Yanmar Training 4tnv Tier III User Manual

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YANMAR 4TNV, Elec.Control.Governor (Tier III)

We build a better future

ENGINE TRAINING for R55-7A, R55W-7A, R80-7A

EDITOR PIETER EVERAERTS

R55-9, R55W-9, R60CR-9, R80CR-9

aug. 2012

CONTENT

PAGE 1] GENERAL 03 2] ELECTRONIC CONTROL SYSTEM (ECO) 06 3] INJECTION PUMP 10 4] EXHAUST GAS RECIRCULATION (EGR) 43 5] COOLANT TEMP SENSOR 45 6] ELECTRICS 47 7] ENGINE VIEW 51 8] ENGINE ERROR CODE SYSTEM 52 9] YANMAR DIAGNOSTIC TOOL 58 10] FUEL PUMP ADJUSTMENT & &REPLACEMENT 61

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Related manuals: TNV-ECO-manual.pdf (>Ceres : TNV-SERIES-ECM, part 1)

TNV-ECO-diagnostic tool.pdf (>Ceres : TNV-SERIES-ECM, part 2) TNV-ECO-troubleshooting.pdf

TNV-INJ-mechanical.pdf (>Ceres: YANMAR FUEL INJECTION) TNV-service-mechanical.pdf (>Ceres: YANMAR 3TNV, 4TNV)

HHIE TRAINING CENTRE

Hyundai Heavy Industries Europe Vossendaal 11 2440 Geel - Belgium Tel 0032 (0)14 56 22 00 Fax 0032 (0)14 56 22 65

Arranged by Pieter Everaerts Instructor HHIE Tel 0032 (0)14 56 22 44 Fax 0032 (0)14 56 22 65

YANMAR R55(W)-7 R80-7 R55(W)-7A R80-7A

Engine model 4TNV94L 4TNV98

4TNV98-EPHYB 4TNV98-ZVHYB

Content / HP (Rated Gross) at rpm 3054cc / 53HP at 2200 rpm 3318cc / 60HP at 2100 rpm 3319cc / 57HP at 2400 rpm 3319cc / 59.6HP at 2100 rpm Max. Torque at RPM 20.6 kgf at 1400 rpm 25.2 kgf at 1000 rpm 20.5 kgf at 1550 rpm 24.5 kgf at 1000 rpm

SETTING MAX RPM 2300±50 (R55-7) 2250±50 2260±50 2250±50 2400±50 (R55W-7) ("M" mode selected) ("H" mode selected)

1. GENERAL - OVERVIEW

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(All listed engines are Yanmar "NV3-Series engines" >> Range 3000...4000cc: all direct injection)

# cyl

cyl bore (mm)

derating output eco -eng.)

Explanation of engine model names (-7A/-9)

E or Z stands for  kind of output P, V  rated eng. speed HY  Hyundai B  excavator

-9 Series  same engines

-7A  "adapted technologie" to meet Tier III

High idle Low idle eng. type (M mode)

 (higher fuel injection pressure)

R55-9 2200±30 1000±30 4NTV98-EPHYBU R55W-9 2200±50 1050±100 4NTV98-EPHYBU

 Electric Control of Exhaust Gas Regulation  Electric Control of Governor (= "ECO")

R60CR-9 2200±50 1000±50 4NTV98-EPHYBU R80CR-9 2100±50 1000±50 4NTV98-ZVHYB

standard output eco -eng.)

HHIE TRAINING CENTRE

At full charge, eng. drop is max “150 rpm”

1. GENERAL - SPECIFICATION

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R55(W)-7A R80-7A

2260 2250

HHIE TRAINING CENTRE

1. GENERAL - ENGINE LAY-OUT

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NV3, adapted (tier III)

Cylinder head with 4 valves

Optimization of injection bore diameter→Reduce PM

Electronic control of EGR (exhaust gas recirculation)  to achieve lower NOx

Electronic Control of Governor (ECO)

HHIE TRAINING CENTRE

2. ELECTRONIC CONTROL SYSTEM (ECO)

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EGR

Air heater

Actuator

Rack position sensor

Engine speed sensor

Electronic control governor

CSD valve (cold start device)

Fuel injection pump

ECU

CAN

OFF

START

Key switch

Switch

Coolant temp. sensor

Starter

Display

Accelerator

HHIE TRAINING CENTRE

2. ELECTRONIC CONTROL SYSTEM  ECO GOVERNOR

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HHIE TRAINING CENTRE

2. ELECTRONIC CONTROL SYSTEM  ECO GOVERNOR

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HHIE TRAINING CENTRE

2. ELECTRONIC CONTROL SYSTEM  2G ECO GOVERNOR

Eco-Governor is Yanmar’s unique electronics control governor system which has been used for over 10 years mainly on agricultural machines. Yanmar has renewed this system to aplly to all equipment and named it “2G Eco-Governor” which means second generation Eco-Governor. In addition an EGR valve is controlled by this system.

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Idling speed control After heat control Communication function

Idling speed will be adjusted depending on cooling water temperature

Engine warm-up time reduced, protection at high idle & less white smoke

Starting aid devices stay activated after start

HHIE TRAINING CENTRE

Data logging by ECO system Connection for troubleshooting

Possible to monitor engine performance System diagnosis incl history

3. INJECTION PUMP - RACK CONTROL

Electronically control rack by ECU

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Target engine speed

Water Temp.

ECU

Actuator force

Actuator

Rack act.

Rack position sensor

Fuel

Solenoid valve CSD

Spring return

Fuel

－

Engine speed sensor

when replacing the pump, data files need to be written to the ECU>> See "TNV-ECO-diagnostic tool.pdf, p51 for more information

HHIE TRAINING CENTRE

Engine speed gear

Rack

3. INJECTION PUMP - RACK CONTROL

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ECU

pin nr. 42

12V fuse ECU

to ECU (pin 42) (neg. control)

to ECU

6 5 4 3 2 1

Rack actuator

Rack position sensor

HHIE TRAINING CENTRE

Relay rack actuator

CR67

Relay ECU Main Power

CR68

3. INJECTION PUMP - RACK CONTROL

CORRECTED PIN LAY OUT FOR CR-68 (ecu main power) AND CR-67 (rack actuator) ON R80-7A

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HHIE TRAINING CENTRE

3. INJECTION PUMP - RACK POSITION SENSOR

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HHIE TRAINING CENTRE

3. INJECTION PUMP - ECO 2G GOVERNOR VERSUS MECHANICAL GOVERNOR

INJ. PUMP WITH EL. GOVERNOR (on -7A & -9) INJ. PUMP WITH MECHANICAL GOVERNOR (on -7)

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Engine speed sensor

• magnetic type

• detects eng. speed with 12 pulsers attached

to the camshaft

HHIE TRAINING CENTRE