YANJVIAH

IIIDUSTRIAL E]{GIilE

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ENTMCIDUGTEON
Welcome to the world of YANMAR Engines! Constant efforts are made to improve the quality
YANMAR has been the leader in industrial diesel and performance of YANMAR products, so some
engines for over 90 years. We developed the details included in this Aperation Manualmay
world's first practical small-sized diesel engine in differ slightly from your engine. lf you have any
1933. Our engineers are continuously developing questions about these differences, please contact
new technology to keep YANMAR on the your authorized YANMAR industrial engine
leading-edge of the industry. The TNV engine is dealer or disiributor.
only one example of the new technology we have
The specifications and components (instrument
Ceveloped. We are committed to maintaining our
panel, fueltank, etc.) described in this manual
environment, and are proud of our history of
innovation, quality and respect for operator safety, may differ from ones installed on your machine.
Please refer to the manual provided by the
To help you enjoy your YANMAR TNV engine for manufacturer of these components.
many years to come, please follow these
recommendations:
. Read and understand this Operation fvlanual
before you operate the machine to ensure that
you foliow safe operating practices and
maintenance procedu res.
o Keep lhis Operation Manualin a convenient
place for easy access.
. lf this Operation Manualis lost or damaged, order
a new one from your authorized YANMAR
industrial engine dealer or distributor.
. Make sure this manual is transferred to
subsequent owners. This manual should be
considered a permanent part of the engine and
remain with it.

ffiWffi&ffi rfJV operation Manuar

INTRODUET'tOT\U

REEORD OF OWNERSHIP
Take a few moments to record the information you need when you contact YANMAR for service, parts or
literature.

Engine model:

Engine serial No.:

Date purchased:

Dealer:

Dealer phone:

SYMBOL EXPLANATION
The following symbols are used throughout this manual to identify specific engine model information

This symbol indicates information pertaining to the following indirect injection engines:
. 2TNV70*
. 3TNV70.
. 3TNV76.
An asterisk (.) inCicates the engines conform to the engine emission regulations (EPA 200e
rules).

This symbol indicates informaiion perlaining to the following direct injection engines:
' 3TNV82A . 3TNV82A-8.
" 3TNV84 . 3TNV84T-Z**
.3TNV84T " 3TNV84T-B.
. 3TNV88 . 3TNV88-Z**
. 4TNV84 . 3TNVB8-8.
. 4TNVB4T . STNVB8-U*
. 4TNV88 . 4TNV84T-2.*
. 4TNV94L . 4TNV84T-8.
. 4TNV98 . 4TNV88-Z**
.4TNV98T " 4TNV88-8.
. 4TNV106 . 4TNIVBS-U-
" 4TNV106T . 4TNV98-2.*
. 4TNV98-E**
. 4TNV98T-Z**
An asterisk (.) indicates the engines conform to the engine emission regulations (EPA 2008
rules).

A double asterisk ("") indicates the engines are electronically controlled and conform to the
engine emission regulations (EPA 2008 rules).

rNV operation Manual Y#trffieffi

 I
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:

spffi#EFEG&€E&ruS
GENERAL
Description of Msdel Fducftben
3 TNV 70 000
'_ Customer code

Rated RPM

Cylinder bore (mm)

Engine series

No. of cylinders

3 TNV 000
lL_ Customer cooe

I
Hated HPM
Governor type symbol (indicating conformance to EPA
Tier 3llnterim Tier 4 standards)

Governor type Applicable

Governor type
symbol engine
Electronic governor
Z Non-derated
(eco-governor)
engine
B Mechanical governor
Electronic governor
E
(eco-governor) Derated engine
U Mechanical governor

Turbocharged (no symbol indicates naturally aspirated)

Engine sub series

Cylinder bore (mm)

Engine series

No. of cylinders

ffi#ffiffiffi rNV operation Manuat 117

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a

SPEEIFICAT!ONS
Engine Speed Speeifieatioms
Notation Available engine speed lntended uses
VH 3200 _ UUOO *ip_r (rpm) Lawn mourer, construction, industrial machine
VM 2000 - aOOO ,;'1-t (rpm) Agricuitural, construction, industrial machines
CH 3000 - .UOO rip-t (rpm) 2-pole generator sets, irrigation pumps
1500 or ',UOO rin-t (rpm) 4-poie generator sets, irrigation pumps
CL
VH: Variable high speed CH: Constant high speed
VM: Variable medium speed CL: Consiant low speed

