Part of the Hyundai Repair Manuals.
Hunting for a Yanmar 3TNV88 service manual PDF? This 720-page factory service manual (OEM #M9961-02E050) covers the full TNV industrial diesel line: 3TNV82A, 84, 84T, 88, plus the 4TNV84, 84T, 88, 94L, 98, 98T, 106, and 106T, along with the R55W-7. Inside you get factory electrical circuit diagrams, hydraulic schematics tracing both main and pilot circuits, and a full troubleshooting section for hydraulic, mechanical, and electrical faults. Disassembly and assembly procedures run from the pump device to the cylinders, backed by page after page of tightening torque tables. Pulling the head? Torque the cylinder head bolts to 61.7 to 65.7 Nm; on the 4TNV106, the main bearing caps take 186.2 to 205.8 Nm. A dead engine pays nobody. This bookmarked PDF has a full text layer, so type the spec, find the number, and get back to your rebuild.
What's Inside This Hyundai R55W-7 Manual
| System | Pages | Key Topics |
|---|---|---|
| Maintenance Standard | 2 | Operational Performance Test, Major Components |
| General | 3-21 | Safety Hints, Specifications |
| Structure and Function | 22-83 | Pump Device, Main Control Valve, Swing Device, Travel Device, Rcv Lever, Rcv Pedal, Brake Pedal, Gear Box |
| Hydraulic System | 84-113 | Hydraulic Circuit, Main Circuit, Pilot Circuit, Single Operation, Combined Operation |
| Electrical System | 114-165 | Component Location, Monitoring System, Electrical Circuit, Electrical Component Specification |
| Troubleshooting | 166-232 | Before Troubleshooting, Hydraulic and Mechanical System, Operational Performance Test, Major Components |
| Disassembly and Assembly | 233-421 | Precaution, Tightening Torque, Pump Device, Main Control Valve, Swing Device, Travel Device, Gear Box, Steering Valve |
| Introduction Guide | 422-423 | Bolt Specifications, Standard Torque Values, Metric Fasteners, Cleaning Components |
| Engine System | 424-425 | Engine Accessories Mounting, Cooling System, Fuel Tank Mounting |
| Electric System | 426 | Electric Components Mounting, Battery, Alternator, Horn |
| Hydraulic System | 427-428 | Hydraulic Components Mounting, Main Control Valve, Cylinders, Boom Swing Cylinder |
| Undercarriage | 429 | Swing Bearing, Oscillating Cylinder, Gear Box, Front Axle, Rear Axle |
| Structure | 430-432 | Cab Accessories Mounting, Cowling Mounting, Cover and Foot Board |
| Work Equipment | 433-720 | Boom Cylinder, Arm Cylinder, Bucket Cylinder, Bucket Control Link, Side Cutter |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| 4-valve head | ||
| Nozzle case nut tightening torque | 39.2 to 44.1 Nm (4 to 4.5 kgf·m) | p. 653 |
| All Models | ||
| Main bearing cap bolt tightening torque | 186.2-205.8 Nm (19.0-21.0 kgf·m) | p. 549 |
| Cylinder head bolt tightening torque | 61.7~65.7 Nm (6.3~6.7 kgf·m) | p. 652 |
| R55W-7 | ||
| Engine oil quantity | 9.2 L | p. 18 |
| Main pump rated pressure | 220 kgf/cm2 | p. 18 |
| Swing motor relief pressure | 200 kgf/cm2 | p. 19 |
| Travel motor relief pressure | 220 kgf/cm2 | p. 19 |
| 3TNV82A | ||
| Engine oil capacity (oil pan) | 3.6 L | p. 458 |
| 3TNV84 | ||
| Engine oil capacity (oil pan) | 6.7 L | p. 459 |
| 4TNV94L | ||
| Engine oil capacity (oil pan) | 10.2 L | p. 465 |
| 4TNV106 | ||
| Engine oil capacity (oil pan) | 14.0 L | p. 468 |
Hyundai R55W-7 Common Problems This Manual Covers
Yanmar 4TNV88 cranks but won't start after fuel filter change, exhaust puffs white smoke
Bleed the fuel system: loosen the bleed screw on the filter housing and work the priming pump until fuel runs bubble-free, then crack the injector lines while cranking. If it still won't fire, pull the nozzles and check spray pattern; on 4-valve heads, torque the nozzle case nuts to 39.2 to 44.1 Nm (page 653) on reassembly.
