Part of the Yanmar Repair Manuals.
Slide a feeler gauge under a TNE rocker arm with the locknut backed off and you are one wrong number away from a burned valve. Yanmar publication AOA5063-2 T 9701 is the factory service manual that carries those numbers for the TNE series industrial diesels: 2TNE68, 3TNE68, 3TNE74, 3TNE78A, 3TNE82A, 3TNE82, 3TNE84, 3TNE88, 4TNE82, 4TNE84, 4TNE88, and the turbocharged 3TNE84T and 4TNE84T.
Across 136 pages it works through compression-based troubleshooting, valve clearance adjustment, injection timing and nozzle pressure checks, then measuring procedures with service data for the cylinder head, block, pistons, connecting rods, camshaft, and crankshaft. The YPFR and YPES fuel injection pumps, the governor, and the turbocharger with its waste gate get their own disassembly and inspection sections.
Guess at a clearance and you pay for it with a second teardown. Measure against the service data in this PDF and the engine goes back together once.
What's Inside This Yanmar TNE Series Manual
| System | Pages | Key Topics |
|---|---|---|
| Specifications and Performance | 7-19 | 2TNE68, 3TNE68, 3TNE74, 3TNE78A, 3TNE82A, 3TNE82, 3TNE84, 3TNE88 |
| Cross Sectional Views | 20-21 | 2-1 Special Swirl Pre-Combustion Chamber System, 2-2 Direct Injection System |
| Cooling Water,Lubricating Oil and Fuel Oil | 22-24 | 3-1 Cooling Water, 3-2 Lubricating Oil, 3-3 Fuel Oil |
| Troubleshooting | 25-27 | 4-1 Trouble Causes and Remedies, 4-2 Trouble Diagnousis Through Measurement of Compression Pressure |
| Special Service Tools and Measuring Instruments | 28-32 | 5-1 Special Service Tools, 5-2 Measuring Instruments |
| Measurement,Inspection and Adjustment | 33-47 | 6-1 Measuring the Compression Pressure, 6-2 Adjusting the Valve Head Clearance, 6-3 Checking the V-Belt Tension |
| Measuring Procedures,Service Data and Corrective Action | 48-74 | Cylinder Head, Cylinder Block, Valve Rocker Arm, Piston, Piston Ring, Connecting Rod, Camshaft, Crankshaft |
| Disassembly and Reassembly | 75-83 | 8-1 Disassembly, 8-2 Precautions Before and During Reassembly |
| Service Data | 84-89 | Cylinder Head, Cylinder Block, Valve Rocker Arm, Piston, Piston Ring, Connecting Rod, Camshaft, Crankshaft |
| Tightening Torque | 90 | 10-1 Main Bolt/Nut, 10-2 Standard Bolt and Nut |
| Fuel Injection Pump for Indirect Injection System | 91-95 | 11-1 Exploded views(YPFR Type), 11-2 Disassembly, 11-3 Inspection, 11-4 Reassembly |
| Fuel Injection Pump for Direct Injection System | 96-108 | 12-1 Exploded Views(YPES Type), 12-2 Special Service Tools for Disassembly and Reassembly, 12-3 Disassembly, 12-4 Inspection, 12-5 Reassembly |
| Governor | 109-120 | 13-1 Exploded Views of Governor for Indirect Injection System, 13-2 Exploded Views of Governor for Direct Injection System, 13-3 Disassembly, 13-4 Inspection, 13-5 Reassembly |
| Turbocharger | 121-126 | 14-1 Specifications, 14-2 Construction, 14-3 Waste Gate Valve Adjusting Method, 14-4 Exploded View of Turbocharger(w/Waste Gate), 14-5 Tightening Torque, 14-6 Service Standards |
| Service Information for Carb Ulg Regulation | 127-133 | 15-1 Emission Control Labels, 15-2 Limiting the High Idle and Low Idle Adjustment Screw, 15-3 Limiting the Fuel Volume Limiter Screw |
| Attached Drawing 1. Exploded Views of Engine Components | 134 | Exhaust Manifold, High-Pressure Fuel Pipe, Fuel Injection Nozzle, Cylinder Head Assembly, Piston, Connecting Rod |
| Attached Drawing 2. Exploded Views of Engine Components | 135-136 | Fuel Injection Pump, Camshaft Assembly, Crankshaft V-Pulley, Gear Case, Crankshaft, Main Bearing Cap |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| All Models | ||
| Cylinder head gasket replacement | Replace the gasket. | p. 27 |
| Nozzle gasket replacement | Replace the gasket. | p. 27 |
| Intake/exhaust valve head clearance (Adjustment) | 0.15 - 0.25 mm | p. 35 |
| 2TNE68 | ||
| Fuel injection timing (FID, b.T.D.C.) | 14±1 deg (VM), 16±1 deg (CH, VH) | p. 7 |
| Engine Displacement | 0.523 L | p. 7 |
| 3TNE68 | ||
| Fuel injection timing (FID, b.T.D.C.) | 14±1 deg (VM), 16±1 deg (CH, VH) | p. 8 |
| 2/3TNE68 | ||
| Valve sinking depth (Intake valve) Standard | 0.3-0.5 mm | p. 48 |
| 2TNE68, 3TNE68, 3TNE74 | ||
| Compression Ratio (Indirect Injection) | 23.0 | p. 7 |
| 3TNE78A, 3TNE82A, 3TNE82, 3TNE84, 3TNE88, 4TNE82, 4TNE84, 4TNE88, 3TNE84T, 4TNE84T | ||
| Compression Ratio (Direct Injection) | 18.0 | p. 10 |
| Fuel Injection Timing (Direct Injection, CL) | 10±1 deg | p. 10 |
| 2TNE68 (VM/CH), 3TNE68 (VM/CH), 3TNE74 (VM/CH) | ||
| Fuel Injection Timing (Indirect Injection, VM/CH) | 14±1 deg | p. 7 |
| 2TNE68 (VM/CH) | ||
| Lubricating Oil Capacity (Max/Effective) | 1.6/0.6 L | p. 7 |
Yanmar TNE Series Common Problems This Manual Covers
Engine cranks but will not start
Low compression, valve clearance out of spec, valve timing, and air in the fuel all produce the same dead crank, and owners burn days swapping parts to tell them apart. The troubleshooting section maps causes to remedies and uses compression pressure measurement to separate a fuel problem from a mechanical one.
