Part of the Yanmar Repair Manuals.
Pick up the Yanmar 3TNV service manual PDF (OEM M9961-02E050) and you get 214 pages of factory-issued procedures covering the 3TNV82A, 3TNV84(T), 4TNV84(T), 3TNV88, and 4TNV88 industrial diesel engines from 1997 through 2008. Inside: full wiring diagrams with circuit routing, lubrication and fuel system schematics, a complete troubleshooting section with quick-reference charts and compression pressure diagnostics, and exploded-view drawings for cylinder head, gear train, cylinder block, and turbocharger assemblies. You also get a tiered periodic maintenance schedule, from the initial 50-hour break-in check through every 2,000-hour overhaul interval, with procedures for each service point. Set intake and exhaust valve clearance to 0.15-0.25 mm; torque the fuel filter element to 20-24 Nm. Your engine is down and every hour it sits costs money. Bookmarked sections and keyword search mean you spend less time hunting and more time wrenching.
What's Inside This Manual
| System | Pages | Key Topics |
|---|---|---|
| Preface | 3 | Tnv Series Engines, Indirect Injection System, Us Epa Certification, California Arb Certification, 97/68/EC Directive, Engine Specifications and Components |
| Safety Labels | 4 | Basic Safety Rules, Safety Precautions, Inspection Procedures, Maintenance Procedures, Danger, Warning, Caution, Notice |
| Safety Precautions | 5-8 | Service Area, Work \u2013 Wear (Garments), Tools, Electrical, Waste Management, Further Precautions |
| Precautions for Service Work | 9-11 | Precautions for Safety, Preparation for Service Work, Precautions in Disassembly, Precautions for Inspection and Measurement, Precautions for Reassembly |
| General | 17-37 | Engine Nomenclature, Specifications, Fuel Oil, Lubricating Oil and Cooling Water, Engine External Views, Structural Description |
| Inspection and Adjustment | 38-68 | Periodic Maintenance Schedule |
| Troubleshooting | 69-74 | Preparation Before Troubleshooting, Quick Reference Table for Troubleshooting, Troubleshooting by Measuring Compression Pressure |
| Disassembly, Inspection and Reassembly of Engines | 75-123 | Complete Disassembly and Reassembly (Introduction, Special Service Tools, Precautions Before and During Reassembly, Operation), Cylinder Head: Disassembly |
| Lubrication System | 124-127 | Lubrication System Diagram, Trochoid Pump Components, Disassembly, Servicing Points, Parts Inspection and Measurement (Trochoid Pump Inspection and Measurement) |
| Cooling System | 128-129 | Cooling Water System, Cooling Water Pump Components, Disassembly (Reverse the Procedure Below for Assembly), Servicing Points |
| Fuel Injection Pump/Governor | 130-133 | Introduction, Fuel Injection Pump (Fuel System Diagram, External View and Components, Disassembly Procedure, Assembly Procedure, Servicing Points) |
| Turbocharger: Disassembly, Inspection and Reassembly | 134-155 | Structure and Functions, Service Standards and Tightening Torque, Periodic Inspection Procedure, Disassembly Procedure, Washing and Inspection Procedure, Reassembly Procedure |
| Starting Motor | 156-191 | For 4Tnv94L/ 98, For 4Tnv106(T) |
| Alternator | 192-195 | The 40A Alternator for 3TNV84 and Other Models |
| Electric Wiring | 196-200 | Electric Wiring Diagram, Precaution on Electric Wiring |
| Service Standards | 201-211 | Engine Tuning, Engine Body, Lubricating Oil System (Trochoid Pump) |
| Tightening Torque for Bolts and Nuts | 212-213 | Tightening Torques for Main Bolts and Nuts, Tightening Torques for Standard Bolts and Nuts |
| Back Cover | 214 |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| 4TNV94L/98 | ||
| Cylinder head bolt tightening torque, 4TNV94L/98 | 103.1~112.9 Nm (10.5~11.5 kgf·m) | p. 212 |
| 4TNV106(T) | ||
| Cylinder head bolt tightening torque, 4TNV106(T) | 188.0~197.8 Nm (19.0~20.0 kgf·m) | p. 212 |
| 3TNV82A~98 | ||
| Intake/exhaust valve head gap (standard valve clearance) | 0.15~0.25 mm | p. 201 |
| All Models | ||
| Fuel filter element replacement interval | Every 250 hours or 3 months | p. 38 |
| Air cleaner element replacement interval | Every 250 hours or 3 months | p. 38 |
| Lube oil filter replacement interval (1st time) | Every 50 hours | p. 38 |
| Lube oil filter replacement interval (2nd time and thereafter) | Every 250 hours or 3 months | p. 38 |
| Thermostat valve opening temperature (standard) | 69.5~72.5 deg C | p. 201 |
| Thermostat valve opening temperature (option) | 80~84 deg C | p. 201 |
| 3TNV82A to 4TNV106(T) | ||
| Fuel filter element tightening torque | 20~24 Nm (2.0~2.4 kgf·m) | p. 52 |
| 3TNV82A~TNV88 (CL) | ||
| Fuel injection pressure (CL models) | 19.6~20.6 MPa (200~210 kgf/cm2) | p. 59 |
| 3TNV82A~TNV88 (VM), 4TNV94L~4TNV106(T) | ||
| Fuel injection pressure (VM models, 4TNV models) | 21.6~22.6 MPa (220~230 kgf/cm2) | p. 59 |
