YANMAR 3TNV-4TNV Series Shop Manual Unduh Grati 4

YANMAR 3TNV-4TNV Series
Shop Manual
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YANMAR engine shop manual
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TNV DI Service Manual
TNV series
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
INDUSTRIAL
ENGINES
This Service Manual has been developed for the exclusive use of service and repair professionals such as
Yanmar authorized Distributors and Yanmar authorized Dealers. It is written with these professionals in
mind and may not contain the necessary detail or safety statements that may be required for a non-
professional to perform the service or repair properly and / or safely. Please contact an authorized Yanmar
repair or service professional before working on your Yanmar product.
Disclaimers:
All information, illustrations and specifications in this manual are based on the latest information available
at the time of publishing. The illustrations used in this manual are intended as representative reference
views only. Moreover, because of our continuous 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

Section 1
TABLE OF
CONTENTS
Page
Table of Contents ................................................................................... iii
Introduction ......................................................................................... 1-1
Yanmar Warranties.............................................................................. 2-1
Safety.................................................................................................... 3-1
General Service Information .............................................................. 4-1
Engine .................................................................................................. 6-1
Periodic Maintenance ......................................................................... 5-1
Fuel System ......................................................................................... 7-1
Cooling System ................................................................................... 8-1
Lubrication System ............................................................................. 9-1
Turbocharger ..................................................................................... 10-1
Starter Motor ...................................................................................... 11-1
Alternator ........................................................................................... 12-1
Electric Wiring ................................................................................... 13-1
Troubleshooting ................................................................................ 14-1
TNV DI Service Manual iii
TABLE OF CONTENTS
This Page Intentionally Left Blank
iv 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 for accurate, quick and safe
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 answers to
any questions relating to field modifications.
TNV DI Service Manual 1-1
INTRODUCTION
1-2 TNV DI Service Manual

Section 2
YANMAR
WARRANTIES
Page
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
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
YANMAR WARRANTIES
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, radiators, air filters, fuel filters, and/or exhaust 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 two-
thousand (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 ownership 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.
YANMAR WARRANTIES Yanmar Limited Warranty
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 (The Japanese language page will be displayed.) For English language “click” on
“English Page.”)
• “Click” on “Network” in the website heading to view the “Yanmar Worldwide Network.”
• Choose and “Click” on the desired product group.
• “Click” on the Icon closest to your region.
• “Click” on the desired country or Associate company to locate your nearest authorized Yanmar industrial
engine dealer or distributor.
• You may also contact Yanmar by clicking on “Inquiry” in the website heading and typing in 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 found to be defective in material and / or workmanship. Such repairs and / or replacements will be
made at a location designated by Yanmar at no cost to the purchaser for parts or labor.
What is Not Covered by this Warranty?

This Warranty does not cover parts affected by or damaged by any reason other than defective 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.
Yanmar Limited Warranty YANMAR WARRANTIES

Yanmar Limited Warranty - Continued
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.
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.
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.
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 compression-
ignition engines must be designed, built and equipped to meet the State’s stringent anti-smog standards. In
all states, 1998 and later non-road compression-ignition engines must be designed, built and equipped to
meet the United States EPA emissions standards. Yanmar warrants the emission control system on your
engine for the periods of time listed below provided there has been no abuse, neglect or improper
maintenance of your engine.
Your emission control system may include parts such as the fuel injection system, electronic control unit,
exhaust gas recirculation (EGR) system and the air induction system. Also included may be hoses, belts,
connectors and other emission-related assemblies.
Where a warrantable condition 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 Operation

The warranty period is five (5) years or 3,000 hours of use, whichever occurs first.
Constant speed engines rated at or above
In the absence of a device to measure the hours of use, the engine has a
50 hp SAE (37 kW)
warranty period of five (5) years.
Constant speed engines rated under 50 hp The warranty period is two (2) years or 3,000 hours of use, whichever occurs first.
SAE (37 kW) with rated speeds greater than In the absence of a device to measure the hours of use, the engine has a
or equal to 3,000 rpm warranty period of two (2) years.
The warranty period is five (5) years or 3,000 hours of use, whichever occurs first.
Engines rated at or above 26 hp SAE
In the absence of a device to measure the hours of use, the engine has a
(19 kW)
warranty period of five (5) years.
The warranty period is two (2) years or 3,000 hours of use, whichever occurs first.
Engines rated under 26 hp SAE (19 kW) In the absence of a device to measure the hours of use, the engine has a
warranty period of two (2) years.
Emission System Warranty 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 Parts:
This warranty covers engine components that are a part of the emission control system of the engine as
delivered by Yanmar to the original retail purchaser. Such components may include the following:
• Fuel Injection System
• Electronic Control System
• Cold Start Enrichment System
• Intake Manifold
• Turbocharger Systems
• Exhaust Manifold
• EGR System
• Positive Crankcase Ventilation System
• Hoses, belts, connectors and assemblies associated with emission control systems
Since emissions-related parts may vary slightly between models, certain models may not contain all of
these parts and other models may contain the functional equivalents.
YANMAR WARRANTIES Emission System Warranty
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 or use
of non-recommended fuels and lubricating oils; accident-caused damage, and replacement of expendable
items made in connection with scheduled maintenance. Yanmar disclaims any responsibility for incidental
or consequential damages such as loss of time, inconvenience, loss of use of equipment / engine or
commercial loss.
Owner’s Warranty Responsibilities:

As the engine owner, you are responsible for the performance of the required maintenance listed in
your owner’s manual. Yanmar recommends that you retain all documentation, including receipts, covering
maintenance on your non-road compression-ignition engine, but Yanmar cannot deny warranty solely for
the lack of receipts, or for your failure to ensure the performance of all scheduled maintenance.
Yanmar may deny your warranty coverage of your non-road compression-ignition engine if a part has failed
due to abuse, neglect, improper maintenance or unapproved modifications.
Your engine is designed to operate on diesel fuel only. Use of any other fuel may result in your engine no
longer operating in compliance with applicable emissions requirements.
You are responsible for initiating the warranty process. You must present your engine to a Yanmar dealer as
soon as a problem exists. The warranty repairs should be completed by the dealer as expeditiously as
possible. If you have any questions regarding your warranty rights and responsibilities, or would like
information on the nearest Yanmar dealer or authorized service center, you should contact Yanmar
America Corporation at 1-800-872-2867.

Section 3
SAFETY
Page
Safety Statements ........................................................................... 3-3

Safety Precautions .......................................................................... 3-4
SAFETY
Safety Statements SAFETY
SAFETY STATEMENTS
A CAUTION
Yanmar is concerned for your safety and your Caution (the word “CAUTION” is in black
machine’s condition. Safety statements are one of letters with a yellow rectangle behind it)
the primary ways to call your attention to the – indicates a potentially hazardous
potential hazards associated with Yanmar TNV situation which, if not avoided, may
engine operation. Follow the precautions listed result in minor or moderate injury.
throughout the manual before operation, during
0000001en
operation and during periodic maintenance
procedures for your safety, the safety of others and
to protect the performance of your engine. Keep the CAUTION
labels from becoming dirty or torn and replace Caution without the safety alert symbol
them if they are lost or damaged. Also, if you need indicates a potentially hazardous
to replace a part that has a label attached to it, situation that can cause damage to the
make sure you order the new part and label at the machine, personal property and / or the
same time. environment or cause the machine to
operate improperly.
This safety alert symbol appears 0000001en
A
with most safety statements. It
means 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
SAFETY Safety Precautions
SAFETY PRECAUTIONS
A DANGER
A DANGER
FIRE AND EXPLOSION HAZARD!

• Diesel fuel is flammable and explosive
under certain conditions.
SCALD HAZARD!
• When you remove any fuel system
• NEVER remove the radiator cap if the
component to perform maintenance
engine is hot. Steam and hot engine
(such as changing the fuel filter) place
coolant will spurt out and seriously
an approved container under the
burn you. Allow the engine to cool
opening to catch the fuel.
down before you attempt to remove
the radiator cap. • NEVER use a shop rag to catch the
fuel. Vapors from the rag are
• Tighten the radiator cap securely after
flammable and explosive.
you check the radiator. Steam can
spurt out during engine operation if • Wipe up any spills immediately.
the cap is loose. • Wear eye protection. The fuel system
• ALWAYS check the level of the engine is under pressure and fuel could spray
coolant by observing the reserve tank. out when you remove any fuel system
component.
• Failure to comply will result in death or
serious injury. • Failure to comply will result in death or
0000002en
serious injury.
0000009en
A DANGER
A DANGER
EXPLOSION HAZARD!
• Keep the area around the battery • Only use the key switch to start the
well-ventilated. While the engine is engine.
running or the battery is charging,
hydrogen gas is produced which can • NEVER jump-start the engine. Sparks
be easily ignited. caused by shorting the battery to the
starter terminals may cause a fire or
• Keep sparks, open flame and any other explosion.
form of ignition away while the engine
is running or battery is charging. • Failure to comply will result in death or
serious injury.
0000004en
serious injury.
0000003en
Safety Precautions SAFETY
A DANGER A DANGER
FIRE AND EXPLOSION HAZARD! FIRE AND EXPLOSION HAZARD!

• Diesel fuel is flammable and explosive • Diesel fuel is flammable and explosive
under certain conditions. under certain conditions.
• If the unit has an electric fuel pump, • Only fill the fuel tank with diesel fuel.
when you prime the fuel system, turn Filling the fuel tank with gasoline may
the key switch to the ON position for result in a fire and will damage the
10 to 15 seconds to allow the electric engine.
fuel pump to prime the system.
• NEVER refuel with the engine running.
• If the unit has a mechanical fuel pump,
when you prime the fuel system, • Wipe up all spills immediately.
operate the fuel priming lever of the • Keep sparks, open flames or any other
mechanical fuel pump several times form of ignition (match, cigarette,
until the fuel filter cup is filled with static electric source) well away when
fuel. refueling.
• Failure to comply will result in death or • NEVER overfill the fuel tank.
serious injury. • Fill the fuel tank. Store any containers
0000010en
containing fuel in a well-ventilated
area, away from any combustibles or
sources of ignition.
serious injury.
0000005en
A DANGER A DANGER

CRUSH HAZARD!
under certain conditions. • When you need to transport an engine
for repair, have a helper assist you to
• Be sure to place the diesel fuel
attach it to a hoist and load it on a
container on the ground when
truck.
transferring the diesel fuel from the
pump to the container. Hold the hose • NEVER stand under a hoisted engine.
nozzle firmly against the side of the If the hoist mechanism fails, the
container while filling it. This prevents engine will fall on you, causing death
static electricity buildup which could or serious injury.
cause sparks and ignite fuel vapors. • Failure to comply will result in death or
• NEVER place diesel fuel or other serious injury.
flammable material such as oil, hay or 0000008en
dried grass close to the engine during

engine operation or shortly after
shutdown.
A DANGER
serious injury.
0000014en

• 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.
serious injury.
0000015en
A DANGER A DANGER

EXPLOSION HAZARD!
• NEVER check the remaining battery under certain conditions.
charge by shorting out the terminals.
• NEVER use diesel fuel as a cleaning
This will result in a spark and may
agent.
cause an explosion or fire. Use a
hydrometer to check the remaining • Failure to comply will result in death or
battery charge. serious injury.
0000012en
• If the electrolyte is frozen, slowly warm
the battery before you recharge it.
serious injury.
0000007en
A DANGER

• NEVER remove the fuel cap with the
engine running.
serious injury.
0000011en

A WARNING A WARNING
SEVER HAZARD! EXHAUST HAZARD!

• Keep hands and other body parts • NEVER operate the engine in an
away from moving / rotating parts enclosed area such as a garage,
such as the cooling fan, flywheel or tunnel, underground room, manhole or
PTO shaft. ship’s hold without proper ventilation.
• Wear tight-fitting clothing and keep • NEVER block windows, vents, or other
your hair short or tie it back while the means of ventilation if the engine is
engine is running. operating in an enclosed area. All
• Remove all jewelry before you operate internal combustion engines create
or service the machine. carbon monoxide gas during
operation. Accumulation of this gas
• NEVER start the engine in gear. within an enclosure could cause
Sudden movement of the engine illness or even death.
and / or machine could cause death or
serious personal injury. • Make sure that all connections are
tightened to specifications after repair
• NEVER operate the engine without the is made to the exhaust system.
guards in place.
• Failure to comply could result in death
• Before you start the engine make sure or serious injury.
that all bystanders are clear of the 0000003en
area.
• Keep children and pets away while the
engine is operating.
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 ALCOHOL AND DRUG HAZARD!
or serious injury.
0000002en
• NEVER operate the engine while you
are under the influence of alcohol or
drugs.
• NEVER operate the engine when you
are feeling ill.
or serious injury.
0000004en
A WARNING A WARNING
BURN HAZARD!
EXPOSURE HAZARD! • If you must drain the engine oil while it

is still hot, stay clear of the hot engine
• Wear personal protective equipment
oil to avoid being burned.
such as gloves, work shoes, eye and
hearing protection as required by the • ALWAYS wear eye protection.
task at hand. • Failure to comply could result in death
• NEVER wear jewelry, unbuttoned or serious injury.
cuffs, ties or loose-fitting clothing 0000011en
when you are working near

moving / rotating parts such as the
cooling fan, flywheel or PTO shaft.
A WARNING
• 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 BURN HAZARD!
wearing a headset to listen to music or • Batteries contain sulfuric acid. NEVER
radio because it will be difficult to hear allow battery fluid to come in contact
the alert signals. with clothing, skin or eyes. Severe
• Failure to comply could result in death burns could result. ALWAYS wear
or serious injury. safety goggles and protective clothing
0000005en
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.
or serious injury.
0000007en
A WARNING A WARNING
HIGH-PRESSURE HAZARD!
ENTANGLEMENT HAZARD!
• Avoid skin contact with the
• Stop the engine before you begin to
high-pressure diesel fuel spray caused
service it.
by a fuel system leak such as a broken
fuel injection line. High-pressure fuel • NEVER leave the key in the key switch
can penetrate your skin and result in when you are servicing the engine.
serious injury. If you are exposed to Someone may accidentally start the
high-pressure fuel spray, obtain engine and not realize you are
prompt medical treatment. servicing it. This could result in a
serious injury.
• NEVER check for a fuel leak with your
hands. ALWAYS use a piece of wood • If you must service the engine while it
or cardboard. Have your authorized is operating, remove all jewelry, tie
Yanmar industrial engine dealer or back long hair, and keep your hands,
distributor repair the damage. other body parts and clothing away
from moving / rotating parts.
or serious injury. • Failure to comply could result in death
0000008en
or serious injury.
0000010en
A WARNING
A WARNING
SHOCK HAZARD! BURN HAZARD!

• Turn off the battery switch (if • Wait until the engine cools before you
equipped) or disconnect the negative drain the engine coolant. Hot engine
battery cable before servicing the coolant may splash and burn you.
electrical system.
• Check the electrical harnesses for or serious injury.
cracks, abrasions, and damaged or 0000016en
corroded connectors. ALWAYS keep

the connectors and terminals clean.
or serious injury.
0000009en
A WARNING A WARNING
SUDDEN MOVEMENT HAZARD!
• Engaging the transmission or PTO at
an elevated engine speed could result
in unexpected movement of the
equipment.
FUME / BURN HAZARD!
• Failure to comply could result in death • Always read and follow safety related
or serious injury. precautions found on containers of
0000006en
hazardous substances like parts
cleaners, primers, sealants and
A WARNING sealant removers.
or serious injury.
0000014en
BURN HAZARD! A WARNING

Never apply over 40 psi (2.8 kgf/cm) to
• Keep your hands and other body parts
the waste gate actuator.
away from hot engine surfaces such
0000026en
as the muffler, exhaust pipe,
turbocharger (if equipped) and engine
block during operation and shortly A WARNING
after you shut the engine down. These • Never inject fuel toward you. Since the
surfaces are extremely hot while the fuel is injected at high pressure from
engine is operating and could the nozzle, it may penetrate the skin,
seriously burn you. resulting in injury.
• Failure to comply could result in death • Never inject fuel toward a fire source.
or serious injury. Atomized fuel is highly flammable and
0000015en
may cause a fire or burn skin.
0000028en
A WARNING
To prevent possible eye injury, always

wear SAFETY GLASSES while servicing
the engine.
0000013en
A WARNING A WARNING
• Never use the E-ECU for other • Replacing the fuel injection pump
purposes than intended or in other involves rewriting the fuel injection
ways than specified by Yanmar. Doing data in the E-ECU.
so could result in the violation of Be sure to contact your local Yanmar
emission control regulations and will dealer before replacing the fuel
void the product warranty. injection pump.
• Improper use or misuse of the E-ECU Failure to rewrite the fuel injection
may result in death or serious injury data before replacing the fuel injection
due to an abrupt and unexpected pump will void the engine warranty.
increase in engine speed. • Improper use or misuse of the E-ECU
9999999en may result in death or serious injury
due to an abrupt and unexpected
increase in engine speed.
A WARNING 9999997en
• Be sure to use the E-ECU in

conjunction with the engines whose
models or serial numbers are A WARNING
specified by Yanmar. • Replacing the E-ECU involves
Other E-ECU/engine combinations migrating the fuel injection data to the
than specified will void the engine existing E-ECU to the new unit.
warranty. Be sure to contact your local Yanmar
• Improper use or misuse of the E-ECU dealer before replacing the E-ECU.
may result in death or serious injury Failure to migrate the fuel injection
due to an abrupt and unexpected data before replacing the E-ECU will
increase in engine speed. void the engine warranty.
9999998en • 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
A CAUTION A CAUTION
COOLANT HAZARD! PINCH HAZARD!

• Wear eye protection and rubber gloves Carefully rotate the alternator toward the
when you handle long life or extended cylinder block while loosening the
life engine coolant. If contact with the V-belt. Failure to comply may result in
eyes or skin should occur, flush eyes minor or moderate injury.
and wash immediately with clean 0000014en
water.
• Failure to comply may result in minor A CAUTION
or moderate injury.
If any oil pump component clearance
0000005en
exceeds its limit, the oil pump must be
replaced as an assembly.
A CAUTION 0000015en
CAUTION
• Only use diesel fuels recommended by
Yanmar for the best engine
performance, to prevent engine
damage and to comply with EPA / ARB
FLYING OBJECT HAZARD! warranty requirements.
• ALWAYS wear eye protection when • Only use clean diesel fuel.
servicing the engine and when using
compressed air or high-pressure • NEVER remove the primary strainer (if
water. Dust, flying debris, compressed equipped) from the fuel tank filler port.
air, pressurized water or steam may If removed, dirt and debris could get
injure your eyes. into the fuel system causing it to clog.
0000004en
• Failure to comply may result in minor
or moderate injury.
0000003en
CAUTION
NEVER attempt to adjust the low or high
A CAUTION idle speed limit screw. This may impair
the safety and performance of the
Be sure to secure the engine solidly to machine and shorten its life. If
prevent injury or damage to parts due to adjustment is ever required, contact
the engine falling during work on the your authorized Yanmar industrial
engine. engine dealer or distributor.
0000009en
0000045en
CAUTION CAUTION
If any problem is noted during the visual Observe the following environmental
check, the necessary corrective action operating conditions to maintain engine
should be taken before you operate the performance and avoid premature
engine. engine wear:
0000021en
• Avoid operating in extremely dusty
conditions.
CAUTION • Avoid operating in the presence of
NEVER hold the key in the START chemical gases or fumes.
position for longer than 15 seconds or • Avoid operating in a corrosive
the starter motor will overheat. atmosphere such as salt water spray.
0000007en
• NEVER install the engine in a
floodplain unless proper precautions
CAUTION are taken to avoid being subject to a
Make sure the engine is installed on a flood.
level surface. If a continuously running • NEVER expose the engine to the rain.
engine is installed at an angle greater 0000003en
than (IDI = 25°, DI = 30°) in any direction
or if an engine runs for short periods of
time (less than three minutes) at an CAUTION
angle greater than (IDI = 30°, DI = 35°) in Observe the following environmental
any direction, engine oil may enter the operating conditions to maintain engine
combustion chamber causing excessive performance and avoid premature
engine speed and white exhaust smoke. engine wear:
This may cause serious engine damage.
• The standard range of ambient
0000010enTNV
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
CAUTION CAUTION
The illustrations and descriptions of • Only use the engine coolant specified.
optional equipment in this manual, such Other engine coolants may affect
as the operator’s console, are for a warranty coverage, cause an internal
typical engine installation. Refer to the buildup of rust and scale and / or
documentation supplied by the optional shorten engine life.
equipment manufacturer for specific • Prevent dirt and debris from
operation and maintenance instructions. contaminating the engine coolant.
0000018en
Carefully clean the radiator cap and
the surrounding area before you
CAUTION remove the cap.
If any indicator illuminates during • NEVER mix different types of engine
engine operation, stop the engine coolants. This may adversely affect the
immediately. Determine the cause and properties of the engine coolant.
repair the problem before you continue 0000006en
to operate the engine.

0000029en
CAUTION
• NEVER overfill the engine with engine
CAUTION oil.
• Only use the engine oil specified. • ALWAYS keep the oil level between the
Other engine oils may affect warranty upper and lower lines on the oil
coverage, cause internal engine cap / dipstick.
components to seize and / or shorten
0000015en
engine life.
• Prevent dirt and debris from
CAUTION
contaminating the engine oil. Carefully
clean the oil cap / dipstick and the For maximum engine life, Yanmar
surrounding area before you remove recommends that when shutting the
the cap. engine down, you allow the engine to
idle, without load, for five minutes. This
• NEVER mix different types of engine will allow the engine components that
oil. This may adversely affect the operate at high temperatures, such as
lubricating properties of the engine oil. the turbocharger (if equipped) and
• NEVER overfill. Overfilling may result exhaust system, to cool slightly before
in white exhaust smoke, engine the engine itself is shut down.
overspeed or internal damage. 0000008en
0000005en
CAUTION
NEVER use an engine starting aid such
as ether. Engine damage will result.
0000009en
CAUTION 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,
• ALWAYS be environmentally engine oil leaks, coolant leaks, and for
responsible. proper operation of the indicators
• Follow the guidelines of the EPA or and / or gauges.
other governmental agencies for the • During the first hour of operation, vary
proper disposal of hazardous the engine speed and the load on the
materials such as engine oil, diesel engine. Short periods of maximum
fuel and engine coolant. Consult the engine speed and load are desirable.
local authorities or reclamation facility. Avoid prolonged operation at
• NEVER dispose of hazardous minimum or maximum engine speeds
materials irresponsibly by dumping and loads for the next four to five
them into a sewer, on the ground, or hours.
into ground water or waterways. • During the break-in period, carefully
• Failure to follow these procedures may observe the engine oil pressure and
seriously harm the environment. engine temperature.
0000013en • During the break-in period, check the
engine oil and coolant levels
CAUTION frequently.
0000011en
NEVER engage the starter motor while
the engine is running. This may damage
the starter motor pinion and / or ring CAUTION
gear. • NEVER attempt to modify the engine’s
0000012en 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 in Warranty Section.
0000044enTNVDISM
CAUTION CAUTION
Protect the air cleaner, turbocharger (if If any indicator fails to illuminate when
equipped) and electric components the key switch is in the ON position, see
from damage when you use steam or your authorized Yanmar industrial
high-pressure water to clean the engine. engine dealer or distributor for service
0000014en before operating the engine.
0000028en
CAUTION
NEVER use high-pressure water or CAUTION
compressed air at greater than 28 psi Establish a periodic maintenance plan
(193 kPa; 19 686 mmAq) or a wire brush according to the engine application and
to clean the radiator fins. Radiator fins make sure you perform the required
damage easily. periodic maintenance at the intervals
0000016en indicated. Failure to follow these
guidelines will impair the engine’s safety
and performance characteristics,
CAUTION shorten the engine’s life and may affect
NEVER attempt to adjust the low or high the warranty coverage on your engine.
idle speed limit screw. This may impair
See Yanmar Limited Warranty in
the safety and performance of the
Warranty Section.
machine and shorten its life. If the idle
speed limit screws require adjustment, Consult your authorized Yanmar dealer
see your authorized Yanmar industrial or distributor for assistance when
engine dealer or distributor. checking items marked with a .
0000017en 0000024enTNVDISM
CAUTION CAUTION
The tightening torque in the Standard If the fuel filter / water separator is
Torque Chart (see General Service positioned higher than the fuel level in
Information section) should be applied the fuel tank, water may not drip out
only to the bolts with a “7” head. (JIS when the fuel filter / water separator
strength classification: 7T) drain cock is opened. If this happens,
turn the air vent screw on the top of the
• Apply 60% torque to bolts fuel filter / water separator 2-3 turns
that are not listed. counterclockwise.
• Apply 80% torque when Be sure to tighten the air vent screw
tightened to aluminum alloy. after the water has drained out.
0000023enTNVDISM 0000025en
CAUTION CAUTION
• When the engine is operated in dusty Do not loosen or remove the four bolts
conditions, clean the air cleaner retaining the fuel injection pump drive
element more frequently. gear to the fuel injection pump hub. Do
• NEVER operate the engine with the air not disassemble the fuel injection pump
cleaner element(s) removed. This may drive gear from the hub. Correct fuel
allow foreign material to enter the injection timing will be very difficult or
engine and damage it. impossible to achieve.
0000031en
0000026en
CAUTION CAUTION
The maximum air intake restriction, in The starter motor can be damaged if
terms of differential pressure operated continuously longer than
measurement, must not exceed 0.90 psi 10 seconds while performing the
(6.23 kPa; 635 mmAq). Clean or replace no-load test.
the air cleaner element if the air intake 0000034en
restriction exceeds the above

mentioned value. CAUTION
0000046en
Do not short-circuit the charging system
between alternator terminals IG and L.
CAUTION Damage to the alternator will result.
It is important to perform daily checks. 0000035en
Periodic maintenance prevents

unexpected downtime, reduces the CAUTION
number of accidents due to poor Do not connect a load between
machine performance and helps extend alternator terminals L and E. Damage to
the life of the engine. the alternator will result.
0000060en 0000036en
CAUTION CAUTION
If the oil pump must be replaced, replace Do not remove the positive (+) battery
it as an assembly only. Do not replace cable from alternator terminal B while
individual components. the engine is operating. Damage to the
0000030en alternator will result.
0000037en
CAUTION
Do not turn the battery switch OFF while
the engine is operating. Damage to the
alternator will result.
0000038en

