YANMAR 4TNE84 4TNE88 3TNE84T 4TNE84T Engine Full Service & Repair Manual
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SERVISE MANU
INDUSTRIAL DIES
MODEL TNE s
FOREWORD
This Service Manual describes the procedure of maintenance and service of the Yanmar industrial
TNE series engine (Special swirl precombustion chamber (hereinafter "Indirect injection system")
and Direct injection systems}.
Before starting service and maintenance of TNE engine, you are requested to read this Service
Manual carefully to your full understanding and to take careful note that the standard TNE engine
may differ in the structure and applicable specification from that loaded on each of individual driven
machines (such as the generator, pump, compressor, and combine, etc.).
For further information, carefully read the Service Manual issued for each driven machine.
This Service Manual in subject to changes, with or without notice, with respect to the structure and
the content of maintenance for the purpose of improving engine quality.
Setup before work
To perform work efficiently, the following setup (preparation) is necessary.
1. Customer ledger check
(1) Previous date of service
(2) Check on which month (and at what time) the last service was performed, what
problem occurred, and what the history of the customer (engine) is.
2. Stock control of parts
(1) Stock check for consumable parts, periodic replacement parts, etc., that are
required for service.
(2) Provision of check list, parts list and parts card.
3. Provision of service record
(1) Work (process) time table
(2) Check sheet (including used parts list)
~)~.uffimentd~~p~1 . .
(4) Operation data and quality (for maintenance of performance and quality)
4. Disassembly and reassembly tools
(1) Tools
(2) Measuring devices
(3) Other instruments and equipment necessary for service
FM23056 JQA-0099
ISO 9001 Certified
This product has been developed, designed and produced in
accordance with the Standards for Quality System of ISO 9001
(International Organization for Standardization) under the
following authorized institutions: JMI (Japan Machinery and
Metals Inspection Institute), SSI (British Standards Institution)
Institution) and EQNET (The European Network tor Quality
System Assessment and Certification).
Certified under the following standards:
ISO 9001 - 19871 BS 5750: Part 1 : 19871
EN 29001 - 19871 JIS Z9901 -1991
CONTENTS
1. Specifications and Performance •..• ................... •.•...•.• ..... •••• .... •••.•.• ........... • ....... •.•...•.•. 1-1
1-1 2TNE68.............................................................................................................. 1-1
1-2 3TNE68 .... .... ....................... ...................... ......................................................... 1-2
1-3 3TNE74 .............................................................................................................. 1-3
1-4 3TNE78A .. ................................. ........ ............ .......................... ........ .......... ........ 1-4
1-5 3TNE82A ........................................................................................................... 1-5
1-6 3TNE82 .............................................................................................................. 1-6
1-7 3TNE84.............................................................................................................. 1-7
1-8 3TNE88 .............................................................................................................. 1-8
1-9 4TNE82.............................................................................................................. 1-9
1-10 4TNE84.............................................................................................................. 1-10
1-11 4TNE88.............................................................................................................. 1-11
1-12 3TNE84T............................................................................................................ 1-12
1-13 4TNE84T............................................................................................................ 1-13
2. Cross Sectional Views ................. • ......... ••.•..•••.•••...• ........... • ....... •...••••• .... •...•...• ..... • ..... •. 2-1
2-1 Special Swirl Pre-combustion Chamber System ............................................... 2-1
2-2 Direct Injection System.......... ................................ ...... ........ .............................. 2-2
3. Cooling Water, Lubricating Oil and Fuel Oil .............................................................. 3-1
3-1 Cooling water ..................................................................................................... 3-1
3-2 lubricating oil........................................ ............................................................. 3-1
3-3 Fuel oil .................... ............. .............. .............. .............. ..... ............................... 3-3
4. Troubleshooting ............................................................................................................ 4-1
4-1 Trouble causes and remedies............................................................................ 4-1
4-2 Trouble diagnosis through measurement of compression pressure .................. 4-3
