2TNV70
Table of contents
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TNV
OPERATION MANUAL
2TNV70
3TNV70 • 3TNV76
3TNV82A
3TNV84 • 3TNV84T • 3TNV88
4TNV84 • 4TNV84T • 4TNV88
4TNV94L
4TNV98 • 4TNV98T
4TNV106 • 4TNV106T
TNV Operation Manual
P/N: 0ATNV0-U0200
series
INDUSTRIAL
ENGINES
Disclaimers:
We reserve the right to change specifications and to improve our products without notice or obligation.
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 Operation Manual
This Manual is Available in other Languages
If you would like a copy of this manual in the English language, please contact your local authorized Yanmar industrial engine dealer or distributor. A list
of authorized Yanmar industrial engine dealers and distributors can be found at:
http://www.yanmar.co.jp/english/index-network.htm
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http://www.yanmar.co.jp/english/index-network.htm
EN
AR
ᴀݠᦤկ݊Ҫ䇁㿔⠜ᴀ
བᵰᙼ䳔㽕ᴀݠⱘЁ᭛⠜ᴀˈ䇋Ϣᔧഄ Yanmar˄⋟偀˅ᎹϮᓩ᪢ᥜᴗ㒣䫔ଚߚ䫔ଚ㘨㋏DŽৃҢҹϟ㔥ഔᡒࠄ
Yanmar˄⋟偀˅ᎹϮᓩ᪢ᥜᴗ㒣䫔ଚߚ䫔ଚৡ˖
http://www.yanmar.co.jp/english/index-network.htm
Tento návod je k dispozici i v dalších jazycích
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http://www.yanmar.co.jp/english/index-network.htm
Denne håndbog kan fås på andre sprog
Hvis du gerne vil have et eksemplar af denne håndbog på dansk, bedes du venligst kontakte den lokale autoriserede forhandler eller importør af
Yanmar industrimotorer. En liste over autoriserede forhandlere og importører af Yanmar industrimotorer kan fi ndes på:
http://www.yanmar.co.jp/english/index-network.htm
Deze handleiding is beschikbaar in andere talen
Wilt u een exemplaar van deze handleiding in het Nederlands hebben, neemt u dan contact op met de dichtstbijzijnde offi ciële dealer of distributeur van
industriemotoren van Yanmar. Kijk voor een lijst met offi ciële dealers of distributeurs van industriemotoren van Yanmar op:
http://www.yanmar.co.jp/english/index-network.htm
Ce manuel est disponible dans d'autres langues
Si vous désirez une copie de ce manuel en français, veuillez contacter votre concessionnaire ou distributeur agréé de moteurs industriels Yanmar.
Vous trouverez la liste des concessionnaires et distributeurs agréés de moteurs industriels Yanmar à l’adresse suivante:
http://www.yanmar.co.jp/english/index-network.htm
ZH
CS
DA
NL
FR
Tätä ohjekirjaa on saatavana muilla kielillä
Jos haluat kappaleen tätä ohjekirjaa suomen kielellä, ota yhteys paikalliseen Yanmarin valtuuttamaan teollisuusmoottorien myynti- tai jakeluliikkeeseen.
Luettelon valtuutetuista Yanmarin teollisuusmoottorien myynti- ja jakeluliikkeistä löydät osoitteesta:
http://www.yanmar.co.jp/english/index-network.htm
Dieses Handbuch steht in anderen Sprachen zur Verfügung
Falls Sie gerne ein Exemplar dieses Handbuchs auf Deutsch hätten, wenden Sie sich bitte an Ihren autorisierten Fach- oder Vertriebshändler für
Yanmar-Industriemotoren. Eine Liste autorisierter Fach- oder Vertriebshändler für Yanmar-Industriemotoren fi nden Sie unter:
http://www.yanmar.co.jp/english/index-network.htm
Το παρόν εγχειρίδιο διατίθεται και σε άλλες γλώσσες
Για την ελληνική έκδοση του εγχειριδίου, παρακαλούμε επικοινωνήστε με τον τοπικό εξουσιοδοτημένο αντιπρόσωπο ή διανομέα των βιο
Yanmar. Επισκεφθείτε την παρακάτω διεύθυνση για να ενημερωθείτε για τους εξουσιοδοτημένους αντιπροσώπους ή διανομείς των βιομηχανικών κινητήρων
Yanmar:
http://www.yanmar.co.jp/english/index-network.htm
A kézikönyv más nyelven is hozzáférhető
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http://www.yanmar.co.jp/english/index-network.htm