CAUTION CAUTION
Do not operate the engine if the Do not use a high-pressure wash
alternator is producing unusual sounds. directly on the alternator. Water will
Damage to the alternator will result. damage the alternator and result in
0000039en inadequate charging.
0000049en
CAUTION
If the engine coolant pump must be CAUTION
replaced, replace the engine coolant Do not reverse the positive (+) and
pump as an assembly only. Do not negative (-) ends of the battery cable.
attempt to repair the engine coolant The alternator diode and stator coil will
pump or replace individual components. be damaged.
0000041en 0000050en
CAUTION CAUTION
Use a new special O-ring between the When the battery indicator goes out, it
engine coolant pump and the joint. Be should not come on again. The battery
sure to use the special O-ring for each indicator only comes on during
engine model. Although the O-ring operation if the alternator fails. However,
dimensions are the same as a if an LED is used in the battery indicator,
commercially available O-ring, the the LED will shine faintly during normal
material is different. operation.
0000042en 0000051en
CAUTION CAUTION
Remove or install the high-pressure fuel Using a non-specified V-belt will cause
injection lines as an assembly whenever inadequate charging and shorten the
possible. Disassembling the belt life. Use the specified belt.
high-pressure fuel injection lines from 0000052en
the retainers or bending any of the fuel

lines will make it difficult to reinstall the
fuel lines.
CAUTION
0000047en
Agricultural or other chemicals,
especially those with a high sulfur
content, can adhere to the IC regulator.
CAUTION This will corrode the conductor and
After marking the position of the pump result in battery over-charging (boiling)
drive gear, do not rotate the engine and charging malfunctions. Consult
crankshaft. Rotating the crankshaft will Yanmar before using the equipment in
cause the fuel injection pump to become such an environment or the warranty is
misaligned. voided.
0000048en 0000053en
CAUTION CAUTION
Make sure that the combined total Removing the battery cables or the
resistance of the battery cable in both battery while the engine is operating
directions between the starter motor may cause damage to the current limiter
and the battery is within the value depending on the electrical equipment
indicated on the wiring diagram. The being used. This situation could cause
starter motor will malfunction or break loss of control of output voltage. The
down if the resistance is higher than the continuous high voltage of 23-24 volts
specified value. (for 5000 rpm dynamo) will damage the
0000054en current limiter and other electrical
equipment.
CAUTION 0000058en
The starter motor is water-proofed

according to JIS D 0203, R2 which CAUTION
protects the motor from rain or general Reversing the battery cable connections
cleaning. Do not use high-pressure at the battery or on the engine will
wash or submerse the starter motor in destroy the SCR diode in the current
water. limiter. This will cause the charging
0000055en system to malfunction and may cause
damage to the electrical harnesses.
CAUTION 0000059en
Use a specialized battery charger to

recharge a battery with a voltage of CAUTION
8 volts or less. Booster starting a battery Avoid damage to the turbocharger or the
with a voltage of 8 volts or less will engine. Do not spray blower wash fluid
generate an abnormally high voltage or water too quickly.
and destroy electrical equipment. Use short strokes from a spray bottle to
0000056en
inject blower wash fluid or water into the
turbocharger.
CAUTION Spraying too much wash fluid or water,
Make sure that the combined total or spraying too quickly will damage the
resistance of the battery cable in both turbocharger.
directions between the starter motor 0000063en
and the battery is within the value

indicated in the Battery Cable
CAUTION
Resistance chart in the Electric Wiring
Section of this manual. The starter Do not allow any material to fall into the
motor will malfunction and fail if the oil lines or the oil inlet and outlet ports
resistance is higher than the specified of the turbocharger.
value. 0000064en
0000057en
CAUTION CAUTION
If the waste valve does not meet Do not rotate the crankshaft with the
specifications, replace the turbocharger injection pump removed.
or have it repaired by a qualified repair 0000083en
facility.
0000078en
CAUTION
Keep the piston pin parts, piston
CAUTION assemblies, and connecting rod
• NEVER attempt to modify the engine’s assemblies together to be returned to
design or safety features such as the same position during the
defeating the engine speed limit reassembly process. Label the parts
control or the diesel fuel injection using an appropriate method.
quantity control. 0000088en
• Modifications may impair the engine’s

safety and performance CAUTION
characteristics and shorten the
Do not allow the honing tool to operate
engine’s life. Any alterations to this
in one position for any length of time.
engine may void its warranty. Be sure
Damage to the cylinder wall will occur.
to use Yanmar genuine replacement
Keep the tool in constant up-and-down
parts.
motion.
0000079en
0000090en
CAUTION CAUTION
Identify all parts and their location using
Any part which is found defective as a
an appropriate method. It is important
result of inspection or any part whose
that all parts are returned to the same
measured value does not satisfy the
position during the reassembly process.
standard or limit must be replaced.
0000080en
0000119en
CAUTION CAUTION
Each pressure adjusting shim removed
Any part determined to not meet the
or added changes the pressure
service standard or limit before the next
threshold by approximately 275 psi
service, as determined from the state of
(1.9 MPa, 19 kgf/cm2). Adding adjusting
current rate of wear, should be replaced
shims increases the threshold pressure.
even though the part currently meets the
Removing adjusting shims reduces the
service standard limit.
pressure threshold.
0000120en
0000081en
CAUTION CAUTION
• NEVER remove or attempt to remove Shut down the engine if the fault
the tamper-proof devices from the indicator comes on.
full-load fuel adjusting screw or the Continuing running the engine with the
high-speed throttle limit screw on the fault indicator being on may result in a
fuel injection pump and governor serious malfunction of or damage to the
assembly. These adjustments have engine, and will void the engine
been made at the factory to meet all warranty.
applicable emissions regulations and
9999999en
then sealed.
• NEVER attempt to make any
adjustments to these sealed
CAUTION
adjustment screws. If adjustments are Do not energize the starter for a period
required, they can be made only by a of longer than 15 seconds.
qualified fuel injection shop that will Take a pause of at least 30 seconds
ensure the injection pump continues between energization of the starter.
to meet all applicable emissions
regulations and then replace the Otherwise the starter could suffer
tamper-proof seals. damage.
9999998en
• Tampering with or removing these
devices may void the “Yanmar Limited
Warranty.” CAUTION
0000146en • High-pressure washing not
recommended.
CAUTION • Avoid using high-pressure washing for
Never use a steel wire brush to clean electronic or electric devices installed
fuel injectors. Damage to the nozzle and in, on or around the engine, including
other components is likely to result. the E-ECU, relays and harness
couplers.
0000172en
Otherwise such devices may suffer

malfunction due to water ingress into
CAUTION them.
Allow the engine to warm-up for at least 9999997en
five minutes and the idle speed of the

engine to return to normal before
engaging the transmission or any PTOs.
Engaging the transmission or PTO at an
elevated engine speed could result in an
unexpected movement of the
equipment.
0000159en
CAUTION
• Do not plug or unplug the E-ECU for a
period of at least 6 seconds after
power to the unit has been turned on
or off.
• Do not touch connector pins of the E-
ECU with bare hands.
Doing so may result in corrosion of the
connector pins and/or damage to the
internal circuits of the E-ECU due to
static electricity.
• Do not force a measuring probe into
the female coupler.
Doing so may cause contact failure of
the connector pins, resulting in
malfunction of the E-ECU.
• Take care to prevent water from
entering the couplers when plugging
or unplugging the connector.
Water inside the couplers may cause
corrosion, resulting in malfunction of
the E-ECU.
• Avoid plugging/unplugging the
connector more than approx. 10 times.
Frequent plugging/unplugging of the
connector may cause contact failure of
the connector pins, resulting in
malfunction of the E-ECU.
• Do not use the E-ECU that has ever
suffered drop impact.
9999996en
CAUTION
Always check the battery for proper
charge.
Otherwise the electronically controlled
engines may fail to start.
9999995en

Section 4
GENERAL SERVICE
INFORMATION
Page
Component Identification................................................................. 4-3

Location of Labels ........................................................................... 4-5
Engine Nameplate (Typical) ...................................................... 4-6
Emission Control Regulations ......................................................... 4-6
EPA / ARB Regulations - USA Only.......................................... 4-6
Emission Control Labels.................................................................. 4-6
The 97/68/EC Directive Certified Engines....................................... 4-7
Engine Family.................................................................................. 4-7
Function of Major Engine Components........................................... 4-8
MAIN ELECTRONIC CONTROL COMPONENTS AND
FEATURES ..................................................................................... 4-9
Function of Cooling System Components ..................................... 4-11
Diesel Fuel .................................................................................... 4-12
Diesel Fuel Specifications ....................................................... 4-12
Filling The Fuel Tank............................................................... 4-13
Priming the Fuel System ......................................................... 4-15
Engine Oil...................................................................................... 4-15
Engine Oil Specifications ........................................................ 4-15
Engine Oil Viscosity................................................................. 4-16
Checking Engine Oil................................................................ 4-16
Adding Engine Oil.................................................................... 4-17
Engine Oil Capacity (Typical) .................................................. 4-17
Engine Coolant.............................................................................. 4-18
Engine Coolant Specifications................................................. 4-19
Filling Radiator with Engine Coolant........................................ 4-19
Engine Coolant Capacity (Typical) .......................................... 4-20
Specifications ................................................................................ 4-21
GENERAL SERVICE INFORMATION
Description of Model Number................................................... 4-21

Engine Speed Specifications.................................................... 4-21
Engine General Specifications ................................................. 4-22
Principal Engine Specifications ...................................................... 4-23
3TNV82A (~ EPA Tier2)........................................................... 4-23
3TNV84 (~ EPA Tier2) ............................................................. 4-24
3TNV84T (~ EPA Tier2) ........................................................... 4-25
3TNV88 (~ EPA Tier2) ............................................................. 4-26
4TNV84 (~ EPA Tier2) ............................................................. 4-27
4TNV84T (~ EPA Tier2) ........................................................... 4-28
4TNV88 (~ EPA Tier2) ............................................................. 4-29
4TNV94L (~ EPA Tier2) ........................................................... 4-30
4TNV98 (~ EPA Tier2) ............................................................. 4-31
4TNV98T (~ EPA Tier2) ........................................................... 4-32
4TNV106 (~ EPA Tier2) ........................................................... 4-33
4TNV106T (~ EPA Tier2) ......................................................... 4-34
3TNV82A-B (complies with EPA Interim Tier4)........................ 4-35
3TNV84T-B (complies with EPA Interim Tier4) ........................ 4-36
3TNV88-U (complies with EPA Interim Tier4).......................... 4-37
3TNV88-B (complies with EPA Interim Tier4) .......................... 4-38
4TNV84T-Z (complies with EPA Interim Tier4) ........................ 4-39
4TNV88-U (complies with EPA Interim Tier4).......................... 4-40
4TNV88-B (complies with EPA Interim Tier4) .......................... 4-41
4TNV98-E (complies with EPA Interim Tier4) .......................... 4-42
4TNV98-Z (complies with EPA Interim Tier4) .......................... 4-43
4TNV98T-Z (complies with EPA Interim Tier4) ........................ 4-44
Engine Service Standards.............................................................. 4-45
Tightening Torques for Standard Bolts and Nuts ........................... 4-46
Abbreviations and Symbols............................................................ 4-48
Abbreviations............................................................................ 4-48
Symbols.................................................................................... 4-48
Unit Conversions............................................................................ 4-49
Unit Prefixes............................................................................. 4-49
Units of Length ......................................................................... 4-49
Units of Volume........................................................................ 4-49
Units of Mass............................................................................ 4-49
Units of Force ........................................................................... 4-49
Units of Torque......................................................................... 4-49
Units of Pressure...................................................................... 4-49
Units of Power .......................................................................... 4-49
Units of Temperature................................................................ 4-49
Component Identification GENERAL SERVICE INFORMATION
COMPONENT IDENTIFICATION
Figure 4-1 shows where the major engine components are located.
3TNV82A(-B),3TNV84,3TNV84T(-B),3TNV88(-B)(-U),4TNV84,4TNV88(-B)(-U),
4TNV94L,4TNV984TNV106,4TNV106T
(1) (2) (20)

(19)
(3)
(18)
(4)
(17)
(16)
(15)
(5) (21)
(14)
(25)
(6)
(13)
(24)
(22)
(23)
0000015B
(12) (11) (10) (9) (8) (7)
1 – Lifting Eye (Flywheel End) 14 – Governor Lever
2 – Turbocharger* 15 – Intake Manifold
3 – Lifting Eye (Engine Cooling Fan End) 16 – Fuel Filter
4 – Engine Coolant Pump 17 – Fuel Inlet
5 – Engine Cooling Fan 18 – Fuel Return to Fuel Tank
6 – Crankshaft V-Pulley 19 – Top Filler Port (Engine Oil)
7 – V-Belt 20 – Rocker Arm Cover
8 – Side Filler Port (Engine Oil) 21 – Air Intake Port (From Air Cleaner)
9 – Drain Plug (Engine Oil)** 22 – Flywheel
10 – Fuel Injection Pump 23 – Starter Motor
11 – Engine Oil Cooler*** 24 – Exhaust Manifold
12 – Engine Oil Filter 25 – Alternator
13 – Dipstick (Engine Oil)
Figure 4-1
* Only applies to 3TNV84T, 4TNV84T, 4TNV98T, 4TNV106T

** The engine oil drain plug location may vary based on oil pan options.
*** Not standard on all direct injection models
GENERAL SERVICE INFORMATION Component Identification
Figure 4-2 shows where the major engine components are located.
4TNV84T-Z, 4TNV98-E, 4TNV98-Z, 4TNV98T-Z
(2) (19) (4) (3) (20) (26)
(18)
(17) (28)
(1)
(16) (27)
(15)
(21)
(14)
(25)
(13) (5)
(22)
(6)
(24)
(23)
(12) (11) (9) (10) (8) (7)
1 – Lifting Eye (Flywheel End) 15 – Intake Manifold

2 – Turbocharger* 16 – Fuel Filter
3 – Lifting Eye (Engine Cooling Fan End) 17 – Fuel Inlet
4 – Engine Coolant Pump 18 – Fuel Return to Fuel Tank
5 – Engine Cooling Fan 19 – Top Filler Port (Engine Oil)
6 – Crankshaft V-Pulley 20 – Rocker Arm Cover
7 – V-Belt 21 – Air Intake Port (From Air Cleaner)
8 – Side Filler Port (Engine Oil) 22 – Flywheel
9 – Drain Plug (Engine Oil)** 23 – Starter Motor
10 – Fuel Injection Pump 24 – Exhaust Manifold
11 – Engine Oil Cooler*** 25 – Alternator
12 – Engine Oil Filter 26 – EGR valve
13 – Dipstick (Engine Oil) 27 – EGR cooler****
14 – Eco-governor 28 – EGR pipe
Figure 4-2
* Only applies to 4TNV84T-Z, 4TNV98T-Z.

** Engine oil drain plug location may vary based on oil pan options.
*** Not standard on all direct injection models.
**** Only applies to 4TNV84T-Z, 4TNV98T-Z.
Location of Labels GENERAL SERVICE INFORMATION
LOCATION OF LABELS
Figure 4-3 shows the location of regulatory and safety labels on Yanmar TNV series engines.
(1) (4) (1) (3)

(4) (2)
0000019A-01
Figure 4-3
Location of labels/nameplates on direct injection model engines

EPA/ARB Certification 97/68/EC Emission Control
Model Engine Nameplate
Label Label
3TNV82A,3TNV84,3TNV84T,3TNV88 On the top of the locker On the top of the locker On the exhaust side of the locker
3TNV82A-B,3TNV88-B,3TNV88-U arm cover(cooling fan end) arm cover (flywheel end) arm cover(near the flywheel)
3TNV84T-B Figure 4-3 left, (4) Figure 4-3 left, (1) Figure 4-3 left, (2)
On the top of the locker On the top of the locker On the exhaust side of the locker
4TNV84,4TNV88,4TNV84T
arm cover(cooling fan end) arm cover(flywheel end) arm cover(near the flywheel)
4TNV88-B,4TNV88-U,4TNV84T-Z
Figure 4-3 left, (4) Figure 4-3 left, (1) Figure 4-3 left, (1)
4TNV94L,4TNV98,4TNV98T On the top of the locker On the top of the locker On the top of the locker arm
4TNV106,4TNV106T arm cover(flywheel end) arm cover(center) cover(fan end)
4TNV98-Z,4TNV98-E,4TNV98T-Z Figure 4-3 right, (4) Figure 4-3 right, (1) Figure 4-3 right, (3)

GENERAL SERVICE INFORMATION Emission Control Regulations
Engine Nameplate (Typical) EMISSION CONTROL LABELS

Since emission control regulations are being issued
on a global basis, it is necessary to identify which
regulations a particular engine complies with. We
have listed several different types of labels you
might find on your engine.
EPA / ARB Labels
" "
0003852
EMISSION CONTROL (EPA) Less than 50 HP SAE (37kW)

REGULATIONS
EPA / ARB Regulations - USA Only
Yanmar TNV engines meet Environmental "
US-2D
"
FUEL
Protection Agency (EPA) (U. S. Federal) emission
control standards as well as the California Air
Resources Board (ARB, California) regulations.
Only engines that conform to ARB regulations can
be sold in the State of California.
Refer to the specific EPA / ARB installation
(page 5-16) and maintenance (page 5-16) in the (EPA) Greater than or Equal to 50 HP SAE (37kW)
Periodic Maintenance Schedule section of this
manual. Also refer to the Emission System
Warranty on page 2-6.
(EPA and ARB) 0000086-01
The 97/68/EC Directive Certified Engines GENERAL SERVICE INFORMATION
THE 97/68/EC DIRECTIVE

CERTIFIED ENGINES 97/68/EC DIRECTIVE
The engines described in this manual have been

certified by the 97/68/EC Directive.
To identify the engines that meet this certification,
the 97/68/EC emission control label is affixed on
(97/68/EC)
the engines.
ENGINE FAMILY
The EPA / ARB labels and the 97/68/EC label all have an Engine Family field. The following is an
explanation of the Engine Family designation:
5 YDX L 1.33 M 3 N
Method of air aspiration
Number of cylinders
Engine speed specifications
Displacement (liter)
Non-road / Off-road engine
Yanmar Diesel
*2005 Model Year
5*: 2005
6 : 2006
7: 2007
8: 2008
9: 2009
GENERAL SERVICE INFORMATION Function of Major Engine Components
FUNCTION OF MAJOR ENGINE COMPONENTS

Components Functions
The air cleaner prevents airborne contaminants from entering the engine. Since
the air cleaner is application specific, it must be carefully selected by an application
Air Cleaner engineer. It is not part of the basic engine package as shipped from the Yanmar
factory. Periodic replacement of the air cleaner filter element is necessary. See the
Periodic Maintenance Schedule on page 5-17 for the replacement frequency.
The alternator is driven by a V-belt which is powered by the crankshaft V-pulley.
Alternator The alternator supplies electricity to the engine systems and charges the battery
while the engine is running.
The engine oil dipstick is used to determine the amount of engine oil in the
Dipstick (Engine Oil)
crankcase.
The electric fuel pump makes sure there is a constant supply of diesel fuel to the
fuel injection pump. The electric fuel pump is electro-magnetic and runs on
Electric Fuel Pump
12 VDC. It must be installed on every application. This is standard equipment with
every engine.
The engine oil filter removes contaminants and sediments from the engine oil.
Engine Oil Filter Periodic replacement of the engine oil filter is necessary. See the Periodic
Maintenance Schedule on page 5-17 for the replacement frequency.
The engine oil cooler helps to keep the engine oil cool. Engine coolant from the
Engine Oil Cooler
cooling system is circulated through an adapter at the base of the engine oil filter
(If Equipped)
assembly and then returned to the coolant pump inlet.
The fuel filter removes contaminants and sediments from the diesel fuel. Periodic
replacement of the fuel filter is necessary. See the Periodic Maintenance Schedule
Fuel Filter
on page 5-17 for the replacement frequency. Please note that the word “diesel”
is implied throughout this manual when the word “fuel” is used.
The fuel filter / water separator removes contaminants, sediments and water from
the diesel fuel going to the fuel filter. This is a required component of the fuel
Fuel Filter / Water Separator system. This is standard equipment with every engine. The separator is installed
between the fuel tank and the electric fuel pump. Periodically drain the water from
the fuel filter / water separator.
The fuel tank is a reservoir that holds diesel fuel. When the fuel leaves the fuel tank
it goes to the fuel filter / water separator. Next the fuel is pumped to the fuel filter
by the electric fuel pump. Then the fuel goes to the fuel injection pump. Since the
Fuel Tank fuel is used to keep the fuel injection pump cool and lubricated, more fuel than
necessary enters the injection pump. When the injection pump pressure reaches
a preset value, a relief valve allows the excess fuel to be returned back to the fuel
tank. The fuel tank is a required engine component.
You can fill the crankcase with engine oil from either the side or the top filler port
Side and Top Filler Port (Engine Oil)
depending upon which one is most convenient.
The starter motor is powered by the battery. When you turn the key switch in the
Starter Motor operator’s console to the START position, the starter motor engages with the ring
gear installed on the flywheel and starts the flywheel in motion.
Turbocharger
The turbocharger pressurizes the air coming into the engine. It is driven by a
(Only applies to 3TNV84T, 4TNV84T,
turbine that is energized by exhaust gases.
4TNV98T, 4TNV106T)
MAIN ELECTRONIC CONTROL COMPONENTS AND FEATURES GENERAL SERVICE INFORMATION
MAIN ELECTRONIC CONTROL COMPONENTS AND FEATURES

4TNV84T-Z, 4TNV98-E, 4TNV98-Z,
4TNV98T-Z
Component/Feature Description
Engine controller (E-ECU) Adjusts the rack position of the fuel injection pump
depending on the speed command signal from the
accelerator sensor, thus regulating the engine speed and
power. The engine controller also regulates the opening of
the EGR valve depending on the engine speed and
power. It serves as the master station for the following
components/control features.
Electronic governor (Eco-governor) Consists of the engine speed sensor, rack actuator, etc.,
and is directly connected to the fuel injection pump in
order to regulate the rack position of the fuel injection
pump depending on the signals communicated with the E-
ECU.
Fuel injection pump (for Eco-governor) Is of single plunger type and equipped with a CSD
solenoid valve that allows the fuel injection timing to
advance and the injection quantity to increase, thereby
improving the cold start performance of the engine.
EGR valve Controls the exhaust gas recirculation flow rate
depending on the engine speed/load signals from the E-
ECU. It is installed on the top of the exhaust manifold.
Accelerator sensor Unlike mechanical governors, the Eco-governor has no
governor lever. The accelerator sensor serves as the
governor lever to provide the speed command signal
(voltage signal) to the E-ECU for engine speed control. It
is installed in the operator cabin of the driven machine.
Constant speed engines for e.g. generator use do not
require accelerator sensors because the engine speed
can be shifted via a switch on the operator's console.
Optional CAN communication capability is available as an option.
Fault indicator Is installed on the operator's console. If a fault occurs in
the E-ECU or Eco-governor, the fault indicator flashes
alerting the operator to a fault. The number of flashes
and/or the flashing pattern vary depending on the type or
Optional source of the fault, enabling quick-fix.
GENERAL SERVICE INFORMATION MAIN ELECTRONIC CONTROL COMPONENTS AND FEATURES
Component/Feature Description
Engine diagnosis tool Allows the operator to troubleshoot the cause of a
problem based on detailed information regarding the
problem occurring in the E-ECU or Eco-governor. This
tool can also be used for data maintenance tasks
including programming and mapping. See
Option for service Troubleshooting Chart on page 7-113.
Engine coolant temperature sensor Allows the CSD and ERG to be controlled in engine cold-
start conditions.
Glow plugs Optional When the key switch is turned to the ON position, the glow
Air heater plugs/air heater are/is energized for up to 15 seconds
(glow plugs) or up to 23 seconds (air heater). The duration
of energization depends on the engine coolant
temperature. The HEAT indicator is on during
energization. When the indicator goes out, turn the key
switch to the START position to start the engine.
After heater Optional In extreme cold start conditions, the after heater is
energized for up to 80 seconds or until the coolant
temperature reaches 10°C after the engine has started, in
order to help ensure the engine continues to run without
stall.This option is not available for glow plug engines.
Droop control Standard with VM series Reduces the engine speed by a certain percentage from
no load to full (rated) load in steady state operation. The
same percentage droop is maintained even when the load
increases at any no-load speed.
Isochronous control Standard with CL series Offers a constant engine speed from no load to full load.
Optional with VM series The engine speed does not decrease even when the load
increases at any no-load speed.
Low-idling speed up Increases the low-idling speed to up to 1000 rpm
depending on the engine coolant temperature. When the
coolant temperature reaches a predetermined value, this
feature returns the engine speed to the normal low idle
setting, thus reducing the warm-up time.
High-idling speed Optional Decreases the high-idling speed depending on the engine
down coolant temperature. When the coolant temperature falls
to a predetermined value, this feature returns the engine
speed to the normal high idle setting, thus minimizing the
emission of white smoke at low temperatures.
Auto deceleration Optional Brings the running engine in low idle mode automatically
when the accelerator pedal is not operated for a
predetermined period of time. When the pedal is
operated, i.e., the accelerator sensor is activated, the low
idle mode is cancelled.
Function of Cooling System Components GENERAL SERVICE INFORMATION
FUNCTION OF COOLING SYSTEM COMPONENTS