5. Special Service Tools and Measuring Instruments ................................................... 5-1
5-1 Special service tools.......... ...................... ..................... .................... ............ ..... 5-1
5-2 Measuring instruments ....................................................................................... 5-3
6. Measurement, Inspection and Adjustment ................................................................ 6-1
6-1 Measuring the compression pressure ......... ................. ................ .......... ............ 6-1
6-2 Adjusting the valve head clearance .................. ................................................. 6-3
6-3 Checking the V -belt tension ...... ............................. ................ ............................ 6-4
6-4 Measuring and checking the injection pressure and spray patterns
of the fuel injection valve ........................................... ........................... .............. 6-4
6-5 Checking and adjusting the fuel injection timing ................................................ 6-8
6-6 Adjusting the no-load maximum (or minimum) revolutions ................................ 6-10
6-7 Checking the COOling water system and radiator for water leakage .................. 6-10
6-8 Checking the battery ............................. ............................................................. 6-11
6-9 Checking sensors .............................................................................................. 6-13
6-10 Checking the oil cooler ....................................................................................... 6-14
6-11 Checking the piston cooling nozzle ................................................................... 6-15
7. Measuring Procedures, Service Data and Corrective Action ................................... 7-1
7-1 Cylinder head ... ...... ........•......... ...... ...................... ........ ........ ... ........... ........ ........ 7-1
7-2 Cylinder block .................................................................................................... 7-7
7-3 Valve rocker arm..... ........ ...... .......... ...... .............. ............................................... 7-10
7-4 Piston and piston ring ...... ...................... .......................................... .................. 7-12
7·5 Connecting rod................ ............ .......... ............. ............. ................................... 7-17
7-6 Camshaft............................................................................................................ 7-20
7-7 Crankshaft.......................................................................................................... 7-22
7-8
7-9
Gears .................................................................................................................
Trochoid pump ................................................................................................. ..
8. Disassembly and Reassembly .....................................................................................
8-1 Disassembly .......................................................................................................
8-2 Precautions before and during reassembly ..................................................... ..
9. Service Data ................................................................................................................. .
9-1 Cylinder head ................................................................................................... ..
9-2 Cylinder block ....................................................................................................
9-3 Valve rocker arm ................................................................................................
9-4 Piston ................................................................................................................ .
9-5 Piston ring ........................................................................................................ ..
9-6 Connecting rod ................................................................................................. ..
9-7 Camshaft ............................................................................................................
9-8 Crankshaft ........................................................................................................ ..
7·25
7-27
8-1
8-1
8-6
9-1
9·1
9-2
9·2
9-3
9-4
9-5
9-5
9-5
9-9 Side gap and backlash ....................................................................................... 9-6
9-1 0 Others ................................................................................................................ 9-6
10. Tightening Torque ........................................................................................................ 10-1
10-1 Main bolVnut ...................................................................................................... 10-1
10-2 Standard bolt and nut.. .................. ...... ..................... .......................................... 10-1
11. Fuel Injection Pump for Indirect Injection System .................................................... 11-1
11·1 Exploded views (YPFR type) .. ........ ........ ................ ..... ............ ........ ..... ... ...... .•.. 11-1
11-2 Disassembly ....................................................................................................... 11-2