Manual Section: 4. Troubleshooting p. 25Clattering valve train and rough idle
Valve clearance drifts with hours, and too tight is worse than too loose: held-open valves lose compression and burn seats. The measurement and adjustment section covers checking compression, setting valve head clearance, and verifying injection pressure and spray pattern at the nozzle.
Manual Section: 6. Measurement,Inspection and Adjustment p. 33Blue smoke and oil consumption
Worn rings, glazed bores, and tired valve guides show up as smoke and falling compression long before a knock does. The measuring procedures chapter gives service data and corrective action for the cylinder head, block, pistons, rings, connecting rods, camshaft, and crankshaft, so you know what to reuse and what to replace.
Manual Section: 7. Measuring Procedures,Service Data and Corrective Action p. 48Uneven fuel delivery between cylinders
A worn injection pump makes one cylinder work harder than the rest, and it feels like a misfire that injector swaps never cure. This manual covers disassembly, inspection, and reassembly of the YPES pump for direct injection engines, with the YPFR pump for indirect injection engines in its own section.
Manual Section: 12. Fuel Injection Pump for Direct Injection System p. 96Hunting or surging at idle
When engine speed swings rhythmically under no load, the governor is usually the culprit, not the pump. The governor section has exploded views for both indirect and direct injection systems plus disassembly, inspection, and reassembly procedures.
Manual Section: 13. Governor p. 109Boost loss on turbocharged models
On the 3TNE84T and 4TNE84T, a lazy waste gate or worn turbo bleeds power under load. The turbocharger section includes the waste gate valve adjusting method, an exploded view, tightening torques, and service standards for judging wear.
Manual Section: 14. Turbocharger p. 121Head gasket failure after overheating
Coolant loss or overheating often ends with a leaking head gasket, and reusing gaskets or improvising torque figures just buys you the job twice. The disassembly and reassembly chapter sets out the teardown order and the precautions that keep the fresh gasket sealed.
Manual Section: 8. Disassembly and Reassembly p. 75Frequently Asked Questions
Which Yanmar engines does this service manual cover?
Thirteen TNE series industrial diesels: 2TNE68, 3TNE68, 3TNE74, 3TNE78A, 3TNE82A, 3TNE82, 3TNE84, 3TNE88, 4TNE82, 4TNE84, 4TNE88, and the turbocharged 3TNE84T and 4TNE84T. The Specifications and Performance section carries a full data sheet for each model. p. 7
Does it include tightening torque specifications?
Yes. The Tightening Torque section covers main bolts and nuts plus standard bolt and nut values, and the reassembly precautions tell you how to apply them so the head and bottom end go back together correctly. p. 90
What is the valve clearance for Yanmar TNE Series engines?
The manual specifies 0.15 to 0.25 mm for intake and exhaust, and the Measurement, Inspection and Adjustment section walks through the adjusting procedure step by step. p. 35
Does it cover fuel injection pump and governor overhaul?
Yes. The YPFR pump for indirect injection engines and the YPES pump for direct injection engines each get exploded views with disassembly, inspection, and reassembly procedures, and the Governor section does the same for both governor types. p. 91
What do I get after purchasing this Yanmar TNE series & variants manual?
Instant PDF download. You get the full 136-page searchable Service Manual immediately after payment. Open it on your laptop, tablet, or phone right in the shop.
Am I able to print pages from this manual?
Yes, print as many copies as you want, and there are no restrictions. Many mechanics print the section they need and bring it to the shop floor.
Reviews
There are no reviews yet.