Components Functions
The TNV engine is liquid-cooled by means of a cooling system. The cooling system
consists of a radiator, radiator cap, engine cooling fan, engine coolant pump,
thermostat, and reserve tank. Note that all cooling system components are
Cooling System required for proper engine operation. Since some of the components are
application specific, they must be carefully selected by an application
engineer. The application specific items are not part of the basic engine
package as shipped from the Yanmar factory.
The engine cooling fan is driven by a V-belt which is powered by the crankshaft
Engine Cooling Fan V-pulley. The purpose of the engine cooling fan is to circulate air through the
radiator.
The engine coolant pump circulates the engine coolant through the cylinder block
Engine Coolant Pump
and the cylinder head and returns the engine coolant to the radiator.
The radiator acts as a heat exchanger. As the engine coolant circulates through
the cylinder block it absorbs heat. The heat in the engine coolant is dissipated in
Radiator
the radiator. As the engine cooling fan circulates air through the radiator, the heat
is transferred to the air.
The radiator cap controls the cooling system pressure. The cooling system is
pressurized to raise the boiling point of the engine coolant. As the engine coolant
temperature rises, the system pressure and the coolant volume increases. When
the pressure reaches a preset value, the release valve in the radiator cap opens
Radiator Cap
and the excess engine coolant flows into the reserve tank. As the engine coolant
temperature is reduced, the system pressure and volume is reduced and the
vacuum valve in the radiator cap opens allowing the engine coolant to flow from
the reserve tank back into the radiator.
The reserve tank contains the overflow of engine coolant from the radiator. If you
Reserve Tank need to add engine coolant to the system, add it to the reserve tank; not the
radiator.
A thermostat is placed in the cooling system to prevent the engine coolant from
circulating into the radiator until the engine coolant temperature reaches a preset
temperature. When the engine is cold, no engine coolant flows through the
Thermostat radiator. Once the engine reaches its operating temperature, the thermostat opens
and allows the engine coolant to flow through the radiator. By letting the engine
warm up as quickly as possible, the thermostat reduces engine wear, deposits and
emissions.
GENERAL SERVICE INFORMATION Diesel Fuel
DIESEL FUEL • Fuel additives are not recommended. Some fuel

additives may cause poor engine performance.
Diesel Fuel Specifications Consult your Yanmar representative for more
information.
Diesel fuel should comply with the following
specifications. The table lists several worldwide • The ash content must not exceed 0.01% by
specifications for diesel fuels. volume.
• The carbon residue content must not exceed
Diesel Fuel Specification Location 0.35% by volume. Less than 0.1% is preferred.
No. 2-D, No. 1-D, • The total aromatics content should not exceed
USA
ASTM D975-94 35% by volume. Less than 30% is preferred.
European • The PAH (polycyclic aromatic hydrocarbons)
EN590:96
Union content should be below 10% by volume.
ISO 8217 DMX International • The metal content of Na, Mg, Si, and Al should be
United equal to or lower than 1 mass ppm. (Test analysis
BS 2869-A1 or A2 method JPI-5S-44-95)
Kingdom
JIS K2204 Grade No. 2 Japan • Lubricity: The wear mark of WS1.4 should be
KSM-2610 Korea Max. 0.018 in (460 µm) at HFRR test.
GB252 China Bio-Diesel Fuels

In Europe and in the United States, as well as some
Additional Technical Fuel Requirements other countries, non-mineral oil based fuel
• The fuel cetane number should be equal to 45 or resources such as RME (Rapeseed Methyl Ester)
higher. and SOME (Soybean Methyl Ester), collectively
known as FAME (Fatty Acid Methyl Esters), are
• The sulfur content must not exceed 0.5% by
being used as extenders for mineral oil derived
volume. Less than 0.05% is preferred.
diesel fuels.
For electronically controlled engines 4TNV84T-Z,
4TNV98-Z, 4TNV98-E, and 4TNV98T-Z, it is Yanmar approves the use of bio-diesel fuels that do
mandatory to use fuel that does not contain not exceed a blend of 5% (by volume) of FAME with
0.05% or more sulfur content. 95% (by volume) of approved mineral oil derived
In general, using a high sulfur fuel may possible diesel fuel. Such bio-diesel fuels are known in the
result in corrosion inside the cylinder. marketplace as B5 diesel fuels.
• Bio-Diesel fuels. See Bio-Diesel Fuels on These B5 diesel fuels must meet certain
page 4-12. requirements.
• NEVER mix kerosene, used engine oil, or 1. The bio-fuels must meet the minimum
residual fuels with the diesel fuel. specifications for the country in which they are
used.
• The water and sediment in the fuel should not • In Europe, bio-diesel fuels must comply with
exceed 0.05% by volume. the European Standard EN14214.
• Keep the fuel tank and fuel-handling equipment • In the United States, bio-diesel fuels must
clean at all times. comply with the American Standard
ASTM D-6751.
• Poor quality fuel can reduce engine performance
and / or cause engine damage. 2. Bio-fuels should be purchased only from
recognized and authorized diesel fuel suppliers.
Diesel Fuel GENERAL SERVICE INFORMATION

Precautions and concerns regarding the use of Filling The Fuel Tank
bio-fuels:
1. Free methanol in FAME may result in corrosion A DANGER
of aluminum and zinc FIE components.
2. Free water in FAME may result in plugging of
fuel filters and increased bacterial growth.
3. High viscosity at low temperatures may result in
fuel delivery problems, injection pump seizures, FIRE AND EXPLOSION HAZARD!
and poor injection nozzle spray atomization.
4. FAME may have adverse effects on some under certain conditions.
elastomers (seal materials) and may result in
fuel leakage and dilution of the engine • Only fill the fuel tank with diesel fuel.
lubricating oil. Filling the fuel tank with gasoline may
result in a fire and will damage the
5. Even bio-diesel fuels that comply with a suitable
engine.
standard as delivered, will require additional
care and attention to maintain the quality of the • NEVER refuel with the engine running.
fuel in the equipment or other fuel tanks. It is • Wipe up all spills immediately.
important to maintain a supply of clean, fresh
fuel. Regular flushing of the fuel system, • Keep sparks, open flames or any other
and / or fuel storage containers, may be form of ignition (match, cigarette,
necessary. static electric source) well away when
refueling.
6. The use of bio-diesel fuels that do not comply
with the standards as agreed to by the diesel • NEVER overfill the fuel tank.
engine manufacturers and the diesel fuel • Fill the fuel tank. Store any containers
injection equipment manufacturers, or bio- containing fuel in a well-ventilated
diesel fuels that have degraded as per the area, away from any combustibles or
precautions and concerns above, may affect sources of ignition.
the warranty coverage of your engine. See
Yanmar Limited Warranty on page 2-3.
serious injury.
0000005en
GENERAL SERVICE INFORMATION Diesel Fuel
A DANGER A DANGER
• Be sure to place the diesel fuel • Before you operate the engine, check
container on the ground when for fuel leaks. Replace rubberized fuel
transferring the diesel fuel from the hoses every two years or every 2000
pump to the container. Hold the hose hours of engine operation, whichever
nozzle firmly against the side of the comes first, even if the engine has
container while filling it. This prevents been out of service. Rubberized fuel
static electricity buildup which could lines tend to dry out and become
cause sparks and ignite fuel vapors. brittle after two years or 2000 hours of
engine operation, whichever comes
• NEVER place diesel fuel or other
first.
flammable material such as oil, hay or
dried grass close to the engine during • Failure to comply will result in death or
engine operation or shortly after serious injury.
shutdown. 0000015en

serious injury. CAUTION
0000014en
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
Engine Oil GENERAL SERVICE INFORMATION

Note that a typical fuel tank is shown. The fuel tank 2. NEVER use the starter motor to crank the
on your equipment may be different. engine in order to prime the fuel system. This
may cause the starter motor to overheat and
1. Clean the area around the fuel cap damage the coils, pinion and / or ring gear.
(Figure 4-4, (1)).
2. Remove the fuel cap (Figure 4-4, (1)) from the
fuel tank (Figure 4-4, (2)).
ENGINE OIL
3. Observe the fuel level sight gauge
(Figure 4-4, (3)) and stop fueling when the CAUTION
gauge shows the fuel tank is full. NEVER
overfill the fuel tank. • Only use the engine oil specified.
Other engine oils may affect warranty
4. Replace the fuel cap (Figure 4-4, (1)) and hand coverage, cause internal engine
tighten. Over-tightening the fuel cap will components to seize and / or shorten
damage it. engine life.
(1) • Prevent dirt and debris from
clean the oil cap / dipstick and the
surrounding area before you remove
(2) the cap.
• NEVER mix different types of engine
oil. This may adversely affect the
lubricating properties of the engine oil.
(3)
• NEVER overfill. Overfilling may result
in white exhaust smoke, engine
0000002A
overspeed or internal damage.
Figure 4-4 0000005en
Priming the Fuel System Engine Oil Specifications

The fuel system needs to be primed under certain Use an engine oil that meets or exceeds the
conditions: following guidelines and classifications:
• Before starting the engine for the first time. Service Categories
• After running out of fuel and fuel has been added • API Service Categories CD or higher
to the fuel tank. (Grade CF or higher for EGR-equipped engines
4TNV84T-Z, 4TNV98-Z, 4TNV98-E, and
• After fuel system maintenance such as changing 4TNV98T-Z)
the fuel filter and draining the fuel filter / water
separator, or replacing a fuel system component. • ACEA Service Categories E-3, E-4, and E-5
To prime the fuel system: • JASO Service Category DH-1
1. Turn the key to the ON position for 10 - 15 Definitions

seconds. This will allow the electric fuel pump • API Classification (American Petroleum Institute)
to prime the fuel system.
• ACEA Classification (Association des
Constructeurs Européens d'Automobilies)
GENERAL SERVICE INFORMATION Engine Oil
• JASO (Japanese Automobile Standards Checking Engine Oil

Organization)
1. Make sure the engine is level.
Notes: 2. Remove the dipstick (Figure 4-6, (1)) and wipe
• Be sure the engine oil, engine oil storage it with clean cloth.
containers, and engine oil filling equipment are 3. Fully reinsert the dipstick.
free of sediment and water. 4. Remove the dipstick. The oil level should be
• Change the engine oil after the first 50 hours of between the upper (Figure 4-6, (2)) and lower
operation and then every 250 hours thereafter. (Figure 4-6, (3)) lines on the dipstick.
5. Fully reinsert the dipstick.
• Select the oil viscosity based on the ambient
temperature where the engine is being operated. (4)
See the SAE Service Grade Viscosity Chart
(Figure 4-5).
• Yanmar does not recommend the use of engine
oil “additives.”
Additional Technical Engine Oil

Requirements:
The engine oil must be changed when the Total
Base Number (TBN) has been reduced to 1.0
mgKOH/g test method; JIS K-201-5.2-2 (HCI),
ASTM D4739 (HCI). (4)
Engine Oil Viscosity (5)

Select the appropriate engine oil viscosity based on
the ambient temperature and use the SAE Service
Grade Viscosity Chart in Figure 4-5. (2)
(1)
SAE 10W
SAE 20W (3)
SAE 10W-30
0000007C
SAE 15W-40
Figure 4-6
SAE 20
SAE 30
SAE 40
SAE 20W - 50
-4°F 14°F 32°F 50°F 68°F 86°F 104°F 122°F

(-20°C) (-10°C) (0°C) (10°C) (20°C) (30°C) (40°C) (50°C)
0000005A
Figure 4-5

Engine Oil GENERAL SERVICE INFORMATION
Adding Engine Oil Engine Oil Capacity (Typical)

1. Make sure the engine is level. Note: These are the engine oil capacities
2. Remove the oil cap (Figure 4-6, (4)). associated with a “deep standard” oil
pan. The oil capacity will vary dependant
3. Add the indicated amount of engine oil at the upon which optional oil pan is used.
top or the side engine oil filler port Refer to the operation manual provided
(Figure 4-6, (5)). by the driven machine manufacturer for
4. Wait three minutes and check the oil level. the actual engine oil capacity of your
5. Add more oil if necessary. machine.
6. Reinstall the oil cap (Figure 4-6, (4)) and The following are the engine oil capacities for
hand-tighten. Over-tightening may damage the various Yanmar TNV engines.
cap.
Dipstick Upper
Engine Model
Limit / Lower Limit
5.8 / 3.8 qt
3TNV82A(-B)
(5.5 / 3.6 L)
7.1 / 4.1 qt
3TNV84,3TNV84T(-B)
(6.7 / 3.9 L)
7.1 / 4.1 qt
3TNV88(-B)(-U)
(6.7 / 3.9 L)
7.8 / 4.2 qt
4TNV84,4TNV84T(-Z)
(7.4 / 4.0 L)
7.8 / 4.2 qt
4TNV88(-B)(-U)
(7.4 / 4.0 L)
11.1 / 6.3 qt
4TNV94L
(10.5 / 6.0 L)
4TNV98(-Z)(-E), 11.1 / 6.3 qt
4TNV98T(-Z) (10.5 / 6.0 L)
4TNV106(CL), 14.8 / 5.3 qt
4TNV106T(CL) (14.0 / 5.0 L)
4TNV106(VM), 14.8 / 6.9 qt
4TNV106T(VM) (14.0 / 6.5 L)
GENERAL SERVICE INFORMATION Engine Coolant
ENGINE COOLANT
A CAUTION
A DANGER
COOLANT HAZARD!
• Wear eye protection and rubber gloves
SCALD HAZARD!
when you handle long life or extended
• NEVER remove the radiator cap if the life engine coolant. If contact with the
engine is hot. Steam and hot engine eyes or skin should occur, flush eyes
coolant will spurt out and seriously and wash immediately with clean
burn you. Allow the engine to cool water.
the radiator cap.
or moderate injury.
• Tighten the radiator cap securely after 0000005en

spurt out during engine operation if
the cap is loose. CAUTION
• ALWAYS check the level of the engine • Only use the engine coolant specified.
coolant by observing the reserve tank. Other engine coolants may affect
warranty coverage, cause an internal
• Failure to comply will result in death or buildup of rust and scale and / or
serious injury. shorten engine life.
0000002en
contaminating the engine coolant.
A WARNING Carefully clean the radiator cap and
remove the cap.
coolants. This may adversely affect the
properties of the engine coolant.
BURN HAZARD!
0000006en
• Wait until the engine cools before you

drain the engine coolant. Hot engine
coolant may splash and burn you.
or serious injury.
0000016en
Engine Coolant GENERAL SERVICE INFORMATION
Engine Coolant Specifications Filling Radiator with Engine Coolant

Use a Long Life Coolant (LLC) or an Extended Life Fill the radiator and reserve tank as follows. This
Coolant (ELC) that meets or exceeds the following procedure is for filling the radiator for the first time
guidelines and specifications: or refilling it after it is flushed. Note that a typical
radiator is illustrated (Figure 4-7).
Additional Technical Coolant
Specifications:
(2)
• ASTM D6210, D4985 (US)
(5)
• JIS K-2234 (Japan)
• SAE J814C, J1941, J1034 or J2036 (3)
(International)
(6) FULL
Alternative Engine Coolant LOW
(4)
If an Extended or Long Life Coolant is not available,
alternatively, you may use an ethylene glycol or
propylene glycol based conventional coolant
(green). (1)
0000029A
Notes:
Figure 4-7
• ALWAYS use a mix of coolant and water.
NEVER use water only. 1. Check to be sure the radiator drain plug is
• Mix the coolant and water per the mixing installed and tightened or the drain cock
instructions on the coolant container. (Figure 4-7, (1)) is closed. Also make sure the
coolant drain plug (Figure 4-8, (1)) in the
• Water quality is important to coolant cylinder block is closed or the oil coolant hoses
performance. Yanmar recommends that soft, (Figure 4-9, (1)) are installed at the oil cooler.
distilled, or demineralized water be used to mix
with coolants.
• NEVER mix extended or long life coolants and
conventional (green) coolants.
• NEVER mix different types and / or colors of
extended life coolants.
• Replace the coolant every 1000 engine hours
or once a year.
(1)
0000027B
Figure 4-8
GENERAL SERVICE INFORMATION Engine Coolant
Engine Coolant Capacity (Typical)

Note: The capacities listed are for the engine
only without a radiator. Refer to the
operation manual provided by the driven
machine manufacturer for the actual
engine coolant capacity on your
machine.
The following are the engine coolant capacities for
various Yanmar TNV engines.
Engine Coolant
Engine Model
(1) 0001579B Capacity
3TNV82A(-B) 1.9 qt (1.8 L)
Figure 4-9
3TNV84,3TNV84T(-B) 2.1 qt (2.0 L)
2. Remove the radiator cap (Figure 4-7, (2)) by 3TNV88(-B)(-U) 2.1 qt (2.0 L)
turning it counter-clockwise about 1/3 of a turn. 4TNV84,4TNV84T(-Z) 2.9 qt (2.7 L)
3. Pour the engine coolant slowly into the radiator 4TNV88(-B)(-U) 2.9 qt (2.7 L)
until it is even with the lip of the engine coolant 4TNV94L 4.4 qt (4.2 L)
filler port. Make sure that air bubbles do not
4TNV98(-Z)(-E),
develop as you fill the radiator. 4TNV98T(-Z)
4.4 qt (4.2 L)
4. Reinstall the radiator cap (Figure 4-7, (2)). 4TNV106, 4TNV106T 6.3 qt (6.0 L)
Align the tabs on the back side of the radiator
cap with the notches on the engine coolant filler
port. Press down and turn the cap clockwise
about 1/3 of a turn.
5. Remove the cap on the reserve tank
(Figure 4-7, (3)), and fill it to the LOW (COLD)
mark (Figure 4-7, (4)) with engine coolant.
Reinstall the cap.
6. Check the hose (Figure 4-7, (5)) that connects
the reserve tank (Figure 4-7, (3)) to the
radiator. Be sure it is securely connected and
there are no cracks or damage. If the hose is
damaged, the engine coolant will leak out
instead of going into the reserve tank.
7. Run the engine until it is at operating
temperature. Check the level of engine coolant
in the reserve tank. When the engine is running
and the engine coolant is at normal
temperature, the coolant level in the tank should
be at the FULL (HOT) mark (Figure 4-7, (6)). If
the engine coolant is not at the FULL (HOT)
mark (Figure 4-7, (6)), add additional engine
coolant to the reserve tank to bring the level to
the FULL (HOT) mark.
Specifications GENERAL SERVICE INFORMATION
SPECIFICATIONS
Description of Model Number
3 TNV 82 A T - Z 0 00
Customer Code
Rated RPM
Governor Type Symbol (Indicating Conformance to EPA Tier 3/Interim Tier
4 Standards)
Governor Type Symbol Governor Type Applicable engine
Z Electronic Governor (Eco-governor)
Non-derated engine
B Mechanical Governor
E Electronic Governor (Eco-governor)
Derated engine
U Mechanical Governor
Turbocharged (No symbol indicates naturally aspirated)
Engine Sub Series
Cylinder Bore (mm)
Engine Series
No. of Cylinders
Engine Speed Specifications

Notation Available Engine Speed Intended Uses
VH 3200 - 3600 RPM (min-1) Lawn Mower, Construction, Industrial Machine
VM 2000 - 3000 RPM (min-1) Agricultural, Construction, Industrial Machines
CH 3000 or 3600 RPM (min-1) 2-pole Generator Sets, Irrigation Pumps
CL 1500 or 1800 RPM (min-1) 4-pole Generator Sets, Irrigation Pumps
VH: Variable High Speed CH: Constant High Speed

VM: Variable Medium Speed CL: Constant Low Speed
GENERAL SERVICE INFORMATION Specifications
Engine General Specifications

Type Vertical In-line, Water Cooled, 4-Cycle Diesel Engine
Direct Injection Models Direct Injection
Combustion System
Indirect Injection Models Swirl Chamber (Ball-Type)
Starting System Electric Starting
Cooling System Radiator
Lubricating System Forced Lubrication with Trochoid Pump
PTO Position Flywheel End
Direction of Rotation Counterclockwise Viewed from Flywheel End
Notes:
1. The information described in Principal Engine Specifications is for a “standard” engine. To obtain the
information for the engine installed in your driven machine, please refer to the manual provided by the
driven machine manufacturer.
2. Engine rating conditions are as follows (SAE J1349, ISO 3046/1):
• Atmospheric Condition: Room temperature 77°F (25°C), Atmospheric pressure 29.53 in. Hg
(100 kPa, 750 mm Hg), Relative humidity 30%
• Fuel Temperature at Fuel Injector Pump Inlet: 104°F (40°C)
• Fuel Feeding Pressure: 20 ± 10 kPa (net) after engine break-in has been performed with the
cooling fan, air cleaner and muffler installed to the engine.
• With Cooling Fan, Air Cleaner, Muffler: Yanmar Standard
• After the Engine Break-In Period. Output Allowable Deviation: ± 3%
• 1 PS = 0.7355 kW
• 1 hp SAE (Society of Automotive Engineers) = 0.7457 kW
Principal Engine Specifications GENERAL SERVICE INFORMATION
PRINCIPAL ENGINE SPECIFICATIONS

3TNV82A (~ EPA Tier2)
Engine Model 3TNV82A
Version CL VM
Type Vertical In-line Diesel Engine
Combustion System Direct Injection
Aspiration Natural
No. of Cylinders 3
Bore × Stroke 82 × 84mm
Displacement 1.331L
min-1 1500 1800
Continuous Rated Output kW 9.9 12.0
PS 13.5 16.3
min-1 1500 1800 2000 2200 2400 2600 2800 3000
Max. Rated Output (Net) kW 11.0 13.2 14.6 16.0 17.5 19.0 20.4 21.9
PS 14.9 17.9 19.9 21.8 23.8 25.8 27.8 29.8
1600 1895 2180 2375 2570 2780 2995 3180
High Idling min-1
± 25 ± 25 ± 25 ± 25 ± 25 ± 25 ± 25 ± 25
Engine Weight (Dry)
138kg 128 kg
*with Flywheel Housing
Direction of Rotation Counterclockwise Viewed From Flywheel End
Cooling System Liquid-Cooled with Radiator
Normal Oil Pressure at Rated
0.34 - 0.49 MPa 0.39 - 0.54 MPa
Engine Speed
Normal Oil Pressure at Low
0.06 MPa
Idle Speed
Electric Starting (Starter Motor: DC12V (1.2 kW)) ***
Starting System Alternator: DC12V, 40A***
Recommended Battery Capacity: 12V, 55Ah*** (5h rating)
Dimensions (L × W × H)* 553 × 489 × 565 mm 528 × 489 × 565 mm
5.5/3.6L
Engine Oil Pan Capacity**
(Dipstick Upper Limit / Lower Limit)
Engine Coolant Capacity 1.8L Engine Only
Standard Cooling Fan 335mm O.D., 6 Blade Pusher-Type ***
Crank V-pulley dia./
φ120/ φ90mm *** φ110/ φ110mm ***
Fan V-pulley dia.
* Engine specifications without radiator.

** Engine oil capacity for a "Deep Standard" oil pan. Refer to the operation manual provided by the driven machine
manufacturer for the actual engine oil capacity of your machine.
*** May vary depending on application.
GENERAL SERVICE INFORMATION Principal Engine Specifications
3TNV84 (~ EPA Tier2)

Engine Model 3TNV84
Version CL VM
Aspiration Natural
No. of Cylinders 3
Displacement 1.496L
min-1 1500 1800
PS 15.3 18.3
min-1 1500 1800 2000 2200 2400 2600 2800 3000
PS 16.8 20.1 22.3 24.6 26.8 29.0 31.3 33.5
1600 1895 2180 2400 2590 2810 2995 3210
High Idling min-1
± 25 ± 25 ± 25 ± 25 ± 25 ± 25 ± 25 ± 25
Engine Weight (Dry)
161kg 155kg
0.34 - 0.49 MPa 0.39 - 0.54 MPa
Engine Speed
0.06 MPa
Idle Speed
Recommended Battery Capacity: 12V, 55 Ah*** (5h rating)
Dimensions (L × W × H)* 589 × 486 × 622mm 564 × 486 × 622mm
6.7/3.9L
φ120/ φ90mm *** φ110/ φ110mm ***
Fan V-pulley dia.
3TNV84T (~ EPA Tier2)

Engine Model 3TNV84T
Version CL VM
Aspiration Turbocharged
No. of Cylinders 3
Displacement 1.496L
min-1 1500 1800
PS 19.0 22.5
min-1 1500 1800 2400 2600 2800 3000
Max. Rated Output (Net) kW 15.8 18.8 25.0 26.8 29.1 30.9
PS 21.5 25.5 34.0 36.5 39.5 42.0
1600 1895 2590 2810 2995 3210
High Idling min-1
± 25 ± 25 ± 25 ± 25 ± 25 ± 25
Engine Weight (Dry)
161 kg 155 kg
0.29 - 0.44 MPa 0.34 - 0.49 MPa 0.39 - 0.54 MPa
Engine Speed
0.06 MPa
Idle Speed
Recommended Battery Capacity: 12V,55 Ah*** (5h rating)
6.7/3.9L
φ120/ φ90mm *** φ110/ φ110mm ***
Fan V-pulley dia.

Engine Model 3TNV88
Version CL VM
Aspiration Natural
No. of Cylinders 3
Displacement 1.642L
min-1 1500 1800
PS 16.7 20.1
min-1 1500 1800 2000 2200 2400 2600 2800 3000
PS 18.4 22.1 24.5 27.0 29.4 31.9 34.2 36.8
1600 1895 2180 2400 2590 2810 2995 3210
High Idling min-1
± 25 ± 25 ± 25 ± 25 ± 25 ± 25 ± 25 ± 25
Engine Weight (Dry)
161kg 155kg
0.34 - 0.49 MPa 0.39 - 0.54 MPa
Engine Speed
0.06 MPa
Idle Speed
Recommended Battery Capacity: 12V, 55Ah *** (5h rating)
6.7/3.9L
φ120/ φ90mm *** φ110/ φ110mm ***
Fan V-pulley dia.