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μηχανικών κινητήρων
FI
DE
EL
HU
TNV Operation Manual
iii
Il presente manuale è disponibile in altre lingue
Se si desidera ricevere una copia di questo manuale in italiano, si prega di rivolgersi al concessionario o distributore autorizzato di motori industriali
Yanmar di zona. L'elenco dei concessionari e distributori autorizzati di motori industriali Yanmar è disponibile al seguente indirizzo:
http://www.yanmar.co.jp/english/index-network.htm
IT
ᧄขᛒ⺑ᦠߪฦ⒳⸒⺆ ࠍߏ↪ߚߛߌ߹ߔޕ
ᣣᧄ⺆ ߩขᛒ⺑ᦠࠍߏᏗᦸߩ߅ቴ᭽ߪޔᦨነࠅߩࡗࡦࡑ↥ᬺ↪ࠛࡦࠫࡦߩᱜⷙ⽼ᄁᐫ߹ߚߪઍℂᐫߦ߅วࠊߖߊߛߐޕࡗࡦࡑ↥ᬺ↪ࠛ
ࡦࠫࡦߩ⽼ᄁࠨࡆࠬࡀ࠶࠻ࡢࠢߦߟߡߪޔએߩࠨࠗ࠻ࠍߏⷩߊߛߐޕ
http://www.yanmar.co.jp/english/index-network.htm
Denne håndboken kan fås på andre språk
Snakk med din Yanmar-forhandler hvis du vil ha denne håndboken på norsk. Du fi nner en liste over autoriserte forhandlere av Yanmar industrimotorer
på:
http://www.yanmar.co.jp/english/index-network.htm
Ten podręcznik jest dostępny w innych językach
-HľHOLSRWU]HEQ\MHVWWHQSRGUÛF]QLNZMÛ]\NXSROVNLPSURV]ÛVNRQWDNWRZDÉVLÛ]DXWRU\]RZDQ\PPLHMVFRZ\PGHDOHUHPOXEG\VWU\EXWRUHP
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VWURQLH
http://www.yanmar.co.jp/english/index-network.htm
Este Manual está Disponível noutros Idiomas
Se desejar uma cópia deste manual em Português, por favor contacte o seu concessionário ou distribuidor autorizado de motores industriais Yanmar.
É possível encontrar uma lista de concessionários e distribuidores autorizados de motores industriais Yanmar em:
http://www.yanmar.co.jp/english/index-network.htm
Настоящая инструкция по эксплуатации доступна и на других языках
За экземпляром настоящей инструкции по эксплуатации на русском языке, пожалуйста обращайтесь к местному официальному дилеру или дистрибьютору
промышленных двигателей Yanmar. Полный список официальных дилеров и дистрибьюторов промышленных двигателей Yanmar находится на сайте:
http://www.yanmar.co.jp/english/index-network.htm
JA
NO
PL
PT
RU
Táto príručka je k disozícii aj v iných jazykoch.
$NE\VWHFKFHOLNµSLXWHMWRSU¯XªN\Y6ORYHQVNRPMD]\NXNRQWDNWXMWHSURV¯PVYRMKRPLHVWQHKRDXWRUL]RYDQ«KRSUHGDMFXDOHERGLVWULE¼WRUD
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http://www.yanmar.co.jp/english/index-network.htm
Este manual está disponible en otros idiomas
Si usted desea un ejemplar de este manual en español, por favor póngase en contacto con su concesionario o distribuidor local autorizado de motores
industriales Yanmar. Puede encontrar una lista de los concesionarios y distribuidores autorizados de motores industriales Yanmar en:
http://www.yanmar.co.jp/english/index-network.htm
Denna handbok fi nns även på andra språk
Om du vill få ett exemplar av denna handbok på svenska, vänligen kontakta närmaste behöriga återförsäljare eller distributör för Yanmar
industrimotorer. En förteckning över godkända återförsäljare och distributörer för Yanmar industrimotorer fi nns på:
http://www.yanmar.co.jp/english/index-network.htm
Bu El Kitabi Başka Dillerdede Mevcuttur
Bu el kitapciğinin Türkçe’sini elde etmek istiyorsaniz, lütfen bölgenizdeki Yanmar sanayí makinelerí yetkili bayii dağitmcisina başvurunuz. Yetkili Yanmar
sanayí motor bayii ve dağitimcilari listesini aşağidaki Internet sayfasinda bulabilirsiniz.
http://www.yanmar.co.jp/english/index-network.htm
SK
ES
SV
TR
iv
TNV Operation Manual
YANMAR
WARRANTIES
TNV Operation Manual
YANMAR LIMITED WARRANTY
What is Covered by this Warranty?
Yanmar warrants to the original retail purchaser that your new Yanmar TNV Series Industrial Engine will
be free from defects in material and / or workmanship for the duration of the warranty period.
How Long is the Warranty Period?
