Yanmar 3TNV88F Service Manual

SERVICE MANUAL

INDUSTRIAL ENGINES 3TNV88F

SERVICE MANUAL

INDUSTRIAL ENGINES

3TNV88F

0BTN4-G00400
PRINTED IN JAPAN

California

product improvement policy, we may modify information, illustrations and/or specifications

Proposition 65 Warning

Diesel engine exhaust and some of its
constituents are known to the state of
California to cause cancer, birth
defects, and other reproductive harm.

Proposition 65 Warning

Battery posts, terminals, and related
accessories contain lead and lead
compounds, chemicals known to the
state of California to cause cancer and
reproductive harm.
Wash hands after handling.

California

Foreword:

This Service Manual has been developed for the exclusive use of service and repair
professionals such as YANMAR authorized distributors and YANMAR authorized dealers.
It is written with these professionals in mind and may not contain the necessary detail or
safety statements that may be required for a non-professional to perform the service or
repair properly and/or safely. Please contact an authorized YANMAR repair or service
professional before working on your YANMAR product.

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

to explain and/or exemplify a product, service or maintenance improvement. We reserve
the right to make any change at any time without notice. YANMAR and are
registered trademarks of YANMAR CO., LTD. in Japan, the United States and/or other
countries.

Head Office:

YANMAR CO., LTD.

Umeda Gate Tower 1-9 Tsurunocho, kita-ku, Osaka, Japan

http://www.yanmar.co.jp

Yanmar America Corporation

101 International Parkway

Adairsville, GA 30103, U.S.A.

TEL: [phone] FAX: [phone]

http://www.yanmar.com

Yanmar Europe B.V.

Brugplein11, 1332 BS Almere -de Vaart,

The Netherlands.

TEL: [phone] FAX: [phone]

http://www.yanmar.nl

Yanmar Asia (Singapore) Corporation Pte. Ltd.

4 Tuas Lane, Singapore 638613

TEL: [phone] FAX: [phone]

http://www.yanmar.co.jp/yasc/

Yanmar Engine (Shanghai) Corporation Ltd.

10F, E-Block POLY PLAZA, No.18 Dongfang Road,

Pudong Shanghai, CHINA P.R.C 200120

TEL: [phone] FAX: [phone]

http://www.yanmar-sha.com

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.

SERVICE MANUAL

Model

Code No.

All Rights Reserved, Copyright

3TNV88F

0BTN4-G00400

Yanmar South America Industria De Maquinas Ltda.

Av. Presidente Vargas 1400, Indaiatuba, S.P., Brazil, CEP: 13338-901

TEL: [phone] FAX: [phone], 2241

http://www.yanmar.com.br

SERVICE MANUAL

3TNV88F

1st edition: June 2012
1st edition 1st rev. : December 2012

Issued by: YANMAR CO., LTD.

Edited by: YANMAR TECHNICAL SERVICE CO., LTD.

TNV DI Service Manual

TABLE OF

CONTENTS

Introduction ......................................................................................... 1-1

YANMAR Warranties........................................................................... 2-1

Safety.................................................................................................... 3-1

General Service Information .............................................................. 4-1

Periodic Maintenance ......................................................................... 5-1

Engine .................................................................................................. 6-1

Fuel System. .......... .............................................................................. 7-1

Cooling System................................................................................... 8-1

Lubrication System............................................................................. 9-1

Page

Starter Motor...................................................................................... 10-1

Alternator........................................................................................... 11-1

Electronic Control System ............................................................... 12-1

Electric Wiring................................................................................... 13-1

Failure Diagnosis .............................................................................. 14-1

TNV DI Service Manual

i

TABLE OF CONTENTS

This Page Intentionally Left Blank

ii

TNV DI Service Manual

3TNV88F Service Manual

Section 1

INTRODUCTION

This Service Manual describes the service
procedures for the TNV series direct injection
engines. These engines are certified by the U.S.
EPA, California ARB for industrial use.

Please use this manual f or accurate, quic k and saf e
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 ans w ers to
any questions relating to field modifications.

3TNV88F Service Manual

1-1

INTRODUCTION

This Page Intentionally Left Blank

1-2

3TNV88F Service Manual

3TNV88F Service Manual

WARRANTIES

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

Section 2

YANMAR

Page

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

3TNV88F Service Manual

2-1

YANMAR WARRANTIES

This Page Intentionally Left Blank

2-2

3TNV88F 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, r adiators , air filters, fue l filters, and/or e xhaust systems
that are supplied and/or installed by manuf acturers other than YANMAR. For w arranty inf ormation on
such external components, please contact the machine or component manufacturer directly or see
your authorized YANMAR dealer or distributor.

