Yanmar Engine Base 3TNV-4TNV Series (Direct Injection System) Service Manual for Hyundai Equipment

This service manual describes the service procedures for the Yanmar Industrial Diesel Engines TNV series of the direct injection system.
The service guide contains general safety precautions, basic engine data, descriptions of repair and troubleshooting procedures, specifications for the maintenance and repair, a list of special tools, pictures, and parts diagrams for Yanmar Industrial Diesel Engines.
This service manual comes in PDF format. We recommend using Adobe PDF Reader, to be sure all images/graphics will display correctly.

Industrial Diesel Engine models covered:
3TNV82A,
3TNV84(T),
3TNV88,
4TNV84(T),
4TNV88,
4TNV94L,
4TNV98(T),
4TNV106(T).

Reference only:
- Mini-Excavator (5Ton, -7Series)
- Skid Steer Loader

Contents:

• 1. General
  • 1.1. Engine Nomenclature
  • 1.2. Specifications
  • 1.3. Fuel Oil, Lubricating Oil, and Cooling Water
  • 1.4. Engine External Views
  • 1.5. Structural Description
  • 1.6. Exhaust Gas Emission Regulation
• 2. Inspection and Adjustment
  • 2.1. Periodic Maintenance Schedule
  • 2.2. Periodic Inspection and Maintenance Procedure
  • 2.3. Adjusting the No-Load Maximum or Minimum Speed
  • 2.4. Sensor Inspection
  • 2.5. Water Leak Check-in Cooling Water System
  • 2.6. Radiator Cap Inspection
  • 2.7. Thermostat Inspection
  • 2.8. Adjusting Operation
  • 2.9. Long Storage
• 3. Troubleshooting
  • 3.1. Preparation Before Troubleshooting
  • 3.2. Quick Reference Table for Troubleshooting
  • 3.3. Troubleshooting by Measuring Compression Pressure
• 4. Disassembly, Inspection, and Reassembly of Engines
  • 4.1. Complete Disassembly and Reassembly
  • 4.2. Cylinder Head: Disassembly, Inspection, and Reassembly
  • 4.3. Gear Train and Camshaft
  • 4.4. Cylinder Block
• 5. Lubrication System
  • 5.1. Lubrication System Diagram
  • 5.2. Trochoid Pump Components
  • 5.3. Disassembly (Reverse the procedure below for assembly)
  • 5.4. Servicing Points
  • 5.5. Part Inspection and Measurement
• 6. Cooling System
  • 6.1. Cooling Water System
  • 6.2. Cooling Water Pump Components
  • 6.3. Disassembly (Reverse the procedure below for assembly)
  • 6.4. Servicing Points
• 7. Fuel Injection Pump/Governor
  • 7.1. Introduction
  • 7.2. Fuel Injection Pump
• 8. Turbocharger: Disassembly, Inspection, and Reassembly
  • 8.1. Structure and Functions
  • 8.2. Service Standards and Tightening Torque
  • 8.3. Periodic Inspection Procedure
  • 8.4. Disassembly Procedure
  • 8.5. Washing and Inspection Procedure
  • 8.6. Reassembly Procedure
  • 8.7. Handling after Disassembly and Reassembly
  • 8.8. Troubleshooting
• 9. Starting Motor
  • 9.1. For 4TNV94L/98
  • 9.2. For 4TNV106(T)
• 10. Alternator
  • 10.1. The 40A Alternator for 3TNV84 and other models
  • 10.2. Troubleshooting
• 11. Electric Wiring
  • 11.1. Electric Wiring Diagram
  • 11.2. Precaution on Electric Wiring
• 12. Service Standards
  • 12.1. Engine Tuning
  • 12.2. Engine Body
  • 12.3. Lubricating Oil System (Trochoid Pump)
• 13. Tightening Torque for Bolts and Nuts
  • 13.1. Tightening Torques for Main Bolts and Nuts
  • 13.2. Tightening Torques for STandard Bolts and Nuts