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 [phone]
Fax [phone]

Arranged by Pieter Everaerts
Instructor HHIE
Tel [phone]
Fax [phone]

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.)

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

1. GENERAL - SPECIFICATION

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R55(W)-7A R80-7A

2260 2250

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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)

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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

ON

START

Key switch

Switch

Coolant temp. sensor

Starter

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Display

Accelerator

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2. ELECTRONIC CONTROL SYSTEM  ECO GOVERNOR

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2. ELECTRONIC CONTROL SYSTEM  ECO GOVERNOR

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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

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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

－

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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

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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

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6 5 4 3 2 1

Rack
actuator

Rack position sensor

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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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3. INJECTION PUMP - RACK POSITION SENSOR

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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

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3. INJECTION PUMP - TROUBLESHOOTING FOR ACTUATOR & GOVERNOR-LEVER

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Temp coolant ≤ 5

at start

Temp coolant > 5
at

ACTIVATION:
CDS valve opens
(for

DISACTIVATION:
CDS valve closes

3. INJECTION PUMP - COLD START DEVICE (CSD)

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Solenoid valve CSD

Electric symbol

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ECU

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max. 5 min)

start

°C

3. INJECTION PUMP - COLD START DEVICE (CSD)

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COLD START DEVICE on
YANMAR engine R55-7A

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3. INJECTION PUMP - COLD START DEVICE (CSD)

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3. INJECTION PUMP - COLD START DEVICE (CSD)

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In case of CSD failure,
normaly only the solenoid

valve (1) needs to be

exchanged. All other parts
can remain in the FIP!
If other parts are or need to
be removed as well, the
easiest way to mount back is
shown in the next slides

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3. INJECTION PUMP - COLD START DEVICE (CSD)

HOW TO RE-MOUNT PARTS OF CSD

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Mount the timer holder

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Insert the timer spring

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3. INJECTION PUMP - COLD START DEVICE (CSD)

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Insert the timer piston
(with some diesel for
lubrication)

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3. INJECTION PUMP - COLD START DEVICE (CSD)

Insert the timer cap

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Timer cap installed

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3. INJECTION PUMP - COLD START DEVICE (CSD)

Place the solenoid plunger

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And the solenoid spring

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3. INJECTION PUMP - COLD START DEVICE (CSD)

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Finaly mount the solenoid

valve. Make sure that the

o-ring is mounted correct
as shown here. At
disassembly the o-ring
cán remain seated on the
solenoid plunger!

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4. EXHAUST GAS RECIRCULATION (EGR)

Electric controlling

EGR

VALVE

ECU

goal of EGR valve:

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Speed & Load
& temp-coolant

Output

Electronic Control
for EGR valve

Intake Air

Exhaust Gas

combustion temp. reduction

NOx reduction

EGR principe:
By recirculating exhaust gases in the intake, the available gases to combust will be diminuished and that causes
slowing down & cooling of the combustion process by several hundred degrees, thus reducing NOx formation.

!! For electronically controlled EGR engine, it is necessary tu use fuel with max. 1000 ppm of sulfur !!!  In

case of too much sulfur parts, sulfuric acid can be formed (due to the presence of recycled sulfur dioxide) and
cause corrosion on the cylinder liner and other major components

EGR domain

Engine Speed

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4. EXHAUST GAS RECIRCULATION (EGR)

Output from ECU to EGR valve:

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Fig 2-22

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EGR

VALVE

(A)

+12V

(A)
(B)

+12V

(B)

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5. COOLANT(WATER) TEMP SENSORS CD-8 & CD-30

yanmar

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Hyundai

water temp. sensor

CD-30

(21EA-62010 for R55-7A )

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Yanmar

water temp. sensor

CD-8

(XJAU-00896 for R55-7A)

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5. COOLANT(WATER) TEMP SENSOR CD-8 (YANMAR )

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Voltage sig.