Engine Generai Speciticatioils

Type Vertical in-line, water cooled, A-cycie diesel engine
Direct injection models Direct injeclion
Combustion sysiem
lndirect injeciion models Swirl chamber (balltype)
Starting system Electric stafting
Cooling system Radiator
Lubricating system Forced lubrication with trochoid pump
PTO position Flywheel end
Direction o{ rotation Counterclockwise viewed from flywheel end

Note:

" The information ciescribed in Principa! Engine Specifications is for a "siandard" engine. To obtain the
information for the engine installed in your driven machine, please refer to the manual provided by the
driven machine manufactu rer.
, Engine rating conditions are as follovls (SAE Jl349, ISO 3046/1):
o Atmospheric condition: Room temperature 25 "C (77 'F), atmospheric pressure 29.53 in. Hg (100 kPa,
75a mmHg), relative humidity 30 %
u Fuel temperature at fuel injector pump inlet: 40 "C (104 "F)
o 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: YANI4AR standard
. Afterthe engine break-in period. Output allowable deviation: *3 %
. 1 PS = 0.7355 kW
, t hp SAE (Society of Automotive Engineers)= 0.7457 kW

118 rNV operation Manual W&ffiffi#ffi

SPECIFIEATIONS

4TNV106 (- EPA Tier 2)

Engine model 4TNVl06

Version CL VM
Type Vertical in-line diesel engine
Combustion system Direct injection
Aspiration Natural
No. of cylinders 4
Bore x stroke s106 x 125 mrn
Displacement 4.412 L
min-1 1 500 1 800
Continuous rated output KW 41.2 49.3
PS 56.0 67.A
mtn- |
1 500 '1800 2000 2204 2400 2500
Max. rated output (net) KW AE A 54.4 56.6 61.4 65.5 67.7
PS 62.0 / 4.\) 77.0 83.5 89.0 92.0
High idling min-1 1600 t 25 1895 + 25 22OS t25 2420 x.25 2615 t25 2725 t 25
Engine weight (dry) with
345 kg 330 kg
flywheel housing*1
PTO position Flywheel end
Direction of rotation Counterclockwise viewed from flywheel end
Cooling system Liquid-cooled with radiator
Lubricating system Forced lubrication with trochoid pump
Normal oil pressure at With baiancer: Q.34 - 0.44 MPa
0.3'l - 0.49 MPa
rated engine speed Without balancer:0.39 - 0.49 MPa
Normal oil pressure at
0.06 MPa
low idle speed
Electric starling (starter motor: DC 12 V (3.0 kW)).3
Starting system Alternator: DC 12 V, 55 A.3
Recommended battery capacity: 12 V, 88 Ah-3
Dimensions
808 x 629 x 803 mm 776 x 629 x 803 mm
(LxWxH).t
Engine oil pan 14.0/5.0 L '14.0/6.5 L
capacity*2 (dipstick upper limit/lower limit) (dipstick upper limiVlower limit)
Engine coolant capacity 6 L engine only
Standard cooling fan 500 mm O.D. 7 blade pusher-type-: 500 mm O.D. 7 blade suction-type-3
Crank V-pulley dia./
s1501a150 mm*3
fan V-pulley dia.
Top clearance 0.906 + 0.059 mm
*1: Engine specifications without radiator.
*2: 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 ca-paclty of your machine.
-3: May vary depending on application.

132 rrriv operation Manual ffiffiffiffiffi

 SPEE!FICAflOruS

4TNV106T (- EFA Tier 2)

Engine rnodel 4TNV1 06T

Version CL VM
Type Vedical in-line diesel engine
Combustion system Direct injection
Aspiration Turbocharged
No. of cylinders 4
Bore x stroke a106 x 125 mm
Displacement 4.412 L
min-1 1 500 1 800
Continuous rated output KW 61.8
PS 70.0 84.0
min-1 1 500 1 800 2000 2200
Max. rated output (net) k\ti 56.8 68.0 69.9 72.0
PS 77.2 92.5 95.0 97.9
High idling min-1 1600t25 1875 + 25 2245 t25 2420 x.25
Engine weight (dry)with
355 kg 340 kg
flywheel housing*1
PTO position Flywheel end
Direction of rotation Counterclockwise viewed from flywheel end
Cooling system Liquid-cooled with radiator
Lubricating system Forced lubrication with trochoid pump
Normal oil pressure at With balancer: 0.34 - 0.44 MPa
0.31 - 0.49 MPa
rated engine speed Without balancer: 0.39 - 0.49 MPa
Normal oil pressure at
0.06 MPa
low idle speed
Electric starling (starler motor DC 12 V (3.0 kW))-3
Starting system Alternator: DC 12 V, 55 A-3
Recommended battery capacity: 12 V,88 Ah-3
Dimensions
808 x 629 x 866 mm 776 x 629 x 866 mm
(LxWxH)-1
Engine oil pan 14.0i5.0 L 14.016.5 L
capacity-2 (dipstick upper limit/lower limit) (dipstick upper limiVlower limii)
Engine coolant capacity 6 L engine only
Standard cooling fan 500 mm O.D. 7 blade pusher-type-3 500 mm O.D.7 blade suction{ype.
Crank V-pulley dia./
s150ls150 mm.3
fan V-pulley dia,
Top clearance 0.906 t 0.059 mm
*1: Engine specifications without radiator.
-2: 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.
"3: May vary depending on application.