Engine Model 4TNV84
Version CL VM
Aspiration Natural
No. of Cylinders 4
Displacement 1.995L
min-1 1500 1800
PS 20.3 24.1
min-1 1500 1800 2000 2200 2400 2600 2800 3000
PS 22.3 26.5 29.8 32.8 35.8 38.7 41.7 44.7
1600 1895 2180 2400 2590 2810 2995 3210
High Idling min-1
± 25 ± 25 ± 25 ± 25 ± 25 ± 25 ± 25 ± 25
Engine Weight (Dry)
183kg 170kg
0.34 - 0.49 MPa 0.39 - 0.54 MPa
Engine Speed
0.06 MPa
Idle Speed
Dimensions (L × W × H)* 683 × 498.5 × 617 mm 658 × 498.5 × 617mm
7.4/4.0L
φ120/ φ90mm *** φ110/ φ110mm ***
Fan V-pulley dia.

Version CL VM
No. of Cylinders 4
Displacement 1.995L
min-1 1500 1800
PS 26.0 33.0
-1
min 1500 1800 2000 2200 2400 2600 2800 3000
PS 29.0 36.5 38.0 41.5 45.5 48.5 52.5 56.0
1600 1895 2180 2400 2590 2810 2995 3210
High Idling min-1
± 25 ± 25 ± 25 ± 25 ± 25 ± 25 ± 25 ± 25
Engine Weight (Dry)
183 kg 170 kg
0.29 - 0.44 MPa 0.36 - 0.5 MPa
Engine Speed
0.06 MPa
Idle Speed
Recommended Battery Capacity: 12V, 64 Ah*** (5h rating)
Dimensions (L × W × H)* 683 × 498.5 × 713 mm 649 × 498.5 × 713 mm
7.4/4.0L
φ120/ φ90mm *** φ110/ φ110mm ***
Fan V-pulley dia.

Engine Model 4TNV88
Version CL VM
Aspiration Natural
No. of Cylinders 4
Displacement 2.190L
min-1 1500 1800
PS 22.3 26.7
min-1 1500 1800 2000 2200 2400 2600 2800 3000
PS 24.5 29.4 32.7 36.0 39.2 42.5 45.8 48.1
1600 1895 2180 2400 2590 2810 2995 3210
High Idling min-1
± 25 ± 25 ± 25 ± 25 ± 25 ± 25 ± 25 ± 25
Engine Weight (Dry)
183 kg 170 kg
0.34 - 0.49 MPa 0.39 - 0.54 MPa
Engine Speed
0.06 MPa
Idle Speed
Recommended Battery Capacity: 12V, 64 Ah*** (5h rating) ***
Dimensions (L × W × H)* 683 × 498.5 × 618 mm 658 × 498.5 × 618 mm
7.4 / 4.0 L
φ120/ φ90mm *** φ110/ φ110mm ***
Fan V-pulley dia.
4TNV94L (~ EPA Tier2)

Engine Model 4TNV94L
Version CL VM
Aspiration Natural
No. of Cylinders 4
Displacement 3.054L
min-1 1500 1800
PS 35.5 42.5
min-1 1500 1800 2000 2200 2400 2500
PS 39.5 47.0 48.0 52.0 56.5 58.5
-1
High Idling min 1600 ± 25 1895 ± 25 2180 ± 25 2400 ± 25 2590 ± 25 2700 ± 25
Engine Weight (Dry)
245 kg 235 kg
0.29 - 0.39 MPa
Engine Speed
0.06 MPa
Idle Speed
Dimensions (L × W × H)* 719 × 498 × 742 mm
10.5/6.0L
φ130/ φ130mm ***
Fan V-pulley dia.

Engine Model 4TNV98
Version CL VM
Aspiration Natural
No. of Cylinders 4
Displacement 3.319L
min-1 1500 1800
PS 42.0 50.0
min-1 1500 1800 2000 2200 2400 2500
PS 47.0 56.0 57.0 62.0 67.0 69.5
High Idling min-1 1600 ± 25 1895 ±25 2180 ± 25 2400 ± 25 2590 ± 25 2700 ± 25
Engine Weight (Dry)
248 kg 235 kg
0.29 - 0.39 MPa
Engine Speed
0.06 MPa
Idle Speed
Dimensions (L × W × H)* 719 × 498 × 742 mm
10.5/6.0L
φ130/ φ130mm ***
Fan V-pulley dia.

Version CL VM
No. of Cylinders 4
Displacement 3.319L
min-1 1500 1800
PS 51.5 62.0
-1
min 1500 1800 2000 2200 2400 2500
PS 57.0 68.5 69.0 75.5 82.0 85.0
High Idling min-1 1600 ± 25 1895 ± 25 2180 ± 25 2400 ± 25 2590 ± 25 2700 ± 25
Engine Weight (Dry)
258 kg 245 kg
0.29 - 0.39 MPa
Engine Speed
0.06 MPa
Idle Speed
Recommended Battery Capacity: 12V, 64Ah ***
Dimensions (L × W × H)* 719 × 575 × 804mm
10.5/6.0L
Standard Cooling Fan 430mm O.D., 8 Blade Suction-Type ***
φ130/ φ130mm ***
Fan V-pulley dia.

Engine Model 4TNV106
Version CL VM
Aspiration Natural
No. of Cylinders 4
Displacement 4.412L
min-1 1500 1800
PS 56.0 67.0
min-1 1500 1800 2000 2200 2400 2500
PS 62.0 74.0 77.0 83.5 89.0 92.0
High Idling min-1 1600 ± 25 1895 ± 25 2205 ± 25 2420 ± 25 2615 ± 25 2725 ± 25
Engine Weight (Dry)
345kg 330kg
Normal Oil Pressure at Rated With balancer: 0.34-0.44 MPa
0.31 - 0.49 MPa
Engine Speed Without balancer: 0.39-0.49 MPa
0.06 MPa
Idle Speed
Recommended Battery Capacity: 12V, 88 Ah***
14.0/5.0L 14.0/6.5L
(Dipstick Upper Limit / Lower Limit) (Dipstick Upper Limit / Lower Limit)
Engine Coolant Capacity 6L Engine Only
Standard Cooling Fan 500mm O.D. 7 Blade Pusher-Type *** 500mm O.D. 7 Blade Suction-Type ***
φ150/ φ150mm ***
Fan V-pulley dia.

Version CL VM
No. of Cylinders 4
Displacement 4.412L
min-1 1500 1800
PS 70.0 84.0
-1
min 1500 1800 2000 2200
Max. Rated Output (Net) kW 56.8 68.0 69.9 72.0
PS 77.2 92.5 95.0 97.9
High Idling min-1 1600 ± 25 1875 ± 25 2205 ± 25 2420 ± 25
Engine Weight (Dry)
355 kg 340 kg
Normal Oil Pressure at Rated With balancer: 0.34-0.44 MPa
0.31 - 0.49 MPa
Engine Speed Without balancer: 0.39-0.49 MPa
0.06 MPa
Idle Speed
Electric Starting (Starter Motor DC12V (3.0 kW)) ***
Recommended Battery Capacity: 12V, 88 Ah***
14.0/5.0L 14.0/6.5L
(Dipstick Upper Limit / Lower Limit) (Dipstick Upper Limit / Lower Limit)
Engine Coolant Capacity 6L Engine Only
Standard Cooling Fan 500mm O.D. 7 Blade Pusher-Type *** 500mm O.D.7 Blade Suction-Type***
φ150/ φ150mm ***
Fan V-pulley dia.
3TNV82A-B (complies with EPA Interim Tier4)

Engine Model 3TNV82A-B
Version CL VM
Type Vertical, 4-cycle water-cooled diesel engine
Aspiration Natural aspiration
No. of Cylinders 3
Bore × Stroke φ82 × 84mm
Displacement 1.331L
min-1
Continuous Rated
kW
Output
PS
min-1 2200 2300 2400 2500 2600 2700 2800 3000
Max. Rated Output kW 16.0 16.8 17.5 18.2 19.0 19.7 20.4 21.9
(Net) PS 21.8 22.8 23.8 24.8 25.8 26.8 27.8 29.8
23.0
2375 2485 2570 2675 2780 2890 2995 3180
High Idling min-1
±25 ±25 ±25 ±25 ±25 ±25 ±25 ±25
Engine Weight (dry)
128kg
Governor Mechanical governor (All-speed governor)
Rated Engine 0.36-0.51 (3.7-
0.31-0.46 (3.2-4.7) MPa
Normal Oil Speed 5.2) MPa
Pressure Low Idle
Speed
≥ 0.06 (≥ 0.6) MPa
Starting System Electric Starting (Starter Motor: DC12V (1.7kW)) ***
Charging system Alternator (DC12V/40A) ***
Recommended Battery
12V-55Ah*** (5h rating)
Capacity
Starting aid device Super-quick Heating Glow plug
5.5L/3.6L
Standard Cooling Fan Resin F type pusher fan - φ335(NF) x 6
φ110/ φ110mm
Fan V-pulley dia.
3TNV84T-B (complies with EPA Interim Tier4)

Engine Model 3TNV84T-B
Version CL VM
No. of Cylinders 3
Displacement 1.496L
min-1
Continuous Rated
kW
Output
PS
min-1 2400 2500 2600 2700 2800
Max. Rated Output
kW 25.0 26.0 26.8 27.9 29.1
(Net)
PS 34.0 35.3 36.5 38.0 39.5
2590 2700 2810 2920 2995
High Idling min-1
±25 ±25 ±25 ±25 ±25
Engine Weight (dry)
155kg
Governor Electronic governor (All-speed governor)
Rated Engine
0.34-0.49 (3.5-5.0) MPa 0.39-0.54 (4.0-5.5) MPa
Normal Oil Speed
Pressure Low Idle
Speed
≥ 0.06 (≥ 0.6) MPa
Recommended Battery
Capacity
Starting aid device Air heater (12V DC 400W)
589 × 486 ×
622mm
6.7L/3.9L
Standard Cooling Fan Resin F type pusher fan - φ350(QF) x 6
φ110/ φ110mm
Fan V-pulley dia.
3TNV88-U (complies with EPA Interim Tier4)

Engine Model 3TNV88-U
Version CL VM
No. of Cylinders 3
Displacement 1.642L
min-1
Continuous Rated
kW
Output
PS
min-1 2200 2300 2400 2500 2600 2700 2800 3000
Max. Rated Output
kW 18.1 18.9 19.7 20.5 21.3 22.2 23.0 24.6
(Net)
PS 24.6 25.7 26.8 27.9 29.0 30.2 31.3 33.5
2400 2510 2590 2700 2810 2920 2995 3210
High Idling min-1
±25 ±25 ±25 ±25 ±25 ±25 ±25 ±25
Engine Weight (dry)
155kg
Rated Engine 0.39-0.54 (4.0-
0.34-0.49 (3.5-5.0) MPa
Pressure Low Idle
Speed
≥ 0.06 (≥ 0.6) MPa
Recommended Battery
Capacity
6.7L/3.9L
φ110/ φ110mm
Fan V-pulley dia.
3TNV88-B (complies with EPA Interim Tier4)

Engine Model 3TNV88-B
Version CL VM
No. of Cylinders 3
Displacement 1.642L
min-1 1500 1800
Continuous Rated
kW 12.3 14.8
Output
PS 16.7 20.1
min-1 1500 1800 2200 2300 2400 2500 2600 2700 2800 3000
Max. Rated Output
kW 13.5 16.3 19.9 20.7 21.6 22.6 23.5 24.3 25.2 27.1
(Net)
PS 18.4 22.1 27.0 28.2 29.4 30.7 31.9 33.1 34.2 36.8
1600 1895 2400 2510 2590 2700 2810 2920 2995 3210
High Idling min-1
±25 ±25 ±25 ±25 ±25 ±25 ±25 ±25 ±25 ±25
Engine Weight (dry)
161kg 155kg
Rated Engine 0.29-0.44 (3.0- 0.39-0.54 (4.0-
0.34-0.49 (3.5-5.0) MPa
Normal Oil Speed 4.5) MPa 5.5) MPa
Pressure Low Idle
Speed
≥ 0.06 (≥ 0.6) MPa
Recommended Battery
Capacity
583 × 514 ×
622mm
6.7L/3.9L
φ120/ φ90mm φ110/ φ110mm
Fan V-pulley dia.
4TNV84T-Z (complies with EPA Interim Tier4)

Engine Model 4TNV84T-Z
Version CL VM
No. of Cylinders 4
Displacement 1.995L
min-1 1500 1800
Continuous Rated
kW 19.1 24.3
Output
PS 26.0 33.0
min-1 1500 1800 2400 2500 2700 2800 3000
Max. Rated Output
kW 21.3 26.9 33.5 34.5 37.1 38.6 41.2
(Net)
PS 29.0 36.5 45.5 47.0 50.5 52.5 56.0
1600 1895 2590 2700 2850 2950 3150
High Idling min-1
±25 ±25 ±25 ±25 ±25 ±25 ±25
Engine Weight (dry)
183kg 170kg
Rated Engine 0.29-0.44 (3.0-
0.36-0.51 (3.7-5.2) MPa
Pressure Low Idle
Speed
≥ 0.06 (≥ 0.6) MPa
Starting System Electric Starting (Starter Motor: DC12V (1.7kW) ***
Recommended Battery
Capacity
Starting aid device Air heater (12V DC 400W)
683 × 499 ×
713mm
7.4L/4.0L
Standard Cooling Fan Resin F type pusher fan - φ370(EF) x 6
φ120/ φ90mm φ110/ φ110mm
Fan V-pulley dia.

4TNV88-U (complies with EPA Interim Tier4)

Engine Model 4TNV88-U
Version CL VM
No. of Cylinders 4
Displacement 2.190L
min-1
Continuous Rated
kW
Output
PS
min-1 2700 2800
Max. Rated Output
kW 29.6 30.7
(Net)
PS (40.2) (41.7)
2920 2995
High Idling min-1
±25 ±25
Engine Weight (dry)
170kg
Rated Engine
0.32-0.47 (3.3-4.8) MPa
Normal Oil Speed
Pressure Low Idle
Speed
≥ 0.06 (≥ 0.6) MPa
Recommended Battery
Capacity
Dimensions (L × W × H)* 684 × 523 × 617 659 × 523 × 617
7.4L/4.0L
φ120/ φ90mm φ110/ φ110mm
Fan V-pulley dia.

4TNV88-B (complies with EPA Interim Tier4)

Engine Model 4TNV88-B
Version CL VM
No. of Cylinders 4
Displacement 2.190L
min-1 1500 1800
Continuous Rated
kW 16.4 19.6
Output
PS 22.3 26.7
min-1 1500 1800 2000 2100 2200 2300 2400 2500 2600 2700 2800 3000
Max. Rated Output
kW 18.0 21.6 24.1 25.3 26.5 27.7 28.8 30.1 31.3 32.5 33.7 35.4
(Net)
PS 24.5 29.4 32.7 34.4 36.0 37.6 39.2 40.9 42.5 44.2 45.8 48.1
1600 1895 2180 2290 2400 2510 2590 2700 2810 2920 2995 3210
High Idling min-1
±25 ±25 ±25 ±25 ±25 ±25 ±25 ±25 ±25 ±25 ±25 ±25
Engine Weight (dry)
183kg 170kg
Rated Engine 0.29-0.44 (3.0-
0.32-0.47 (3.3-4.8) MPa
Pressure Low Idle
Speed
≥ 0.06 (≥ 0.6) MPa
Recommended Battery
Capacity
Dimensions (L × W × H)* 684 × 523 × 617 659 × 523 × 617
7.4L/4.0L
φ120/ φ90 φ110/ φ110
Fan V-pulley dia.
4TNV98-E (complies with EPA Interim Tier4)

Engine Model 4TNV98-E
Version CL VM
No. of Cylinders 4
Displacement 3.319L
min-1
Continuous Rated
kW
Output
PS
min-1 2100 2200 2300 2400 2500
Max. Rated Output
kW 36.8 38.2 39.7 41.6 43.0
(Net)
PS 50.0 52.0 54.0 56.5 58.5
High Idling min-1 2250 ± 25 2350 ± 25 2450 ± 25 2550 ± 25 2650 ± 25
Engine Weight (dry)
240kg
Rated Engine
0.29-0.39 (3.0-4.0) MPa
Normal Oil Speed
Pressure Low Idle
0.06 (0.6) MPa
Speed
Recommended Battery
Capacity
Starting aid device Air heater (12VDC/500W)
10.2L/5.7L
Standard Cooling Fan Resin F type pusher fan - φ410(AI) x 6
φ130/ φ130mm
Fan V-pulley dia.
4TNV98-Z (complies with EPA Interim Tier4)

Engine Model 4TNV98-Z
Version CL VM
No. of Cylinders 4
Displacement 3.319L
min-1 1500 1800
Continuous Rated
kW 30.9 36.8
Output
PS 42.0 50.0
min-1 1500 1800 2000 2100 2200 2300 2400 2500
Max. Rated Output
kW 34.6 41.2 41.9 43.8 45.6 47.4 49.3 51.1
(Net)
PS 47.0 56.0 57.0 59.5 62.0 64.5 67.0 69.5
High Idling min-1 1530 ± 25 1830 ± 25 2150 ± 25 2250 ± 25 2350 ± 25 2450 ± 25 2550 ± 25 2650 ± 25
Engine Weight (dry)
248kg 235kg
Rated Engine
0.29-0.39 (3.0-4.0) MPa
Normal Oil Speed
Pressure Low Idle
0.06 (0.6) MPa
Speed
Recommended Battery
Capacity
10.2L/5.7L
Standard Cooling Fan Resin F type pusher fan - φ410(AI) x 6
φ130/ φ130mm
Fan V-pulley dia.
4TNV98T-Z (complies with EPA Interim Tier4)

Engine Model 4TNV98T-Z
Version CL VM
No. of Cylinders 4
Displacement 3.319L
min-1 1500 1800
Continuous Rated
kW 37.9 45.6
Output
PS 51.5 62.0
min-1 1500 1800 2200 2300 2400 2500
Max. Rated Output
kW 41.9 50.4 55.5 58.0 60.3 62.5
(Net)
PS 57.0 68.5 75.5 78.8 82.0 85.0
High Idling min-1 1530 ± 25 1830 ± 25 2350 ± 25 2450 ± 25 2550 ± 25 2650 ± 25
Engine Weight (dry)
258kg 245kg
Rated Engine
0.29-0.39 (3.0-4.0) MPa
Normal Oil Speed
Pressure Low Idle
Speed
≥ 0.06 (≥ 0.6) MPa
Recommended Battery
Capacity
10.2L/5.7L
Standard Cooling Fan Resin F type pusher fan - φ430(UX) x 6
φ130/ φ130mm
Fan V-pulley dia.
Engine Service Standards GENERAL SERVICE INFORMATION
ENGINE SERVICE STANDARDS

Reference
Inspection Item Standard Limit
page
All models
except 0.006 - 0.010 in. See Measuring
-
4TNV106 and (0.15 - 0.25 mm) and Adjusting
Intake / Exhaust Valve Clearance 4TNV106T Valve Clearance
4TNV106 and 0.010 - 0.014 in. on page 6-66
-
4TNV106T (0.25 - 0.35 mm)
Fuel Injection
See Checking and Adjusting Fuel Injection Timing on page 7-30.
Timing
Fuel Injection
See Test and Adjustment Specifications on page 7-12.
Pressure
443 - 473 psi 340 - 370 psi
3TNV82A (3.06 - 3.26 MPa; (2.35 - 3.55 MPa;
30 - 32 kgf / cm²) 24 - 26 kgf / cm²)
455 - 485 psi 355 - 385 psi See
Compression 3TNV84, 4TNV84 (3.14 - 3.34 MPa; (2.45 - 2.65 MPa; Troubleshooting
Pressure at 32 - 34 kgf / cm²) 25 - 27 kgf / cm²) By Measuring
250 rpm 411 - 441 psi 340 - 370 psi Compression
(250 min¯¹) 3TNV84T, 4TNV84T (2.84 - 3.04 MPa; (2.35 - 2.55 MPa; Pressure on
29 - 31 kgf / cm) 24 - 26 kgf / cm²) page 15-187
3TNV88, 4TNV88, 4TNV94L, 483 - 513 psi 384 - 414 psi
4TNV98, 4TNV98T, 4TNV106, (3.33 - 3.53 MPa; (2.65 - 2.85 MPa;
4TNV106T 34 - 36 kgf / cm²) 27 - 29 kgf / cm²)
29 - 43 psi
Deviation Between Cylinders All Models (0.2 - 0.3 MPa; - -
2 - 3 kgf/cm²)
5.8 - 8.8 psi
Oil Pressure Switch Operating Pressure (0.04 - 0.06 MPa; - -
0.4 - 0.6 kgf / cm²)
Valve Opening Full Opening Lift
Temperature Temperature
0.32 in (8 mm) or
157°F - 163°F
All Models above See Thermostat
Thermostat (70°C - 73°C)
185°F (85°C) on page 8-11
0.39 in (10 mm) or
All Models 176°F - 183°F
above
Option (80°C - 84°C)
203°F (95°C)
See
225°F - 235°F Temperature
Coolant Temperature Switch -
(107°C - 113°C) Switch on
page 8-10
GENERAL SERVICE INFORMATION Tightening Torques for Standard Bolts and Nuts
TIGHTENING TORQUES FOR STANDARD BOLTS AND NUTS

Use the correct amount of torque when you tighten
the fasteners on the machine. Applying excessive CAUTION
torque may damage the fastener or component and The tightening torque in the Standard
not enough torque may cause a leak or component Torque Chart (see General Service
failure. Information section) should be applied
only to the bolts with a “7” head. (JIS
strength classification: 7T)
• Apply 60% torque to bolts

that are not listed.
• Apply 80% torque when
tightened to aluminum alloy.
0000023enTNVDISM
Nominal Thread
Item x Pitch Tightening Torque Remarks
Diameter
7 - 9 ft-lb
(87 -104 in.-lb,
M6 x 1.0 mm
9.8 -11.8 N·m,
1.0 -1.2 kgf·m)
17 - 21 ft-lb
(200 - 251 in.-lb,
M8 x 1.25 mm
22.6 - 28.4 N·m,
2.3 - 2.9 kgf·m)
33 - 40 ft-lb Use 80% of the value at left
M10 x 1.5 mm (44.1 - 53.9 N·m, when the tightening part is
Hexagon Bolt (7T) and
4.5 - 5.5 kgf·m) aluminum.
Nut
Use 60% of the value at left for
58 - 72 ft-lb 4T bolts and lock nuts.
M12 x 1.75 mm (78.4 - 98.0 N·m,
8.0 - 10 kgf·m)
94 - 108 ft-lb
M14 x 1.5 mm (127.5 - 147.1 N·m,
13 - 15 kgf·m)
159 - 174 ft-lb
M16 x 1.5 mm (215.7- 235.4 N·m,
22 - 24 kgf·m)
7 ft-lb
1/8 mm
(87 in.-lb, 9.8 N·m, 1.0 kgf·m)
14 ft-lb
1/4 mm
(173 in.-lb, 19.6 N·m, 2.0 kgf·m)
PT PLug -
22 ft-lb
3/8 mm
(29.4 N·m, 3.0 kgf·m)
43 ft-lb
1/2 mm
(58.8 N·m, 6.0 kgf·m)
Tightening Torques for Standard Bolts and Nuts GENERAL SERVICE INFORMATION
Nominal Thread
Item x Pitch Tightening Torque Remarks
Diameter
9 - 12 ft-lb
(112 - 148 in.-lb,
M8
12.7 - 16.7 N·m,
1.3 - 1.7 kgf·m)
14 - 19 ft-lb
(173 - 225 in.-lb,
M10
19.6 - 18.734 N·m,
2.0 - 3.5 kgf·m)
Pipe Joint Bolt 18 - 25 ft-lb -
M12 (24.5 - 34.3 N·m,
2.5 - 3.5 kgf·m)
29 - 36 ft-lb
M14 (39.2 - 49.0 N·m,
4.0 - 5.0 kgf·m)
36 - 43 ft-lb
M16 (49.0 - 58.8 N·m,
5.0 - 6.0 kgf·m)
Note: Torque values shown in this manual are for clean, non-lubricated fasteners unless otherwise
specified.
GENERAL SERVICE INFORMATION Abbreviations and Symbols
ABBREVIATIONS AND JASO Japanese Automobile Standards