11·3 Inspection......... .................................................................................................. 11-3
11-4 Reassembly .............................. ................... ................. ........... ............. ............. 11-5
12. Fuel Injection Pump for Direct Injection System ....................................................... 12-1
12-1 Exploded Views (YPES type)............................................................................. 12·1
12-2 Special service tools for disassembly and reassembly.... .................................. 12·2
12-3 Disassembly.......................... ........ ..................................................................... 12-3
12-4 Inspection........................................................................................................... 12-7
12-5 Reassembly .......................................................... ......................... ........ ...... ...... 12·9
13. Governor ................................................................................................. ....................... 13·1
13-1 Exploded views of governorfor indirect injection system ... ............................... 13-1
13-2 Exploded views of governor for direct injection system ..................................... 13-2
13-3 Disassembly................ ............................. ..... .... .......................... ..... ........... ....... 13-3
13-4 Inspection........................................................................................................... 13-7
13-5 Reassembly.... ....... ...... ...... .................... ........ ........... ................. ................ .... .... 13-9
14. Turbocharger ................................................................................................................. 14·1
14-1 Specifications ..................................................................................................... 14·1
14-2 Construction ....................................................................................................... 14-1
14-3 Waste gate valve adjusting method .... .... .... ........ ...... .... ................ ..... ......... ....... 14-3
14·4 Exploded view of Turbocharger (wI waste gate) .. ... ........ .... .... ............ .......... ..... 14-5
14-5 Tightening torque ............................. ................ ........... ............ ........................... 14-6
14-6 Service standards .............................................................................................. 14-6
15. Service Information for CARS ULG regulation .......................................................... 15·1
15-1 Emission control labels ................................................................................... :.. 15-1
15-2 Limiting the high idle and low idle adjustment screw......................................... 15-6
15-3 Limiting the fuel volume limiter screw.... ............................................................ 15-7
Attached Drawing 1. Exploded Views of Engine Components ..................................... A·1
Attached Drawing 2. Exploded Views of Engine Components ..................................... A·2
o Descriptive Breakdown of Model Name
o TN E 0 0 (A) (T) - 0 0
-,-
'------. Shipping identifier
Turbocharger
L-_________ Model subdivision
Cylinder bore (mm)
Model code
Number of cylinders (3 or 4)
o Application Category
Application code Usage Eng. Rev. type
Revolution speed (rpm)
CL
1500/1800
Generator drive Constant
CH
3000/3600
VM
2000 ~ 3000
General use Variable
VH
3000 ~ 3600
* For engine application category described in Chapter 1. Specifications and Performance.
1. Specifications and Performance
1. Specifications and Performance
1-1 2TNE68 * Output conditions: Intake back pressure $ 250 mmAq, Exhaust back pressure $ 550 mmAq,
other conditions complying with JIS 0 1005-1986. After minimum 30 hour's run·in.
Model
2TNE68
Item Unit
Application - VM
I
CH VH
Type
-
Vertical, 4·cycle water·cooled diesel engine
Combustion system - Special swirl pre·combustion chamber
No. of cylinders - Bore x Stroke mm 2-68x72
Displacement e
0.523
Firing_order - 1-2
Revolution speed rpm 2000 2200 2400 2600 2800 3000 3000 3600 3200 3400 3600
Continuous
kW(HP) - -
- - - -
7.72 9.12
- -
-
Output*
rating (10.5) (12.4)
5.74 6.25 6.84 7.43 7.94 8.46 8,46 10.0 8.68 9.19 9.64
Max. rating kW(HP)
(7.8) (8.5) (9.3) (10.1 ) (10.8) (11.5) (11.5) (13.6) (11.8) (12.5) (13.1 )
Max. revolution speed at
2180'~ 2375'~ 2570'~ 2780+~ 2970'~ 3180+~ 3180'~ 3780+~ 3425'~ 3640~
3850+~
no load
Min. revolution speed at
rpm
no load
5800 51500 5800
Direction of rotation - Counterclockwise (viewed from flywheel)
Power take off - Flywheel
en
Compression ratio
z
- 23.0
0
Fuel injection timing
~
(FlO, b.T.D.C.)
deg 14±1 16±1
C,)
Compression pressure MPa
u::
3.24±O.1 (33±1), at 250 rpm
i3
IlkQficm"
w
Fuel injection pressure MPa
11.8·'g (120·'g)
0..
en
.Ikgf/cm')
Recommended diesel gas oil - ISO 8217 DMA, BS 2869 AI or A2 (Cetane No. 45 min.)
Lubrication system
-
Forced lubrication with trochoid pump
Lubricating oil capacity
e 1.6/0.6 2.311.0
Max/Effective
Recommended lubricating oil
- API grade CC class or higher
Cooling system - Liquid coolinglRadiator
Cooling water capacity e 0.6 (for engine only)
Cooling fan
mm Discharge type, 5 x $290
No. of blade x dia.
