Yanmar 3TNV82A, 3TNV88-U, 3TNV88, 3TNV88-B, 4TNV84 Service Manual
...
SERVICE MANUAL
3TNV82A
3TNV82A-B
3TNV84
3TNV84T
3TNV84T-B
3TNV88
3TNV88-B
3TNV88-U
4TNV84
4TNV84T
4TNV84T-Z
4TNV88
4TNV88-B
4TNV88-U
4TNV94L
4TNV98
4TNV98-Z
4TNV98-E
4TNV98T
4TNV98T-Z
4TNV106
4TNV106T
California
Proposition 65 Warning
California
Proposition 65 Warning
Diesel engine exhaust and some of its
constituents are known to the state of
California to cause cancer, birth
defects, and other reproductive harm.
Battery posts, terminals, and related
accessories contain lead and lead
compounds, chemicals known to the
state of California to cause cancer and
reproductive harm.
Wash hands after handling.
TNV DI Service Manual
TNV
SERVICE MANUAL
3TNV82A(-B) • 3TNV84 • 3TNV84T(-B) •
3TNV88(-B)(-U)
4TNV84 • 4TNV84T(-Z) •
4TNV88(-B)(-U)
4TNV94L
4TNV98(-Z)(-E) • 4TNV98T(-Z)
4TNV106 • 4TNV106T
P/N: 0BTNV-G00101
series
INDUSTRIAL
ENGINES
This Service Manual has been developed for the exclusive use of service and repair prof essionals 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 nonprofessional to perform the service or repair properly and / or safely. Please contact an authorized Yanmar
repair or service professional before working on your Yanmar product.
Disclaimers:
All information, illustrations and specifications in this manual are based on the latest information available
at the time of publishing. The illustrations used in this manual are intended as representative reference
views only. Moreover, because of our continuous product improvement policy, we may modify information,
illustrations, and / or specifications to explain and / or exemplify a product, service, or maintenance
improvement. We reserve the right to make any change at any time.
Yanmar and are registered trademarks of Yanmar Co., Ltd. in Japan, the United States and /
or other countries.
All Rights Reserved:
No part of this publication may be reproduced or used in any form by any means - graphic, electronic, or
mechanical, including photocopying, recording, taping, or information storage and retrieval systems without the written permission of Yanmar Co., Ltd.
© 2005 Yanmar Co. Ltd.
ii
TNV DI Service Manual
TNV DI Service Manual
Section 1
TABLE OF
CONTENTS
Table of Contents................................................................................... iii
Introduction ........................................................................... .............. 1-1
Yanmar Warranties.............................................................................. 2-1
Safety................................................................................................ .... 3-1
General Service Information .............................................................. 4-1
Periodic Maintenance ..................................................................... .... 5-1
Engine .................................................................................... .............. 6-1
Page
Fuel System......................................................................................... 7-1
Cooling System................................................................................... 8-1
Lubrication System............................................................................. 9-1
Turbocharger..................................................................................... 10-1
Starter Motor...................................................................................... 11-1
Alternator........................................................................................... 12-1
ELECTRONIC CONTROL SYSTEM .................................................. 13-1
Electric Wiring................................................................................... 14-1
TNV DI Service Manual
iii
TABLE OF CONTENTS
This Page Intentionally Left Blank
iv
TNV DI Service Manual
TNV DI Service Manual
Section 1
INTRODUCTION
This Service Manual describes the service
procedures for the TNV series direct injection
engines. These engines are certified by the U.S.
EPA, California ARB and/or the 97/68/EC Directive
for industrial use.
Please use this manual 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.