Organization
SYMBOLS k kelvin
kg kilogram
Abbreviations kgf/cm² kilogram force per square centimeter
kgf/m kilogram force per meter
A ampere km kilometers
AC alternating current kPa kilopascal
ACEA Association des Constructeurs kW kilowatt
Européens d’Automobilies L liter
Ah ampere-hour L/hr liter per hour
API American Petroleum Institute lb pound
lbf pound force
ARB Air Resources Board
m meter
ATDC after top dead center
mL milliliter
BDC bottom dead center
mm millimeter
BTDC before top dead center mmAq millimeter Aqueous (water)
°C degree Celsius MPa megapascal
CARB California Air Resources Board mV millivolt
CCA cold cranking amp N newton
cfm cubic feet per minute N·m newton meter
cm centimeter No. number
cm³ cubic centimeter O.D. outside diameter
cm³/min cubic centimeter per minute oz ounce
Pa pascal
cu in. cubic inch
PS horsepower (metric)
D diameter
psi pound per square inch
DC direct current
qt quart (U.S.)
DI direct injection R radius
DVA direct volt adapter rpm revolutions per minute
EPA Environmental Protection Agency SAE Society of Automotive Engineers
ESG electronic speed governor sec. second
°F degree Fahrenheit t short ton 2000 lb
fl oz fluid ounce (U.S.) TBN total base number
fl oz/min fluid ounce (U.S.) per minute TDC top dead center
ft foot V volt
VAC volt alternating current
ft-lb foot pound
VDC volt direct current
ft-lbf/min foot pound force per minute
W watt
g gram
gal gallon (U.S.) Symbols
gal/hr gallon (U.S.) per hour
gal/min gallon (U.S.) per minute ° degree
GL gear lubricant + plus
hp horsepower (U.S.)
- minus
hr hour
± plus or minus
I.D. inside diameter
Ω ohm
ID identification μ micro
IDI indirect injection % percent
in. inch
in.Aq inches Aqueous (water)
in.Hg inches Mercury
in.-lb inch pound
j joule
Unit Conversions GENERAL SERVICE INFORMATION
UNIT CONVERSIONS Units of Torque

ft-lb x 1.3558 = N·m
Unit Prefixes
ft-lb x 0.1383 = kgf/m
Prefix Symbol Power in.-lb x 0.1130 = N·m
mega M x 1,000,000 in.-lb x 0.0115 = kgf/m
kilo k x 1,000 kgf/m x 7.2330 = ft-lb
centi c x 0.01 kgf/m x 86.8000 = in.-lb
milli m x 0.001 kgf/m x 9.8070 = N·m
micro μ x 0.000001 N·m x 0.7376 = ft-lb
N·m x 8.8510 = in.-lb
Units of Length N·m x 0.1020 = kgf/m
mile x 1.6090 = km Units of Pressure
ft x 0.3050 =m
in. x 2.5400 = cm psi x 0.0689 = bar
in. x 25.4000 = mm psi x 6.8950 = kPa
km x 0.6210 = mile psi x 0.0703 = kg/cm²
m x 3.2810 = ft bar x 14.5030 = psi
cm x 0.3940 = in. bar x 100.0000 = kPa
mm x 0.0394 = in. bar x 29.5300 = inHg (60°F)
kPa x 0.1450 = psi
Units of Volume kPa x 0.0100 = bar
kPa x 0.0102 = kg/cm²
gal (U.S.) x 3.78540 =L
kg/cm² x 98.0700 = psi
qt (U.S.) x 0.94635 =L
kg/cm² x 0.9807 = bar
cu in. x 0.01639 =L
kg/cm² x 14.2200 = kPa
cu in. x 16.38700 = mL
in.Hg (60°) x 0.0333 = bar
fl oz (U.S.) x 0.02957 =L
in.Hg (60°) x 3.3770 = kPa
fl oz (U.S.) x 29.57000 = mL
in.Hg (60°) x 0.0344 = kg/cm²
cm³ x 1.00000 = mL
mmAq x 0.0394 = in.Aq
cm³ x 0.03382 = fl oz (U.S.)
Units of Power
Units of Mass
hp (metric x 0.9863201 = hp SAE
lb x 0.45360 = kg
or PS)
oz x 28.35000 =g
hp (metric x 0.7354988 = kW
kg x 2.20500 = lb
or PS)
g x 0.03527 = oz
hp SAE x 1.0138697 = hp (metric or PS)
Units of Force hp SAE x 0.7456999 = kW
kW x 1.3596216 = hp (metric or PS)
lbf x 4.4480 =N kW x 1.3410221 = hp SAE
lbf x 0.4536 = kgf
N x 0.2248 = lbf Units of Temperature
N x 0.1020 = kgf
°F = (1.8 x °C) + 32
kgf x 2.2050 = lbf
°C = 0.556 x (°F - 32)
kgf x 9.8070 =N
GENERAL SERVICE INFORMATION Unit Conversions


Section 5
PERIODIC
MAINTENANCE
Page
Before You Begin Servicing ............................................................ 5-3

Introduction.................................................................................... 5-16
The Importance of Periodic Maintenance................................ 5-16
Performing Periodic Maintenance ........................................... 5-16
Yanmar Replacement Parts .................................................... 5-16
Required EPA / ARB Maintenance -USA Only........................ 5-16
EPA / ARB Installation Requirements - USA Only .................. 5-16
Periodic Maintenance Schedule .................................................... 5-17
Periodic Maintenance Procedures ................................................ 5-20
After Initial 50 Hours of Operation ........................................... 5-20
Every 50 Hours of Operation ................................................... 5-24
Every 250 Hours of Operation ................................................. 5-27
Every 500 Hours of Operation ................................................. 5-32
Every 1000 Hours of Operation ............................................... 5-36
PERIODIC MAINTENANCE
Before You Begin Servicing PERIODIC MAINTENANCE
BEFORE YOU BEGIN

A DANGER
SERVICING
A DANGER
SCALD HAZARD!
• NEVER remove the radiator cap if the
EXPLOSION HAZARD!
engine is hot. Steam and hot engine
coolant will spurt out and seriously
• NEVER check the remaining battery burn you. Allow the engine to cool
charge by shorting out the terminals. down before you attempt to remove
This will result in a spark and may the radiator cap.
hydrometer to check the remaining • Tighten the radiator cap securely after
battery charge. you check the radiator. Steam can
• If the electrolyte is frozen, slowly warm the cap is loose.
• ALWAYS check the level of the engine
• Failure to comply will result in death or coolant by observing the reserve tank.
serious injury.
0000007en
serious injury.
0000002en
A DANGER

• 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.
serious injury.
0000004en
PERIODIC MAINTENANCE Before You Begin Servicing
A DANGER A DANGER

• Only fill the fuel tank with diesel fuel. • Before you operate the engine, check
Filling the fuel tank with gasoline may for fuel leaks. Replace rubberized fuel
result in a fire and will damage the hoses every two years or every 2000
engine. hours of engine operation, whichever
comes first, even if the engine has
• NEVER refuel with the engine running.
been out of service. Rubberized fuel
• Wipe up all spills immediately. lines tend to dry out and become
• Keep sparks, open flames or any other brittle after two years or 2000 hours of
form of ignition (match, cigarette, engine operation, whichever comes
static electric source) well away when first.
refueling. • Failure to comply will result in death or
• NEVER overfill the fuel tank. serious injury.
0000015en
• Fill the fuel tank. Store any containers
containing fuel in a well-ventilated
area, away from any combustibles or A DANGER
sources of ignition.
serious injury.
0000005en

• NEVER remove the fuel cap with the
engine running.
serious injury.
0000011en
A DANGER A DANGER

CRUSH HAZARD!
under certain conditions. • When you need to transport an engine
for repair, have a helper assist you to
• Be sure to place the diesel fuel
attach it to a hoist and load it on a
container on the ground when
truck.
transferring the diesel fuel from the
pump to the container. Hold the hose • NEVER stand under a hoisted engine.
nozzle firmly against the side of the If the hoist mechanism fails, the
container while filling it. This prevents engine will fall on you, causing death
static electricity buildup which could or serious injury.
cause sparks and ignite fuel vapors. • Failure to comply will result in death or
• NEVER place diesel fuel or other serious injury.
flammable material such as oil, hay or 0000008en
dried grass close to the engine during

engine operation or shortly after
shutdown.
serious injury.
0000014en
A DANGER

agent.
serious injury.
0000012en
A DANGER A DANGER

• When you remove any fuel system • Place an approved container under the
component to perform maintenance air bleed port when you prime the fuel
(such as changing the fuel filter) place system. Never use a shop rag to catch
an approved container under the the fuel. Wipe up any spills
opening to catch the fuel. immediately. ALWAYS close the air
• NEVER use a shop rag to catch the bleed port after you complete priming
fuel. Vapors from the rag are the system.
flammable and explosive. • Wear eye protection. The fuel system
• Wipe up any spills immediately. is under pressure and fuel could spray
out when you open the air bleed port.
• Wear eye protection. The fuel system
is under pressure and fuel could spray • If the unit has an electric fuel pump,
out when you remove any fuel system turn the key switch to the ON position
component. for 10 to 15 seconds, or until the fuel
coming out of the air bleed port is free
• Failure to comply will result in death or of bubbles, to allow the electric fuel
serious injury. pump to prime the system.
0000009en
• 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.
serious injury.
0000006en
A WARNING A WARNING
EXHAUST HAZARD! SEVER HAZARD!

• NEVER operate the engine in an • Keep hands and other body parts
enclosed area such as a garage, away from moving / rotating parts
tunnel, underground room, manhole or such as the cooling fan, flywheel or
ship’s hold without proper ventilation. PTO shaft.
• NEVER block windows, vents, or other • Wear tight-fitting clothing and keep
means of ventilation if the engine is your hair short or tie it back while the
operating in an enclosed area. All engine is running.
internal combustion engines create • Remove all jewelry before you operate
carbon monoxide gas during or service the machine.
operation. Accumulation of this gas
within an enclosure could cause • NEVER start the engine in gear.
illness or even death. Sudden movement of the engine
and / or machine could cause death or
• Make sure that all connections are serious personal injury.
tightened to specifications after repair
is made to the exhaust system. • NEVER operate the engine without the
guards in place.
or serious injury. • Before you start the engine make sure
0000003en
that all bystanders are clear of the
area.
• Keep children and pets away while the
engine is operating.
• Check before starting the engine that
any tools or shop rags used during
maintenance have been removed from
the area.
or serious injury.
0000002en
A WARNING A WARNING
SUDDEN MOVEMENT HAZARD!
• Engaging the transmission or PTO at
an elevated engine speed could result
in unexpected movement of the
equipment.
ALCOHOL AND DRUG HAZARD!
or serious injury. • NEVER operate the engine while you
0000006en
are under the influence of alcohol or
drugs.
A WARNING • NEVER operate the engine when you

are feeling ill.
or serious injury.
0000004en
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.
or serious injury.
0000015en
A WARNING A WARNING
BURN HAZARD!
EXPOSURE HAZARD! • Batteries contain sulfuric acid. NEVER

allow battery fluid to come in contact
• Wear personal protective equipment
with clothing, skin or eyes. Severe
such as gloves, work shoes, eye and
burns could result. ALWAYS wear
hearing protection as required by the
safety goggles and protective clothing
task at hand.
• NEVER wear jewelry, unbuttoned fluid contacts the eyes and / or skin,
cuffs, ties or loose-fitting clothing immediately flush the affected area
when you are working near with a large amount of clean water and
moving / rotating parts such as the obtain prompt medical treatment.
cooling fan, flywheel or PTO shaft.
• ALWAYS tie back long hair when you or serious injury.
are working near moving / rotating 0000007en
parts such as a cooling fan, flywheel,

or PTO shaft.
A WARNING
• NEVER operate the engine while
wearing a headset to listen to music or
radio because it will be difficult to hear
the alert signals.
HIGH-PRESSURE HAZARD!
or serious injury.
0000005en
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.
hands. ALWAYS use a piece of wood
or cardboard. Have your authorized
Yanmar industrial engine dealer or
distributor repair the damage.
or serious injury.
0000008en
A WARNING A WARNING
BURN HAZARD!
SHOCK HAZARD!
• If you must drain the engine oil while it
• Turn off the battery switch (if
equipped) or disconnect the negative
battery cable before servicing the
electrical system. • ALWAYS wear eye protection.
• Check the electrical harnesses for • Failure to comply could result in death
cracks, abrasions, and damaged or or serious injury.
corroded connectors. ALWAYS keep 0000011en
the connectors and terminals clean.

• Failure to comply could result in death A WARNING
or serious injury.
0000009en
A WARNING
BURN HAZARD!
• Wait until the engine cools before you
ENTANGLEMENT HAZARD! • Failure to comply could result in death
• Stop the engine before you begin to or serious injury.
service it. 0000016en
• 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
or serious injury.
0000010en
A CAUTION CAUTION
warranty requirements.
COOLANT HAZARD! • Only use clean diesel fuel.
• Wear eye protection and rubber gloves • NEVER remove the primary strainer (if
when you handle long life or extended equipped) from the fuel tank filler port.
life engine coolant. If contact with the If removed, dirt and debris could get
eyes or skin should occur, flush eyes into the fuel system causing it to clog.
and wash immediately with clean 0000004en
water.
• Failure to comply may result in minor CAUTION
or moderate injury. • Only use the engine oil specified.
0000005en
coverage, cause internal engine
A CAUTION components to seize and / or shorten
engine life.
the cap.
FLYING OBJECT HAZARD! • NEVER mix different types of engine
oil. This may adversely affect the
• ALWAYS wear eye protection when
servicing the engine and when using lubricating properties of the engine oil.
compressed air or high-pressure • NEVER overfill. Overfilling may result
water. Dust, flying debris, compressed in white exhaust smoke, engine
air, pressurized water or steam may overspeed or internal damage.
injure your eyes. 0000005en

or moderate injury.
0000003en

CAUTION CAUTION
• Only use the engine coolant specified. Observe the following environmental
Other engine coolants may affect operating conditions to maintain engine
warranty coverage, cause an internal performance and avoid premature
buildup of rust and scale and / or engine wear:
shorten engine life. • Avoid operating in extremely dusty
• Prevent dirt and debris from conditions.
contaminating the engine coolant. • Avoid operating in the presence of
Carefully clean the radiator cap and chemical gases or fumes.
remove the cap. • Avoid operating in a corrosive
atmosphere such as salt water spray.
coolants. This may adversely affect the • NEVER install the engine in a
properties of the engine coolant. floodplain unless proper precautions
0000006en
are taken to avoid being subject to a
flood.
CAUTION • NEVER expose the engine to the rain.

0000003en
• NEVER attempt to modify the engine’s
design or safety features such as
defeating the engine speed limit CAUTION
control or the diesel fuel injection Observe the following environmental
quantity control. operating conditions to maintain engine
• Modifications may impair the engine’s performance and avoid premature
safety and performance engine wear:
characteristics and shorten the • The standard range of ambient
engine’s life. Any alterations to this temperatures for the normal operation
engine may void its warranty. Be sure of Yanmar engines is from +5°F (-15°C)
to use Yanmar genuine replacement to +113°F (+45°C).
parts.
• If the ambient temperature exceeds
0000079en
+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
CAUTION CAUTION
NEVER hold the key in the START New Engine Break-in:
position for longer than 15 seconds or • On the initial engine start-up, allow the
the starter motor will overheat. engine to idle for approximately 15
0000007en
minutes while you check for proper
engine oil pressure, diesel fuel leaks,
CAUTION engine oil leaks, coolant leaks, and for
proper operation of the indicators
For maximum engine life, Yanmar
and / or gauges.
recommends that when shutting the
engine down, you allow the engine to • During the first hour of operation, vary
idle, without load, for five minutes. This the engine speed and the load on the
will allow the engine components that engine. Short periods of maximum
operate at high temperatures, such as engine speed and load are desirable.
the turbocharger (if equipped) and Avoid prolonged operation at
exhaust system, to cool slightly before minimum or maximum engine speeds
the engine itself is shut down. and loads for the next four to five
0000008en
hours.
• During the break-in period, carefully
CAUTION observe the engine oil pressure and
engine temperature.
NEVER use an engine starting aid such
as ether. Engine damage will result. • During the break-in period, check the
0000009en
engine oil and coolant levels
frequently.
0000011en
CAUTION
Make sure the engine is installed on a
level surface. If a continuously running
CAUTION
engine is installed at an angle greater NEVER engage the starter motor while
than (IDI = 25°, DI = 30°) in any direction the engine is running. This may damage
or if an engine runs for short periods of the starter motor pinion and / or ring
time (less than three minutes) at an gear.
angle greater than (IDI = 30°, DI = 35°) in 0000012en
any direction, engine oil may enter the

combustion chamber causing excessive CAUTION
engine speed and white exhaust smoke.
This may cause serious engine damage. It is important to perform daily checks.
0000010enTNV Periodic maintenance prevents
unexpected downtime, reduces the
number of accidents due to poor
machine performance and helps extend
the life of the engine.
0000060en
CAUTION CAUTION
NEVER use high-pressure water or
compressed air at greater than 28 psi
(193 kPa; 19 686 mmAq) or a wire brush
to clean the radiator fins. Radiator fins
damage easily.
• ALWAYS be environmentally 0000016en
responsible.
• Follow the guidelines of the EPA or CAUTION
other governmental agencies for the NEVER attempt to adjust the low or high
proper disposal of hazardous idle speed limit screw. This may impair
materials such as engine oil, diesel the safety and performance of the
fuel and engine coolant. Consult the machine and shorten its life. If the idle
local authorities or reclamation facility. speed limit screws require adjustment,
• NEVER dispose of hazardous see your authorized Yanmar industrial
materials irresponsibly by dumping engine dealer or distributor.
them into a sewer, on the ground, or 0000017en
into ground water or waterways.

• Failure to follow these procedures may CAUTION
seriously harm the environment. Establish a periodic maintenance plan
0000013en
according to the engine application and
make sure you perform the required
CAUTION periodic maintenance at the intervals
indicated. Failure to follow these
Protect the air cleaner, turbocharger (if
equipped) and electric components
from damage when you use steam or
shorten the engine’s life and may affect
high-pressure water to clean the engine.
the warranty coverage on your engine.
0000014en

Warranty Section.
CAUTION
Consult your authorized Yanmar dealer
• NEVER overfill the engine with engine or distributor for assistance when
oil. checking items marked with a .
• ALWAYS keep the oil level between the 0000024enTNVDISM
upper and lower lines on the oil

cap / dipstick.
0000015en
CAUTION
If the fuel filter / water separator is
positioned higher than the fuel level in
the fuel tank, water may not drip out
when the fuel filter / water separator
drain cock is opened. If this happens,
turn the air vent screw on the top of the
fuel filter / water separator 2-3 turns
counterclockwise.
Be sure to tighten the air vent screw
after the water has drained out.
0000025en
CAUTION
• When the engine is operated in dusty
conditions, clean the air cleaner
element more frequently.
• NEVER operate the engine with the air
cleaner element(s) removed. This may
allow foreign material to enter the
engine and damage it.
0000026en
CAUTION
The maximum air intake restriction, in
terms of differential pressure
measurement, must not exceed 0.90 psi
(6.23 kPa; 635 mmAq). Clean or replace
the air cleaner element if the air intake
mentioned value.
0000046en
PERIODIC MAINTENANCE Introduction
INTRODUCTION Perform periodic maintenance procedures in an

open, level area free from traffic. If possible,
This section of the Service Manual describes the perform the procedures indoors to prevent
procedures for proper care and maintenance of the environmental conditions, such as rain, wind, or
engine. snow, from damaging the machine.
The Importance of Periodic Yanmar Replacement Parts
Maintenance Yanmar recommends that you use genuine Yanmar
Engine deterioration and wear occurs in proportion parts when replacement parts are needed.
to length of time the engine has been in service and Genuine replacement parts help ensure long
the conditions the engine is subject to during engine life.
operation. Periodic maintenance prevents
unexpected downtime, reduces the number of Required EPA / ARB Maintenance -
accidents due to poor machine performance and USA Only
helps extend the life of the engine.
To maintain optimum engine performance and
Performing Periodic Maintenance compliance with the Environmental Protection
Agency (EPA) Regulations Non-road Engines and
the California Air Resources Board (ARB,
A WARNING California), it is essential that you follow the
Periodic Maintenance Schedule on page 5-17 and
Periodic Maintenance Procedures on page 5-20.
EPA / ARB Installation

EXHAUST HAZARD!
Requirements - USA Only
• NEVER operate the engine in an The following are the installation requirements for
enclosed area such as a garage, the EPA / ARB. Unless these requirements are met,
tunnel, underground room, manhole or the exhaust gas emissions will not be within the
ship’s hold without proper ventilation. limits specified by the EPA and ARB.
• NEVER block windows, vents, or other Maximum Exhaust Gas Restriction shall be:
means of ventilation if the engine is
• 3TNV84T(-B): 1.42 psi (9.81 kPa; 1000 mm
operating in an enclosed area. All
Aq) or less
internal combustion engines create
carbon monoxide gas during • 4TNV98T(-Z): 1.71 psi (11.77 kPa; 1200 mm
operation. Accumulation of this gas Aq) or Iess
within an enclosure could cause • 3TNV82A(-B),3TNV84,3TNV88(-B)(-U),
illness or even death. 4TNV94L,4TNV98(-Z)(-E): 2.22 psi (15.3 kPa;
• Make sure that all connections are 1560 mm Aq) or Iess
tightened to specifications after repair Maximum air intake restriction shall be 0.90 psi
is made to the exhaust system. (6.23 kPa; 635 mm Aq) or less. Clean or replace
• Failure to comply could result in death the air cleaner element if the air intake restriction
or serious injury. exceeds the above mentioned value.
0000003en
Periodic Maintenance Schedule PERIODIC MAINTENANCE
PERIODIC MAINTENANCE
SCHEDULE
Daily and periodic maintenance is important to
keep the engine in good operating condition. The
following is a summary of maintenance items by
periodic maintenance intervals. Periodic
maintenance intervals vary depending on engine
application, loads, diesel fuel and engine oil used
and are hard to establish definitively. The following
should be treated only as a general guideline.
CAUTION
Establish a periodic maintenance plan
according to the engine application and
make sure you perform the required
periodic maintenance at the intervals
indicated. Failure to follow these
shorten the engine’s life and may affect
the warranty coverage on your engine.
Warranty Section.
Consult your authorized Yanmar dealer
or distributor for assistance when
checking items marked with a .
0000024enTNVDISM
PERIODIC MAINTENANCE Periodic Maintenance Schedule
: Check : Replace : Contact your authorized Yanmar industrial engine dealer or distributor
Periodic Maintenance Interval
System Check Item Daily Every Every Every Every Every Every
50 250 500 1000 1500 2000
hours hours hours hours hours hours
Check and Refill Engine Coolant

Check and Clean Radiator Fins
Check and Adjust Cooling Fan V-belt 2nd and

1st time
after
Cooling
System or
every 1
year
Drain, Flush and Refill Cooling System With New Coolant which-
ever
comes
first
Cylinder Adjust Intake / Exhaust Valve Clearance

Head Lap Intake / Exhaust Valve Seats. If necessary
Electrical Check Indicators

Equipment Check Battery
Check Engine Oil Level
Engine Oil Drain and Fill Engine Oil 2nd and

1st time
after
Replace Engine Oil Filter
Engine
Check and Adjust Governor Lever and
Speed
Engine Speed Control
Control
Inspect, Clean And Test Fuel Injectors
Inspect Turbocharger
(Blower Wash as Necessary)
3TNV84T, 4TNV84T, 4TNV98T, 4TNV106T,
3TNV84T-B, 4TNV84T-Z, 4TNV98T-Z
Emission Inspect, Clean and Test EGR Valve

Control 4TNV84T, 4TNV98T
Warranty
Clean EGR Lead Valve
4TNV84T, 4TNV98T
Clean EGR Cooler
(Clean to Blow Water/Air Passages)
4TNV84T, 4TNV98T
Inspect Crankcase Breather System
Check and Refill Fuel Tank Level
Drain Fuel Tank
Drain Fuel Filter / Water Separator
Fuel
Check Fuel Filter / Water Separator
Clean Fuel Filter / Water Separator
Replace Fuel Filter
Replace Fuel System and

Hoses or every
Cooling System Hoses
2 yrs.
Periodic Maintenance Schedule PERIODIC MAINTENANCE
: Check : Replace : Contact your authorized Yanmar industrial engine dealer or distributor
Periodic Maintenance Interval
System Check Item Daily Every Every Every Every Every Every
50 250 500 1000 1500 2000
hours hours hours hours hours hours
Intake and
Clean or Replace Air Cleaner Element
Exhaust
Complete
Overall Visual Check Daily
Engine
Note: These procedures are considered normal maintenance and are performed at the owner’s expense.
PERIODIC MAINTENANCE Periodic Maintenance Procedures
PERIODIC MAINTENANCE CAUTION

PROCEDURES • Only use the engine oil specified.
After Initial 50 Hours of Operation coverage, cause internal engine
components to seize and / or shorten
Perform the following maintenance after the initial engine life.
50 hours of operation. • Prevent dirt and debris from
• Replace Engine Oil and Engine Oil Filter contaminating the engine oil. Carefully
• Check and Adjust Cooling Fan V-Belt surrounding area before you remove
the cap.
Replace Engine Oil and Engine Oil Filter
A WARNING oil. This may adversely affect the
lubricating properties of the engine oil.
• NEVER overfill. Overfilling may result
overspeed or internal damage.
0000005en
BURN HAZARD!
• If you must drain the engine oil while it CAUTION
• ALWAYS wear eye protection.
or serious injury.
0000011en
• ALWAYS be environmentally
responsible.
A WARNING • Follow the guidelines of the EPA or

other governmental agencies for the
SUDDEN MOVEMENT HAZARD! proper disposal of hazardous
• Engaging the transmission or PTO at materials such as engine oil, diesel
an elevated engine speed could result fuel and engine coolant. Consult the
in unexpected movement of the local authorities or reclamation facility.
equipment. • NEVER dispose of hazardous
• Failure to comply could result in death materials irresponsibly by dumping
or serious injury. them into a sewer, on the ground, or
0000006en
• Failure to follow these procedures may
seriously harm the environment.
0000013en
Periodic Maintenance Procedures PERIODIC MAINTENANCE

The engine oil in a new engine becomes 7. After all oil has been drained from the engine,
contaminated from the initial break-in of internal reinstall the oil drain plug (Figure 5-2, (1)) and
parts. It is very important that the initial oil and filter tighten to 139.8 - 47.0 ft·lb (53.9 - 63.7 N·m;
change is performed as scheduled. 5.5 - 6.5 kgf·m).
Note: The oil drain plug may be in another 8. Dispose of used oil properly.
location if an optional oil pan is used. Remove the engine oil filter as follows:
Drain the engine oil as follows: 1. Turn the engine oil filter (Figure 5-2, (2))
counterclockwise (Figure 5-2, (3)) using a filter
1. Make sure the engine is level.
wrench.
2. Start the engine and bring it up to operating
temperature. (3)
3. Stop the engine.
(4)
4. Remove one of the oil filler caps
(Figure 5-1, (1)) to vent the engine crankcase
and allow the engine oil to drain more easily.
5. Position a container under the engine to collect
waste oil.
(2)
(1)
(1)
0000062B
Figure 5-2
(1) 0000084 2. Clean the engine oil filter mounting face.
3. Lightly coat the gasket on the new oil filter with
engine oil. Install the new engine oil filter
manually by turning it clockwise
(Figure 5-2, (4)) until it contacts the mounting
surface. Tighten to 14 - 17 ft·lb (19.6 - 23.5
N·m; 2.0 - 2.4 kgf·m) or one additional turn
using the filter wrench.
0000084B
Figure 5-1
6. Remove the oil drain plug (Figure 5-2, (1)) from
the engine oil pan. Allow oil to drain.
Engine Oil Filter Part No. (4)
Standard Dust proof *