Crank V·pulley dia.l
mm $95/$85
Fan V·pulley dia.
Governor - Mechanical centrifugal governor (All speed ty~
Starting system - Electrical
*1 DimenSions L x W x H 373.5 x 417 x 498/383.5 x 417 x 498 383.5 x 409 x 540
373.5 x 417 x 540 I
mm
383.5x417 x 540
*1 Dry weight kg
55/65 65 55/65
Transient speed
% $12 510 512
difference
w
Governing
Steady state
59 I 58
I
C,)
perform·
% 57 56 $5 $7
z speed band
<{
ance
~
(full speed
Recovery time 56
a:
sec
0 range)
u.
Fluctuation of
a:
rpm 530 520 530
w
revolution
0..
I
Rated operation
MPa
0.25±0.05 0.29±0.05
O.34±O·~r
L.a. press.
(2.5±O.5) (3.0±0.5) (3.5±O.5
Idling
(kgf/cm')
,,0.06 (;>0.6)
*1. Designation of engine dimension and dry weight in numerals.
CUCH application: engine with flywheel housing
VMNH application: engine with back plateiwith flywheel hausing
1-1
1. Specificallons and Performance
1-2 3TNE68
• Output conditions: Intake back pressure ~ 250 mmAq, Exhaust back pressure ~ 550 mmAq,
other conditions complying with JIS D 1005-1986. After minimum 30 hour's run-in.
Model
3TNE68
Item Unit
Application - VM CH
T
VH
Type
-
Vertical, 4-cvcle water-cooled diesel en!line
Combustion svstem
-
Special swirl pre-combustion chamber
No. of cvlinders - Bore x Stroke mm 3-68x72
Displacement € 0.784
Firing order - 1-3-2-1
Revolution speed rpm 2000 2200 2400 2600 2800 3000 3000 3600 3200 3400 3600
Continuous
kW(HP) - - -
- - -
11.7 13.7
- - -
Output*
rating (15.7) (18.4)
Max. rating kW(HP)
8.6 9.4 10.3 11.2 12.0 12.9 12.9 15.1 13.1 13.8 14.5
(11.5) (12.6) (13.8) (15.0) (16.1) (17.3) (17.3) (20.2 (17.6) (18.5) (19.4)
Max. revolution speed at
2180": 2375 ": 2570": 2780 ": 2970": 3180": 3180'~ 3780'~ 3455'~ 3670 ": 3890 ":
no load
Min. revolution speed at
rpm
no load
$800 $1500 $800
Direction of rotation - Counterclockwise (viewed from flywheel)
Power take off - Flywheel
Ul
Compression ratio
-
23.0
z
0
Fuel injection timing
~
(FlO, b.T.D.C.)
deg 14±1 16±1
u
Compression pressure MPa
u:
3.24±0.1 (33±1), at 250 rpm
5
(kaf/cm')
w
Fuel injection pressure MPa
11.8+'~ (120+'g)
Il.
Ul
(kaf/cm')
Recommended diesel gas oil
- ISO 8217 DMA, BS 2869 AI or A2 (Cetane No. 45 min.)
Lubrication system - Forced lubrication with trochoid pump
Lubricating oil capacity
€ 2.4/1.0 3.0/1.0
Max/Effective
Recommended lubricating oil
-
API !lrade CC class or higher
Cooling system -
Liquid coolinglRadiator
Cooling water capacity € 0.9 (for engine only)
Coolingfan
mm Pusher type, 5 x $310
No. of blade x dia.
Crank V-pulley dia.!
mm $105/$85
Fan V-pulley dia.
Governor
-
Mechanical centrifugal governor (All speed type)
Starting system
- Electrical
*1 Dimensions Lx W x H 463.5 x 401 x 496 I 473.5 x 401 x 496 473.5x401 x 496
463.5 x 401 x 4961
mm
473.5 x 401 x 496
*1 Dry weight kg
70/81 81 70/81
Transient speed
% $12 SID s12
difference
w
Governing
Steady state
$9 I $8 I
I
u
perform- % 57 $6 $5 $8
z
sDeed band
« ance
::;;
(full speed
Recovery time $6 a: sec
0 range)
"-
Fluctuation of
a:
rpm :>30 :>20 $30
w
revolution
Il.