0.3 ~ 4.7 V

(HOT temp COLD temp)

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Yanmar
water temp. sensor
CD-8

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6a. LOCATION OF YANMAR ECU (& other electric components)

R55-7A

ENGINE
CONTROL
UNIT

R55-7A

DIAGNOSTIC PLUG

YANMAR CN 148

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ECU

RESISTOR RS-1

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CR23
START
RELAY

CR24
AIR HEATER
RELAY

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6a. LOCATION OF YANMAR ECU (& other electric components)

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R80CR-9 (first model)

VIEW BEHIND CAB

ECU

ENGINE CONTROL
UNIT

R80CR-9

(later model)

VIEW

RH SIDE OF CAB

ECU

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DIAGNOSTIC PLUG

YANMAR CN148

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VIEW BEHIND CAB

ECU

R60CR-9

(later model)

6b. STARTER CONTROL

Starter Control

Starter safety control

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Changeable（Option）

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325 rpm

675 rpm

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6c. ECU INPUTS & OUTPUTS

Eng. oil ps

Overheat lamp

(accel dial)

Find detailed info on ECU in/outputs:
in "elec-control-manual"  p. 2-15/2-16-2-17

M-mode function

Eng. oil ps

Cluster

- 50 -

water temp
HYUNDAI

YANMAR

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Plug for
diagnose &
programming

to CDS

valve

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page 17

7. ENGINE VIEW

Air cleaner SW

CD 10

CSD valve (Cold

start device) CD 62

EGR valve (Exhaust

Gas Recirculation)

CN 193

RACK

ACTUATOR

CN 194

Lift pump

CN 145

Water Temp

CD 8

(Yanmar)

Water Temp

CD 30

(Hyundai)

Pre heater

CN 80

Eng Oil

press CD 18

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Tacho

(speed)

sensor

CD 17

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8a. ENGINE ERROR CODE SYSTEM -7A Series

When the ECU (engine control unit) detects an active engine fault,
the engine fault warning lamp on the cluster lights up and the beeper inside cluster starts beeping

Each engine fault code generates a specified amount of beeps with specified length:
Example 1

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LISTEN TO LENGTH &
FREQUENCE OF
BEEPS FOR
TROUBLESHOOTING !

“Accelerator engine failure”  BEEPS CODE = “5”
In this case the beeper creates 5 “short” beeps

Example 2

“ERG valve failure”  BEEPS CODE = “1 - 3”
In this case the beeper creates 1 “long” beep,

followed by 3 “short” beeps

In case of simultaneous engine faults, the different beep patterns will appear successively, in order of increasing number of beeps.
A complete overview of the engine errors list can be found on next pages

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ENGINE ERROR CODES LIST

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Number

of

beeps

ENGINE ERROR CODES LIST

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Number

of

beeps

ENGINE ERROR CODES LIST

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Number

of

beeps

8b. ENGINE ERROR CODE SYSTEM -9 Series

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SEE FULL LIST ON NEXT PAGES

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Find more info about Hyundai error
codes & Cluster functioning in the
manual: “CLUSTER 5~8 ton exc.”

YANMAR

To visualise other fault
codes, use the buttons:

8b. ENGINE ERROR CODE SYSTEM -9 Series

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9. YANMAR ENGINE DIAGNOSTIC TOOL (YEDST)

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PC Requirements PC/AT compatible

Part nr. of Yanmar Engine Diagnostic Tool : XJAU-01062

interface

USB cable

+ "CD"

cable to connect
in CN148
(diagn. plug)

Mind that some repair works (or others) can only be done by application
of the YEDST tool !

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-replacing of pump

-calibrating of ECU

-tuning of engine

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ECU

9. YANMAR ENGINE DIAGNOSTIC TOOL (YEDST) - EXTRACT

>> CONFIGURATION MENU (FOR REPLACE OF ECU, PUMP)

When you mount a new ECU, you need to copy the data from the injection
pump to the ECU: the data per injection pump is "individual " and "engine
specific.