The Yanmar standard limited warranty period begins on the date of the delivery of the new Yanmar TNV
Series Industrial Engine to the first retail purchaser and extends for a period of twenty-four (24) months
or two-thousand (2000) engine operation hours, whichever occurs first. An extended warranty is
provided for these specific parts: The cylinder block, cylinder head, crankshaft, connecting rods,
flywheel, flywheel housing, camshaft, timing gear, and gear case. These listed parts are warranted for a
period, also beginning with the date of the delivery of the new Yanmar engine to the first retail purchaser,
of thirty-six (36) months or three-thousand (3000) engine operation hours whichever occurs 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. You are
responsible for the transportation of the engine to and from the repair location as designated by Yanmar.
Yanmar strongly recommends you register your engine as soon as possible after purchase in order to
facilitate any future warranty matters.
TNV Operation Manual
v
YANMAR WARRANTIES
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
• Click on “Network” to view “Yanmar Worldwide Distribution Network.”
• Click on “Sales Network.”
• Click on the country. Click on “Go” to view the list of authorized Yanmar industrial engine dealers or
distributors.
• Select the authorized Yanmar industrial engine dealer or distributor nearest your location. Note: “Land”
denotes an industrial dealer or distributor.
• You may also contact Yanmar by clicking on “Inquiry” on the Yanmar Japan home page.
(The Japanese page will be displayed. For English, click on “English Page.”
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 necessary to correct any defects in materials and / or workmanship
discovered during the warranty period. Such repairs and / or replacements will be made at a location
designated by Yanmar.
What is Not Covered by this Warranty?
This Warranty does not cover parts affected by or damaged by, 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.
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.
vi
TNV Operation Manual
YANMAR WARRANTIES
Yanmar Limited Warranty - Continued
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.
Customer Registration
Customer registration is very important for the original retail purchaser to enable Yanmar to
provide the best support for your engine.
At the time of purchase, Yanmar highly recommends registering the customer’s information through
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 Operation Manual
vii
YANMAR WARRANTIES
YANMAR CO., LTD. LIMITED EMISSION CONTROL SYSTEM
WARRANTY - USA ONLY
Your Warranty Rights and Obligations:
California
The California Air Resources Board and Yanmar Co., Ltd. (“Yanmar”) is pleased to explain the emission
control system warranty on your off-road compression-ignition model year 2000 or later engine. In
California, new heavy-duty off-road engines must be designed, built and equipped to meet the State’s
stringent anti-smog standards.
All States
Yanmar warrants that the engine is: (1) designed, built and equipped so as to conform with all applicable
emissions regulations, including in California, all applicable regulations adopted by the Air Resources
Board; and (2) free from defects in materials and workmanship which cause such engine to fail to
conform with applicable emissions regulations for its warranty period.
Yanmar warrants the emission control system on your engine for the periods of time listed in the following
table 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 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 heavy-duty off-road engine at no charge to
you for diagnosis, parts or labor. Warranty services or repairs will be provided at an authorized Yanmar
industrial engine dealer or distributor.
Manufacturer’s Warranty Period:
The emission related parts on your model year 2000 or later heavy-duty off-road 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
Engines rated under 25.5 hp SAE (19 kW) Warranty period is two (2) years or 1,500 hours of use, whichever occurs first. In
the absence of a device to measure hours of use, the engine has a warranty
period of two (2) years.
Engines rated at or above 25.5 hp SAE (19
kW)
Constant speed engines rated under 50 hp
SAE (37 kW) with rated speeds greater than
or equal to 3,000 rpm
Constant speed engines rated at or above
50 hp SAE (37 kW)
Warranty period is five (5) years or 3,000 hours of use, whichever occurs first. In
the absence of a device to measure hours of use, the engine has a warranty
period of five (5) years.
Warranty period is two (2) years or 1,500 hours of use, whichever occurs first. In
the absence of a device to measure hours of use, the engine has a warranty
period of five (5) years.
Warranty period is five (5) years or 3,000 hours of use, whichever occurs first. In
the absence of a device to measure hours of use, the engine has a warranty
period of five (5) years.
viii
TNV Operation Manual
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 Systems / Parts Covered by this Warranty:
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
• Cold Start Enrichment System
• Intake Manifold
• Turbocharger Systems
• Exhaust Manifold
• Positive Crankshaft Ventilation (PCV) System
•PCV Valve
• Oil Filler Cap
TNV Operation Manual
ix
YANMAR WARRANTIES
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, improper storage, or
use of non-recommended fuels and lubricating
oils; accident-caused damage, and replacement
of expendable (and / or consumable) 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 heavy-duty off-road engine owner, you
are responsible for the performance of the
required maintenance listed in your Operation
Manual. Yanmar recommends that you retain all
documentation, including receipts, covering
maintenance on your heavy-duty off-road engine,
but Yanmar cannot deny warranty solely for the
lack of receipts, or for your failure to ensure the
performance of all scheduled maintenance.