This warranty is provided in lieu of all other warranties, express or implied. YANMAR specifically disclaims
any implied warranties of merchantability or fitness for a particular purpose, except where such disclaimer
is prohibited by law. If such disclaimer is prohibited by law, then implied warranties shall be limited in
duration to the life of the express warranty.

How Long is the Warranty Period?

The YANMAR standard limited warranty period runs for a period of twenty-four (24) months or two­thousand (2000) engine operation hours, whichever occurs first. An extended limited warranty of 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 thir ty
(30) days of discov ering the failure. You must provide proof of o wnership 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.

3TNV88F Service Manual

2-3

YANMAR WARRANTIES

YANMAR limited warranty - continued

YANMAR Limited Warranty

To Locate an Authorized YANMAR Industrial Engine Dealer or Distributor:

You can locate your nearest authorized YANMAR industrial engine dealer or distributor by visiting the
YANMAR Co., Ltd. website at:

http://www.yanmar.co.jp (The Japanese language page will be displayed.) For English language “click” on
“English Page.”)

• “Click” on “Network” in the website heading to view the “Yanmar Worldwide Network.”

• Choose and “Click” on the desired product group.

• “Click” on the Icon closest to your region.

• “Click” on the desired country or associate company to locate your nearest authorized YANMAR
industrial engine dealer or distributor.

• You may also contact YANMAR by clicking on “Inquiry” in the website heading and typing in you r 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 cov er parts affected b y or damaged b y an y reason othe r than def ectiv e ma terials 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

3TNV88F Service Manual

YANMAR Limited Warranty

YANMAR limited warranty - continued

YANMAR WARRANTIES

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 f or damages and othe r 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 , b ut n ot 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 hav e 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.

3TNV88F 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 Y ANMAR, are pleased to explain the emission control system warranty
on your industrial compression-ignition engine. In California, 2013 MY and subsequent model years off­road compression-ignition engines must be designed, built and equipped to meet the state’s stringent anti­smog standards. In all states, 1998 and later non-road compression-ignition engines must be designed,
built and equipped to meet the United States EPA emissions standards. YANMAR warrants the emission
control system on your engine for the periods of time listed below provided there has been no abuse,
neglect or improper maintenance of your engine.

Your emission control system may include parts such as the fuel injection system, Electronic Control Unit,
Exhaust Gas Recirculation (EGR) system and the air induction system. Also included may be hoses, belts ,
connectors and other emission-related assemblies.

Where a warrantable condition e xists , YANMAR will repair your non-road compression-ignition engine at n o
charge to you including diagnosis, parts and labor.

Manufacturer’s Warranty Period:

The model year 1998 or later certified and labeled non-road compression-ignition engines are warranted
for the periods listed below. If any emission-related part on your engine is found to be defective during the
applicable warranty period, the part will be replaced by YANMAR.

If your engine is

certified as

Variable speed or
constant speed

Constant speed 19  kW < 37 3,000 rpm or higher

Constant speed 19  kW < 37 Less than 3,000 rpm

Variable speed 19  kW < 37 Any speed

Variable speed or
constant speed

And its maximum

power is

kW < 19 Any speed

kW  37 Any speed

And its rated speed is Then its warranty period is

1,500 hours or two (2) years whichever comes first.
In the absence of a device to measure the hours of use,
the engine has a warranty period of two (2) years.

1,500 hours or two (2) years whichever comes first.
In the absence of a device to measure the hours of use,
the engine has a warranty period of two (2) years.

3,000 hours or five (5) years whichever comes first.
In the absence of a device to measure the hours of use, the
engine has a warranty period of five (5) years.

3,000 hours or five (5) years whichever comes first.
In the absence of a device to measure the hours of use,
the engine has a warranty period of five (5) years.

3,000 hours or five (5) years whichever comes first.
In the absence of a device to measure the hours of use,
the engine has a warranty period of five (5) years.

2-6

3TNV88F Service Manual

Emission System Warranty

Limited emission control system warranty - USA only - continued

YANMAR WARRANTIES

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 f or the warranty period. Warran ted parts scheduled for replacement as require d maintenan ce in
the operation manual are w arranted f or the period of time prior to the first scheduled replacement. An y 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 ma y not be used. The use of an y n on-exempted add-on or
modified parts shall be grounds for disallowing a warranty.

Warranted Parts:

This warranty covers engine components that are a part of the emission control system of the engine as
delivered by YANMAR to the original retail purchaser. Such components may include the following:

• Fuel injection system

• Electronic control system

• Cold start enrichment system

• Intake manifold

• Turbocharger systems

• Exhaust manifold

• EGR system

• Positive crankcase ventilation system

• Hoses, belts, connectors and assemblies associated with emission control systems
Since emissions-related parts may vary slightly between models, certain models may not contain all of

these parts and other models may contain the functional equivalents.