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Wffitrffi#ffi rNV operation Manuar 133

*..
 TAELE @F
GOruTENTS
Page
YANMAR WARRANTIES........... ........ 1

YANMAR LIMITED WARRANTY ....,......... 1

What is Covered by this Warranty? 1

How Long is the Warranty Period? 1

What the Engine Owner must Do: 2

To Locate an Authorized YANMAR lndustrial Engine Dealer or
Distributor: 2
What YANMAR will Do: .......... 2
What is not Covered by this Warranty? J
Warranty Limitations: ...........,... 3
Warranty Modifications: ....,...... 3
Questions: 3
Retail Purchaser Registration............... 4
EIViISS|ON SYSTEIVI WARRANTY .............. 5
YANMAR CO., LTD. Emission Control System Warranty
- USA On1y.......... ..................... 5
Your Warranty Rights and Obligations:......". ............... 5
Manufacturer's Warranty Period: ............... s
Warranty Coverage: ................ 6

Exclusions: ................ ..............7

Owner's Warranty Responsibiliiies: ...........7
What the Emergency Stationary Type Engine Owner must Do:.... 7
EMTSSTON-RELATED TNSTALLATTON TNSTRUCTTONS (REF)........ I
lnstallation of Non-road Engines into Equipment,.............,.....,..... 8
Allowable Air lntake Restriction and Exhaust Back Pressure........ 8
Breather System..... ............... 11
ln-Use Testing Requirements............. ..... 11
Emission Control Labe1......... ................... 11
Fuel Inlet Label .... 12
lnstallation Evaluation. ...........12
Engine Maintenance...........,... ................. 12

ffiHffiffi# rNV operation Manuar Ir

TAELE OF CONTENTS
SAFETY """"' 13
SAFETY STATEMENTS.......... ..'................" 1s
SAFETY PRECAUTIONS ",....,,,, 14
' Before You Operate.........'... ....".""""""' 14
During Operation and Maintenance ...."" 14

PRODUCT OVERVIEW ..,....'..........'. 25

YANMAFI TNV ENGINE FEATURES AND APPLICATIONS .,,,,,.,,...25
COMPONENT IDENTIFICATION ,'"..,,,,.."..' 26
LOCATION OF LABELS ............. .........'.'.'... 29
Engine Nameplate (Typical) """""""""" 30
EPA/ARB Emission Control Regulations USA Only'.'..""""""' 30
-
Emission Control Labels....... ....,"..'.'..""' 30
EPA/CARB Labels (Typical) '.'...........""" 30
The 97l68lEC Directive Certified Engines ..... ..'....." 31
Engine Family....... .'.........' "" 31
FUNCTION OF MAJOR ENGINE COMPONENTS.......... ....,....,,.,.... 32
FUNCTION OF COOLING SYSTEM COM PONENTS.....,,.,,,..,.,.., ", 34
ELECTRONIC CONTROL SYSTEM............ ......".'......... 35
Main Electronic Control Components and Features........""."""' 38
GAUGES AND INDICATORS ,.,,40
Gauges..... '"""""' 40
lndicators.. '.....'...' 41