TNV DI Service Manual
1-1
INTRODUCTION
This Page Intentionally Left Blank
1-2
TNV DI Service Manual
TNV DI 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
Retail Purchaser Registration................ ........... ........... .......... .... 2-5
Emission System Warranty............................................... .......... .... 2-6
Section 2
YANMAR
Page
Yanmar Co., Ltd. Limited Emission Control System
Warranty - USA Only....................................................................... 2-6
Your Warranty Rights and Obligations:..................................... 2-6
Manufacturer’s Warranty Period:............................................... 2-6
Warranty Coverage: .................................................................. 2-7
Warranted Parts: ....................................................................... 2-7
Exclusions: ................................................................................ 2-8
Owner’s Warranty Responsibilities:........................................... 2-8
TNV DI Service Manual
2-1
YANMAR WARRANTIES
This Page Intentionally Left Blank
2-2
TNV DI Service Manual
Yanmar Limited Warranty
YANMAR WARRANTIES
YANMAR LIMITED WARRANTY
What is Covered by this Warranty?
Yanmar warrants to the original retail purchaser that a new Yanmar TNV Series Industrial Engine will be
free from defects in material and / or workmanship for the duration of the warranty period.
Note: Yanmar engines may be equipped with external components including, but not limited to: wiring
harnesses, electrical devices, control panels, r adiators , air filters, fue l filters, and/or e xhaust systems
that are supplied and/or installed by manufacturers other than Yanmar. For warranty information on
such external components, please contact the machine or component manufacturer directly or see
your authorized Yanmar dealer or distributor.
THIS WARRANTY IS PROVIDED IN LIEU OF ALL OTHER WARRANTIES, EXPRESS OR IMPLIED.
YANMAR SPECIFICALLY DISCLAIMS ANY IMPLIED WARRANTIES OF MERCHANTABILITY OR
FITNESS FOR A PARTICULAR PURPOSE, except where such disclaimer is prohibited by law. IF SUCH
DISCLAIMER IS PROHIBITED BY LAW, THEN IMPLIED WARRANTIES SHALL BE LIMITED IN
DURATION TO THE LIFE OF THE EXPRESS WARRANTY.
How Long is the Warranty Period?
The Yanmar standard limited warranty period runs for a period of twenty-four (24) months or twothousand (2000) engine operation hours, whichever occurs first. An extended limited warranty of thirty-
six (36) months or three thousand (3000) engine operating hours, whichever occurs first, is provided for
these specific parts only: the cylinder block, cylinder head, crankshaft forging, connecting rods, flywheel,
flywheel housing, camshaft, timing gear, and gear case. The Warranty Period for both the standard limited
warranty and the extended limited warranty (by duration or operation hours) begins on the date of delivery
to the original retail purchaser and is valid only until the applicable warranted duration has passed or the
operation hours are exceeded, whichever comes first.
What the Engine Owner Must Do:
If you believe your Yanmar engine has experienced a failure due to a defect in material and / or
workmanship, you must contact an authorized Yanmar industrial engine dealer or distributor within thirty
(30) days of discovering the failure. You must provide proof of 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.
TNV DI 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 a uthorized Yanmar industrial engine dealer or distributor by visiting the Yanmar
Corp., LTD. website at:
http://www.yanmar.co.jp (The Japanese language page will be displayed.) For English language “click” on
“English Page.”)
• “Click” on “Network” in the website heading to vie w the “Yanmar Worldwide Network. ”
• Choose and “Click” on the desired product grou p.
• “Click” on the Icon closest to your region.
• “Click” on the desired country or Associate company to locate your nearest authorize d Y anmar industrial
engine dealer or distributor .
• Y o u may also contact Y anmar b y clicking on “Inquiry” in the website heading and typing in your question
or comment.
What Yanmar Will Do:
Yanmar warrants to the original retail purchaser of a new Yanmar engine that Yanmar will make such
repairs and / or replacements at Yanmar’s option, of any part(s) of the Yanmar product covered by this
Warranty f ound to be def ectiv e 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 co v er parts affected by or damaged b y any reason other than def ectiv e materials or
workmanship including, but not limited to, accident, misuse, abuse, “Acts of God,” neglect, improper
installation, improper maintenance, improper storage, the use of unsuitable attachments or parts, the use
of contaminated fuels, the use of fuels, oils, lubricants, or fluids other than those recommended in your
Yanmar Operation Manual, unauthorized alterations or modifications, ordinary wear and tear, and rust or
corrosion. This Warranty does not cover the cost of parts and / or labor required to perform normal /
scheduled maintenance on your Yanmar engine. This Warranty does not cover consumable parts such as,
but not limited to, filters, belts, hoses, fuel injector nozzles, lubricants and cleaning fluids. This Warranty
does not cover the cost of shipping the product to or from the Warranty repair facility.