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 off-road engine
to an authorized Yanmar industrial engine dealer
or distributor as soon as a problem exists. The
warranty repairs should be completed by the
dealer or distributor as expeditiously as possible.
If you have any questions regarding your
warranty rights and responsibilities, or would like
information on the nearest authorized Yanmar
industrial engine dealer or distributor, you should
contact Yanmar America Corp. at
1-800-872-2867.
x
TNV Operation Manual
INTRODUCTION
TNV Operation Manual
Welcome to the world of Yanmar Engines!
Yanmar has been the leader in industrial diesel
engines for over 90 years. We developed the
world’s first practical small-sized diesel engine in
1933. Our engineers are continuously developing
new technology to keep Yanmar on the leadingedge of the industry. The TNV engine is only one
example of the new technology we have
developed. We are committed to maintaining our
environment, and are proud of our history of
innovation, quality and respect for operator safety.
To help you enjoy your Yanmar TNV engine for
many years to come, please follow these
recommendations:
• Read and understand this Operation Manual
before you operate the machine to ensure that
you follow safe operating practices and
maintenance procedures.
• Keep this Operation Manual in a convenient
place for easy access.
• Constant efforts are made to improve the
quality and performance of Yanmar products, so
some details included in this Operation Manual
may differ slightly from your engine. If you have
any questions about these differences, please
contact your authorized Yanmar industrial
engine dealer or distributor.
• The specifications and components (instrument
panel, fuel tank, etc.) described in this manual
may differ from ones installed on your machine.
Please refer to the manual provided by the
manufacturer of these components.
• If this Operation Manual is lost or damaged,
order a new one from your authorized Yanmar
industrial engine dealer or distributor.
• Make sure this manual is transferred to
subsequent owners. This manual should be
considered a permanent part of the engine and
remain with it.
TNV Operation Manual
1
INTRODUCTION
RECORD OF OWNERSHIP
Take a few moments to record the information you need when you contact Yanmar for service, parts or
literature.
Engine Model: _____________________________________________________________________
Engine Serial No.: __________________________________________________________________
Date Purchased: ___________________________________________________________________
Dealer:____________________________________________________________________________
Dealer Phone:______________________________________________________________________
Symbol Explanation
The following symbols are used throughout this manual to identify specific engine model information.
This symbol indicates information pertaining to the following indirect injection engines:
•2TNV70
•3TNV70
•3TNV76
This symbol indicates information pertaining to the following direct injection engines:
•3TNV82A
•3TNV84
•3TNV84T
•3TNV88
•4TNV84
•4TNV84T
•4TNV88
•4TNV94L
•4TNV98
•4TNV98T
•4TNV106
•4TNV106T
2
TNV Operation Manual
TABLE OF
CONTENTS
TNV Operation Manual
Introduction ................................................................................................ 1
Record of Ownership.............................................................................. 2
Yanmar Warranties .................................................................................... v
Yanmar Limited Warranty....................................................................... v
What is Covered by this Warranty?.................................................. v
How Long is the Warranty Period?................................................... v
What the Engine Owner Must Do:.................................................... v
To Locate an Authorized Yanmar Industrial Engine
Dealer or Distributor: ....................................................................... vi
What Yanmar Will Do: ..................................................................... vi
What is Not Covered by this Warranty? .......................................... vi
Warranty Limitations:....................................................................... vi
Warranty Modifications:.................................................................. vii
Questions: ...................................................................................... vii
Customer Registration.................................................................... vii
Yanmar Co., Ltd. Limited Emission Control
System Warranty - USA Only.............................................................. viii
Your Warranty Rights and Obligations: ......................................... viii
Manufacturer’s Warranty Period:................................................... viii
Warranty Coverage: ........................................................................ ix
Warranted Systems / Parts Covered by this Warranty:................... ix
Exclusions: ....................................................................................... x
Owner’s Warranty Responsibilities:.................................................. x
Page
Table of Contents....................................................................................... 3
Safety .......................................................................................................... 1
Safety Statements.................................................................................. 1
Safety Precautions ................................................................................. 2
Before You Operate ......................................................................... 2
TNV Operation Manual
3
TABLE OF CONTENTS
During Operation and Maintenance ................................................. 2
Product Overview..................................................................................... 15
Yanmar TNV Engine Features and Applications.................................. 15
Component Identification ..................................................................... 16
Location of Labels ................................................................................ 18
EPA / ARB Emission Control Regulations - USA Only ........................ 19
Emission Control Labels ...................................................................... 19
EPA / ARB Labels .......................................................................... 19
The 97/68/EC Directive Certified Engines............................................ 20
Engine Family ...................................................................................... 20
Function of Major Engine Components................................................ 21
Function of Cooling System Components............................................ 23
Gauges and Indicators ......................................................................... 24
Gauges........................................................................................... 24
Indicators........................................................................................ 25
Controls................................................................................................ 26
Key Switch...................................................................................... 26
Inlet Air Heater ............................................................................... 27
Glow Plugs ..................................................................................... 27
Governor Lever .............................................................................. 28
Engine Stop Solenoid..................................................................... 28
Before You Operate ................................................................................. 29