3TNV88F Service Manual

2-7

YANMAR WARRANTIES

Limited emission control system warranty - USA only - continued

Emission System Warranty

Exclusions:

Failures other than those arising from defects in material and/or workmanship are not covered by this
warranty. The warranty does not extend to the following: malfunctions caused by abuse, misuse, improper
adjustment, modification, alteration, tampering, disconnection, improper or inadequate maintenance or use
of non-recommended fuels and lubricating oils; accident-caused damage, and replacement of expendable
items made in connection with scheduled maintenance. YANMAR disclaims any responsibility for
incidental or consequential damages such as loss of time, inconvenience, loss of use of equipment/engine
or commercial loss.

Owner’s Warranty Responsibilities:

As the engine owner, you are responsible for the performance of the required maintenance listed in
your owner’s manual. YANMAR recommends that you retain all documentation, including receipts,

covering maintenance on your non-road compression-ignition engine, but YANMAR cannot deny warranty
solely for the lack of receipts, or for your failure to ensure the performance of all scheduled maintenance.

YANMAR may deny your warranty coverage of your non-road compression-ignition engine if a part has
failed due to abuse, neglect, improper maintenance or unapproved modifications.

Your engine is designed to operate on diesel fuel only. Use of any other fuel may result in your engine no
longer operating in compliance with applicable emissions requirements.

You are responsible for initiating the warranty process. You must present your engine to a YANMAR dealer
as soon as a problem exists. The warranty repairs should be completed by the dealer as expeditiously as
possible. If you have any questions regarding your warranty rights and responsibilities, or would like
information on the nearest YANMAR dealer or authorized service center, you should contact YANMAR
America Corporation.

Website: www.yanmar.com
E-mail: CS [e-mail]
Toll free telephone number: 1-800-872-2867, 1-855-416-7091

2-8

3TNV88F Service Manual

3TNV88F Service Manual

Safety Statements........................................................................... 3-3

Safety Precautions.......................................................................... 3-4

Section 3

SAFETY

Page

3TNV88F Service Manual

3-1

SAFETY

This Page Intentionally Left Blank

3-2

3TNV88F Service Manual

Safety Statements

DANGER

WARNING

CAUTION

NOTICE

SAFETY STATEMENTS

SAFETY

YANMAR is concerned for your safety and your
machine’s condition. Safety statements are one of
the primary ways to call your attention to the
potential hazards associated with YANMAR TNV
engine operation. Follow the precautions listed
throughout the manual before operation, during
operation and during periodic maintenance
procedures for your safety, the safety of others and
to protect the performance of your engine . Ke ep the
labels from becoming dirty or torn and replace
them if they are lost or damaged. Also, if you need
to replace a part that has a label attached to it,
make sure you order the new part and label at the
same time.

This safety alert symbol appears
with most safety statements. It
means attention, become alert,

A

your safety is in vo lved! Please read
and abide by the message that
follows the safety alert symbol.

DANGER indicates a hazardous situation
which, if not avoided, will result in death or
serious injury.

WARNING indicates a hazardous situation
which, if not avoided, could result in death or
serious injury.

CAUTION indicates a hazardous situation
which, if not avoided, could result in minor or
moderate injury.

NOTICE indicates a situation which can cause
damage to the machine, personal property and/or
the environment or cause the equipment to operate
improperly.

3TNV88F Service Manual

3-3

SAFETY

DANGER

DANGER

DANGER

SAFETY PRECAUTIONS

Scald Hazard!

• Never remove the radiator cap if
the engine is hot. Steam and hot
engine coolant will spurt out and
seriously burn you. Allow the
engine to cool down before you
attempt to remove the radiator
cap.

• Tighten the radiator cap securely after you
check the radiator. Steam can spurt out
during engine operation if the cap is loose.

• Always check the level of the engine coolant
by observing the reserve tank.

• Failure to comply will result in death or
serious injury.

Safety Precautions

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 pr otection. T he fuel system is und er
pressure and fuel could spray out when you
remove any fuel system component.

• Only use the key switch to start the engine.

Explosion Hazard!

• Keep the area around the battery
well-ventilated. While the engine
is running or the battery is
charging, hydrogen gas is
produced which can be easily
ignited.

• Keep sparks, open flame and any other form
of ignition away while the engine is running or
battery is charging.

• Never check the remaining battery charge by
shorting out the terminals. This will result in a
spark and may cause an explosion or fire. Use
a hydrometer to check the remaining battery
charge.

• If the electrolyte is frozen, slowly warm the
battery before you recharge it.

• Failure to comply will result in death or
serious injury.

• Never jump-start the engine. Sparks caused
by shorting the battery to the starter terminals
may cause a fire or explosion.

