber (b) is also
connected to the drain passage through the drain port (Dr1).
Therefore the piston (A) is held at the position shown in the figure.
And the hydraulic pressure to hold the boom cylinder is applied to the lock valve chamber as shown
in the figure, pressing the needle valve and lock valve to their seats respectively. Then it prevents
leakage on the head side of boom cylinder, and also prevents the arm cylinder from its movement due
to leakage.

Function of Lock Valve (piston holding)

24-36
[24. COMPONENTS SYSTEM]

2. Release
When the pilot pressure is applied to the pilot port (Pb8') for releasing lock valve, the piston (A) is
moved to the right side opening the needle valve through piston (B).
At that time, the return oil from boom cylinder passes through the throttle on lock valve, then lock
valve chamber --> pilot piston chamber --> drilled hole in turn, and flows into the tank path through
the throttle hole (drilled hole) on boom spool pushing up the steel ball.
The opening of the needle valve results in the pressure drop in the lock valve chamber. The return
oil from the boom cylinder opens the lock valve, and flows into the tank passage through the notch
(groove) of the boom spool and the throttle (drilled hole).

Function of Lock Valve (release)

24

24-37
[24. COMPONENTS SYSTEM]

(7) Operation of relief valve


1. Operation at relief condition
a.
The pressure oil passes through the inside of the piston placed in the pressure regulating valve (main
valve) and fills in "A" chamber inside of the piston through the orifice "B" to securely seat the pressure
regulating valve and the socket, and the socket and the body seat.

b.
When the pressure of the oil in the P port reaches to the set pressure of the spring, the pressure oil
acts on the adjust valve through the piston and opens the adjust valve.
Then, the pressure oil passes through the inside of the piston, orifice B, A chamber, ring orifice, and
drilled hole D in order, and flows out to the tank circuit around the socket.

c.
The pressure in "A" chamber drops because the adjust valve is open, consequently the pressure oil
in the P port flows out to the tank circuit through the drilled hole "E".

d.
When the pressure on the P port drops lower than the spring set pressure of the adjust valve, the
adjust valve is pushed against the seat by the adjust valve spring force of the adjust valve and the
pressure in "A" chamber is equal to the pressure in the P port, consequently the adjust valve is also
pushed against the seat and returns to the former condition(Fig. 24.1.4.5-(7)-1-a).

24-38
[24. COMPONENTS SYSTEM]

2. Suction operation
When the negative pressure is generated in the P port, the oil is supplied through the tank circuit.
When the pressure of the tank circuit from the P port rises, the socket is pushed up.
Consequently, the space between the body seat and the socket opens, and the oil flows from the tank
passage into the P port and the space fills with the oil.

(8) Operation of anti-cavitation valve


When the negative pressure is generated in the P port, the oil is supplied through the tank circuit.
When the pressure from the P port rises, the valve is pushed up.
Consequently, the space between the body seat and the socket opens, and the oil flows from the tank
circuit into the P port and the space fills with the oil.

24

24-39
[24. COMPONENTS SYSTEM]

This page is blank for editing convenience.

24-40
[24. COMPONENTS SYSTEM]

24.1.5 SLEWING MOTOR


24.1.5.1 GENERAL VIEW

24.1.5.2 HYDRAULIC CIRCUIT

24.1.5.3 SPECIFICATIONS
Model (Type) MSG-27P-16E-17
cm3/rev
Displacement 20.7 (1.26)
(cu-in/rev)
Rated flow L/min (gal/min) 20.6 (5.44)
Hydraulic motor
Parking brake torque N-m (lbf-ft) 1022 (754) or more
Parking brake releasing pressure MPa (psi) Min 2.0 (290), Max 6.4 (928)
Parking brake timing sec 2.5 to 4.9 24
Relief valve Set pressure MPa (psi) 20.0 (2900) at 20.5 L (5.4 gal)/min
Reduction Reducting ratio 1/15.5
Weight kg (lb) 38 (84)

24-41
[24. COMPONENTS SYSTEM]

24.1.5.4 CONSTRUCTION

No. NAME Q'TY No. NAME Q'TY No. NAME Q'TY


1 Housing 1 21 Ball bearing 1 46 Socket bolt (M12X30) 5
2 Pinion shaft 1 22 Shaft 1 47 Orifice 1
3 Collar 1 23 Thrust plate 1 48 Timer valve assy 1
4 Plate 1 24 Cylinder block 1 Jan-48 Sleeve 1
5 Taper roller bearing 1 25 Collar 1 Feb-48 O-ring (1B P10A) 1
6 Oil seal 1 26 Spring 1 Mar-48 O-ring (1B P12) 1
7 Taper roller bearing 1 27 Washer 1 Apr-48 O-ring (1B P14) 1
8 Shim t2 (Shim select) 2 28 Snap ring 1 May-48 Spool 1
Shim t3 (Shim select) 2 29 Pin 3 49 Washer 1
Shim t4 (Shim select) 2 30 Retainer holder 1 50 Spring 1
Shim t5 (Shim select) 2 31 Retainer plate 1 51 O-ring (1B P18) 1
Shim t13 (Shim select) 2 32 Piston assy 9 52 Plug 1
Shim t14 (Shim select) 2 33 Disk 1 53 Relief valve assy 2
9 Collar 1 34 Brake piston 1 54 Check valve 2
10 Holder 1 35 O-ring (1B G110) 1 55 Spring 2
11 Thrust washer 3 36 O-ring (1B G135) 1 56 Plug 2
12 Inner race 3 37 Spring seat 2 57 O-ring (1B P14) 2
13 Needle bearing 3 38 Spring 1 58 Plug 2
14 Planetary gear 3 39 O-ring 1 59 O-ring (1B P8) 2
15 Thrust plate 1 40 Cover 1 60 Plug 1
16 Drive gear 1 41 Ball bearing 1 61 O-ring (1B P11) 1
17 Plug 1 42 Pin 1 62 Socket bolt (M12X30) 2
18 O-ring (1B P8) 1 43 Valve plate 1 63 Name plate 1
19 O-ring 1 44 Pin 2 64 Rivet 2
20 Casing 1 45 O-ring (1B P21) 2 65 Thrust plate 1

24-42
[24. COMPONENTS SYSTEM]

No. NAME Q'TY No. NAME Q'TY No. NAME Q'TY


66 Sun gear 1 69 Needle bearing 4 72 Holder 1
67 Screw 4 70 Inner race 4
68 Planetary gear 4 71 Thrust washer 4

Relief valve assy (No.53)

24.1.5.5 FUNCTION AND OPERATION


(1) Swash plate motor
The cylinder block (24) is equipped with 9 pistons (32). And the end face of cylinder block (24) is in
contact with valve plate (43) having two crescent ports C and D (high and low pressure switching
distributor).
(Principles of torque generation)
On leading the high pressure oil (pressure P) to the A port, the swash plate is pushed by the force of
each piston (F = PXA, A : Piston cross sectional area) and the piston receives the reaction force
from the swash plate for the piston and the directional torque of the reaction rotation is generated.
And the sum total of the rotation directional torque produces a turning force in cylinder block (24) and
the torque is conducted to shaft (22) through the spline resulting in the piston rotation.
And, the output torque and the rotation number are found from the following equation.
Where,

24

24-43
[24. COMPONENTS SYSTEM]

Construction of slewing motor

24-44
[24. COMPONENTS SYSTEM]

(2) Parking brake


The parking brake is of hydraulic release and chamber type multi-disk construction.
1. When parking brake is ON, (Refer to Fig. "Parking brake is ON condition")
When the pressure oil for releasing the brake is cut off, regarding the disk (33) joined to the exterior
of the cylinder block with a spline, brake piston (34) which is secured with pin on the case is pushed
by spring (38), and cylinder block (24) and casing (20) are fixed by the frictional force. Consequently
the shaft is locked.
2. When parking brake is OFF, (Refer to Fig. "Parking brake is OFF condition")
When the brake releasing pressure is led to brake cylinder chamber "C" through PG port, brake
piston (34) operates resisting the force of spring (38), removing the friction with disk (33), and the
shaft rotates freely.

(3) Hydraulic timer (Specification with hydraulic timer only)


The hydraulic timer is provided to protect the parking brake from dragging and plays to secure delay
time so that the parking brake does not actuate when the hydraulic dynamic brake is absorbing swing
inertia energy, and the delay time is set by restricting the delivery oil from the cylinder chamber with
orifice and by controlling the flow rate.
By returning the control valve from motor rotating condition to the neutral position, the valve switching
pressure "SH" interlocking with switching signal for the control valve lowers, and for the valve, the
brake cylinder chamber is interlocked with the drain port through the valve as shown in the figure. (In
this condition, the energy of the upper structure is transformed into heat energy and absorbed by the
relief valve and the hydraulic dynamic braking action.).
On the other hand, the oil led to the brake cylinder chamber "C" tries to move in the direction to push
the disk by the spring force acting on the brake piston, but as the flow rate of the delivery oil from
the brake cylinder chamber is controlled by the orifice of the valve, the brake piston is not in contact
with the disk before an elapse of the specified time and the brake does not work.

PG (Brake releasing pressure) OFF

24

Parking brake is ON condition

24-45
[24. COMPONENTS SYSTEM]

PG (Brake releasing pressure) ON

Parking brake is OFF condition

24-46
[24. COMPONENTS SYSTEM]

24

24-47
[24. COMPONENTS SYSTEM]

(4) Operating principle of relief valve


The relief valve is used to decide the driving power and brake force when slewing the hydraulic
excavator and each is equipped with main port A and B. And it is constructed so that the relief valve
return oil returns in a circuit to the main low pressure line on the other side.
And, it is provided with a shockless function to reduce the shock produced when speeding up or down.
The relief valve is made up of the
a. Area difference & direct operated type relief valve
b. Shockless piston.
The installation of shockless type relief valve is effective for the reduction of the shock, reduction of
the stress generated on the structure of the machine.

Construction of relief valve

24-48
[24. COMPONENTS SYSTEM]

The relief valve is operated by the following two steps.

1st step:
When starting operation, the interior of the spring (5) is held in low pressure because shockless
piston (14) moves. Consequently the pressure receiving area (S2) of poppet (2) becomes equal to the
area (S1) of seat (3) and has a large pressure receiving area when compared with the area (S1-S2)
for the regular relief set pressure.
Therefore the low pressure holding time is decided by the diameter of the poppet orifice, the pressure
receiving area of the free piston and the free piston stroke.

1st step: Operation of relief valve

2nd step:
After the movement of shockless piston (14), the pressure inside of spring chamber (5) rises and
becomes equal to the pressure the front and behind of poppet (2). And the relief valve is operated
by the regular set pressure.

2nd step: Operation of relief valve

The pressure wave forms in the conventional type and the shockless type are shown below.

24

Comparison of pressure wave forms

24-49
[24. COMPONENTS SYSTEM]

(5) Make-up valve (check valve, No.54)


The make-up valve performs the following two functions.
The 1st function is to prevent the cavitation produced when overrunning to avoid the overrun of the
upper structure. The motor revolved by the inertia force of the upper structure causing the pumping
action, and when the motor speed is over the speed equivalent to the oil quantity fed into the motor,
the shortage of oil is made up from the outside to the motor main circuit through the make-up valve to
protect the circuit from the generation of vacuum.
The 2nd function is, when the closed circuit is formed between the control valve and the motor as
when braking, to protect the circuit from the generation of the vacuum by making up the shortage
due to the motor drain and valve leak from the make up valve to maintain the braking function in the
regular circuit condition.

24-50
[24. COMPONENTS SYSTEM]

(6) Reduction Unit (2-stage planetary)


Refer to the cross sectional view.
The motor shaft (22) is connected to the drive gear (16) with the spline on it. The driving power on
the hydraulic motor is transmitted from the drive gear (16) to the planetary gear (14) which is engaged
to the drive gear (16). The planetary gear (14) is engaged to the ring gear on the reduction unit
housing (1). Then it revolves around the ring gear with its rotation. The planetary gear (14) is held on
the holder (10) with the bearing, and the holder (10) transmits the revolving motion of planetary gear
(14) to the sun gear (66) which is engaged to the holder (10) with the spline on it. The sun gear
(66) is engaged to the planetary gear (68), and transmits the revolving motion to the planetary gear
(68) as the same routing as the first stage. Since the planetary gear (68) is held on the holder (72)
with the bearing, the holder (72) transmits the revolving motion of the planetary gear (68) to the
pinion shaft (2) which is engaged to the pinion shaft (2) with the spline on it.

24

24-51
[24. COMPONENTS SYSTEM]

24.1.6 TRAVEL MOTOR


24.1.6.1 SPECIFICATIONS
(1) General View

(2) Specifications
Model (Type) GM04VA
Rated output revolution (1st / 2nd) rpm 36.7 / 64.0
Reduction unit Output torque (1st / 2nd) N-m (lbf-ft) 3470 / 1900 (2560 / 1400)
Reduction ratio 1 / 53.7
3
Displacement (1st / 2nd) cm /rev (cu-in/rev) 20.5 / 11.5 (1.25 / 0.70)
Rated operating pressure MPa (psi) 23.0 (3340)
Rated output revolution (1st / 2nd) min-1(rpm) 1970 / 3439
Hydraulic motor
Rated flow L/min (gal/min) 41.2 / 10.9
2-Speed shifting pressure MPa (psi) 3.5 (507)
Automatic 2-speed shifting pressure MPa (psi) 18.5 (2680)
Static friction torque N-m (lbf-ft) 32.4 (23.9)
Parking brake
Releasing pressure MPa (psi) 0.89 (129)
Weight kg (lb) 43 (95)

24-52
[24. COMPONENTS SYSTEM]

24.1.6.2 CONSTRUCTION
(1) Construction (Outline)

24

24-53
[24. COMPONENTS SYSTEM]

(2) Sectional view

24-54
[24. COMPONENTS SYSTEM]

No. NAME Q'TY No. NAME Q'TY


1 Hub 1 161 --Piston 1
2 Spindle 1 162 --Shoe 1
3 Carrier 1 163 -Seal ring 1
4 Sun gear (1) 1 102 Shaft 1
5 Planetary gear (1) 3 103 Swash plate 1
6 Sun gear (2) 1 107 Retainer plate 1
7 Planetary gear (2) 4 108 Thrust ball 1
9 Thrust washer (1) 2 109 Timing plate 1
11 Thrust collar (4) 4 110 Washer 2
12 Thrust washer (3) 7 112 Piston 1
13 Cover 1 113 Spring 8
14 Coupling 1 114 Spring 1
22 Ring nut 1 115 Friction plate 1
24 Ball bearing 2 116 Separator plate 2
27 Needle roller bearing with retainer 3 132 Oil seal 1
28 Needle roller bearing with retainer 4 135 O-ring 1
29 Inner race 3 139 O-ring 1
30 Inner race 4 145 Snap ring 1
Floating seal kit 1 149 Ball bearing 1
31 Floating seal 2 150 Ball bearing 1
33 Plug with flange 1 151 Roller 3
35 O-ring 1 167 Pivot 2
37 O-ring 1 177 Parallel pin 2
39 Plug 2 190 Spring 1
40 Hexagon head screw 7 Rear flange assembly 1
41 Steel ball 1 -Rear flange kit 1
42 Parallel pin 2 201 --Rear flange 1
43 O-ring 2 223 --Spool 1
44 O-ring 1 -Spool kit 1
45 Ring 1 263 --Spool 1
47 Hexagon socket set screw 2 264 --Oil stopper 1
54 Hexagon socket plug 1 221 -Plug 2
Cylinder and piston kit 1 224 -Plug 2
104 -Cylinder block 1 225 -Stopper 2
-Piston kit 1 226 -Plug 2
--Piston assembly 7 227 -Valve 2
105 ---Piston 1 228 -Spring 2 24
106 ---Shoe 1 230 -Spring 2
Piston kit 1 236 -O-ring 2
-Piston assembly 1 237 -O-ring 2

24-55
[24. COMPONENTS SYSTEM]

No. NAME Q'TY No. NAME Q'TY


252 -Hexagon socket plug 4 279 -Filter 1
254 -Hexagon socket plug 4 280 -Plug with flange 1
266 -Spring 1 299 -Name plate 1
268 -Steel ball 1 241 Parallel pin 2
273 -O-ring 2 243 Capscrew 6
275 -Orifice 1

24-56
[24. COMPONENTS SYSTEM]

24.1.6.3 FUNCTION
24.1.6.3.1Reduction Unit
(1) Function
This reduction gear unit is composed of two stage planetary gear mechanism.
The reduction gear reduces the high speed of hydraulic motor and converts it low-speed, high- torque
rotation.

(2) Operating Description


The rotation of hydraulic motor shaft is transmitted to sun gear (4) of the first stage which is linked
with shaft (102) in spline.
Sun gear (4) is meshed with three planetary gears (5), and three planetary gears (5) mesh with hub
(1) while rotating on their axis.
At that time, the hub is rotated by the rotation of the planetary gears (5).
The hub rotation is transmitted to carrier (3) which connected to planetary gears (5), and that causes
sun gear (6) rotation of the second stage.
The rotation of sun gear (6) is transmitted to the hub via four planetary gears (7) of the second stage.
The generated rotation of reduction gear is output rotation.

24.1.6.3.2Hydraulic Motor Section (Brake valve, parking brake, high and low speed change
mechanism)
(1) Function
1. Hydraulic motor: Hydraulic motor is referred to as a swash plate type axial piston motor which
converts the pressure oil power fed by pump into rotary motion.
2. Brake valve
a.
Travel motor controls the force of rotational inertia of the body to brake and stop the rotation
smoothly.
b.
Check valve function to prevent hydraulic motor from cavitation.
c. 24
Open the port to release the parking brake force at travel motor operation, and close the port at a
standstill.
3. Parking brake:
The parking brake is used to the prevent machine from running away or slipping while parking on
a slope using the friction plate type brake mechanism, and is installed on the hydraulic motor.
4. High / Low 2-speed shifting mechanism: By means of changing the tilt angle of the swash plate to
change the stroke volume of piston with help of the function on the shifting valve and control
piston, the speed is shifted to high speed with low torque or low speed with high torque.

24-57
[24. COMPONENTS SYSTEM]

(2) Operation
1. Hydraulic motor
Hydraulic oil fed by pump enters rear flange
(201) of travel motor, and is led from timing
plate (109) to cylinder block (104) through brake
valve mechanism. This pressure oil is led to
only the one side of Y1-Y2 tied between top
dead point and bottom dead point of piston
(105) stroke. And the pressure led to one side
of cylinder block pushes 4 or 5 pistons (105),
generating the power {F (N) = 100 X P (MPa)
X A (cm2)}. This power enters on swash plate
(103), but swash plate (103) is fixed having an
angle (Alfa) against axis of drive shaft (102),
and divided into component of force (F2, F3).
And the radial component of force (F3)
generated various torque (T = F3 X ri) against
line Y1-Y2. The total torque [T = (F3 X ri)] is
connected to turning effort, and rotates cylinder
block (104) through piston (105).
This cylinder block (104) is connected with drive
shaft (102) with spline, and rotates drive shaft
(102) to transmit torque.

2. Brake valve
a. Operation (Brake released)
The pressure oil is led to through port (A),
opens valve (227), and led to port (C) on the
section side of hydraulic motor to rotate
hydraulic motor. At the same time, the
pressure oil enters chamber (b) through
passage (a) from the small hole of spool
(223), and exerts on the end of spool to
generate the force.
Then the force of spring (228) slides the spool
placed on the neutral position leftward.
The sliding of spool forms the space (passage)
between spool and rear flange with spool
groove. This passage is connected to port (D)
and port (B) of the return circuit of the
hydraulic motor, and the return oil returns to
tank side, enabling hydraulic motor to rotate.
Then, the sliding of spool (223) leads pressure
oil to port (P). The pressure oil led to port (P)
moves piston (112) of parking brake, and
releases parking braking force. (For details,
refer to item "Parking brake".) If pressurized oil
is supplied from port (B) the movements of
spool (223) and valve (227) are reversed so
that the hydraulic motor is rotated reversely.

24-58
[24. COMPONENTS SYSTEM]

b. Stop / Stall (braking action)


If pressurized oil supply through the port (A) is
suspended while travelling, the hydraulic force
to push up the spool is lost, and the spool
(223) which is slided to left side, tries to return
to the neutral position through the stopper (225)
due to the spring (228) force. At that time,
through the oil in the chamber (b) tries to flow
out to the port (A) side through the passage (a)
in the spool, its flow is restricted and some
back pressure is generated by the throttle effect
in the passage (a) controlling the return speed
of the spool. At the same time, the hydraulic
motor tries to rotate with its inertia force even
though the pressurized oil is suspended, and
the return oil from the hydraulic motor tries to
return to the port (B) side from the port (D)
through the passages on spool groove and rear
flange.
When the spool entirely return to the neutral
position, the passage on the hydraulic motor of
the oil return side is completely closed by the
spool, and the hydraulic motor ceases its
rotation. While machine working, the brake valve
smoothly stops rotation of the hydraulic motor
which tries to rotate with its inertia force, by
means of throttling the return side passage of
the hydraulic motor, generating back pressure
due to shape of the spool groove and
controlling the return speed of the spool.
On the other hand, when braking is operated,
the hydraulic motor tries to rotate with its inertia
force and to intake oil with its pumping function.
However, because the intake side is closed its
passage with the spool, the oil supply is
suspended. This causes cavitation in the
hydraulic motor. To prevent the cavitation, the
valve (227) is operated by very slight negative
pressure to open the passages of port (A)
side and intake port (C) of the hydraulic motor.
And when pressurized oil is supplied through
the port (B), each motion of the above
mentioned parts becomes symmetrical right 24
and left to stop the hydraulic motor.

24-59
[24. COMPONENTS SYSTEM]

c. Self-traveling
While machine is being operated, as the travel
speed is increased due to steep slope, the oil
flow rate of the hydraulic motor is higher than
the supply flow rate of the hydraulic oil pump.
The rotation of the hydraulic motor in this case
is called a self-traveling (Overrun).
While self-traveling, the oil pressure is lowered
similar to the stopping condition. Then brake
valve is moved similar to the stopping condition,
throttles passage in the return side of hydraulic
motor, and generate backing pressure.
In addition, the force of inertia decreases the
revolution of hydraulic motor to revolution having
a balance with the supply flow rate of pump.

3. Parking brake
a. Traveling
The pressure oil led trough brake valve
actuates on spool (223) of brake valve on the
hydraulic motor section, opens passage to
parking brake, and is led to cylinder chamber
(a) compressed of spindle (2) and piston (112)
on the reduction gear section.
If the pressure of oil which is 0.89MPa(129
psi) or higher it exceeds the force of spring
moving piston (112) toward rear flange (201)
side. This movement of piston (112) reduces
the push power to separator plate (116) and
friction plate (115), and makes the movement of
friction plate (115) which is installed to cylinder
block (104) on hydraulic motor section free
releasing the brake power to cylinder block
(104).

24-60
[24. COMPONENTS SYSTEM]

b. Stopping
If pressure oil from brake valve is cut, and the
pressure in cylinder chamber (a) lowers
0.89MPa(129 psi) or less, the piston (112) goes
to rightward by the force of spring (113).
Also, the force of the spring pushes mating
plate (116) and friction plate (115), which is in
a free state because piston (112) is pushed,
against spindle (2) on the reduction gear
section. The frictional force produced by the
push power stops the rotation of cylinder block
(104), and transmits braking torque 32.4N-m
(23.9 lbf-ft) to hydraulic motor shaft. And since
oil is controlled through the proper oil passage,
it results in smooth operation.

4. High / Low 2-speed shifting mechanism


a. Low speed
When the pilot pressure is not supplied through the port (D), the valve (263) is pushed up to the
upper position due to the spring (266) force and pressurized oil through the port (A) or (B), the
pressurized oil is cut off at port (C), and oil in the chamber (P) is released into the drain (motor case)
through the valve (263). Accordingly, the tilt angle of the swash plate (103) becomes the maximum
θ1 resulting the maximum stroke volume and low speed rotation of the hydraulic motor.

24

24-61
[24. COMPONENTS SYSTEM]

b. High speed
When 3.5 MPa (507 psi) of the pilot pressure is supplied through the port (D), it defeats the spring
(263) force and pressurized oil through the port (A) or (B) to push down the valve (263) to lower
position, the pressurized oil at the port (C) is led to the chamber (P) through the valve (263), and the
piston (161) pushes the swash plate (103) up to the plane X and maintain it at its position. At that
time, the tilt angle of the swash plate becomes the minimum θ 2 resulting the minimum stroke
volume and high speed rotation of the hydraulic motor.

c. Automatic shifting to low speed during high speed operation


If the load is increased while high speed operation, the oil pressure at the port (A) or (B) is also
increased. And when the oil pressure reaches to 18.5MPa (2680 psi), it excesses the pilot pressure
of 3.5MPa(507 psi), and the valve (263) is pushed up to upper position, and oil in the chamber (P) is
released into the drain (motor case) through the valve (263). At that time, the swash plate (103) gets
touch with the plane Y of spindle, and the tilt angle of swash plate becomes the maximum θ 1 and
is maintained at its position resulting low speed rotation.

24-62
[24. COMPONENTS SYSTEM]

24.1.7 SWIVEL JOINT


24.1.7.1 GENERAL VIEW

General view

24.1.7.2 SPECIFICATIONS
Model (Type) YV-7200
Port No. A, B, C, D E, F P G (Drain)
Max. working pressure MPa (psi) 24.5 (3550) <-- 20.6 (2990) 0.5 (73)
Pressure test MPa (psi) 36.8 (5340) <-- 30.9 (4480) 1.0 (145)
Flow L/min (gal/min) 60 (15.8) 30 (7.9) 5 (1.3) <--
Revolution rpm Less than 15
Weight kg (lb) Approx 22 (49)

24

24-63
[24. COMPONENTS SYSTEM]

24.1.7.3 CONSTRUCTION

Construction

No. NAME Q'TY No. NAME Q'TY


1 SHAFT 1 9 DUST SEAL 1
2 BODY 1 10 DUST SEAL 1
3 FLANGE 1 11 SNAP RING 1
4 THRUST RING 1 12 BOLT 4
5 PIN 1 13 PLUG 3
6 SLIPPER SEAL 4 14 SPRING WASHER 4
7 O-RING 1 15 BACK-UP RING 1
8 O-RING 1 16 SLIPPER SEAL 3

24-64
[24. COMPONENTS SYSTEM]

24.1.7.4 FUNCTION
The swivel joint is installed at the slewing
center of machine, and is to maintain the
connection of hydraulic oil circuits regardless to
the slewing angle on the upper frame. On the
body (2) and shaft (1) which are able to
independently rotate with each other, the
necessary number of ports (3) are provided
corresponding to the number of circuits. The
necessary number of grooves is machined on
both of the body (2) at its inner periphery and
the shaft (1) at its outer periphery, and these
grooves are sealed at upper and lower
portions with the seal (4) The hydraulic oil
flowing into the shaft from the port (3) is able
to keep its flowing along through the hydraulic
circuit (5) which is provided between the body
(2) and shaft (1), and the circuits maintained
without any hindrance due to the independent
rotation of the body (2) and shaft (1).

24

24-65
[24. COMPONENTS SYSTEM]

24.1.8 CYLINDER
24.1.8.1 SPECIFICATIONS
(1) General View

General view of cylinder

24-66
[24. COMPONENTS SYSTEM]

SK35SR-5
Center distance of mounting
Cylinder Bore /
Stroke pins Dry weight
Cylinder Rod Dia. Cushion
mm (ft-in) Full extend B / Full retract A kg (lb)
mm (ft-in)
mm (ft-in)
80 dia. / 45 dia.
Boom (Canopy) 578 (1'10.8") 1486 / 908 (4'10.5" / 2'11.7") 35 (77)
(3.15" / 1.77")
Rod side
80 dia. / 45 dia.
Boom (Cab) 555 (1'9.8") 1463 / 908 (4'9.6" / 2'11.7") 35 (77)
(3.15" / 1.77")
80 dia. / 45 dia.
Arm 560 (1'10") 1432 / 872 (4'8.4" / 2'10.3") Head side 32 (71)
(3.15" / 1.77")
65 dia / 40 dia.
Bucket 497 (1'7.6") 1272 / 775 (4'2.1" / 2'6.5") None 20 (44)
(2.56" / 1.57")
80 dia. / 45 dia.
Swing 488 (1'7.2") 1286 / 798 (4'2.6" / 2'7.4") None 37 (82)
(3.15" / 1.77")
100 dia / 50 dia.
Dozer 160 (6.3") 633 / 473 (2'09" /1'6.6") None 27 (60)
(3.94" / 1.97")

24

24-67
[24. COMPONENTS SYSTEM]

24.1.8.2 CONSTRUCTION AND FUNCTION


24.1.8.2.1Construction
(1) Boom cylinder

Construction of boom cylinder

No. NAME Q'TY No. NAME Q'TY No. NAME Q'TY


1 CYLINDER TUBE ASSY 1 10 O-RING 1 19 SETSCREW 1
2 PIN BUSHING 2 11 HOLDER 1 20 STEEL BALL 1
3 PISTON ROD ASSY 1 12 SPACER 1 21 CUSHION BEARING 1
4 CYLINDER HEAD 1 13 CUSHION SEAL 1 22 TUBE ASSY 1
5 BUSHING 1 14 COLLAR 1 23 CAPSCREW 1
6 U-RING 1 15 BACK-UP RING 1 24 LOCK WASHER 1
7 WIPER RING 1 16 PISTON 1 25 WASHER 1
8 O-RING 2 17 SEAL RING ASSY 1 26 DUST SEAL 4
9 BACK-UP RING 1 18 SLIDE RING 1 27 GREASE NIPPLE 2

24-68
[24. COMPONENTS SYSTEM]

(2) Arm cylinder

Construction of Arm cylinder

No. NAME Q'TY No. NAME Q'TY No. NAME Q'TY


1 CYLINDER TUBE ASSY 1 8 O-RING 1 15 STEEL BALL 1
2 PIN BUSHING 2 9 BACK-UP RING 1 16 CUSHION BEARING 1
3 PISTON ROD ASSY 1 10 O-RING 1 17 CUSHION SEAL 1
4 CYLINDER HEAD 1 11 PISTON 1 18 STOPPER 2
5 BUSHING 1 12 SEAL RING ASSY 1 19 SNAP RING 1
6 U-RING 1 13 SLIDE RING 2 20 DUST SEAL 4
7 WIPER RING 1 14 SETSCREW 1 21 GREASE NIPPLE 2

24

24-69
[24. COMPONENTS SYSTEM]

(3) Bucket cylinder

Construction of bucket cylinder

No. NAME Q'TY No. NAME Q'TY No. NAME Q'TY


1 CYLINDER TUBE ASSY 1 7 U-RING 1 13 DUST SEAL 1
2 PIN BUSHING 1 8 WIPER RING 1 14 SLIDE RING 2
3 PISTON ROD ASSY 1 9 O-RING 1 15 SETSCREW 1
4 PIN BUSHING 1 10 BACK-UP RING 1 16 STEEL BALL 1
5 CYLINDER HEAD 1 11 O-RING 1 17 DUST SEAL 4
6 BUSHING 1 12 PISTON 1 18 GREASE NIPPLE 2

24-70
[24. COMPONENTS SYSTEM]

(4) Swing cylinder

Construction of swing cylinder

No. NAME Q'TY No. NAME Q'TY No. NAME Q'TY


1 CYLINDER TUBE ASSY 1 7 WIPER RING 1 13 SLIDE RING 2
2 PIN BUSHING 2 8 O-RING 1 14 SETSCREW 1
3 PISTON ROD ASSY 1 9 BACK-UP RING 1 15 STEEL BALL 1
4 CYLINDER HEAD 1 10 O-RING 1 16 DUST SEAL 4
5 BUSHING 1 11 PISTON 1 17 GREASE NIPPLE 1
6 U-RING 1 12 SEAL RING ASSY 1

24

24-71
[24. COMPONENTS SYSTEM]

(5) Dozer cylinder

Construction of dozer cylinder

No. NAME Q'TY No. NAME Q'TY No. NAME Q'TY


1 CYLINDER TUBE ASSY 1 7 WIPER RING 1 13 SLIDE RING 2
2 PIN BUSHING 2 8 O-RING 1 14 SETSCREW 1
3 PISTON ROD ASSY 1 9 BACK-UP RING 1 15 STEEL BALL 1
4 CYLINDER HEAD 1 10 O-RING 1 16 DUST SEAL 4
5 BUSHING 1 11 PISTON 1 17 GREASE NIPPLE 1
6 U-RING 1 12 SEAL RING ASSY 1 18 GREASE NIPPLE 1

24-72
[24. COMPONENTS SYSTEM]

24.1.8.2.2Function (Example for boom cylinder)


(1) Fundamental Function
This is a kind of hydraulic actuator, and converts the energy in pressurized oil supplied by the
hydraulic pump to a large force linear direction by means of the piston, as well as changing over the
operating direction for either extension or retraction by means of actuating the valve lever to change
over the direction of pressurized oil flow. Such conversion of energy force and change over the
operating direction are of the fundamental function of this cylinder.

(2) Function of each Parts


The following description is based on a cylinder with a typical structure (Boom cylinder).
1. Cylinder Head Assy
The cylinder head assy also works as a bearing by means of pressing the bushing (5) into the
cylinder head (4). The oil leakage is prevented by insersion of the U-ring (6) into the bore of cylinder
head. The dust invasion is protected by pressing the wiper ring (7) into the bore of cylinder head. By
means of fitting with the cushion bearing (22) at adjacent to the fully extended position of the
cylinder, a high oil pressure is generated to absorb the cylinder shock at the fully extended position.
And the cylinder head has another function of charging and discharging highly pressurized oil from
the inside of cylinder tube to the port.

Cylinder head assy

a. Bushing (5)
The bushing (5) is pressed into the bore on cylinder head to support the piston rod. Along with
the slide ring installed outer periphery of the piston, the bushing (5) bears radial load imposed on
the cylinder, and performs linear movement against the piston rod at high facial pressure, and
minimized the eccentricity of piston rod that badly affects to the sealing effect by supporting its
one end.
b. Wiper Ring (7)
The wiper ring (7) is located at the entrance where the piston rod comes in and out. Its function 24
is to protect invasion of dust and water into the cylinder to secure good sealing effect of the
U-ring (6), as well as to remove dust and mud adhered on the piston rod.

24-73
[24. COMPONENTS SYSTEM]

2. Piston Assy
The piston assy has the seal ring (18) which is inserted at the center portion of the piston (17), to
prevent leakage of pressurized oil from either chamber of left or right to the other chamber. The slide
rings (19) are inserted in both sides of the seal ring (18) to bear radial load imposed on the cylinder,
and also to catch contaminations.

Piston assy

a. Seal Ring (18)


The location of seal ring (18) is the center of piston. The seal ring (18) is to seal the circular
gap between the piston and the cylinder tube utilizing a tension of the O-ring, to form both
chambers of high pressure side and low pressure side isolating from each other making the
piston as the border.
b. Slide Ring (19)
Two slide rings are provided at both sides of the seal ring (18) directly getting in touch with the
cylinder tube. Along with the bushing (5), the slide rings (19) bear radial load imposed on the
cylinder, perform linear movement against inside face of cylinder at high facial pressure, and
minimize the eccentricity of piston rod that badly affects to the sealing effect by supporting it at
one end. And the slide ring has another function of burying and catching contaminations between
the cylinder tube and the slide rings.
c. Cushion Bearing (22)
The cushion bearing (22) is located between the piston and the stepped portion of piston rod.
Along with the cylinder head, it has the functions to form a circular gap adjacent to the fully
extended position, and to throttle the oil to absorb the collision speed of cylinder at the fully
extended position to soften the shock.

24-74
[24. COMPONENTS SYSTEM]

24.2 ELECTRICAL EQUIPMENT

24.2.1 ELECTRICAL EQUIPMENT LIST

Group Code Part Name Part No.


D-1 DIODE YN02D01001P1
D-2 DIODE
D-3 DIODE
D-4 DIODE
Diode
D-12 DIODE
D-14 DIODE
D-18 DIODE
D-20 DIODE
E-1 FUSE BOX PW73E00003F1
E-2 GENERATOR (ALTERNATOR) E/G accessory (119626-77210)
E-3 HORN PY53S00002P1
E-4 FUSIBLE LINK PH73S00001P1
E-6 GAUGE CLUSTER PH59S00005F1
E-7 POWER SOCKET PF81S01001P1
E-8 GLOW PLUG E/G accessory (129008-77800)

Electical E-9 FUSE PW13E01080P1


Fittings E-10 RADIO (OPT) Cab accessory (PW54S00002P1)
E-11 OVER LOAD BUZZER YJ53S01001D3
E-12 HEATER (OPT) PM21M00005F1
E-13 BATTERY PW72S00004P1
E-14 SEQUENCE BOX PA24S00002P3
E-20 TRAVEL ALARM (OPT) PW53S00002F1
E-26 HOUR METER YT58S00006P1
E-32 FUSE 2479R655S10
L-1 ROOM LAMP PM80S00006P1
Light L-2 BOOM WORKING LIGHT PM80S00008F1
L-5 CANOPY WORKING LIGHT PW80S00003F1
M-1 STARTER MOTOR E/G accessory (129242-77010)
M-2 WIPER MOTOR (CAB) Cab accessory (PM76S00001F1)
Cab accessory
Motor M-3 WASHER MOTOR (CAB)
(PE54C00002S002)
M-4 DECELERATION MOTOR PW20S00012F1
M-6 FUEL PUMP PW22P00001P1
24
R-1 BATTERY RELAY PH24S00001P1
R-2 SAFETY RELAY PX24S00001P1
Relay R-3 DECELERATION RELAY PA24E01001P1
R-6 TIMER UNIT PH25S00002P1
R-7 E/G STOP RELAY PX24S00003P1

24-75
[24. COMPONENTS SYSTEM]

Group Code Part Name Part No.


R-8 CHARGE INDICATOR RELAY PA24E01001P1
Relay
R-9 CAB / CANOPY WORKING LIGHT RELAY
SE-1 FUEL SENSOR PX52S00006F1
Sensor
SE-2 COOLANT THERMO SENSOR PA24S00003P1
SV-1 LEVER LOCK SOL.
PX35V00003F1
SV-2 2-SPEED SELECT SOL.
Solenoid
SV-3 E/G STOP SOL. E/G accessory (119233-77932)
SV-5 POWER SHIFT SOL. (Cooler Spec) YJ35V00004F2
PSV-D NIBBLER OPEN PROPORTIONAL SOL.
PW35V00002F1
Proportional PSV-E NIBBLER CLOSE PROPORTIONAL SOL.
Solenoid Valve PSV-F REVOLUTION LEFT(A1) PROPORTIONAL SOL. (OPT) Pending
PSV-G REVOLUTION RIGHT(A2) PROPORTIONAL SOL. (OPT)

SW-1 KEY SWITCH PW50S00005S001


SW-2 WORKING LIGHT SW. PV24E01001P2
SW-3 2-SPEED SELECT SW. YN03M01286S002
SW-4 WIPER WASHER SW. PY50S00004P2
SW-5 E/G COOLANT TEMP. SW. PM50S00006P1
SW-6 E/G OIL PRESSURE SW. E/G accessory (114250-39450)
SW-7 HORN SW. YN50E01001P2
SW-9 LEVER LOCK SW. PA50S00001P1
SW-10 HEATER SW. (OPT) PY50S00003P2
SW-11 DECELERATION SW. PM50S00005P1
SW-17 TILT ANGLE SELECT SW. PW03M01350F1
Switch SW-23 TRAVEL ALARM SELECT SW. 2479U1190F16
SW-24 TRAVEL RIGHT(FORWARD) PRESSURE SW. (OPT) GB50S00049F2
SW-25 TRAVEL RIGHT(REVERSE) PRESSURE SW. (OPT)

SW-26 TRAVEL LEFT(FORWARD) PRESSURE SW. (OPT)

SW-27 TRAVEL LEFT(REVERSE) PRESSURE SW. (OPT)

SW-30 SLEWING LEVER PRESSURE SW. (LEFT)


SW-31 SLEWING LEVER PRESSURE SW. (RIGHT)
SW-35 NIBBLER OPEN-CLOSE SW. PW03M01958F1
SW-37 (A1, A2) REVOLUTION SW. (OPT) PW03M01959F1
SW-39 OVER LOAD PRESS. SW. 72117480 (DIN 43650)
SW-40 OVER LOAD SW. 2479U1190F33
SW-46 BATTERY DISCONNECT SW. LP50S00003P1

The part number may be changed owing to modification, use them only for reference.