GAUGES AND INDICATORS OF ELECTRONIC

CONTROL SYSTEM ..,.,.,.,.",..,.,, 42
Gauges..... ..."""" 42
lndicators .............42
CONTRO1S.............. ...........'.'..'. 43
Key Switch .........43
Glow Plugs ....'-"" 45
lnlet Air Heater ...' 45
Governor Lever ................'."' 46
Speed Control of Electronically Controiled En9ines............' '.....' 46
Engine Stop So1enoid............ ................-.47
Electronic Engine Speed Control ............ 47
BEFORE YOU OPERATE.,..,..,.. ,.,,.,49
DIESEL FUEL ........... 50
Diesel Fuel Specifications ....' 50
Filling the Fuel Tank......... ....' 56
Priming the Fuel SYstem .'....' 57
ENGINE O11........... ...........'..'..'.., 58
Engine Oil Specifications .'.... 58
Engine OilViscosity............... '..."'..".'...'. 58
Checking Engine Oi|............. ................'.. 59
Adding Engine Oi1.........,... ..... 59
Engine Oil Capacity (Typical) ........'.."""' 60

IV
rNV operation Manual Wffiffiffiffi
 TABLE OF CONTEIUTS
ENGTNE COOLANT ....................61
Engine Coolant Speciflcations.............. ..................... 62
Filling Radiator with Engine Coolant..... .... 62
Daily Check of the Cooling System ......... 63
" Engine Coolant Capacity (Typical) .......... 63
DAILY CHECKS ........ 64
Visual Checks..... ...............,... 64
Check Diesel Fuel, Engine Oil and Engine Coolant Leve|s........, 64
Check Engine Speed Control ................. 64
Check Operator's Console ....64
Check lndicators.. .................. 65
.............
EINGINE OPEffiATIONI ........ 69
START|NG ENGTNE ...................70
COLD START DEVICE ,,,,,,,.,.,,,,.71
CHECKING THE ENGINE DURING OPERATION ........... .,,,.,..,.,...,, 72
SPEED
ADJUST ENGINIE ,...,,,.,,74
SHUTTING DOWN THE ENGINE........,... ,,,,.74
PEHIODIC
MAffi{TENANCE.......... ....75
PRECAUTIONS ,..,,..,76
The lmportance of Periodic Maintenance.................................... 76
Performing Periodic Maintenance..,............ .............. 76
The lmportance of Daily Checks ,............ ..................76
Keep a Log of Engine Hours and Daily Checks ........76
YANMAR Replacement Parts..... .._..........76
Tools Required .... 76
Ask Your Authorized YANMAR lndustrial Engine Dealer or
Distributor for Help..... ............ 70
Required EPA/ARB Maintenance USA On|y.......... ..................... T6
EPA/ARB lnstallation Requirements USA Only.......... ...,............. T7
Tightening Fasteners. ............77
STANDARD TORQUE CHART..... ......,.,.,,,...77
PERIODIC MAINTENANCE SCHEDULE ...,.78
Periodic Maintenance Chart ............ ....... 78
PERIODIC MAINTENANCE PROCEDURES .....,........... 80
After lnitial 50 Hours of Operation............... .............. 80
Every 50 Hours of Operation............... ....82
Every250HoursofOperation............... .,..................85
Every500HoursofOperation............... ....................91
Every 1000 Hours of Operation ........... .... gZ
Every 1500 Hours of Operation........... .... gB
Every 2000 Hours of Operation............ ..................... gg
Every 3000 Hours of Operation............ ................... 101

ffitrffieffi rNV operation Manual

a,
l
TABLE OF CONTEhITS
TROUBLESHOOTING ... 103
Troubleshooting Chart ................ f O+
TROUBLESHOOT|NG OF ELECTRONIC CONTROL SYSTEM.,., 106
, Capability
Fault Detection ,.. 106
DiagnosisToo1.......... ........... 108
TROUBLESHOOTTNG tNFORMATtON........... .....,....... 109
LIST OF POSSiBLE FAULTS OF ELECTRONICALLY
......,.....
CoNTROLLED ENGINES ...... ....... 110
LONG-TEHM STORAGE............... ................... 113
BEFORE YOU PLACE THE ENGINE IN LONG-TERM STORAGE... 114
BETURNING THE ENGINE TO SERVICE...,,.......... ..., 115
SPEC|FICATION|S ........ 117
GENERAL ..,,,,..,,,..,., 117
Description of Model Number.... ............ 117
Engine Speed Specifications.............. ... 118
Engine General Specifications ............. ................... 18 1