• If the unit has an electric fuel pump, when you
prime the fuel system, turn the key switch to
the ON position for 10 to 15 seconds to allow
the electric fuel pump to prime the system.

• If the unit has a mechanical fuel pump, when
you prime the fuel system, operate the fuel
priming lever of the mechanical fuel pump
several times until the fuel filter cup is filled
with fuel.

• Only fill the fuel tank with diesel fuel. Filling
the fuel tank with gasoline may result in a fire
and will damage the engine.

• Never refuel with the engine running.

• Keep sparks, open flames or any other form of
ignition (match, cigarette, static electric
source) well away when refueling.

• Never overfill the fuel tank.

3-4

• Fill the fuel tank. Store any containers
containing fuel in a well-ventilated area, away
from any combustibles or sources of ignition.

3TNV88F Service Manual

Safety Precautions

DANGER

(Continued)

DANGER

WARNING

SAFETY

• Be sure to place the diesel fuel container on
the ground when transferring the diesel fuel
from the pump to the container. Hold the hose
nozzle firmly against the side of the container
while filling it. This prevents static electricity
buildup which could cause sparks and ignite
fuel vapors.

• Never place diesel fuel or other flammable
material such as oil, hay or dried grass close
to the engine during engine operation or
shortly after shutdown.

• Before you operate the engine, check for fuel
leaks. Replace rubberized fuel hoses every
two years or every 2000 hours of engine
operation, whichever comes first, even if the
engine has been out of service. Rubberized
fuel lines tend to dry out and become brittle
after two years or 2000 hours of engine
operation, whichever comes first.

• Never remove the fuel cap with the engine
running.

• Never use diesel fuel as a cleaning agent.

• Place an approved container under the air
bleed port when you prime the fuel system.
Never use a shop rag to catch the fuel. Wipe
up any spills immediately. Always close the
air bleed port after you complete priming the
system.

Crush Hazard!

• When you need to transport an
engine for repair, have a helper
assist you to attach it to a hoist
and load it on a truck.

• Never stand under a hoisted engine. If the
hoist mechanism fails, the engine will fall on
you, causing death or serious injury.

• Failure to comply will result in death or
serious injury.

Sever Hazard!

• Keep hands and other body parts
away from moving/rotating parts
such as the cooling fan, flywheel
or PTO shaft.

• Wear tight-fitting clothing and keep your hair
short or tie it back while the engine is
running.

• Remove all jewelry before you operate or
service the machine.

• Never start the engine in gear. Sudden
movement of the engine and/or machine
could cause death or serious personal injury.

• Wear eye pr otection. The fuel system is under
pressure and fuel could spray out when you
open the air bleed port.

• If the unit has an electric fuel pump, turn the
key switch to the ON position for 10 to 15
seconds, or until the fuel coming out of the air
bleed port is free of bubbles, to allow the
electric fuel pump to prime the system.

• If the unit has a mechanical fuel pump,
operate the fuel priming pump several times
until the fuel coming out of the air bleed port
is free of bubbles.

• Failure to comply will result in death or
serious injury.

• Never operate the engine without the guards
in place.

• Before you start the engine make sure tha t 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.

3TNV88F Service Manual

3-5

SAFETY

WARNING

WARNING

WARNING

WARNING

Safety Precautions

Exhaust Hazard!

• Never operate the engine in an
enclosed area such as a garage,
tunnel, underground room,
manhole or ship’s hold without
proper ventilation.

• Never block windows, vents, or other means
of ventilation if the engine is operating in an
enclosed area. All internal combustion
engines create carbon monoxide gas during
operation. Accumulation of this gas within an
enclosure could cause illness or even death.

• Make sure that all connections are tightened
to specifications after repair is made to the
exhaust system.

• Failure to comply could result in death or
serious injury.

Alcohol and Drug Hazard!

• Never operate the engine while
you are under the influence of
alcohol or drugs.

• Never operate the engine when you are
feeling ill.

• Failure to comply could result in death or
serious injury.

Exposure Hazard!

• Wear personal protective
equipment such as gloves, work
shoes, eye and hearing protection
as required by the task at hand.

• Never wear jewelry, unbuttoned cuffs, ties or
loose-fitting clothing when you are working
near moving/rotating parts such as the
cooling fan, flywheel or PTO shaft.

• Always tie back long hair when you are
working near moving/rotating parts such as a
cooling fan, flywheel, or PTO shaft.

• Never operate the engine while wearing a
headset to listen to music or radio because it
will be difficult to hear the alert signals.

• Failure to comply could result in death or
serious injury.

Burn Hazard!

• If you must drain the engine oil
while it is still hot, stay clear of
the hot engine oil to avoid being
burned.

• Always wear eye protection.

• Wait until the engine cools before you drain
the engine coolant. Hot engine coolant may
splash and burn you.

3-6

• 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.