Diesel Fuel ........................................................................................... 33
Diesel Fuel Specifications .............................................................. 33
Filling The Fuel Tank...................................................................... 34
Priming The Fuel System ............................................................... 36
Engine Oil............................................................................................. 38
Engine Oil Specifications................................................................ 38
Engine Oil Viscosity........................................................................ 38
Checking Engine Oil....................................................................... 38
Adding Engine Oil........................................................................... 39
Engine Oil Capacity (Typical) ......................................................... 39
Engine Coolant..................................................................................... 40
Engine Coolant Specifications........................................................ 41
Filling Radiator With Engine Coolant.............................................. 42
Daily Check of the Cooling System ................................................ 43
Engine Coolant Capacity (Typical) ................................................. 43
Daily Checks ........................................................................................ 44
Visual Checks................................................................................. 44
4
TNV Operation Manual
TABLE OF CONTENTS
Check Diesel Fuel, Engine Oil, and Engine Coolant Levels........... 44
Check Engine Speed Control ......................................................... 44
Check Operator’s Console ............................................................. 45
Check Indicators............................................................................. 45
Engine Operation ..................................................................................... 47
Starting Engine..................................................................................... 53
Cold Start Device ................................................................................. 55
Checking the Engine During Operation................................................ 55
Adjust Engine Speed............................................................................ 57
Shutting Down the Engine.................................................................... 58
Periodic Maintenance .............................................................................. 59
Precautions .......................................................................................... 71
The Importance of Periodic Maintenance....................................... 71
Performing Periodic Maintenance .................................................. 71
The Importance of Daily Checks .................................................... 71
Keep a Log of Engine Hours and Daily Checks ............................. 71
Yanmar Replacement Parts ........................................................... 71
Tools Required ............................................................................... 71
Ask Your Authorized Yanmar Industrial Engine
Dealer or Distributor For Help ........................................................ 71
Required EPA / ARB Maintenance - USA Only.............................. 72
EPA / ARB Installation Requirements - USA Only ......................... 72
Tightening Fasteners...................................................................... 72
Standard Torque Chart......................................................................... 72
Periodic Maintenance Schedule........................................................... 73
Periodic Maintenance Procedures ....................................................... 75
After Initial 50 Hours of Operation .................................................. 75
Every 50 Hours of Operation.......................................................... 80
Every 250 Hours of Operation........................................................ 83
Every 500 Hours of Operation........................................................ 88
Every 1000 Hours of Operation...................................................... 93
Every 1500 Hours of Operation...................................................... 96
Every 2000 Hours of Operation...................................................... 97
Troubleshooting....................................................................................... 99
Troubleshooting Chart.......................................................................... 99
Troubleshooting Information............................................................... 102
Long Term Storage ................................................................................ 103
Before You Place the Engine In Long Term Storage ......................... 103
Returning the Engine to Service......................................................... 104
Specifications......................................................................................... 105
General............................................................................................... 105
TNV Operation Manual
5
TABLE OF CONTENTS
Description of Model Number....................................................... 105
Engine Speed Specifications........................................................ 106
Engine General Specifications ..................................................... 106
Principal Engine Specifications .......................................................... 107
2TNV70 ........................................................................................ 107
3TNV70 ........................................................................................ 108
3TNV76 ........................................................................................ 109
3TNV82A...................................................................................... 110
3TNV84 ........................................................................................ 111
3TNV84T ...................................................................................... 112
3TNV88 ........................................................................................ 113
4TNV84 ........................................................................................ 114
4TNV84T ...................................................................................... 115
4TNV88 ........................................................................................ 116
4TNV94L ...................................................................................... 117
4TNV98 ........................................................................................ 118
4TNV98T ...................................................................................... 119
4TNV106 ...................................................................................... 120
4TNV106T .................................................................................... 121
6
TNV Operation Manual
TNV Operation Manual
SAFETY
SAFETY STATEMENTS
Yanmar is concerned for your safety and your
machine’s condition. Safety statements are one
of the primary ways to call your attention to the
potential hazards associated with Yanmar TNV
engine operation. Follow the precautions listed
throughout the manual before operation, during
operation and during periodic maintenance
procedures for your safety, the safety of others
and to protect the performance of your engine.
Keep the labels from becoming dirty or torn and
replace them if they are lost or damaged. Also, if
you need to replace a part that has a label
attached to it, make sure you order the new part
and label at the same time.