PRINCIPAL ENGINE SPECIFICATIONS ... 119

vt rNV operation Manual ffi#ffi$ffi

LONG-TERM STORAGE

This Fage lntentEonalEy Left Biaatk

116
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l
 L*P$G.TERIIfi STGHAGE

ffiETUffiEUEruG THE EruGENE TG SEffiVECE

1. Perform the Daily Checks on page 64.
2. The engine should be pre-oiled before startup.
Crank the engine, leaving the fuel system shut
off so the engine will not start, for 15 seconds.
Then pause for 30 seconds. Repeat the
procedure untiiyou have cranked the engine for
a total of one minute. This will circulate the oil in
the engine's lubrication system.
3. Prime the fuel system. See Priming the Fuel
System on page 57.
4. Start the engine. Allow the enEine to idle for
approximately 15 minutes while you check for:
. Proper oil pressure
. Fuel, engine oil, or coolant leaks
e Proper operation of the indicaiors and/or
gauges
5. Avoid prolonged operation at minimum or
maximum engine speeds and loads for the
remainder of the first hour of operation.

l
W#ffi&ffi rNV operation r\4anual 115

.)l
TONIG.TERM STORAGE

BEFORE YGU PLACE ThIE ENGINE IN LGruG-TERIM STCHAGE

Expiosiem Hazard! Protect the air cleaner, turbocharger (if equipped)

and electric components from damage when you
" Never sl'lort out the b,attery use steam or high-pressure water to clean the
terminals, including when
checking the rernaining battery engine.
charge. This wil! result in a spark
and rnay cause an explosion or
Perform the next Preventive Maintenance
fire. [.!se a hydrometer to check
procedure. For example, if there are 10 hours
the rernaining battery charge.
remaining before the 250 hour maintenance, you
It the electrolyte is frozen, slowly warrn the should do the maintenance before you place the
battery before you recharEe it. engine in storage.
Failure to cornply will result in death or
See Periodic Maintenance Schedule on page 78.
serious iniury.
1, Flush the radiator and refill with Long Life
Awenrulruo Engine Coolant. See Englne Coolant
Specifications on page 62 for engine coolani
Buyc? Hazard!
specifications and See Filling Radiator with
. Batteries contain sulfurlc acid.

#
Engine Coolant on page 62for the procedure
lr-------...-, i{ever allow battery fluird to corne for draining and refilling the cooling system.
is: contact with clothing, skin or
eyes. Severe burns could result.
2. Clean the exterior of the engine so it is free of
grease and oil.
Always wear safety goggles and
protective clothiirg w[:en 3. Draln the fueltank or make sure it is completely
servieing the batiery. lf battery full. See Filling the FuelTank on page 56.
fluid contaets the eyes and/or 4. Lubricate exposed parts cf the engine speed
skin, immediately flush the conirol system.
affected area with a large amount
of clean water and obtain prompt
5. Protect the air cleaner, muffter and electrical
componenis (alternator, starter motor,
anedicai treatg'vrent.
switches, EGR valve, controller) from water and
Failure to cormply could result in death or dust.
serious iniury.
6. Disconnect the negative (-) battery cable to
prevent the baitery from discharging.
A eaurloru 7. Check the battery fluid and add distilled water
FEyEffie Oblect F{azard! as required. See Check battery on page 84.
o Always wear eye protection when
B. Charge the battery once a month during
servicinE the engine and when storage.
using compressed air or
high-pressure water. Eust, flying 9. Rotate the engine without starting, every four to
debris, compressed air, six months.
pressurized water or steam may
inlure your eyes.
Failure to cornply may result in minor or
moderate iniury.

114 rNVoperation Manual ffiW&€ffiffi

 PHODUCT OVERVIEW

3TNV82A, 3TN!V84, 3TNV84T, 3JNy8ruTNV84, rtTNV84T, 4TNV88, 4TNV94L,

4TNVgB, 4TNVgBT, 4Tr',u v 1 06, 6TNV 1 oe;) srru vB2A- B, arNVB4T-z, 3TNVB4T-8,
gr N vB B-2, gr N vB B - E, gr N vB eEzffi-v8 B-2, 4T N v I B- B, 4T N v8 B- u

Figure 2 shows where major dlrect injection engine components are located.

17

16

15

14

12 11 10

'l - Lifting eye (flywheel end) 14-Governor lever

2 -Turbochdrger*1 15-lntake manifold
3 - Lifting eye (engine cooling fan end) 16- Fuel filter
4 - Engine coolant pump 17- Fuel inlet
5 - Engine cooling fan 1 8Fuel return to f uel iank
-
6 -Crankshaft V-pulley 19-Top filler pofi (engine oil)
7 -V-belt 20-Rocker arm cover
8 -Side filler port (engine oil) 21 - Ak intake port (from air cleaner)
9 -Drain plug (engine oil).2 22 - Flywheel
10-Fuel injection pump 23-Starter motor
11 - Engine oil cooler*3 24- Exhaust manifold
12-Engine oilfilter 25 -Aliernator
13 - Dipstick (engine oil)

Figure 2
*1:
Only applies to 3TNV84T 4TNV84T TNV99T 4TNV106T.
*2:
Engine oil drain plug location may vary based on oil pan optians.
r,, Not standard on all direct injection models.