3TNV88F Service Manual

Safety Precautions

WARNING

WARNING

WARNING

WARNING

WARNING

SAFETY

Burn Hazard!

• Batteries contain sulfuric acid.
Never allow battery fluid to come
in contact with clothing, skin or
eyes. Severe burns could result.
Always wear safety goggles and
protective clothing when
servicing the battery. If battery
fluid contacts the eyes and/or
skin, immediately flush the
affected area with a large amount
of clean water and obtain prompt
medical treatment.

• Failure to comply could result in death or
serious injury.

High-Pressure Hazard!

• Avoid skin contact with the
high-pressure diesel fuel spray
caused by a fuel system leak such
as a broken fuel injection line.
High-pressure fuel can penetrate
your skin and result in serious
injury. If you are exposed to high­pressure fuel spray, obtain
prompt medical treatment.

• Never check for a fuel leak with your hands.
Always use a piece of wood or cardboard.
Have your authorized YANMAR industrial
engine dealer or distributor repair the
damage.

• Failure to comply could result in death or
serious injury.

Shock Hazard!

• Turn off the battery switch (if
equipped) or disconnect the
negative battery cable before
servicing the electrical system.

• Check the electrical harnesses for cracks,
abrasions, and damaged or corroded
connectors. Always keep the connectors and
terminals clean.

• Failure to comply could result in death or
serious injury.

Entanglement Hazard!

• Stop the engine before you begin
to service it.

• Never leave the key in the key switch when
you are servicing the engine. Someone may
accidentally start the engine and not realize
you are servicing it. This could result in a
serious injury.

• If you must service the engine while it is
operating, remove all jewelry, tie back long
hair, and keep your hands, other body parts
and clothing away fr om moving/rotating parts.

• Failure to comply could result in death or
serious injury.

Sudden Movement Hazard!

3TNV88F Service Manual

• Engaging the transmission or PTO at an
elevated engine speed could result in
unexpected movement of the equipment.

• Failure to comply could result in death or
serious injury.

3-7

SAFETY

WARNING

WARNING

WARNING

WARNING

WARNING

WARNING

WARNING

WARNING

Safety Precautions

To prevent possible eye injury,
always wear safety glasses while
servicing the engine.

Fume/Burn Hazard!

• Always read and
follow safety related
precautions found on
containers of
hazardous substances
like parts cleaners,
primers, sealants and
sealant removers.

• Failure to comply could result in death or
serious injury.

Never apply over 40 PSI (2.8 kgf/cm) to the
waste gate actuator.

• Be sure to use the E-ECU in conjunction with
the engines whose models or serial numbers
are specified by YANMAR.
Other E-ECU/engine combinations than
specified will void the engine warranty.

• Improper use or misuse of the E-ECU may
result in death or serious injury due to an
abrupt and unexpected increase in engine
speed.

• Replacing the fuel injection pump involves
rewriting the fuel injection data in the E-ECU.
Be sure to contact your local YANMAR dealer
before replacing the fuel injection pump.
Failure to rewrite the fuel injection data bef ore
replacing the fuel injection pump will void the
engine warranty.

• Improper use or misuse of the E-ECU may
result in death or serious injury due to an
abrupt and unexpected increase in engine
speed.

• Never inject fuel toward you. Since the fuel is
injected at high pressure from the nozzle, it
may penetrate the skin, resulting in injury.

• Never inject fuel toward a fire source.
Atomized fuel is highly flammable and may
cause a fire or burn skin.

• Never use the E-ECU for other purposes than
intended or in other ways than specified by
YANMAR. Doing so could result in the
violation of emission control regulations and
will void the product warranty.

• 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.

• Replacing the E-ECU involves migrating the
fuel injection data to the existing E-ECU to the
new unit.
Be sure to contact your local YANMAR dealer
before replacing the E-ECU.
Failure to migrate the fuel injection data
before replacing the E-ECU will void the
engine warranty.

• Improper use or misuse of the E-ECU may
result in death or serious injury due to an
abrupt and unexpected increase in engine
speed.

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Safety Precautions

CAUTION

CAUTION

CAUTION

CAUTION

CAUTION

CAUTION

NOTICE

NOTICE

NOTICE

NOTICE

SAFETY

Coolant Hazard!

• Wear eye protection
and rubber gloves
when you handle long
life or extended life
engine coolant. If
contact with the eyes
or skin should occur,
flush eyes and wash
immediately with
clean water.

• Failure to comply may result in minor or
moderate injury.

Flying Object Hazard!

• Always wear eye protection when
servicing the engine and when
using compressed air or high­pressure water. Dust, flying
debris, compressed air,
pressurized water or steam may
injure your eyes.

• Failure to comply may result in minor or
moderate injury.