24-76
[24. COMPONENTS SYSTEM]

24.2.2 SPECIFICATIONS ELECTRICAL EQUIPMENT

24

24-77
[24. COMPONENTS SYSTEM]

24-78
[24. COMPONENTS SYSTEM]

24

24-79
[24. COMPONENTS SYSTEM]

24-80
[24. COMPONENTS SYSTEM]

24

24-81
[24. COMPONENTS SYSTEM]

24-82
[24. COMPONENTS SYSTEM]

24

24-83
[24. COMPONENTS SYSTEM]

24-84
[24. COMPONENTS SYSTEM]

24

24-85
[24. COMPONENTS SYSTEM]

24-86
[24. COMPONENTS SYSTEM]

24

24-87
[24. COMPONENTS SYSTEM]

24-88
[24. COMPONENTS SYSTEM]

24

24-89
[24. COMPONENTS SYSTEM]

24-90
[24. COMPONENTS SYSTEM]

24

24-91
[24. COMPONENTS SYSTEM]

24-92
[42. TROUBLESHOOTING (HYDRAULIC SYSTEM)]

42. TROUBLE SHOOTING


42
(HYDRAULIC SYSTEM)
TABLE OF CONTENTS

42.1 GENERAL PRECAUTIONS ……………………………………………………………………………………42-3


42.1.1 CONFIRM ACTUAL TROUBLED CONDITIONS AT SITE …………………………………………42-3
42.2 TROUBLE DIAGNOSIS : HYDRAULIC ……………………………………………………………………42-5
42.3 TROUBLESHOOTING …………………………………………………………………………………………42-6
42.3.1 ATTACHMENT ……………………………………………………………………………………………42-6
42.3.2 TRAVEL OPERATION ……………………………………………………………………………………42-8
42.3.3 SLEWING OPERATION …………………………………………………………………………………42-10
42.3.4 PUMP ………………………………………………………………………………………………………42-11

Book Code No. S5PW4231E02

42-1
[42. TROUBLESHOOTING (HYDRAULIC SYSTEM)]

Issue Date of Issue Applicable Machines Remarks


SK30SR-5 : PW14- S5PW4231E01
First Edition March, 2010
SK35SR-5 : PX15- (KCM North America)
SK30SR-5 : PW14-46519~ S5PW4231E02
Revision June, 2010
SK35SR-5 : PX15-21105~ (KCM North America)
CX31B : PW14-46519~
CX36B : PX15-21105~ (CASE-NA)
E30B : PW14-46519~
E35B : PX15-21105~ (NH-NA)

SK50SR-5 : PJ06-09807~
(KCM North America)

CX50B : PJ06-09807~
(CASE-NA)

E50B : PJ06-09807~
(NH-NA)
CX31B : PW14-46519~
CX36B : PX15-21105~ (CASE-AUS)
SK30SR-5 : PW14-46519~
SK35SR-5 : PX15-21105~ (KCM S.E.ASIA&OCE)
E30B : PW14-46519~
E35B : PX15-21105~ (NH-AUS)
SK40SR-5 : PH07-06609~
SK50SR-5 : PJ06-09807~ (KCM S.E.ASIA&OCE)

E50B : PJ06-09807~
(NH-AUS)

CX50B : PJ06-09807~
(CASE-AUS)

SK27SR-5 : PV13-33453~
(NA)

CX27B : PV13-33453~
(CASE-NA)

E27B : PV13-33453~
(NH-NA)
SK20SR-5 : PM10-10609~
SK27SR-5 : PV13-33453~ (KCM S.E.ASIA&OCE)

CX27B : PV13-33453~
(CASE-Australia)

E27B : PV13-33453~
(NH-AUS)

September, 2013 SK27SR-5 : PV13-34084~


(NA)

SK35SR-5 : PX15-22809~
(NA)

December, 2013 SK27SR-5 : PV13-34084~


(EUR)

SK30SR-5 : PW14-46519~
(EUR)

SK35SR-5 : PX15-22809~
(EUR)

42-2
[42. TROUBLESHOOTING (HYDRAULIC SYSTEM)]

42.1 GENERAL PRECAUTIONS

Troubleshooting provides the process to investigate the cause of trouble in order when a trouble
occurred. This manual describes the way how to solve the specific phenomenon systematically as
quick as possible. For the troubleshooting concerning the inside of equipment, refer to the
troubleshooting for each manual of the equipment.

42
42.1.1 CONFIRM ACTUAL TROUBLED CONDITIONS AT SITE
(1) Get to the site as quickly as possible.
Verify the machine model, serial number,
situation of trouble and field, and notify possible
arrival time to the user.

Make field investigation

(2) Verify background of trouble occurred.


1. Model name and serial number.
2. Kind of attachment.
Check that the combination of attachments
was proper and that the operating manner
was not unreasonable.
3. Operating time on the hour-meter.
4. Record of troubles.
First trouble or repeated trouble.
5. History of the trouble and additional
modifications.
Reoccurrence of the same trouble in the Verifying background of trouble occurred.
past or trouble due to additional
modification.

(3) How to diagnose trouble


1. Verify defective part.
2. Reproduce the troubled conditions.
3. Where the defective part can not be
verified, surmise the possible causes
systematically.
4. Verify the surmised cause.
5. Report estimated repairing method,
procedures and term to the user. Diagnosing trouble by means troubleshooting.

42-3
[42. TROUBLESHOOTING (HYDRAULIC SYSTEM)]

(4) Explanation of the cause of trouble


1. Explain the cause of trouble to the user.
For example, explain the oil leakage through the piston is caused by defect on the piston rod.
And the proper operating manner of the machine should be explained to the user to prevent
reoccurrence of the same kind of trouble.
2. Handling of damaged parts
The damaged parts to be claimed and returned are the evidence, so they should be handled with
care. For example, protect them from invasion of water, soil, etc., into ports on a hydraulic
equipment, etc., at the returning them. And also use care not to give any damages and breakage
for transport.

42-4
[42. TROUBLESHOOTING (HYDRAULIC SYSTEM)]

42.2 TROUBLE DIAGNOSIS : HYDRAULIC

42

Abbreviation
E/G : Engine
SOL : Solenoid
SW : Switch
ATT : Attachment
C/V : Control valve
R/V : Relief valve
V : Valve

42-5
[42. TROUBLESHOOTING (HYDRAULIC SYSTEM)]

42.3 TROUBLESHOOTING

42.3.1 ATTACHMENT
42.3.1.1 ATTACHMENT OPERATIONAL FAILURE (Excluding swing operations)

42.3.1.2 ATTACHMNT SPEED IS SLOW

42-6
[42. TROUBLESHOOTING (HYDRAULIC SYSTEM)]

42.3.1.3 ATTACHMENT OPERATING POWER IS LOW

42

42.3.1.4 MALFUNCTION OF ATTACHMENT

42-7
[42. TROUBLESHOOTING (HYDRAULIC SYSTEM)]

42.3.2 TRAVEL OPERATION


42.3.2.1 TRAVEL OPERATIONAL FAILURE

42.3.2.2 TRAVEL SPEED IS SLOW

42-8
[42. TROUBLESHOOTING (HYDRAULIC SYSTEM)]

42.3.2.3 TRAVEL POWER IS LOW

42

42.3.2.4 IT DEVIATES IN TRAVEL INDEPENDENT OPERATION

42-9
[42. TROUBLESHOOTING (HYDRAULIC SYSTEM)]

42.3.3 SLEWING OPERATION


42.3.3.1 SLEWING OPERATIONAL FAILURE

42.3.3.2 SLEWING SPEED IS SLOW

42.3.3.3 SLEWING POWER IS LOW

42-10
[42. TROUBLESHOOTING (HYDRAULIC SYSTEM)]

42.3.3.4 MALFUNCTION OF SLEWING OPERATION

42

42.3.4 PUMP
42.3.4.1 ENGINE SPEED IS REDUCED DUE TO PUMP LOAD

42.3.4.2 MALFUNCTION OF PUMP

42-11
[42. TROUBLESHOOTING (HYDRAULIC SYSTEM)]

42-12
[43. TROUBLESHOOTING (ELECTRICAL SYSTEM)]

43. TROUBLESHOOTING
(ELECTRICAL SYSTEM)
TABLE OF CONTENTS
43
43.1 TROUBLE DIAGNOSIS : ELECTRIC SYSTEM ……………………………………………………………43-3
43.2 TROUBLESHOOTING …………………………………………………………………………………………43-4
43.2.1 GENERAL …………………………………………………………………………………………………43-4
43.2.2 ATTACHMENT OPERATION ……………………………………………………………………………43-8
43.2.3 TRAVEL OPERATION ……………………………………………………………………………………43-11
43.2.4 DECELERATION …………………………………………………………………………………………43-12

Book Code No. S5PW4331E02

43-1
[43. TROUBLESHOOTING (ELECTRICAL SYSTEM)]

Issue Date of Issue Applicable Machines Remarks


SK30SR-5 : PW14- S5PW4331E01
First Edition March, 2010
SK35SR-5 : PX15- (KCM North America)
SK30SR-5 : PW14-46519~ S5PW4331E02
Revision June, 2010
SK35SR-5 : PX15-21105~ (KCM North America)
CX31B : PW14-46519~
CX36B : PX15-21105~ (CASE-NA)
E30B : PW14-46519~
E35B : PX15-21105~ (NH-NA)

SK50SR-5 : PJ06-09807~
(KCM North America)

CX50B : PJ06-09807~
(CASE-NA)

E50B : PJ06-09807~
(NH-NA)
CX31B : PW14-46519~
CX36B : PX15-21105~ (CASE-AUS)
SK30SR-5 : PW14-46519~
SK35SR-5 : PX15-21105~ (KCM S.E.ASIA&OCE)
E30B : PW14-46519~
E35B : PX15-21105~ (NH-AUS)
SK40SR-5 : PH07-06609~
SK50SR-5 : PJ06-09807~ (KCM S.E.ASIA&OCE)

E50B : PJ06-09807~
(NH-AUS)

CX50B : PJ06-09807~
(CASE-AUS)

SK27SR-5 : PV13-33453~
(NA)

CX27B : PV13-33453~
(CASE-NA)

E27B : PV13-33453~
(NH-NA)
SK20SR-5 : PM10-10609~
SK27SR-5 : PV13-33453~ (KCM S.E.ASIA&OCE)

CX27B : PV13-33453~
(CASE-Australia)

E27B : PV13-33453~
(NH-AUS)

September, 2013 SK27SR-5 : PV13-34084~


(NA)

SK35SR-5 : PX15-22809~
(NA)

December, 2013 SK27SR-5 : PV13-34084~


(EUR)

SK30SR-5 : PW14-46519~
(EUR)

SK35SR-5 : PX15-22809~
(EUR)

43-2
[43. TROUBLESHOOTING (ELECTRICAL SYSTEM)]

43.1 TROUBLE DIAGNOSIS : ELECTRIC SYSTEM

43

43-3
[43. TROUBLESHOOTING (ELECTRICAL SYSTEM)]

43.2 TROUBLESHOOTING

43.2.1 GENERAL
43.2.1.1 ENGINE DOES NOT START.

43-4
[43. TROUBLESHOOTING (ELECTRICAL SYSTEM)]

43

43-5
[43. TROUBLESHOOTING (ELECTRICAL SYSTEM)]

43.2.1.2 HORN DOES NOT SOUND.

43.2.1.3 WORKING LIGHT DOES NOT LIGHT UP.

43-6
[43. TROUBLESHOOTING (ELECTRICAL SYSTEM)]

43.2.1.4 HOURMETER DOES NOT ACTUATE.

43

43.2.1.5 FUEL GAUGE DOES NOT ACTUATE.

43.2.1.6 WATER TEMPERATURE METER DOES NOT ACTUATE.

43-7
[43. TROUBLESHOOTING (ELECTRICAL SYSTEM)]

43.2.2 ATTACHMENT OPERATION


43.2.2.1 ALL CONTROLS DO NOT FUNCTION

43-8
[43. TROUBLESHOOTING (ELECTRICAL SYSTEM)]

43

43-9
[43. TROUBLESHOOTING (ELECTRICAL SYSTEM)]

43-10
[43. TROUBLESHOOTING (ELECTRICAL SYSTEM)]

43.2.3 TRAVEL OPERATION


43.2.3.1 TRAVEL 1 & 2 SPEED CHANGE CAN NOT BE CARRIED OUT.

43

43-11
[43. TROUBLESHOOTING (ELECTRICAL SYSTEM)]

43.2.4 DECELERATION
43.2.4.1 DECEL CHANGE OPERATION IN OPTION CAN NOT BE CARRIED OUT.

43-12
[44. TROUBLESHOOTING (ENGINE)]

44. TROUBLESHOOTING
(ENGINE)
TABLE OF CONTENTS

44.1 TROUBLE DIAGNOSIS : ENGINE …………………………………………………………………………44-3


44.2 TROUBLESHOOTING …………………………………………………………………………………………44-6
44.2.1 STARTING TROUBLE ……………………………………………………………………………………44-6
44.2.2 E/G ROTATION TROUBLE ………………………………………………………………………………44-8
44.2.3 OUTPUT DROPS DOWN ………………………………………………………………………………44-9
44.2.4 OTHER TROUBLE…………………………………………………………………………………………44-10
44

Book Code No. S5PW4431E02

44-1
[44. TROUBLESHOOTING (ENGINE)]

Issue Date of Issue Applicable Machines Remarks


SK30SR-5 : PW14- S5PW4431E01
First Edition March, 2010
SK35SR-5 : PX15- (KCM North America)
SK30SR-5 : PW14-46519~ S5PW4431E02
Revision June, 2010
SK35SR-5 : PX15-21105~ (KCM North America)

E50B : PJ06-09807~
(NH-AUS)

CX50B : PJ06-09807~
(CASE-AUS)

SK27SR-5 : PV13-33453~
(NA)

CX27B : PV13-33453~
(CASE-NA)

E27B : PV13-33453~
(NH-NA)
SK20SR-5 : PM10-10609~
SK27SR-5 : PV13-33453~ (KCM S.E.ASIA&OCE)

CX27B : PV13-33453~
(CASE-Australia)

E27B : PV13-33453~
(NH-AUS)

September, 2010 SK55SRX : PS02-00101~


(KCM North America)

CX55BMSR : PS02-00101~
(CASE-NA)

E55BX : PS02-00101~
(NH-NA)

December, 2010 SK55SRX : PS02-00101~


(KOR)

January, 2011 SK50P : PS02-00101~


(SE Asia)

March, 2011 SK55SRX : PS02-00101~


(AUS)

CX55BX : PS02-00101~
(CASE-AUS)

E55BX : PS02-00101~
(NH-AUS)

September, 2013 SK27SR-5 : PV13-34084~


(NA)

SK35SR-5 : PX15-22809~
(NA)

December, 2013 SK27SR-5 : PV13-34084~


(EUR)

SK55SRX-6 : PS03-05001~
(OCE)

SK30SR-5 : PW14-46519~
(EUR)

SK35SR-5 : PX15-22809~
(EUR)

44-2
[44. TROUBLESHOOTING (ENGINE)]

44.1 TROUBLE DIAGNOSIS : ENGINE

44

44-3
[44. TROUBLESHOOTING (ENGINE)]

44-4
[44. TROUBLESHOOTING (ENGINE)]

44

44-5
[44. TROUBLESHOOTING (ENGINE)]

44.2 TROUBLESHOOTING

44.2.1 STARTING TROUBLE


44.2.1.1 STARTER DOES NOT ROTATE

44-6
[44. TROUBLESHOOTING (ENGINE)]

44.2.1.2 STARTER ROTATES BUT HARD TO START

44

44-7
[44. TROUBLESHOOTING (ENGINE)]

44.2.2 E/G ROTATION TROUBLE

44-8
[44. TROUBLESHOOTING (ENGINE)]

44.2.3 OUTPUT DROPS DOWN


44.2.3.1 ENGINE OUTPUT NOT ENOUGH

44

44.2.3.2 KNOCKING AT HIGH TEMPERATURE

44-9
[44. TROUBLESHOOTING (ENGINE)]

44.2.4 OTHER TROUBLE


44.2.4.1 EXHAUST TROUBLE

A breather mechanism of blow-by gas reduction system is applied to the engine as shown in the
drawing. Remove and plug the suction manifold to check blow-by gas.

44-10
[44. TROUBLESHOOTING (ENGINE)]

44.2.4.2 EXCESSIVE OIL CONSUMPTION

44.2.4.3 EXCESSIVE FUEL CONSUMPTION

44

44.2.4.4 ENGINE NOT STOP WHEN KEY TURNED OFF

44-11
[44. TROUBLESHOOTING (ENGINE)]

44-12
[51. ENGINE]

51. ENGINE
PREFACE
51
This manual explains the engine proper and is a faithful of YANMAR DIESEL ENGINE'S service
manuals.

Book Code No. S5PW5131E02

51-1
[51. ENGINE]

Issue Date of Issue Applicable Machines Remarks


SK30SR-5 : PW14- S5PW5131E01
First Edition March, 2010
SK35SR-5 : PX15- (KCM North America)
SK30SR-5 : PW14-46519~ S5PW5131E02
Revision June, 2010
SK35SR-5 : PX15-21105~ (KCM North America)
CX31B : PW14-46519~
CX36B : PX15-21105~ (CASE-NA)
E30B : PW14-46519~
E35B : PX15-21105~ (NH-NA)

SK50SR-5 : PJ06-09807~
(KCM North America)

CX50B : PJ06-09807~
(CASE-NA)

E50B : PJ06-09807~
(NH-NA)
SK30SR-5 : PW14-46519~
SK35SR-5 : PX15-21105~ (KCM S.E.ASIA&OCE)
CX31B : PW14-46519~
CX36B : PX15-21105~ (CASE-AUS)
E30B : PW14-46519~
E35B : PX15-21105~ (NH-AUS)
SK40SR-5 : PH07-06609~
SK50SR-5 : PJ06-09807~ (KCM S.E.ASIA&OCE)

E50B : PJ06-09807~
(NH-AUS)

CX50B : PJ06-09807~
(CASE-AUS)

September, 2010 SK55SRX : PS02-00101~


(KCM North America)

CX55BMSR : PS02-00101~
(CASE-NA)

E55BX : PS02-00101~
(NH-NA)

December, 2010 SK55SRX : PS02-00101~


(KOR)

January, 2011 SK50P : PS02-00101~


(SE Asia)

March, 2011 SK55SRX : PS02-00101~


(AUS)

CX55BX : PS02-00101~
(CASE-AUS)

E55BX : PS02-00101~
(NH-AUS)

September, 2013 SK35SR-5 : PX15-22809~


(NA)

December, 2013 SK30SR-5 : PW14-46519~


(EUR)

SK35SR-5 : PX15-22809~
(EUR)

51-2
TNV DI Service Manual

TNV series
SERVICE MANUAL
3TNV82A(-B) • 3TNV84 • 3TNV84T(-B) •
3TNV88(-B)(-U)
4TNV84 • 4TNV84T(-Z) •
4TNV88(-B)(-U)
4TNV94L
4TNV98(-Z)(-E) • 4TNV98T(-Z)
4TNV106 • 4TNV106T

P/N: 0BTNV-G00101

INDUSTRIAL
ENGINES
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.

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.
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.
© 2005 Yanmar Co. Ltd.

ii TNV DI Service Manual


TNV DI Service Manual
Section 1

TABLE OF
CONTENTS
Page
Table of Contents ................................................................................... iii
Introduction ......................................................................................... 1-1
Yanmar Warranties.............................................................................. 2-1
Safety.................................................................................................... 3-1
General Service Information .............................................................. 4-1
Engine .................................................................................................. 6-1
Periodic Maintenance ......................................................................... 5-1
Fuel System ......................................................................................... 7-1
Cooling System ................................................................................... 8-1
Lubrication System ............................................................................. 9-1
Turbocharger ..................................................................................... 10-1
Starter Motor...................................................................................... 11-1
Alternator ........................................................................................... 12-1
Electric Wiring ................................................................................... 13-1
Troubleshooting ................................................................................ 14-1

TNV DI Service Manual iii


TABLE OF CONTENTS

This Page Intentionally Left Blank

iv TNV DI Service Manual


TNV DI 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 and/or the 97/68/EC Directive
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.

TNV DI Service Manual 1-1


INTRODUCTION

This Page Intentionally Left Blank

1-2 TNV DI Service Manual


TNV DI Service Manual
Section 2

YANMAR
WARRANTIES
Page
Yanmar Limited Warranty................................................................ 2-3
What is Covered by this Warranty? .......................................... 2-3
How Long is the Warranty Period? ........................................... 2-3
What the Engine Owner Must Do: ............................................ 2-3
To Locate an Authorized Yanmar Industrial Engine
Dealer or Distributor: ................................................................. 2-4
What Yanmar Will Do: ............................................................... 2-4
What is Not Covered by this Warranty? ................................... 2-4
Warranty Limitations: ................................................................ 2-5
Warranty Modifications: ............................................................ 2-5
Questions: ................................................................................. 2-5
Retail Purchaser Registration.................................................... 2-5
Emission System Warranty ............................................................. 2-6
Yanmar Co., Ltd. Limited Emission Control System
Warranty - USA Only....................................................................... 2-6
Your Warranty Rights and Obligations: ..................................... 2-6
Manufacturer’s Warranty Period:............................................... 2-6
Warranty Coverage: .................................................................. 2-7
Warranted Parts: ....................................................................... 2-7
Exclusions: ................................................................................ 2-8
Owner’s Warranty Responsibilities:........................................... 2-8

TNV DI Service Manual 2-1


YANMAR WARRANTIES

This Page Intentionally Left Blank

2-2 TNV DI Service Manual


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 two-
thousand (2000) engine operation hours, whichever occurs first. An extended limited warranty of thirty-
six (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.

TNV DI Service Manual 2-3


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
Corp., 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.

2-4 TNV DI Service Manual


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.

Retail Purchaser Registration

It is very important for the original retail purchaser to register the Yanmar product. Registration enables
Yanmar to provide the best support for your Yanmar product.
At the time of purchase, Yanmar highly recommends registering the retail purchaser’s information through
the website http://www.yanmar.co.jp as soon as possible.
If it is not possible to access the website, please contact the nearest authorized Yanmar industrial engine
dealer or distributor.

TNV DI Service Manual 2-5


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, model year 2000 or later off-road compression-
ignition engines must be designed, built and equipped to meet the State’s stringent anti-smog 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.

Engine Type Warranty Period by Number of Years or Hours of Operation


The warranty period is five (5) years or 3,000 hours of use, whichever occurs first.
Constant speed engines rated at or above
In the absence of a device to measure the hours of use, the engine has a
50 hp SAE (37 kW)
warranty period of five (5) years.
Constant speed engines rated under 50 hp The warranty period is two (2) years or 3,000 hours of use, whichever occurs first.
SAE (37 kW) with rated speeds greater than In the absence of a device to measure the hours of use, the engine has a
or equal to 3,000 rpm warranty period of two (2) years.
The warranty period is five (5) years or 3,000 hours of use, whichever occurs first.
Engines rated at or above 26 hp SAE
In the absence of a device to measure the hours of use, the engine has a
(19 kW)
warranty period of five (5) years.
The warranty period is two (2) years or 3,000 hours of use, whichever occurs first.
Engines rated under 26 hp SAE (19 kW) In the absence of a device to measure the hours of use, the engine has a
warranty period of two (2) years.

2-6 TNV DI Service Manual


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.

TNV DI Service Manual 2-7


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 at 1-800-872-2867.

2-8 TNV DI Service Manual


TNV DI Service Manual
Section 3

SAFETY
Page
Safety Statements ........................................................................... 3-3
Safety Precautions .......................................................................... 3-4

TNV DI Service Manual 3-1


SAFETY

This Page Intentionally Left Blank

3-2 TNV DI Service Manual


Safety Statements SAFETY

SAFETY STATEMENTS
A CAUTION
Yanmar is concerned for your safety and your Caution (the word “CAUTION” is in black
machine’s condition. Safety statements are one of letters with a yellow rectangle behind it)
the primary ways to call your attention to the – indicates a potentially hazardous
potential hazards associated with Yanmar TNV situation which, if not avoided, may
engine operation. Follow the precautions listed result in minor or moderate injury.
throughout the manual before operation, during
0000001en
operation and during periodic maintenance
procedures for your safety, the safety of others and
to protect the performance of your engine. Keep the CAUTION
labels from becoming dirty or torn and replace Caution without the safety alert symbol
them if they are lost or damaged. Also, if you need indicates a potentially hazardous
to replace a part that has a label attached to it, situation that can cause damage to the
make sure you order the new part and label at the machine, personal property and / or the
same time. environment or cause the machine to
operate improperly.
This safety alert symbol appears 0000001en

A
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.

A DANGER
Danger (the word “DANGER” is in white
letters with a red rectangle behind
it) - indicates an imminently hazardous
situation which, if not avoided, will
result in death or serious injury. Danger
is limited to the most extreme
situations.
0000001en

A WARNING
Warning (the word “WARNING” is in
black letters with an orange rectangle
behind it) – indicates a potentially
hazardous situation which, if not
avoided, could result in death or serious
injury.
0000001en

TNV DI Service Manual 3-3


SAFETY Safety Precautions

SAFETY PRECAUTIONS
A DANGER
A DANGER

FIRE AND EXPLOSION HAZARD!


• Diesel fuel is flammable and explosive
under certain conditions.
SCALD HAZARD!
• When you remove any fuel system
• NEVER remove the radiator cap if the
component to perform maintenance
engine is hot. Steam and hot engine
(such as changing the fuel filter) place
coolant will spurt out and seriously
an approved container under the
burn you. Allow the engine to cool
opening to catch the fuel.
down before you attempt to remove
the radiator cap. • NEVER use a shop rag to catch the
fuel. Vapors from the rag are
• Tighten the radiator cap securely after
flammable and explosive.
you check the radiator. Steam can
spurt out during engine operation if • Wipe up any spills immediately.
the cap is loose. • Wear eye protection. The fuel system
• ALWAYS check the level of the engine is under pressure and fuel could spray
coolant by observing the reserve tank. out when you remove any fuel system
component.
• Failure to comply will result in death or
serious injury. • Failure to comply will result in death or
0000002en
serious injury.
0000009en

A DANGER
A DANGER

EXPLOSION HAZARD! FIRE AND EXPLOSION HAZARD!


• Keep the area around the battery • Only use the key switch to start the
well-ventilated. While the engine is engine.
running or the battery is charging,
hydrogen gas is produced which can • NEVER jump-start the engine. Sparks
be easily ignited. caused by shorting the battery to the
starter terminals may cause a fire or
• Keep sparks, open flame and any other explosion.
form of ignition away while the engine
is running or battery is charging. • Failure to comply will result in death or
serious injury.
• Failure to comply will result in death or
0000004en
serious injury.
0000003en

3-4 TNV DI Service Manual


Safety Precautions SAFETY

A DANGER A DANGER

FIRE AND EXPLOSION HAZARD! FIRE AND EXPLOSION HAZARD!


• Diesel fuel is flammable and explosive • Diesel fuel is flammable and explosive
under certain conditions. under certain conditions.
• If the unit has an electric fuel pump, • Only fill the fuel tank with diesel fuel.
when you prime the fuel system, turn Filling the fuel tank with gasoline may
the key switch to the ON position for result in a fire and will damage the
10 to 15 seconds to allow the electric engine.
fuel pump to prime the system.
• NEVER refuel with the engine running.
• If the unit has a mechanical fuel pump,
when you prime the fuel system, • Wipe up all spills immediately.
operate the fuel priming lever of the • Keep sparks, open flames or any other
mechanical fuel pump several times form of ignition (match, cigarette,
until the fuel filter cup is filled with static electric source) well away when
fuel. refueling.
• Failure to comply will result in death or • NEVER overfill the fuel tank.
serious injury. • Fill the fuel tank. Store any containers
0000010en
containing fuel in a well-ventilated
area, away from any combustibles or
sources of ignition.
• Failure to comply will result in death or
serious injury.
0000005en

TNV DI Service Manual 3-5


SAFETY Safety Precautions

A DANGER A DANGER

FIRE AND EXPLOSION HAZARD!


• Diesel fuel is flammable and explosive CRUSH HAZARD!
under certain conditions. • When you need to transport an engine
for repair, have a helper assist you to
• Be sure to place the diesel fuel
attach it to a hoist and load it on a
container on the ground when
truck.
transferring the diesel fuel from the
pump to the container. Hold the hose • NEVER stand under a hoisted engine.
nozzle firmly against the side of the If the hoist mechanism fails, the
container while filling it. This prevents engine will fall on you, causing death
static electricity buildup which could or serious injury.
cause sparks and ignite fuel vapors. • Failure to comply will result in death or
• NEVER place diesel fuel or other serious injury.
flammable material such as oil, hay or 0000008en

dried grass close to the engine during


engine operation or shortly after
shutdown.
A DANGER
• Failure to comply will result in death or
serious injury.
0000014en

FIRE AND EXPLOSION HAZARD!


• Diesel fuel is flammable and explosive
under certain conditions.
• 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.
• Failure to comply will result in death or
serious injury.
0000015en

3-6 TNV DI Service Manual


Safety Precautions SAFETY

A DANGER A DANGER

FIRE AND EXPLOSION HAZARD!


EXPLOSION HAZARD! • Diesel fuel is flammable and explosive
• NEVER check the remaining battery under certain conditions.
charge by shorting out the terminals.
• NEVER use diesel fuel as a cleaning
This will result in a spark and may
agent.
cause an explosion or fire. Use a
hydrometer to check the remaining • Failure to comply will result in death or
battery charge. serious injury.
0000012en
• If the electrolyte is frozen, slowly warm
the battery before you recharge it.
• Failure to comply will result in death or
serious injury.
0000007en

A DANGER

FIRE AND EXPLOSION HAZARD!


• Diesel fuel is flammable and explosive
under certain conditions.
• NEVER remove the fuel cap with the
engine running.
• Failure to comply will result in death or
serious injury.
0000011en

TNV DI Service Manual 3-7


SAFETY Safety Precautions

A WARNING A WARNING

SEVER HAZARD! EXHAUST HAZARD!


• Keep hands and other body parts • NEVER operate the engine in an
away from moving / rotating parts enclosed area such as a garage,
such as the cooling fan, flywheel or tunnel, underground room, manhole or
PTO shaft. ship’s hold without proper ventilation.
• Wear tight-fitting clothing and keep • NEVER block windows, vents, or other
your hair short or tie it back while the means of ventilation if the engine is
engine is running. operating in an enclosed area. All
• Remove all jewelry before you operate internal combustion engines create
or service the machine. carbon monoxide gas during
operation. Accumulation of this gas
• NEVER start the engine in gear. within an enclosure could cause
Sudden movement of the engine illness or even death.
and / or machine could cause death or
serious personal injury. • Make sure that all connections are
tightened to specifications after repair
• NEVER operate the engine without the is made to the exhaust system.
guards in place.
• Failure to comply could result in death
• Before you start the engine make sure or serious injury.
that all bystanders are clear of the 0000003en
area.
• Keep children and pets away while the
engine is operating.
A WARNING
• 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 ALCOHOL AND DRUG HAZARD!
or serious injury.
0000002en
• 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.
0000004en

3-8 TNV DI Service Manual


Safety Precautions SAFETY

A WARNING A WARNING

BURN HAZARD!
EXPOSURE HAZARD! • If you must drain the engine oil while it
is still hot, stay clear of the hot engine
• Wear personal protective equipment
oil to avoid being burned.
such as gloves, work shoes, eye and
hearing protection as required by the • ALWAYS wear eye protection.
task at hand. • Failure to comply could result in death
• NEVER wear jewelry, unbuttoned or serious injury.
cuffs, ties or loose-fitting clothing 0000011en

when you are working near


moving / rotating parts such as the
cooling fan, flywheel or PTO shaft.
A WARNING
• 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 BURN HAZARD!
wearing a headset to listen to music or • Batteries contain sulfuric acid. NEVER
radio because it will be difficult to hear allow battery fluid to come in contact
the alert signals. with clothing, skin or eyes. Severe
• Failure to comply could result in death burns could result. ALWAYS wear
or serious injury. safety goggles and protective clothing
0000005en
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.
0000007en

TNV DI Service Manual 3-9


SAFETY Safety Precautions

A WARNING A WARNING

HIGH-PRESSURE HAZARD! ENTANGLEMENT HAZARD!


• Avoid skin contact with the • Stop the engine before you begin to
high-pressure diesel fuel spray caused service it.
by a fuel system leak such as a broken
fuel injection line. High-pressure fuel • NEVER leave the key in the key switch
can penetrate your skin and result in when you are servicing the engine.
serious injury. If you are exposed to Someone may accidentally start the
high-pressure fuel spray, obtain engine and not realize you are
prompt medical treatment. servicing it. This could result in a
serious injury.
• NEVER check for a fuel leak with your
hands. ALWAYS use a piece of wood • If you must service the engine while it
or cardboard. Have your authorized is operating, remove all jewelry, tie
Yanmar industrial engine dealer or back long hair, and keep your hands,
distributor repair the damage. other body parts and clothing away
from moving / rotating parts.
• Failure to comply could result in death
or serious injury. • Failure to comply could result in death
0000008en
or serious injury.
0000010en

A WARNING
A WARNING

SHOCK HAZARD! BURN HAZARD!


• Turn off the battery switch (if • Wait until the engine cools before you
equipped) or disconnect the negative drain the engine coolant. Hot engine
battery cable before servicing the coolant may splash and burn you.
electrical system.
• Failure to comply could result in death
• Check the electrical harnesses for or serious injury.
cracks, abrasions, and damaged or 0000016en
corroded connectors. ALWAYS keep
the connectors and terminals clean.
• Failure to comply could result in death
or serious injury.
0000009en

3-10 TNV DI Service Manual


Safety Precautions SAFETY

A WARNING A WARNING
SUDDEN MOVEMENT HAZARD!
• Engaging the transmission or PTO at
an elevated engine speed could result
in unexpected movement of the
equipment.
FUME / BURN HAZARD!
• Failure to comply could result in death • Always read and follow safety related
or serious injury. precautions found on containers of
0000006en
hazardous substances like parts
cleaners, primers, sealants and
A WARNING sealant removers.
• Failure to comply could result in death
or serious injury.
0000014en

BURN HAZARD! A WARNING


Never apply over 40 psi (2.8 kgf/cm) to
• Keep your hands and other body parts
the waste gate actuator.
away from hot engine surfaces such
0000026en
as the muffler, exhaust pipe,
turbocharger (if equipped) and engine
block during operation and shortly A WARNING
after you shut the engine down. These • Never inject fuel toward you. Since the
surfaces are extremely hot while the fuel is injected at high pressure from
engine is operating and could the nozzle, it may penetrate the skin,
seriously burn you. resulting in injury.
• Failure to comply could result in death • Never inject fuel toward a fire source.
or serious injury. Atomized fuel is highly flammable and
0000015en
may cause a fire or burn skin.
0000028en

A WARNING

To prevent possible eye injury, always


wear SAFETY GLASSES while servicing
the engine.
0000013en

TNV DI Service Manual 3-11


SAFETY Safety Precautions

A WARNING A WARNING
• Never use the E-ECU for other • Replacing the fuel injection pump
purposes than intended or in other involves rewriting the fuel injection
ways than specified by Yanmar. Doing data in the E-ECU.
so could result in the violation of Be sure to contact your local Yanmar
emission control regulations and will dealer before replacing the fuel
void the product warranty. injection pump.
• Improper use or misuse of the E-ECU Failure to rewrite the fuel injection
may result in death or serious injury data before replacing the fuel injection
due to an abrupt and unexpected pump will void the engine warranty.
increase in engine speed. • Improper use or misuse of the E-ECU
9999999en may result in death or serious injury
due to an abrupt and unexpected
increase in engine speed.
A WARNING 9999997en
• Be sure to use the E-ECU in
conjunction with the engines whose
models or serial numbers are A WARNING
specified by Yanmar. • Replacing the E-ECU involves
Other E-ECU/engine combinations migrating the fuel injection data to the
than specified will void the engine existing E-ECU to the new unit.
warranty. Be sure to contact your local Yanmar
• Improper use or misuse of the E-ECU dealer before replacing the E-ECU.
may result in death or serious injury Failure to migrate the fuel injection
due to an abrupt and unexpected data before replacing the E-ECU will
increase in engine speed. void the engine warranty.
9999998en • 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.
9999996en

3-12 TNV DI Service Manual


Safety Precautions SAFETY

A CAUTION A CAUTION

COOLANT HAZARD! PINCH HAZARD!


• Wear eye protection and rubber gloves Carefully rotate the alternator toward the
when you handle long life or extended cylinder block while loosening the
life engine coolant. If contact with the V-belt. Failure to comply may result in
eyes or skin should occur, flush eyes minor or moderate injury.
and wash immediately with clean 0000014en
water.
• Failure to comply may result in minor
or moderate injury.
A CAUTION
If any oil pump component clearance
0000005en
exceeds its limit, the oil pump must be
replaced as an assembly.
A CAUTION 0000015en

CAUTION
• Only use diesel fuels recommended by
Yanmar for the best engine
performance, to prevent engine
damage and to comply with EPA / ARB
FLYING OBJECT HAZARD! warranty requirements.
• ALWAYS wear eye protection when • Only use clean diesel fuel.
servicing the engine and when using
compressed air or high-pressure • NEVER remove the primary strainer (if
water. Dust, flying debris, compressed equipped) from the fuel tank filler port.
air, pressurized water or steam may If removed, dirt and debris could get
injure your eyes. into the fuel system causing it to clog.
0000004en
• Failure to comply may result in minor
or moderate injury.
0000003en
CAUTION
NEVER attempt to adjust the low or high
A CAUTION idle speed limit screw. This may impair
the safety and performance of the
Be sure to secure the engine solidly to machine and shorten its life. If
prevent injury or damage to parts due to adjustment is ever required, contact
the engine falling during work on the your authorized Yanmar industrial
engine. engine dealer or distributor.
0000009en
0000045en

TNV DI Service Manual 3-13


SAFETY Safety Precautions

CAUTION CAUTION
If any problem is noted during the visual Observe the following environmental
check, the necessary corrective action operating conditions to maintain engine
should be taken before you operate the performance and avoid premature
engine. engine wear:
0000021en
• Avoid operating in extremely dusty
conditions.
CAUTION • Avoid operating in the presence of
NEVER hold the key in the START chemical gases or fumes.
position for longer than 15 seconds or • Avoid operating in a corrosive
the starter motor will overheat. atmosphere such as salt water spray.
0000007en
• NEVER install the engine in a
floodplain unless proper precautions
CAUTION are taken to avoid being subject to a
Make sure the engine is installed on a flood.
level surface. If a continuously running • NEVER expose the engine to the rain.
engine is installed at an angle greater 0000003en
than (IDI = 25°, DI = 30°) in any direction
or if an engine runs for short periods of
time (less than three minutes) at an CAUTION
angle greater than (IDI = 30°, DI = 35°) in Observe the following environmental
any direction, engine oil may enter the operating conditions to maintain engine
combustion chamber causing excessive performance and avoid premature
engine speed and white exhaust smoke. engine wear:
This may cause serious engine damage.
• The standard range of ambient
0000010enTNV
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.
0000065en

3-14 TNV DI Service Manual


Safety Precautions SAFETY

CAUTION CAUTION
The illustrations and descriptions of • Only use the engine coolant specified.
optional equipment in this manual, such Other engine coolants may affect
as the operator’s console, are for a warranty coverage, cause an internal
typical engine installation. Refer to the buildup of rust and scale and / or
documentation supplied by the optional shorten engine life.
equipment manufacturer for specific • Prevent dirt and debris from
operation and maintenance instructions. contaminating the engine coolant.
0000018en
Carefully clean the radiator cap and
the surrounding area before you
CAUTION remove the cap.
If any indicator illuminates during • NEVER mix different types of engine
engine operation, stop the engine coolants. This may adversely affect the
immediately. Determine the cause and properties of the engine coolant.
repair the problem before you continue 0000006en

to operate the engine.