2-4
TNV DI Service Manual
Yanmar Limited Warranty
Yanmar Limited Warranty - Continued
YANMAR WARRANTIES
Warranty Limitations:
The foregoing is Yanmar’ s onl y obl igation to y ou and y ou r exc lusive remed y f or breac h 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 f or breach of warranties. This W arranty gi ves y ou 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 W arr anty is and shall remain the complet e and
exclusive agreement between the parties with respect to warranties, superseding all prior agreements,
written and oral, and all other communications between the parties relating to warranties. No person or
entity is authorized to give any other warranty or to assume any other obligation on behalf of
Yanmar, either orally or in writing.
Questions:
If you have any questions or concerns regarding this Warranty, please call or write to the nearest
authorized Yanmar industrial engine dealer or distributor or other authorized facility.
Retail Purchaser Registration
It is very important for the original retail purchaser to register the Yanmar product. Registration enables
Yanmar to provide the best support for your Yanmar product.
At the time of purchase, Yanmar highly recommends registering the retail purchaser’s information through
the website http://www.yanmar.co.jp as soon as possible.
If it is not possible to access the website, please contact the nearest authorized Yanmar industrial engine
dealer or distributor.
TNV DI Service Manual
2-5
YANMAR WARRANTIES
Emission System Warranty
EMISSION SYSTEM WARRANTY
YANMAR CO., LTD. LIMITED EMISSION CONTROL SYSTEM WARRANTY - USA ONLY
Your Warranty Rights and Obligations:
California
The California Air Resources Board (CARB), the Environmental Protection Agency (EPA) and Yanmar Co.,
Ltd. hereafter referred to as Yanmar, are pleased to explain the emission control system warranty on
your industrial compression-ignition engine. In California, model year 2000 or later off-road compressionignition engines must be designed, built and equipped to meet the State’ s stringent anti-smog stan dards. In
all states, 1998 and later non-road compression-ignition engines must be designed, built and equipped to
meet the United States EPA emissions standards. Yanmar warrants the emission control system on your
engine for the periods of time listed below provided there has been no abuse, neglect or improper
maintenance of your engine.
Your emission control system may include parts such as the fuel injection system, electronic control unit,
exhaust gas recirculation (EGR) system and the air induction system. Also included may be hoses, belts,
connectors and other emission-related assemblies.
Where a warrantable condition exists, Yanmar will repair your non-road compression-ignition engine at no
charge to you including diagnosis, parts and labor.
Manufacturer’s Warranty Period:
The model year 1998 or later certified and labeled non-road compression-ignition engines are warranted
for the periods listed below. If any emission-related part on your engine is found to be defective during the
applicable warranty period, the part will be replaced by Yanmar.
Engine Type Warranty Period by Number of Years or Hours of Operatio n
Constant speed engines rated at or above
50 hp SAE (37 kW)
Constant speed engines rated under 50 hp
SAE (37 kW) with rated speeds greater than
or equal to 3,000 rpm
Engines rated at or above 26 hp SAE
(19 kW)
Engines rated under 26 hp SAE (19 kW)
The warranty period is five (5) years or 3,000 hours of use, whichever occurs first.
In the absence of a device to measure the hours of use, the engine has a
warranty period of five (5) years.
The warranty period is two (2) years or 3,000 hours of use, whichever occurs first.
In the absence of a device to measure the hours of use, the engine has a
warranty period of two (2) years.
The warranty period is five (5) years or 3,000 hours of use, whichever occurs first.
In the absence of a device to measure the hours of use, the engine has a
warranty period of five (5) years.
The warranty period is two (2) years or 3,000 hours of use, whichever occurs first.
In the absence of a device to measure the hours of use, the engine has a
warranty period of two (2) years.