If any oil pump component clearance exceeds
its limit, the oil pump must be replaced as an
assembly.

To refuel the engine oil, refuel slowly after
removing the dipstick and both caps. If you
refuel rapidly, the oil intrusion to the intake
occurs through the PCV valve of the valve
cover. It will result in an oil hammer at engine
start, which may cause damage to the engine.

• 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.

Be sure to secure the engine solidly to prevent
injury or damage to parts due to the engine
falling during work on the engine.

Pinch Hazard!

Carefully rotate the alternator
toward the cylinder block while
loosening the V-belt. Failure to
comply may result in minor or
moderate injury.

Never attempt to adjust the low or high idle speed
limit screw. This may impair the safety and
performance of the machine and shorten its life. If
adjustment is ever required, contact your
authorized YANMAR industrial engine dealer or
distributor.

If any problem is noted during the visual check, the
necessary corrective action should be taken before
you operate the engine.

Never ho ld the k ey in the START position f or longer
than 15 seconds or the starter motor will overheat.

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SAFETY

NOTICE

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NOTICE

NOTICE

NOTICE

Safety Precautions

Make sure the engine is installed on a le v el surface .
If a continuously running engine is installed at an
angle greater than (IDI = 25°, DI = 30°) in any
direction or if an engine runs for short periods of
time (less than three minutes) at an angle greater
than (IDI = 30°, DI = 35°) in any direction, engine oil
may enter the combustion chamber causing
excessive engine speed and white exhaust smoke.
This may cause serious engine damage.

Observe the following environmental operating
conditions to maintain engine performance and
avoid premature engine w ea r:

• Avoid operating in extremely dusty conditions.

• Avoid operating in the presence of chemical
gases or fumes.

• Avoid operating in a corrosive atmosphere such
as salt water spray.

• Never install the engine in a floodplain unless
proper precautions are taken to avoid being
subject to a flood.

• Never expose the engine to the rain.

Observe the following environmental operating
conditions to maintain engine performance and
avoid premature engine w ea r:

• The standard range of ambient temperatures for
the normal operation of YANMAR engines is from
+5 °F (-15 °C) to +113 °F (+45 °C).

• If the ambient temperature exceeds +113 °F (+45
°C) the engine may overheat and cause the
engine oil to break down.

• If the ambient temperature is below +5 °F (-15 °C)
the engine will be hard to start and the engine oil
may not flow easily.

• Contact your authorized YANMAR industrial
engine dealer or distributor if the engine will be
operated outside of this standard temperature
range.

The illustrations and descriptions of optional
equipment in this manual, such as the operator’s
console, are for a typical engine installation. Refer
to the documentation supplied by the optional
equipment manufacturer for specific operation and
maintenance instructions.

If any indicator illuminates during engine operation,
stop the engine immediately. Determine the cause
and repair the problem before you continue to
operate the engine.

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Safety Precautions

NOTICE

NOTICE

NOTICE

NOTICE

NOTICE

NOTICE

NOTICE

SAFETY

• Only use the engine oil specified. Other engine
oils may affect warranty coverage, cause internal
engine components to seize and/or shorten
engine life.

• Prevent dirt and debris from contaminating the
engine oil. Carefully clean the oil cap/dipstick and
the surrounding area before you remove the cap.

• Never mix different types of engine oil. This may
adversely affect the lubricating properties of the
engine oil.

• Never overfill. Overfilling may result in white
exhaust smoke, engine overspeed or internal
damage.

• Only use the engine coolant specified. Other
engine coolants may affect warranty coverage,
cause an internal buildup of rust and scale and/or
shorten engine life.

• Prevent dirt and debris from contaminating the
engine coolant. Carefully clean the radiator cap
and the surrounding area before you remove the
cap.

• Never mix diff eren t types of engine coolants . This
may adversely affect the properties of the engine
coolant.

For maximum engine life, YANMAR recommends
that when shutting the engine down, you allow the
engine to idle, without load, for five minutes. This
will allow the engine components that operate at
high temperatures, such as the turbocharger (if
equipped) and exhaust system, to cool slightly
before the engine itself is shut down.

Never use an engine starting aid such as ether.
Engine damage will result.

• Always be environmentally
responsible.

• Follow the guidelines of the EPA or other
governmental agencies for the prope r dispo sal 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.

• Never overfill the engine with engine oil.

• Always keep the oil level between the upper and
lower lines on the oil cap/dipstick.

Never engage the starter motor while the engine is
running. This may damage the starter motor pinion
and/or ring gear.

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SAFETY

NOTICE

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NOTICE

NOTICE

NOTICE

NOTICE

NOTICE

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Safety Precautions

New engine break-in:

• On the initial engine start-up, allow the engine to
idle for appro ximately 15 minutes while y ou chec k
for proper engine oil pressure, diesel fuel leaks,
engine oil leaks, coolant leaks, and for proper
operation of the indicators and/or gauges.