0000029en
CAUTION
• NEVER overfill the engine with engine
CAUTION oil.
• Only use the engine oil specified. • ALWAYS keep the oil level between the
Other engine oils may affect warranty upper and lower lines on the oil
coverage, cause internal engine cap / dipstick.
components to seize and / or shorten
0000015en
engine life.
• Prevent dirt and debris from
CAUTION
contaminating the engine oil. Carefully
clean the oil cap / dipstick and the For maximum engine life, Yanmar
surrounding area before you remove recommends that when shutting the
the cap. engine down, you allow the engine to
idle, without load, for five minutes. This
• NEVER mix different types of engine will allow the engine components that
oil. This may adversely affect the operate at high temperatures, such as
lubricating properties of the engine oil. the turbocharger (if equipped) and
• NEVER overfill. Overfilling may result exhaust system, to cool slightly before
in white exhaust smoke, engine the engine itself is shut down.
overspeed or internal damage. 0000008en

0000005en

CAUTION
NEVER use an engine starting aid such
as ether. Engine damage will result.
0000009en

TNV DI Service Manual 3-15


SAFETY Safety Precautions

CAUTION CAUTION
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,
• ALWAYS be environmentally engine oil leaks, coolant leaks, and for
responsible. proper operation of the indicators
• Follow the guidelines of the EPA or and / or gauges.
other governmental agencies for the • During the first hour of operation, vary
proper disposal of hazardous the engine speed and the load on the
materials such as engine oil, diesel engine. Short periods of maximum
fuel and engine coolant. Consult the engine speed and load are desirable.
local authorities or reclamation facility. Avoid prolonged operation at
• NEVER dispose of hazardous minimum or maximum engine speeds
materials irresponsibly by dumping and loads for the next four to five
them into a sewer, on the ground, or hours.
into ground water or waterways. • During the break-in period, carefully
• Failure to follow these procedures may observe the engine oil pressure and
seriously harm the environment. engine temperature.
0000013en • During the break-in period, check the
engine oil and coolant levels
CAUTION frequently.
0000011en
NEVER engage the starter motor while
the engine is running. This may damage
the starter motor pinion and / or ring CAUTION
gear. • NEVER attempt to modify the engine’s
0000012en 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.
0000044enTNVDISM

3-16 TNV DI Service Manual


Safety Precautions SAFETY

CAUTION CAUTION
Protect the air cleaner, turbocharger (if If any indicator fails to illuminate when
equipped) and electric components the key switch is in the ON position, see
from damage when you use steam or your authorized Yanmar industrial
high-pressure water to clean the engine. engine dealer or distributor for service
0000014en before operating the engine.
0000028en

CAUTION
NEVER use high-pressure water or CAUTION
compressed air at greater than 28 psi Establish a periodic maintenance plan
(193 kPa; 19 686 mmAq) or a wire brush according to the engine application and
to clean the radiator fins. Radiator fins make sure you perform the required
damage easily. periodic maintenance at the intervals
0000016en indicated. Failure to follow these
guidelines will impair the engine’s safety
and performance characteristics,
CAUTION shorten the engine’s life and may affect
NEVER attempt to adjust the low or high the warranty coverage on your engine.
idle speed limit screw. This may impair
See Yanmar Limited Warranty in
the safety and performance of the
Warranty Section.
machine and shorten its life. If the idle
speed limit screws require adjustment, Consult your authorized Yanmar dealer
see your authorized Yanmar industrial or distributor for assistance when
engine dealer or distributor. checking items marked with a .
0000017en 0000024enTNVDISM

CAUTION CAUTION
The tightening torque in the Standard If the fuel filter / water separator is
Torque Chart (see General Service positioned higher than the fuel level in
Information section) should be applied the fuel tank, water may not drip out
only to the bolts with a “7” head. (JIS when the fuel filter / water separator
strength classification: 7T) drain cock is opened. If this happens,
turn the air vent screw on the top of the
• Apply 60% torque to bolts fuel filter / water separator 2-3 turns
that are not listed. counterclockwise.
• Apply 80% torque when Be sure to tighten the air vent screw
tightened to aluminum alloy. after the water has drained out.
0000023enTNVDISM 0000025en

TNV DI Service Manual 3-17


SAFETY Safety Precautions

CAUTION CAUTION
• When the engine is operated in dusty Do not loosen or remove the four bolts
conditions, clean the air cleaner retaining the fuel injection pump drive
element more frequently. gear to the fuel injection pump hub. Do
• NEVER operate the engine with the air not disassemble the fuel injection pump
cleaner element(s) removed. This may drive gear from the hub. Correct fuel
allow foreign material to enter the injection timing will be very difficult or
engine and damage it. impossible to achieve.
0000031en
0000026en

CAUTION CAUTION
The maximum air intake restriction, in The starter motor can be damaged if
terms of differential pressure operated continuously longer than
measurement, must not exceed 0.90 psi 10 seconds while performing the
(6.23 kPa; 635 mmAq). Clean or replace no-load test.
the air cleaner element if the air intake 0000034en

restriction exceeds the above


mentioned value. CAUTION
0000046en
Do not short-circuit the charging system
between alternator terminals IG and L.
CAUTION Damage to the alternator will result.
It is important to perform daily checks. 0000035en

Periodic maintenance prevents


unexpected downtime, reduces the CAUTION
number of accidents due to poor Do not connect a load between
machine performance and helps extend alternator terminals L and E. Damage to
the life of the engine. the alternator will result.
0000060en 0000036en

CAUTION CAUTION
If the oil pump must be replaced, replace Do not remove the positive (+) battery
it as an assembly only. Do not replace cable from alternator terminal B while
individual components. the engine is operating. Damage to the
0000030en alternator will result.
0000037en

CAUTION
Do not turn the battery switch OFF while
the engine is operating. Damage to the
alternator will result.
0000038en

3-18 TNV DI Service Manual


Safety Precautions SAFETY

CAUTION CAUTION
Do not operate the engine if the Do not use a high-pressure wash
alternator is producing unusual sounds. directly on the alternator. Water will
Damage to the alternator will result. damage the alternator and result in
0000039en inadequate charging.
0000049en

CAUTION
If the engine coolant pump must be CAUTION
replaced, replace the engine coolant Do not reverse the positive (+) and
pump as an assembly only. Do not negative (-) ends of the battery cable.
attempt to repair the engine coolant The alternator diode and stator coil will
pump or replace individual components. be damaged.
0000041en 0000050en

CAUTION CAUTION
Use a new special O-ring between the When the battery indicator goes out, it
engine coolant pump and the joint. Be should not come on again. The battery
sure to use the special O-ring for each indicator only comes on during
engine model. Although the O-ring operation if the alternator fails. However,
dimensions are the same as a if an LED is used in the battery indicator,
commercially available O-ring, the the LED will shine faintly during normal
material is different. operation.
0000042en 0000051en

CAUTION CAUTION
Remove or install the high-pressure fuel Using a non-specified V-belt will cause
injection lines as an assembly whenever inadequate charging and shorten the
possible. Disassembling the belt life. Use the specified belt.
high-pressure fuel injection lines from 0000052en
the retainers or bending any of the fuel
lines will make it difficult to reinstall the
fuel lines.
CAUTION
0000047en
Agricultural or other chemicals,
especially those with a high sulfur
content, can adhere to the IC regulator.
CAUTION This will corrode the conductor and
After marking the position of the pump result in battery over-charging (boiling)
drive gear, do not rotate the engine and charging malfunctions. Consult
crankshaft. Rotating the crankshaft will Yanmar before using the equipment in
cause the fuel injection pump to become such an environment or the warranty is
misaligned. voided.
0000048en 0000053en

TNV DI Service Manual 3-19


SAFETY Safety Precautions

CAUTION CAUTION
Make sure that the combined total Removing the battery cables or the
resistance of the battery cable in both battery while the engine is operating
directions between the starter motor may cause damage to the current limiter
and the battery is within the value depending on the electrical equipment
indicated on the wiring diagram. The being used. This situation could cause
starter motor will malfunction or break loss of control of output voltage. The
down if the resistance is higher than the continuous high voltage of 23-24 volts
specified value. (for 5000 rpm dynamo) will damage the
0000054en current limiter and other electrical
equipment.
CAUTION 0000058en

The starter motor is water-proofed


according to JIS D 0203, R2 which CAUTION
protects the motor from rain or general Reversing the battery cable connections
cleaning. Do not use high-pressure at the battery or on the engine will
wash or submerse the starter motor in destroy the SCR diode in the current
water. limiter. This will cause the charging
0000055en system to malfunction and may cause
damage to the electrical harnesses.
CAUTION 0000059en

Use a specialized battery charger to


recharge a battery with a voltage of CAUTION
8 volts or less. Booster starting a battery Avoid damage to the turbocharger or the
with a voltage of 8 volts or less will engine. Do not spray blower wash fluid
generate an abnormally high voltage or water too quickly.
and destroy electrical equipment. Use short strokes from a spray bottle to
0000056en
inject blower wash fluid or water into the
turbocharger.
CAUTION Spraying too much wash fluid or water,
Make sure that the combined total or spraying too quickly will damage the
resistance of the battery cable in both turbocharger.
directions between the starter motor 0000063en

and the battery is within the value


indicated in the Battery Cable
CAUTION
Resistance chart in the Electric Wiring
Section of this manual. The starter Do not allow any material to fall into the
motor will malfunction and fail if the oil lines or the oil inlet and outlet ports
resistance is higher than the specified of the turbocharger.
value. 0000064en

0000057en

3-20 TNV DI Service Manual


Safety Precautions SAFETY

CAUTION CAUTION
If the waste valve does not meet Do not rotate the crankshaft with the
specifications, replace the turbocharger injection pump removed.
or have it repaired by a qualified repair 0000083en
facility.
0000078en
CAUTION
Keep the piston pin parts, piston
CAUTION assemblies, and connecting rod
• NEVER attempt to modify the engine’s assemblies together to be returned to
design or safety features such as the same position during the
defeating the engine speed limit reassembly process. Label the parts
control or the diesel fuel injection using an appropriate method.
quantity control. 0000088en

• Modifications may impair the engine’s


safety and performance CAUTION
characteristics and shorten the
Do not allow the honing tool to operate
engine’s life. Any alterations to this
in one position for any length of time.
engine may void its warranty. Be sure
Damage to the cylinder wall will occur.
to use Yanmar genuine replacement
Keep the tool in constant up-and-down
parts.
motion.
0000079en
0000090en

CAUTION CAUTION
Identify all parts and their location using
Any part which is found defective as a
an appropriate method. It is important
result of inspection or any part whose
that all parts are returned to the same
measured value does not satisfy the
position during the reassembly process.
standard or limit must be replaced.
0000080en
0000119en

CAUTION CAUTION
Each pressure adjusting shim removed
Any part determined to not meet the
or added changes the pressure
service standard or limit before the next
threshold by approximately 275 psi
service, as determined from the state of
(1.9 MPa, 19 kgf/cm2). Adding adjusting
current rate of wear, should be replaced
shims increases the threshold pressure.
even though the part currently meets the
Removing adjusting shims reduces the
service standard limit.
pressure threshold.
0000120en
0000081en

TNV DI Service Manual 3-21


SAFETY Safety Precautions

CAUTION CAUTION
• NEVER remove or attempt to remove Shut down the engine if the fault
the tamper-proof devices from the indicator comes on.
full-load fuel adjusting screw or the Continuing running the engine with the
high-speed throttle limit screw on the fault indicator being on may result in a
fuel injection pump and governor serious malfunction of or damage to the
assembly. These adjustments have engine, and will void the engine
been made at the factory to meet all warranty.
applicable emissions regulations and
9999999en
then sealed.
• NEVER attempt to make any
adjustments to these sealed
CAUTION
adjustment screws. If adjustments are Do not energize the starter for a period
required, they can be made only by a of longer than 15 seconds.
qualified fuel injection shop that will Take a pause of at least 30 seconds
ensure the injection pump continues between energization of the starter.
to meet all applicable emissions
regulations and then replace the Otherwise the starter could suffer
tamper-proof seals. damage.
9999998en
• Tampering with or removing these
devices may void the “Yanmar Limited
Warranty.” CAUTION
0000146en • High-pressure washing not
recommended.
CAUTION • Avoid using high-pressure washing for
Never use a steel wire brush to clean electronic or electric devices installed
fuel injectors. Damage to the nozzle and in, on or around the engine, including
other components is likely to result. the E-ECU, relays and harness
couplers.
0000172en
Otherwise such devices may suffer
malfunction due to water ingress into
CAUTION them.
Allow the engine to warm-up for at least 9999997en
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.
0000159en

3-22 TNV DI Service Manual


Safety Precautions SAFETY

CAUTION
• 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 E-ECU.
• 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.
• 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.
9999996en

CAUTION
Always check the battery for proper
charge.
Otherwise the electronically controlled
engines may fail to start.
9999995en

TNV DI Service Manual 3-23


SAFETY Safety Precautions

This Page Intentionally Left Blank

3-24 TNV DI Service Manual


TNV DI Service Manual
Section 4

GENERAL SERVICE
INFORMATION
Page
Component Identification................................................................. 4-3
Location of Labels ........................................................................... 4-5
Engine Nameplate (Typical) ...................................................... 4-6
Emission Control Regulations ......................................................... 4-6
EPA / ARB Regulations - USA Only .......................................... 4-6
Emission Control Labels.................................................................. 4-6
The 97/68/EC Directive Certified Engines....................................... 4-7
Engine Family.................................................................................. 4-7
Function of Major Engine Components ........................................... 4-8
MAIN ELECTRONIC CONTROL COMPONENTS AND
FEATURES ..................................................................................... 4-9
Function of Cooling System Components ..................................... 4-11
Diesel Fuel .................................................................................... 4-12
Diesel Fuel Specifications ....................................................... 4-12
Filling The Fuel Tank ............................................................... 4-13
Priming the Fuel System ......................................................... 4-15
Engine Oil...................................................................................... 4-15
Engine Oil Specifications ........................................................ 4-15
Engine Oil Viscosity................................................................. 4-16
Checking Engine Oil ................................................................ 4-16
Adding Engine Oil.................................................................... 4-17
Engine Oil Capacity (Typical) .................................................. 4-17
Engine Coolant.............................................................................. 4-18
Engine Coolant Specifications................................................. 4-19
Filling Radiator with Engine Coolant........................................ 4-19
Engine Coolant Capacity (Typical) .......................................... 4-20
Specifications ................................................................................ 4-21

TNV DI Service Manual 4-1


GENERAL SERVICE INFORMATION
Description of Model Number................................................... 4-21
Engine Speed Specifications.................................................... 4-21
Engine General Specifications ................................................. 4-22
Principal Engine Specifications ...................................................... 4-23
3TNV82A (~ EPA Tier2) ........................................................... 4-23
3TNV84 (~ EPA Tier2) ............................................................. 4-24
3TNV84T (~ EPA Tier2) ........................................................... 4-25
3TNV88 (~ EPA Tier2) ............................................................. 4-26
4TNV84 (~ EPA Tier2) ............................................................. 4-27
4TNV84T (~ EPA Tier2) ........................................................... 4-28
4TNV88 (~ EPA Tier2) ............................................................. 4-29
4TNV94L (~ EPA Tier2) ........................................................... 4-30
4TNV98 (~ EPA Tier2) ............................................................. 4-31
4TNV98T (~ EPA Tier2) ........................................................... 4-32
4TNV106 (~ EPA Tier2) ........................................................... 4-33
4TNV106T (~ EPA Tier2) ......................................................... 4-34
3TNV82A-B (complies with EPA Interim Tier4)........................ 4-35
3TNV84T-B (complies with EPA Interim Tier4) ........................ 4-36
3TNV88-U (complies with EPA Interim Tier4) .......................... 4-37
3TNV88-B (complies with EPA Interim Tier4) .......................... 4-38
4TNV84T-Z (complies with EPA Interim Tier4) ........................ 4-39
4TNV88-U (complies with EPA Interim Tier4) .......................... 4-40
4TNV88-B (complies with EPA Interim Tier4) .......................... 4-41
4TNV98-E (complies with EPA Interim Tier4) .......................... 4-42
4TNV98-Z (complies with EPA Interim Tier4) .......................... 4-43
4TNV98T-Z (complies with EPA Interim Tier4) ........................ 4-44
Engine Service Standards.............................................................. 4-45
Tightening Torques for Standard Bolts and Nuts ........................... 4-46
Abbreviations and Symbols............................................................ 4-48
Abbreviations............................................................................ 4-48
Symbols.................................................................................... 4-48
Unit Conversions ............................................................................ 4-49
Unit Prefixes ............................................................................. 4-49
Units of Length ......................................................................... 4-49
Units of Volume ........................................................................ 4-49
Units of Mass............................................................................ 4-49
Units of Force ........................................................................... 4-49
Units of Torque......................................................................... 4-49
Units of Pressure...................................................................... 4-49
Units of Power .......................................................................... 4-49
Units of Temperature................................................................ 4-49

4-2 TNV DI Service Manual


Component Identification GENERAL SERVICE INFORMATION

COMPONENT IDENTIFICATION
Figure 4-1 shows where the major engine components are located.
3TNV82A(-B),3TNV84,3TNV84T(-B),3TNV88(-B)(-U),4TNV84,4TNV88(-B)(-U),
4TNV94L,4TNV984TNV106,4TNV106T

(1) (2) (20)


(19)
(3)
(18)
(4)

(17)

(16)

(15)
(5) (21)
(14)

(25)
(6)
(13)

(24)
(22)
(23)
0000015B
(12) (11) (10) (9) (8) (7)
1 – Lifting Eye (Flywheel End) 14 – Governor Lever
2 – Turbocharger* 15 – Intake Manifold
3 – Lifting Eye (Engine Cooling Fan End) 16 – Fuel Filter
4 – Engine Coolant Pump 17 – Fuel Inlet
5 – Engine Cooling Fan 18 – Fuel Return to Fuel Tank
6 – Crankshaft V-Pulley 19 – Top Filler Port (Engine Oil)
7 – V-Belt 20 – Rocker Arm Cover
8 – Side Filler Port (Engine Oil) 21 – Air Intake Port (From Air Cleaner)
9 – Drain Plug (Engine Oil)** 22 – Flywheel
10 – Fuel Injection Pump 23 – Starter Motor
11 – Engine Oil Cooler*** 24 – Exhaust Manifold
12 – Engine Oil Filter 25 – Alternator
13 – Dipstick (Engine Oil)
Figure 4-1

* Only applies to 3TNV84T, 4TNV84T, 4TNV98T, 4TNV106T


** The engine oil drain plug location may vary based on oil pan options.
*** Not standard on all direct injection models

TNV DI Service Manual 4-3


GENERAL SERVICE INFORMATION Component Identification

Figure 4-2 shows where the major engine components are located.
4TNV84T-Z, 4TNV98-E, 4TNV98-Z, 4TNV98T-Z

(2) (19) (4) (3) (20) (26)

(18)

(17) (28)
(1)
(16) (27)
(15)
(21)
(14)
(25)
(13) (5)
(22)
(6)
(24)

(23)

(12) (11) (9) (10) (8) (7)

1 – Lifting Eye (Flywheel End) 15 – Intake Manifold


2 – Turbocharger* 16 – Fuel Filter
3 – Lifting Eye (Engine Cooling Fan End) 17 – Fuel Inlet
4 – Engine Coolant Pump 18 – Fuel Return to Fuel Tank
5 – Engine Cooling Fan 19 – Top Filler Port (Engine Oil)
6 – Crankshaft V-Pulley 20 – Rocker Arm Cover
7 – V-Belt 21 – Air Intake Port (From Air Cleaner)
8 – Side Filler Port (Engine Oil) 22 – Flywheel
9 – Drain Plug (Engine Oil)** 23 – Starter Motor
10 – Fuel Injection Pump 24 – Exhaust Manifold
11 – Engine Oil Cooler*** 25 – Alternator
12 – Engine Oil Filter 26 – EGR valve
13 – Dipstick (Engine Oil) 27 – EGR cooler****
14 – Eco-governor 28 – EGR pipe
Figure 4-2

* Only applies to 4TNV84T-Z, 4TNV98T-Z.


** Engine oil drain plug location may vary based on oil pan options.
*** Not standard on all direct injection models.
**** Only applies to 4TNV84T-Z, 4TNV98T-Z.

4-4 TNV DI Service Manual


Location of Labels GENERAL SERVICE INFORMATION

LOCATION OF LABELS
Figure 4-3 shows the location of regulatory and safety labels on Yanmar TNV series engines.

(1) (4) (1) (3)


(4) (2)

0000019A-01

Figure 4-3

Location of labels/nameplates on direct injection model engines


EPA/ARB Certification 97/68/EC Emission Control
Model Engine Nameplate
Label Label
3TNV82A,3TNV84,3TNV84T,3TNV88 On the top of the locker On the top of the locker On the exhaust side of the locker
3TNV82A-B,3TNV88-B,3TNV88-U arm cover(cooling fan end) arm cover (flywheel end) arm cover(near the flywheel)
3TNV84T-B Figure 4-3 left, (4) Figure 4-3 left, (1) Figure 4-3 left, (2)
On the top of the locker On the top of the locker On the exhaust side of the locker
4TNV84,4TNV88,4TNV84T
arm cover(cooling fan end) arm cover(flywheel end) arm cover(near the flywheel)
4TNV88-B,4TNV88-U,4TNV84T-Z
Figure 4-3 left, (4) Figure 4-3 left, (1) Figure 4-3 left, (1)
4TNV94L,4TNV98,4TNV98T On the top of the locker On the top of the locker On the top of the locker arm
4TNV106,4TNV106T arm cover(flywheel end) arm cover(center) cover(fan end)
4TNV98-Z,4TNV98-E,4TNV98T-Z Figure 4-3 right, (4) Figure 4-3 right, (1) Figure 4-3 right, (3)

TNV DI Service Manual 4-5


GENERAL SERVICE INFORMATION Emission Control Regulations

Engine Nameplate (Typical) 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 / ARB Labels

" "

0003852

EMISSION CONTROL (EPA) Less than 50 HP SAE (37kW)


REGULATIONS
EPA / ARB Regulations - USA Only
Yanmar TNV engines meet Environmental " US-2D " FUEL
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 5-16) and maintenance (page 5-16) in the (EPA) Greater than or Equal to 50 HP SAE (37kW)
Periodic Maintenance Schedule section of this
manual. Also refer to the Emission System
Warranty on page 2-6.

(EPA and ARB) 0000086-01

4-6 TNV DI Service Manual


The 97/68/EC Directive Certified Engines GENERAL SERVICE INFORMATION

THE 97/68/EC DIRECTIVE


CERTIFIED ENGINES 97/68/EC DIRECTIVE

The engines described in this manual have been


certified by the 97/68/EC Directive.
To identify the engines that meet this certification,
the 97/68/EC emission control label is affixed on
(97/68/EC)
the engines.

ENGINE FAMILY
The EPA / ARB labels and the 97/68/EC label all have an Engine Family field. The following is an
explanation of the Engine Family designation:

5 YDX L 1.33 M 3 N
Method of air aspiration

Number of cylinders

Engine speed specifications

Displacement (liter)

Non-road / Off-road engine

Yanmar Diesel

*2005 Model Year

5*: 2005

6 : 2006

7: 2007

8: 2008

9: 2009

TNV DI Service Manual 4-7


GENERAL SERVICE INFORMATION Function of Major Engine Components

FUNCTION OF MAJOR ENGINE COMPONENTS


Components Functions
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
Air Cleaner 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 5-17 for the replacement frequency.
The alternator is driven by a V-belt which is powered by the crankshaft V-pulley.
Alternator The alternator supplies electricity to the engine systems and charges the battery
while the engine is running.
The engine oil dipstick is used to determine the amount of engine oil in the
Dipstick (Engine Oil)
crankcase.
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
Electric Fuel Pump
12 VDC. It must be installed on every application. This is standard equipment with
every engine.
The engine oil filter removes contaminants and sediments from the engine oil.
Engine Oil Filter Periodic replacement of the engine oil filter is necessary. See the Periodic
Maintenance Schedule on page 5-17 for the replacement frequency.
The engine oil cooler helps to keep the engine oil cool. Engine coolant from the
Engine Oil Cooler
cooling system is circulated through an adapter at the base of the engine oil filter
(If Equipped)
assembly and then returned to the coolant pump inlet.
The fuel filter removes contaminants and sediments from the diesel fuel. Periodic
replacement of the fuel filter is necessary. See the Periodic Maintenance Schedule
Fuel Filter
on page 5-17 for the replacement frequency. Please note that the word “diesel”
is implied throughout this manual when the word “fuel” is used.
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
Fuel Filter / Water Separator 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.
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 Tank 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.
You can fill the crankcase with engine oil from either the side or the top filler port
Side and Top Filler Port (Engine Oil)
depending upon which one is most convenient.
The starter motor is powered by the battery. When you turn the key switch in the
Starter Motor 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.
Turbocharger
The turbocharger pressurizes the air coming into the engine. It is driven by a
(Only applies to 3TNV84T, 4TNV84T,
turbine that is energized by exhaust gases.
4TNV98T, 4TNV106T)

4-8 TNV DI Service Manual


MAIN ELECTRONIC CONTROL COMPONENTS AND FEATURES GENERAL SERVICE INFORMATION

MAIN ELECTRONIC CONTROL COMPONENTS AND FEATURES


4TNV84T-Z, 4TNV98-E, 4TNV98-Z,
4TNV98T-Z
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.
Fault indicator Is installed on the operator's console. If a fault occurs in
the E-ECU 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
Optional source of the fault, enabling quick-fix.

TNV DI Service Manual 4-9


GENERAL SERVICE INFORMATION MAIN ELECTRONIC CONTROL COMPONENTS AND FEATURES

Component/Feature Description
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
Option for service Troubleshooting Chart on page 7-113.
Engine coolant temperature sensor Allows the CSD and ERG to be controlled in engine cold-
start conditions.
Glow plugs Optional When the key switch is turned to the ON position, the glow
Air heater plugs/air heater are/is energized for up to 15 seconds
(glow plugs) or up to 23 seconds (air heater). 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.
After heater Optional In extreme cold start conditions, the after heater is
energized for up to 80 seconds or until the coolant
temperature reaches 10°C after the engine has started, in
order to help ensure the engine continues to run without
stall.This option is not available for glow plug engines.
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 Offers a constant engine speed from no load to full load.
Optional with VM series 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 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 Optional Decreases the high-idling speed depending on the engine
down 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.

4-10 TNV DI Service Manual


Function of Cooling System Components GENERAL SERVICE INFORMATION

FUNCTION OF COOLING SYSTEM COMPONENTS


Components Functions
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
Cooling System 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.
The engine cooling fan is driven by a V-belt which is powered by the crankshaft
Engine Cooling Fan V-pulley. The purpose of the engine cooling fan is to circulate air through the
radiator.
The engine coolant pump circulates the engine coolant through the cylinder block
Engine Coolant Pump
and the cylinder head and returns the engine coolant to the 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
Radiator
the radiator. As the engine cooling fan circulates air through the radiator, the heat
is transferred to the air.
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
Radiator Cap
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.
The reserve tank contains the overflow of engine coolant from the radiator. If you
Reserve Tank need to add engine coolant to the system, add it to the reserve tank; not the
radiator.
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
Thermostat 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.

TNV DI Service Manual 4-11


GENERAL SERVICE INFORMATION Diesel Fuel

DIESEL FUEL • Fuel additives are not recommended. Some fuel


additives may cause poor engine performance.
Diesel Fuel Specifications Consult your Yanmar representative for more
information.
Diesel fuel should comply with the following
specifications. The table lists several worldwide • The ash content must not exceed 0.01% by
specifications for diesel fuels. volume.
• The carbon residue content must not exceed
Diesel Fuel Specification Location 0.35% by volume. Less than 0.1% is preferred.
No. 2-D, No. 1-D, • The total aromatics content should not exceed
USA
ASTM D975-94 35% by volume. Less than 30% is preferred.
European • The PAH (polycyclic aromatic hydrocarbons)
EN590:96
Union content should be below 10% by volume.
ISO 8217 DMX International • The metal content of Na, Mg, Si, and Al should be
United equal to or lower than 1 mass ppm. (Test analysis
BS 2869-A1 or A2 method JPI-5S-44-95)
Kingdom
JIS K2204 Grade No. 2 Japan • Lubricity: The wear mark of WS1.4 should be
KSM-2610 Korea Max. 0.018 in (460 µm) at HFRR test.

GB252 China Bio-Diesel Fuels


In Europe and in the United States, as well as some
Additional Technical Fuel Requirements other countries, non-mineral oil based fuel
• The fuel cetane number should be equal to 45 or resources such as RME (Rapeseed Methyl Ester)
higher. and SOME (Soybean Methyl Ester), collectively
known as FAME (Fatty Acid Methyl Esters), are
• The sulfur content must not exceed 0.5% by
being used as extenders for mineral oil derived
volume. Less than 0.05% is preferred.
diesel fuels.
For electronically controlled engines 4TNV84T-Z,
4TNV98-Z, 4TNV98-E, and 4TNV98T-Z, it is Yanmar approves the use of bio-diesel fuels that do
mandatory to use fuel that does not contain not exceed a blend of 5% (by volume) of FAME with
0.05% or more sulfur content. 95% (by volume) of approved mineral oil derived
In general, using a high sulfur fuel may possible diesel fuel. Such bio-diesel fuels are known in the
result in corrosion inside the cylinder. marketplace as B5 diesel fuels.
• Bio-Diesel fuels. See Bio-Diesel Fuels on These B5 diesel fuels must meet certain
page 4-12. requirements.
• NEVER mix kerosene, used engine oil, or 1. The bio-fuels must meet the minimum
residual fuels with the diesel fuel. specifications for the country in which they are
used.
• The water and sediment in the fuel should not • In Europe, bio-diesel fuels must comply with
exceed 0.05% by volume. the European Standard EN14214.
• Keep the fuel tank and fuel-handling equipment • In the United States, bio-diesel fuels must
clean at all times. comply with the American Standard
ASTM D-6751.
• Poor quality fuel can reduce engine performance
and / or cause engine damage. 2. Bio-fuels should be purchased only from
recognized and authorized diesel fuel suppliers.

4-12 TNV DI Service Manual


Diesel Fuel GENERAL SERVICE INFORMATION
Precautions and concerns regarding the use of Filling The Fuel Tank
bio-fuels:
1. Free methanol in FAME may result in corrosion A DANGER
of aluminum and zinc FIE components.
2. Free water in FAME may result in plugging of
fuel filters and increased bacterial growth.
3. High viscosity at low temperatures may result in
fuel delivery problems, injection pump seizures, FIRE AND EXPLOSION HAZARD!
and poor injection nozzle spray atomization.
• Diesel fuel is flammable and explosive
4. FAME may have adverse effects on some under certain conditions.
elastomers (seal materials) and may result in
fuel leakage and dilution of the engine • Only fill the fuel tank with diesel fuel.
lubricating oil. Filling the fuel tank with gasoline may
result in a fire and will damage the
5. Even bio-diesel fuels that comply with a suitable
engine.
standard as delivered, will require additional
care and attention to maintain the quality of the • NEVER refuel with the engine running.
fuel in the equipment or other fuel tanks. It is • Wipe up all spills immediately.
important to maintain a supply of clean, fresh
fuel. Regular flushing of the fuel system, • Keep sparks, open flames or any other
and / or fuel storage containers, may be form of ignition (match, cigarette,
necessary. static electric source) well away when
refueling.
6. The use of bio-diesel fuels that do not comply
with the standards as agreed to by the diesel • NEVER overfill the fuel tank.
engine manufacturers and the diesel fuel • Fill the fuel tank. Store any containers
injection equipment manufacturers, or bio- containing fuel in a well-ventilated
diesel fuels that have degraded as per the area, away from any combustibles or
precautions and concerns above, may affect sources of ignition.
the warranty coverage of your engine. See
• Failure to comply will result in death or
Yanmar Limited Warranty on page 2-3.
serious injury.
0000005en

TNV DI Service Manual 4-13


GENERAL SERVICE INFORMATION Diesel Fuel

A DANGER A DANGER

FIRE AND EXPLOSION HAZARD! FIRE AND EXPLOSION HAZARD!


• Diesel fuel is flammable and explosive • Diesel fuel is flammable and explosive
under certain conditions. under certain conditions.
• Be sure to place the diesel fuel • Before you operate the engine, check
container on the ground when for fuel leaks. Replace rubberized fuel
transferring the diesel fuel from the hoses every two years or every 2000
pump to the container. Hold the hose hours of engine operation, whichever
nozzle firmly against the side of the comes first, even if the engine has
container while filling it. This prevents been out of service. Rubberized fuel
static electricity buildup which could lines tend to dry out and become
cause sparks and ignite fuel vapors. brittle after two years or 2000 hours of
engine operation, whichever comes
• NEVER place diesel fuel or other
first.
flammable material such as oil, hay or
dried grass close to the engine during • Failure to comply will result in death or
engine operation or shortly after serious injury.
shutdown. 0000015en

• Failure to comply will result in death or


serious injury. CAUTION
0000014en
• 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.
0000004en

4-14 TNV DI Service Manual


Engine Oil GENERAL SERVICE INFORMATION
Note that a typical fuel tank is shown. The fuel tank 2. NEVER use the starter motor to crank the
on your equipment may be different. engine in order to prime the fuel system. This
may cause the starter motor to overheat and
1. Clean the area around the fuel cap damage the coils, pinion and / or ring gear.
(Figure 4-4, (1)).
2. Remove the fuel cap (Figure 4-4, (1)) from the
fuel tank (Figure 4-4, (2)). ENGINE OIL
3. Observe the fuel level sight gauge
(Figure 4-4, (3)) and stop fueling when the CAUTION
gauge shows the fuel tank is full. NEVER
overfill the fuel tank. • Only use the engine oil specified.
Other engine oils may affect warranty
4. Replace the fuel cap (Figure 4-4, (1)) and hand coverage, cause internal engine
tighten. Over-tightening the fuel cap will components to seize and / or shorten
damage it. engine life.
(1) • Prevent dirt and debris from
contaminating the engine oil. Carefully
clean the oil cap / dipstick and the
surrounding area before you remove
(2) the cap.
• NEVER mix different types of engine
oil. This may adversely affect the
lubricating properties of the engine oil.
(3)
• NEVER overfill. Overfilling may result
in white exhaust smoke, engine
0000002A
overspeed or internal damage.
Figure 4-4 0000005en

Priming the Fuel System Engine Oil Specifications


The fuel system needs to be primed under certain Use an engine oil that meets or exceeds the
conditions: following guidelines and classifications:
• Before starting the engine for the first time. Service Categories
• After running out of fuel and fuel has been added • API Service Categories CD or higher
to the fuel tank. (Grade CF or higher for EGR-equipped engines
4TNV84T-Z, 4TNV98-Z, 4TNV98-E, and
• After fuel system maintenance such as changing 4TNV98T-Z)
the fuel filter and draining the fuel filter / water
separator, or replacing a fuel system component. • ACEA Service Categories E-3, E-4, and E-5

To prime the fuel system: • JASO Service Category DH-1

1. Turn the key to the ON position for 10 - 15 Definitions


seconds. This will allow the electric fuel pump • API Classification (American Petroleum Institute)
to prime the fuel system.
• ACEA Classification (Association des
Constructeurs Européens d'Automobilies)

TNV DI Service Manual 4-15


GENERAL SERVICE INFORMATION Engine Oil

• JASO (Japanese Automobile Standards Checking Engine Oil


Organization)
1. Make sure the engine is level.
Notes: 2. Remove the dipstick (Figure 4-6, (1)) and wipe
• Be sure the engine oil, engine oil storage it with clean cloth.
containers, and engine oil filling equipment are 3. Fully reinsert the dipstick.
free of sediment and water. 4. Remove the dipstick. The oil level should be
• Change the engine oil after the first 50 hours of between the upper (Figure 4-6, (2)) and lower
operation and then every 250 hours thereafter. (Figure 4-6, (3)) lines on the dipstick.
5. Fully reinsert the dipstick.
• Select the oil viscosity based on the ambient
temperature where the engine is being operated. (4)
See the SAE Service Grade Viscosity Chart
(Figure 4-5).
• Yanmar does not recommend the use of engine
oil “additives.”

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). (4)

Engine Oil Viscosity (5)


Select the appropriate engine oil viscosity based on
the ambient temperature and use the SAE Service
Grade Viscosity Chart in Figure 4-5. (2)
(1)
SAE 10W
SAE 20W (3)
SAE 10W-30
0000007C
SAE 15W-40
Figure 4-6
SAE 20
SAE 30
SAE 40
SAE 20W - 50

-4°F 14°F 32°F 50°F 68°F 86°F 104°F 122°F


(-20°C) (-10°C) (0°C) (10°C) (20°C) (30°C) (40°C) (50°C)
0000005A

Figure 4-5

4-16 TNV DI Service Manual


Engine Oil GENERAL SERVICE INFORMATION
Adding Engine Oil Engine Oil Capacity (Typical)
1. Make sure the engine is level. Note: These are the engine oil capacities
2. Remove the oil cap (Figure 4-6, (4)). associated with a “deep standard” oil
pan. The oil capacity will vary dependant
3. Add the indicated amount of engine oil at the upon which optional oil pan is used.
top or the side engine oil filler port Refer to the operation manual provided
(Figure 4-6, (5)). by the driven machine manufacturer for
4. Wait three minutes and check the oil level. the actual engine oil capacity of your
5. Add more oil if necessary. machine.
6. Reinstall the oil cap (Figure 4-6, (4)) and The following are the engine oil capacities for
hand-tighten. Over-tightening may damage the various Yanmar TNV engines.
cap.
Dipstick Upper
Engine Model
Limit / Lower Limit
5.8 / 3.8 qt
3TNV82A(-B)
(5.5 / 3.6 L)
7.1 / 4.1 qt
3TNV84,3TNV84T(-B)
(6.7 / 3.9 L)
7.1 / 4.1 qt
3TNV88(-B)(-U)
(6.7 / 3.9 L)
7.8 / 4.2 qt
4TNV84,4TNV84T(-Z)
(7.4 / 4.0 L)
7.8 / 4.2 qt
4TNV88(-B)(-U)
(7.4 / 4.0 L)
11.1 / 6.3 qt
4TNV94L
(10.5 / 6.0 L)
4TNV98(-Z)(-E), 11.1 / 6.3 qt
4TNV98T(-Z) (10.5 / 6.0 L)
4TNV106(CL), 14.8 / 5.3 qt
4TNV106T(CL) (14.0 / 5.0 L)
4TNV106(VM), 14.8 / 6.9 qt
4TNV106T(VM) (14.0 / 6.5 L)

TNV DI Service Manual 4-17


GENERAL SERVICE INFORMATION Engine Coolant

ENGINE COOLANT
A CAUTION
A DANGER

COOLANT HAZARD!
• Wear eye protection and rubber gloves
SCALD HAZARD!
when you handle long life or extended
• NEVER remove the radiator cap if the life engine coolant. If contact with the
engine is hot. Steam and hot engine eyes or skin should occur, flush eyes
coolant will spurt out and seriously and wash immediately with clean
burn you. Allow the engine to cool water.
down before you attempt to remove
• Failure to comply may result in minor
the radiator cap.
or moderate injury.
• Tighten the radiator cap securely after 0000005en
you check the radiator. Steam can
spurt out during engine operation if
the cap is loose. CAUTION
• ALWAYS check the level of the engine • Only use the engine coolant specified.
coolant by observing the reserve tank. Other engine coolants may affect
warranty coverage, cause an internal
• Failure to comply will result in death or buildup of rust and scale and / or
serious injury. shorten engine life.
0000002en
• Prevent dirt and debris from
contaminating the engine coolant.
A WARNING 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.
BURN HAZARD! 0000006en
• 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.
0000016en

4-18 TNV DI Service Manual


Engine Coolant GENERAL SERVICE INFORMATION
Engine Coolant Specifications Filling Radiator with Engine Coolant
Use a Long Life Coolant (LLC) or an Extended Life Fill the radiator and reserve tank as follows. This
Coolant (ELC) that meets or exceeds the following procedure is for filling the radiator for the first time
guidelines and specifications: 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 (3)
(International)
(6) FULL

Alternative Engine Coolant 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)
0000029A
Notes:
Figure 4-7
• ALWAYS use a mix of coolant and water.
NEVER use water only. 1. Check to be sure the radiator drain plug is
• Mix the coolant and water per the mixing installed and tightened or the drain cock
instructions on the coolant container. (Figure 4-7, (1)) is closed. Also make sure the
coolant drain plug (Figure 4-8, (1)) in the
• Water quality is important to coolant cylinder block is closed or the oil coolant hoses
performance. Yanmar recommends that soft, (Figure 4-9, (1)) are installed at the oil cooler.
distilled, or demineralized water be used to mix
with coolants.
• NEVER mix extended or long life coolants and
conventional (green) coolants.
• NEVER mix different types and / or colors of
extended life coolants.
• Replace the coolant every 1000 engine hours
or once a year.
(1)

0000027B

Figure 4-8

TNV DI Service Manual 4-19


GENERAL SERVICE INFORMATION Engine Coolant

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 following are the engine coolant capacities for
various Yanmar TNV engines.

Engine Coolant
Engine Model
(1) 0001579B Capacity
3TNV82A(-B) 1.9 qt (1.8 L)
Figure 4-9
3TNV84,3TNV84T(-B) 2.1 qt (2.0 L)
2. Remove the radiator cap (Figure 4-7, (2)) by 3TNV88(-B)(-U) 2.1 qt (2.0 L)
turning it counter-clockwise about 1/3 of a turn. 4TNV84,4TNV84T(-Z) 2.9 qt (2.7 L)
3. Pour the engine coolant slowly into the radiator 4TNV88(-B)(-U) 2.9 qt (2.7 L)
until it is even with the lip of the engine coolant 4TNV94L 4.4 qt (4.2 L)
filler port. Make sure that air bubbles do not
4TNV98(-Z)(-E),
develop as you fill the radiator. 4TNV98T(-Z)
4.4 qt (4.2 L)
4. Reinstall the radiator cap (Figure 4-7, (2)). 4TNV106, 4TNV106T 6.3 qt (6.0 L)
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.
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.

4-20 TNV DI Service Manual


Specifications GENERAL SERVICE INFORMATION

SPECIFICATIONS
Description of Model Number
3 TNV 82 A T - Z 0 00
Customer Code

Rated RPM
Governor Type Symbol (Indicating Conformance to EPA Tier 3/Interim Tier
4 Standards)
Governor Type Symbol Governor Type Applicable engine
Z Electronic Governor (Eco-governor)
Non-derated engine
B Mechanical Governor
E Electronic Governor (Eco-governor)
Derated engine
U Mechanical Governor

Turbocharged (No symbol indicates naturally aspirated)

Engine Sub Series

Cylinder Bore (mm)

Engine Series

No. of Cylinders

Engine Speed Specifications


Notation Available Engine Speed Intended Uses
VH 3200 - 3600 RPM (min-1) Lawn Mower, Construction, Industrial Machine
VM 2000 - 3000 RPM (min-1) Agricultural, Construction, Industrial Machines
-1
CH 3000 or 3600 RPM (min ) 2-pole Generator Sets, Irrigation Pumps
-1
CL 1500 or 1800 RPM (min ) 4-pole Generator Sets, Irrigation Pumps

VH: Variable High Speed CH: Constant High Speed


VM: Variable Medium Speed CL: Constant Low Speed

TNV DI Service Manual 4-21


GENERAL SERVICE INFORMATION Specifications

Engine General Specifications


Type Vertical In-line, Water Cooled, 4-Cycle Diesel Engine
Direct Injection Models Direct Injection
Combustion System
Indirect Injection Models Swirl Chamber (Ball-Type)
Starting System Electric Starting
Cooling System Radiator
Lubricating System Forced Lubrication with Trochoid Pump
PTO Position Flywheel End
Direction of Rotation Counterclockwise Viewed from Flywheel End

Notes:
1. The information described in Principal Engine Specifications is 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.
2. 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 mm Hg), 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 TNV DI Service Manual


Principal Engine Specifications GENERAL SERVICE INFORMATION

PRINCIPAL ENGINE SPECIFICATIONS


3TNV82A (~ EPA Tier2)
Engine Model 3TNV82A
Version CL VM
Type Vertical In-line Diesel Engine
Combustion System Direct Injection
Aspiration Natural
No. of Cylinders 3
Bore × Stroke 82 × 84mm
Displacement 1.331L
min-1 1500 1800
Continuous Rated Output kW 9.9 12.0
PS 13.5 16.3
min-1 1500 1800 2000 2200 2400 2600 2800 3000
Max. Rated Output (Net) kW 11.0 13.2 14.6 16.0 17.5 19.0 20.4 21.9
PS 14.9 17.9 19.9 21.8 23.8 25.8 27.8 29.8
1600 1895 2180 2375 2570 2780 2995 3180
High Idling min-1
± 25 ± 25 ± 25 ± 25 ± 25 ± 25 ± 25 ± 25
Engine Weight (Dry)
138kg 128 kg
*with Flywheel Housing
PTO Position Flywheel End
Direction of Rotation Counterclockwise Viewed From Flywheel End
Cooling System Liquid-Cooled with Radiator
Lubricating System Forced Lubrication with Trochoid Pump
Normal Oil Pressure at Rated
Engine Speed 0.34 - 0.49 MPa 0.39 - 0.54 MPa
Normal Oil Pressure at Low 0.06 MPa
Idle Speed
Electric Starting (Starter Motor: DC12V (1.2 kW)) ***
Starting System Alternator: DC12V, 40A***
Recommended Battery Capacity: 12V, 55Ah*** (5h rating)
Dimensions (L × W × H)* 553 × 489 × 565 mm 528 × 489 × 565 mm
5.5/3.6L
Engine Oil Pan Capacity**
(Dipstick Upper Limit / Lower Limit)
Engine Coolant Capacity 1.8L Engine Only
Standard Cooling Fan 335mm O.D., 6 Blade Pusher-Type ***
Crank V-pulley dia./
Fan V-pulley dia. φ120/ φ90mm *** φ110/ φ110mm ***

* Engine specifications without radiator.