This safety alert symbol appears with
most safety statements. It means
A
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
A CAUTION
Caution (the word “CAUTION” is in black
letters with a yellow rectangle behind it)
– indicates a potentially hazardous
situation which, if not avoided, may
result in minor or moderate injury.
0000001en
CAUTION
Caution without the safety alert symbol
indicates a potentially hazardous
situation that can cause damage to the
machine, personal property and / or the
environment or cause the machine to
operate improperly.
0000001en
TNV Operation Manual
1
SAFETY
SAFETY PRECAUTIONS
Before You Operate
CAUTION
NEVER permit anyone to operate the
engine or driven machine without proper
training.
• Read and understand this Operation
Manual before you operate the
machine to ensure that you follow safe
operating practices and maintenance
procedures.
• Machine safety signs and labels are
additional reminders for safe operating
and maintenance techniques.
• See your authorized Yanmar industrial
engine dealer or distributor for
additional training.
0000002en
During Operation and Maintenance
A DANGER
SCALD HAZARD!
• NEVER remove the radiator cap if the
engine is hot. Steam and hot engine
coolant will spurt out and seriously
burn you. Allow the engine to cool
down before you attempt to remove
the radiator cap.
• Securely tighten the radiator cap after
you check the radiator. Steam can
spurt out during engine operation if
the cap is loose.
• ALWAYS check the level of engine
coolant by observing the reserve tank.
• Failure to comply will result in death or
serious injury.
0000002en
A DANGER
EXPLOSION HAZARD!
• Keep the area around the battery well
ventilated. While the engine is running
or the battery is charging, hydrogen
gas is produced which can be easily
ignited.
• Keep sparks, open flame and any other
form of ignition away.
• Failure to comply will result in death or
serious injury.
0000003en
2
TNV Operation Manual
SAFETY
A DANGER
FIRE AND EXPLOSION HAZARD!
• Diesel fuel is extremely 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 extremely
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
A DANGER
A DANGER
FIRE AND EXPLOSION HAZARD!
• Diesel fuel is extremely flammable and
explosive under certain conditions.
• Place an approved container under the
air bleed port when you prime the fuel
system. Never use a shop rag to catch
the fuel. Wipe up any spills
immediately. ALWAYS close the air
bleed port after you complete priming
the system.
• Wear eye protection. The fuel system
is under pressure and fuel could spray
out when you open the air bleed port.
• If the unit has an electric fuel pump,
turn the key switch to the ON position
for 10 to 15 seconds, or until the fuel
coming out of the air bleed port is free
of bubbles, to allow the electric fuel
pump to prime the system.
• If the unit has a mechanical fuel pump,
operate the fuel priming pump several
times until the fuel coming out of the
air bleed port is free of bubbles.
FIRE AND EXPLOSION HAZARD!
• Only use the key switch to start the
engine.
• NEVER jump start the engine. Sparks
caused by jumping the battery to the
starter terminals may cause a fire or
explosion.
• Failure to comply will result in death or
serious injury.
0000004en
• Failure to comply will result in death or
serious injury.
0000006en
TNV Operation Manual
3
SAFETY
A DANGER
FIRE AND EXPLOSION HAZARD!
• Diesel fuel is extremely flammable and
explosive under certain conditions.
• 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.
• NEVER open the air vent valve while
the fuel system is being primed. The
fuel filter has an internal air bleed port.
• Failure to comply will result in death or
serious injury.
0000013en
A DANGER
A DANGER
FIRE AND EXPLOSION HAZARD!
• Diesel fuel is extremely flammable and
explosive under certain conditions.
• NEVER remove the fuel cap with
engine running.
• Failure to comply will result in death or
serious injury.
0000011en
A DANGER
FIRE AND EXPLOSION HAZARD!
• Diesel fuel is extremely flammable and
explosive under certain conditions.
• Only fill fuel tank with diesel fuel.
Filling fuel tank with gasoline may
result in a fire.
• NEVER refuel with engine running.
FIRE AND EXPLOSION HAZARD!
• Diesel fuel is extremely 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
• Wipe up all spills immediately.
• Keep sparks, open flames or any other
form of ignition (match, cigarette,
static electric source) away when
fueling / refueling.
• NEVER overfill the fuel tank.
• Fill fuel tank and store fuel in a wellventilated area only.
• Failure to comply will result in death or
serious injury.
0000005en
4
TNV Operation Manual
SAFETY
A DANGER
FIRE AND EXPLOSION HAZARD!
• Diesel fuel is extremely flammable and
explosive under certain conditions.
• Be sure to place the diesel fuel
container on the ground when
transferring 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 build-up 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 shut
down.
A DANGER
FIRE AND EXPLOSION HAZARD!
• Diesel fuel is extremely 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
• Failure to comply will result in death or
serious injury.
0000014en
A DANGER
CRUSH HAZARD!