• During the first hour of operation, vary the engine
speed and the load on the engine. Short periods
of maximum engine speed and load are
desirable. Avoid prolonged operation at minimum
or maximum engine speeds and loads for the
next four to five hours.

• During the break-in period, carefully observe the
engine oil pressure and engine temperature.

• During the break-in period, check the engine oil
and coolant levels frequently.

• Never attempt to modify the engine’s design or
safety features such as defeating the engine
speed limit control or the fuel injection quantity
control.

Never attempt to adjust the low or high idle speed
limit screw. This may impair the safety and
performance of the machine and shorten its life. If
the idle speed limit screws require adjustment, see
your authorized YANMAR industrial engine dealer
or distributor.

The tightening torque in the Standard Torque Chart
(see General Service Information section) should
be applied only to the bolts with a “7” head. (JIS
strength classification: 7T)

• Apply 60 % torque to bolts that are
not listed.

• Apply 80 % torque when tightened to
aluminum alloy.

If any indicator fails to illuminate when the key
switch is in the ON position, see your authorized
YANMAR industrial engine dealer or distributor for
service before operating the engine.

• 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.

Protect the air cleaner, turbocharger (if equipped)
and electric components from damage when you
use steam or high-pressure water to clean the
engine.

Never use high-pressure water or compressed air
at greater than 28 PSI (193 kPa ; 19686 mmAq) or a
wire brush to clean the radiator fins. Radiator fins
damage easily.

Establish a periodic maintenance plan according to
the engine application and make sure you perform
the required periodic maintenance at the intervals
indicated. Failure to follow these guidelines will
impair the engine’s safety and performance
characteristics, shorten the engine’s life and may
affect the warranty coverage on your engine.

See YANMAR Limited Warranty in Warranty
Section.

Consult your authorized YANMAR dealer or
distributor for assistance when checking items
marked with a

.

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Safety Precautions

NOTICE

NOTICE

NOTICE

NOTICE

NOTICE

NOTICE

NOTICE

NOTICE

NOTICE

NOTICE

NOTICE

NOTICE

NOTICE

SAFETY

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 separ ator 2 ­3 turns counterclockwise.

Be sure to tighten the air vent screw a fter the w ater
has drained out.

• 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.

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.

Do not loosen or remove the f our bolts retaining the
fuel injection pump drive gear to the fuel injection
pump hub. Do not disassemble the fuel injection
pump drive gear from the hub . Correct fuel injection
timing will be very difficult or impossible to achieve.

The starter motor can be damaged if operated
continuously longer than 10 seconds while
performing the no-load test.

Do not short-circuit the charging system between
alternator terminals IG and L. Damage to the
alternator will result.

Do not connect a load between alternator terminals
L and E. Damage to the alternator will result.

Do not remove the positive (+) battery cable from
alternator terminal B while the engine is operating.

Damage to the alternator will result.
It is important to perform daily checks.
Periodic maintenance prevents unexpected

downtime, reduces the number of accidents due to
poor machine performance and helps extend the
life of the engine.

If the oil pump must be replaced, replace it as an
assembly only. Do not replace individual
components.

Do not turn the battery switch OFF while the engine

is operating. Damage to the alternator will result.

Do not operate the engine if the alternator is

producing unusual sounds. Damage to the

alternator will result.

If the engine coolant pump must be replaced,

replace the engine coolant pump as an assembly

only. Do not attempt to repair the engine coolant

pump or replace individual components.

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SAFETY

NOTICE

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NOTICE

NOTICE

NOTICE

NOTICE

NOTICE

NOTICE

NOTICE

NOTICE

NOTICE

NOTICE

Safety Precautions

Use a new special O-ring between the engine
coolant pump and the joint. Be sure to use the
special O-ring for each engine model. Although the
O-ring dimensions are the same as a commercially
available O-ring, the material is different.

Remove or install the high-pressure fuel injection
lines as an assembly whenever possible.
Disassembling the high-pressure fuel injection lines
from the retainers or bending any of the fuel lines
will make it difficult to reinstall the fuel lines.

After marking the position of the pump drive gear,
do not rotate the engine crankshaft. Rotating the
crankshaft will cause the fuel injection pump to
become misaligned.

Do not use a high-pressure wash directly on the
alternator. Water will damage the alternator and
result in inadequate charging.

Do not reverse the positive (+) and negative (-)
ends of the battery cable. The alternator diode and
stator coil will be damaged.

Agricultural or other chemicals, especially those
with a high sulfur content, can adhere to the IC
regulator. This will corrode the co nductor and result
in battery over-charging (boiling) and charging
malfunctions. Consult YANMAR before using the
equipment in such an environment or the warranty
is voided.