2-6
TNV DI Service Manual
Emission System Warranty
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 warr anted 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. Warranted parts scheduled for replacement as required maintenance 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 f or damages to other engine comp onents caused by the f ailure
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, an d shall not re duce Yanmar’s warranty obligations. Addon or modified parts that are not exempted may not be used. The use of any non-exempted add-on or
modified parts shall be grounds for disallowing a warranty.
Warranted Parts:
This warranty covers engine components that are a part of the emission control system of the engine as
delivered by Yanmar to the original retail purchaser. Such components may include the following:
• Fuel Injection System
• Electronic Control System
• Cold Start Enrichment System
• Intake Manifold
• Turbocharger Systems
• Exhaust Manifold
• EGR System
• Positiv e Crankcase Ventilation System
• Hoses, belts, connectors and asse mblies associated with emission control systems
Since emissions-related parts may vary slightly between models, certain models may not contain all of
these parts and other models may contain the functional equivalents.
TNV DI Service Manual
2-7
YANMAR WARRANTIES
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 pe rf ormance of the required maintenance listed in
your owner’s manual. Yanmar recommends that y ou retain all documentation, including receipts , cov ering
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 ma y den y y our w arranty co v er age of y our non-ro ad 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 f or initiating the warranty process . You must present your engine to a Yanmar dealer as
soon as a problem exists. The warranty repairs should be completed by the dealer as expeditiously as
possible. If you have any questions regarding your warranty rights and responsibilities, or would like
information on the nearest Yanmar dealer or authorized service center, you should contact Yanmar
America Corporation at 1-800-872-2867.
2-8
TNV DI Service Manual
TNV DI Service Manual
Safety Statements........................................................................... 3-3
Safety Precautions.......................................................................... 3-4
Section 3
SAFETY
Page
TNV DI Service Manual
3-1
SAFETY
This Page Intentionally Left Blank
3-2
TNV DI Service Manual
Safety Statements
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 . 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 v olved! Please read
and abide by the message that
follows the safety alert symbol.
A CAUTION
Caution (the word “CA UTION” is in blac k
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
A DANGER
Danger (the word “DANGER” is in white
letters with a red rectangle behind
it) - indicates an imminently hazardous
situation which, if not avoided, will
result in death or serious injury. Danger
is limited to the most extreme
situations.
0000001en
A WARNING
Warning (the word “WARNING” is in
black letters with an orange rectangle
behind it) – indicates a potentially
hazardous situation which, if not
avoided, could result in death or serious
injury.
0000001en
TNV DI Service Manual
3-3
SAFETY
SAFETY PRECAUTIONS
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.
• Tighten the radiator cap securely after
you check the radiator. Steam can
spurt out during engine operation if
the cap is loose.
• ALWAYS check the level of the engine
coolant by observing the reserve tank.
• Failure to comply will result in death or
serious injury.
0000002en
Safety Precautions
A DANGER
FIRE AND EXPLOSION HAZARD!
• Diesel fuel is flammable and explosive
under certain conditions.
• When you remove any fuel system
component to perform maintenance
(such as changing the fuel filter) place
an approved container under the
opening to catch the fuel.
• NEVER use a shop rag to catch the
fuel. Vapors from the rag are
flammable and explosive.
• Wipe up any spills immediately.
• Wear eye protection. The fuel system
is under pressure and fuel could spray
out when you remove any fuel system
component.
• Failure to comply will result in death or
serious injury.
0000009en
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 an y other
form of ignition away while the engine
is running or battery is charging.
• Failure to comply will result in death or
serious injury.
0000003en
A DANGER
FIRE AND EXPLOSION HAZARD!
• Only use the key switch to start the
engine.
• NEVER jump-start the engine. Sparks
caused by shorting the battery to the
starter terminals may cause a fire or
explosion.
• Failure to comply will result in death or
serious injury.
0000004en
3-4
TNV DI Service Manual
Safety Precautions
SAFETY
A DANGER
FIRE AND EXPLOSION HAZARD!
• Diesel fuel is 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.
• Failure to comply will result in death or
serious injury.