Manual Section: Fuel Injection Pump Troubleshooting p. 653White exhaust smoke at operating temperature, coolant level drops, oil looks milky
Pressure-test the cooling system cold and watch for bubbles in the radiator neck with the engine running. Milky oil confirms coolant intrusion, so pull the head and check it for warp. On the 3TNV82A, fit a new gasket, torque head bolts to 61.7 to 65.7 Nm (page 652) in sequence, then refill the pan with 3.6 L of fresh oil (page 458).
Manual Section: Disassembly and Assembly p. 652Hydraulic oil overheats and engine labors during combined boom and travel operation
Check hydraulic oil level first, then blow debris out of the cooler fins with compressed air from the inside out. On the R55W-7, test main pump relief pressure against the 220 kgf/cm2 rating listed on page 18, and work the overheating chart in the troubleshooting section starting on page 166. Replace cloudy or contaminated oil before retesting.
Manual Section: Troubleshooting p. 166Low oil pressure warning at idle when hot, oil level rising between services
Check the dipstick with the machine parked level, five minutes after shutdown. Drain a sample: thin oil that smells of diesel means fuel dilution from a dribbling injector, so pull and test the nozzles before condemning the oil pump. Refill the 4TNV94L pan with 10.2 L (page 465) and recheck pressure at full operating temperature.
Manual Section: Fuel Injection Pump Troubleshooting p. 465Deep knock from the bottom end under load, oil pressure gauge reads low hot
Drain the oil and cut the filter open; metal glitter in the pleats confirms bearing wear. Drop the pan, remove the caps one at a time, and measure clearance with plastigauge. On the 4TNV106, torque main bearing cap bolts to 186.2 to 205.8 Nm (page 549) on reassembly and prime the oil system before the first start.
Manual Section: Disassembly and Assembly p. 549Frequently Asked Questions
What are the torque specifications for the cylinder head bolts on a Yanmar TNV84-88 engine?
For the TNV84-88 engine, the cylinder head bolts should be tightened in two steps. The first step is 41.1 to 46.9 Nm (4.2 to 4.8 kgf-m), and the second step is 85.3 to 91.1 Nm (8.7 to 9.3 kgf-m). p. 530
What is the standard valve clearance for a 3TNV82A engine?
The standard valve clearance for the 3TNV82A engine is 0.15 to 0.25 mm for both intake and exhaust valves. p. 641
What is the recommended oil capacity for the 3TNV82A engine oil pan?
The total oil capacity for the 3TNV82A engine oil pan is 5.5 liters, with an effective capacity of 1.9 liters. p. 458
What is the standard injection starting pressure for the 4TNV94L/4TNV106(T) fuel injection nozzle?
The standard injection starting pressure for the 4TNV94L and 4TNV106(T) fuel injection nozzle is 21.6 to 22.6 MPa (220 to 230 kgf/cm²). p. 712
What is the standard V-belt tension for the engine?
The standard V-belt tension, measured by pressing with a thumb at the middle of the belt span with approximately 98N (10kgf), should result in a deflection of 8 to 12 mm for a new V-belt and 10 to 14 mm for a used V-belt at position A. p. 483
Is this Yanmar 3TNV82A manual a PDF I download?
A single searchable PDF file of 720 pages, downloadable right after payment. Nothing ships, nothing waits in the mail.
Can I print a copy of this Yanmar 3TNV82A Service Manual for the shop?
Printing is allowed without restriction. Pull the pages you need for the job and bin them when they get greasy.
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