3TNV82A
3TNV84
- 4TNV98
3TNV82A-B 129150-35153
3TNV88-B
- 4TNV98-Z 119005-35151
4TNV98-E
4TNV98T
4TNV98T-Z (4)
119005-35151
4TNV106,
4TNV106T (5)
* Consult the operation manual for the driven

machine for applicability of the dust proof
filter. (2)
(1)
4. Add new engine oil to the engine as specified in
Adding Engine Oil on page 4-17.
(3)
CAUTION 0000007C
• NEVER overfill the engine with engine Figure 5-3

oil.
9. Reinstall the oil filler cap (Figure 5-3, (4)). If
• ALWAYS keep the oil level between the any engine oil is spilled, wipe it away with a
upper and lower lines on the oil clean cloth.
cap / dipstick.
0000015en Check and Adjust Cooling Fan V-Belt
The V-belt will slip if it does not have the proper
5. Warm up the engine by running it for five
tension. This will prevent the alternator from
minutes and check for any engine oil leaks.
generating sufficient power. Also, the engine will
6. After engine is warm, shut it off and let it sit for overheat due to the engine coolant pump pulley
10 minutes. slipping.
7. Recheck the engine oil level.
Check and adjust the V-belt tension (deflection) as
8. Add engine oil (Figure 5-3, (5)) as needed until follows:
the level is between the upper (Figure 5-3, (2))
and lower lines (Figure 5-3, (3)) shown on the 1. Press the V-belt down with your thumb with a
dipstick (Figure 5-3, (1)). force of approximately 22 ft·lb (98 N·m; 10 kgf)
to check the deflection.
There are three positions to check for V-belt
tension (Figure 5-4, (A), (B) and (C)). You can
check the tension at whichever position is the
most accessible. The proper deflection of a used
V-belt at each position is:

Used V-Belt Tension

A B C
3/8 - 1/2 in. 1/4 - 3/8 in. 5/16 - 1/2 in.
(10 - 14 mm) (7 - 10 mm) (9 - 13 mm)
(2)
(1)
Note: A “Used V-Belt” refers to a V-belt which
has been used on a running engine for
five minutes or more. 0000584
(B) Figure 5-6
(A)
(C)
0000063B
Figure 5-4
2. If necessary, adjust the V-belt tension. Loosen

the adjusting bolt (Figure 5-5, (1)) and move
the alternator (Figure 5-5, (2)) with a pry bar
(Figure 5-5, (3)) to tighten the V-belt to the
desired tension. Then tighten the adjusting bolt.
(3)
(1)
(2) 0000064B
Figure 5-5
3. Tighten the V-belt to the proper tension. There

must be clearance (Figure 5-6, (1)) between
the V-belt and the bottom of the pulley groove. If
there is no clearance (Figure 5-6, (2)) between
the V-belt and the bottom of the pulley groove,
replace the V-belt.
4. Check the V-belt for cracks, oil or wear. If any of

these conditions exist, replace the V-belt. Every 50 Hours of Operation
5. Install the new V-belt. Refer to the table for
proper tension. After you complete the initial 50 hour maintenance
procedures, perform the following procedures every
New V-Belt Tension 50 hours thereafter.
A B C
• Drain Fuel Filter / Water Separator
5/16 - 7/16 in. 3/16 - 5/16 in. 1/4 - 7/16 in.
(8 - 12 mm) (5 - 8 mm) (7 - 11 mm) • Check Battery
6. After adjusting, run the engine for 5 minutes or Drain Fuel Filter / Water Separator
more. Check the tension again using the
specifications for a used V-belt. A DANGER
Used V-Belt Tension
A B C
3/8 - 1/2 in. 1/4 - 3/8 in. 5/16 - 1/2 in.
(10 - 14 mm) (7 - 10 mm) (9 - 13 mm)
• When you remove any fuel system
component to perform maintenance
(such as changing the fuel filter) place
an approved container under the
• NEVER use a shop rag to catch the
fuel. Vapors from the rag are
• Wipe up any spills immediately.
is under pressure and fuel could spray
out when you remove any fuel system
component.
serious injury.
0000009en

The cup of the separator is made from semi-
CAUTION transparent material. In the cup is a red colored
If the fuel filter / water separator is float ring. The float ring will rise to the surface of the
positioned higher than the fuel level in water to show how much needs to be drained. Also,
the fuel tank, water may not drip out some optional fuel filter / water separators are
when the fuel filter / water separator equipped with a sensor to detect the amount of
drain cock is opened. If this happens, contaminants. This sensor sends a signal to an
turn the air vent screw on the top of the indicator to alert the operator.
fuel filter / water separator 2-3 turns
Drain the fuel filter / water separator as follows:
counterclockwise.
Be sure to tighten the air vent screw 1. Position an approved container under the fuel
after the water has drained out. filter / water separator (Figure 5-7, (1)) to
0000025en
collect the contaminants.
CAUTION (2)
(3)
(1)
responsible.
• Follow the guidelines of the EPA or (4) 0000012C
proper disposal of hazardous Figure 5-7
materials such as engine oil, diesel 2. Close (Figure 5-7, (2)) the fuel cock
fuel and engine coolant. Consult the (Figure 5-7, (3)).
local authorities or reclamation facility.
3. Loosen the drain cock (Figure 5-7, (4)) at the
• NEVER dispose of hazardous bottom of the fuel filter / water separator. Drain
materials irresponsibly by dumping any water collected inside.
them into a sewer, on the ground, or
into ground water or waterways. 4. Hand-tighten the drain cock.
• Failure to follow these procedures may CAUTION

If the fuel filter / water separator is
0000013en
positioned higher than the fuel level in
Drain the fuel filter / water separator whenever the fuel tank, water may not drip out
there are contaminants, such as water, collected in when the fuel filter / water separator
the bottom of the cup. NEVER wait until the drain cock is opened. If this happens,
scheduled periodic maintenance if contaminants turn the air vent screw on the top of the
are discovered. fuel filter / water separator 2-3 turns
counterclockwise.
Be sure to tighten the air vent screw
after the water has drained out.
0000025en
5. Open the fuel cock (Figure 5-7, (3)).

6. Be sure to prime the diesel fuel system when
A WARNING
you are finished. See Priming the Fuel System
on page 4-15.
7. Check for leaks.
Check Battery
BURN HAZARD!
A DANGER • 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
fluid contacts the eyes and / or skin,
EXPLOSION HAZARD!
immediately flush the affected area
• NEVER check the remaining battery with a large amount of clean water and
charge by shorting out the terminals. obtain prompt medical treatment.
This will result in a spark and may
or serious injury.
hydrometer to check the remaining
0000007en
battery charge.
• If the electrolyte is frozen, slowly warm
CAUTION
serious injury.
0000007en
responsible.
• Follow the guidelines of the EPA or
proper disposal of hazardous
materials such as engine oil, diesel
fuel and engine coolant. Consult the
• NEVER dispose of hazardous
materials irresponsibly by dumping
0000013en

• When the amount of fluid nears the lower limit
(Figure 5-8, (1)), fill with distilled water Every 250 Hours of Operation
(Figure 5-8, (2)) so it is at the upper limit
(Figure 5-8, (3)). If operation continues with Perform the following maintenance every 250 hours
insufficient battery fluid, the battery life is of operation.
shortened, and the battery may overheat and
explode. During the summer, check the fluid • Drain Fuel Tank
level more often than specified. • Replace Engine Oil and Engine Oil Filter
• Check and Clean Radiator Fins
(3) • Check and Adjust Cooling Fan V-Belt
(2) • Check and Adjust the Governor Lever and
• Clean Air Cleaner Element
(1)
Drain Fuel Tank
A DANGER
0000067A
Figure 5-8
• If the engine cranking speed is so slow that the

engine does not start, recharge the battery. FIRE AND EXPLOSION HAZARD!
• If the engine still will not start after charging, • Diesel fuel is flammable and explosive
have your authorized Yanmar industrial engine under certain conditions.
dealer or distributor check the battery and the • When you remove any fuel system
engine’s starting system. component to perform maintenance
• If operating the machine where the ambient (such as changing the fuel filter) place
temperature could drop to 5°F (-15°C) or less, an approved container under the
remove the battery from the machine at the end opening to catch the fuel.
of the day. Store the battery in a warm place • NEVER use a shop rag to catch the
until the next use. This will help start the engine fuel. Vapors from the rag are
easily at low ambient temperatures. flammable and explosive.
• Wipe up any spills immediately.
component.
serious injury.
0000009en
4. Drain the tank until clean diesel fuel with no

CAUTION water and dirt flows out. Reinstall and tighten
the drain plug firmly.
5. Reinstall the fuel cap.
6. Check for leaks.
Replace Engine Oil and Engine Oil Filter

responsible. CAUTION
• Follow the guidelines of the EPA or • Only use the engine oil specified.
other governmental agencies for the Other engine oils may affect warranty
proper disposal of hazardous coverage, cause internal engine
materials such as engine oil, diesel components to seize and / or shorten
fuel and engine coolant. Consult the engine life.
• NEVER dispose of hazardous contaminating the engine oil. Carefully
materials irresponsibly by dumping clean the oil cap / dipstick and the
them into a sewer, on the ground, or surrounding area before you remove
into ground water or waterways. the cap.
• Failure to follow these procedures may • NEVER mix different types of engine
seriously harm the environment. oil. This may adversely affect the
0000013en lubricating properties of the engine oil.
Note that a typical fuel tank is illustrated. • NEVER overfill. Overfilling may result
1. Position an approved container under the diesel overspeed or internal damage.
fuel tank (Figure 5-9, (1)) to collect the 0000005en
contaminates.
2. Remove the fuel cap (Figure 5-9, (3)).
3. Remove the drain plug (Figure 5-9, (2)) of the
fuel tank to drain the contaminates (water, dirt,
etc.) from the bottom of the tank.
(3)
(1)
(2)
0000065A
Figure 5-9

Check and Clean Radiator Fins
CAUTION
A CAUTION
responsible.
• Follow the guidelines of the EPA or FLYING OBJECT HAZARD!
compressed air or high-pressure
water. Dust, flying debris, compressed
air, pressurized water or steam may
• NEVER dispose of hazardous injure your eyes.
or moderate injury.
0000003en
seriously harm the environment. Dirt and dust adhering to the radiator fins reduce
0000013en
the cooling performance, causing overheating.
Make it a rule to check the radiator fins daily and
Change the engine oil every 250 hours of operation clean as needed.
after the initial change at 50 hours. Replace the
engine oil filter at the same time. See Replace Note that a typical radiator is shown in Figure 5-10
Engine Oil and Engine Oil Filter on page 5-20. for illustrative purposes only.
• Blow off dirt and dust from fins and radiator with
28 psi (0.19 MPa; 2 kgf/cm2) or less of
compressed air (Figure 5-10, (1)). Be careful
not to damage the fins with the compressed air.
• If there is a large amount of contamination on
the fins, apply detergent, thoroughly clean and
rinse with tap water.
CAUTION
NEVER use high-pressure water or
compressed air at greater than 28 psi
(193 kPa; 19 686 mmAq) or a wire brush
to clean the radiator fins. Radiator fins
damage easily.
0000016en
Checking and adjusting the governor lever:

1. Check that the governor lever (Figure 5-11, (1))
makes uniform contact with the high idle
(Figure 5-11, (2)) and low idle
(1) (Figure 5-11, (3)) speed limit screws when the
FULL
LOW
engine speed control is in the high idle speed or
low idle speed position.
0000085A
(2) (3)
Figure 5-10
Check and Adjust Cooling Fan V-Belt

(1)
Check and adjust the cooling fan V-belt every 250
hours of operation after the initial 50 hour V-belt
maintenance. See Check and Adjust Cooling Fan
V-Belt on page 5-22.
(4)
Check and Adjust the Governor Lever and
000006 9A
(This does not apply to the following
electronically controlled engines: 4TNV84T- Figure 5-11
Z, 4TNV98-E, Z, and 4TNV98T-Z.) 2. If the governor lever does not make contact with
The governor lever and engine speed control the high idle or low idle speed limit screw, adjust
(throttle lever, pedal, etc.) of the machine are the throttle cable.
connected together by a throttle cable or rod. If the 3. In some engine speed control applications,
cable becomes stretched, or the connections loosen the throttle cable lock nut
loosen, the governor lever may not respond to (Figure 5-11, (4)) and adjust the cable so the
change of engine speed control position. This may governor lever makes proper contact with the
make operation of the machine unsafe. Check the high / low idle speed limit screw.
cable periodically and adjust if necessary.
NEVER force the throttle cable or pedal to move. CAUTION
This may deform the governor lever or stretch the NEVER attempt to adjust the low or high
cable and cause irregular operation of the engine idle speed limit screw. This may impair
speed control. 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

Clean Air Cleaner Element 3. Blow air (Figure 5-12, (3)) through the element
Note that a typical air cleaner is shown in from the inside out using 42 - 71 psi
Figure 5-12 and Figure 5-13 for illustrative (0.29 - 0.49 MPa; 3.0 - 5.0 kgf/cm2)
purposes only. compressed air to remove the particulates. Use
the lowest possible air pressure to remove the
The engine performance is adversely affected dust without damaging the element.
when the air cleaner element is clogged with dust. 4. If the air cleaner is equipped with a double
Be sure to clean the air filter element periodically. element, only remove and replace the inner
1. Unlatch and remove the air cleaner cover element (Figure 5-13, (1)) if the engine lacks
(Figure 5-12, (1)). power or the dust indicator actuates (if
equipped).
(6) (4)
(2)
(5)
(3)
(1)
(1)
0000070A
Figure 5-12 0000071A
2. Remove the element (Figure 5-12, (2)) (outer Figure 5-13

element if equipped with two elements). 5. The inner element should not be removed when
cleaning or replacing the outer element. The
A CAUTION inner element is used to prevent dust from
entering the engine while servicing the outer
element.
FLYING OBJECT HAZARD!

compressed air or high-pressure
water. Dust, flying debris, compressed
air, pressurized water or steam may
injure your eyes.
or moderate injury.
0000003en
6. Replace the element with a new one if the

element is damaged, excessively dirty or oily. Every 500 Hours of Operation
7. Clean inside of the air cleaner cover.
Perform the following maintenance every 500 hours
8. Install the element into the air cleaner case of operation.
(Figure 5-12, (4)).
9. Reinstall the air cleaner cover making sure you • Replace Air Cleaner Element
match the arrow (Figure 5-12, (5)) on the cover • Replace Fuel Filter
with the arrow on the case (Figure 5-12, (6)). • Clean Fuel Filter / Water Separator
10. Latch the air cleaner cover to the case.
Replace Air Cleaner Element
CAUTION
• When the engine is operated in dusty
CAUTION
conditions, clean the air cleaner The maximum air intake restriction, in
element more frequently. terms of differential pressure
measurement, must not exceed 0.90 psi
• NEVER operate the engine with the air
(6.23 kPa; 635 mmAq). Clean or replace
cleaner element(s) removed. This may
the air cleaner element if the air intake
allow foreign material to enter the
engine and damage it.
mentioned value.
0000026en
0000046en
Replace the air cleaner element (Figure 5-12, (2))

every 500 hours even if it is not damaged or dirty.
When replacing the element, clean the inside of the
air cleaner case (Figure 5-12, (4)).
If the air cleaner is equipped with a double element,
only remove and replace the inner element
(Figure 5-13, (1)) if the engine lacks power or the
dust indicator actuates (if equipped). This is in
addition to replacing the outer element.

Replace Fuel Filter
CAUTION
A DANGER

responsible.
under certain conditions. • Follow the guidelines of the EPA or
• When you remove any fuel system proper disposal of hazardous
component to perform maintenance materials such as engine oil, diesel
(such as changing the fuel filter) place fuel and engine coolant. Consult the
an approved container under the local authorities or reclamation facility.
• NEVER use a shop rag to catch the materials irresponsibly by dumping
fuel. Vapors from the rag are them into a sewer, on the ground, or
flammable and explosive. into ground water or waterways.
• Wipe up any spills immediately. • Failure to follow these procedures may
• Wear eye protection. The fuel system seriously harm the environment.
is under pressure and fuel could spray 0000013en

component. Replace the fuel filter at specified intervals to
prevent contaminants from adversely affecting the
• Failure to comply will result in death or diesel fuel flow.
serious injury.
0000009en
1. Stop the engine and allow it to cool.
2. Close the fuel cock of the fuel filter / water
CAUTION separator.
For maximum engine life, Yanmar 3. Remove the fuel filter with a filter wrench,
recommends that when shutting the turning it to the left (Figure 5-14, (1)). When
engine down, you allow the engine to removing the fuel filter, carefully hold it to
idle, without load, for five minutes. This prevent the fuel from spilling. Wipe up all spilled
will allow the engine components that fuel.
operate at high temperatures, such as
the turbocharger (if equipped) and
exhaust system, to cool slightly before
the engine itself is shut down.
0000008en
Clean Fuel Filter / Water Separator
A DANGER
(1) (2) • Diesel fuel is flammable and explosive

0000072A
agent.
Figure 5-14
4. Clean the filter mounting surface and apply a serious injury.
small amount of diesel fuel to the gasket of the 0000012en
new fuel filter.

5. Install the new fuel filter. Turn to the right A DANGER
(Figure 5-14, (2)) and hand-tighten it only until
it comes in contact with the mounting surface.
Tighten to 14 - 17 ft·lb (19.6 - 23.5 N·m;
2.0 - 2.4 kgf·m) or one additional turn using the
filter wrench.
Applicable Fuel Filter Part No. • Diesel fuel is flammable and explosive
Standard Dust proof * under certain conditions.
3TNV82A, • When you remove any fuel system
-4TNV98 component to perform maintenance
119802-55801 (such as changing the fuel filter) place
3TNV82A-B,
-4TNV98-B 129907-55801 an approved container under the
4TNV98T,
4TNV98T-Z, 123907-55801 • NEVER use a shop rag to catch the
-4TNV106T fuel. Vapors from the rag are
* Consult the operation manual for the driven • Wipe up any spills immediately.
machine for applicability of the dust proof
filter. • Wear eye protection. The fuel system
6. Open the fuel cock of the fuel filter / water out when you remove any fuel system
separator. component.
7. Prime the fuel system. See Priming the Fuel • Failure to comply will result in death or
System on page 4-15. serious injury.
8. Check for leaks. 0000009en

Periodically clean the fuel filter / water separator
CAUTION element and inside cup.
1. Position an approved container under the cup
(Figure 5-15, (1)) of the fuel filter / water
separator to collect the contaminants.
(5) (9)
responsible.
(2)
other governmental agencies for the (10)
proper disposal of hazardous (6)
(3)
(8)
• NEVER dispose of hazardous (1)
materials irresponsibly by dumping (4)
0000013en
(7)
0000073A
Figure 5-15
2. Close (Figure 5-15, (2)) the fuel cock

(Figure 5-15, (3)).
3. Loosen the drain cock (Figure 5-15, (4)) and
drain the contaminants. See Drain Fuel
Filter / Water Separator on page 5-24.
4. Turn the retaining ring (Figure 5-15, (5)) to the
left (Figure 5-15, (10)) and remove the cup
(Figure 5-15, (6)). If equipped, disconnect the
sensor wire (Figure 5-15, (7)) from the cup
before removing the cup.
5. Carefully hold the cup to prevent fuel from
spilling. If you spill any fuel, clean up the spill
completely.
6. Remove the float ring (Figure 5-15, (8)) from

the cup. Pour the contaminants into the Every 1000 Hours of Operation
container and dispose of it properly.
7. Clean the element (Figure 5-15, (9)) and inside Perform the following maintenance every 1000
cup. Replace the element if it is damaged. hours of operation.
• Drain, Flush and Refill Cooling System With
Applicable Element Part No.
New Coolant
All Models 119802-55710
• Adjust Intake / Exhaust Valve Clearance
8. Install the element and O-ring in the bracket. Drain, Flush and Refill Cooling System With
9. Position the float ring in the cup. New Coolant
10. Check the condition of the cup O-ring. Replace
if necessary. A DANGER
11. Install the cup to the bracket by tightening the
retaining ring to the right (Figure 5-15, (6)) to a
torque of 11 - 15 ft·lb (15 - 20 N·m;
1.5 - 2.0 kgf·m).
12. Close the drain cock. Reconnect the sensor
wire if equipped. SCALD HAZARD!
13. Open the fuel cock (Figure 5-15, (3)). • NEVER remove the radiator cap if the
14. Prime the fuel system. See Priming the Fuel engine is hot. Steam and hot engine
System on page 4-15. coolant will spurt out and seriously
15. Check for leaks. burn you. Allow the engine to cool
the radiator cap.
• Tighten the radiator cap securely after
the cap is loose.
• ALWAYS check the level of the engine
coolant by observing the reserve tank.
serious injury.
0000002en
A WARNING CAUTION
BURN HAZARD!
• Wait until the engine cools before you responsible.
• Failure to comply could result in death proper disposal of hazardous
or serious injury. materials such as engine oil, diesel
0000016en fuel and engine coolant. Consult the
A CAUTION • NEVER dispose of hazardous
0000013en
COOLANT HAZARD!
• Wear eye protection and rubber gloves Engine coolant contaminated with rust or scale
when you handle long life or extended reduces the cooling effect. Even when extended life
life engine coolant. If contact with the engine coolant is properly mixed, the engine
eyes or skin should occur, flush eyes coolant gets contaminated as its ingredients
and wash immediately with clean deteriorate. Drain, flush and refill the cooling
water. system with new coolant every 1000 hours or once
a year, whichever comes first.
or moderate injury. 1. Allow engine and coolant to cool.
0000005en
2. Remove the radiator cap (Figure 5-16, (1)).
3. Remove the drain plug or open the drain cock
(Figure 5-16, (2)) at the lower portion of the
radiator and drain the engine coolant.
(1)
FULL
LOW
(2) 0000074A
Figure 5-16
4. Drain the coolant from the engine block.

• On models not equipped with an oil cooler,
remove the coolant drain plug
(Figure 5-17, (1)) from the engine block.
(1)
0000027B
Figure 5-17

• On models equipped with an oil cooler, remove
the coolant hose (Figure 5-18, (1)) at the oil Every 1500 Hours of Operation
cooler.
Perform the following maintenance every 1500
hours of operation.
• Inspect, Clean and Test Fuel Injectors
• Inspect Turbocharger (Blower Wash as
Necessary) - 3TNV84T, 4TNV84T, 4TNV98T
and 4TNV106T, 3TNV84T-B, 4TNV84T-Z,
4TNV98T-Z
• Inspect, Clean and Test EGR Valve
4TNV84T-Z, 4TNV98T-E, 4TNV98-Z,
4TNV98T-Z
• Inspect and Clean EGR Lead Valve
4TNV84T-Z, 4TNV98T-Z
(1) 0001579B
• Clean EGR Cooler
Figure 5-18 4TNV84T-Z, 4TNV98T-Z
5. After draining the engine coolant, flush the • Inspect Crankcase Breather System
radiator and engine block to remove any rust,
Inspect, Clean and Test Fuel Injectors
scale and contaminants. Then reinstall and
tighten the drain plug or close the drain cock in
the radiator. Reinstall and tighten the cylinder A WARNING
block drain plug or reconnect the coolant hose
at the oil cooler.
6. Fill radiator and engine with engine coolant.
See Filling Radiator with Engine Coolant on
page 4-19. HIGH-PRESSURE HAZARD!
Adjust Intake / Exhaust Valve Clearance high-pressure diesel fuel spray caused
Proper adjustment is necessary to maintain the by a fuel system leak such as a broken
correct timing for opening and closing the valves. fuel injection line. High-pressure fuel
Improper adjustment will cause the engine to run can penetrate your skin and result in
noisily, resulting in poor engine performance and serious injury. If you are exposed to
engine damage. See Intake / Exhaust Valve and high-pressure fuel spray, obtain
Guide on page 6-7. prompt medical treatment.
hands. ALWAYS use a piece of wood
or cardboard. Have your authorized
Yanmar industrial engine dealer or
distributor repair the damage.
or serious injury.
0000008en
Proper operation of the fuel injectors is required to Clean EGR Cooler

obtain the optimum injection pattern for full engine 4TNV84T-Z, 4TNV98T-Z
performance. The EPA / ARB requires that the fuel
injectors are inspected, cleaned and tested every The EGR cooler is apt to be contaminated with rust
1500 hours. See Testing of Fuel Injectors on and scale that deteriorate the cooling performance.
page 7-38. Carbon accumulation in the exhaust gas passage
of the cooler hinders circulation of exhaust gas,
This procedure is considered normal maintenance resulting in deterioration in exhaust gas cleanup
and is performed at the owner’s expense. This performance.
procedure is not covered by the Yanmar Limited
Warranty. To prevent such a problem, clean the cooler at least
every 1500 hours.
Inspect Turbocharger (Blower Wash as
Necessary) - 3TNV84T, 4TNV98T, 4TNV84T, Consult your local Yanmar dealer for this service.
and 4TNV106T, 3TNV84T-Z, 4TNV84T-Z,
EGR cooler
4TNV98T-Z
Turbocharger service is required by the EPA / ARB
every 1500 hours. Inspect, clean and blower wash
the unit if necessary (see Periodic Inspection on
page 10-13). If you notice that the engine seems
sluggish or the exhaust color is abnormal NEVER
wait until the next service interval.
Inspect, Clean and Test EGR Valve

4TNV84T-Z, 4TNV98T-E, 4TNV98-Z, 4TNV98T-Z
The EGR valve is a key component for cleaning
exhaust gas.
EGR valve
To prevent the valve from deteriorating in exhaust EGR lead valve
gas recirculation performance due to carbon
accumulation, inspect, clean and test the valve at
least every 1500 hours.
Figure 5-19
Consult your local Yanmar dealer for this service.
Inspect Crankcase Breather System
Inspect and Clean EGR Lead Valve
Proper operation of the crankcase breather system
4TNV84T-Z, 4TNV98T-Z is required to maintain the emission requirements
The EGR lead valve is located in the passage of of the engine. The EPA / ARB requires that the
recirculated gas. crankcase breather system is inspected every 1500
hours.
To prevent carbon accumulation in or clogging of
the lead valve, inspect and clean the lead valve at There are three different crankcase breather
regular intervals. systems used on the TNV engines. Only the non-
turbo TNV engines crankcase breather system
Consult your local Yanmar dealer for this service. requires periodic maintenance.