** Engine oil capacity for a "Deep Standard" oil pan. Refer to the operation manual provided by the driven machine
manufacturer for the actual engine oil capacity of your machine.
*** May vary depending on application.

TNV DI Service Manual 4-23


GENERAL SERVICE INFORMATION Principal Engine Specifications

3TNV84 (~ EPA Tier2)


Engine Model 3TNV84
Version CL VM
Type Vertical In-line Diesel Engine
Combustion System Direct Injection
Aspiration Natural
No. of Cylinders 3
Bore × Stroke 84 × 90mm
Displacement 1.496L
min-1 1500 1800
Continuous Rated Output kW 11.3 13.5
PS 15.3 18.3
min-1 1500 1800 2000 2200 2400 2600 2800 3000
Max. Rated Output (Net) kW 12.4 14.8 16.4 18.1 19.7 21.3 23.0 24.6
PS 16.8 20.1 22.3 24.6 26.8 29.0 31.3 33.5
High Idling min-1 1600 1895 2180 2400 2590 2810 2995 3210
± 25 ± 25 ± 25 ± 25 ± 25 ± 25 ± 25 ± 25
Engine Weight (Dry)
161kg 155kg
*with Flywheel Housing
PTO Position Flywheel End
Direction of Rotation Counterclockwise Viewed From Flywheel End
Cooling System Liquid-Cooled with Radiator
Lubricating System Forced Lubrication with Trochoid Pump
Normal Oil Pressure at Rated
0.34 - 0.49 MPa 0.39 - 0.54 MPa
Engine Speed
Normal Oil Pressure at Low
Idle Speed 0.06 MPa
Electric Starting (Starter Motor: DC12V (1.2 kW)) ***
Starting System Alternator: DC12V, 40A***
Recommended Battery Capacity: 12V, 55 Ah*** (5h rating)
Dimensions (L × W × H)* 589 × 486 × 622mm 564 × 486 × 622mm
Engine Oil Pan Capacity** 6.7/3.9L
(Dipstick Upper Limit / Lower Limit)
Engine Coolant Capacity 2.0L Engine Only
Standard Cooling Fan 335mm O.D., 6 Blade Pusher-Type ***
Crank V-pulley dia./
φ120/ φ90mm *** φ110/ φ110mm ***
Fan V-pulley dia.
* Engine specifications without radiator.
** Engine oil capacity for a "Deep Standard" oil pan. Refer to the operation manual provided by the driven machine
manufacturer for the actual engine oil capacity of your machine.
*** May vary depending on application.

4-24 TNV DI Service Manual


Principal Engine Specifications GENERAL SERVICE INFORMATION
3TNV84T (~ EPA Tier2)
Engine Model 3TNV84T
Version CL VM
Type Vertical In-line Diesel Engine
Combustion System Direct Injection
Aspiration Turbocharged
No. of Cylinders 3
Bore × Stroke 84 × 90mm
Displacement 1.496L
min-1 1500 1800
Continuous Rated Output kW 14.0 16.5
PS 19.0 22.5
min-1 1500 1800 2400 2600 2800 3000
Max. Rated Output (Net) kW 15.8 18.8 25.0 26.8 29.1 30.9
PS 21.5 25.5 34.0 36.5 39.5 42.0
High Idling min-1 1600 1895 2590 2810 2995 3210
± 25 ± 25 ± 25 ± 25 ± 25 ± 25
Engine Weight (Dry)
161 kg 155 kg
*with Flywheel Housing
PTO Position Flywheel End
Direction of Rotation Counterclockwise Viewed From Flywheel End
Cooling System Liquid-Cooled with Radiator
Lubricating System Forced Lubrication with Trochoid Pump
Normal Oil Pressure at Rated
0.29 - 0.44 MPa 0.34 - 0.49 MPa 0.39 - 0.54 MPa
Engine Speed
Normal Oil Pressure at Low
Idle Speed 0.06 MPa
Electric Starting (Starter Motor: DC12V (1.2 kW)) ***
Starting System Alternator: DC12V, 40A***
Recommended Battery Capacity: 12V,55 Ah*** (5h rating)
Dimensions (L × W × H)* 589 × 486 × 622mm 564 × 486 × 622mm
Engine Oil Pan Capacity** 6.7/3.9L
(Dipstick Upper Limit / Lower Limit)
Engine Coolant Capacity 2.0L Engine Only
Standard Cooling Fan 350mm O.D., 6 Blade Pusher-Type ***
Crank V-pulley dia./
φ120/ φ90mm *** φ110/ φ110mm ***
Fan V-pulley dia.
* Engine specifications without radiator.
** Engine oil capacity for a "Deep Standard" oil pan. Refer to the operation manual provided by the driven machine
manufacturer for the actual engine oil capacity of your machine.
*** May vary depending on application.

TNV DI Service Manual 4-25


GENERAL SERVICE INFORMATION Principal Engine Specifications

3TNV88 (~ EPA Tier2)


Engine Model 3TNV88
Version CL VM
Type Vertical In-line Diesel Engine
Combustion System Direct Injection
Aspiration Natural
No. of Cylinders 3
Bore × Stroke 88 × 90mm
Displacement 1.642L
min-1 1500 1800
Continuous Rated Output kW 12.3 14.8
PS 16.7 20.1
min-1 1500 1800 2000 2200 2400 2600 2800 3000
Max. Rated Output (Net) kW 13.5 16.3 18.0 19.9 21.6 23.5 25.2 27.1
PS 18.4 22.1 24.5 27.0 29.4 31.9 34.2 36.8
High Idling min-1 1600 1895 2180 2400 2590 2810 2995 3210
± 25 ± 25 ± 25 ± 25 ± 25 ± 25 ± 25 ± 25
Engine Weight (Dry)
161kg 155kg
*with Flywheel Housing
PTO Position Flywheel End
Direction of Rotation Counterclockwise Viewed From Flywheel End
Cooling System Liquid-Cooled with Radiator
Lubricating System Forced Lubrication with Trochoid Pump
Normal Oil Pressure at Rated
0.34 - 0.49 MPa 0.39 - 0.54 MPa
Engine Speed
Normal Oil Pressure at Low
Idle Speed 0.06 MPa
Electric Starting (Starter Motor: DC12V (1.2 kW)) ***
Starting System Alternator: DC12V, 40A***
Recommended Battery Capacity: 12V, 55Ah *** (5h rating)
Dimensions (L × W × H)* 589 × 486 × 622mm 564 × 486 × 622mm
Engine Oil Pan Capacity** 6.7/3.9L
(Dipstick Upper Limit / Lower Limit)
Engine Coolant Capacity 2.0L Engine Only
Standard Cooling Fan 335mm O.D., 6 Blade Pusher-Type ***
Crank V-pulley dia./
φ120/ φ90mm *** φ110/ φ110mm ***
Fan V-pulley dia.
* Engine specifications without radiator.
** Engine oil capacity for a "Deep Standard" oil pan. Refer to the operation manual provided by the driven machine
manufacturer for the actual engine oil capacity of your machine.
*** May vary depending on application.

4-26 TNV DI Service Manual


Principal Engine Specifications GENERAL SERVICE INFORMATION
4TNV84 (~ EPA Tier2)
Engine Model 4TNV84
Version CL VM
Type Vertical In-line Diesel Engine
Combustion System Direct Injection
Aspiration Natural
No. of Cylinders 4
Bore × Stroke 84 × 90mm
Displacement 1.995L
min-1 1500 1800
Continuous Rated Output kW 14.9 17.7
PS 20.3 24.1
min-1 1500 1800 2000 2200 2400 2600 2800 3000
Max. Rated Output (Net) kW 16.4 19.5 21.9 24.1 26.3 28.5 30.7 32.9
PS 22.3 26.5 29.8 32.8 35.8 38.7 41.7 44.7
High Idling min-1 1600 1895 2180 2400 2590 2810 2995 3210
± 25 ± 25 ± 25 ± 25 ± 25 ± 25 ± 25 ± 25
Engine Weight (Dry)
183kg 170kg
*with Flywheel Housing
PTO Position Flywheel End
Direction of Rotation Counterclockwise Viewed From Flywheel End
Cooling System Liquid-Cooled with Radiator
Lubricating System Forced Lubrication with Trochoid Pump
Normal Oil Pressure at Rated
0.34 - 0.49 MPa 0.39 - 0.54 MPa
Engine Speed
Normal Oil Pressure at Low
Idle Speed 0.06 MPa
Electric Starting (Starter Motor: DC12V (1.4 kW)) ***
Starting System Alternator: DC12V, 40A***
Recommended Battery Capacity: 12V, 64Ah*** (5h rating)
Dimensions (L × W × H)* 683 × 498.5 × 617 mm 658 × 498.5 × 617mm
Engine Oil Pan Capacity** 7.4/4.0L
(Dipstick Upper Limit / Lower Limit)
Engine Coolant Capacity 2.7L Engine Only
Standard Cooling Fan 370mm O.D., 6 Blade Pusher-Type ***
Crank V-pulley dia./
φ120/ φ90mm *** φ110/ φ110mm ***
Fan V-pulley dia.
* Engine specifications without radiator.
** Engine oil capacity for a "Deep Standard" oil pan. Refer to the operation manual provided by the driven machine
manufacturer for the actual engine oil capacity of your machine.
*** May vary depending on application.

TNV DI Service Manual 4-27


GENERAL SERVICE INFORMATION Principal Engine Specifications

4TNV84T (~ EPA Tier2)


Engine Model 4TNV84T
Version CL VM
Type Vertical In-line Diesel Engine
Combustion System Direct Injection
Aspiration Turbocharged
No. of Cylinders 4
Bore × Stroke 84 × 90mm
Displacement 1.995L
min-1 1500 1800
Continuous Rated Output kW 19.1 24.3
PS 26.0 33.0
min-1 1500 1800 2000 2200 2400 2600 2800 3000
Max. Rated Output (Net) kW 21.3 26.9 27.9 30.5 33.5 35.7 38.6 41.2
PS 29.0 36.5 38.0 41.5 45.5 48.5 52.5 56.0
High Idling min-1 1600 1895 2180 2400 2590 2810 2995 3210
± 25 ± 25 ± 25 ± 25 ± 25 ± 25 ± 25 ± 25
Engine Weight (Dry)
183 kg 170 kg
*with Flywheel Housing
PTO Position Flywheel End
Direction of Rotation Counterclockwise Viewed From Flywheel End
Cooling System Liquid-Cooled with Radiator
Lubricating System Forced Lubrication with Trochoid Pump
Normal Oil Pressure at Rated
0.29 - 0.44 MPa 0.36 - 0.5 MPa
Engine Speed
Normal Oil Pressure at Low
Idle Speed 0.06 MPa
Electric Starting (Starter Motor: DC12V (1.4 kW)) ***
Starting System Alternator: DC12V, 40A***
Recommended Battery Capacity: 12V, 64 Ah*** (5h rating)
Dimensions (L × W × H)* 683 × 498.5 × 713 mm 649 × 498.5 × 713 mm
Engine Oil Pan Capacity** 7.4/4.0L
(Dipstick Upper Limit / Lower Limit)
Engine Coolant Capacity 2.7L Engine Only
Standard Cooling Fan 370mm O.D., 6 Blade Pusher-Type ***
Crank V-pulley dia./
φ120/ φ90mm *** φ110/ φ110mm ***
Fan V-pulley dia.
* Engine specifications without radiator.
** Engine oil capacity for a "Deep Standard" oil pan. Refer to the operation manual provided by the driven machine
manufacturer for the actual engine oil capacity of your machine.
*** May vary depending on application.

4-28 TNV DI Service Manual


Principal Engine Specifications GENERAL SERVICE INFORMATION
4TNV88 (~ EPA Tier2)
Engine Model 4TNV88
Version CL VM
Type Vertical In-line Diesel Engine
Combustion System Direct Injection
Aspiration Natural
No. of Cylinders 4
Bore × Stroke 88 × 90mm
Displacement 2.190L
min-1 1500 1800
Continuous Rated Output kW 16.4 19.6
PS 22.3 26.7
min-1 1500 1800 2000 2200 2400 2600 2800 3000
Max. Rated Output (Net) kW 18.0 21.6 24.1 26.5 28.8 31.3 33.7 35.4
PS 24.5 29.4 32.7 36.0 39.2 42.5 45.8 48.1
High Idling min-1 1600 1895 2180 2400 2590 2810 2995 3210
± 25 ± 25 ± 25 ± 25 ± 25 ± 25 ± 25 ± 25
Engine Weight (Dry)
183 kg 170 kg
*with Flywheel Housing
PTO Position Flywheel End
Direction of Rotation Counterclockwise Viewed From Flywheel End
Cooling System Liquid-Cooled with Radiator
Lubricating System Forced Lubrication with Trochoid Pump
Normal Oil Pressure at Rated
0.34 - 0.49 MPa 0.39 - 0.54 MPa
Engine Speed
Normal Oil Pressure at Low
Idle Speed 0.06 MPa
Electric Starting (Starter Motor: DC12V (1.4 kW)) ***
Starting System Alternator: DC12V, 40A***
Recommended Battery Capacity: 12V, 64 Ah*** (5h rating) ***
Dimensions (L × W × H)* 683 × 498.5 × 618 mm 658 × 498.5 × 618 mm
Engine Oil Pan Capacity** 7.4 / 4.0 L
(Dipstick Upper Limit / Lower Limit)
Engine Coolant Capacity 2.7L Engine Only
Standard Cooling Fan 370mm O.D., 6 Blade Pusher-Type ***
Crank V-pulley dia./
φ120/ φ90mm *** φ110/ φ110mm ***
Fan V-pulley dia.
* Engine specifications without radiator.
** Engine oil capacity for a "Deep Standard" oil pan. Refer to the operation manual provided by the driven machine
manufacturer for the actual engine oil capacity of your machine.
*** May vary depending on application.

TNV DI Service Manual 4-29


GENERAL SERVICE INFORMATION Principal Engine Specifications

4TNV94L (~ EPA Tier2)


Engine Model 4TNV94L
Version CL VM
Type Vertical In-line Diesel Engine
Combustion System Direct Injection
Aspiration Natural
No. of Cylinders 4
Bore × Stroke 94 × 110mm
Displacement 3.054L
min-1 1500 1800
Continuous Rated Output kW 26.1 31.3
PS 35.5 42.5
min-1 1500 1800 2000 2200 2400 2500
Max. Rated Output (Net) kW 29.1 34.6 35.3 38.2 41.6 43.0
PS 39.5 47.0 48.0 52.0 56.5 58.5
High Idling min-1 1600 ± 25 1895 ± 25 2180 ± 25 2400 ± 25 2590 ± 25 2700 ± 25
Engine Weight (Dry) 245 kg 235 kg
*with Flywheel Housing
PTO Position Flywheel End
Direction of Rotation Counterclockwise Viewed From Flywheel End
Cooling System Liquid-Cooled with Radiator
Lubricating System Forced Lubrication with Trochoid Pump
Normal Oil Pressure at Rated 0.29 - 0.39 MPa
Engine Speed
Normal Oil Pressure at Low
0.06 MPa
Idle Speed
Electric Starting (Starter Motor: DC12V (2.3 kW)) ***
Starting System Alternator: DC12V, 40A***
Recommended Battery Capacity: 12V, 64Ah*** (5h rating)
Dimensions (L × W × H)* 719 × 498 × 742 mm
10.5/6.0L
Engine Oil Pan Capacity** (Dipstick Upper Limit / Lower Limit)
Engine Coolant Capacity 4.2L Engine Only
Standard Cooling Fan 410mm O.D., 6 Blade Pusher-Type ***
Crank V-pulley dia./ φ130/ φ130mm ***
Fan V-pulley dia.
* Engine specifications without radiator.
** Engine oil capacity for a "Deep Standard" oil pan. Refer to the operation manual provided by the driven machine
manufacturer for the actual engine oil capacity of your machine.
*** May vary depending on application.

4-30 TNV DI Service Manual


Principal Engine Specifications GENERAL SERVICE INFORMATION
4TNV98 (~ EPA Tier2)
Engine Model 4TNV98
Version CL VM
Type Vertical In-line Diesel Engine
Combustion System Direct Injection
Aspiration Natural
No. of Cylinders 4
Bore × Stroke 98 × 110mm
Displacement 3.319L
min-1 1500 1800
Continuous Rated Output kW 30.9 36.8
PS 42.0 50.0
min-1 1500 1800 2000 2200 2400 2500
Max. Rated Output (Net) kW 34.6 41.2 41.9 45.6 49.3 51.1
PS 47.0 56.0 57.0 62.0 67.0 69.5
High Idling min-1 1600 ± 25 1895 ±25 2180 ± 25 2400 ± 25 2590 ± 25 2700 ± 25
Engine Weight (Dry) 248 kg 235 kg
*with Flywheel Housing
PTO Position Flywheel End
Direction of Rotation Counterclockwise Viewed From Flywheel End
Cooling System Liquid-Cooled with Radiator
Lubricating System Forced Lubrication with Trochoid Pump
Normal Oil Pressure at Rated 0.29 - 0.39 MPa
Engine Speed
Normal Oil Pressure at Low
0.06 MPa
Idle Speed
Electric Starting (Starter Motor: DC12V (2.3 kW)) ***
Starting System Alternator: DC12V, 40A***
Recommended Battery Capacity: 12V, 64Ah*** (5h rating)
Dimensions (L × W × H)* 719 × 498 × 742 mm
10.5/6.0L
Engine Oil Pan Capacity** (Dipstick Upper Limit / Lower Limit)
Engine Coolant Capacity 4.2L Engine Only
Standard Cooling Fan 410mm O.D., 6 Blade Pusher-Type ***
Crank V-pulley dia./ φ130/ φ130mm ***
Fan V-pulley dia.
* Engine specifications without radiator.
** Engine oil capacity for a "Deep Standard" oil pan. Refer to the operation manual provided by the driven machine
manufacturer for the actual engine oil capacity of your machine.
*** May vary depending on application.

TNV DI Service Manual 4-31


GENERAL SERVICE INFORMATION Principal Engine Specifications

4TNV98T (~ EPA Tier2)


Engine Model 4TNV98T
Version CL VM
Type Vertical In-line Diesel Engine
Combustion System Direct Injection
Aspiration Turbocharged
No. of Cylinders 4
Bore × Stroke 98 × 110mm
Displacement 3.319L
min-1 1500 1800
Continuous Rated Output kW 37.9 45.6
PS 51.5 62.0
min-1 1500 1800 2000 2200 2400 2500
Max. Rated Output (Net) kW 41.9 50.4 50.7 55.5 60.3 62.5
PS 57.0 68.5 69.0 75.5 82.0 85.0
High Idling min-1 1600 ± 25 1895 ± 25 2180 ± 25 2400 ± 25 2590 ± 25 2700 ± 25
Engine Weight (Dry) 258 kg 245 kg
*with Flywheel Housing
PTO Position Flywheel End
Direction of Rotation Counterclockwise Viewed From Flywheel End
Cooling System Liquid-Cooled with Radiator
Lubricating System Forced Lubrication with Trochoid Pump
Normal Oil Pressure at Rated 0.29 - 0.39 MPa
Engine Speed
Normal Oil Pressure at Low
0.06 MPa
Idle Speed
Electric Starting (Starter Motor: DC12V (2.3 kW)) ***
Starting System Alternator: DC12V, 40A***
Recommended Battery Capacity: 12V, 64Ah ***
Dimensions (L × W × H)* 719 × 575 × 804mm
10.5/6.0L
Engine Oil Pan Capacity** (Dipstick Upper Limit / Lower Limit)
Engine Coolant Capacity 4.2L Engine Only
Standard Cooling Fan 430mm O.D., 8 Blade Suction-Type ***
Crank V-pulley dia./ φ130/ φ130mm ***
Fan V-pulley dia.
* Engine specifications without radiator.
** Engine oil capacity for a "Deep Standard" oil pan. Refer to the operation manual provided by the driven machine
manufacturer for the actual engine oil capacity of your machine.
*** May vary depending on application.

4-32 TNV DI Service Manual


Principal Engine Specifications GENERAL SERVICE INFORMATION
4TNV106 (~ EPA Tier2)
Engine Model 4TNV106
Version CL VM
Type Vertical In-line Diesel Engine
Combustion System Direct Injection
Aspiration Natural
No. of Cylinders 4
Bore × Stroke 106 × 125mm
Displacement 4.412L
min-1 1500 1800
Continuous Rated Output kW 41.2 49.3
PS 56.0 67.0
min-1 1500 1800 2000 2200 2400 2500
Max. Rated Output (Net) kW 45.6 54.4 56.6 61.4 65.5 67.7
PS 62.0 74.0 77.0 83.5 89.0 92.0
High Idling min-1 1600 ± 25 1895 ± 25 2205 ± 25 2420 ± 25 2615 ± 25 2725 ± 25
Engine Weight (Dry) 345kg 330kg
*with Flywheel Housing
PTO Position Flywheel End
Direction of Rotation Counterclockwise Viewed From Flywheel End
Cooling System Liquid-Cooled with Radiator
Lubricating System Forced Lubrication with Trochoid Pump
Normal Oil Pressure at Rated 0.31 - 0.49 MPa With balancer: 0.34-0.44 MPa
Engine Speed Without balancer: 0.39-0.49 MPa
Normal Oil Pressure at Low
0.06 MPa
Idle Speed
Electric Starting (Starter Motor: DC12V (3.0 kW)) ***
Starting System Alternator: DC12V, 55A***
Recommended Battery Capacity: 12V, 88 Ah***
Dimensions (L × W × H)* 808 × 629 × 803 mm 776 × 629 × 803 mm
14.0/5.0L 14.0/6.5L
Engine Oil Pan Capacity** (Dipstick Upper Limit / Lower Limit) (Dipstick Upper Limit / Lower Limit)
Engine Coolant Capacity 6L Engine Only
Standard Cooling Fan 500mm O.D. 7 Blade Pusher-Type *** 500mm O.D. 7 Blade Suction-Type ***
Crank V-pulley dia./ φ150/ φ150mm ***
Fan V-pulley dia.
* Engine specifications without radiator.
** Engine oil capacity for a "Deep Standard" oil pan. Refer to the operation manual provided by the driven machine
manufacturer for the actual engine oil capacity of your machine.
*** May vary depending on application.

TNV DI Service Manual 4-33


GENERAL SERVICE INFORMATION Principal Engine Specifications

4TNV106T (~ EPA Tier2)


Engine Model 4TNV106T
Version CL VM
Type Vertical In-line Diesel Engine
Combustion System Direct Injection
Aspiration Turbocharged
No. of Cylinders 4
Bore × Stroke 106 × 125mm
Displacement 4.412L
min-1 1500 1800
Continuous Rated Output kW 51.5 61.8
PS 70.0 84.0
min-1 1500 1800 2000 2200
Max. Rated Output (Net) kW 56.8 68.0 69.9 72.0
PS 77.2 92.5 95.0 97.9
High Idling min-1 1600 ± 25 1875 ± 25 2205 ± 25 2420 ± 25
Engine Weight (Dry) 355 kg 340 kg
*with Flywheel Housing
PTO Position Flywheel End
Direction of Rotation Counterclockwise Viewed From Flywheel End
Cooling System Liquid-Cooled with Radiator
Lubricating System Forced Lubrication with Trochoid Pump
Normal Oil Pressure at Rated 0.31 - 0.49 MPa With balancer: 0.34-0.44 MPa
Engine Speed Without balancer: 0.39-0.49 MPa
Normal Oil Pressure at Low
0.06 MPa
Idle Speed
Electric Starting (Starter Motor DC12V (3.0 kW)) ***
Starting System Alternator: DC12V, 55A***
Recommended Battery Capacity: 12V, 88 Ah***
Dimensions (L × W × H)* 808 × 629 × 866 mm 776 × 629 × 866 mm
14.0/5.0L 14.0/6.5L
Engine Oil Pan Capacity** (Dipstick Upper Limit / Lower Limit) (Dipstick Upper Limit / Lower Limit)
Engine Coolant Capacity 6L Engine Only
Standard Cooling Fan 500mm O.D. 7 Blade Pusher-Type *** 500mm O.D.7 Blade Suction-Type***
Crank V-pulley dia./ φ150/ φ150mm ***
Fan V-pulley dia.
* Engine specifications without radiator.
** Engine oil capacity for a "Deep Standard" oil pan. Refer to the operation manual provided by the driven machine
manufacturer for the actual engine oil capacity of your machine.
*** May vary depending on application.

4-34 TNV DI Service Manual


Principal Engine Specifications GENERAL SERVICE INFORMATION
3TNV82A-B (complies with EPA Interim Tier4)
Engine Model 3TNV82A-B
Version CL VM
Type Vertical, 4-cycle water-cooled diesel engine
Combustion System Direct Injection
Aspiration Natural aspiration
No. of Cylinders 3
Bore × Stroke φ82 × 84mm
Displacement 1.331L
min-1
Continuous Rated
Output kW
PS
min-1 2200 2300 2400 2500 2600 2700 2800 3000
Max. Rated Output kW 16.0 16.8 17.5 18.2 19.0 19.7 20.4 21.9
(Net) PS 21.8 22.8 23.8 24.8 25.8 26.8 27.8 29.8
23.0
High Idling min-1 2375 2485 2570 2675 2780 2890 2995 3180
±25 ±25 ±25 ±25 ±25 ±25 ±25 ±25
Engine Weight (dry)
128kg
*with Flywheel Housing
PTO Position Flywheel End
Direction of Rotation Counterclockwise Viewed From Flywheel End
Governor Mechanical governor (All-speed governor)
Cooling System Liquid-Cooled with Radiator
Lubricating System Forced Lubrication with Trochoid Pump
Rated Engine 0.36-0.51 (3.7-
Speed 0.31-0.46 (3.2-4.7) MPa 5.2) MPa
Normal Oil
Pressure Low Idle
Speed
≥ 0.06 (≥ 0.6) MPa
Starting System Electric Starting (Starter Motor: DC12V (1.7kW)) ***
Charging system Alternator (DC12V/40A) ***
Recommended Battery
Capacity 12V-55Ah*** (5h rating)
Starting aid device Super-quick Heating Glow plug
Dimensions (L × W × H)* 546 × 492 × 561mm
5.5L/3.6L
Engine Oil Pan Capacity**
(Dipstick Upper Limit / Lower Limit)
Engine Coolant Capacity 1.8L Engine Only
Standard Cooling Fan Resin F type pusher fan - φ335(NF) x 6
Crank V-pulley dia./ φ110/ φ110mm
Fan V-pulley dia.
* Engine specifications without radiator.
** Engine oil capacity for a "Deep Standard" oil pan. Refer to the operation manual provided by the driven machine
manufacturer for the actual engine oil capacity of your machine.
*** May vary depending on application.

TNV DI Service Manual 4-35


GENERAL SERVICE INFORMATION Principal Engine Specifications

3TNV84T-B (complies with EPA Interim Tier4)


Engine Model 3TNV84T-B
Version CL VM
Type Vertical, 4-cycle water-cooled diesel engine
Combustion System Direct Injection
Aspiration Turbocharged
No. of Cylinders 3
Bore × Stroke φ84 × 90mm
Displacement 1.496L
min-1
Continuous Rated
Output kW
PS
min-1 2400 2500 2600 2700 2800
Max. Rated Output
(Net) kW 25.0 26.0 26.8 27.9 29.1
PS 34.0 35.3 36.5 38.0 39.5
2590 2700 2810 2920 2995
High Idling min-1
±25 ±25 ±25 ±25 ±25
Engine Weight (dry)
*with Flywheel Housing 155kg
PTO Position Flywheel End
Direction of Rotation Counterclockwise Viewed From Flywheel End
Governor Electronic governor (All-speed governor)
Cooling System Liquid-Cooled with Radiator
Lubricating System Forced Lubrication with Trochoid Pump
Rated Engine 0.34-0.49 (3.5-5.0) MPa 0.39-0.54 (4.0-5.5) MPa
Normal Oil Speed
Pressure Low Idle
Speed
≥ 0.06 (≥ 0.6) MPa
Starting System Electric Starting (Starter Motor: DC12V (1.7kW)) ***
Charging system Alternator (DC12V/40A) ***
Recommended Battery 12V-55Ah*** (5h rating)
Capacity
Starting aid device Air heater (12V DC 400W)
Dimensions (L × W × H)* 589 × 486 × 564 × 486 × 622mm
622mm
6.7L/3.9L
Engine Oil Pan Capacity**
(Dipstick Upper Limit / Lower Limit)
Engine Coolant Capacity 2.0L Engine Only
Standard Cooling Fan Resin F type pusher fan - φ350(QF) x 6
Crank V-pulley dia./ φ110/ φ110mm
Fan V-pulley dia.
* Engine specifications without radiator.
** Engine oil capacity for a "Deep Standard" oil pan. Refer to the operation manual provided by the driven machine
manufacturer for the actual engine oil capacity of your machine.
*** May vary depending on application.

4-36 TNV DI Service Manual


Principal Engine Specifications GENERAL SERVICE INFORMATION
3TNV88-U (complies with EPA Interim Tier4)
Engine Model 3TNV88-U
Version CL VM
Type Vertical, 4-cycle water-cooled diesel engine
Combustion System Direct Injection
Aspiration Natural aspiration
No. of Cylinders 3
Bore × Stroke φ88 × 90mm
Displacement 1.642L
min-1
Continuous Rated
Output kW
PS
min-1 2200 2300 2400 2500 2600 2700 2800 3000
Max. Rated Output
(Net) kW 18.1 18.9 19.7 20.5 21.3 22.2 23.0 24.6
PS 24.6 25.7 26.8 27.9 29.0 30.2 31.3 33.5
2400 2510 2590 2700 2810 2920 2995 3210
High Idling min-1
±25 ±25 ±25 ±25 ±25 ±25 ±25 ±25
Engine Weight (dry)
*with Flywheel Housing 155kg
PTO Position Flywheel End
Direction of Rotation Counterclockwise Viewed From Flywheel End
Governor Mechanical governor (All-speed governor)
Cooling System Liquid-Cooled with Radiator
Lubricating System Forced Lubrication with Trochoid Pump
Rated Engine 0.34-0.49 (3.5-5.0) MPa 0.39-0.54 (4.0-
Normal Oil Speed 5.5) MPa
Pressure Low Idle
Speed
≥ 0.06 (≥ 0.6) MPa
Starting System Electric Starting (Starter Motor: DC12V (1.7kW)) ***
Charging system Alternator (DC12V/40A) ***
Recommended Battery 12V-55Ah*** (5h rating)
Capacity
Starting aid device Super-quick Heating Glow plug
Dimensions (L × W × H)* 568 × 514 × 622mm
6.7L/3.9L
Engine Oil Pan Capacity** (Dipstick Upper Limit / Lower Limit)
Engine Coolant Capacity 2.0L Engine Only
Standard Cooling Fan Resin F type pusher fan - φ335(NF) x 6
Crank V-pulley dia./
φ110/ φ110mm
Fan V-pulley dia.
* Engine specifications without radiator.
** Engine oil capacity for a "Deep Standard" oil pan. Refer to the operation manual provided by the driven machine
manufacturer for the actual engine oil capacity of your machine.
*** May vary depending on application.

TNV DI Service Manual 4-37


GENERAL SERVICE INFORMATION Principal Engine Specifications

3TNV88-B (complies with EPA Interim Tier4)


Engine Model 3TNV88-B
Version CL VM
Type Vertical, 4-cycle water-cooled diesel engine
Combustion System Direct Injection
Aspiration Natural aspiration
No. of Cylinders 3
Bore × Stroke φ88 × 90mm
Displacement 1.642L
min-1 1500 1800
Continuous Rated
Output kW 12.3 14.8
PS 16.7 20.1
min-1 1500 1800 2200 2300 2400 2500 2600 2700 2800 3000
Max. Rated Output
(Net) kW 13.5 16.3 19.9 20.7 21.6 22.6 23.5 24.3 25.2 27.1
PS 18.4 22.1 27.0 28.2 29.4 30.7 31.9 33.1 34.2 36.8
1600 1895 2400 2510 2590 2700 2810 2920 2995 3210
High Idling min-1
±25 ±25 ±25 ±25 ±25 ±25 ±25 ±25 ±25 ±25
Engine Weight (dry)
*with Flywheel Housing 161kg 155kg
PTO Position Flywheel End
Direction of Rotation Counterclockwise Viewed From Flywheel End
Governor Mechanical governor (All-speed governor)
Cooling System Liquid-Cooled with Radiator
Lubricating System Forced Lubrication with Trochoid Pump
Rated Engine 0.29-0.44 (3.0- 0.34-0.49 (3.5-5.0) MPa 0.39-0.54 (4.0-
Normal Oil Speed 4.5) MPa 5.5) MPa
Pressure Low Idle
Speed
≥ 0.06 (≥ 0.6) MPa
Starting System Electric Starting (Starter Motor: DC12V (1.7kW)) ***
Charging system Alternator (DC12V/40A) ***
Recommended Battery 12V-55Ah*** (5h rating)
Capacity
Starting aid device Super-quick Heating Glow plug
Dimensions (L × W × H)* 583 × 514 × 568 × 514 × 622mm
622mm
6.7L/3.9L
Engine Oil Pan Capacity**
(Dipstick Upper Limit / Lower Limit)
Engine Coolant Capacity 2.0L Engine Only
Standard Cooling Fan Resin F type pusher fan - φ335(NF) x 6
Crank V-pulley dia./ φ120/ φ90mm φ110/ φ110mm
Fan V-pulley dia.
* Engine specifications without radiator.
** Engine oil capacity for a "Deep Standard" oil pan. Refer to the operation manual provided by the driven machine
manufacturer for the actual engine oil capacity of your machine.
*** May vary depending on application.

4-38 TNV DI Service Manual


Principal Engine Specifications GENERAL SERVICE INFORMATION
4TNV84T-Z (complies with EPA Interim Tier4)
Engine Model 4TNV84T-Z
Version CL VM
Type Vertical, 4-cycle water-cooled diesel engine
Combustion System Direct Injection
Aspiration Turbocharged
No. of Cylinders 4
Bore × Stroke φ84 × 90mm
Displacement 1.995L
min-1 1500 1800
Continuous Rated
Output kW 19.1 24.3
PS 26.0 33.0
min-1 1500 1800 2400 2500 2700 2800 3000
Max. Rated Output
(Net) kW 21.3 26.9 33.5 34.5 37.1 38.6 41.2
PS 29.0 36.5 45.5 47.0 50.5 52.5 56.0
1600 1895 2590 2700 2850 2950 3150
High Idling min-1
±25 ±25 ±25 ±25 ±25 ±25 ±25
Engine Weight (dry)
*with Flywheel Housing 183kg 170kg
PTO Position Flywheel End
Direction of Rotation Counterclockwise Viewed From Flywheel End
Governor Electronic governor (All-speed governor)
Cooling System Liquid-Cooled with Radiator
Lubricating System Forced Lubrication with Trochoid Pump
Rated Engine 0.29-0.44 (3.0- 0.36-0.51 (3.7-5.2) MPa
Normal Oil Speed 4.5) MPa
Pressure Low Idle
Speed
≥ 0.06 (≥ 0.6) MPa
Starting System Electric Starting (Starter Motor: DC12V (1.7kW) ***
Charging system Alternator (DC12V/40A) ***
Recommended Battery 12V-64Ah*** (5h rating)
Capacity
Starting aid device Air heater (12V DC 400W)
Dimensions (L × W × H)* 683 × 499 × 649 × 499 × 713mm
713mm
7.4L/4.0L
Engine Oil Pan Capacity**
(Dipstick Upper Limit / Lower Limit)
Engine Coolant Capacity 2.7L Engine Only
Standard Cooling Fan Resin F type pusher fan - φ370(EF) x 6
Crank V-pulley dia./ φ120/ φ90mm φ110/ φ110mm
Fan V-pulley dia.
* Engine specifications without radiator.
** Engine oil capacity for a "Deep Standard" oil pan. Refer to the operation manual provided by the driven machine
manufacturer for the actual engine oil capacity of your machine.
*** May vary depending on application.

TNV DI Service Manual 4-39


GENERAL SERVICE INFORMATION Principal Engine Specifications

4TNV88-U (complies with EPA Interim Tier4)


Engine Model 4TNV88-U
Version CL VM
Type Vertical, 4-cycle water-cooled diesel engine
Combustion System Direct Injection
Aspiration Natural aspiration
No. of Cylinders 4
Bore × Stroke φ88 × 90mm
Displacement 2.190L
min-1
Continuous Rated
Output kW
PS
min-1 2700 2800
Max. Rated Output
(Net) kW 29.6 30.7
PS (40.2) (41.7)
2920 2995
High Idling min-1
±25 ±25
Engine Weight (dry)
*with Flywheel Housing 170kg
PTO Position Flywheel End
Direction of Rotation Counterclockwise Viewed From Flywheel End
Governor Mechanical governor (All-speed governor)
Cooling System Liquid-Cooled with Radiator
Lubricating System Forced Lubrication with Trochoid Pump
Rated Engine 0.32-0.47 (3.3-4.8) MPa
Normal Oil Speed
Pressure Low Idle
Speed
≥ 0.06 (≥ 0.6) MPa
Starting System Electric Starting (Starter Motor: DC12V (1.7kW)) ***
Charging system Alternator (DC12V/40A) ***
Recommended Battery 12V-64Ah*** (5h rating)
Capacity
Starting aid device Super-quick Heating Glow plug
Dimensions (L × W × H)* 684 × 523 × 617 659 × 523 × 617
7.4L/4.0L
Engine Oil Pan Capacity** (Dipstick Upper Limit / Lower Limit)
Engine Coolant Capacity 2.7L Engine Only
Standard Cooling Fan Resin F type pusher fan - φ370(EF) x 6
Crank V-pulley dia./
φ120/ φ90mm φ110/ φ110mm
Fan V-pulley dia.
* Engine specifications without radiator.
** Engine oil capacity for a "Deep Standard" oil pan. Refer to the operation manual provided by the driven machine
manufacturer for the actual engine oil capacity of your machine.
*** May vary depending on application.

4-40 TNV DI Service Manual


Principal Engine Specifications GENERAL SERVICE INFORMATION
4TNV88-B (complies with EPA Interim Tier4)
Engine Model 4TNV88-B
Version CL VM
Type Vertical, 4-cycle water-cooled diesel engine
Combustion System Direct Injection
Aspiration Natural aspiration
No. of Cylinders 4
Bore × Stroke φ88 × 90mm
Displacement 2.190L
min-1 1500 1800
Continuous Rated
Output kW 16.4 19.6
PS 22.3 26.7
min-1 1500 1800 2000 2100 2200 2300 2400 2500 2600 2700 2800 3000
Max. Rated Output
(Net) kW 18.0 21.6 24.1 25.3 26.5 27.7 28.8 30.1 31.3 32.5 33.7 35.4
PS 24.5 29.4 32.7 34.4 36.0 37.6 39.2 40.9 42.5 44.2 45.8 48.1
1600 1895 2180 2290 2400 2510 2590 2700 2810 2920 2995 3210
High Idling min-1
±25 ±25 ±25 ±25 ±25 ±25 ±25 ±25 ±25 ±25 ±25 ±25
Engine Weight (dry)
*with Flywheel Housing 183kg 170kg
PTO Position Flywheel End
Direction of Rotation Counterclockwise Viewed From Flywheel End
Governor Mechanical governor (All-speed governor)
Cooling System Liquid-Cooled with Radiator
Lubricating System Forced Lubrication with Trochoid Pump
Rated Engine 0.29-0.44 (3.0- 0.32-0.47 (3.3-4.8) MPa
Normal Oil Speed 4.5) MPa
Pressure Low Idle
Speed
≥ 0.06 (≥ 0.6) MPa
Starting System Electric Starting (Starter Motor: DC12V (1.7kW)) ***
Charging system Alternator (DC12V/40A) ***
Recommended Battery 12V-64Ah*** (5h rating)
Capacity
Starting aid device Super-quick Heating Glow plug
Dimensions (L × W × H)* 684 × 523 × 617 659 × 523 × 617
7.4L/4.0L
Engine Oil Pan Capacity** (Dipstick Upper Limit / Lower Limit)
Engine Coolant Capacity 2.7L Engine Only
Standard Cooling Fan Resin F type pusher fan - φ370(EF) x 6
Crank V-pulley dia./
φ120/ φ90 φ110/ φ110
Fan V-pulley dia.
* Engine specifications without radiator.
** Engine oil capacity for a "Deep Standard" oil pan. Refer to the operation manual provided by the driven machine
manufacturer for the actual engine oil capacity of your machine.
*** May vary depending on application.