0000010en
A DANGER
FIRE AND EXPLOSION HAZARD!
• Diesel fuel is flammable and explosive
under certain conditions.
• Only fill the fuel tank with diesel fuel.
Filling the fuel tank with gasoline may
result in a fire and will damage the
engine.
• NEVER refuel with the engine running.
• Wipe up all spills immediately.
• Keep sparks, open flames or any other
form of ignition (match, cigarette,
static electric source) well away when
refueling.
• NEVER overfill the fuel tank.
• Fill the fuel tank. Store any containers
containing fuel in a well-ventilated
area, away from any combustibles or
sources of ignition.
• Failure to comply will result in death or
serious injury.
0000005en
TNV DI Service Manual
3-5
SAFETY
Safety Precautions
A DANGER
FIRE AND EXPLOSION HAZARD!
• Diesel fuel is flammable and explosive
under certain conditions.
• 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.
A DANGER
CRUSH HAZARD!
• When you need to transport an engine
for repair, have a helper assist you to
attach it to a hoist and load it on a
truck.
• NEVER stand under a hoisted engine.
If the hoist mechanism fails, the
engine will fall on you, causing death
or serious injury.
• Failure to comply will result in death or
serious injury.
0000008en
A DANGER
• Failure to comply will result in death or
serious injury.
0000014en
FIRE AND EXPLOSION HAZARD!
• Diesel fuel is flammable and explosive
under certain conditions.
• Before you operate the engine, check
for fuel leaks. Replace rubberized fuel
hoses every two years or every 2000
hours of engine operation, whichever
comes first, even if the engine has
been out of service. Rubberized fuel
lines tend to dry out and become
brittle after two years or 2000 hours of
engine operation, whichever comes
first.
• Failure to comply will result in death or
serious injury.
0000015en
3-6
TNV DI Service Manual
Safety Precautions
SAFETY
A DANGER
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 fr ozen, slowly warm
the battery before you recharge it.
• Failure to comply will result in death or
serious injury.
0000007en
A DANGER
A DANGER
FIRE AND EXPLOSION HAZARD!
• Diesel fuel is flammable and explosive
under certain conditions.
• NEVER use diesel fuel as a cleaning
agent.
• Failure to comply will result in death or
serious injury.
0000012en
FIRE AND EXPLOSION HAZARD!
• Diesel fuel is flammable and explosive
under certain conditions.
• NEVER remove the fuel cap with the
engine running.
• Failure to comply will result in death or
serious injury.
0000011en
TNV DI Service Manual
3-7
SAFETY
Safety Precautions
A WARNING
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.
A WARNING
EXHAUST HAZARD!
• NEVER operate the engine in an
enclosed area such as a garage,
tunnel, underground r oom, 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 dea th
or serious injury.
0000003en
• Keep children and pets awa y while the
engine is operating.
• Check before starting the engine that
any tools or shop rags used during
maintenance have been removed fr om
the area.
• Failure to comply could result in dea th
or serious injury.
0000002en
A WARNING
ALCOHOL AND DRUG HAZARD!
• NEVER operate the engine while you
are under the influence of alcohol or
drugs.
• NEVER operate the engine when you
are feeling ill.
• Failure to comply could result in dea th
or serious injury.
0000004en
3-8
TNV DI Service Manual
Safety Precautions
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 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 re sult in death
or serious injury.
0000005en
A WA RN IN G
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.
• Failure to comply could re sult in death
or serious injury.
0000011en
A WA RN IN G
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 cl othing
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 re sult in death
or serious injury.
0000007en
TNV DI Service Manual
3-9
SAFETY
Safety Precautions
A WARNING
HIGH-PRESSURE HAZARD!
• Avoid skin contact with the
high-pressure diesel fuel spray caused
by a fuel system leak such as a br oken
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 dea th
or serious injury.
0000008en
A WARNING
ENTANGLEMENT HAZARD!
• Stop the engine before you begin to
service it.
• NEVER leave the key in the ke y 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 dea th
or serious injury.
0000010en
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 dea th
or serious injury.