Wtrffiffiffi rNV operation lr,4anual 27

 PffiODUET OVERVIEW

LOCATION OF LAtsELS
Figure 4 shows the location of regulatory and safety labels on YANMAR TNV series indirect
in.iection. model engines.

The typical location of the emission control

infornration label is shown (Figure 4, (1)).

Tyoical location of the engine nameplate is shown

(Figure 4, (2)J.

Figure 4

ffiffi Flgure 5 shows the location of regulatory and safety labels on YANMAR TNV series direct
injection model engines.
MM

Figwre 5

E Location of labels/nameplates Gn direct iniectlon model engEnes

EPA/ARB certification 97 l68lEC emission control
Model Engine nameplate
label label
3TNV82A, 3TNV84, 3TNV84T, On the top of the locker arm On the top of the locker arm On the exhaust side of the locker
3TNV88, 3TNV82A-8, 3TNV88.Z, cover (cooling fan end) cover (flywheel end) arm cover (near the flywheel)
3TNV88.B, 3TNV88.U, Figure 5 left, (4) FiEure 5 left, (1) Figure 5 left, (2)
STNV84T.B, 3TNV84T.Z
4TNV84, 4TNV88, 4TNV84T, On tlre top of the locker arm On the top of the locker arm On the exhaust side of the locker
4TNV88-2, 4TNV88.B, cover (cooling fan end) cover (fiywheel end) arm cover (near the flywheel)
4TNV88-U, 4TNV84T-Z Figure 5 left, (4) Figure 5left, (1) Figure 5left, (1)
4TNV94L, 4TNV98, 4TNV98T, On the top of the locker arm On the top of the locker arm On the top of the locker arm
4TNV1 06, 4TNV1 06T, 4TNV98.Z, cover (flywheel end) cover (center) Figure 5 cover (fan end)
4TNV98-E, 4TNV98T-Z Figure 5 right, (4) right, (1) Figure 5 right, (3)

reffiffieffi rNV operation Manuat 29

PRODUCT OVERVIEW

Engine NamePlate (TYPical) Emission eontrol Labels

Since emission control regulations are being issued
on a global basis, it is necessary to identify which
MODEI- regulations a particular engine complies with. We
have listed several different types of labels you
might find on your engine.

DISPLACEMENT. EPA/CARB Labels (TYPical)

ENGINE NO.
g EPA

EMISSION{ CONTROL INFORMATION

Yg,NffiAN GO", LT{3. THIS ENGINE COMPLIES WITH U.S, EPA HEGULATIONS FOR f--] MY

NONROAD AND STATIONARY DIESEL ENGINES.

MADE IN JAPAN ULTRA LOW SULFUH FUEL ONLY Plt/ :0.309 / kWh
043 921 - ! 0X0 0

eNcrrr uoneL : [- -- --l r. c. s.: f..- :-..

EPA/ARB Emisslon Control REFER TO OWNEH'S MANUAL FOH |\,{AINTENANCE SPECIFICATIONS AND

Regulations - USA OnlY

YANMAR TNV engines meet Environmental Y#lNNr#.fr. ro**o* rr.,n*"'
Protection Agency (EPA) (U. S. Federal) emission
controi standards as well as the California Air
Resources Board (ARB, California) regulations'
E EPA and CARB
Only engines that conform to ARB regulations can
be sold in the State of California. EMISSION CONTHOL INFORMATION
COMPLIES WITH U. S, EPA AND CALIFORNIA REGULATIONS
Refer lo EPNARB lnstallation Requirements USA rCg f .-] I\,1. Y. NONROAD AND STATIONAHY / OFF.ROAD DIESEL ENGINES

Only on page 77 and Required EPNARB ULTRA LOW SULFUR FUEL ONLY

Maintenance USA Anly on page 76 in the Periodic

Maintenance section of this manual. Also refer to
e.C S. : f--l
the YANMAR CO., LTD. Emission ControlSystem REFER TO OWNEB'S IilANUAL FOR MAINTENANCE SPECIFICATIONS AND

Warranty - USA Only on Page 5. ADJUSTIlIENTS.