Make sure that the combined total resistance of the
battery cable in both directions between the starter
motor and the battery is within the value indicated
on the wiring diagram. The starter motor will
malfunction or break down if the resistance is
higher than the specified value.

The starter motor is water-proofed according to JIS
D 0203, R2 which protects the motor from rain or
general cleaning. Do not use high-pressure wash
or submerse the starter motor in water.

Use a specialized battery charger to recharge a
battery with a voltage of 8 volts or less. Booster
starting a batter y with a voltage of 8 volts or less
will generate an abnormally high voltage and
destroy electrical equipment.

When the battery indicator goes out, it should not
come on again. The battery indicator only comes
on during operation if the alternator fails. However,
if an LED is used in the battery indicator, the LED
will shine faintly during normal operation.

Using a non-specified V-belt will cause inadequate
charging and shorten the belt life. Use the specified
belt.

Make sure that the combined total resistance of the
battery cable in both directions between the starter
motor and the battery is within the value indicated
in the Battery Cable Resistance chart in the Electric
Wiring Section of this manual. The starter motor will
malfunction and fail if the resistance is higher than
the specified value.

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Safety Precautions

NOTICE

NOTICE

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NOTICE

NOTICE

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NOTICE

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NOTICE

NOTICE

SAFETY

Removing the battery cables or the battery while
the engine is operating may cause damage to the
current limiter depending on the electrical
equipment being used. This situation could cause
loss of control of output voltage. The continuous
high voltage of 23 - 24 volts (for 5000 min
dynamo) will damage the current limiter and other
electrical equipment.

Reversing the battery cable connections at the
battery or on the engine will destroy the SCR diode
in the current limiter. This will cause the charging
system to malfunction and may cause damage to
the electrical harnesses.

Avoid damage to the turbocharger or the engine.
Do not spray blower wash fluid or water too quickly.

Use short strokes from a spray bottle to inject
blower wash fluid or water into the turbocharger.

Spraying too much wash fluid or water, or spraying
too quickly will damage the turbocharger.

-1

(rpm)

• Never attempt to modify the engine’s design or
safety features such as defeating the engine
speed limit control or the diesel fuel injection
quantity control.

• Modifications may impair the engine’s safety and
performance characteristics and shorten the
engine’s life. Any alterations to this engine may
void its warranty. Be sure to use YANMAR
genuine replacement parts.

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.

Each pressure adjusting shim removed or added
changes the pressure threshold by approximately
275 PSI (1.9 MPa, 19 kgf/cm
shims increases the threshold pressure. Removing
adjusting shims reduces the pressure threshold.

2

). Adding adjusting

Do not allow any material to fall into the oil lines or
the oil inlet and outlet ports of the turbocharger.

If the waste valve does not meet specifications,
replace the turbocharger or have it repaired by a
qualified repair facility.

Do not rotate the crankshaft with the injection pump
removed.

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.

Do not allow the honing tool to operate in one
position for any length of time. Damage to the
cylinder wall will occur. Keep the tool in constant
up-and-down motion.

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SAFETY

NOTICE

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Safety Precautions

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.

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.

• Never remove or attempt to remove the tamper­proof devices from the full-load fuel adjusting
screw or the high-speed throttle limit scre w on the
fuel injection pump and governor assembly.
These adjustments have been made at the
factory to meet all applicable emissions
regulations and then sealed.

• Never attempt to make any adjustments to these
sealed adjustment screws. If adjustments are
required, they can be made only by a qualified
fuel injection shop that will ensure the injection
pump continues to meet all applicable emissions
regulations and then replace the tamper-proof
seals.

Shut down the engine if the fault indicator comes
on.

Continuing running the engine with the fault
indicator being on may result in a serious
malfunction of or damage to the engine, and will
void the engine warranty.

Do not energize the starter for a period of longer
than 15 seconds.

Take a pause of at least 30 seconds between
energization of the starter.

Otherwise the starter could suffer damage.

• High-pressure washing not recommended.

• Avoid using high-pressure washing for electronic
or electric devices installed in, on or around the
engine, including the E-ECU, relays and harness
couplers.

Otherwise such devices ma y suffer malf unction due
to water ingress into them.

• Tampering with or removing these devices may
void the “YANMAR Limited Warranty.”

Never use a steel wire brush to clean fuel injectors .
Damage to the nozzle and other components is
likely to result.

Allow the engine to warm-up for at least five
minutes and the idle speed of the engine to return
to normal before engaging the transmission or any
PTOs. Engaging the transmission or PTO at an
elevated engine speed could result in an
unexpected movement of the equipment.

Always check the battery for proper charge.
Otherwise the electronically controlled engines ma y

fail to start.

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3TNV88F Service Manual