0000009en
A WARNING
BURN HAZARD!
• Wait until the engine cools before you
drain the engine coolant. Hot engine
coolant may splash and burn you.
• Failure to comply could result in dea th
or serious injury.
0000016en
3-10
TNV DI Service Manual
Safety Precautions
SAFETY
A WARNING
SUDDEN MOVEMENT HAZARD!
• Engaging the transmission or PTO at
an elevated engine speed could result
in unexpected movement of the
equipment.
• Failure to comply could re sult in death
or serious injury.
0000006en
A WARNING
BURN HAZARD!
• Keep your hands and other bod y 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 re sult in death
or serious injury.
0000015en
A WARNING
A WA RN IN G
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 resul t in death
or serious injury.
0000014en
A WA RN IN G
Never apply over 40 psi (2.8 kgf/cm) to
the waste gate actuator.
0000026en
A WA RN IN G
• Never inject fuel towar d y ou. 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.
0000028en
To prevent possible eye injury, always
wear SAFETY GLASSES while servicing
the engine.
0000013en
TNV DI Service Manual
3-11
SAFETY
Safety Precautions
A WARNING
• 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.
9999999en
A WARNING
• Be sure to use the E-ECU in
conjunction with the engines whose
models or serial numbers are
specified by Yanmar.
Other E-ECU/engine combinations
than specified will void the engine
warranty.
• Improper use or misuse of the E-ECU
may result in death or serious injury
due to an abrupt and unexpected
increase in engine speed.
9999998en
A WARNING
• Replacing the fuel injection pump
involves rewriting the fuel injection
data in the E-ECU.
Be sure to contact your local Yanmar
dealer before replacing the fuel
injection pump.
Failure to rewrite the fuel injection
data before replacing the fuel injection
pump will void the engine warranty.
• Improper use or misuse of the E-ECU
may result in death or serious injury
due to an abrupt and unexpected
increase in engine speed.
9999997en
A WARNING
• Replacing the E-ECU involves
migrating the fuel injection data to the
existing E-ECU to the new unit.
Be sure to contact your local Yanmar
dealer before replacing the E-ECU.
Failure to migrate the fuel injection
data before replacing the E-ECU will
void the engine warranty.
• Improper use or misuse of the E-ECU
may result in death or serious injury
due to an abrupt and unexpected
increase in engine speed.
9999996en
3-12
TNV DI Service Manual
Safety Precautions
SAFETY
A CAUTION
COOLANT HAZARD!
• Wear ey e protection and rubber glo ves
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.
0000005en
A CAUTION
FLYING OBJECT HAZARD!
• ALWAYS wear eye protection when
servicing the engine and when using
compressed air or high-pressure
water . Dust, flying debris, compressed
air, pressurized water or steam may
injure your eyes.
• Failure to comply may result in minor
or moderate injury.
0000003en
A CAUTION
Be sure to secure the engine solidly to
prevent injury or damage to parts due to
the engine falling during work on the
engine.
0000009en
A CAUTION
PINCH HAZARD!
Carefully rotate the alternator toward the
cylinder block while loosening the
V-belt. Failure to comply may result in
minor or moderate injury.
0000014en
A CAUTION
If any oil pump component clearance
exceeds its limit, the oil pump must be
replaced as an assembly.
0000015en
CAUTION
• Only use diesel fuels recommended b y
Yanmar for the best engine
performance, to prevent engine
damage and to comply with EPA / ARB
warranty requirements.
• Only use clean diesel fuel.
• NEVER remove the primary strainer (if
equipped) from the fuel tank filler port.
If removed, dirt and debris could get
into the fuel system causing it to clog.
0000004en
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
TNV DI Service Manual
3-13
SAFETY
Safety Precautions
CAUTION
If any prob lem is noted during the visual
check, the necessary corrective action
should be taken before you operate the
engine.
0000021en
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 (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 e xcessive
engine speed and white exhaust smoke.
This may cause serious engine damage.
0000010enTNV
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:
• 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.
0000065en
3-14
TNV DI Service Manual
Loading...