Rated operation
MPa
~.25±0.~~ I
~:29±O.~~
I
~:34±0.~~
L.O. press. 2.5±O.5 3.0±0.5 3.5±O.5
Idling
(kgf/em')
>0.06 (?0.6)-
*1. Designation of engine dimension and dry weight in numerals.
CUCH application: engine with flywheel housing
VMNH application: engine with back platelwith flywheel hausing
1-2
1. Specifications and Performance
1-3 3TNE74
*Output conditions: Intake back pressure ~ 250 mmAq, Exhaust back pressure ~ 550 mmAq,
other conditions complying with JIS 0 1005-1986. After minimum 30 hour's run·in.
Model
3TNE74
Item Unit
Application - VM CH
~
VH
Type -
Vertical, 4·cycle water·cooled diesel engine
Combustion system
-
Special swirl pre·combustion chamber
No. of cylinders - Bore x Stroke mm 3-74x78
Displacement
f!
1.006
Firing order
-
1-3-2-1
Revolution speed rpm 2000 2200 2400 2600 2800 3000 3000 3600 3200 3400 3600
Continuous
kW(HP) - - - -
-
-
15.1 17.4
- - -
Output*
rating (20.2) (23.3)
11.0 12.1 13.2 14.3 15.5 16.6 16.6 19.1 16.6 17.1 17.7
Max. rating kW(HP)
(14.8) (16.2) (17.7) (19.2) (20.8) (22.3) (22.3) (25.6) (22.3) 22.9 (23.7)
Max. revolution speed at
2180+~ 2375'~ 2570'~ 2780": 2970'~ 3180": 3180'~ 3780": 3455~ 3670": 3890~
no load
Min. revolution speed at
rpm
no load
~800 ~1500 ~800
Direction of rotation - Counterclockwise (viewed from flywheel)
Power take off - Flywheel
(/)
Compression ratio
z
- 23.0
0
Fuel injection timing
~
(FlO, b.T.D.C.)
deg 14±1 16±1
()
Compression pressure MPa
iL:
3.43±O.1 (35±1), at 250 rpm
(3 (kgf/cm')
UJ
Fuel injection pressure MPa
11.8·'g (120·'g)
"-
(/)
kgf/cm')
Recommended diesel gas oil - ISO 8217 DMA, BS 2869 Alar A2 (Cetane No.: 45 min.)
Lubrication system
-
Forced lubrication with trochoid pump
Lubricating oil capacity
f! 2.411.0 3.311.4
Max/Effective
Recommended lubricating oil - API grade CC class or higher
Cooling system - Liquid coolinQ/Radiator
Coolil1g water capacity f! 0.9 (for engine only)
Cooling fan
mm Pusher type, 5 x ~310 Pusher type, 6 x ~335
No. of blade x dia.
Crank V·pulley dia.!
mm ~110/<1>8S ~110/~97
Fan V·pulley dia.
Governor - Mechanical centrifugal governor LAII speed type)
Starting system - Electrical
*1 Dimensions L x W x H
469.1 x 440 x S02/476.6 x 440 x S02 476.6 x 440 x 502
469.1 x 440 x S021
mm
476.6x 440 x 502
*1 Dry weight kg 8SI102 100 8SI100
Transient speed
% $12 $10 ,;12
difference
UJ Governing
Steady state
,,9 I ,,8
I
()
perform·
% ,;7 ,,6
"S
,,8
z speed band
..:
ance
~
(full speed
Recovery time ,,6
0: sec
rr
range)
0:
Fluctuation of
,,30 ,;20 ,,30
UJ
revolution
rpm
"-
Rated operation
MPa ~:2S±0.~~ I
0.29±O.05
1
0.34±O.OS
L.O. press. 2.S+0.S . (3.0±O.S) (3.S±O.S)
Idling
(kgf/cm')
>0.06 (;'0.6)
*1. Designation of engine dimension and dry weight in numerals.