• When you need to transport an engine
for repair have a helper assist you
attach it to a hoist and load it on a
truck.
• NEVER stand under hoisted engine. If
the hoist mechanism fails, the engine
will fall on you, causing serious injury
or death.
• Failure to comply will result in death or
serious injury.
0000008en
A DANGER
EXPLOSION HAZARD!
• NEVER check the remaining battery
charge by shorting out the terminals.
This will result in a spark and may
cause an explosion or fire. Use a
hydrometer to check the remaining
battery charge.
• If the electrolyte is frozen, slowly warm
the battery before you recharge it.
• Failure to comply will result in death or
serious injury.
0000007en
TNV Operation Manual
5
SAFETY
A WARNING
SEVER HAZARD!
• Keep hands and other body parts
away from moving / rotating parts
such as the cooling fan, flywheel or
PTO shaft.
• Wear tight fitting clothing and keep
your hair short or tie it back while the
engine is running.
• Remove all jewelry before you operate
or service the machine.
• NEVER start the engine in gear.
Sudden movement of the engine
and / or machine could cause death or
serious personal injury.
• NEVER operate the engine without the
guards in place.
• Before you start the engine make sure
that all bystanders are clear of the
area.
• Keep children and pets away while the
engine is operating.
A WARNING
EXHAUST HAZARD!
• NEVER operate the engine in an
enclosed area such as a garage,
tunnel, underground room, manhole or
ship’s hold without proper ventilation.
• NEVER block windows, vents, or other
means of ventilation if the engine is
operating in an enclosed area. All
internal combustion engines create
carbon monoxide gas during
operation. Accumulation of this gas
within an enclosure could cause
illness or even death.
• Make sure that all connections are
tightened to specifications after repair
is made to the exhaust system.
• Failure to comply could result in death
or serious injury.
0000003en
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
or serious injury.
0000002en
ALCOHOL AND DRUG HAZARD!
• NEVER operate the engine while you
under the influence of alcohol or
are
drugs.
• NEVER operate the engine when you
are feeling ill.
• Failure to comply could result in death
or serious injury.
0000004en
6
TNV Operation Manual
SAFETY
A WARNING
EXPOSURE HAZARD!
• Wear personal protective equipment
such as gloves, work shoes, eye and
hearing protection as required by the
task at hand.
• NEVER wear jewelry, unbuttoned
cuffs, ties or loose fitting clothing
when you are working near
moving / rotating parts such as the
cooling fan, flywheel or PTO shaft.
• ALWAYS tie long hair back 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
warning signals.
A WARNING
BURN HAZARD!
• Batteries contain sulfuric acid. NEVER
allow battery fluid to come in contact
with clothing, skin or eyes. Severe
burns could result. ALWAYS wear
safety goggles and protective clothing
when servicing the battery. If contact
with the skin and / or eyes should
occur, flush with a large amount of
water and obtain prompt medical
treatment.
• Failure to comply could result in death
or serious injury.
0000007en
A WARNING
• Failure to comply could result in death
or serious injury.
0000005en
A WARNING
BURN HAZARD!
• If you must drain the engine oil while it
is still hot, stay clear of the hot engine
oil to avoid being scalded. Make sure
you wear eye protection.
• Failure to comply could result in death
or serious injury.
0000011en
HIGH PRESSURE HAZARD!
• Avoid skin contact with 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 Operation Manual
7
SAFETY
A WARNING
SHOCK HAZARD!
• Turn off the battery switch (if
equipped) or disconnect the negative
battery cable before servicing the
electrical system.
• Check the electrical harnesses for
cracks, abrasions, and damaged or
corroded connectors. ALWAYS keep
the connectors and terminals clean.
• Failure to comply could result in death
or serious injury.
0000009en
A WARNING
SEVER HAZARD!
• Stop the engine before you begin to
service it.
A WARNING
BURN HAZARD!
• Wait until the engine cools before you
drain the engine coolant. Hot engine
coolant may splash and burn you.
• Failure to comply could result in death
or serious injury.
0000016en
A WARNING
SUDDEN MOVEMENT HAZARD!
• Allow the engine to warm-up for at
least 5 minutes to allow the engine idle
speed to return to normal before
engaging the transmission or any PTO
attachments. Engaging the
transmission or PTO at an elevated
engine speed could result in an
unexpected movement of the
equipment.
• Failure to comply could result in death
or serious injury.
0000006en
• 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
8
TNV Operation Manual
SAFETY
A WARNING
BURN HAZARD!
• Keep your hands, and other body
parts, away from hot engine surfaces
such as the muffler, exhaust pipe,
turbocharger (if equipped) and engine
block during operation and shortly
after you shut the engine down. These
surfaces are extremely hot while the
engine is operating and could
seriously burn you.