Y#,N gfr ArR" vAHMAn,o.,rr["'

30 rNV operation Manual Weffiffi€ffi

 PRODIJET OVERVIEW

The 97l68/Ee Directive eertified

Engines I MPORTANT ENGINE INFORMATION
THIS ENG|NE CONFORMS TO 97/68/EC DIHECTIVE
The enEines described in this manual have been ENSINE FATVILY : L______
certified by the 97l68lEC Directive. ENGINE MODEL : [_---_-_---_-]
APPROVAL NUMBER : f .-----
To identify the engines that meet this certification,
he 97l68lEC emission control label is affixed on VANffiAfr G{s.,LTE,,
the engines. (s7168/EC)

Engine Family
The EPA/ARB labels and the 97l68lEC label all have an Engine Familyfield.
The following is an explanation of the Engine Family designation:

9 YDX L 1.33 M 3 N
L-rrirethod of air aspiration
I
I Nr*ber of cylinders
Engine speed specifications

isplacement (L)

-roadioff-road engine

YANMAR diesel

Model year

9: 2009

A: 2010

B: 20'11

C:2012
D:2013
E:2014
F:2015

ffi#ffi&ffi rNV operation Manuar 31

 PRODUET OVERVEEW

Components Functions
The mechanical fuel pump is a diaphragm-type of pump and is installed on the fuel

ffi |1";!uni"'tt'"' injection pump body. The mechanical fuel pump is driven by a cam on the camshaft of
the fuel injection pump. An electric fuel pump is available as an option. The mechanical
fuel pump is not installed on the fuel injection pump if the electric fuel pump option is
installed.
Side and top filler port You can fill the crankcase with engine oil frorn either the side or top filler port
(engine oil) depending upon which one is most convenient.
Starter motor The siarter motor is powered by the battery. When you turn ihe key switch in the
operator's console to the START position, the stader motor engages with the ring gear
installed on the flywheel and starts the flywheel in motion.

Hm Hj[","ifii::i"
EUEUJS 3TNV84T, The turbocharger pressurizes the air coming into the engine. lt is driven by a turbine that
4TNV84T, is energized by exhaust gases.
4Tt'lv98T,
4TNV1 06T)

Bf.#B#ffiffiffi niv operation Manuar JJ

PRODUCT OVEHVIEW

FUNCTION OF COOLING SYSTEM COMPONENTS

Components Functions
Cooling system 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 systern components are reqwired for proper
engine operation. Since some of the components are application
specific, they must be carefully selected by an applieation engineer.
The apptication specific items are not part of the basic engine packaEe
as shipped from the YANMAR tactory.
. Engine cooling fan The engine cooling fan is driven by a V-belt which is powered by the
crankshaft V-pulley. The purpose of the engine cooling fan is to circulate air
through the radiatoi'.
. Engine coolant pump The engine coolant pump circulates the engine coolani through the cylinder
block and cylinder head and returns the engine coolant to the radiator.
. 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 the radiator. As the engine cooling fan circulates air through
the radiator, the heat is transferred to the air.
. Radiator cap The radiator cap controls the cooling sysiem pressure. The cooling system
is pressurized to raise ihe boiling point cf 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 vaive in
the radiator cap opens and the excess engine coolant flows into the reserve
iank. As the engine coolant temperature is reduced, the system pressure
and volume is reduced and the vacuum valve in ihe radiator cap opens
allowing engine coolant to flow from the reserve tanx back into the radiator.
. Reserve tank The reserve tank contains ihe overflow of engine coolant from the radiator.
if you need to add engine coolant to the system, add it to the reserve tank,
not the radiator.
o Thermostat A thermosiat is placed in the cooling system to prevent engine coolant irom
circulating into ihe radiator until the engine coolant temperature reaches a
preset temperature. When the engine is cold, no engine coolant flows
ihrough the radiator. Once the engine reaches its operating temperature the
ihermostat opens and allows 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.