TNV DI Service Manual 4-41


GENERAL SERVICE INFORMATION Principal Engine Specifications

4TNV98-E (complies with EPA Interim Tier4)


Engine Model 4TNV98-E
Version CL VM
Type Vertical, 4-cycle water-cooled diesel engine
Combustion System Direct Injection
Aspiration Natural aspiration
No. of Cylinders 4
Bore × Stroke 98 × 110mm
Displacement 3.319L
min-1
Continuous Rated
Output kW
PS
min-1 2100 2200 2300 2400 2500
Max. Rated Output
(Net) kW 36.8 38.2 39.7 41.6 43.0
PS 50.0 52.0 54.0 56.5 58.5
High Idling min-1 2250 ± 25 2350 ± 25 2450 ± 25 2550 ± 25 2650 ± 25
Engine Weight (dry) 240kg
*with Flywheel Housing
PTO Position Flywheel End
Direction of Rotation Counterclockwise Viewed From Flywheel End
Governor Electronic governor (All-speed governor)
Cooling System Liquid-Cooled with Radiator
Lubricating System Forced Lubrication with Trochoid Pump
Rated Engine
0.29-0.39 (3.0-4.0) MPa
Normal Oil Speed
Pressure Low Idle
Speed 0.06 (0.6) MPa
Starting System Electric Starting (Starter Motor: DC12V (2.3kW)) ***
Charging system Alternator (DC12V/40A) ***
Recommended Battery
12V-64Ah*** (5h rating)
Capacity
Starting aid device Air heater (12VDC/500W)
Dimensions (L × W × H)* 719 × 540 × 721mm
Engine Oil Pan Capacity** 10.2L/5.7L
(Dipstick Upper Limit / Lower Limit)
Engine Coolant Capacity 4.2L Engine Only
Standard Cooling Fan Resin F type pusher fan - φ410(AI) x 6
Crank V-pulley dia./
Fan V-pulley dia. φ130/ φ130mm

* Engine specifications without radiator.


** Engine oil capacity for a "Deep Standard" oil pan. Refer to the operation manual provided by the driven machine
manufacturer for the actual engine oil capacity of your machine.
*** May vary depending on application.

4-42 TNV DI Service Manual


Principal Engine Specifications GENERAL SERVICE INFORMATION
4TNV98-Z (complies with EPA Interim Tier4)
Engine Model 4TNV98-Z
Version CL VM
Type Vertical, 4-cycle water-cooled diesel engine
Combustion System Direct Injection
Aspiration Natural aspiration
No. of Cylinders 4
Bore × Stroke 98 × 110mm
Displacement 3.319L
min-1 1500 1800
Continuous Rated
Output kW 30.9 36.8
PS 42.0 50.0
min-1 1500 1800 2000 2100 2200 2300 2400 2500
Max. Rated Output
(Net) kW 34.6 41.2 41.9 43.8 45.6 47.4 49.3 51.1
PS 47.0 56.0 57.0 59.5 62.0 64.5 67.0 69.5
High Idling min-1 1530 ± 25 1830 ± 25 2150 ± 25 2250 ± 25 2350 ± 25 2450 ± 25 2550 ± 25 2650 ± 25
Engine Weight (dry) 248kg 235kg
*with Flywheel Housing
PTO Position Flywheel End
Direction of Rotation Counterclockwise Viewed From Flywheel End
Governor Electronic governor (All-speed governor)
Cooling System Liquid-Cooled with Radiator
Lubricating System Forced Lubrication with Trochoid Pump
Rated Engine
0.29-0.39 (3.0-4.0) MPa
Normal Oil Speed
Pressure Low Idle
Speed 0.06 (0.6) MPa
Starting System Electric Starting (Starter Motor: DC12V (2.3kW)) ***
Charging system Alternator (DC12V/40A) ***
Recommended Battery
12V-64Ah*** (5h rating)
Capacity
Starting aid device Air heater (12VDC/500W)
Dimensions (L × W × H)* 719 × 540 × 721mm
Engine Oil Pan Capacity** 10.2L/5.7L
(Dipstick Upper Limit / Lower Limit)
Engine Coolant Capacity 4.2L Engine Only
Standard Cooling Fan Resin F type pusher fan - φ410(AI) x 6
Crank V-pulley dia./
Fan V-pulley dia. φ130/ φ130mm

* Engine specifications without radiator.


** Engine oil capacity for a "Deep Standard" oil pan. Refer to the operation manual provided by the driven machine
manufacturer for the actual engine oil capacity of your machine.
*** May vary depending on application.

TNV DI Service Manual 4-43


GENERAL SERVICE INFORMATION Principal Engine Specifications

4TNV98T-Z (complies with EPA Interim Tier4)


Engine Model 4TNV98T-Z
Version CL VM
Type Vertical, 4-cycle water-cooled diesel engine
Combustion System Direct Injection
Aspiration Turbocharged
No. of Cylinders 4
Bore × Stroke 98 × 110mm
Displacement 3.319L
min-1 1500 1800
Continuous Rated
Output kW 37.9 45.6
PS 51.5 62.0
min-1 1500 1800 2200 2300 2400 2500
Max. Rated Output
(Net) kW 41.9 50.4 55.5 58.0 60.3 62.5
PS 57.0 68.5 75.5 78.8 82.0 85.0
High Idling min-1 1530 ± 25 1830 ± 25 2350 ± 25 2450 ± 25 2550 ± 25 2650 ± 25
Engine Weight (dry) 258kg 245kg
*with Flywheel Housing
PTO Position Flywheel End
Direction of Rotation Counterclockwise Viewed From Flywheel End
Governor Electronic governor (All-speed governor)
Cooling System Liquid-Cooled with Radiator
Lubricating System Forced Lubrication with Trochoid Pump
Rated Engine
0.29-0.39 (3.0-4.0) MPa
Normal Oil Speed
Pressure Low Idle
Speed ≥ 0.06 (≥ 0.6) MPa
Starting System Electric Starting (Starter Motor: DC12V (2.3kW)) ***
Charging system Alternator (DC12V/40A) ***
Recommended Battery
12V-64Ah*** (5h rating)
Capacity
Starting aid device Air heater (12VDC/500W)
10.2L/5.7L
Engine Oil Pan Capacity**
(Dipstick Upper Limit / Lower Limit)
Engine Coolant Capacity 4.2L Engine Only
Standard Cooling Fan Resin F type pusher fan - φ430(UX) x 6
Crank V-pulley dia./ φ130/ φ130mm
Fan V-pulley dia.
* Engine specifications without radiator.
** Engine oil capacity for a "Deep Standard" oil pan. Refer to the operation manual provided by the driven machine
manufacturer for the actual engine oil capacity of your machine.
*** May vary depending on application.

4-44 TNV DI Service Manual


Engine Service Standards GENERAL SERVICE INFORMATION

ENGINE SERVICE STANDARDS


Reference
Inspection Item Standard Limit
page
All models
except 0.006 - 0.010 in. See Measuring
-
4TNV106 and (0.15 - 0.25 mm) and Adjusting
Intake / Exhaust Valve Clearance 4TNV106T Valve Clearance
4TNV106 and 0.010 - 0.014 in. on page 6-66
-
4TNV106T (0.25 - 0.35 mm)
Fuel Injection
See Checking and Adjusting Fuel Injection Timing on page 7-30.
Timing
Fuel Injection
See Test and Adjustment Specifications on page 7-12.
Pressure
443 - 473 psi 340 - 370 psi
3TNV82A (3.06 - 3.26 MPa; (2.35 - 3.55 MPa;
30 - 32 kgf / cm²) 24 - 26 kgf / cm²)
455 - 485 psi 355 - 385 psi See
Compression 3TNV84, 4TNV84 (3.14 - 3.34 MPa; (2.45 - 2.65 MPa; Troubleshooting
Pressure at 32 - 34 kgf / cm²) 25 - 27 kgf / cm²) By Measuring
250 rpm 411 - 441 psi 340 - 370 psi Compression
(250 min¯¹) 3TNV84T, 4TNV84T (2.84 - 3.04 MPa; (2.35 - 2.55 MPa; Pressure on
29 - 31 kgf / cm) 24 - 26 kgf / cm²) page 15-187
3TNV88, 4TNV88, 4TNV94L, 483 - 513 psi 384 - 414 psi
4TNV98, 4TNV98T, 4TNV106, (3.33 - 3.53 MPa; (2.65 - 2.85 MPa;
4TNV106T 34 - 36 kgf / cm²) 27 - 29 kgf / cm²)
29 - 43 psi
Deviation Between Cylinders All Models (0.2 - 0.3 MPa; - -
2 - 3 kgf/cm²)
5.8 - 8.8 psi
Oil Pressure Switch Operating Pressure (0.04 - 0.06 MPa; - -
0.4 - 0.6 kgf / cm²)
Valve Opening Full Opening Lift
Temperature Temperature
0.32 in (8 mm) or
157°F - 163°F
All Models above See Thermostat
Thermostat (70°C - 73°C)
185°F (85°C) on page 8-11
0.39 in (10 mm) or
All Models 176°F - 183°F
above
Option (80°C - 84°C)
203°F (95°C)
See
225°F - 235°F Temperature
Coolant Temperature Switch -
(107°C - 113°C) Switch on
page 8-10

TNV DI Service Manual 4-45


GENERAL SERVICE INFORMATION Tightening Torques for Standard Bolts and Nuts

TIGHTENING TORQUES FOR STANDARD BOLTS AND NUTS


Use the correct amount of torque when you tighten
the fasteners on the machine. Applying excessive CAUTION
torque may damage the fastener or component and The tightening torque in the Standard
not enough torque may cause a leak or component Torque Chart (see General Service
failure. 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.
0000023enTNVDISM

Nominal Thread
Item x Pitch Tightening Torque Remarks
Diameter
7 - 9 ft-lb
(87 -104 in.-lb,
M6 x 1.0 mm
9.8 -11.8 N·m,
1.0 -1.2 kgf·m)
17 - 21 ft-lb
M8 x 1.25 mm (200 - 251 in.-lb,
22.6 - 28.4 N·m,
2.3 - 2.9 kgf·m)
33 - 40 ft-lb Use 80% of the value at left
M10 x 1.5 mm (44.1 - 53.9 N·m, when the tightening part is
Hexagon Bolt (7T) and
Nut 4.5 - 5.5 kgf·m) aluminum.
Use 60% of the value at left for
58 - 72 ft-lb 4T bolts and lock nuts.
M12 x 1.75 mm (78.4 - 98.0 N·m,
8.0 - 10 kgf·m)
94 - 108 ft-lb
M14 x 1.5 mm (127.5 - 147.1 N·m,
13 - 15 kgf·m)
159 - 174 ft-lb
M16 x 1.5 mm (215.7- 235.4 N·m,
22 - 24 kgf·m)

1/8 mm 7 ft-lb
(87 in.-lb, 9.8 N·m, 1.0 kgf·m)
14 ft-lb
1/4 mm
(173 in.-lb, 19.6 N·m, 2.0 kgf·m)
PT PLug -
22 ft-lb
3/8 mm (29.4 N·m, 3.0 kgf·m)

1/2 mm 43 ft-lb
(58.8 N·m, 6.0 kgf·m)

4-46 TNV DI Service Manual


Tightening Torques for Standard Bolts and Nuts GENERAL SERVICE INFORMATION

Nominal Thread
Item x Pitch Tightening Torque Remarks
Diameter
9 - 12 ft-lb
(112 - 148 in.-lb,
M8
12.7 - 16.7 N·m,
1.3 - 1.7 kgf·m)
14 - 19 ft-lb
M10 (173 - 225 in.-lb,
19.6 - 18.734 N·m,
2.0 - 3.5 kgf·m)
Pipe Joint Bolt 18 - 25 ft-lb -
M12 (24.5 - 34.3 N·m,
2.5 - 3.5 kgf·m)
29 - 36 ft-lb
M14 (39.2 - 49.0 N·m,
4.0 - 5.0 kgf·m)
36 - 43 ft-lb
M16 (49.0 - 58.8 N·m,
5.0 - 6.0 kgf·m)

Note: Torque values shown in this manual are for clean, non-lubricated fasteners unless otherwise
specified.

TNV DI Service Manual 4-47


GENERAL SERVICE INFORMATION Abbreviations and Symbols

ABBREVIATIONS AND JASO Japanese Automobile Standards


Organization
SYMBOLS k kelvin
kg kilogram
Abbreviations kgf/cm² kilogram force per square centimeter
kgf/m kilogram force per meter
A ampere km kilometers
AC alternating current kPa kilopascal
ACEA Association des Constructeurs kW kilowatt
Européens d’Automobilies L liter
Ah ampere-hour L/hr liter per hour
API American Petroleum Institute lb pound
lbf pound force
ARB Air Resources Board
m meter
ATDC after top dead center
mL milliliter
BDC bottom dead center
mm millimeter
BTDC before top dead center mmAq millimeter Aqueous (water)
°C degree Celsius MPa megapascal
CARB California Air Resources Board mV millivolt
CCA cold cranking amp N newton
cfm cubic feet per minute N·m newton meter
cm centimeter No. number
cm³ cubic centimeter O.D. outside diameter
cm³/min cubic centimeter per minute oz ounce
Pa pascal
cu in. cubic inch
PS horsepower (metric)
D diameter
psi pound per square inch
DC direct current
qt quart (U.S.)
DI direct injection R radius
DVA direct volt adapter rpm revolutions per minute
EPA Environmental Protection Agency SAE Society of Automotive Engineers
ESG electronic speed governor sec. second
°F degree Fahrenheit t short ton 2000 lb
fl oz fluid ounce (U.S.) TBN total base number
fl oz/min fluid ounce (U.S.) per minute TDC top dead center
ft foot V volt
VAC volt alternating current
ft-lb foot pound
VDC volt direct current
ft-lbf/min foot pound force per minute
W watt
g gram
gal gallon (U.S.) Symbols
gal/hr gallon (U.S.) per hour
gal/min gallon (U.S.) per minute ° degree
GL gear lubricant + plus
hp horsepower (U.S.) - minus
hr hour
± plus or minus
I.D. inside diameter
Ω ohm
ID identification μ micro
IDI indirect injection % percent
in. inch
in.Aq inches Aqueous (water)
in.Hg inches Mercury
in.-lb inch pound
j joule

4-48 TNV DI Service Manual


Unit Conversions GENERAL SERVICE INFORMATION

UNIT CONVERSIONS Units of Torque


ft-lb x 1.3558 = N·m
Unit Prefixes ft-lb x 0.1383 = kgf/m
Prefix Symbol Power in.-lb x 0.1130 = N·m
mega M x 1,000,000 in.-lb x 0.0115 = kgf/m
kilo k x 1,000 kgf/m x 7.2330 = ft-lb
centi c x 0.01 kgf/m x 86.8000 = in.-lb
milli m x 0.001 kgf/m x 9.8070 = N·m
micro μ x 0.000001 N·m x 0.7376 = ft-lb
N·m x 8.8510 = in.-lb
Units of Length N·m x 0.1020 = kgf/m
mile x 1.6090 = km Units of Pressure
ft x 0.3050 =m
in. x 2.5400 = cm psi x 0.0689 = bar
in. x 25.4000 = mm psi x 6.8950 = kPa
km x 0.6210 = mile psi x 0.0703 = kg/cm²
m x 3.2810 = ft bar x 14.5030 = psi
cm x 0.3940 = in. bar x 100.0000 = kPa
mm x 0.0394 = in. bar x 29.5300 = inHg (60°F)
kPa x 0.1450 = psi
Units of Volume kPa x 0.0100 = bar
kPa x 0.0102 = kg/cm²
gal (U.S.) x 3.78540 =L
kg/cm² x 98.0700 = psi
qt (U.S.) x 0.94635 =L
kg/cm² x 0.9807 = bar
cu in. x 0.01639 =L
kg/cm² x 14.2200 = kPa
cu in. x 16.38700 = mL
in.Hg (60°) x 0.0333 = bar
fl oz (U.S.) x 0.02957 =L
in.Hg (60°) x 3.3770 = kPa
fl oz (U.S.) x 29.57000 = mL
in.Hg (60°) x 0.0344 = kg/cm²
cm³ x 1.00000 = mL
mmAq x 0.0394 = in.Aq
cm³ x 0.03382 = fl oz (U.S.)

Units of Mass Units of Power


hp (metric x 0.9863201 = hp SAE
lb x 0.45360 = kg
or PS)
oz x 28.35000 =g
hp (metric x 0.7354988 = kW
kg x 2.20500 = lb
or PS)
g x 0.03527 = oz
hp SAE x 1.0138697 = hp (metric or PS)
Units of Force hp SAE x 0.7456999 = kW
kW x 1.3596216 = hp (metric or PS)
lbf x 4.4480 =N kW x 1.3410221 = hp SAE
lbf x 0.4536 = kgf
N x 0.2248 = lbf Units of Temperature
N x 0.1020 = kgf
°F = (1.8 x °C) + 32
kgf x 2.2050 = lbf
°C = 0.556 x (°F - 32)
kgf x 9.8070 =N

TNV DI Service Manual 4-49


GENERAL SERVICE INFORMATION Unit Conversions

This Page Intentionally Left Blank

4-50 TNV DI Service Manual


TNV DI Service Manual
Section 5

PERIODIC
MAINTENANCE
Page
Before You Begin Servicing ............................................................ 5-3
Introduction.................................................................................... 5-16
The Importance of Periodic Maintenance................................ 5-16
Performing Periodic Maintenance ........................................... 5-16
Yanmar Replacement Parts .................................................... 5-16
Required EPA / ARB Maintenance -USA Only........................ 5-16
EPA / ARB Installation Requirements - USA Only .................. 5-16
Periodic Maintenance Schedule.................................................... 5-17
Periodic Maintenance Procedures ................................................ 5-20
After Initial 50 Hours of Operation ........................................... 5-20
Every 50 Hours of Operation ................................................... 5-24
Every 250 Hours of Operation ................................................. 5-27
Every 500 Hours of Operation ................................................. 5-32
Every 1000 Hours of Operation ............................................... 5-36
Every 1500 Hours of Operation ............................................... 5-39
Every 2000 Hours of Operation ............................................... 5-42

TNV DI Service Manual 5-1


PERIODIC MAINTENANCE

This Page Intentionally Left Blank

5-2 TNV DI Service Manual


Before You Begin Servicing PERIODIC MAINTENANCE

BEFORE YOU BEGIN


A DANGER
SERVICING
A DANGER

SCALD HAZARD!
• NEVER remove the radiator cap if the
EXPLOSION HAZARD! engine is hot. Steam and hot engine
coolant will spurt out and seriously
• NEVER check the remaining battery burn you. Allow the engine to cool
charge by shorting out the terminals. down before you attempt to remove
This will result in a spark and may the radiator cap.
cause an explosion or fire. Use a
hydrometer to check the remaining • Tighten the radiator cap securely after
battery charge. you check the radiator. Steam can
spurt out during engine operation if
• If the electrolyte is frozen, slowly warm the cap is loose.
the battery before you recharge it.
• ALWAYS check the level of the engine
• Failure to comply will result in death or coolant by observing the reserve tank.
serious injury.
• Failure to comply will result in death or
0000007en
serious injury.
0000002en
A DANGER

FIRE AND EXPLOSION HAZARD!


• Only use the key switch to start the
engine.
• NEVER jump-start the engine. Sparks
caused by shorting the battery to the
starter terminals may cause a fire or
explosion.
• Failure to comply will result in death or
serious injury.
0000004en

TNV DI Service Manual 5-3


PERIODIC MAINTENANCE Before You Begin Servicing

A DANGER A DANGER

FIRE AND EXPLOSION HAZARD! FIRE AND EXPLOSION HAZARD!


• Diesel fuel is flammable and explosive • Diesel fuel is flammable and explosive
under certain conditions. under certain conditions.
• Only fill the fuel tank with diesel fuel. • Before you operate the engine, check
Filling the fuel tank with gasoline may for fuel leaks. Replace rubberized fuel
result in a fire and will damage the hoses every two years or every 2000
engine. hours of engine operation, whichever
comes first, even if the engine has
• NEVER refuel with the engine running.
been out of service. Rubberized fuel
• Wipe up all spills immediately. lines tend to dry out and become
• Keep sparks, open flames or any other brittle after two years or 2000 hours of
form of ignition (match, cigarette, engine operation, whichever comes
static electric source) well away when first.
refueling. • Failure to comply will result in death or
• NEVER overfill the fuel tank. serious injury.
0000015en
• Fill the fuel tank. Store any containers
containing fuel in a well-ventilated
area, away from any combustibles or A DANGER
sources of ignition.
• Failure to comply will result in death or
serious injury.
0000005en

FIRE AND EXPLOSION HAZARD!


• Diesel fuel is flammable and explosive
under certain conditions.
• NEVER remove the fuel cap with the
engine running.
• Failure to comply will result in death or
serious injury.
0000011en

5-4 TNV DI Service Manual


Before You Begin Servicing PERIODIC MAINTENANCE

A DANGER A DANGER

FIRE AND EXPLOSION HAZARD!


• Diesel fuel is flammable and explosive CRUSH HAZARD!
under certain conditions. • When you need to transport an engine
for repair, have a helper assist you to
• Be sure to place the diesel fuel
attach it to a hoist and load it on a
container on the ground when
truck.
transferring the diesel fuel from the
pump to the container. Hold the hose • NEVER stand under a hoisted engine.
nozzle firmly against the side of the If the hoist mechanism fails, the
container while filling it. This prevents engine will fall on you, causing death
static electricity buildup which could or serious injury.
cause sparks and ignite fuel vapors. • Failure to comply will result in death or
• NEVER place diesel fuel or other serious injury.
flammable material such as oil, hay or 0000008en

dried grass close to the engine during


engine operation or shortly after
shutdown.
• Failure to comply will result in death or
serious injury.
0000014en

A DANGER

FIRE AND EXPLOSION HAZARD!


• Diesel fuel is flammable and explosive
under certain conditions.
• NEVER use diesel fuel as a cleaning
agent.
• Failure to comply will result in death or
serious injury.
0000012en

TNV DI Service Manual 5-5


PERIODIC MAINTENANCE Before You Begin Servicing

A DANGER A DANGER

FIRE AND EXPLOSION HAZARD! FIRE AND EXPLOSION HAZARD!


• Diesel fuel is flammable and explosive • Diesel fuel is flammable and explosive
under certain conditions. under certain conditions.
• When you remove any fuel system • Place an approved container under the
component to perform maintenance air bleed port when you prime the fuel
(such as changing the fuel filter) place system. Never use a shop rag to catch
an approved container under the the fuel. Wipe up any spills
opening to catch the fuel. immediately. ALWAYS close the air
• NEVER use a shop rag to catch the bleed port after you complete priming
fuel. Vapors from the rag are the system.
flammable and explosive. • Wear eye protection. The fuel system
• Wipe up any spills immediately. is under pressure and fuel could spray
out when you open the air bleed port.
• Wear eye protection. The fuel system
is under pressure and fuel could spray • If the unit has an electric fuel pump,
out when you remove any fuel system turn the key switch to the ON position
component. for 10 to 15 seconds, or until the fuel
coming out of the air bleed port is free
• Failure to comply will result in death or of bubbles, to allow the electric fuel
serious injury. pump to prime the system.
0000009en
• 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.
• Failure to comply will result in death or
serious injury.
0000006en

5-6 TNV DI Service Manual


Before You Begin Servicing PERIODIC MAINTENANCE

A WARNING A WARNING

EXHAUST HAZARD! SEVER HAZARD!


• NEVER operate the engine in an • Keep hands and other body parts
enclosed area such as a garage, away from moving / rotating parts
tunnel, underground room, manhole or such as the cooling fan, flywheel or
ship’s hold without proper ventilation. PTO shaft.
• NEVER block windows, vents, or other • Wear tight-fitting clothing and keep
means of ventilation if the engine is your hair short or tie it back while the
operating in an enclosed area. All engine is running.
internal combustion engines create • Remove all jewelry before you operate
carbon monoxide gas during or service the machine.
operation. Accumulation of this gas
within an enclosure could cause • NEVER start the engine in gear.
illness or even death. Sudden movement of the engine
and / or machine could cause death or
• Make sure that all connections are serious personal injury.
tightened to specifications after repair
is made to the exhaust system. • NEVER operate the engine without the
guards in place.
• Failure to comply could result in death
or serious injury. • Before you start the engine make sure
0000003en
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.
0000002en

TNV DI Service Manual 5-7


PERIODIC MAINTENANCE Before You Begin Servicing

A WARNING A WARNING
SUDDEN MOVEMENT HAZARD!
• Engaging the transmission or PTO at
an elevated engine speed could result
in unexpected movement of the
equipment.
ALCOHOL AND DRUG HAZARD!
• Failure to comply could result in death
or serious injury. • NEVER operate the engine while you
0000006en
are under the influence of alcohol or
drugs.

A WARNING • NEVER operate the engine when you


are feeling ill.
• Failure to comply could result in death
or serious injury.
0000004en

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.
0000015en

5-8 TNV DI Service Manual


Before You Begin Servicing PERIODIC MAINTENANCE

A WARNING A WARNING

BURN HAZARD!
EXPOSURE HAZARD! • Batteries contain sulfuric acid. NEVER
allow battery fluid to come in contact
• Wear personal protective equipment
with clothing, skin or eyes. Severe
such as gloves, work shoes, eye and
burns could result. ALWAYS wear
hearing protection as required by the
safety goggles and protective clothing
task at hand.
when servicing the battery. If battery
• NEVER wear jewelry, unbuttoned fluid contacts the eyes and / or skin,
cuffs, ties or loose-fitting clothing immediately flush the affected area
when you are working near with a large amount of clean water and
moving / rotating parts such as the obtain prompt medical treatment.
cooling fan, flywheel or PTO shaft.
• Failure to comply could result in death
• ALWAYS tie back long hair when you or serious injury.
are working near moving / rotating 0000007en
parts such as a cooling fan, flywheel,
or PTO shaft.
A WARNING
• 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
HIGH-PRESSURE HAZARD!
or serious injury.
0000005en
• 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
high-pressure 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.
0000008en

TNV DI Service Manual 5-9


PERIODIC MAINTENANCE Before You Begin Servicing

A WARNING A WARNING

BURN HAZARD!
SHOCK HAZARD!
• If you must drain the engine oil while it
• Turn off the battery switch (if
is still hot, stay clear of the hot engine
equipped) or disconnect the negative
oil to avoid being burned.
battery cable before servicing the
electrical system. • ALWAYS wear eye protection.
• Check the electrical harnesses for • Failure to comply could result in death
cracks, abrasions, and damaged or or serious injury.
corroded connectors. ALWAYS keep 0000011en

the connectors and terminals clean.


• Failure to comply could result in death A WARNING
or serious injury.
0000009en

A WARNING
BURN HAZARD!
• Wait until the engine cools before you
drain the engine coolant. Hot engine
coolant may splash and burn you.
ENTANGLEMENT HAZARD! • Failure to comply could result in death
• Stop the engine before you begin to or serious injury.
service it. 0000016en

• 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.
0000010en

5-10 TNV DI Service Manual


Before You Begin Servicing PERIODIC MAINTENANCE

A CAUTION CAUTION
• Only use diesel fuels recommended by
Yanmar for the best engine
performance, to prevent engine
damage and to comply with EPA / ARB
warranty requirements.
COOLANT HAZARD! • Only use clean diesel fuel.
• Wear eye protection and rubber gloves • NEVER remove the primary strainer (if
when you handle long life or extended equipped) from the fuel tank filler port.
life engine coolant. If contact with the If removed, dirt and debris could get
eyes or skin should occur, flush eyes into the fuel system causing it to clog.
and wash immediately with clean 0000004en

water.
• Failure to comply may result in minor CAUTION
or moderate injury. • Only use the engine oil specified.
0000005en
Other engine oils may affect warranty
coverage, cause internal engine
A CAUTION 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.
FLYING OBJECT HAZARD! • NEVER mix different types of engine
• ALWAYS wear eye protection when oil. This may adversely affect the
servicing the engine and when using lubricating properties of the engine oil.
compressed air or high-pressure • NEVER overfill. Overfilling may result
water. Dust, flying debris, compressed in white exhaust smoke, engine
air, pressurized water or steam may overspeed or internal damage.
injure your eyes. 0000005en

• Failure to comply may result in minor


or moderate injury.
0000003en

TNV DI Service Manual 5-11


PERIODIC MAINTENANCE Before You Begin Servicing

CAUTION CAUTION
• Only use the engine coolant specified. Observe the following environmental
Other engine coolants may affect operating conditions to maintain engine
warranty coverage, cause an internal performance and avoid premature
buildup of rust and scale and / or engine wear:
shorten engine life. • Avoid operating in extremely dusty
• Prevent dirt and debris from conditions.
contaminating the engine coolant. • Avoid operating in the presence of
Carefully clean the radiator cap and chemical gases or fumes.
the surrounding area before you
remove the cap. • Avoid operating in a corrosive
atmosphere such as salt water spray.
• NEVER mix different types of engine
coolants. This may adversely affect the • NEVER install the engine in a
properties of the engine coolant. floodplain unless proper precautions
0000006en
are taken to avoid being subject to a
flood.

CAUTION • NEVER expose the engine to the rain.


0000003en
• NEVER attempt to modify the engine’s
design or safety features such as
defeating the engine speed limit CAUTION
control or the diesel fuel injection Observe the following environmental
quantity control. operating conditions to maintain engine
• Modifications may impair the engine’s performance and avoid premature
safety and performance engine wear:
characteristics and shorten the • The standard range of ambient
engine’s life. Any alterations to this temperatures for the normal operation
engine may void its warranty. Be sure of Yanmar engines is from +5°F (-15°C)
to use Yanmar genuine replacement to +113°F (+45°C).
parts.
• If the ambient temperature exceeds
0000079en
+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.
0000065en

5-12 TNV DI Service Manual


Before You Begin Servicing PERIODIC MAINTENANCE

CAUTION CAUTION
NEVER hold the key in the START New Engine Break-in:
position for longer than 15 seconds or • On the initial engine start-up, allow the
the starter motor will overheat. engine to idle for approximately 15
0000007en
minutes while you check for proper
engine oil pressure, diesel fuel leaks,
CAUTION engine oil leaks, coolant leaks, and for
proper operation of the indicators
For maximum engine life, Yanmar
and / or gauges.
recommends that when shutting the
engine down, you allow the engine to • During the first hour of operation, vary
idle, without load, for five minutes. This the engine speed and the load on the
will allow the engine components that engine. Short periods of maximum
operate at high temperatures, such as engine speed and load are desirable.
the turbocharger (if equipped) and Avoid prolonged operation at
exhaust system, to cool slightly before minimum or maximum engine speeds
the engine itself is shut down. and loads for the next four to five
0000008en hours.
• During the break-in period, carefully
CAUTION observe the engine oil pressure and
engine temperature.
NEVER use an engine starting aid such
as ether. Engine damage will result. • During the break-in period, check the
0000009en
engine oil and coolant levels
frequently.
0000011en
CAUTION
Make sure the engine is installed on a
level surface. If a continuously running
CAUTION
engine is installed at an angle greater NEVER engage the starter motor while
than (IDI = 25°, DI = 30°) in any direction the engine is running. This may damage
or if an engine runs for short periods of the starter motor pinion and / or ring
time (less than three minutes) at an gear.
angle greater than (IDI = 30°, DI = 35°) in 0000012en

any direction, engine oil may enter the


combustion chamber causing excessive CAUTION
engine speed and white exhaust smoke.
This may cause serious engine damage. It is important to perform daily checks.
0000010enTNV Periodic maintenance prevents
unexpected downtime, reduces the
number of accidents due to poor
machine performance and helps extend
the life of the engine.
0000060en

TNV DI Service Manual 5-13


PERIODIC MAINTENANCE Before You Begin Servicing

CAUTION CAUTION
NEVER use high-pressure water or
compressed air at greater than 28 psi
(193 kPa; 19 686 mmAq) or a wire brush
to clean the radiator fins. Radiator fins
damage easily.
• ALWAYS be environmentally 0000016en

responsible.
• Follow the guidelines of the EPA or CAUTION
other governmental agencies for the NEVER attempt to adjust the low or high
proper disposal of hazardous idle speed limit screw. This may impair
materials such as engine oil, diesel the safety and performance of the
fuel and engine coolant. Consult the machine and shorten its life. If the idle
local authorities or reclamation facility. speed limit screws require adjustment,
• NEVER dispose of hazardous see your authorized Yanmar industrial
materials irresponsibly by dumping engine dealer or distributor.
them into a sewer, on the ground, or 0000017en

into ground water or waterways.


• Failure to follow these procedures may CAUTION
seriously harm the environment. Establish a periodic maintenance plan
0000013en according to the engine application and
make sure you perform the required
CAUTION periodic maintenance at the intervals
indicated. Failure to follow these
Protect the air cleaner, turbocharger (if
guidelines will impair the engine’s safety
equipped) and electric components
and performance characteristics,
from damage when you use steam or
shorten the engine’s life and may affect
high-pressure water to clean the engine.
the warranty coverage on your engine.
0000014en
See Yanmar Limited Warranty in
Warranty Section.
CAUTION
Consult your authorized Yanmar dealer
• NEVER overfill the engine with engine or distributor for assistance when
oil. checking items marked with a .
• ALWAYS keep the oil level between the 0000024enTNVDISM
upper and lower lines on the oil
cap / dipstick.
0000015en

5-14 TNV DI Service Manual


Before You Begin Servicing PERIODIC MAINTENANCE

CAUTION
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.
0000025en

CAUTION
• 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.
0000026en

CAUTION
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.
0000046en

TNV DI Service Manual 5-15


PERIODIC MAINTENANCE Introduction

INTRODUCTION Perform periodic maintenance procedures in an


open, level area free from traffic. If possible,
This section of the Service Manual describes the perform the procedures indoors to prevent
procedures for proper care and maintenance of the environmental conditions, such as rain, wind, or
engine. snow, from damaging the machine.
The Importance of Periodic Yanmar Replacement Parts
Maintenance Yanmar recommends that you use genuine Yanmar
Engine deterioration and wear occurs in proportion parts when replacement parts are needed.
to length of time the engine has been in service and Genuine replacement parts help ensure long
the conditions the engine is subject to during engine life.
operation. Periodic maintenance prevents
unexpected downtime, reduces the number of Required EPA / ARB Maintenance -
accidents due to poor machine performance and USA Only
helps extend the life of the engine.
To maintain optimum engine performance and
Performing Periodic Maintenance compliance with the Environmental Protection
Agency (EPA) Regulations Non-road Engines and
the California Air Resources Board (ARB,
A WARNING California), it is essential that you follow the
Periodic Maintenance Schedule on page 5-17 and
Periodic Maintenance Procedures on page 5-20.

EPA / ARB Installation


EXHAUST HAZARD! Requirements - USA Only
• NEVER operate the engine in an The following are the installation requirements for
enclosed area such as a garage, the EPA / ARB. Unless these requirements are met,
tunnel, underground room, manhole or the exhaust gas emissions will not be within the
ship’s hold without proper ventilation. limits specified by the EPA and ARB.

• NEVER block windows, vents, or other Maximum Exhaust Gas Restriction shall be:
means of ventilation if the engine is
• 3TNV84T(-B): 1.42 psi (9.81 kPa; 1000 mm
operating in an enclosed area. All
Aq) or less
internal combustion engines create
carbon monoxide gas during • 4TNV98T(-Z): 1.71 psi (11.77 kPa; 1200 mm
operation. Accumulation of this gas Aq) or Iess
within an enclosure could cause • 3TNV82A(-B),3TNV84,3TNV88(-B)(-U),
illness or even death. 4TNV94L,4TNV98(-Z)(-E): 2.22 psi (15.3 kPa;
• Make sure that all connections are 1560 mm Aq) or Iess
tightened to specifications after repair Maximum air intake restriction shall be 0.90 psi
is made to the exhaust system. (6.23 kPa; 635 mm Aq) or less. Clean or replace
• Failure to comply could result in death the air cleaner element if the air intake restriction
or serious injury. exceeds the above mentioned value.
0000003en

5-16 TNV DI Service Manual


Periodic Maintenance Schedule PERIODIC MAINTENANCE

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.

CAUTION
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 .
0000024enTNVDISM

TNV DI Service Manual 5-17


PERIODIC MAINTENANCE Periodic Maintenance Schedule

: Check : Replace : Contact your authorized Yanmar industrial engine dealer or distributor
Periodic Maintenance Interval

System Check Item Daily Every Every Every Every Every Every
50 250 500 1000 1500 2000
hours hours hours hours hours hours

Check and Refill Engine Coolant


Check and Clean Radiator Fins

Check and Adjust Cooling Fan V-belt 1st time 2nd and
after
Cooling
System or
every 1
year
Drain, Flush and Refill Cooling System With New Coolant which-
ever
comes
first

Cylinder Adjust Intake / Exhaust Valve Clearance


Head Lap Intake / Exhaust Valve Seats. If necessary

Electrical Check Indicators


Equipment Check Battery
Check Engine Oil Level

Engine Oil Drain and Fill Engine Oil 2nd and


1st time
after
Replace Engine Oil Filter
Engine
Check and Adjust Governor Lever and
Speed Engine Speed Control
Control
Inspect, Clean And Test Fuel Injectors

Inspect Turbocharger
(Blower Wash as Necessary)
3TNV84T, 4TNV84T, 4TNV98T, 4TNV106T,
3TNV84T-B, 4TNV84T-Z, 4TNV98T-Z

Emission Inspect, Clean and Test EGR Valve


Control 4TNV84T, 4TNV98T
Warranty
Clean EGR Lead Valve
4TNV84T, 4TNV98T
Clean EGR Cooler
(Clean to Blow Water/Air Passages)
4TNV84T, 4TNV98T
Inspect Crankcase Breather System
Check and Refill Fuel Tank Level
Drain Fuel Tank
Drain Fuel Filter / Water Separator
Fuel
Check Fuel Filter / Water Separator
Clean Fuel Filter / Water Separator
Replace Fuel Filter

Replace Fuel System and


Hoses Cooling System Hoses or every
2 yrs.

5-18 TNV DI Service Manual


Periodic Maintenance Schedule PERIODIC MAINTENANCE
: Check : Replace : Contact your authorized Yanmar industrial engine dealer or distributor
Periodic Maintenance Interval

System Check Item Daily Every Every Every Every Every Every
50 250 500 1000 1500 2000
hours hours hours hours hours hours
Intake and
Clean or Replace Air Cleaner Element
Exhaust
Complete
Engine Overall Visual Check Daily

Note: These procedures are considered normal maintenance and are performed at the owner’s expense.

TNV DI Service Manual 5-19


PERIODIC MAINTENANCE Periodic Maintenance Procedures

PERIODIC MAINTENANCE CAUTION


PROCEDURES • Only use the engine oil specified.
Other engine oils may affect warranty
After Initial 50 Hours of Operation coverage, cause internal engine
components to seize and / or shorten
Perform the following maintenance after the initial engine life.
50 hours of operation. • Prevent dirt and debris from
• Replace Engine Oil and Engine Oil Filter contaminating the engine oil. Carefully
clean the oil cap / dipstick and the
• Check and Adjust Cooling Fan V-Belt surrounding area before you remove
the cap.
Replace Engine Oil and Engine Oil Filter
• NEVER mix different types of engine
A WARNING 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.
0000005en

BURN HAZARD!
• If you must drain the engine oil while it CAUTION
is still hot, stay clear of the hot engine
oil to avoid being burned.
• ALWAYS wear eye protection.
• Failure to comply could result in death
or serious injury.
0000011en
• ALWAYS be environmentally
responsible.

A WARNING • Follow the guidelines of the EPA or


other governmental agencies for the
SUDDEN MOVEMENT HAZARD! proper disposal of hazardous
• Engaging the transmission or PTO at materials such as engine oil, diesel
an elevated engine speed could result fuel and engine coolant. Consult the
in unexpected movement of the local authorities or reclamation facility.
equipment. • NEVER dispose of hazardous
• Failure to comply could result in death materials irresponsibly by dumping
or serious injury. them into a sewer, on the ground, or
0000006en
into ground water or waterways.
• Failure to follow these procedures may
seriously harm the environment.
0000013en

5-20 TNV DI Service Manual


Periodic Maintenance Procedures PERIODIC MAINTENANCE
The engine oil in a new engine becomes 7. After all oil has been drained from the engine,
contaminated from the initial break-in of internal reinstall the oil drain plug (Figure 5-2, (1)) and
parts. It is very important that the initial oil and filter tighten to 139.8 - 47.0 ft·lb (53.9 - 63.7 N·m;
change is performed as scheduled. 5.5 - 6.5 kgf·m).
Note: The oil drain plug may be in another 8. Dispose of used oil properly.
location if an optional oil pan is used. Remove the engine oil filter as follows:
Drain the engine oil as follows: 1. Turn the engine oil filter (Figure 5-2, (2))
counterclockwise (Figure 5-2, (3)) using a filter
1. Make sure the engine is level.
wrench.
2. Start the engine and bring it up to operating
temperature. (3)
3. Stop the engine.
(4)
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.
5. Position a container under the engine to collect
waste oil.