The non-turbo TNV engines use a crankcase Failure of the diaphragm and / or spring will cause
breather system that has a spring-backed the loss of pressure control and allow an excessive
diaphragm (Figure 5-20, (1)) in the valve cover amount of crankcase fumes to be routed to the
(Figure 5-20, (2)). When the crankcase pressure intake manifold. This could result in excessive
reaches a predetermined value, the diaphragm deposits in the intake system, high engine exhaust
opens a passage that allows crankcase fumes to smoke levels, excessive engine oil consumption,
be routed to the intake manifold. and / or engine run-on due to the burning of the
engine oil.
To inspect the diaphragm and spring
(Figure 5-20, (3)):
1. Remove the bolts retaining the diaphragm cover
(Figure 5-20, (4)).
(4)
(3)
(5)
(1)
(2)
0002135
Figure 5-20
2. Remove the diaphragm cover, spring,

diaphragm plate (Figure 5-20, (5)) and
diaphragm.
3. Inspect the diaphragm for tears. Inspect the
spring for distortion. Replace components if
necessary.
4. Reinstall the diaphragm, diaphragm plate,
spring and diaphragm cover. Tighten the
diaphragm bolts to specified torque.
Lap the Intake and Exhaust Valves

Every 2000 Hours of Operation
Adjustment is necessary to maintain proper contact
of the valves and seats. See Inspection of Intake
Perform the following maintenance every 2000 and Exhaust Valves on page 6-42.
hours of operation.
• Check and Replace Fuel Hoses and Engine

Coolant Hoses
• Lap the Intake and Exhaust Valves.
If necessary
Check and Replace Fuel Hoses and Engine

Coolant Hoses
CAUTION
responsible.
0000013en
Regularly check the fuel system and engine coolant

system hoses. If they are cracked or degraded,
replace them. Replace the hoses at least every two
years.

Section 6
ENGINE
Page
Before You Begin Servicing ............................................................ 6-3

Introduction...................................................................................... 6-6
Cylinder Head Specifications .......................................................... 6-6
Adjustment Specifications ......................................................... 6-6
Cylinder Head............................................................................ 6-6
Intake / Exhaust Valve and Guide ............................................. 6-7
Push Rod................................................................................... 6-9
Rocker Arm and Shaft ............................................................... 6-9
Valve Spring ............................................................................ 6-10
Camshaft and Timing Gear Train Specifications........................... 6-11
Camshaft ................................................................................. 6-11
Idler Gear Shaft and Bushing .................................................. 6-13
Timing Gear Backlash ............................................................. 6-13
Crankshaft and Piston Specifications............................................ 6-14
Crankshaft ............................................................................... 6-14
Thrust Bearing......................................................................... 6-15
Piston....................................................................................... 6-16
Piston Ring .............................................................................. 6-18
Connecting Rod....................................................................... 6-22
Tappet ..................................................................................... 6-23
Cylinder Block Specifications ........................................................ 6-24
Cylinder Block.......................................................................... 6-24
Special Torque Chart .................................................................... 6-25
Torque for Bolts and Nuts........................................................ 6-25
Special Service Tools.................................................................... 6-28
Measuring Instruments.................................................................. 6-32
2-Valve Cylinder Head .................................................................. 6-34
2-Valve Cylinder Head Components ....................................... 6-34
ENGINE
Components of a two-valve cylinder head ............................... 6-35

Disassembly of 2-Valve Cylinder Head .................................... 6-36
Cleaning of Cylinder Head Components.................................. 6-40
Inspection of Cylinder Head Components................................ 6-40
Reassembly of Cylinder Head.................................................. 6-44
4-Valve Cylinder Head ................................................................... 6-49
4-Valve Cylinder Head Components ........................................ 6-49
Disassembly of 4-Valve Cylinder Head .................................... 6-50
Cleaning of Cylinder Head Components.................................. 6-55
Inspection of Cylinder Head Components................................ 6-56
Reassembly of Cylinder Head.................................................. 6-61
Measuring and Adjusting Valve Clearance .................................... 6-66
2-Valve Cylinder Heads............................................................ 6-67
4-Valve Cylinder Heads............................................................ 6-68
Crankshaft and Camshaft Components ......................................... 6-71
Disassembly of Engine............................................................. 6-72
Disassembly of Camshaft and Timing Components ................ 6-73
Disassembly of Crankshaft and Piston Components ............... 6-78
Inspection of Crankshaft and Camshaft Components.............. 6-82
Honing and Boring.................................................................... 6-88
Reassembly of Crankshaft and Piston Components................ 6-89
Reassembly of Camshaft and Timing Components................. 6-95
Final Reassembly of Engine..................................................... 6-99
EGR system ................................................................................. 6-100
EGR system ........................................................................... 6-100
EGR system ........................................................................... 6-102
Inspecting/cleaning EGR related components ....................... 6-105
Before You Begin Servicing ENGINE
BEFORE YOU BEGIN

A WARNING
SERVICING
A WARNING
FUME / BURN HAZARD!

• Always read and follow safety related
precautions found on containers of
hazardous substances like parts
To prevent possible eye injury, always
cleaners, primers, sealants and
wear SAFETY GLASSES while servicing
sealant removers.
the engine.
0000013en
or serious injury.
A WARNING
0000014en
A CAUTION
ENTANGLEMENT HAZARD!
• Stop the engine before you begin to
service it.
• NEVER leave the key in the key switch FLYING OBJECT HAZARD!
when you are servicing the engine. • ALWAYS wear eye protection when
Someone may accidentally start the servicing the engine and when using
engine and not realize you are compressed air or high-pressure
servicing it. This could result in a water. Dust, flying debris, compressed
serious injury. air, pressurized water or steam may
• If you must service the engine while it injure your eyes.
is operating, remove all jewelry, tie • Failure to comply may result in minor
back long hair, and keep your hands, or moderate injury.
other body parts and clothing away 0000003en

• Failure to comply could result in death A CAUTION
or serious injury.
Be sure to secure the engine solidly to
0000010en
prevent injury or damage to parts due to
the engine falling during work on the
engine.
0000009en
ENGINE Before You Begin Servicing
CAUTION CAUTION
• Only use the engine oil specified. Any part which is found defective as a
Other engine oils may affect warranty result of inspection or any part whose
coverage, cause internal engine measured value does not satisfy the
components to seize and / or shorten standard or limit must be replaced.
engine life. 0000119en

contaminating the engine oil. Carefully CAUTION
Any part determined to not meet the
service standard or limit before the next
the cap.
service, as determined from the state of
• NEVER mix different types of engine current rate of wear, should be replaced
oil. This may adversely affect the even though the part currently meets the
lubricating properties of the engine oil. service standard limit.
• NEVER overfill. Overfilling may result 0000120en

overspeed or internal damage. CAUTION
0000005en
Remove or install the high-pressure fuel
injection lines as an assembly whenever
CAUTION possible. Disassembling the
• Only use the engine coolant specified. high-pressure fuel injection lines from
Other engine coolants may affect the retainers or bending any of the fuel
warranty coverage, cause an internal lines will make it difficult to reinstall the
buildup of rust and scale and / or fuel lines.
shorten engine life. 0000047en

contaminating the engine coolant. CAUTION
Carefully clean the radiator cap and Do not loosen or remove the four bolts
the surrounding area before you retaining the fuel injection pump drive
remove the cap. gear to the fuel injection pump hub. Do
• NEVER mix different types of engine not disassemble the fuel injection pump
coolants. This may adversely affect the drive gear from the hub. Correct fuel
properties of the engine coolant. injection timing will be very difficult or
0000006en
impossible to achieve.
0000031en
CAUTION
Identify all parts and their location using
an appropriate method. It is important
that all parts are returned to the same
position during the reassembly process.
0000080en
Before You Begin Servicing ENGINE
CAUTION
Keep the piston pin parts, piston
assemblies, and connecting rod
assemblies together to be returned to
the same position during the
reassembly process. Label the parts
using an appropriate method.
0000088en
CAUTION
Do not allow the honing tool to operate
in one position for any length of time.
Damage to the cylinder wall will occur.
Keep the tool in constant up-and-down
motion.
0000090en
ENGINE Introduction
INTRODUCTION
This section of the Service Manual describes servicing of the engine.
CYLINDER HEAD SPECIFICATIONS

Adjustment Specifications
Valve Bridge Clearance
Model Valve Clearance
(4-Valve Head Only)
0.006 - 0.010 in.
All except 4TNV106, 4TNV106T 0
(0.15 - 0.25 mm)
0.010 - 0.014 in.
4TNV106, 4TNV106T 0
(0.25 - 0.35 mm)
Cylinder Head
Reference
Page
0.0020 in. 0.0059 in.
Combustion Surface Distortion (Flatness)
(0.05 mm) or less (0.15 mm)
0.0138 - 0.0217 in.
Intake 0.0315 in. (0.8 mm)
3TNV82A (0.35 - 0.55 mm)
(2-Valve Head) 0.0118 - 0.0197 in.
Exhaust 0.0315 in. (0.8 mm)
(0.30 - 0.50 mm)
3TNV84, 3TNV84T, 0.0118 - 0.0197 in.
Intake 0.0315 in. (0.8 mm)
3TNV88, 4TNV84, (0.30 - 0.50 mm)
4TNV84T, 4TNV88 See Valve
(2-Valve Head) 0.0118 - 0.0197 in. Recession on
4TNV84T (4-Valve Exhaust 0.0315 in. (0.8 mm)
(0.30 - 0.50 mm) page 6-42
Valve Recession Head) and 6-58.
0.0142 - 0.0220 in.
4TNV94L, 4TNV98, Intake 0.0315 in. (0.8 mm)
(0.36 - 0.56 mm)
4TNV98T
(4-Valve Head) 0.0138 - 0.0217 in.
(0.35 - 0.55 mm)
0.0197 - 0.0276 in.
Intake 0.0394 in. (1.0 mm)
4TNV106, 4TNV106T (0.50 - 0.70 mm)
(4-Valve Head) 0.0276 - 0.0354 in.
(0.70 - 0.90 mm)
Intake 120° - See Valve
Seat Angle Face and
Valve Seat Exhaust 90° -
Valve Seat
(2-Valve, 4-Valve)
Seat Correction Angle 40°, 150° - on page 6-43
and 6-59.
Cylinder Head Specifications ENGINE
Intake / Exhaust Valve and Guide

Reference
Page
0.2756 - 0.2762 in. 0.2787 in.
Guide Inside Diameter
(7.000 - 7.015 mm) (7.08 mm)
Valve Stem Outside 0.2734 - 0.2740 in. 0.2717 in.
Intake
Diameter (6.945 - 9.960 mm) (6.90 mm)
0.0016 - 0.0028 in. 0.0071 in. See
Valve Stem Bend Inspection of
3TNV82A (0.040 - 0.070 mm) (0.18 mm)
Valve Guides
(2-Valve Head) 0.2756 - 0.2762 in. 0.2787 in.
Guide Inside Diameter on
(7.000 - 7.015 mm) (7.08 mm) page 6-41.
Exhaust
Diameter (6.940 - 6.955 mm) (6.90 mm)
0.0018 - 0.0030 in. 0.0071 in.
Valve Stem Bend
(0.045 - 0.075 mm) (0.18 mm)
0.3154 - 0.3159 in. 0.3189 in.
(8.010 - 8.025 mm) (8.10 mm)
Intake
Diameter (7.955 - 7.975 mm) (7.90 mm)
0.0014 - 0.0028 in. 0.0071 in. See
4TNV84, Valve Stem Bend
(0.035 - 0.070 mm) (0.18 mm) Inspection of
3TNV84, 3TNV84T,
Valve Guides
4TNV88, 4TNV88 0.3156 - 0.3161 in. 0.3189 in.
(2-Valve Head) (8.015 - 8.030 mm) (8.10 mm) page 6-41.
Valve Stem Outside 0.3132 -.3134 in. 0.3110 in.
Exhaust
Diameter (7.955 - 7.960 mm) (7.90 mm)
0.0018 - 0.0030 in. 0.0071 in.
Valve Stem Bend
(0.045 - 0.075 mm) (0.18 mm)
0.2362 - 0.2368 in. 0.2394 in.
(6.000 - 6.015 mm) (6.08 mm)
Intake
Diameter (5.960 - 5.975 mm) (5.90 mm)
0.0010 - 0.0022 in. 0.0059 in. See
4TNV84T (0.025 - 0.055 mm) (0.15 mm)
Valve Guides
(4-Valve Head) 0.2362 - 0.2368 in. 0.2394 in.
(6.000 - 6.015 mm) (6.08 mm) page 6-41.
Exhaust
Diameter (5.945 - 5.960 mm) (5.90 mm)
0.0016 - 0.0028 in. 0.0067 in.
Valve Stem Bend
(0.040 - 0.070 mm) (0.17 mm)
ENGINE Cylinder Head Specifications
(Intake / Exhaust Valve and Guide Cont.)
Reference
Page
0.2756 - 0.2762 in. 0.2787 in.
(7.000 - 7.015 mm) (7.08 mm)
Intake
Diameter (6.945 - 6.960 mm) (6.90 mm)
0.0016 - 0.0028 in. 0.0067 in. See
4TNV94L Oil Clearance Inspection of
(0.040 - 0.070 mm) (0.17 mm)
4TNV98, 4TNV98T Valve Guides
(4-Valve Head) 0.2756 - 0.2762 in. 0.2787 in. on
(7.000 - 7.015 mm) (7.08 mm) page 6-41.
Exhaust
Diameter (6.940 - 6.955 mm) (6.90 mm)
0.0018 - 0.0030 in. 0.0067 in.
Valve Stem Bend
(0.045 - 0.075 mm) (0.17 mm)
0.2759 - 0.2764 in. 0.2787 in.
(7.008 - 7.020 mm) (7.08 mm)
Intake
Diameter (6.945 - 6.960 mm) (6.92 mm)
0.0019 - 0.0030 in. 0.0063 in. See
4TNV106T (0.048 - 0.075 mm) (0.16 mm)
Valve Guides
(4-Valve Head) 0.2759 - 0.2764 in. 0.2787 in.
(7.008 - 7.020 mm) (7.08 mm) page 6-41.
Exhaust
Diameter (6.960 - 6.975 mm) (6.90 mm)
0.0013 - 0.0024 in. 0.0071 in.
Valve Stem Bend
(0.033 - 0.060 mm) (0.18 mm)
0.4606 - 0.4724 in.
3TNV82A -
(11.70 - 12.00 mm)
3TNV84, 3TNV84T, 0.5791 -0.5905 in.
-
4TNV84, 4TNV88 (14.71 - 15.00 mm) See
Valve Guide Projection From 0.3228 - 0.3346 in. Reassembly
4TNV84T - of Valve
Cylinder Head (8.20 - 8.50 mm)
Guides on
4TNV94L, 4TNV98, 0.3819 - 0.3937 in. page 6-44
-
4TNV98T (9.70 - 10.00 mm) and 6-61.
0.5276 - 0.5354 in.
4TNV106, 4TNV106T -
(13.40 - 13.60 mm)
Valve Guide Installation Method Cold-fitted -
Cylinder Head Specifications ENGINE
Reference
Page
Valve Stem Seal Projection From Cylinder Head
0.618 - 0.629 in.
3TNV82A -
(15.7 - 16.0 mm)
2 Valves 4TNV84 -
0.736 - 0.748 in. See
3TNV84 (T) - Reassembly
(18.7 - 19.0 mm)
4TNV88 - of Intake and
0.389 - 0.401 in. Exhaust
4TNV84T - Valves on
(9.9 - 10.2 mm)
page 6-45.
4TNV94L 0.460 - 0.472 in. -
4 Valves
4TNV98 (T) (11.7 - 12.0 mm) -
0.606 - 0.614 in.
4TNV106 (T) -
(15.4 - 15.6 mm)
Push Rod
Reference
Page
See Push
Less than 0.0012 in. Rod Bend on
Push Rod Bend - All Models
0.0012 in. (0.03 mm) (0.03 mm) page 6-41
and 6-56.
Rocker Arm and Shaft

Reference
Model Inspection Item Standard Limit
Page
0.6299 - 0.6307 in. 0.6327 in.
Arm Shaft Hole Diameter
3TNV82A, 3TNV84, (16.000 - 16.020 mm) (16.07 mm)
3TNV84T, 3TNV88, 0.6286 - 0.6293 in. 0.6276 in.
Shaft Outside Diameter
4TNV84, 4TNV84T, (15.966 - 15.984 mm) (15.94 mm)
See
4TNV88 0.0006 - 0.0021 in. 0.0051 in.
Oil Clearance Inspection of
(0.016 - 0.054 mm) (0.13 mm) Rocker Arm
0.7283 - 0.7291 in. 0.7311 in. Assembly on
Arm Shaft Hole Diameter page 6-41
(18.500 - 18.520 mm) (18.57 mm)
4TNV94L, 4TNV98, and 6-56.
0.7272 - 0.7280 in. 0.7260 in.
4TNV98T, 4TNV106, Shaft Outside Diameter
(18.470 - 18.490 mm) (18.44 mm)
4TNV106T
0.0004 - 0.0020 in. 0.0051 in.
Oil Clearance
(0.010 - 0.050 mm) (0.13 mm)
ENGINE Cylinder Head Specifications
Valve Spring
Reference
Inspection Item Model Standard Limit
Page
1.7480 in. 1.7283 in.
3TNV82A (2-Valve Head)
(44.4 mm) (43.9 mm)
4TNV84, 3TNV84, 3TNV84T, 4TNV88 1.6535 in. 1.6339 in.
(2-Valve Head) (42.0 mm) (41.5 mm)
1.4724 in. 1.4528 in.
Free Length 4TNV84T (4-Valve Head)
(37.4 mm) (36.9 mm)
4TNV94L, 4TNV98, 4TNV98T (4-Valve 1.5630 in. 1.5433 in.
Head) (39.7 mm) (39.2 mm)
See
1.9921 in. 1.9724 in. Inspection of
4TNV106, 4TNV106T (4-Valve Head)
(50.6 mm) (50.1 mm) Valve
0.0551 in. Springs on
3TNV82A (2-Valve Head) - page 6-44
(1.4 mm)
and 6-60.
4TNV84, 3TNV84, 3TNV84T, 0.0551 in.
-
4TNV88 (2-Valve Head) (1.4 mm)
0.0551 in.
Squareness 4TNV84T (4-Valve Head) -
(1.3 mm)
4TNV94L, 4TNV98, 4TNV98T (4-Valve 0.0551 in.
-
Head) (1.4 mm)
0.0551 in.
4TNV106, 4TNV106T (4-Valve Head) -
(1.5 mm)
Camshaft and Timing Gear Train Specifications ENGINE
CAMSHAFT AND TIMING GEAR TRAIN SPECIFICATIONS

Camshaft
Reference
Page
See Removal
0.0020 - 0.0079 in. 0.0118 in. of Camshaft
End Play
(0.05 - 0.20 mm) (0.030 mm) on
page 6-76.
0 - 0.0008 in. 0.0020 in.
Bend (1/2 the dial gauge reading)
(0 - 0.02 mm) (0.05 mm)
3TNV82A, 3TNV84,
1.5197 - 1.5276 in. 1.5098 in. See
3TNV84T, 3TNV88, 4TNV84,
4TNV84T, 4TNV88
Camshaft on
Cam Lobe Height 4TNV94L, 4TNV98, 1.7087 - 1.7165 in. 1.6988 in. page 6-87.
4TNV98T (43.400 - 43.600 mm) (43.150 mm)
2.0039 - 2.0118 in. 1.9941 in.
4TNV106, 4TNV106T
(50.900 - 51.100 mm) (50.650 mm)
Shaft Outside Diameter / Bearing Inside Diameter
1.7713 - 1.7738 in. 1.7768 in.
Bushing Inside Diameter
(44.990 - 45.055 mm) (45.130 mm)
1.7687 - 1.7697 in. 1.7673 in.
Gear End Camshaft Outside Diameter
(44.925 - 44.950 mm) (44.890 mm)
0.0016 - 0.0051 in. 0.0094 in.
Oil Clearance
(0.040 - 0.130 mm) (0.240 mm)
3TNV82A, 1.7716 - 1.7726 in. 1.7756 in.
3TNV84, Bore Inside Diameter
(45.000 - 45.025 mm) (45.100 mm) See
3TNV84T,
1.7681 - 1.7691 in. 1.7667 in. Inspection of
3TNV88, Intermediate Camshaft Outside Diameter
(44.910 - 44.935 mm) (44.875 mm) Camshaft on
4TNV84,
0.0026 - 0.0045 in. 0.0089 in. page 6-87.
4TNV84T, Oil Clearance
4TNV88 (0.065 - 0.115 mm) (0.225 mm)
1.7716 - 1.7726 in. 1.7756 in.
Bore Inside Diameter
(45.000 - 45.025 mm) (45.100 mm)
1.7687 - 1.7697 in. 1.7673 in.
Flywheel End Camshaft Outside Diameter
(44.925 - 44.950 mm) (44.890 mm)
0.0020 - 0.0039 in. 0.0083 in.
Oil Clearance
(0.050 - 0.100 mm) (0.210 mm)
ENGINE Camshaft and Timing Gear Train Specifications
(Camshaft Cont.)
Reference
Page
1.9681 - 1.9707 in. 1.9736 in.
(49.990 - 50.055 mm) (50.130 mm)
1.9655 - 1.9665 in. 1.7673 in.
(49.925 - 49.950 mm) (49.890 mm)
0.0016 - 0.0051 in. 0.0094 in.
Oil Clearance
(0.040 - 0.130 mm) (0.240 mm)
1.9685 - 1.9695 in. 1.9724 in.
(50.000 - 50.025 mm) (50.100 mm)
4TNV94L,
1.9650 - 1.9659 in. 1.9636 in.
4TNV98, Intermediate Camshaft Outside Diameter
(49.910 - 49.935 mm) (49.875 mm)
4TNV98T
0.0026 - 0.0045 in. 0.0089 in;
Oil Clearance
(0.065 - 0.115 mm) (0.225 mm)
1.9685 - 1.9695 in. 1.9724 in.
(50.000 - 50.025 mm) (50.100 mm)
1.9655 - 1.9665 in. 1.7673 in.
(49.925 - 49.950 mm) (49.890 mm)
0.0020 - 0.0039 in. 0.0083 in. See
Oil Clearance
2.2827 - 2.2854 in. 2.2876 in. Camshaft on
Bushing Inside Diameter page 6-87.
(57.980 - 58.050 mm) (58.105 mm)
2.2799 - 2.2811 in. 2.2785 in.
(57.910 - 57.940 mm) (57.875 mm)
0.0016 - 0.0055 in. 0.0098 in.
Oil Clearance
(0.040 - 0.140 mm) (0.250 mm)
2.2835 - 2.2846 in. 2.2876 in.
(58.000 - 58.030 mm) (58.105 mm)
4TNV106, 2.2793 - 2.2805 in. 2.2779 in.
Intermediate Camshaft Outside Diameter
4TNV106T (57.895 - 57.925 mm) (57.860 mm)
0.0030 - 0.0053 in. 0.0096 in.
Oil Clearance
(0.075 - 0.135 mm) (0.245 mm)
2.2835 - 2.2846 in. 2.2876 in.
(58.000 - 58.030 mm) (58.105 mm)
2.2799 - 2.2811 in. 2.2785 in.
(57.910 - 57.940 mm) (57.875 mm)
0.0020 - 0.0047 in. 0.0091 in.
Oil Clearance
(0.050 - 0.120 mm) (0.230 mm)
Camshaft and Timing Gear Train Specifications ENGINE
Idler Gear Shaft and Bushing

Reference
Page
1.8091 - 1.8100 in. 1.8071 in.
Shaft Outside Diameter See
(45.950 - 45.975 mm) (45.900 mm)
Inspection of
1.8110 - 4.8120 in. 1.8140 in.
Bushing Inside Diameter Idler Gear
(46.000 - 46.025 mm) (46.075 mm)
and Shaft on
0.0010 - 0.0030 in. 0.0069 in. page 6-87.
Oil Clearance
(0.025 - 0.075 mm) (0.175 mm)
Timing Gear Backlash

Reference
Page
3TNV82A
3TNV84, 3TNV84T, Crank Gear, Cam Gear, Idler Gear,
0.0028 - 0.0059 in. 0.0067 in.
3TNV88, 4TNV84, Fuel Injection Pump Gear and PTO
(0.07 - 0.15 mm) (0.17 mm)
4TNV84T, Gear
4TNV88 See
Crank Gear, Cam Gear, Idler Gear, Checking
0.0031 - 0.0055 in. 0.0063 in. Timing Gear
Fuel Injection Pump Gear and PTO
4TNV94L (0.08 - 0.14 mm) (0.16 mm) Backlash on
Gear
4TNV98, 4TNV98T, page 6-73.
0.0035 - 0.0059 in. 0.0067 in.
4TNV106, Lubricating Oil Pump Gear
(0.09 - 0.15 mm) (0.17 mm)
4TNV106T
Balancer Drive Gear 0.0047 - 0.0071 in. 0.0079 in.
(Only for 4TNV106T) (0.12 - 0.18 mm) (0.20 mm)
ENGINE Crankshaft and Piston Specifications
CRANKSHAFT AND PISTON SPECIFICATIONS