CUCH application: engine with flywheel housing
VMNH application: engine with back plate/with flywheel hausing
1-3
1. Specincations and Performance
1-4 3TNE78A
* Output conditions: Intake back pressure ~ 250 mmAq, Exhaust back pressure ~ 550 mmAq,
other conditions complying with JIS D 1005-1986. After minimum 30 hou(s run-in.
Model
3TNE78A
item Unit
Application - CL VM
I
CH VH
Type - Vertical, 4-cycle water-cooled diesel engine
Combustion system - Direct injection system
No. of cylinders - Bore x Stroke mm 3-78x84
Displacement t!
1.204
Firing order - 1-3-2-1
Revolution speed rpm 1500 1800 2000 2200 2400 2600 2800 3000 3000 3600 3200 3400 3600
Continuous
kW(HP)
9.1 10.8
- - - - - -
18.0 21.0
- -
-
Output*
rating (12.2) (14.5) (24.1) (28.2)
Max. rating kW(HP)
9.9 11.9 13.2 14.6 15.9 17.2 18.5 19.9 19.9 23.2 20.5 21.6 23.2
(13.3 (16.0) (17.7) (19.6) (21.3) (23.1) (24.8) (26.7) (26.7) (31. t) (27.5) (29.0) (31.1)
Max. revolution speed at
1575~ 1870~ 2180~ 2375'~ 2570'~ 2780~
,.
3180'~ 3150~ 3745~
..,
3670~
3800+~
no load
2970 0 3455 ,
Min. revolution speed at
rpm
no load
~1200 ~800 ~1500 ~800
Direction of rotation
- Counterclockwise (viewed from fly~heel)
Power take off
- Flywheel
en
Compression ratio
z
- 18.0
0
Fuel injection timing
~
(FID, b.T.D.C.)
deg 10±1 12±1 14±1 16±1 24±1 18±1 20±1 24±1
()
Compression pressure MPa
u::
3.14±O.1 (32±1), at 250 rpm
U
(kgf/cm')
w
Fuel injection pressure MPa
a.
19.6+'g (200+'g )
en
I (kgf/cm')
Recommended diesel gas oil - ISO 8217 DMA, BS 2869 Al or A2 (Cetane No.: 45 min.)
Lubrication system
- Forced lubrication with trochoid pump
Lubricating oil capacity
t! 3.6/1.3 5.0/1.7
Max/Effective
Recommended lubricating oil - API grade CC class or higher
Cooling system
- Liquid cooling/Radiator
Cooling water capac~y t! 1.8 (for engine only)
Cooling fan
mm Pusher type, 6 x ~335
No. of blade x dia.
Crank V-pulley dia.!
mm ~120/~90 ~110/~110
Fan V-pulley dia.
Governor
-
Mechanical centrifuQal Qovernor (All speed type)
Starting system - Electrical
*1 Dimensions L x W x H mm 553x489x565 520.5 x 489 x 565/528 x 489 x 565 528 x 4a9 x 565
520.5 x 489 x 565/
528 x 489 x 565
*1 Dry weight
kg 138 1121128 124 112/124
Transient speed
% S10 S8 ~12 ~10 ~8 ,,12
difference
w
Governing
Steady state
,,91
S8
1
1
()
perform- % ,,5 S4
g
,,6 S5 S4 s8
z speed band
c(
ance
::0
(full speed
Recovery time ,,5 ~6 ,,5 ,,6 cr: sec
0 range)
"-
Fluctuation of
cr:
S15 525· S30
w
revolution
rpm
a.
Rated operation
0.29±O.05
O.34±O.OS
L.O. press.
MPa
(3.0±0.5)
(3.S±O.5)
Idling
(kgf/cm')
>0.06 (?0.6)
*1. Designation of engine dimension and dry weight in numerals.
CUCH application: engine with flywheel housing
VMNH application: engine with back plateiwith flywheel hausing
1-4
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