(2)

(1)

(1)
0000062B

Figure 5-2
(1) 0000084 2. Clean the engine oil filter mounting face.
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.

0000084B

Figure 5-1
6. Remove the oil drain plug (Figure 5-2, (1)) from
the engine oil pan. Allow oil to drain.

TNV DI Service Manual 5-21


PERIODIC MAINTENANCE Periodic Maintenance Procedures

Engine Oil Filter Part No. (4)


Standard Dust proof *
3TNV82A
3TNV84
- 4TNV98
3TNV82A-B 129150-35153
3TNV88-B
- 4TNV98-Z 119005-35151
4TNV98-E
4TNV98T
4TNV98T-Z (4)
119005-35151
4TNV106,
4TNV106T (5)

* Consult the operation manual for the driven


machine for applicability of the dust proof
filter. (2)
(1)
4. Add new engine oil to the engine as specified in
Adding Engine Oil on page 4-17.
(3)
CAUTION 0000007C

• NEVER overfill the engine with engine Figure 5-3


oil.
9. Reinstall the oil filler cap (Figure 5-3, (4)). If
• ALWAYS keep the oil level between the any engine oil is spilled, wipe it away with a
upper and lower lines on the oil clean cloth.
cap / dipstick.
0000015en Check and Adjust Cooling Fan V-Belt
The V-belt will slip if it does not have the proper
5. Warm up the engine by running it for five
tension. This will prevent the alternator from
minutes and check for any engine oil leaks.
generating sufficient power. Also, the engine will
6. After engine is warm, shut it off and let it sit for overheat due to the engine coolant pump pulley
10 minutes. slipping.
7. Recheck the engine oil level.
Check and adjust the V-belt tension (deflection) as
8. Add engine oil (Figure 5-3, (5)) as needed until follows:
the level is between the upper (Figure 5-3, (2))
and lower lines (Figure 5-3, (3)) shown on the 1. Press the V-belt down with your thumb with a
dipstick (Figure 5-3, (1)). 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:

5-22 TNV DI Service Manual


Periodic Maintenance Procedures PERIODIC MAINTENANCE

Used V-Belt Tension


A B C
3/8 - 1/2 in. 1/4 - 3/8 in. 5/16 - 1/2 in.
(10 - 14 mm) (7 - 10 mm) (9 - 13 mm)
(2)

Note: A “Used V-Belt” refers to a V-belt which (1)


has been used on a running engine for
five minutes or more. 0000584

(B) Figure 5-6

(A)
(C)

0000063B

Figure 5-4
2. If necessary, adjust the V-belt tension. Loosen
the adjusting bolt (Figure 5-5, (1)) and 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 bolt.

(3)

(1)

(2) 0000064B

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.

TNV DI Service Manual 5-23


PERIODIC MAINTENANCE Periodic Maintenance Procedures

4. Check the V-belt for cracks, oil or wear. If any of


these conditions exist, replace the V-belt. Every 50 Hours of Operation
5. Install the new V-belt. Refer to the table for
proper tension. After you complete the initial 50 hour maintenance
procedures, perform the following procedures every
New V-Belt Tension 50 hours thereafter.
A B C
• Drain Fuel Filter / Water Separator
5/16 - 7/16 in. 3/16 - 5/16 in. 1/4 - 7/16 in.
(8 - 12 mm) (5 - 8 mm) (7 - 11 mm) • Check Battery

6. After adjusting, run the engine for 5 minutes or Drain Fuel Filter / Water Separator
more. Check the tension again using the
specifications for a used V-belt. A DANGER
Used V-Belt Tension
A B C
3/8 - 1/2 in. 1/4 - 3/8 in. 5/16 - 1/2 in.
(10 - 14 mm) (7 - 10 mm) (9 - 13 mm)
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.
0000009en

5-24 TNV DI Service Manual


Periodic Maintenance Procedures PERIODIC MAINTENANCE
The cup of the separator is made from semi-
CAUTION transparent material. In the cup is a red colored
If the fuel filter / water separator is float ring. The float ring will rise to the surface of the
positioned higher than the fuel level in water to show how much needs to be drained. Also,
the fuel tank, water may not drip out some optional fuel filter / water separators are
when the fuel filter / water separator equipped with a sensor to detect the amount of
drain cock is opened. If this happens, contaminants. This sensor sends a signal to an
turn the air vent screw on the top of the indicator to alert the operator.
fuel filter / water separator 2-3 turns
Drain the fuel filter / water separator as follows:
counterclockwise.
Be sure to tighten the air vent screw 1. Position an approved container under the fuel
after the water has drained out. filter / water separator (Figure 5-7, (1)) to
0000025en
collect the contaminants.

CAUTION (2)

(3)

(1)
• ALWAYS be environmentally
responsible.
• Follow the guidelines of the EPA or (4) 0000012C
other governmental agencies for the
proper disposal of hazardous Figure 5-7
materials such as engine oil, diesel 2. Close (Figure 5-7, (2)) the fuel cock
fuel and engine coolant. Consult the (Figure 5-7, (3)).
local authorities or reclamation facility.
3. Loosen the drain cock (Figure 5-7, (4)) at the
• NEVER dispose of hazardous bottom of the fuel filter / water separator. Drain
materials irresponsibly by dumping any water collected inside.
them into a sewer, on the ground, or
into ground water or waterways. 4. Hand-tighten the drain cock.

• Failure to follow these procedures may CAUTION


seriously harm the environment.
If the fuel filter / water separator is
0000013en
positioned higher than the fuel level in
Drain the fuel filter / water separator whenever the fuel tank, water may not drip out
there are contaminants, such as water, collected in when the fuel filter / water separator
the bottom of the cup. NEVER wait until the drain cock is opened. If this happens,
scheduled periodic maintenance if contaminants turn the air vent screw on the top of the
are discovered. fuel filter / water separator 2-3 turns
counterclockwise.
Be sure to tighten the air vent screw
after the water has drained out.
0000025en

TNV DI Service Manual 5-25


PERIODIC MAINTENANCE Periodic Maintenance Procedures

5. Open the fuel cock (Figure 5-7, (3)).


6. Be sure to prime the diesel fuel system when
A WARNING
you are finished. See Priming the Fuel System
on page 4-15.
7. Check for leaks.

Check Battery
BURN HAZARD!
A DANGER • 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,
EXPLOSION HAZARD! immediately flush the affected area
• NEVER check the remaining battery with a large amount of clean water and
charge by shorting out the terminals. obtain prompt medical treatment.
This will result in a spark and may
• Failure to comply could result in death
cause an explosion or fire. Use a
or serious injury.
hydrometer to check the remaining
0000007en
battery charge.
• If the electrolyte is frozen, slowly warm
the battery before you recharge it. CAUTION
• Failure to comply will result in death or
serious injury.
0000007en

• 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.
0000013en

5-26 TNV DI Service Manual


Periodic Maintenance Procedures PERIODIC MAINTENANCE
• When the amount of fluid nears the lower limit
(Figure 5-8, (1)), fill with distilled water Every 250 Hours of Operation
(Figure 5-8, (2)) so it is at the upper limit
(Figure 5-8, (3)). If operation continues with Perform the following maintenance every 250 hours
insufficient battery fluid, the battery life is of operation.
shortened, and the battery may overheat and
explode. During the summer, check the fluid • Drain Fuel Tank
level more often than specified. • Replace Engine Oil and Engine Oil Filter
• Check and Clean Radiator Fins
(3) • Check and Adjust Cooling Fan V-Belt
(2) • Check and Adjust the Governor Lever and
Engine Speed Control
• Clean Air Cleaner Element
(1)
Drain Fuel Tank

A DANGER
0000067A

Figure 5-8
• If the engine cranking speed is so slow that the
engine does not start, recharge the battery. FIRE AND EXPLOSION HAZARD!
• If the engine still will not start after charging, • Diesel fuel is flammable and explosive
have your authorized Yanmar industrial engine under certain conditions.
dealer or distributor check the battery and the • When you remove any fuel system
engine’s starting system. component to perform maintenance
• If operating the machine where the ambient (such as changing the fuel filter) place
temperature could drop to 5°F (-15°C) or less, an approved container under the
remove the battery from the machine at the end opening to catch the fuel.
of the day. Store the battery in a warm place • NEVER use a shop rag to catch the
until the next use. This will help start the engine fuel. Vapors from the rag are
easily at low ambient temperatures. 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.
0000009en

TNV DI Service Manual 5-27


PERIODIC MAINTENANCE Periodic Maintenance Procedures

4. Drain the tank until clean diesel fuel with no


CAUTION water and dirt flows out. Reinstall and tighten
the drain plug firmly.
5. Reinstall the fuel cap.
6. Check for leaks.

Replace Engine Oil and Engine Oil Filter


• ALWAYS be environmentally
responsible. CAUTION
• Follow the guidelines of the EPA or • Only use the engine oil specified.
other governmental agencies for the Other engine oils may affect warranty
proper disposal of hazardous coverage, cause internal engine
materials such as engine oil, diesel components to seize and / or shorten
fuel and engine coolant. Consult the engine life.
local authorities or reclamation facility.
• Prevent dirt and debris from
• NEVER dispose of hazardous contaminating the engine oil. Carefully
materials irresponsibly by dumping clean the oil cap / dipstick and the
them into a sewer, on the ground, or surrounding area before you remove
into ground water or waterways. the cap.
• Failure to follow these procedures may • NEVER mix different types of engine
seriously harm the environment. oil. This may adversely affect the
0000013en lubricating properties of the engine oil.
Note that a typical fuel tank is illustrated. • NEVER overfill. Overfilling may result
in white exhaust smoke, engine
1. Position an approved container under the diesel overspeed or internal damage.
fuel tank (Figure 5-9, (1)) to collect the 0000005en
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.

(3)

(1)

(2)
0000065A

Figure 5-9

5-28 TNV DI Service Manual


Periodic Maintenance Procedures PERIODIC MAINTENANCE
Check and Clean Radiator Fins
CAUTION
A CAUTION

• ALWAYS be environmentally
responsible.
• Follow the guidelines of the EPA or FLYING OBJECT HAZARD!
other governmental agencies for the
• ALWAYS wear eye protection when
proper disposal of hazardous
servicing the engine and when using
materials such as engine oil, diesel
compressed air or high-pressure
fuel and engine coolant. Consult the
water. Dust, flying debris, compressed
local authorities or reclamation facility.
air, pressurized water or steam may
• NEVER dispose of hazardous injure your eyes.
materials irresponsibly by dumping
• Failure to comply may result in minor
them into a sewer, on the ground, or
or moderate injury.
into ground water or waterways.
0000003en
• Failure to follow these procedures may
seriously harm the environment. Dirt and dust adhering to the radiator fins reduce
0000013en
the cooling performance, causing overheating.
Make it a rule to check the radiator fins daily and
Change the engine oil every 250 hours of operation clean as needed.
after the initial change at 50 hours. Replace the
engine oil filter at the same time. See Replace Note that a typical radiator is shown in Figure 5-10
Engine Oil and Engine Oil Filter on page 5-20. 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.

CAUTION
NEVER use high-pressure water or
compressed air at greater than 28 psi
(193 kPa; 19 686 mmAq) or a wire brush
to clean the radiator fins. Radiator fins
damage easily.
0000016en

TNV DI Service Manual 5-29


PERIODIC MAINTENANCE Periodic Maintenance Procedures

Checking and adjusting the governor lever:


1. Check that the governor lever (Figure 5-11, (1))
makes uniform contact with the high idle
(Figure 5-11, (2)) and low idle
(1) (Figure 5-11, (3)) speed limit screws when the
FULL

LOW
engine speed control is in the high idle speed or
low idle speed position.

0000085A
(2) (3)
Figure 5-10

Check and Adjust Cooling Fan V-Belt


(1)
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
V-Belt on page 5-22.
(4)
Check and Adjust the Governor Lever and
Engine Speed Control
0000069A
(This does not apply to the following
electronically controlled engines: 4TNV84T- Figure 5-11
Z, 4TNV98-E, Z, and 4TNV98T-Z.) 2. If the governor lever does not make contact with
The governor lever and engine speed control the high idle or low idle speed limit screw, adjust
(throttle lever, pedal, etc.) of the machine are the throttle cable.
connected together by a throttle cable or rod. If the 3. In some engine speed control applications,
cable becomes stretched, or the connections loosen the throttle cable lock nut
loosen, the governor lever may not respond to (Figure 5-11, (4)) and adjust the cable so the
change of engine speed control position. This may governor lever makes proper contact with the
make operation of the machine unsafe. Check the high / low idle speed limit screw.
cable periodically and adjust if necessary.
NEVER force the throttle cable or pedal to move. CAUTION
This may deform the governor lever or stretch the NEVER attempt to adjust the low or high
cable and cause irregular operation of the engine idle speed limit screw. This may impair
speed control. 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.
0000017en

5-30 TNV DI Service Manual


Periodic Maintenance Procedures PERIODIC MAINTENANCE
Clean Air Cleaner Element 3. Blow air (Figure 5-12, (3)) through the element
Note that a typical air cleaner is shown in from the inside out using 42 - 71 psi
Figure 5-12 and Figure 5-13 for illustrative (0.29 - 0.49 MPa; 3.0 - 5.0 kgf/cm2)
purposes only. compressed air to remove the particulates. Use
the lowest possible air pressure to remove the
The engine performance is adversely affected dust without damaging the element.
when the air cleaner element is clogged with dust. 4. If the air cleaner is equipped with a double
Be sure to clean the air filter element periodically. element, only remove and replace the inner
1. Unlatch and remove the air cleaner cover element (Figure 5-13, (1)) if the engine lacks
(Figure 5-12, (1)). power or the dust indicator actuates (if
equipped).
(6) (4)
(2)
(5)
(3)

(1)

(1)

0000070A

Figure 5-12 0000071A

2. Remove the element (Figure 5-12, (2)) (outer Figure 5-13


element if equipped with two elements). 5. The inner element should not be removed when
cleaning or replacing the outer element. The
A CAUTION inner element is used to prevent dust from
entering the engine while servicing the outer
element.

FLYING OBJECT HAZARD!


• ALWAYS wear eye protection when
servicing the engine and when using
compressed air or high-pressure
water. Dust, flying debris, compressed
air, pressurized water or steam may
injure your eyes.
• Failure to comply may result in minor
or moderate injury.
0000003en

TNV DI Service Manual 5-31


PERIODIC MAINTENANCE Periodic Maintenance Procedures

6. Replace the element with a new one if the


element is damaged, excessively dirty or oily. Every 500 Hours of Operation
7. Clean inside of the air cleaner cover.
Perform the following maintenance every 500 hours
8. Install the element into the air cleaner case of operation.
(Figure 5-12, (4)).
9. Reinstall the air cleaner cover making sure you • Replace Air Cleaner Element
match the arrow (Figure 5-12, (5)) on the cover • Replace Fuel Filter
with the arrow on the case (Figure 5-12, (6)). • Clean Fuel Filter / Water Separator
10. Latch the air cleaner cover to the case.
Replace Air Cleaner Element
CAUTION
• When the engine is operated in dusty
CAUTION
conditions, clean the air cleaner The maximum air intake restriction, in
element more frequently. terms of differential pressure
measurement, must not exceed 0.90 psi
• NEVER operate the engine with the air
(6.23 kPa; 635 mmAq). Clean or replace
cleaner element(s) removed. This may
the air cleaner element if the air intake
allow foreign material to enter the
restriction exceeds the above
engine and damage it.
mentioned value.
0000026en
0000046en

Replace the air cleaner element (Figure 5-12, (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 5-12, (4)).
If the air cleaner is equipped with a double element,
only remove and replace the inner element
(Figure 5-13, (1)) if the engine lacks power or the
dust indicator actuates (if equipped). This is in
addition to replacing the outer element.

5-32 TNV DI Service Manual


Periodic Maintenance Procedures PERIODIC MAINTENANCE
Replace Fuel Filter
CAUTION
A DANGER

FIRE AND EXPLOSION HAZARD! • ALWAYS be environmentally


responsible.
• Diesel fuel is flammable and explosive
under certain conditions. • Follow the guidelines of the EPA or
other governmental agencies for the
• When you remove any fuel system proper disposal of hazardous
component to perform maintenance materials such as engine oil, diesel
(such as changing the fuel filter) place fuel and engine coolant. Consult the
an approved container under the local authorities or reclamation facility.
opening to catch the fuel.
• NEVER dispose of hazardous
• NEVER use a shop rag to catch the materials irresponsibly by dumping
fuel. Vapors from the rag are them into a sewer, on the ground, or
flammable and explosive. into ground water or waterways.
• Wipe up any spills immediately. • Failure to follow these procedures may
• Wear eye protection. The fuel system seriously harm the environment.
is under pressure and fuel could spray 0000013en

out when you remove any fuel system


component. Replace the fuel filter at specified intervals to
prevent contaminants from adversely affecting the
• Failure to comply will result in death or diesel fuel flow.
serious injury.
0000009en
1. Stop the engine and allow it to cool.
2. Close the fuel cock of the fuel filter / water
CAUTION separator.
For maximum engine life, Yanmar 3. Remove the fuel filter with a filter wrench,
recommends that when shutting the turning it to the left (Figure 5-14, (1)). When
engine down, you allow the engine to removing the fuel filter, carefully hold it to
idle, without load, for five minutes. This prevent the fuel from spilling. Wipe up all spilled
will allow the engine components that fuel.
operate at high temperatures, such as
the turbocharger (if equipped) and
exhaust system, to cool slightly before
the engine itself is shut down.
0000008en

TNV DI Service Manual 5-33


PERIODIC MAINTENANCE Periodic Maintenance Procedures

Clean Fuel Filter / Water Separator

A DANGER

FIRE AND EXPLOSION HAZARD!


(1) (2) • Diesel fuel is flammable and explosive
under certain conditions.
• NEVER use diesel fuel as a cleaning
0000072A
agent.
Figure 5-14 • Failure to comply will result in death or
4. Clean the filter mounting surface and apply a serious injury.
small amount of diesel fuel to the gasket of the 0000012en

new fuel filter.


5. Install the new fuel filter. Turn to the right A DANGER
(Figure 5-14, (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.
FIRE AND EXPLOSION HAZARD!
Applicable Fuel Filter Part No. • Diesel fuel is flammable and explosive
Standard Dust proof * under certain conditions.
3TNV82A, • When you remove any fuel system
-4TNV98 component to perform maintenance
119802-55801 (such as changing the fuel filter) place
3TNV82A-B,
-4TNV98-B 129907-55801 an approved container under the
opening to catch the fuel.
4TNV98T,
4TNV98T-Z, 123907-55801 • NEVER use a shop rag to catch the
-4TNV106T fuel. Vapors from the rag are
flammable and explosive.
* Consult the operation manual for the driven • Wipe up any spills immediately.
machine for applicability of the dust proof
filter. • Wear eye protection. The fuel system
is under pressure and fuel could spray
6. Open the fuel cock of the fuel filter / water out when you remove any fuel system
separator. component.
7. Prime the fuel system. See Priming the Fuel • Failure to comply will result in death or
System on page 4-15. serious injury.
8. Check for leaks. 0000009en

5-34 TNV DI Service Manual


Periodic Maintenance Procedures PERIODIC MAINTENANCE
Periodically clean the fuel filter / water separator
CAUTION element and inside cup.
1. Position an approved container under the cup
(Figure 5-15, (1)) of the fuel filter / water
separator to collect the contaminants.

(5) (9)
• ALWAYS be environmentally
responsible.
(2)
• Follow the guidelines of the EPA or
other governmental agencies for the (10)
proper disposal of hazardous (6)
(3)
materials such as engine oil, diesel
fuel and engine coolant. Consult the
local authorities or reclamation facility.
(8)
• NEVER dispose of hazardous (1)
materials irresponsibly by dumping (4)
them into a sewer, on the ground, or
into ground water or waterways.
• Failure to follow these procedures may
seriously harm the environment.
0000013en

(7)
0000073A

Figure 5-15
2. Close (Figure 5-15, (2)) the fuel cock
(Figure 5-15, (3)).
3. Loosen the drain cock (Figure 5-15, (4)) and
drain the contaminants. See Drain Fuel
Filter / Water Separator on page 5-24.
4. Turn the retaining ring (Figure 5-15, (5)) to the
left (Figure 5-15, (10)) and remove the cup
(Figure 5-15, (6)). If equipped, disconnect the
sensor wire (Figure 5-15, (7)) 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.

TNV DI Service Manual 5-35


PERIODIC MAINTENANCE Periodic Maintenance Procedures

6. Remove the float ring (Figure 5-15, (8)) from


the cup. Pour the contaminants into the Every 1000 Hours of Operation
container and dispose of it properly.
7. Clean the element (Figure 5-15, (9)) and inside Perform the following maintenance every 1000
cup. Replace the element if it is damaged. hours of operation.
• Drain, Flush and Refill Cooling System With
Applicable Element Part No.
New Coolant
All Models 119802-55710
• Adjust Intake / Exhaust Valve Clearance
8. Install the element and O-ring in the bracket. Drain, Flush and Refill Cooling System With
9. Position the float ring in the cup. New Coolant
10. Check the condition of the cup O-ring. Replace
if necessary. A DANGER
11. Install the cup to the bracket by tightening the
retaining ring to the right (Figure 5-15, (6)) to a
torque of 11 - 15 ft·lb (15 - 20 N·m;
1.5 - 2.0 kgf·m).
12. Close the drain cock. Reconnect the sensor
wire if equipped. SCALD HAZARD!
13. Open the fuel cock (Figure 5-15, (3)). • NEVER remove the radiator cap if the
14. Prime the fuel system. See Priming the Fuel engine is hot. Steam and hot engine
System on page 4-15. coolant will spurt out and seriously
15. Check for leaks. 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.
0000002en

5-36 TNV DI Service Manual


Periodic Maintenance Procedures PERIODIC MAINTENANCE

A WARNING CAUTION

BURN HAZARD! • ALWAYS be environmentally


• Wait until the engine cools before you responsible.
drain the engine coolant. Hot engine • Follow the guidelines of the EPA or
coolant may splash and burn you. other governmental agencies for the
• Failure to comply could result in death proper disposal of hazardous
or serious injury. materials such as engine oil, diesel
0000016en fuel and engine coolant. Consult the
local authorities or reclamation facility.
A CAUTION • 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.
0000013en
COOLANT HAZARD!
• Wear eye protection and rubber gloves Engine coolant contaminated with rust or scale
when you handle long life or extended reduces the cooling effect. Even when extended life
life engine coolant. If contact with the engine coolant is properly mixed, the engine
eyes or skin should occur, flush eyes coolant gets contaminated as its ingredients
and wash immediately with clean deteriorate. Drain, flush and refill the cooling
water. system with new coolant every 1000 hours or once
a year, whichever comes first.
• Failure to comply may result in minor
or moderate injury. 1. Allow engine and coolant to cool.
0000005en
2. Remove the radiator cap (Figure 5-16, (1)).
3. Remove the drain plug or open the drain cock
(Figure 5-16, (2)) at the lower portion of the
radiator and drain the engine coolant.

TNV DI Service Manual 5-37


PERIODIC MAINTENANCE Periodic Maintenance Procedures

(1)

FULL

LOW

(2) 0000074A

Figure 5-16
4. Drain the coolant from the engine block.
• On models not equipped with an oil cooler,
remove the coolant drain plug
(Figure 5-17, (1)) from the engine block.

(1)

0000027B

Figure 5-17

5-38 TNV DI Service Manual


Periodic Maintenance Procedures PERIODIC MAINTENANCE
• On models equipped with an oil cooler, remove
the coolant hose (Figure 5-18, (1)) at the oil Every 1500 Hours of Operation
cooler.
Perform the following maintenance every 1500
hours of operation.
• Inspect, Clean and Test Fuel Injectors
• Inspect Turbocharger (Blower Wash as
Necessary) - 3TNV84T, 4TNV84T, 4TNV98T
and 4TNV106T, 3TNV84T-B, 4TNV84T-Z,
4TNV98T-Z
• Inspect, Clean and Test EGR Valve
4TNV84T-Z, 4TNV98T-E, 4TNV98-Z,
4TNV98T-Z
• Inspect and Clean EGR Lead Valve
4TNV84T-Z, 4TNV98T-Z
(1) 0001579B
• Clean EGR Cooler
Figure 5-18 4TNV84T-Z, 4TNV98T-Z
5. After draining the engine coolant, flush the • Inspect Crankcase Breather System
radiator and engine block to remove any rust,
Inspect, Clean and Test Fuel Injectors
scale and contaminants. Then reinstall and
tighten the drain plug or close the drain cock in
the radiator. Reinstall and tighten the cylinder A WARNING
block drain plug or reconnect the coolant hose
at the oil cooler.
6. Fill radiator and engine with engine coolant.
See Filling Radiator with Engine Coolant on
page 4-19. HIGH-PRESSURE HAZARD!
• Avoid skin contact with the
Adjust Intake / Exhaust Valve Clearance high-pressure diesel fuel spray caused
Proper adjustment is necessary to maintain the by a fuel system leak such as a broken
correct timing for opening and closing the valves. fuel injection line. High-pressure fuel
Improper adjustment will cause the engine to run can penetrate your skin and result in
noisily, resulting in poor engine performance and serious injury. If you are exposed to
engine damage. See Intake / Exhaust Valve and high-pressure fuel spray, obtain
Guide on page 6-7. 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.
0000008en

TNV DI Service Manual 5-39


PERIODIC MAINTENANCE Periodic Maintenance Procedures

Proper operation of the fuel injectors is required to Clean EGR Cooler


obtain the optimum injection pattern for full engine 4TNV84T-Z, 4TNV98T-Z
performance. The EPA / ARB requires that the fuel
injectors are inspected, cleaned and tested every The EGR cooler is apt to be contaminated with rust
1500 hours. See Testing of Fuel Injectors on and scale that deteriorate the cooling performance.
page 7-38. Carbon accumulation in the exhaust gas passage
of the cooler hinders circulation of exhaust gas,
This procedure is considered normal maintenance resulting in deterioration in exhaust gas cleanup
and is performed at the owner’s expense. This performance.
procedure is not covered by the Yanmar Limited
Warranty. To prevent such a problem, clean the cooler at least
every 1500 hours.
Inspect Turbocharger (Blower Wash as
Necessary) - 3TNV84T, 4TNV98T, 4TNV84T, Consult your local Yanmar dealer for this service.
and 4TNV106T, 3TNV84T-Z, 4TNV84T-Z,
EGR cooler
4TNV98T-Z
Turbocharger service is required by the EPA / ARB
every 1500 hours. Inspect, clean and blower wash
the unit if necessary (see Periodic Inspection on
page 10-13). If you notice that the engine seems
sluggish or the exhaust color is abnormal NEVER
wait until the next service interval.

Inspect, Clean and Test EGR Valve


4TNV84T-Z, 4TNV98T-E, 4TNV98-Z, 4TNV98T-Z
The EGR valve is a key component for cleaning
exhaust gas.
EGR valve
To prevent the valve from deteriorating in exhaust EGR lead valve
gas recirculation performance due to carbon
accumulation, inspect, clean and test the valve at
least every 1500 hours.
Figure 5-19
Consult your local Yanmar dealer for this service.
Inspect Crankcase Breather System
Inspect and Clean EGR Lead Valve
Proper operation of the crankcase breather system
4TNV84T-Z, 4TNV98T-Z is required to maintain the emission requirements
The EGR lead valve is located in the passage of of the engine. The EPA / ARB requires that the
recirculated gas. crankcase breather system is inspected every 1500
hours.
To prevent carbon accumulation in or clogging of
the lead valve, inspect and clean the lead valve at There are three different crankcase breather
regular intervals. systems used on the TNV engines. Only the non-
turbo TNV engines crankcase breather system
Consult your local Yanmar dealer for this service. requires periodic maintenance.

5-40 TNV DI Service Manual


Periodic Maintenance Procedures PERIODIC MAINTENANCE
The non-turbo TNV engines use a crankcase Failure of the diaphragm and / or spring will cause
breather system that has a spring-backed the loss of pressure control and allow an excessive
diaphragm (Figure 5-20, (1)) in the valve cover amount of crankcase fumes to be routed to the
(Figure 5-20, (2)). When the crankcase pressure intake manifold. This could result in excessive
reaches a predetermined value, the diaphragm deposits in the intake system, high engine exhaust
opens a passage that allows crankcase fumes to smoke levels, excessive engine oil consumption,
be routed to the intake manifold. and / or engine run-on due to the burning of the
engine oil.
To inspect the diaphragm and spring
(Figure 5-20, (3)):
1. Remove the bolts retaining the diaphragm cover
(Figure 5-20, (4)).

(4)
(3)

(5)

(1)
(2)

0002135

Figure 5-20
2. Remove the diaphragm cover, spring,
diaphragm plate (Figure 5-20, (5)) and
diaphragm.
3. Inspect the diaphragm for tears. Inspect the
spring for distortion. Replace components if
necessary.
4. Reinstall the diaphragm, diaphragm plate,
spring and diaphragm cover. Tighten the
diaphragm bolts to specified torque.

TNV DI Service Manual 5-41


PERIODIC MAINTENANCE Periodic Maintenance Procedures

Lap the Intake and Exhaust Valves


Every 2000 Hours of Operation
Adjustment is necessary to maintain proper contact
of the valves and seats. See Inspection of Intake
Perform the following maintenance every 2000 and Exhaust Valves on page 6-42.
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

CAUTION

• 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.
0000013en

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.

5-42 TNV DI Service Manual


TNV DI Service Manual
Section 6

ENGINE
Page
Before You Begin Servicing ............................................................ 6-3
Introduction...................................................................................... 6-6
Cylinder Head Specifications .......................................................... 6-6
Adjustment Specifications ......................................................... 6-6
Cylinder Head............................................................................ 6-6
Intake / Exhaust Valve and Guide ............................................. 6-7
Push Rod................................................................................... 6-9
Rocker Arm and Shaft ............................................................... 6-9
Valve Spring ............................................................................ 6-10
Camshaft and Timing Gear Train Specifications........................... 6-11
Camshaft ................................................................................. 6-11
Idler Gear Shaft and Bushing .................................................. 6-13
Timing Gear Backlash ............................................................. 6-13
Crankshaft and Piston Specifications............................................ 6-14
Crankshaft ............................................................................... 6-14
Thrust Bearing ......................................................................... 6-15
Piston....................................................................................... 6-16
Piston Ring .............................................................................. 6-18
Connecting Rod....................................................................... 6-22
Tappet ..................................................................................... 6-23
Cylinder Block Specifications ........................................................ 6-24
Cylinder Block.......................................................................... 6-24
Special Torque Chart .................................................................... 6-25
Torque for Bolts and Nuts........................................................ 6-25
Special Service Tools.................................................................... 6-28
Measuring Instruments.................................................................. 6-32
2-Valve Cylinder Head .................................................................. 6-34
2-Valve Cylinder Head Components ....................................... 6-34

TNV DI Service Manual 6-1


ENGINE
Components of a two-valve cylinder head ............................... 6-35
Disassembly of 2-Valve Cylinder Head .................................... 6-36
Cleaning of Cylinder Head Components .................................. 6-40
Inspection of Cylinder Head Components................................ 6-40
Reassembly of Cylinder Head.................................................. 6-44
4-Valve Cylinder Head ................................................................... 6-49
4-Valve Cylinder Head Components ........................................ 6-49
Disassembly of 4-Valve Cylinder Head .................................... 6-50
Cleaning of Cylinder Head Components .................................. 6-55
Inspection of Cylinder Head Components................................ 6-56
Reassembly of Cylinder Head.................................................. 6-61
Measuring and Adjusting Valve Clearance .................................... 6-66
2-Valve Cylinder Heads............................................................ 6-67
4-Valve Cylinder Heads............................................................ 6-68
Crankshaft and Camshaft Components ......................................... 6-71
Disassembly of Engine............................................................. 6-72
Disassembly of Camshaft and Timing Components ................ 6-73
Disassembly of Crankshaft and Piston Components ............... 6-78
Inspection of Crankshaft and Camshaft Components.............. 6-82
Honing and Boring.................................................................... 6-88
Reassembly of Crankshaft and Piston Components................ 6-89
Reassembly of Camshaft and Timing Components ................. 6-95
Final Reassembly of Engine..................................................... 6-99
EGR system ................................................................................. 6-100
EGR system ........................................................................... 6-100
EGR system ........................................................................... 6-102
Inspecting/cleaning EGR related components ....................... 6-105

6-2 TNV DI Service Manual


Before You Begin Servicing ENGINE

BEFORE YOU BEGIN


A WARNING
SERVICING
A WARNING

FUME / BURN HAZARD!


• Always read and follow safety related
precautions found on containers of
hazardous substances like parts
To prevent possible eye injury, always cleaners, primers, sealants and
wear SAFETY GLASSES while servicing sealant removers.
the engine.
0000013en
• Failure to comply could result in death
or serious injury.

A WARNING
0000014en

A CAUTION

ENTANGLEMENT HAZARD!
• Stop the engine before you begin to
service it.
• NEVER leave the key in the key switch FLYING OBJECT HAZARD!
when you are servicing the engine. • ALWAYS wear eye protection when
Someone may accidentally start the servicing the engine and when using
engine and not realize you are compressed air or high-pressure
servicing it. This could result in a water. Dust, flying debris, compressed
serious injury. air, pressurized water or steam may
• If you must service the engine while it injure your eyes.
is operating, remove all jewelry, tie • Failure to comply may result in minor
back long hair, and keep your hands, or moderate injury.
other body parts and clothing away 0000003en
from moving / rotating parts.
• Failure to comply could result in death A CAUTION
or serious injury.
Be sure to secure the engine solidly to
0000010en
prevent injury or damage to parts due to
the engine falling during work on the
engine.
0000009en

TNV DI Service Manual 6-3


ENGINE Before You Begin Servicing

CAUTION CAUTION
• Only use the engine oil specified. Any part which is found defective as a
Other engine oils may affect warranty result of inspection or any part whose
coverage, cause internal engine measured value does not satisfy the
components to seize and / or shorten standard or limit must be replaced.
engine life. 0000119en

• Prevent dirt and debris from


contaminating the engine oil. Carefully CAUTION
clean the oil cap / dipstick and the
Any part determined to not meet the
surrounding area before you remove
service standard or limit before the next
the cap.
service, as determined from the state of
• NEVER mix different types of engine current rate of wear, should be replaced
oil. This may adversely affect the even though the part currently meets the
lubricating properties of the engine oil. service standard limit.
• NEVER overfill. Overfilling may result 0000120en

in white exhaust smoke, engine


overspeed or internal damage. CAUTION
0000005en
Remove or install the high-pressure fuel
injection lines as an assembly whenever
CAUTION possible. Disassembling the
• Only use the engine coolant specified. high-pressure fuel injection lines from
Other engine coolants may affect the retainers or bending any of the fuel
warranty coverage, cause an internal lines will make it difficult to reinstall the
buildup of rust and scale and / or fuel lines.
shorten engine life. 0000047en

• Prevent dirt and debris from


contaminating the engine coolant. CAUTION
Carefully clean the radiator cap and Do not loosen or remove the four bolts
the surrounding area before you retaining the fuel injection pump drive
remove the cap. gear to the fuel injection pump hub. Do
• NEVER mix different types of engine not disassemble the fuel injection pump
coolants. This may adversely affect the drive gear from the hub. Correct fuel
properties of the engine coolant. injection timing will be very difficult or
0000006en
impossible to achieve.
0000031en

CAUTION
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.
0000080en

6-4 TNV DI Service Manual


Before You Begin Servicing ENGINE

CAUTION
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.
0000088en

CAUTION
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.
0000090en

TNV DI Service Manual 6-5


ENGINE Introduction

INTRODUCTION
This section of the Service Manual describes servicing of the engine.

CYLINDER HEAD SPECIFICATIONS


Adjustment Specifications
Valve Bridge Clearance
Model Valve Clearance
(4-Valve Head Only)
0.006 - 0.010 in.
All except 4TNV106, 4TNV106T 0
(0.15 - 0.25 mm)
0.010 - 0.014 in.
4TNV106, 4TNV106T 0
(0.25 - 0.35 mm)

Cylinder Head
Reference
Inspection Item Standard Limit
Page
0.0020 in. 0.0059 in.
Combustion Surface Distortion (Flatness)
(0.05 mm) or less (0.15 mm)
0.0138 - 0.0217 in.
Intake 0.0315 in. (0.8 mm)
3TNV82A (0.35 - 0.55 mm)
(2-Valve Head) 0.0118 - 0.0197 in.
Exhaust 0.0315 in. (0.8 mm)
(0.30 - 0.50 mm)
3TNV84, 3TNV84T, 0.0118 - 0.0197 in.
Intake 0.0315 in. (0.8 mm)
3TNV88, 4TNV84, (0.30 - 0.50 mm)
4TNV84T, 4TNV88 See Valve
(2-Valve Head) 0.0118 - 0.0197 in. Recession on
4TNV84T (4-Valve Exhaust 0.0315 in. (0.8 mm)
(0.30 - 0.50 mm) page 6-42
Valve Recession Head) and 6-58.
0.0142 - 0.0220 in.
4TNV94L, 4TNV98, Intake 0.0315 in. (0.8 mm)
(0.36 - 0.56 mm)
4TNV98T
(4-Valve Head) 0.0138 - 0.0217 in.
Exhaust 0.0315 in. (0.8 mm)
(0.35 - 0.55 mm)
0.0197 - 0.0276 in.
Intake 0.0394 in. (1.0 mm)
4TNV106, 4TNV106T (0.50 - 0.70 mm)
(4-Valve Head) 0.0276 - 0.0354 in.
Exhaust 0.0472 in. (1.2 mm)
(0.70 - 0.90 mm)
Intake 120° - See Valve
Seat Angle Face and
Valve Seat Exhaust 90° -
Valve Seat
(2-Valve, 4-Valve)
Seat Correction Angle 40°, 150° - on page 6-43
and 6-59.

6-6 TNV DI Service Manual


Cylinder Head Specifications ENGINE
Intake / Exhaust Valve and Guide
Reference
Inspection Item Standard Limit
Page
0.2756 - 0.2762 in. 0.2787 in.
Guide Inside Diameter
(7.000 - 7.015 mm) (7.08 mm)
Valve Stem Outside 0.2734 - 0.2740 in. 0.2717 in.
Intake
Diameter (6.945 - 9.960 mm) (6.90 mm)
0.0016 - 0.0028 in. 0.0071 in. See
Valve Stem Bend Inspection of
3TNV82A (0.040 - 0.070 mm) (0.18 mm)
Valve Guides
(2-Valve Head) 0.2756 - 0.2762 in. 0.2787 in.
Guide Inside Diameter on
(7.000 - 7.015 mm) (7.08 mm) page 6-41.
Valve Stem Outside 0.2732 - 0.2754 in. 0.2717 in.
Exhaust
Diameter (6.940 - 6.955 mm) (6.90 mm)
0.0018 - 0.0030 in. 0.0071 in.
Valve Stem Bend
(0.045 - 0.075 mm) (0.18 mm)
0.3154 - 0.3159 in. 0.3189 in.
Guide Inside Diameter
(8.010 - 8.025 mm) (8.10 mm)
Valve Stem Outside 0.3132 - 0.3140 in. 0.3110 in.
Intake
Diameter (7.955 - 7.975 mm) (7.90 mm)
0.0014 - 0.0028 in. 0.0071 in. See
4TNV84, Valve Stem Bend
(0.035 - 0.070 mm) (0.18 mm) Inspection of
3TNV84, 3TNV84T,
Valve Guides
4TNV88, 4TNV88 0.3156 - 0.3161 in. 0.3189 in.
Guide Inside Diameter on
(2-Valve Head) (8.015 - 8.030 mm) (8.10 mm) page 6-41.
Valve Stem Outside 0.3132 -.3134 in. 0.3110 in.
Exhaust
Diameter (7.955 - 7.960 mm) (7.90 mm)
0.0018 - 0.0030 in. 0.0071 in.
Valve Stem Bend
(0.045 - 0.075 mm) (0.18 mm)
0.2362 - 0.2368 in. 0.2394 in.
Guide Inside Diameter
(6.000 - 6.015 mm) (6.08 mm)
Valve Stem Outside 0.2346 - 0.2352 in. 0.2323 in.
Intake
Diameter (5.960 - 5.975 mm) (5.90 mm)
0.0010 - 0.0022 in. 0.0059 in. See
Valve Stem Bend Inspection of
4TNV84T (0.025 - 0.055 mm) (0.15 mm)
Valve Guides
(4-Valve Head) 0.2362 - 0.2368 in. 0.2394 in.
Guide Inside Diameter on
(6.000 - 6.015 mm) (6.08 mm) page 6-41.
Valve Stem Outside 0.2341 - 0.2346 in. 0.2323 in.
Exhaust
Diameter (5.945 - 5.960 mm) (5.90 mm)
0.0016 - 0.0028 in. 0.0067 in.
Valve Stem Bend
(0.040 - 0.070 mm) (0.17 mm)

TNV DI Service Manual 6-7


ENGINE Cylinder Head Specifications

(Intake / Exhaust Valve and Guide Cont.)