• Failure to comply could result in death
or serious injury.
0000015en
A CAUTION
A CAUTION
FLYING OBJECT HAZARD!
• ALWAYS wear eye protection when
servicing 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
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!
• 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, wash with clean water.
• Failure to comply may result in minor
or moderate injury.
0000005en
• Only use clean diesel fuel.
• NEVER remove primary strainer from
the fuel tank filler port. If removed, dirt
and debris could get into the fuel
system causing it to clog.
0000004en
CAUTION
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.
0000045en
CAUTION
If any problem is noted during the visual
check, the necessary corrective action
should be taken before you operate the
engine.
0000021en
TNV Operation Manual
9
SAFETY
CAUTION
NEVER hold the key in the START
position for longer than 15 seconds or
the starter motor will overheat.
0000007en
CAUTION
Make sure the engine is installed on a
level surface. If a continuously running
engine is installed at an angle greater
than 30° (in any direction) or if an engine
runs for short periods of time (less than
3 minutes) at an angle greater than 35°
(in any direction) engine oil may enter
the combustion chamber causing
exessive engine speed and generate
white smoke. This may cause serious
engine damage.
0000010en
CAUTION
Observe the following environmental
operating conditions to maintain engine
performance and avoid premature
engine wear:
• Avoid operating in extremely dusty
conditions.
• Avoid operating in the presence of
chemical gases or fumes.
• Avoid operating in a corrosive
atmosphere such as salt water spray.
• NEVER install the engine in a
floodplain unless proper precautions
are taken to avoid being subject to a
flood.
• NEVER expose the engine to the rain.
0000003en
CAUTION
Observe the following environmental
operating conditions to maintain engine
performance and avoid premature
engine wear:
• NEVER run the engine if the ambient
temperature is above +113°F (+45°C)
or below +5°F (-15°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 falls
below +5°F (-15°C) rubber
components such as gaskets and
seals will harden causing premature
engine wear and damage.
◆ Contact your authorized Yanmar
industrial engine dealer or
distributor if the engine will be
operated in either temperature
extreme.
• Contact your authorized Yanmar
industrial engine dealer or distributor
if you need to operate the engine at
high altitudes. At high altitudes the
engine will lose power, run rough, and
produce exhaust gases that exceed
the design specifications.
0000065en
CAUTION
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.
0000018en
10
CAUTION
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.
0000029en
TNV Operation Manual
SAFETY
CAUTION
• Only use the engine oil specified.
Other engine oils may affect warranty
coverage, cause internal engine
components to seize, or shorten
engine life.
• Prevent dirt and debris from
contaminating 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.
0000005en
CAUTION
• Only use the engine coolant specified.
Other engine coolants may affect
warranty coverage, cause an internal
build up of rust and scale and / or
shorten engine life.
• Prevent dirt and debris from
contaminating engine coolant.
Carefully clean the radiator cap and
the surrounding area before you
remove the cap.
• NEVER mix different types of engine
coolants. This may adversely affect the
properties of the engine coolant.
0000006en
CAUTION
• NEVER overfill the engine with engine
oil.
CAUTION
For maximum engine life, Yanmar
recommends that when shutting the
engine down, you allow the engine to
idle, without load, for 5 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.
0000008en
CAUTION
NEVER use an engine starting aid such
as ether. Engine damage will result.
0000009en
CAUTION
Be responsible to the environment.
Follow these procedures for hazardous
waste disposal. Failure to follow these
procedures may seriously harm the
environment.
• Follow the guidelines of the EPA or
other governmental agency 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.
0000013en
• ALWAYS keep the oil level between
upper and lower lines on the dipstick.
TNV Operation Manual
0000015en
11
SAFETY
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,
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 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 4 to 5 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.
0000011en
CAUTION
NEVER engage the starter motor while
the engine is running. This may damage
the starter motor pinion and / or ring
gear.
0000012en
CAUTION
• NEVER attempt to modify the engine’s
design or safety features such as
defeating the engine speed limit
control or the fuel injection quantity
control.
• Failure to comply may impair the
engine’s safety and performance
characteristics and shorten the
engine’s life. Any alterations to this
engine may affect the warranty
coverage of your engine. See Yanmar
Limited Warranty on page v.
0000044enTNVIDI-DIOM
CAUTION
Protect the air cleaner, turbocharger (if
equipped) and electric components
from damage when you use steam or
use high-pressure water to clean the
engine.
0000014en
CAUTION
NEVER use high pressure water or
compressed air at greater than 28 psi or
a wire brush to clean the radiator fins.
Radiator fins damage easily.
0000016en
CAUTION
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.
0000017en
CAUTION
The tightening torque in the Standard
Torque Chart (page 72) 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.
0000023enTNVIDI-DIOM
CAUTION
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.
0000028en
12
TNV Operation Manual
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