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FULL INFO  SEE

PAGES 44...48 OF

YEDST MANUAL

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...

Pump data controller

...

...

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9. YANMAR ENGINE DIAGNOSTIC TOOL (YEDST) - EXTRACT

When you mount a new injection pump, the data from this pump needs to
be written to the ECU: in that case the ECU is updated according to the
settings of the new pump

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☞

At page 50

of YEDST

manual

>> CALIBRATION MENU (YEDST)

(APS)

>> TUNING (YEDST)

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☞

☞

At page 51

of YEDST

manual

At page 52

of YEDST

manual

10a. FUEL PUMP ADJUSTMENT

Before you adjust the pump timing make sure to
mark the current position! Also attach a mark
sticker on the engine next to the mark on the fuel
pump so you can measure how far you adjust the
fuel pump.

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10a. FUEL PUMP ADJUSTMENT

To be able to adjust the fuel pump you first have to loosen 7 bolts. 3 on the rear support and 4
on the flange at the distribution side. In red line you see the position of 2 of them behind the
pump house. These can be reached using a ¼, 14mm socket and extensions as shown in the
picture. The nuts and bolts don’t have to be removed just loosened.

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10a. FUEL PUMP ADJUSTMENT

The fuel pump can be tilted to advance or retard the fuel injection moment. To make this
possible the 7 bolts used to fixate the pump are provided with slotted holes.

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10a. FUEL PUMP ADJUSTMENT

To advance the fuel injection you have to turn clockwise when looking to the front of the
engine, the delay the fuel injection, turn counter-clockwise.

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10b. FUEL PUMP REPLACEMENT

If you like to replace the fuel pump you have to follow the previous steps but this time
completely remove the 7 mounting bolts on the pump and the support on the rear of the pump.
You also have to disconnect the fuel, oil & electric lines. Be carefull for high pressure when you
are disconnecting the fuel lines!
Proceed by removing the fuel pump drive gear cover. Then remove the center nut. NEVER
loosen the four flange bolts! They connect the fuel pump drive gear to the flange through slotted
holes. When they are loosened the fuel pump drive gear can rotate freely and all references of
timing will be lost!

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10b. FUEL PUMP REPLACEMENT

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Normally it is enough to put a mark on fuel pump drive gear
and idler to be able to reassemble the pump on the correct
position after removal. But when the injection pump was
mounted in the wrong position or the engine has rotated after
removal of the pump there is a more precise way to put
everything right on time.
On the crankshaft pully are 3 timing marks, 2 bulges and 1
notch. You have to align this notch to the 0° mark on the
distribution cover (TDC cyl.1), make sure that cyl 1 is not only
on his TDC but also on compression AND be able to see the
“B” mark on the idler in the middle (not to high or to low) of
the opening from the fuel pump driver cover. These 3
situations combined appear only once every !50! Crankshaft
revolutions so a little patience can be helpfull...
When you have the engine in this position you can align the

“B” mark on the fuel pump drive gear with the “B” mark of the

idler and the gears will be positioned perfectly.

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10b. FUEL PUMP REPLACEMENT

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If you replace the pump you have to calculate the injection timing difference between these pumps:

1) Remove the old pump and take a note of the timing index recorded in that pump.

2) Read the timing on the new pump and calculate the difference between new and old angle.

3) Put the pump temporarily on the gear case and install the drive gear accordingly to the ID marks you
made earlier. (Tightening torque of installation nut => 113 – 123 Nm)

4) Use the marking on the sticker to adjust the calculated (2) injection angle difference.

5) If you have calculated a positive angle correction value, push the fuel pump away from the cylinder block

to delay the injection timing and vice versa to advance the timing in case of a negative value.

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10b. FUEL PUMP REPLACEMENT

If there is no timing index on the pump body
you can find it in this table buy using the

pump ID number.

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END

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