Reference
Inspection Item Standard Limit
Page
0.2756 - 0.2762 in. 0.2787 in.
Guide Inside Diameter
(7.000 - 7.015 mm) (7.08 mm)
Valve Stem Outside 0.2734 - 0.2740 in. 0.2717 in.
Intake
Diameter (6.945 - 6.960 mm) (6.90 mm)
0.0016 - 0.0028 in. 0.0067 in. See
4TNV94L Oil Clearance Inspection of
(0.040 - 0.070 mm) (0.17 mm)
4TNV98, 4TNV98T Valve Guides
(4-Valve Head) 0.2756 - 0.2762 in. 0.2787 in. on
Guide Inside Diameter
(7.000 - 7.015 mm) (7.08 mm) page 6-41.
Valve Stem Outside 0.2732 - 0.2738 in. 0.2717 in.
Exhaust
Diameter (6.940 - 6.955 mm) (6.90 mm)
0.0018 - 0.0030 in. 0.0067 in.
Valve Stem Bend
(0.045 - 0.075 mm) (0.17 mm)
0.2759 - 0.2764 in. 0.2787 in.
Guide Inside Diameter
(7.008 - 7.020 mm) (7.08 mm)
Valve Stem Outside 0.2734 - 0.2740 in. 0.2724 in.
Intake
Diameter (6.945 - 6.960 mm) (6.92 mm)
0.0019 - 0.0030 in. 0.0063 in. See
Valve Stem Bend Inspection of
4TNV106T (0.048 - 0.075 mm) (0.16 mm)
Valve Guides
(4-Valve Head) 0.2759 - 0.2764 in. 0.2787 in.
Guide Inside Diameter on
(7.008 - 7.020 mm) (7.08 mm) page 6-41.
Valve Stem Outside 0.2740 - 0.2746 in. 0.2717 in.
Exhaust
Diameter (6.960 - 6.975 mm) (6.90 mm)
0.0013 - 0.0024 in. 0.0071 in.
Valve Stem Bend
(0.033 - 0.060 mm) (0.18 mm)
0.4606 - 0.4724 in.
3TNV82A -
(11.70 - 12.00 mm)
3TNV84, 3TNV84T, 0.5791 -0.5905 in.
-
4TNV84, 4TNV88 (14.71 - 15.00 mm) See
Valve Guide Projection From 0.3228 - 0.3346 in. Reassembly
4TNV84T - of Valve
Cylinder Head (8.20 - 8.50 mm)
Guides on
4TNV94L, 4TNV98, 0.3819 - 0.3937 in. page 6-44
-
4TNV98T (9.70 - 10.00 mm) and 6-61.
0.5276 - 0.5354 in.
4TNV106, 4TNV106T -
(13.40 - 13.60 mm)
Valve Guide Installation Method Cold-fitted -

6-8 TNV DI Service Manual


Cylinder Head Specifications ENGINE
Reference
Inspection Item Standard Limit
Page
Valve Stem Seal Projection From Cylinder Head
0.618 - 0.629 in.
3TNV82A -
(15.7 - 16.0 mm)
2 Valves 4TNV84 -
0.736 - 0.748 in. See
3TNV84 (T) - Reassembly
(18.7 - 19.0 mm)
4TNV88 - of Intake and
0.389 - 0.401 in. Exhaust
4TNV84T - Valves on
(9.9 - 10.2 mm)
page 6-45.
4TNV94L 0.460 - 0.472 in. -
4 Valves
4TNV98 (T) (11.7 - 12.0 mm) -
0.606 - 0.614 in.
4TNV106 (T) -
(15.4 - 15.6 mm)

Push Rod
Reference
Inspection Item Standard Limit
Page
See Push
Less than 0.0012 in. Rod Bend on
Push Rod Bend - All Models
0.0012 in. (0.03 mm) (0.03 mm) page 6-41
and 6-56.

Rocker Arm and Shaft


Reference
Model Inspection Item Standard Limit
Page
0.6299 - 0.6307 in. 0.6327 in.
Arm Shaft Hole Diameter
3TNV82A, 3TNV84, (16.000 - 16.020 mm) (16.07 mm)
3TNV84T, 3TNV88, 0.6286 - 0.6293 in. 0.6276 in.
Shaft Outside Diameter
4TNV84, 4TNV84T, (15.966 - 15.984 mm) (15.94 mm)
See
4TNV88 0.0006 - 0.0021 in. 0.0051 in.
Oil Clearance Inspection of
(0.016 - 0.054 mm) (0.13 mm) Rocker Arm
0.7283 - 0.7291 in. 0.7311 in. Assembly on
Arm Shaft Hole Diameter page 6-41
(18.500 - 18.520 mm) (18.57 mm)
4TNV94L, 4TNV98, and 6-56.
0.7272 - 0.7280 in. 0.7260 in.
4TNV98T, 4TNV106, Shaft Outside Diameter
(18.470 - 18.490 mm) (18.44 mm)
4TNV106T
0.0004 - 0.0020 in. 0.0051 in.
Oil Clearance
(0.010 - 0.050 mm) (0.13 mm)

TNV DI Service Manual 6-9


ENGINE Cylinder Head Specifications

Valve Spring
Reference
Inspection Item Model Standard Limit
Page
1.7480 in. 1.7283 in.
3TNV82A (2-Valve Head)
(44.4 mm) (43.9 mm)
4TNV84, 3TNV84, 3TNV84T, 4TNV88 1.6535 in. 1.6339 in.
(2-Valve Head) (42.0 mm) (41.5 mm)
1.4724 in. 1.4528 in.
Free Length 4TNV84T (4-Valve Head)
(37.4 mm) (36.9 mm)
4TNV94L, 4TNV98, 4TNV98T (4-Valve 1.5630 in. 1.5433 in.
Head) (39.7 mm) (39.2 mm)
See
1.9921 in. 1.9724 in. Inspection of
4TNV106, 4TNV106T (4-Valve Head)
(50.6 mm) (50.1 mm) Valve
0.0551 in. Springs on
3TNV82A (2-Valve Head) - page 6-44
(1.4 mm)
and 6-60.
4TNV84, 3TNV84, 3TNV84T, 0.0551 in.
-
4TNV88 (2-Valve Head) (1.4 mm)
0.0551 in.
Squareness 4TNV84T (4-Valve Head) -
(1.3 mm)
4TNV94L, 4TNV98, 4TNV98T (4-Valve 0.0551 in.
-
Head) (1.4 mm)
0.0551 in.
4TNV106, 4TNV106T (4-Valve Head) -
(1.5 mm)

6-10 TNV DI Service Manual


Camshaft and Timing Gear Train Specifications ENGINE

CAMSHAFT AND TIMING GEAR TRAIN SPECIFICATIONS


Camshaft
Reference
Inspection Item Standard Limit
Page
See Removal
0.0020 - 0.0079 in. 0.0118 in. of Camshaft
End Play
(0.05 - 0.20 mm) (0.030 mm) on
page 6-76.
0 - 0.0008 in. 0.0020 in.
Bend (1/2 the dial gauge reading)
(0 - 0.02 mm) (0.05 mm)
3TNV82A, 3TNV84,
1.5197 - 1.5276 in. 1.5098 in. See
3TNV84T, 3TNV88, 4TNV84,
(38.600 - 38.800 mm) (38.350 mm) Inspection of
4TNV84T, 4TNV88
Camshaft on
Cam Lobe Height 4TNV94L, 4TNV98, 1.7087 - 1.7165 in. 1.6988 in. page 6-87.
4TNV98T (43.400 - 43.600 mm) (43.150 mm)
2.0039 - 2.0118 in. 1.9941 in.
4TNV106, 4TNV106T
(50.900 - 51.100 mm) (50.650 mm)
Shaft Outside Diameter / Bearing Inside Diameter
1.7713 - 1.7738 in. 1.7768 in.
Bushing Inside Diameter
(44.990 - 45.055 mm) (45.130 mm)
1.7687 - 1.7697 in. 1.7673 in.
Gear End Camshaft Outside Diameter
(44.925 - 44.950 mm) (44.890 mm)
0.0016 - 0.0051 in. 0.0094 in.
Oil Clearance
(0.040 - 0.130 mm) (0.240 mm)
3TNV82A, 1.7716 - 1.7726 in. 1.7756 in.
3TNV84, Bore Inside Diameter
(45.000 - 45.025 mm) (45.100 mm) See
3TNV84T,
1.7681 - 1.7691 in. 1.7667 in. Inspection of
3TNV88, Intermediate Camshaft Outside Diameter
(44.910 - 44.935 mm) (44.875 mm) Camshaft on
4TNV84,
0.0026 - 0.0045 in. 0.0089 in. page 6-87.
4TNV84T, Oil Clearance
4TNV88 (0.065 - 0.115 mm) (0.225 mm)
1.7716 - 1.7726 in. 1.7756 in.
Bore Inside Diameter
(45.000 - 45.025 mm) (45.100 mm)
1.7687 - 1.7697 in. 1.7673 in.
Flywheel End Camshaft Outside Diameter
(44.925 - 44.950 mm) (44.890 mm)
0.0020 - 0.0039 in. 0.0083 in.
Oil Clearance
(0.050 - 0.100 mm) (0.210 mm)

TNV DI Service Manual 6-11


ENGINE Camshaft and Timing Gear Train Specifications

(Camshaft Cont.)
Reference
Inspection Item Standard Limit
Page
1.9681 - 1.9707 in. 1.9736 in.
Bushing Inside Diameter
(49.990 - 50.055 mm) (50.130 mm)
1.9655 - 1.9665 in. 1.7673 in.
Gear End Camshaft Outside Diameter
(49.925 - 49.950 mm) (49.890 mm)
0.0016 - 0.0051 in. 0.0094 in.
Oil Clearance
(0.040 - 0.130 mm) (0.240 mm)
1.9685 - 1.9695 in. 1.9724 in.
Bushing Inside Diameter
(50.000 - 50.025 mm) (50.100 mm)
4TNV94L,
1.9650 - 1.9659 in. 1.9636 in.
4TNV98, Intermediate Camshaft Outside Diameter
(49.910 - 49.935 mm) (49.875 mm)
4TNV98T
0.0026 - 0.0045 in. 0.0089 in;
Oil Clearance
(0.065 - 0.115 mm) (0.225 mm)
1.9685 - 1.9695 in. 1.9724 in.
Bushing Inside Diameter
(50.000 - 50.025 mm) (50.100 mm)
1.9655 - 1.9665 in. 1.7673 in.
Flywheel End Camshaft Outside Diameter
(49.925 - 49.950 mm) (49.890 mm)
0.0020 - 0.0039 in. 0.0083 in. See
Oil Clearance
(0.050 - 0.100 mm) (0.210 mm) Inspection of
2.2827 - 2.2854 in. 2.2876 in. Camshaft on
Bushing Inside Diameter page 6-87.
(57.980 - 58.050 mm) (58.105 mm)
2.2799 - 2.2811 in. 2.2785 in.
Gear End Camshaft Outside Diameter
(57.910 - 57.940 mm) (57.875 mm)
0.0016 - 0.0055 in. 0.0098 in.
Oil Clearance
(0.040 - 0.140 mm) (0.250 mm)
2.2835 - 2.2846 in. 2.2876 in.
Bushing Inside Diameter
(58.000 - 58.030 mm) (58.105 mm)
4TNV106, 2.2793 - 2.2805 in. 2.2779 in.
Intermediate Camshaft Outside Diameter
4TNV106T (57.895 - 57.925 mm) (57.860 mm)
0.0030 - 0.0053 in. 0.0096 in.
Oil Clearance
(0.075 - 0.135 mm) (0.245 mm)
2.2835 - 2.2846 in. 2.2876 in.
Bushing Inside Diameter
(58.000 - 58.030 mm) (58.105 mm)
2.2799 - 2.2811 in. 2.2785 in.
Flywheel End Camshaft Outside Diameter
(57.910 - 57.940 mm) (57.875 mm)
0.0020 - 0.0047 in. 0.0091 in.
Oil Clearance
(0.050 - 0.120 mm) (0.230 mm)

6-12 TNV DI Service Manual


Camshaft and Timing Gear Train Specifications ENGINE
Idler Gear Shaft and Bushing
Reference
Inspection Item Standard Limit
Page
1.8091 - 1.8100 in. 1.8071 in.
Shaft Outside Diameter See
(45.950 - 45.975 mm) (45.900 mm)
Inspection of
1.8110 - 4.8120 in. 1.8140 in.
Bushing Inside Diameter Idler Gear
(46.000 - 46.025 mm) (46.075 mm)
and Shaft on
0.0010 - 0.0030 in. 0.0069 in. page 6-87.
Oil Clearance
(0.025 - 0.075 mm) (0.175 mm)

Timing Gear Backlash


Reference
Model Inspection Item Standard Limit
Page
3TNV82A
3TNV84, 3TNV84T, Crank Gear, Cam Gear, Idler Gear,
0.0028 - 0.0059 in. 0.0067 in.
3TNV88, 4TNV84, Fuel Injection Pump Gear and PTO
(0.07 - 0.15 mm) (0.17 mm)
4TNV84T, Gear
4TNV88 See
Crank Gear, Cam Gear, Idler Gear, Checking
0.0031 - 0.0055 in. 0.0063 in. Timing Gear
Fuel Injection Pump Gear and PTO
4TNV94L (0.08 - 0.14 mm) (0.16 mm) Backlash on
Gear
4TNV98, 4TNV98T, page 6-73.
0.0035 - 0.0059 in. 0.0067 in.
4TNV106, Lubricating Oil Pump Gear
(0.09 - 0.15 mm) (0.17 mm)
4TNV106T
Balancer Drive Gear 0.0047 - 0.0071 in. 0.0079 in.
(Only for 4TNV106T) (0.12 - 0.18 mm) (0.20 mm)

TNV DI Service Manual 6-13


ENGINE Crankshaft and Piston Specifications

CRANKSHAFT AND PISTON SPECIFICATIONS


Crankshaft
Note: Check appropriate parts catalog for various sizes of replacement main bearing inserts.

Reference
Inspection Item Standard Limit
Page
0.0008 in.
Bend (1/2 the dial gauge reading) -
(0.02 mm)
Journal Outside 1.6910 - 1.6914 in. 1.6891 in.
Diameter (42.952 - 42.962 mm) (42.902 mm)
Bearing Inside 1.6929 - 1.6946 in.
-
Diameter (43.000 - 43.042 mm)
3TNV82A
Bearing Insert 0.0585 -.0591 in.
-
Thickness (1.487 - 1.500 mm)
0.0015 - 0.0035 in. 0.0059 in.
Oil Clearance
(0.038 - 0.090 mm) (0.150 mm)
Journal Outside 1.8879 - 1.8883 in. 1.8859 in.
Diameter (47.952 - 47.962 mm) (47.902 mm)
3TNV84,
3TNV84T, Bearing Inside 1.8898 - 1.8909 in.
-
3TNV88, Diameter (48.000 - 48.026 mm)
4TNV84, Bearing Insert 0.0587 - 0.0591 in.
4TNV84T - See
Thickness (1.492 - 1.500 mm)
4TNV88 Inspection of
0.0015 - 0.0029 in. 0.0059 in.
Oil Clearance Crankshaft
Connecting Rod (0.038 - 0.074 mm) (0.150 mm)
on
Journals Journal Outside 2.2816 - 2.2820 in. 2.2796 in. page 6-86.
Diameter (57.952 - 57.962 mm) (57.902 mm)
Bearing Inside 2.2835 - 2.2845 in.
4TNV94L, -
Diameter (58.000 - 58.026 mm)
4TNV98,
4TNV98T Bearing Insert 0.0587 - 0.0591 in.
-
Thickness (1.492 - 1.500 mm)
0.0015 - 0.0029 in. 0.0059 in.
Oil Clearance
(0.038 - 0.074 mm) (0.150 mm)
Journal Outside 2.5178 - 2.5182 in. 2.5158 in.
Diameter (63.952 - 63.962 mm) (63.902 mm)
Bearing Inside 2.5203 - 2.5213 in.
-
4TNV106, Diameter (64.016 - 64.042 mm)
4TNV106T Bearing Insert 0.0781 - 0.0784 in.
-
Thickness (1.984 - 1.992 mm)
0.0021 - 0.0035 in. 0.0059 in.
Oil Clearance
(0.054 - 0.090 mm) (0.150 mm)

6-14 TNV DI Service Manual


Crankshaft and Piston Specifications ENGINE
(Crankshaft Cont.)

Reference
Inspection Item Standard Limit
Page
Journal Outside 1.8485 - 1.8489 in. 1.8465 in.
Diameter (46.952 - 46.962 mm) (46.902 mm)
Bearing Inside 1.8504 - 1.8516 in.
-
Diameter (47.000 - 47.032 mm)
3TNV82A
Bearing Insert 0.0782 - 0.0787 in.
-
Thickness (1.987 - 2.000 mm)
0.0015 - 0.0031 in. 0.0059 in.
Oil Clearance
(0.038 - 0.080 mm) (0.150 mm)
Journal Outside 1.9666-1.9670 in. 1.9646 in.
Diameter (49.952-49.962 mm) (49.902 mm)
3TNV84,
3TNV84T, Bearing Inside 1.9685 - 1.9693 in.
-
3TNV88, Diameter (50.000 - 50.020 mm)
4TNV84, Bearing Insert 0.0785 - 0.0791 in.
4TNV84T -
Thickness (1.995 - 2.010 mm)
4TNV88 See
0.0015 - 0.0027 in. 0.0059 in.
Oil Clearance Inspection of
(0.038 - 0.068 mm) (0.150 mm)
Main Bearing Journal Crankshaft
Journal Outside 2.5572 - 2.5576 in. 2.5552 in. on
Diameter (64.952 - 64.962 mm) (64.902 mm) page 6-86.
Bearing Inside 2.5590 - 2.5598 in.
4TNV94L, -
Diameter (65.000 - 65.020 mm)
4TNV98,
4TNV98T Bearing Insert 0.0785 - 0.0791 in.
-
Thickness (1.995 - 2.010 mm)
0.0015 - 0.0027 in. 0.0059 in.
Oil Clearance
(0.038 - 0.068 mm) (0.150 mm)
Journal Outside 2.9902 - 2.9906 in. 2.9883 in.
Diameter (75.952 - 75.962 mm) (75.902 mm)
Bearing Inside 2.9927 - 2.9935 in.
-
4TNV106, Diameter (76.014 - 76.034 mm)
4TNV106T Bearing Insert 0.0980 - 0.0985 in.
-
Thickness (2.488 - 2.503 mm)
0.0020 - 0.0032 in. 0.0059 in.
Oil Clearance
(0.052 - 0.082 mm) (0.150 mm)

Thrust Bearing
Reference
Inspection Item Standard Limit
Page
See Removal
0.0051 - 0.0091 in. 0.0110 in. of Crankshaft
Crankshaft End Play - All Models
(0.13 - 0.23 mm) (0.28 mm) on
page 6-80.

TNV DI Service Manual 6-15


ENGINE Crankshaft and Piston Specifications

Piston
Reference
Inspection Item Standard Limit
Page
3.2264 - 3.2275 in. 3.2246 in.
3TNV82A
(81.950 - 81.980 mm) (81.905 mm)
3TNV84, 3TNV84T, 3.3047 - 3.3059 in. 3.3029 in.
4TNV84, 4TNV84T (83.940 - 83.970 mm) (83.895 mm)
3.4622 - 3.4634 in. 3.4604 in.
3TNV88,4TNV88
Piston Outside Diameter (87.940 - 87.970 mm) (87.895 mm)
(Measure at 90° to the Piston Pin.) 3.6982 - 3.6994 in. 3.6968 in.
4TNV94L
(93.935 - 93.965 mm) (93.900 mm)
3.8555 - 3.8567 in. 3.8541 in.
4TNV98, 4TNV98T
(97.930 - 97.960 mm) (97.895 mm) See
4.1705 - 4.1716 in. 4.1685 in. Inspection of
4TNV106, 4TNV106T Pistons,
(105.930 - 105.960 mm) (105.880 mm)
Piston Rings
0.6299 in. and Wrist Pin
3TNV82A -
(16 mm) on
3TNV84, 3TNV84T, 0.9449 in. page 6-83.
-
4TNV84, 4TNV84T (24 mm)
0.9449 in.
Piston Diameter Measure Location 3TNV88,4TNV88 -
(24 mm)
(Upward From the Bottom of the
Piston.) 0.8661 in.
4TNV94L -
(22 mm)
0.8661 in.
4TNV98, 4TNV98T -
(22 mm)
1.1811 in.
4TNV106, 4TNV106T -
(30 mm)

6-16 TNV DI Service Manual


Crankshaft and Piston Specifications ENGINE
(Piston Cont.)

Reference
Inspection Item Standard Limit
Page
0.9055 - 0.9059 in. 0.9070 in.
Hole Inside Diameter
(23.000 - 23.009 mm) (23.039 mm)
0.9053 - 0.9055 in. 0.9041 in.
3TNV82A Pin Outside Diameter
(22.995 - 23.000 mm) (22.965 mm)
0.0000 - 0.0006 in. 0.0029 in.
Oil Clearance
(0.000 - 0.014 mm) (0.074 mm)

3TNV84, 1.0236 - 1.0240 in. 1.0252 in.


Hole Inside Diameter
3TNV84T, (26.000 - 26.009 mm) (26.039 mm)
3TNV88, 1.0234 - 1.0236 in. 1.0222 in.
Pin Outside Diameter
4TNV84, (25.995 - 26.000 mm) (25.965 mm) See
4TNV84T 0.0000 - 0.0006 in. 0.0029 in. Inspection of
4TNV88 Oil Clearance Pistons,
(0.000 - 0.014 mm) (0.074 mm)
Piston Pin Piston Rings
1.1811 - 1.1815 in. 1.1826 in. and Wrist Pin
Hole Inside Diameter
(30.000 - 30.009 mm) (30.039 mm) on
4TNV94L,
1.1807 - 1.1811 in. 1.1795 in. page 6-83.
4TNV98, Pin Outside Diameter
(29.989 - 30.000 mm) (29.959 mm)
4TNV98T
0.0000 - 0.0008 in. 0.0031 in.
Oil Clearance
(0.000 - 0.020 mm) (0.080 mm)
1.4567 - 1.4571 in. 1.4582 in.
Hole Inside Diameter
(37.000 - 37.011 mm) (37.039 mm)
4TNV106, 1.4563 - 1.4567 in. 1.4551 in.
Pin Outside Diameter
4TNV106T (36.989 - 37.000 mm) (36.959 mm)
0.0000 - 0.0009 in. 0.0031 in.
Oil Clearance
(0.000 - 0.022 mm) (0.080 mm)

TNV DI Service Manual 6-17


ENGINE Crankshaft and Piston Specifications

Piston Ring
Reference
Model Inspection Item Standard Limit
Page
0.0813 - 0.0819 in.
Ring Groove Width -
(2.065 - 2.080 mm)
0.0776 - 0.0783 in. 0.0768 in.
Ring Width
(1.970 - 1.990 mm) (1.950 mm)
Top Ring
0.0030 - 0.0043 in.
Side Clearance -
(0.075 - 0.110 mm)
0.0079 - 0.0157 in. 0.0193 in.
End Gap
(0.200 - 0.400 mm) (0.490 mm)
0.0801 - 0.0807 in. 0.0846 in.
Ring Groove Width
(2.035 - 2.050 mm) (2.150 mm) See
3TNV82A, 0.0776 - 0.0783 in. 0.0768 in. Inspection of
3TNV84, Ring Width Pistons,
(1.970 - 1.990 mm) (2.150 mm)
3TNV84T, Second Ring Piston Rings
4TNV84, 0.0018 - 0.0031 in. 0.0079 in. and Wrist
Side Gap
4TNV84T (0.045 - 0.080 mm) (0.200 mm) Pin on
0.0079 - 0.0157 in. 0.0193 in. page 6-83.
End Gap
(0.200 - 0.400 mm) (0.490 mm)
0.1581 - 0.1587 in. 0.1626 in.
Ring Groove Width
(4.015 - 4.030 mm) (4.130 mm)
0.1563 - 0.1571 in. 0.01555 in.
Ring Width
(3.970 - 3.990 mm) (3.950 mm)
Oil Ring
0.0010 - 0.0024 in. 0.0071 in.
Side Clearance
(0.025 - 0.060 mm) (0.180 mm)
0.0079 - 0.0157 in. 0.0193 in.
End Gap
(0.200 - 0.400 mm) (0.490 mm)

6-18 TNV DI Service Manual


Crankshaft and Piston Specifications ENGINE
(Piston Ring Cont.)

Reference
Model Inspection Item Standard Limit
Page
0.0811 - 0.0817 in.
Ring Groove Width -
(2.060 - 2.075 mm)
0.0776 - 0.0783 in. 0.0768 in.
Ring Width
(1.970 - 1.990 mm) (1.950 mm)
Top Ring
0.0028 - 0.0041 in.
Side Clearance -
(0.070 - 0.105 mm)
0.0079 - 0.157 in. 0.0193 in.
End Gap
(0.200 -.0400 mm) (0.490 mm)
0.0797 - 0.0803 in. 0.0843 in.
Ring Groove Width
(2.025 - 2.040 mm) (2.140 mm) See
0.0776 -- 0.0783 in. 0.0768 in. Inspection of
Ring Width Pistons,
3TNV88, (1.970 - 1.990 mm) (1.950 mm)
Second Ring Piston Rings
4TNV88 0.0014 - 0.0028 in. 0.0075 in.
Side Clearance and Wrist
(0.035 - 0.070 mm) (0.190 mm) Pin on
0.0079 - 0.0157 in. 0.0193 in. page 6-83.
End Gap
(0.200 - 0.400 mm) (0.490 mm)
0.1581 - 0.1587 in. 0.1626 in.
Ring Groove Width
(4.015 - 4.030 mm) (4.130 mm)
0.1563 -.1571 in. 0.1555 in.
Ring Width
(3.970 - 3.990 mm) (3.950 mm)
Oil Ring
0.0010 - 0.0024 in. 0.0071 in.
Side Clearance
(0.025 - 0.060 mm) (0.180 mm)
0.0079 - 0.0157 in. 0.0193 in.
End Gap
(0.200 - 0.400 mm) (0.490 mm)

TNV DI Service Manual 6-19


ENGINE Crankshaft and Piston Specifications

(Piston Ring Cont.)

Reference
Model Inspection Item Standard Limit
Page
0.0803 - 0.0811 in.
Ring Groove Width -
(2.040 - 2.060 mm)
0.0764 - 0.0772 in. 0.0756 in.
Ring Width
(1.940 - 1.960 mm) (1.920 mm)
Top Ring
0.0031 - 0.0047 in.
Side Clearance -
(0.080 - 0.120 mm)
0.0098 - 0.0177 in. 0.0213 in.
End Gap
(0.250 - 0.450 mm) (0.540 mm)
0.0819 - 0.0825 in. 0.0864 in.
Ring Groove Width
(2.080 - 2.095 mm) (2.195 mm) See
0.0776 - 0.0783 in. 0.0768 in. Inspection of
4TNV94L, Ring Width Pistons,
(1.970 - 1.990 mm) (1.950 mm)
4TNV98, Second Ring Piston Rings
4TNV98T 0.0035 - 0.0049 in. 0.0096 in. and Wrist
Side Clearance
(0.090 - 0.125 mm) (0.245 mm) Pin on
0.0177 - 0.0256 in. 0.0287 in. page 6-83.
End Gap
(0.450 - 0.650 mm) (0.730 mm)
0.1187 - 0.1193 in. 0.1232 in.
Ring Groove Width
(3.015 - 3.030 mm) (3.130 mm)
0.1169 - 0.1177 in. 0.1161 in.
Ring Width
(2.970 - 2.990 mm) (2.950 mm)
Oil Ring
0.0010 - 0.0024 in. 0.0071 in.
Side Clearance
(0.025 - 0.060 mm) (0.180 mm)
0.0098 - 0.0177 in. 0.0217 in.
End Gap
(0.250 - 0.450 mm) (0.550 mm)

6-20 TNV DI Service Manual


Crankshaft and Piston Specifications ENGINE
(Piston Ring Cont.)

Reference
Model Inspection Item Standard Limit
Page
0.0992 - 0.1000 in.
Ring Groove Width -
(2.520 - 2.540 mm)
0.0961 - 0.0969 in. 0.0953 in.
Ring Width
(2.440 - 2.460 mm) (2.420 mm)
Top Ring
0.0024 - 0.0039 in.
Side Clearance -
(0.060 - 0.100 mm)
0.0118 - 0.0177 in. 0.0213 in.
End Gap
(0.300 - 0.450 mm) (0.540 mm)
0.0815 - 0.0821 in. 0.0860 in.
Ring Groove Width
(2.070 - 2.085 mm) (2.185 mm) See
0.0776 - 0.0783 in. 0.0768 in. Inspection of
Ring Width Pistons,
4TNV106, (1.970 - 1.990 mm) (1.950 mm)
Second Ring Piston Rings
4TNV106T 0.0031 - 0.0045 in. 0.0093 in.
Side Clearance and Wrist
(0.080 - 0.115 mm) (0.235 mm) Pin on
0.0177 - 0.0236 in. 0.0268 in. page 6-83.
End Gap
(0.450 - 0.600 mm) (0.680 mm)
0.1187 - 0.1193 in. 0.1232 in.
Ring Groove Width
(3.015 - 3.030 mm) (3.130 mm)
0.1169 - 0.1177 in. 0.1161 in.
Ring Width
(2.970 - 2.990 mm) (2.950 mm)
Oil Ring
0.0010 - 0.0024 in. 0.0071 in.
Side Clearance
(0.025 - 0.060 mm) (0.180 mm)
0.0118 - 0.0197 in. 0.0236 in.
End Gap
(0.300 - 0.500 mm) (0.600 mm)

TNV DI Service Manual 6-21


ENGINE Crankshaft and Piston Specifications

Connecting Rod
Connecting Rod Small End
Reference
Model Inspection Item Standard Limit
Page
Wrist Pin Bushing 0.9065 - 0.9070 in. 0.9082 in.
Inside Diameter (23.025 - 23.038 mm) (23.068 mm)
Wrist Pin Outside 0.9053 - 0.9055 in. 0.9042 in.
3TNV82A
Diameter (22.995 - 23.000 mm) (22.967 mm)
0.0010 - 0.0017 in. 0.0040 in.
Oil Clearance
(0.025 - 0.043 mm) (0.101 mm)
Wrist Pin Bushing 1.0234 - 1.0251 in. 1.0263 in.
Inside Diameter (26.025 - 26.038 mm) (26.068 mm)
3TNV84, 3TNV84T, 3TNV88, Wrist Pin Outside 1.0234 - 1.0236 in. 1.0223 in.
4TNV84, 4TNV84T, 4TNV88 Diameter (25.995 - 26.000 mm) (25.967 mm)
0.0010 - 0.0017 in. 0.0040 in. See
Oil Clearance Inspection of
(0.025 - 0.043 mm) (0.101 mm)
Connecting
Wrist Pin Bushing 1.1821 - 1.1826 in. 1.1838 in. Rod on
Inside Diameter (30.025 - 30.038 mm) (30.068 mm) page 6-85.
Wrist Pin Outside 1.1806 - 1.1811 in. 1.1795 in.
4TNV94L, 4TNV98, 4TNV98T
Diameter (29.987 - 30.000 mm) (29.959 mm)
0.0010 - 0.0020 in. 0.0043 in.
Oil Clearance
(0.025 - 0.51 mm) (0.109 mm)
Wrist Pin Bushing 1.4577 - 1.4582 in. 1.4594 in.
Inside Diameter (37.025 - 37.038 mm) (37.068 mm)
Wrist Pin Outside 1.4563 - 1.4567 in. 1.4552 in.
4TNV106, 4TNV106T
Diameter (36.989 - 37.000 mm) (36.961 mm)
0.0010 - 0.0019 in. 0.0042 in.
Oil Clearance
(0.025 - 0.049 mm) (0.107 mm)

Connecting Rod Big End


Reference
Inspection Item Standard Limit
Page
See
Inspection of
0.0079 - 0.0157 in.
Side Clearance - All Models - Connecting
(0.20 - 0.40 mm)
Rod on
page 6-85.

See Special Torque Chart on page 6-25 for other specifications.

6-22 TNV DI Service Manual


Crankshaft and Piston Specifications ENGINE
Tappet
Reference
Model Inspection Item Standard Limit
Page
Tappet Bore (Block) Inside 0.4724 - 0.4734 in. 0.4742 in.
3TNV82A, 3TNV84, Diameter (12.000 - 12.025 mm) (12.045 mm)
3TNV84T, 3TNV88, 0.4715 - 0.4720 in. 0.4707 in.
Tappet Stem Outside Diameter
4TNV84, 4TNV84T, (11.975 - 11.990 mm) (11.955 mm)
4TNV88 0.0004 - 0.0020 in. 0.0035 in.
Oil Clearance
(0.010 - 0.050 mm) (0.090 mm)
Tappet Bore (Block) Inside 0.4724 - 0.4731 in. 0.4739 in.
Diameter (12.000 - 12.018 mm) (12.038 mm) See
4TNV94L, 4TNV98, 0.4715 - 0.4720 in. 0.4707 in. Inspection of
Tappet Stem Outside Diameter
4TNV98T (11.975 - 11.990 mm) (11.955 mm) Tappets on
0.0004 - 0.0017 in. 0.0033 in. page 6-85.
Oil Clearance
(0.010 - 0.043 mm) (0.083 mm)
Tappet Bore (Block) Inside 0.5512 - 0.5519 in. 0.5527 in.
Diameter (14.000 - 14.018 mm) (14.038 mm)
0.5498 - 0.5505 in. 0.5491 in.
4TNV106, 4TNV106T Tappet Stem Outside Diameter
(13.966 - 13.984 mm) (13.946 mm)
0.0006 - 0.0020 in. 0.0036 in.
Oil Clearance
(0.015 - 0.052 mm) (0.092 mm)

TNV DI Service Manual 6-23


ENGINE Cylinder Block Specifications

CYLINDER BLOCK SPECIFICATIONS


Cylinder Block
Reference
Inspection Item Model Standard Limit
Page
3.2283 - 3.2295 in. 3.2362 in.
3TNV82A
(82.000 - 82.030 mm) (82.200 mm)
3TNV84, 3TNV84T, 3.3071 - 3.3083 in. 3.3150 in.
4TNV84, 4TNV84T (84.000 - 84.030 mm) (84.200 mm)
3.4646 - 3.4657 in. 3.4724 in.
3TNV88, 4TNV88
(88.000 - 88.030 mm) (88.200 mm) See
Cylinder Inside Diameter Inspection of
3.7008 - 3.7020 in. 3.7059 in.
4TNV94L Cylinder
(94.000 - 94.030 mm) (94.130 mm)
Block on
3.8583 - 3.8594 in. 3.8634 in. page 6-83.
4TNV98, 4TNV98T
(98.000 - 98.030 mm) (98.130 mm)
4.1732 - 4.1744 in. 4.1783 in.
4TNV106, 4TNV106T
(106.000 - 106.030 mm) (106.130 mm)
Roundness 0.0004 in. (0.01 mm) 0.0012 in.
Cylinder Bore
Taper or less (0.03 mm)

6-24 TNV DI Service Manual


Special Torque Chart ENGINE

SPECIAL TORQUE CHART


Torque for Bolts and Nuts
Lubricating Oil
Thread Diameter Application
Component Model Torque
and Pitch (Thread Portion and
Seat Surface)
46 - 49 ft·lb
3TNV82A M9 x 1.25 mm (61.7 - 65.7 N·m;
6.3 - 6.7 kgf·m)
3TNV82A, 3TNV84,
63 - 67 ft·lb
3TNV84T, 3TNV88,
M10 x 1.25 mm (85.3 - 91.1 N·m;
4TNV84, 4TNV84T,
Cylinder 8.7 - 9.3 kgf·m)
4TNV88 Applied
Head Bolt
76 - 83 ft·lb
4TNV94L, 4TNV98,
M11 x 1.25 mm (103.1 - 112.9 N·m;
4TNV98T
10.5 - 11.5 kgf·m)
139 - 146 ft·lb
4TNV106, 4TNV106T M13 x 1.5 mm (188.0 - 112.9 N·m;
19.0 - 20.0 kgf·m)
27 - 30 ft·lb
3TNV82A M8 x 1.0 mm (37.2 - 41.2 N·m;
3.8 - 4.2 kgf·m)
3TNV82A, 3TNV84,
33 - 36 ft·lb
3TNV84T, 3TNV88,
M9 x 1.0 mm (44.1 - 49.0 N·m;
4TNV84, 4TNV84T,
Connecting 4.5 - 5.0 kgf·m)
4TNV88 Applied
Rod Bolt
40 - 43 ft·lb
4TNV94L, 4TNV98,
M10 x 1.0 mm (53.9 - 58.8 N·m;
4TNV98T
5.5 - 6.0 kgf·m)
58 - 62 ft·lb
4TNV106, 4TNV106T M11 x 1.0 mm (78.5 - 83.4 N·m;
8.0 - 8.5 kgf·m)
3TNV82A, 3TNV84,
61 - 65 ft·lb
3TNV84T, 3TNV88,
M10 x 1.25 mm (83.3 - 88.2 N·m;
4TNV84, 4TNV84T,
Flywheel 8.5 - 9.0 kgf·m)
4TNV88 Applied
Bolt
4TNV94L, 4TNV98, 137 - 152 ft·lb
4TNV98T, 4TNV106, M14 x 1.5 mm (186.2 - 205.8 N·m;
4TNV106T 19 - 21 kgf·m)
83 - 91 ft·lb
EPA Flange
4TNV106, 4TNV106T M8 x 1.5 mm (113 - 123 N·m; Not Applied
Bolt
11.5 - 12.5 kgf·m)

TNV DI Service Manual 6-25


ENGINE Special Torque Chart

(Torque for Bolts and Nuts Cont.)

Lubricating Oil
Thread Diameter Application
Component Model Torque
and Pitch (Thread Portion and
Seat Surface)
56 - 60 ft·lb
3TNV82A M10 x 1.25 mm (76.4 - 80.4 N·m;
7.8 - 8.2 kgf·m)
3TNV84, 3TNV84T, 69 - 72 ft·lb
3TNV88, 4TNV84, M12 x 1.5 mm (93.2 - 98.1 N·m;
Main Bearing Cap 4TNV84T, 4TNV88 9.5 - 10.5 kgf·m)
Applied
Bolt 80 - 87 ft·lb
4TNV94L, 4TNV98,
M11 x 1.25 mm (108.1 - 117.9 N·m;
4TNV98T
11.0 - 12.0 kgf·m)
137 - 152 ft·lb
4TNV106, 4TNV106T M14 x 1.5 mm (186.2 - 205.8 N·m;
19 - 21 kgf·m)
3TNV82A, 3TNV84,
83 - 91 ft·lb
3TNV84T, 3TNV88,
M14 x 1.5 mm (112.7 - 122.7 N·m;
4TNV84, 4TNV84T,
Crankshaft Pulley 11.5 - 12.5 kgf·m)
4TNV88 Applied
Bolt
4TNV94L, 4TNV98, 80 - 94 ft·lb
4TNV98T, 4TNV106, M14 x 1.5 mm (107.9 - 127.5 N·m;
4TNV106T 11.0 - 13.0 kgf·m)
3TNV82A, 3TNV84,
18 - 21 ft·lb
3TNV84T, 3TNV88,
M8 x 1.25 mm (24.4 - 28.4 N·m;
4TNV84, 4TNV84T,
Fuel Injector 2.5 - 2.9 kgf·m)
4TNV88 Not Applied
Bolt
4TNV94L, 4TNV98, 17 - 21 ft·lb
4TNV98T, 4TNV106, M8 x 1.25 mm (22.6 - 28.4 N·m;
4TNV106T 2.3 - 2.9 kgf·m)
3TNV82A, 3TNV84,
58 - 65 ft·lb
3TNV84T, 3TNV88,
M14 x 1.5 mm (78 - 88 N·m;
4TNV84, 4TNV84T,
Fuel Pump Drive 8 - 9 kgf·m)
4TNV88 Not Applied
Gear Nut
4TNV94L, 4TNV98, 83 - 90 ft·lb
4TNV98T, 4TNV106, M18 x 1.5 mm (113 - 123 N·m;
4TNV106T 11.5 - 12.5 kgf·m)
3TNV82A, 3TNV84,
22 - 25 ft·lb
3TNV84T, 3TNV88,
M12 x 1.5 mm (29.4 - 34.3 N·m;
4TNV84, 4TNV84T,
High-Pressure 3.0 - 3.5 kgf·m)
4TNV88 Not Applied
Fuel Lines Bolt
4TNV94L, 4TNV98, 174 - 217 in·lb
4TNV98T, 4TNV106, M12 x 1.5 mm (19.6 - 24.5 N·m;
4TNV106T 2.0 - 2.5 kgf·m)

6-26 TNV DI Service Manual


Special Torque Chart ENGINE
(Torque for Bolts and Nuts Cont.)

Lubricating Oil
Thread Diameter Application
Component Model Torque
and Pitch (Thread Portion and
Seat Surface)
4TNV94L, 4TNV98, 70 - 86 in·lb
Fuel Return Line
4TNV98T, 4TNV106, M6 x 1.0 mm (7.8 - 9.8 N·m; Not Applied
Joint Bolt
4TNV106T 0.8 - 1.0 kgf·m)
Rocker Arm 148 - 199 in·lb
Cover 4TNV106, 4TNV106T M8 x 1.25 mm (16.7 - 22.5 N·m; Not Applied
Bolt 1.7 - 2.3 kgf·m)
3TNV82A-B, 133 - 177 in·lb
Glow Plug 3TNV88-B,-U, M10 x 1.25 mm (15 - 20 N·m Not Applied
4TNV88-B,-U 1.53 - 2.04 kgf·m)
3TNV82A-B,
Glow Connector 9 - 13 in·lb
3TNV88-B,-U, M4 x 0.7 mm Not Applied
Nut (1 - 1.5 N·m)
4TNV88-B,-U

See Tightening Torques for Standard Bolts and Nuts on page 4-46 for standard hardware torque values.