Crankshaft
Note: Check appropriate parts catalog for various sizes of replacement main bearing inserts.
Reference
Page
0.0008 in.
Bend (1/2 the dial gauge reading) -
(0.02 mm)
Journal Outside 1.6910 - 1.6914 in. 1.6891 in.
Diameter (42.952 - 42.962 mm) (42.902 mm)
Bearing Inside 1.6929 - 1.6946 in.
-
Diameter (43.000 - 43.042 mm)
3TNV82A
Bearing Insert 0.0585 -.0591 in.
-
Thickness (1.487 - 1.500 mm)
0.0015 - 0.0035 in. 0.0059 in.
Oil Clearance
(0.038 - 0.090 mm) (0.150 mm)
Diameter (47.952 - 47.962 mm) (47.902 mm)
3TNV84,
3TNV84T, Bearing Inside 1.8898 - 1.8909 in.
-
3TNV88, Diameter (48.000 - 48.026 mm)
4TNV84, Bearing Insert 0.0587 - 0.0591 in.
4TNV84T - See
Thickness (1.492 - 1.500 mm)
4TNV88 Inspection of
0.0015 - 0.0029 in. 0.0059 in.
Oil Clearance Crankshaft
Connecting Rod (0.038 - 0.074 mm) (0.150 mm)
on
Journals Journal Outside 2.2816 - 2.2820 in. 2.2796 in. page 6-86.
Diameter (57.952 - 57.962 mm) (57.902 mm)
4TNV94L, -
Diameter (58.000 - 58.026 mm)
4TNV98,
4TNV98T Bearing Insert 0.0587 - 0.0591 in.
-
Thickness (1.492 - 1.500 mm)
0.0015 - 0.0029 in. 0.0059 in.
Oil Clearance
(0.038 - 0.074 mm) (0.150 mm)
Diameter (63.952 - 63.962 mm) (63.902 mm)
-
4TNV106, Diameter (64.016 - 64.042 mm)
-
Thickness (1.984 - 1.992 mm)
0.0021 - 0.0035 in. 0.0059 in.
Oil Clearance
(0.054 - 0.090 mm) (0.150 mm)
Crankshaft and Piston Specifications ENGINE

(Crankshaft Cont.)
Reference
Page
Diameter (46.952 - 46.962 mm) (46.902 mm)
-
Diameter (47.000 - 47.032 mm)
3TNV82A
Bearing Insert 0.0782 - 0.0787 in.
-
Thickness (1.987 - 2.000 mm)
0.0015 - 0.0031 in. 0.0059 in.
Oil Clearance
(0.038 - 0.080 mm) (0.150 mm)
Journal Outside 1.9666-1.9670 in. 1.9646 in.
Diameter (49.952-49.962 mm) (49.902 mm)
3TNV84,
3TNV84T, Bearing Inside 1.9685 - 1.9693 in.
-
3TNV88, Diameter (50.000 - 50.020 mm)
4TNV84, Bearing Insert 0.0785 - 0.0791 in.
4TNV84T -
Thickness (1.995 - 2.010 mm)
4TNV88 See
0.0015 - 0.0027 in. 0.0059 in.
(0.038 - 0.068 mm) (0.150 mm)
Main Bearing Journal Crankshaft
Journal Outside 2.5572 - 2.5576 in. 2.5552 in. on
Diameter (64.952 - 64.962 mm) (64.902 mm) page 6-86.
4TNV94L, -
Diameter (65.000 - 65.020 mm)
4TNV98,
-
Thickness (1.995 - 2.010 mm)
0.0015 - 0.0027 in. 0.0059 in.
Oil Clearance
(0.038 - 0.068 mm) (0.150 mm)
Diameter (75.952 - 75.962 mm) (75.902 mm)
-
4TNV106, Diameter (76.014 - 76.034 mm)
-
Thickness (2.488 - 2.503 mm)
0.0020 - 0.0032 in. 0.0059 in.
Oil Clearance
(0.052 - 0.082 mm) (0.150 mm)
Thrust Bearing
Reference
Page
See Removal
0.0051 - 0.0091 in. 0.0110 in. of Crankshaft
Crankshaft End Play - All Models
(0.13 - 0.23 mm) (0.28 mm) on
page 6-80.
Piston
Reference
Page
3.2264 - 3.2275 in. 3.2246 in.
3TNV82A
(81.950 - 81.980 mm) (81.905 mm)
3TNV84, 3TNV84T, 3.3047 - 3.3059 in. 3.3029 in.
4TNV84, 4TNV84T (83.940 - 83.970 mm) (83.895 mm)
3.4622 - 3.4634 in. 3.4604 in.
3TNV88,4TNV88
Piston Outside Diameter (87.940 - 87.970 mm) (87.895 mm)
(Measure at 90°to the Piston Pin.) 3.6982 - 3.6994 in. 3.6968 in.
4TNV94L
(93.935 - 93.965 mm) (93.900 mm)
3.8555 - 3.8567 in. 3.8541 in.
4TNV98, 4TNV98T
(97.930 - 97.960 mm) (97.895 mm) See
4TNV106, 4TNV106T Pistons,
(105.930 - 105.960 mm) (105.880 mm)
Piston Rings
0.6299 in. and Wrist Pin
3TNV82A -
(16 mm) on
3TNV84, 3TNV84T, 0.9449 in. page 6-83.
-
4TNV84, 4TNV84T (24 mm)
0.9449 in.
Piston Diameter Measure Location 3TNV88,4TNV88 -
(24 mm)
(Upward From the Bottom of the
Piston.) 0.8661 in.
4TNV94L -
(22 mm)
0.8661 in.
4TNV98, 4TNV98T -
(22 mm)
1.1811 in.
4TNV106, 4TNV106T -
(30 mm)

(Piston Cont.)
Reference
Page
0.9055 - 0.9059 in. 0.9070 in.
Hole Inside Diameter
(23.000 - 23.009 mm) (23.039 mm)
0.9053 - 0.9055 in. 0.9041 in.
3TNV82A Pin Outside Diameter
(22.995 - 23.000 mm) (22.965 mm)
0.0000 - 0.0006 in. 0.0029 in.
Oil Clearance
(0.000 - 0.014 mm) (0.074 mm)
3TNV84, 1.0236 - 1.0240 in. 1.0252 in.

3TNV84T, (26.000 - 26.009 mm) (26.039 mm)
3TNV88, 1.0234 - 1.0236 in. 1.0222 in.
Pin Outside Diameter
4TNV84, (25.995 - 26.000 mm) (25.965 mm) See
4TNV84T 0.0000 - 0.0006 in. 0.0029 in. Inspection of
4TNV88 Oil Clearance Pistons,
(0.000 - 0.014 mm) (0.074 mm)
Piston Pin Piston Rings
1.1811 - 1.1815 in. 1.1826 in. and Wrist Pin
(30.000 - 30.009 mm) (30.039 mm) on
4TNV94L,
1.1807 - 1.1811 in. 1.1795 in. page 6-83.
4TNV98, Pin Outside Diameter
(29.989 - 30.000 mm) (29.959 mm)
4TNV98T
0.0000 - 0.0008 in. 0.0031 in.
Oil Clearance
(0.000 - 0.020 mm) (0.080 mm)
1.4567 - 1.4571 in. 1.4582 in.
(37.000 - 37.011 mm) (37.039 mm)
4TNV106, 1.4563 - 1.4567 in. 1.4551 in.
Pin Outside Diameter
4TNV106T (36.989 - 37.000 mm) (36.959 mm)
0.0000 - 0.0009 in. 0.0031 in.
Oil Clearance
(0.000 - 0.022 mm) (0.080 mm)
Piston Ring
Reference
Page
0.0813 - 0.0819 in.
Ring Groove Width -
(2.065 - 2.080 mm)
0.0776 - 0.0783 in. 0.0768 in.
Ring Width
(1.970 - 1.990 mm) (1.950 mm)
Top Ring
0.0030 - 0.0043 in.
Side Clearance -
(0.075 - 0.110 mm)
0.0079 - 0.0157 in. 0.0193 in.
End Gap
(0.200 - 0.400 mm) (0.490 mm)
0.0801 - 0.0807 in. 0.0846 in.
Ring Groove Width
(2.035 - 2.050 mm) (2.150 mm) See
3TNV82A, 0.0776 - 0.0783 in. 0.0768 in. Inspection of
3TNV84, Ring Width Pistons,
(1.970 - 1.990 mm) (2.150 mm)
3TNV84T, Second Ring Piston Rings
4TNV84, 0.0018 - 0.0031 in. 0.0079 in. and Wrist
Side Gap
4TNV84T (0.045 - 0.080 mm) (0.200 mm) Pin on
0.0079 - 0.0157 in. 0.0193 in. page 6-83.
End Gap
(0.200 - 0.400 mm) (0.490 mm)
0.1581 - 0.1587 in. 0.1626 in.
Ring Groove Width
(4.015 - 4.030 mm) (4.130 mm)
0.1563 - 0.1571 in. 0.01555 in.
Ring Width
(3.970 - 3.990 mm) (3.950 mm)
Oil Ring
0.0010 - 0.0024 in. 0.0071 in.
Side Clearance
(0.025 - 0.060 mm) (0.180 mm)
0.0079 - 0.0157 in. 0.0193 in.
End Gap
(0.200 - 0.400 mm) (0.490 mm)

(Piston Ring Cont.)
Reference
Page
0.0811 - 0.0817 in.
Ring Groove Width -
(2.060 - 2.075 mm)
0.0776 - 0.0783 in. 0.0768 in.
Ring Width
(1.970 - 1.990 mm) (1.950 mm)
Top Ring
0.0028 - 0.0041 in.
Side Clearance -
(0.070 - 0.105 mm)
0.0079 - 0.157 in. 0.0193 in.
End Gap
(0.200 -.0400 mm) (0.490 mm)
0.0797 - 0.0803 in. 0.0843 in.
Ring Groove Width
(2.025 - 2.040 mm) (2.140 mm) See
0.0776 -- 0.0783 in. 0.0768 in. Inspection of
Ring Width Pistons,
3TNV88, (1.970 - 1.990 mm) (1.950 mm)
Second Ring Piston Rings
4TNV88 0.0014 - 0.0028 in. 0.0075 in.
Side Clearance and Wrist
(0.035 - 0.070 mm) (0.190 mm) Pin on
0.0079 - 0.0157 in. 0.0193 in. page 6-83.
End Gap
(0.200 - 0.400 mm) (0.490 mm)
0.1581 - 0.1587 in. 0.1626 in.
Ring Groove Width
(4.015 - 4.030 mm) (4.130 mm)
0.1563 -.1571 in. 0.1555 in.
Ring Width
(3.970 - 3.990 mm) (3.950 mm)
Oil Ring
0.0010 - 0.0024 in. 0.0071 in.
Side Clearance
(0.025 - 0.060 mm) (0.180 mm)
0.0079 - 0.0157 in. 0.0193 in.
End Gap
(0.200 - 0.400 mm) (0.490 mm)
(Piston Ring Cont.)
Reference
Page
0.0803 - 0.0811 in.
Ring Groove Width -
(2.040 - 2.060 mm)
0.0764 - 0.0772 in. 0.0756 in.
Ring Width
(1.940 - 1.960 mm) (1.920 mm)
Top Ring
0.0031 - 0.0047 in.
Side Clearance -
(0.080 - 0.120 mm)
0.0098 - 0.0177 in. 0.0213 in.
End Gap
(0.250 - 0.450 mm) (0.540 mm)
0.0819 - 0.0825 in. 0.0864 in.
Ring Groove Width
(2.080 - 2.095 mm) (2.195 mm) See
4TNV94L, Ring Width Pistons,
(1.970 - 1.990 mm) (1.950 mm)
4TNV98, Second Ring Piston Rings
4TNV98T 0.0035 - 0.0049 in. 0.0096 in. and Wrist
Side Clearance
(0.090 - 0.125 mm) (0.245 mm) Pin on
0.0177 - 0.0256 in. 0.0287 in. page 6-83.
End Gap
(0.450 - 0.650 mm) (0.730 mm)
0.1187 - 0.1193 in. 0.1232 in.
Ring Groove Width
(3.015 - 3.030 mm) (3.130 mm)
0.1169 - 0.1177 in. 0.1161 in.
Ring Width
(2.970 - 2.990 mm) (2.950 mm)
Oil Ring
0.0010 - 0.0024 in. 0.0071 in.
Side Clearance
(0.025 - 0.060 mm) (0.180 mm)
0.0098 - 0.0177 in. 0.0217 in.
End Gap
(0.250 - 0.450 mm) (0.550 mm)

(Piston Ring Cont.)
Reference
Page
0.0992 - 0.1000 in.
Ring Groove Width -
(2.520 - 2.540 mm)
0.0961 - 0.0969 in. 0.0953 in.
Ring Width
(2.440 - 2.460 mm) (2.420 mm)
Top Ring
0.0024 - 0.0039 in.
Side Clearance -
(0.060 - 0.100 mm)
0.0118 - 0.0177 in. 0.0213 in.
End Gap
(0.300 - 0.450 mm) (0.540 mm)
0.0815 - 0.0821 in. 0.0860 in.
Ring Groove Width
(2.070 - 2.085 mm) (2.185 mm) See
Ring Width Pistons,
4TNV106, (1.970 - 1.990 mm) (1.950 mm)
Second Ring Piston Rings
4TNV106T 0.0031 - 0.0045 in. 0.0093 in.
Side Clearance and Wrist
(0.080 - 0.115 mm) (0.235 mm) Pin on
0.0177 - 0.0236 in. 0.0268 in. page 6-83.
End Gap
(0.450 - 0.600 mm) (0.680 mm)
0.1187 - 0.1193 in. 0.1232 in.
Ring Groove Width
(3.015 - 3.030 mm) (3.130 mm)
0.1169 - 0.1177 in. 0.1161 in.
Ring Width
(2.970 - 2.990 mm) (2.950 mm)
Oil Ring
0.0010 - 0.0024 in. 0.0071 in.
Side Clearance
(0.025 - 0.060 mm) (0.180 mm)
0.0118 - 0.0197 in. 0.0236 in.
End Gap
(0.300 - 0.500 mm) (0.600 mm)
Connecting Rod
Connecting Rod Small End
Reference
Page
Wrist Pin Bushing 0.9065 - 0.9070 in. 0.9082 in.
Inside Diameter (23.025 - 23.038 mm) (23.068 mm)
Wrist Pin Outside 0.9053 - 0.9055 in. 0.9042 in.
3TNV82A
Diameter (22.995 - 23.000 mm) (22.967 mm)
0.0010 - 0.0017 in. 0.0040 in.
Oil Clearance
(0.025 - 0.043 mm) (0.101 mm)
3TNV84, 3TNV84T, 3TNV88, Wrist Pin Outside 1.0234 - 1.0236 in. 1.0223 in.
4TNV84, 4TNV84T, 4TNV88 Diameter (25.995 - 26.000 mm) (25.967 mm)
0.0010 - 0.0017 in. 0.0040 in. See
(0.025 - 0.043 mm) (0.101 mm)
Connecting
Wrist Pin Bushing 1.1821 - 1.1826 in. 1.1838 in. Rod on
Inside Diameter (30.025 - 30.038 mm) (30.068 mm) page 6-85.
4TNV94L, 4TNV98, 4TNV98T
Diameter (29.987 - 30.000 mm) (29.959 mm)
0.0010 - 0.0020 in. 0.0043 in.
Oil Clearance
(0.025 - 0.51 mm) (0.109 mm)
4TNV106, 4TNV106T
Diameter (36.989 - 37.000 mm) (36.961 mm)
0.0010 - 0.0019 in. 0.0042 in.
Oil Clearance
(0.025 - 0.049 mm) (0.107 mm)
Connecting Rod Big End

Reference
Page
See
Inspection of
0.0079 - 0.0157 in.
Side Clearance - All Models - Connecting
(0.20 - 0.40 mm)
Rod on
page 6-85.
See Special Torque Chart on page 6-25 for other specifications.
Tappet
Reference
Page
Tappet Bore (Block) Inside 0.4724 - 0.4734 in. 0.4742 in.
3TNV82A, 3TNV84, Diameter (12.000 - 12.025 mm) (12.045 mm)
3TNV84T, 3TNV88, 0.4715 - 0.4720 in. 0.4707 in.
Tappet Stem Outside Diameter
4TNV84, 4TNV84T, (11.975 - 11.990 mm) (11.955 mm)
4TNV88 0.0004 - 0.0020 in. 0.0035 in.
Oil Clearance
(0.010 - 0.050 mm) (0.090 mm)
Diameter (12.000 - 12.018 mm) (12.038 mm) See
4TNV94L, 4TNV98, 0.4715 - 0.4720 in. 0.4707 in. Inspection of
Tappet Stem Outside Diameter
4TNV98T (11.975 - 11.990 mm) (11.955 mm) Tappets on
0.0004 - 0.0017 in. 0.0033 in. page 6-85.
Oil Clearance
(0.010 - 0.043 mm) (0.083 mm)
Diameter (14.000 - 14.018 mm) (14.038 mm)
0.5498 - 0.5505 in. 0.5491 in.
4TNV106, 4TNV106T Tappet Stem Outside Diameter
(13.966 - 13.984 mm) (13.946 mm)
0.0006 - 0.0020 in. 0.0036 in.
Oil Clearance
(0.015 - 0.052 mm) (0.092 mm)
ENGINE Cylinder Block Specifications
CYLINDER BLOCK SPECIFICATIONS

Cylinder Block
Reference
Inspection Item Model Standard Limit
Page
3.2283 - 3.2295 in. 3.2362 in.
3TNV82A
(82.000 - 82.030 mm) (82.200 mm)
3TNV84, 3TNV84T, 3.3071 - 3.3083 in. 3.3150 in.
4TNV84, 4TNV84T (84.000 - 84.030 mm) (84.200 mm)
3.4646 - 3.4657 in. 3.4724 in.
3TNV88, 4TNV88
(88.000 - 88.030 mm) (88.200 mm) See
Cylinder Inside Diameter Inspection of
3.7008 - 3.7020 in. 3.7059 in.
4TNV94L Cylinder
(94.000 - 94.030 mm) (94.130 mm)
Block on
3.8583 - 3.8594 in. 3.8634 in. page 6-83.
4TNV98, 4TNV98T
(98.000 - 98.030 mm) (98.130 mm)
4.1732 - 4.1744 in. 4.1783 in.
4TNV106, 4TNV106T
(106.000 - 106.030 mm) (106.130 mm)
Roundness 0.0004 in. (0.01 mm) 0.0012 in.
Cylinder Bore
Taper or less (0.03 mm)
Special Torque Chart ENGINE
SPECIAL TORQUE CHART

Torque for Bolts and Nuts
Lubricating Oil
Thread Diameter Application
Component Model Torque
and Pitch (Thread Portion and
Seat Surface)
46 - 49 ft·lb
3TNV82A M9 x 1.25 mm (61.7 - 65.7 N·m;
6.3 - 6.7 kgf·m)
3TNV82A, 3TNV84,
63 - 67 ft·lb
3TNV84T, 3TNV88,
M10 x 1.25 mm (85.3 - 91.1 N·m;
4TNV84, 4TNV84T,
Cylinder 8.7 - 9.3 kgf·m)
4TNV88 Applied
Head Bolt
76 - 83 ft·lb
4TNV94L, 4TNV98,
M11 x 1.25 mm (103.1 - 112.9 N·m;
4TNV98T
10.5 - 11.5 kgf·m)
139 - 146 ft·lb
4TNV106, 4TNV106T M13 x 1.5 mm (188.0 - 112.9 N·m;
19.0 - 20.0 kgf·m)
27 - 30 ft·lb
3TNV82A M8 x 1.0 mm (37.2 - 41.2 N·m;
3.8 - 4.2 kgf·m)
3TNV82A, 3TNV84,
33 - 36 ft·lb
3TNV84T, 3TNV88,
M9 x 1.0 mm (44.1 - 49.0 N·m;
4TNV84, 4TNV84T,
Connecting 4.5 - 5.0 kgf·m)
4TNV88 Applied
Rod Bolt
40 - 43 ft·lb
4TNV94L, 4TNV98,
M10 x 1.0 mm (53.9 - 58.8 N·m;
4TNV98T
5.5 - 6.0 kgf·m)
58 - 62 ft·lb
4TNV106, 4TNV106T M11 x 1.0 mm (78.5 - 83.4 N·m;
8.0 - 8.5 kgf·m)
3TNV82A, 3TNV84,
61 - 65 ft·lb
3TNV84T, 3TNV88,
M10 x 1.25 mm (83.3 - 88.2 N·m;
4TNV84, 4TNV84T,
Flywheel 8.5 - 9.0 kgf·m)
4TNV88 Applied
Bolt
4TNV94L, 4TNV98, 137 - 152 ft·lb
4TNV98T, 4TNV106, M14 x 1.5 mm (186.2 - 205.8 N·m;
4TNV106T 19 - 21 kgf·m)
83 - 91 ft·lb
EPA Flange
4TNV106, 4TNV106T M8 x 1.5 mm (113 - 123 N·m; Not Applied
Bolt
11.5 - 12.5 kgf·m)

ENGINE Special Torque Chart
(Torque for Bolts and Nuts Cont.)
Lubricating Oil
Seat Surface)
56 - 60 ft·lb
3TNV82A M10 x 1.25 mm (76.4 - 80.4 N·m;
7.8 - 8.2 kgf·m)
3TNV84, 3TNV84T, 69 - 72 ft·lb
3TNV88, 4TNV84, M12 x 1.5 mm (93.2 - 98.1 N·m;
Main Bearing Cap 4TNV84T, 4TNV88 9.5 - 10.5 kgf·m)
Applied
Bolt 80 - 87 ft·lb
4TNV94L, 4TNV98,
M11 x 1.25 mm (108.1 - 117.9 N·m;
4TNV98T
11.0 - 12.0 kgf·m)
137 - 152 ft·lb
4TNV106, 4TNV106T M14 x 1.5 mm (186.2 - 205.8 N·m;
19 - 21 kgf·m)
3TNV82A, 3TNV84,
83 - 91 ft·lb
3TNV84T, 3TNV88,
M14 x 1.5 mm (112.7 - 122.7 N·m;
4TNV84, 4TNV84T,
Crankshaft Pulley 11.5 - 12.5 kgf·m)
4TNV88 Applied
Bolt
4TNV94L, 4TNV98, 80 - 94 ft·lb
4TNV98T, 4TNV106, M14 x 1.5 mm (107.9 - 127.5 N·m;
4TNV106T 11.0 - 13.0 kgf·m)
3TNV82A, 3TNV84,
18 - 21 ft·lb
3TNV84T, 3TNV88,
M8 x 1.25 mm (24.4 - 28.4 N·m;
4TNV84, 4TNV84T,
Fuel Injector 2.5 - 2.9 kgf·m)
4TNV88 Not Applied
Bolt
4TNV94L, 4TNV98, 17 - 21 ft·lb
4TNV98T, 4TNV106, M8 x 1.25 mm (22.6 - 28.4 N·m;
4TNV106T 2.3 - 2.9 kgf·m)
3TNV82A, 3TNV84,
58 - 65 ft·lb
3TNV84T, 3TNV88,
M14 x 1.5 mm (78 - 88 N·m;
4TNV84, 4TNV84T,
Fuel Pump Drive 8 - 9 kgf·m)
4TNV88 Not Applied
Gear Nut
4TNV94L, 4TNV98, 83 - 90 ft·lb
4TNV98T, 4TNV106, M18 x 1.5 mm (113 - 123 N·m;
4TNV106T 11.5 - 12.5 kgf·m)
3TNV82A, 3TNV84,
22 - 25 ft·lb
3TNV84T, 3TNV88,
M12 x 1.5 mm (29.4 - 34.3 N·m;
4TNV84, 4TNV84T,
High-Pressure 3.0 - 3.5 kgf·m)
4TNV88 Not Applied
Fuel Lines Bolt
4TNV94L, 4TNV98, 174 - 217 in·lb
4TNV98T, 4TNV106, M12 x 1.5 mm (19.6 - 24.5 N·m;
4TNV106T 2.0 - 2.5 kgf·m)
Special Torque Chart ENGINE

(Torque for Bolts and Nuts Cont.)
Lubricating Oil
Seat Surface)
4TNV94L, 4TNV98, 70 - 86 in·lb
Fuel Return Line
4TNV98T, 4TNV106, M6 x 1.0 mm (7.8 - 9.8 N·m; Not Applied
Joint Bolt
4TNV106T 0.8 - 1.0 kgf·m)
Rocker Arm 148 - 199 in·lb
Cover 4TNV106, 4TNV106T M8 x 1.25 mm (16.7 - 22.5 N·m; Not Applied
Bolt 1.7 - 2.3 kgf·m)
3TNV82A-B, 133 - 177 in·lb
Glow Plug 3TNV88-B,-U, M10 x 1.25 mm (15 - 20 N·m Not Applied
4TNV88-B,-U 1.53 - 2.04 kgf·m)
3TNV82A-B,
Glow Connector 9 - 13 in·lb
3TNV88-B,-U, M4 x 0.7 mm Not Applied
Nut (1 - 1.5 N·m)
4TNV88-B,-U
See Tightening Torques for Standard Bolts and Nuts on page 4-46 for standard hardware torque values.




















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YANMAR 3TNV-4TNV Series Shop Manual Unduh Grati 4

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TNV DI Service Manual

Table of Contents ................................................................................... iii

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

Yanmar Warranties.............................................................................. 2-1

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

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

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

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

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

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

Turbocharger ..................................................................................... 10-1

Starter Motor ...................................................................................... 11-1

Alternator ........................................................................................... 12-1

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

Troubleshooting ................................................................................ 14-1

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iv TNV DI Service Manual

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TNV DI Service Manual

TNV DI Service Manual 1-1

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1-2 TNV DI Service Manual

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TNV DI Service Manual

Yanmar Limited Warranty................................................................ 2-3

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Yanmar Limited Warranty YANMAR WARRANTIES

YANMAR LIMITED WARRANTY

How Long is the Warranty Period?

What the Engine Owner Must Do:

TNV DI Service Manual 2-3

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YANMAR WARRANTIES Yanmar Limited Warranty

Yanmar Limited Warranty - Continued

To Locate an Authorized Yanmar Industrial Engine Dealer or Distributor:

What Yanmar Will Do:

What is Not Covered by this Warranty?

2-4 TNV DI Service Manual

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Yanmar Limited Warranty YANMAR WARRANTIES

Retail Purchaser Registration