TNV DI Service Manual 6-27


ENGINE Special Service Tools

SPECIAL SERVICE TOOLS


No. Tool Name Applicable Model and Tool Size Illustration

Model L1 L2 d1 d2
3TNV82A
4TNV94L,
4TNV98, 0.787 in. 2.953 in. 0.256 in. 0.394 in.
0000827
4TNV98T (20 mm) (75 mm) (6.5 mm) (10 mm)
4TNV106,
Valve Guide Tool 4TNV106T
1 (For Removing
Valve Guide) 4TNV84,
3TNV84,
0.787 in. 2.953 in. 0.295 in. 0.433 in.
3TNV84T,
(20 mm) (75 mm) (7.5 mm) (11 mm)
3TNV88,
4TNV88
0.787 in. 2.953 in. 0.217 in. 0.354 in.
4TNV84T
(20 mm) (75 mm) (5.5 mm) (9 mm)
Locally Manufactured

Model L1 L2 d1 d2
0.472 in. 2.362 in. 0.512 in. 0.748 in.
3TNV82A
(12 mm) (60 mm) (13 mm) (19 mm)
4TNV84,
3TNV84,
0.591 in. 2.559 in. 0.551 in. 0.787 in.
3TNV84T, 0000828
(15 mm) (65 mm) (14 mm) (20 mm)
Valve Guide Tool 4TNV88,
2 (For Installing 4TNV88
Valve Guide) 0.335 in. 2.362 in. 0.433 in. 0.669 in.
4TNV84T
(8.5 mm) (60 mm) (11 mm) (17 mm)
4TNV94L,
0.276 in. 2.362 in. 0.512 in. 0.630 in.
4TNV98,
(7 mm) (60 mm) (13 mm) (16 mm)
4TNV98T
4TNV106, 0.535 in. 2.559 in. 0.512 in. 0.630 in.
4TNV106T (13.6 mm) (65 mm) (13 mm) (16 mm)
Locally Manufactured

Fuel Injector
3 Removal Tool Yanmar Part No. 129470-92305
(2-Valve Head)

6-28 TNV DI Service Manual


Special Service Tools ENGINE
(Special Service Tools Cont.)

No. Tool Name Applicable Model and Tool Size Illustration

Model L1 L2 d1 d2
0.984 in. 3.346 in. 0.906 in. 1.024 in.
3TNV82A
(25 mm) (85 mm) (23 mm) (26 mm)
3TNV84,
Connecting Rod
3TNV84T,
Bushing
3TNV88, 0.787 in. 3.937 in. 1.024 in. 1.142 in.
Replacer 0000829
4TNV84, (20 mm) (100 mm) (26 mm) (29 mm)
4 (For Removal/
4TNV84T,
Installation of
4TNV88,
Connecting Rod
Bushing) 4TNV94L,
0.787 in. 3.937 in. 1.181 in. 1.299 in.
4TNV98,
(20 mm) (100 mm) (30 mm) (33 mm)
4TNV98T
4TNV106, 0.787 in. 3.937 in. 1.457 in. 1.575 in.
4TNV106T (20 mm) (100 mm) (37 mm) (40 mm)
Locally Manufactured

Valve Spring
Compressor
Yanmar Part No.
5 (For Removal/
129100-92630
Installation of 0000830
Valve Spring)

Model d1 d2 d3 L1 L2 L3
0.598 0.827 0.472 0.622 2.559 0.157
in. in. in. in. in. in.
3TNV82A
(15.2 (21 (12 (15.8 (65 (4
mm) mm) mm) mm) mm) mm)
3TNV84,
0.638 0.866 0.531 0.740 2.559 0.157
3TNV84T,
in. in. in. in. in. in.
3TNV88,
(16.2 (22 (13.5 (18.8 (65 (4
4TNV84,
mm) mm) mm) mm) mm) mm)
Stem Seal 4TNV88
Installer 0.508 0.748 0.453 0.394 2.559 0.157
6
(for Installing in. in. in. in. in. in.
Valve Stem Seal) 4TNV84T
(12.9 (19 (11.5 (10 (65 (4
mm) mm) mm) mm) mm) mm)
0.598 0.827 0.472 0.465 2.559 0.157
4TNV94L, 0000820
in. in. in. in. in. in.
4TNV98,
(15.2 (21 (12 (11.8 (65 (4
4TNV98T
mm) mm) mm) mm) mm) mm)
0.598 0.827 0.472 0.610 2.559 0.157
4TNV106, in. in. in. in. in. in.
4TNV106T (15.2 (21 (12 (15.5 (65 (4
mm) mm) mm) mm) mm) mm)
Locally Manufactured

TNV DI Service Manual 6-29


ENGINE Special Service Tools

(Special Service Tools Cont.)

No. Tool Name Applicable Model and Tool Size Illustration


Filter Wrench
(For Removal /
7 Available Locally
Installation of
Engine Oil Filter) 0000821

Model L1 L2 d1 d2
3TNV82A,
3TNV84,
3TNV84T,
0.709 in. 2.756 in. 1.772 in. 1.890 in.
3TNV88,
Camshaft (18 mm) (70 mm) (45 mm) (48 mm)
4TNV84,
Bushing Tool 0000822
4TNV84T,
8 (For Extracting 4TNV88
Camshaft
4TNV94L,
Bushing) 0.709 in. 2.756 in. 1.968 in. 2.087 in.
4TNV98,
(18 mm) (70 mm) (50 mm) (553 mm)
4TNV98T
4TNV106, 0.709 in. 2.756 in. 2.283 in. 2.402 in.
4TNV106T (18 mm) (70 mm) (58 mm) (61 mm)
Allowance: d1 d2
Locally Manufactured

Model Yanmar Part No. Cylinder Bore


3.071 - 3.307 in.
3TNV82A 129400-92420
(78 - 84 mm)
3TNV88,
Flex-Hone 3.268 - 3.740 in.
4TNV88, 129400-92430
9 (For Preparation (83 - 95 mm)
4TNV94L
of Cylinder Walls) 0000823
3.504 - 3.976 in.
4TNV98 129400-92440
(89 - 101 mm)
4TNV106, 3.740 - 4.252 in.
129400-92450
4TNV106T (95 - 108 mm)

Piston Ring
Yanmar Part No. 95550-002476
Compressor
10 The Piston Insertion Tool is Applicable for
(For Installing
2.362 - 4.921 in. (60 - 125 mm) Diameter Pistons
Piston)
0000824

Piston Ring
Expander
11 (For Removal / Available Locally
Installation of
Piston Ring) 0000825

6-30 TNV DI Service Manual


Special Service Tools ENGINE
(Special Service Tools Cont.)

No. Tool Name Applicable Model and Tool Size Illustration

Locally Manufactured 0000826


(1)
Crankshaft Pulley
12 (4TNV94L, 4TNV98(T) series)
Installing Tool
(Knurl knob (1))

0002134

6.3

0.05 A 0.1 A
(16) 36
20
5 M14 x 1.5
0.
C
0.

16 C
5

Pulley Installing 3TNV82A - 4TNV88 1


13 C
ø 35.4 -0.05
-0.15

Tool For all series


ø6

1
C

A
3
52
Knurling

TNV DI Service Manual 6-31


ENGINE Measuring Instruments

MEASURING INSTRUMENTS
No. Instrument Name Application Illustration

1 Dial Indicator Locally Available Measure shaft bend and end play

0000831

Measurements of narrow or deep portions that


2 Test Indicator Locally Available
cannot be measured by dial gauge

0000832

3 Magnetic Stand Locally Available For holding the dial gauge when measuring

0000833

For measuring the outside diameters of


4 Micrometer Locally Available
crankshaft, pistons, piston pins, etc.

0000834

Cylinder Bore For measuring the inside diameters of cylinder


5 Locally Available
Gauge liners, bearing bores, etc.
0000835

For measuring outside diameters, depth,


6 Calipers Locally Available
thickness and width
0000836

7 Depth Micrometer Locally Available For measuring of valve recession

0000837

For measuring valve spring inclination and


8 Square Locally Available
straightness of parts

0000838

6-32 TNV DI Service Manual


Measuring Instruments ENGINE
No. Instrument Name Application Illustration

9 V-Block Locally Available For measuring shaft bend

0000839

For tightening nuts and bolts to the specified


10 Torque Wrench Locally Available
torque

0000840

For measuring piston ring gaps, piston ring


11 Feeler Gauge Locally Available
clearance, and valve adjustment clearance

0000841

TNV DI Service Manual 6-33


ENGINE 2-Valve Cylinder Head

2-VALVE CYLINDER HEAD


2-Valve Cylinder Head Components
(3)
(1)
(2) (4)
(5)
(6) (7)

(34)

(8)
(32)
(33)

(9) (10)
(11)
(12)
(29)
(17) (13)
(30) (18) (14)
(28) (31) (15)
(19)

(20) (16)
(27)
(21)

(22)

(23)

(26)
(24)
(25) 0001919

Figure 6-1

6-34 TNV DI Service Manual


2-Valve Cylinder Head ENGINE
1 – Valve Cover Nut Components of a two-valve cylinder
2 – Valve Cover Nut O-Ring
3 – Crankcase Breather Cover
head
4 – Diaphragm Spring Cylinder head with glow plugs (two-valve
5 – Diaphragm Plate type)Applicable Model
6 – Crankcase Breather Diaphragm 3TNV82A-B, 3TNV88-B,-U, 4TNV88-B,-U
(non-turbocharged engines only)
7 – Oil Fill Cap
8 – Valve Cover Gasket (3)
9 – Rocker Arm Shaft Spring
10 – Valve Adjusting Screw Lock Nut
11 – Valve Adjusting Screw
12 – Rocker Arm
13 – Rocker Arm Shaft (2)
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 (1)
21 – Valve Stem Seal
22 – Valve Guide
23 – Cylinder Head
Figure 6-2
24 – Intake Valve
25 – Exhaust Valve 1 – Cylinder Head
26 – Cylinder Head Gasket 2 – Glow plug
27 – Fuel Injector Retainer 3 – Harness, Glow plug
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

TNV DI Service Manual 6-35


ENGINE 2-Valve Cylinder Head

Disassembly of 2-Valve Cylinder


Head
Prepare a clean, flat working surface on a (1)
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.
1. Drain the coolant from the engine into a suitable
container. See Drain, Flush and Refill Cooling
System With New Coolant on page 5-36.

CAUTION
0002087A
Identify all parts and their location using
an appropriate method. It is important Figure 6-4
that all parts are returned to the same
position during the reassembly process. 4. Remove the intake manifold bolts
(Figure 6-5, (1)). Remove the intake manifold
0000080en
(Figure 6-5, (2)). Discard the intake manifold
2. Disconnect the electrical wire from the intake air gasket (Figure 6-5, (3)).
heater (Figure 6-3, (1)).
(5)

(4)
(1) (5)

(6)
(7)

(2) (3)

0001682
(1)
Figure 6-5
Figure 6-3
5. Remove the exhaust manifold bolts
3. Disconnect the coolant hoses from the cold (Figure 6-5, (4)) and nuts (Figure 6-5, (5)).
start device (Figure 6-4, (1)) on the fuel Remove the exhaust manifold (Figure 6-5, (6))
injection pump. and the exhaust manifold gasket
(Figure 6-5, (7)).
6. Remove the coolant pump. See Disassembly of
Engine Coolant Pump on page 8-10.
7. Remove the high-pressure lines and fuel
injectors from the cylinder head. See Removal
of Fuel Injectors on page 7-35.

6-36 TNV DI Service Manual


2-Valve Cylinder Head ENGINE
Removing the glow plugs Removal of Valve Cover
1. Remove the glow plug harness 1. Remove the valve cover nuts (Figure 6-7, (1)).
(Figure 6-6, (2)) from each glow plug 2. Remove the O-ring (Figure 6-7, (2)) on each
(Figure 6-6, (1)). valve cover nut.
2. Remove the glow plug from the cylinder head.
(1)
(2)
(2)

(1) (3)

(4)
0001920

Figure 6-7
3. Remove the valve cover (Figure 6-7, (3)) and
the valve cover gasket (Figure 6-7, (4)).
Figure 6-6
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.

TNV DI Service Manual 6-37


ENGINE 2-Valve Cylinder Head

Removal of Rocker Arm Assembly


(7)
1. Remove the bolts (Figure 6-8, (1)) that retain (6)
the rocker arm shaft supports. (1)
(2)
2. Remove the rocker arm shaft assembly from
the cylinder head.
Note: Identify the push rods so they can be (3)
(4)
reinstalled in their original locations.
3. Remove the push rods and identify for
installation. (5)

0001951

Figure 6-9
(1)
3. Remove the valve adjusting screw
(Figure 6-9, (6)) and the lock nut
(Figure 6-9, (7)) from the rocker arms.

Removal of Cylinder Head


1. Loosen the cylinder head bolts following the
sequence shown in (Figure 6-10).

(2)
8 14 5
0001950 2 12 9 3

(1)
Figure 6-8 4 10 11 1
6 13 7

Disassembly of Rocker Arm Assembly


1. Remove the rocker arm shaft alignment stud (2)
(Figure 6-9, (4)) from support (Figure 6-9, (5)).
7 16 14 6
1 9 18 12 4
Note: The rocker arm shaft fits tightly in the
(1)
rocker arm supports. Clamp the support 3 11 17 10 2

in a padded vise. Twist and pull out on 5 13 15 8

the rocker arm shaft to remove. Reverse 0001864

this process when you reinstall the 1 – Cooling Fan End


rocker arm shaft into the supports. 2 – Camshaft Side

2. Slide the rocker arm shaft (Figure 6-9, (3)) out Figure 6-10
of the rocker arm supports (Figure 6-9, (5)),
springs (Figure 6-9, (1)), and rocker arms
(Figure 6-9, (2)).
Note: Mark the rocker arms so they can be
reinstalled with the original matching
valve and pushrod.

6-38 TNV DI Service Manual


2-Valve Cylinder Head ENGINE
2. Remove the cylinder head bolts Removal of Intake / Exhaust Valves
(Figure 6-11, (1)). 1. Place the cylinder head on the work bench with
3. Lift the cylinder head away from the cylinder the combustion side down.
block. Discard the cylinder head gasket 2. Remove the valve cap (Figure 6-13, (1)) and
(Figure 6-11, (2)). Position the cylinder head on keep with the valve it was installed on.
the work bench to prevent damage to the
combustion surface. 3. Using the valve spring compressor tool,
compress one of the valve springs
(Figure 6-12).
(1)

0000191

Figure 6-12
4. Remove the valve keepers (Figure 6-13, (2)).
(2) 5. Slowly release the tension on the valve spring.
6. Remove the spring retainer (Figure 6-13, (3))
and valve spring (Figure 6-13, (4)).

(1)
(2)
(3)
(4)
0001690 (5)
Figure 6-11

(6)

0001684

Figure 6-13
7. Repeat the procedure with all remaining valves.

TNV DI Service Manual 6-39


ENGINE 2-Valve Cylinder Head

Note: If the valves are to be reused, identify Cleaning of Cylinder Head


them so they can be installed in their
Components
original location.
8. Turn the cylinder head so the exhaust port side A WARNING
faces down. Remove the intake and exhaust
valves (Figure 6-13, (6)) from the cylinder
head.
9. Remove the valve stem seals
(Figure 6-13, (5)).
FUME / BURN HAZARD!
Removal of Valve Guides
• Always read and follow safety related
Note: Removal of the valve guides should be precautions found on containers of
postponed until inspection and hazardous substances like parts
measurement procedures have been cleaners, primers, sealants and
performed. See Inspection of Valve sealant removers.
Guides on page 6-41.
• Failure to comply could result in death
1. If the valve guides were not within or serious injury.
specifications, use a drift pin and hammer to 0000014en
drive the valve guides (Figure 6-14, (1)) out of
the cylinder head. Thoroughly clean all components using a non-
metallic brush and an appropriate solvent. Each
part must be free of carbon, metal filings and other
debris.
(1)
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.

001689 CAUTION
Figure 6-14 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.
0000119en

6-40 TNV DI Service Manual


2-Valve Cylinder Head ENGINE
Inspect the contact areas (Figure 6-16, (1)) for
CAUTION excessive wear or damage.
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.
0000120en

(1)
Inspection of Push Rods (1)

Push Rod Bend


Determine if the bend of the push rods are within 0001916

the specified limit.


Figure 6-16
1. Place the push rods on a flat inspection block or
layout bed. Rocker Arm Shaft Outside Diameter
2. Roll the push rods until a gap can be observed Use a micrometer to measure the rocker arm shaft
between a portion of the push rod and the diameter. Measure at each rocker arm location in
surface of the block or layout bed. two directions 90° apart (Figure 6-17). See Rocker
Arm and Shaft on page 6-9 for the service limit.
3. Use a feeler gauge to measure the gap
(Figure 6-15). See Push Rod on page 6-9 for
the service limit.

0001952
0000204

Figure 6-15 Figure 6-17

Inspection of Rocker Arm Assembly Inspection of Valve Guides


Visually inspect the valve guides for distortions,
Rocker Arm Shaft Hole Diameter scoring or other damage.
Use a test indicator and micrometer to determine if
the inside diameter of all the rocker arm support Note: Measure the valve guides while they are
brackets and the rocker arms (Figure 6-16) are installed in the cylinder head.
within the specified limits. See Rocker Arm and
Shaft on page 6-9 for the service limit.

TNV DI Service Manual 6-41


ENGINE 2-Valve Cylinder Head

Use a telescoping gauge and micrometer to Valve Stem Diameter


measure the inside diameter at each end of the Use a micrometer to measure the valve stem
valve guide. Measure in three places and 90° apart diameter. Measure the valve stem near the
(Figure 6-18). See Intake / Exhaust Valve and combustion end and near the opposite end
Guide on page 6-7 for the service limit. Replace (Figure 6-20, (1)). See Intake / Exhaust Valve and
valve guides if not within specification. Guide on page 6-7 for the service limit.

(1)

0001869 0000197

Figure 6-18 Figure 6-20


Inspection of Cylinder Head Valve Stem Bend
Cylinder Head Distortion Place the valve stem on a flat inspection block or
layout bed. Roll the valve until a gap can be
Place the cylinder head flat and inverted
observed between a portion of the valve stem and
(combustion side up) on the bench. Use a straight
the surface of the block or bed. Use a feeler gauge
edge and a feeler gauge to measure cylinder head
to measure the gap (Figure 6-21). See
distortion (Figure 6-19). Measure diagonally and
Intake / Exhaust Valve and Guide on page 6-7 for
along each side. See Cylinder Head on page 6-6
the service limit.
for the service limit.

0000199

Figure 6-21
0000192
Valve Recession
Figure 6-19
Note: The valve guides must be installed to
If distortion exceeds the service limit, resurface or perform this check.
replace the cylinder head. Remove only enough
material to make the cylinder head flat, but do not Insert the valves into their original locations and
remove more than 0.008 in. (0.20 mm). press them down until they are fully seated. Use a
depth micrometer (Figure 6-22) to measure the
Inspection of Intake and Exhaust Valves difference between the cylinder head gasket
surface and the combustion surface of each
Visually inspect the intake and exhaust valves.
exhaust and intake valve (Figure 6-23). See
Replace any valves that are obviously discolored,
Cylinder Head on page 6-6 for the service limit.
heavily pitted or otherwise damaged.

6-42 TNV DI Service Manual


2-Valve Cylinder Head ENGINE
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 6-24, (1)) and even in width.

0000193

Figure 6-22

(1)

0001691B

Figure 6-24
Also visually inspect the valve seat for even
0001755 contact.
Figure 6-23
Light cutting can be performed by the use of a
Valve Face and Valve Seat hand-operated cutter (Figure 6-25, (3)).
Always check the clearance between the valve and
valve guide before grinding or lapping the valve (1)
seats. See Intake / Exhaust Valve and Guide on 150° 40°
page 6-7 for the service limit. If the clearance
exceeds the limit, replace the valve and / or valve (3)
guide to bring the clearance within the limit. (2)

Roughness or burrs will cause poor seating of a


valve. Visually inspect the seating surfaces of each 0001862

valve and valve seat to determine if lapping or Figure 6-25


grinding is needed.
The valve seat diameter can be adjusted by top-
Visually inspect all valve faces and valve seats for grinding with a 150° stone to make the seat
pitting, distortion, cracking, or evidence of diameter smaller, and bottom-grinding using a 40°
overheating. Usually the valves and the valve seats stone to make the seat diameter larger. Once the
can be lapped or ground to return them to seat location has been corrected, grind and lap the
serviceable condition. Severely worn or damaged seat angle (Figure 6-25, (1)) to specification. See
components will require replacement. Cylinder Head on page 6-6 for specifications.

TNV DI Service Manual 6-43


ENGINE 2-Valve Cylinder Head

Grind the valve face and / or valve seat only Free Length
enough to return them to serviceable condition. Use a caliper to measure the length of the spring
Grinding is needed if the valve and the valve seat (Figure 6-27). See Valve Spring on page 6-10 for
do not contact correctly. Check the recession after the service limit.
grinding.
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.

2
3
1

4
Be sure to thoroughly wash all parts to remove all

5
9

6
grinding powder or compound.

8
7
Inspection of Valve Springs
Inspect the valve springs. If damage or corrosion is
seen, or if measurements exceed the specified
limits, replace the springs. 0000200

Figure 6-27
Fractures
Check for fractures on the inside and outside Reassembly of Cylinder Head
portions of the springs. If the valve spring is
fractured, replace the valve spring. Use new gaskets, O-rings and seals for the
reassembly of the cylinder head.
Corrosion
IMPORTANT
Check for corrosion of the spring material caused Liberally oil all components during
by oxidation. reassembly to prevent premature wear or
Squareness damage.
Use a flat surface and a square to check each Reassembly of Valve Guides
spring for squareness (Figure 6-26). See Valve
Spring on page 6-10 for the service limit. 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.

0000201

Figure 6-26

6-44 TNV DI Service Manual


2-Valve Cylinder Head ENGINE
2. Immediately after removing the valve guides Reassembly of Intake and Exhaust Valves
from the freezer, insert the valve guides
(Figure 6-28, (1)) in their proper positions. IMPORTANT
Always install new valve stem seals.
The exhaust valve stem seals are different
than the intake valve stem seals and can be
(1) identified by either the paint marks on the
outside of the seals or by the color of the
seal spring (Figure 6-30, (4)). Ensure they
are installed in the correct locations.

Marking
Engine Model
Intake Exhaust
3TNV84, 3TNV88, Yellow (Paint
3TNV84T, 4TNV84, None on outside of
001689 4TNV88 seal)
Figure 6-28 Black (Seal
3TNV82A None
Spring)
3. Finish installing the valve guides
(Figure 6-29, (1)) into the cylinder head to the 1. Oil the lip of the valve stem seal
proper height (Figure 6-29, (3)) using the valve (Figure 6-30, (2)). Using the valve stem seal
guide installation tool (Figure 6-29, (2)). See installation tool (Figure 6-30, (1)), install a new
Valve Guide Projection specification starting on valve stem seal on each of the valve guides
page 6-7. (Figure 6-30, (3)).

(2)

(1)

(3)
(4)

(1) (2)
0001756A
(3)
Figure 6-29

0001873B

Figure 6-30
2. Measure the distance (Figure 6-31, (1)) from
the cylinder head to valve stem seal to ensure
proper clearance (Figure 6-31, (2)) between
the guide and the seal. See Valve Stem Seal
Projection specification on page 6-9.

TNV DI Service Manual 6-45


ENGINE 2-Valve Cylinder Head

7. Insert the valve keepers (Figure 6-32, (2)) and


slowly release the tension on the valve spring.
Install the valve cap (Figure 6-32, (1)). Repeat
the steps on all the remaining valves.
(2) 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 6-33, (2)) on the cylinder block.
0001874
2. Position the cylinder head on the cylinder head
Figure 6-31 gasket.
3. Place the cylinder head assembly on its
exhaust port side. (1)
4. Place all the valves (Figure 6-32, (6)) in their
proper location in the cylinder head.

(1)
(2)
(3)
(4)
(5)

(2)

(6)

0001684

0001690
Figure 6-32
5. Place the cylinder head on the workbench with Figure 6-33
the combustion side down to install the valve
springs. Install the valve spring
(Figure 6-32, (4)) and the spring retainer
(Figure 6-32, (5)).
6. Using the valve spring compressor tool,
compress the valve spring.

6-46 TNV DI Service Manual


2-Valve Cylinder Head ENGINE
3. Lightly oil the threads of the cylinder head bolts 1. Lubricate the rocker arm shaft. Slide the rocker
(Figure 6-33, (1)). Tighten the bolts to the arm supports (Figure 6-36, (5)), springs
specified torque in two steps as shown in the (Figure 6-36, (1)) and rocker arms
chart below. Tighten in the sequence shown in (Figure 6-36, (2)) onto the shaft.
(Figure 6-34). See Special Torque Chart on Note: The rocker arm shaft fits tightly in the
page 6-25 for specification. rocker arm supports. Clamp the support
First Step 1/2 of final torque
in a padded vise. Twist and push on the
rocker arm shaft to reinstall.
Second Step Final torque
Note: To properly align the rocker arm shaft
4. Insert the push rods in their respective with the rocker arm shaft supports, first
positions. reinstall a rocker arm support
(Figure 6-36, (5)) having a hole for the
(2) shaft alignment stud (Figure 6-36, (4)).
13
7
3
1
6
10
12
Align the hole in the rocker arm shaft and
(1) the hole in the rocker arm support.
11 5 4 14
Reinstall the alignment stud.
9 2 8

(7)
(6)
(2)
(1)
12 3 5 13 (2)
18 10 1 7 15

(1)
16 8 2 9 17
14 6 4 11 (3)
(4)
0001875

1 – Fan End
2 – Camshaft Side
(5)
Figure 6-34

Reassembly of Rocker Arm Reassembly


0001951
Note: Ensure the lubrication holes
(Figure 6-35, (1)) in the rocker arm shaft Figure 6-36
are oriented correctly with respect to the
Note: Figure 6-36 shows components for one
rocker arms (Figure 6-35, (2)).
cylinder. Components for all remaining
cylinders are assembled in the same
(2)
order.
2. Place the rocker arm shaft assembly onto the
(1)
cylinder head.
3. If removed, reinstall the valve adjusting screws
(Figure 6-36, (6)) and the lock the nuts
(Figure 6-36, (7)).
4. Align the push rods with their respective rocker
arms.
(1) 0001914
5. Reinstall and tighten the rocker arm shaft
Figure 6-35 retaining bolts to the specified torque.

TNV DI Service Manual 6-47


ENGINE 2-Valve Cylinder Head

6. Tighten the rocker arm shaft alignment studs. 6. Install each glow plug (Figure 6-38, (1)), and
7. Adjust the valve clearance. See Measuring and tighten it with the specified torque. Install each
Adjusting Valve Clearance on page 6-66. electrical harness (Figure 6-38, (1)), and
tighten it with the specified torque.
Reassembly of the Valve Cover
1. Lightly grease a new valve cover gasket (2)
(Figure 6-37, (4)). Place the gasket in the
groove of the valve cover (Figure 6-37, (3)).
2. Place the valve cover on the cylinder head. (1)
3. Be sure new O-rings (Figure 6-37, (2)) are
installed on the valve cover nuts. Reinstall and
tighten the valve cover nuts (Figure 6-37, (1)).
4. Reinstall the exhaust manifold using a new
gasket. Tighten the bolts to the specified
torque.

(1)
(2)

Figure 6-38
7. Reinstall the fuel injectors. See Installation of
the Fuel Injectors on page 7-42.
(3) 8. Reinstall the high pressure and the return fuel
injection lines. See Installation of the Fuel
Injectors on page 7-42
9. Reinstall the engine coolant pump. See
(4)
Reassembly of Engine Coolant Pump on
0001920 page 8-11.
Figure 6-37 10. Reinstall the coolant hoses on the cold start
5. Reinstall the intake manifold using a new device on the fuel injection pump.
gasket. Tighten the bolts to the specified 11. Reinstall the alternator. See Installation of
torque. Alternator on page 12-16.

6-48 TNV DI Service Manual


4-Valve Cylinder Head ENGINE

4-VALVE CYLINDER HEAD


4-Valve Cylinder Head Components
(1)
(2)
(3)
(4) (5)
(36)
(6)
(7)

(35)
(8)

(34)
(9)
(11) (12)
(10)
(33)
(14) (15)
(31) (13)
(30) (32)
(29)
(28)
(27) (16)
(26)
(24)
(25)
(23) (17)
(18)

(22)

(19)

(21)

(20) 0001861

Figure 6-39

TNV DI Service Manual 6-49


ENGINE 4-Valve Cylinder Head

1 – Crankcase Breather Cover Disassembly of 4-Valve Cylinder


2 – Diaphragm Spring
3 – Diaphragm Cup Head
4 – Crankcase Breather Diaphragm Prepare a clean, flat working surface on a
5 – Oil Fill Cap workbench large enough to accommodate the
6 – Valve Cover Nut cylinder head assembly. Discard all gaskets,
7 – Valve Cover Nut O-Ring
O-rings and seals. Use new gaskets, O-rings and
8 – Valve Cover Gasket
9 – Support Bolt
seals on reassembly of the cylinder head.
10 – Rocker Arm Shaft Support 1. Drain the coolant from the engine into a suitable
11 – Wave Washer container. See Drain, Flush and Refill Cooling
12 – Fuel Injector Retainer Bolt
System With New Coolant on page 5-36.
13 – Valve Adjusting Screw (Primary)
14 – Valve Adjusting Screw Lock Nut (Primary)
15 – Rocker Arm Shaft Aligning Stud CAUTION
16 – Fuel Injector Retainer Identify all parts and their location using
17 – Valve Stem Seal an appropriate method. It is important
18 – Valve Guide that all parts are returned to the same
19 – Cylinder Head position during the reassembly process.
20 – Intake Valve
0000080en
21 – Exhaust Valve
22 – Cylinder Head Gasket 2. Remove the high pressure fuel injection lines
23 – Fuel Injector Nozzle Protector
(Figure 6-40, (1)). See Removal of Fuel
24 – Fuel Injector Nozzle Seat
25 – Valve Spring
Injectors on page 7-35.
26 – Valve Bridge Guide
27 – Spring Retainer
28 – Valve Keepers
29 – Valve Bridge (1)
30 – Valve Bridge Seat
31 – Valve Adjusting Screw Lock Nut
(Secondary)
32 – Valve Adjusting Screw (Secondary)
33 – Push Rod
34 – Rocker Arm Shaft
35 – Crankcase Breather Components
36 – Valve Cover (3)

(2)
0001876

Figure 6-40

6-50 TNV DI Service Manual


4-Valve Cylinder Head ENGINE

CAUTION (2)
Remove or install the high-pressure fuel
injection lines as an assembly whenever
possible. Disassembling the (3) (6)
(1)
high-pressure fuel injection lines from (7)
the retainers or bending any of the fuel (5)
lines will make it difficult to reinstall the
(4)
fuel lines.
0000047en

3. Disconnect the fuel return hose


(Figure 6-40, (2)) from the cylinder head. (12)
4. Disconnect the hoses (Figure 6-40, (3)) from
the cold start device on the fuel injection pump. (11) (8)
This cooling water pipe is not used in (10) (9)
0001860

electronically controlled engines 4TNV84T-Z,


Figure 6-41
4TNV98-Z, 4TNV98-E and 4TNV98T-Z.
Instead, these engines use a solenoid valve 10. Remove the engine coolant pump. See
and connecting coupler but, when removing the Disassembly of Engine Coolant Pump on
cylinder head only, it is not necessary to remove page 8-10.
the connecting coupler.
5. Remove the turbocharger-to-intake manifold
hose (Figure 6-41, (1)) (if equipped).
6. Disconnect the electrical wire from the intake air
heater (Figure 6-41, (12)).
7. Remove the intake manifold bolts
(Figure 6-41, (11)). Remove the intake
manifold (Figure 6-41, (10)). Discard the intake
manifold gasket (Figure 6-41, (9)).
8. Disconnect the turbocharger oil supply
(Figure 6-41, (2)) and the return lines
(Figure 6-41, (4)) (if equipped).
9. Remove the exhaust manifold bolts
(Figure 6-41, (7)). Remove the exhaust
manifold (Figure 6-41, (6)) with the
turbocharger attached. Discard the exhaust
manifold gasket. (Figure 6-41, (5)).

TNV DI Service Manual 6-51


ENGINE 4-Valve Cylinder Head

Removal of Valve Cover


Note: The high pressure fuel injection lines and (3)
valve cover grommets must be removed
prior to removing the valve cover. See (4)
Removal of Fuel Injectors on page 7-35.
(5)
1. Remove the high-pressure fuel lines.
2. Use a flat-blade screwdriver (Figure 6-42) to
remove the fuel injection line grommets
(Figure 6-43, (1)) from the valve cover
(Figure 6-43, (3)) and fuel injectors (2)
(6)
(Figure 6-43, (2)). There is a notch at the 3 (1)
o’clock position in the valve cover opening to
insert the screwdriver.

Figure 6-42
3. Remove the valve cover nuts (Figure 6-43, (4)). 0001877

4. Remove the O-ring (Figure 6-43, (5)) on each Figure 6-43


valve cover nut.
5. Remove the valve cover (Figure 6-43, (3)).
Discard the valve cover gasket
(Figure 6-43, (6)).
6. Inspect and clean the crankcase breather
assembly. See Inspect Crankcase Breather
System on page 5-40.

6-52 TNV DI Service Manual


4-Valve Cylinder Head ENGINE
Removal of Rocker Arm Assembly Disassembly of Rocker Arm Assembly
1. Remove the fuel injectors from the cylinder Note: Identify the rocker arms so they can be
head. See Removal of Fuel Injectors on reinstalled with the original matching
page 7-35. valve and pushrod.
2. Remove the bolts (Figure 6-44, (1)) that retain 1. Remove the rocker arm shaft alignment studs
the rocker arm shaft supports to the cylinder (Figure 6-45, (5)) from the rocker arm shaft
head. supports (Figure 6-45, (6)).
3. Remove the rocker arm and shaft assembly 2. Slide the supports, wave washers
from the cylinder head. (Figure 6-45, (7)), rocker arms
Note: Identify the push rods and valve bridges (Figure 6-45, (8)), and fuel injector retainers
so they can be installed in their original (Figure 6-45, (4)) off the rocker shaft
locations. (Figure 6-45, (1)), leaving these parts in order
on the bench surface.
4. Remove the push rods (Figure 6-44, (2)).
5. Remove the valve bridge assemblies (1)
(Figure 6-44, (3)). Remove the seat
(Figure 6-44, (4)) from each valve bridge. (3)
6. Identify all parts so that they will be reinstalled (2)
(4) (5)
in their original locations.

(1)

(8)
(7)
(6)
0001866
(4)
(3) Figure 6-45
(2)
Note: Figure 6-45 shows components for one
cylinder. Components for all remaining
cylinders are assembled in the same
order.
3. Remove the valve adjusting screw
(Figure 6-45, (2)) and the lock nut
000187
(Figure 6-45, (3)) from the rocker arms.

Figure 6-44

TNV DI Service Manual 6-53


ENGINE 4-Valve Cylinder Head

Removal of Cylinder Head


1. Loosen the cylinder head bolts following the (1)
sequence shown in (Figure 6-46).

(2)
8 14 5
2 12 9 3

(1)
4 10 11 1
6 13 7

(2)
7 16 14 6
1 9 18 12 4

(1)
3 11 17 10 2
5 13 15 8 (2)
0001864

1 – Cooling Fan End


2 – Camshaft Side
Figure 6-46 0001872

2. Remove the cylinder head bolts Figure 6-47


(Figure 6-47, (1)).
Removal of Intake and Exhaust Valves
3. Lift the cylinder head away from the cylinder
block. Discard the cylinder head gasket 1. Place the cylinder head on the work bench with
(Figure 6-47, (2)). Place the cylinder head on the combustion side down.
the work bench to prevent damage to the 2. Using the valve spring compressor tool,
combustion surface. compress one of the valve springs
(Figure 6-48).

0000191

Figure 6-48

6-54 TNV DI Service Manual


4-Valve Cylinder Head ENGINE
3. Remove the valve keepers (Figure 6-49, (1)). Removal of Valve Guides
4. Slowly release the tension on the valve spring. Note: Removal of the valve guides should be
5. Remove the spring retainer (Figure 6-49, (2)), postponed until inspection and
valve spring (Figure 6-49, (3)). measurement procedures have been
performed. See Inspection of Valve
(1) Guides on page 6-57.
(7) (2) 1. Using a drift pin and hammer, drive the valve
(6) guides (Figure 6-50, (1)) out of the cylinder
(3) head.
(4)
(1)

(5)

0001867

0001868
Figure 6-49
Figure 6-50
6. Repeat the procedure with all the remaining
valves. Cleaning of Cylinder Head
Note: If the valves are to be reused, identify Components
them so they can be installed in their
original location.
A WARNING
7. Remove the injector nozzle protectors
(Figure 6-49, (6)) and the seats
(Figure 6-49, (7)).
8. Turn the cylinder head so the exhaust port side
faces down. Remove the intake and exhaust
valves (Figure 6-49, (5)) from the cylinder FUME / BURN HAZARD!
head. • Always read and follow safety related
9. Remove the valve stem seals precautions found on containers of
(Figure 6-49, (4)). hazardous substances like parts
cleaners, primers, sealants and
sealant removers.
• Failure to comply could result in death
or serious injury.
0000014en

TNV DI Service Manual 6-55


ENGINE 4-Valve Cylinder Head

Thoroughly clean all components using a non- Inspection of Push Rods


metallic brush and an appropriate solvent. Each
part must be free of carbon, metal filings and other Push Rod Bend
debris. 1. Place the push rods on a flat inspection block or
layout bed.
Inspection of Cylinder Head 2. Roll the push rods until a gap can be observed
Components between a portion of the push rod and the
Visually inspect the parts. Replace any parts that surface of the block or layout bed.
are obviously discolored, heavily pitted or otherwise 3. Use a feeler gauge to measure the gap
damaged. Discard any parts that do not meet its (Figure 6-51). See Push Rod on page 6-9 for
specified limit. the service limit.

CAUTION
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.
0000119en

CAUTION
Any part determined to not meet the 0000204
service standard or limit before the next
service, as determined from the state of Figure 6-51
current rate of wear, should be replaced
Inspection of Rocker Arm Assembly
even though the part currently meets the
service standard limit. Rocker Arm Shaft Hole Diameter
0000120en
1. Use a telescoping gauge and micrometer to
determine if the inside diameter of all the rocker
arm support brackets and the rocker arms
(Figure 6-52) are within the specified limits.
See Rocker Arm and Shaft on page 6-9 for the
service limit.
2. Inspect the contact areas (Figure 6-52, (1)) for
excessive wear or damage.

6-56 TNV DI Service Manual


4-Valve Cylinder Head ENGINE
Inspection of Valve Guides
Valve Guide Inside Diameter
Visually inspect the valve guides for distortions,
scoring or other damage.
Note: Measure the valve guides while they are
(1) installed in cylinder head.
(1)
Use a telescoping gauge and micrometer to
measure the inside diameter at each end of the
0001916 valve guide. Measure in three places and 90° apart
(Figure 6-54). See Intake / Exhaust Valve and
Figure 6-52 Guide on page 6-7 for the service limit. Replace the
valve guides if not within specification.
Rocker Arm Shaft Outside Diameter
Use a micrometer to measure the rocker arm shaft
diameter (Figure 6-53). Measure at each rocker
arm location in two directions 90° apart
(Figure 6-53). See Rocker Arm and Shaft on
page 6-9 for the service limit. 0001869

Figure 6-54

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 feeler gauge to measure cylinder head
distortion (Figure 6-55). Measure diagonally and
along each side. See Cylinder Head on page 6-6
for the service limit.

0001952

Figure 6-53

0000192

Figure 6-55

TNV DI Service Manual 6-57


ENGINE 4-Valve Cylinder Head

If distortion exceeds the service limit, resurface or Valve Stem Bend


replace the cylinder head. Remove only enough Place the valve stem on a flat inspection block or
material to make the cylinder head flat, but do not layout bed. Roll the valve until a gap can be
remove more than 0.008 in (0.20 mm). observed between a portion of the valve stem and
the surface of the block or bed. Use a feeler gauge
Inspection of Intake and Exhaust Valves to measure the gap (Figure 6-57). See
Visually inspect the intake and exhaust valves. Intake / Exhaust Valve and Guide on page 6-7 for
Replace any valves that are obviously discolored, the service limit.
heavily pitted or otherwise damaged.

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 6-56, (1)). See Intake / Exhaust Valve and
Guide on page 6-7 for the service limit.

(1) 0000199

Figure 6-57
0000197 Valve Recession
Note: The valve guides must be installed to
Figure 6-56 perform this check.
Insert the valves into their original locations and
press them down until they are fully seated. Use a
depth micrometer (Figure 6-58) to measure the
difference between the cylinder head gasket
surface and the combustion surface of each
exhaust and intake valve (Figure 6-59). See
Cylinder Head on page 6-6 for the service limit.

0000193

Figure 6-58
Note: 2-Valve cylinder head is shown. 4-Valve
cylinder head is similar.

6-58 TNV DI Service Manual


4-Valve Cylinder Head ENGINE
Coat the valve seat with a thin coat of bluing
compound. Install the valve and rotate to distribute