34 rNV operation Manuar W##ffiffiffi

 PRGDUCT GVEHVIHYd

ELECTffiGruEE CGruTHOL SYSTEffi

4TN V84T-2, 4Tf,,i V98- E, 4TNVg8-2, 4T'Fi Vg gT-Z

AwaarutruG
" Never use the E-ECU for other purposes than Shut down the engine if the fault indicator comes
intended or in other ways than specified by on.
YANMAR. Doing so could result in the Continuing running the engine with the fault
violation of ernission control regulatlons and indicator being on may result in a serious
will void tlre product warranty. malfunction of or damage to the engine, and will
o Be sure to use the E-ECU !n coniul'rction wlth void the engine warranty.
the engines witose rnodels or serial nurnbers
are specified by YANft/iAfi.
Other E-ECtJ/engine combEnations thasr
specified wi!l void the enEine warranty. Do not energize the starter for a period of longer
than 1 5 seconds.
. Replacing the fuel iniection pump irBvolves
rewriting the fuel injection data in the E-ECL. Take a pause of at least 30 seconds between
Be sure to contact youlr local YAil{MAf; dealer energization of the starter.
before replac!ng the fuel in5ectioi'a puncp. Otherwise the starter could suffer damage.
Failure to rewrite the fue! injection data before
replacing the fuel injection pusrxp will void the
engine warranty.
. ReplacinE the E-ECU invoEryes raigrating ti:e
. High-pressure washing not recommended..
fuel injection data to the exlsting E-ECU to the ' Avoid using hiEh-pressure washing for elecironic
new unit. or electric devices installed in, on or around the
Be sure to contact your loeaE YANMAfi dealen engine, including the E-ECU, relays and harness
before replaeing the E-ECU. couplers.
Failune to rnigrate the fuel inlection data
Otheryrise such devices may suffe;' ,.nalfunction
before replaclng tEre E'ECU will vold the
due to water ingress into them.
ea:gine warranty.
. lmproper !.,!se or misuse of the E-ECU may
result in death or serious irrjury due to an
ahrupt and unexpected iRerease ira engine
speed.

Yffitrffiffiffi rNV operation Manuar .i5

PRGDUET OVERVIEW

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 rnalfunction 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,
resultrng in malfunction of the E-ECU'
. Do not use ihe E-ECU that has ever suffered
drop impact.

Always check the battery for proper charge.

Otherwise the electronically controlied engines may
fail to start.

JO
rNV operation Manr-ral Wffiffiffi#ffi
 PRODUCT O\IERV!EW
Model 4TNV84T-2, 4TNV98-E, 4fNVgB-Z and . Engine speed control schemes
4TNV98T-Z engines con''ie wiih the Exhaust Gas Droop control/Low-idling speed up/Auto
Recirculation (EGR) system to conform to the deceleration/High-idling speed down/Black
engine emission regulations (EPA 2008 rules). smoke suppression
The EGR system and an electronic governor
(Eco-governor) constitute an eiectronic engine
. Starting aid
Auto preheating/After heating
control system.

The electronic engine control system regulates the

. Engine failure detection
exhaust gas recirculation flow rate and the fuel . CAN communication with the control system of
injection volume depending on the engine load and the driven machine
speed signals from the engine controller (E-ECU),
so that the exhaust gas is kept clean according to The above features are detailed in the table on the
the emission control regulations. Figure 6 next pages.
illustrates the electronic engine control system.
Consult the operation manual for the driven
Features of the electi"onic engine control system machine for applicability of the features that
include: depends on the machine.

Eco-governor
Fuel injection
?rTp fl
Actuator

Stop switch
{t*-**.-*-

'L--*ffi
l
Operatols console
iJ
i----*-*-*"€..@
Starler
;
Accelerator sensor

Figure 6

W$ffiffiffiffi rNV operarion Manuar 37

-

PRODUCT OVERVIEW
Main Electronie contro! components and Features
4TNV84T-2, 4TI$V98.E, 4TNV 98-z., 4TN\I98T'Z

tuel iniection pump depending on the

Engine controller (E-ECU) @e the accelerator:"l:ot' lhyt t:S:l1tl1S".
.pl"J signal from
ih" "or*and
speed and power' The engine controller also regulates the
"ngin" and power'
;p";i.g of the EGR valve depending on the engine speed
following components/control
It serves as ihe master station for the

C*tbt. the engine .pu"d rack actuator' etc'' and is directly

Electronic governor (Eco-governor) "i injection
""ntot,
pump in order to regulate the rack
connecteO to the fuel
po"ition of the fuel in.iection pump depending on the signals
communicated with the E-ECU.
solenoid valve that
ts of singt" plunger type and equipped with a CSD
Fuel injection pump (for Eco-governor) quantity to
allows tie fuel iryection timing to advance and the injection
performance o{ the engine'
increase, thereby improving tfre cold start
on the
controt. tr," exhaust gas recirculation flow rate depending
from the E-ECU' lt is installed on the top o{
engine speediload signals

Untit<e mecfranical governors, the Eco-governor

has no governor lever'
to provide the
The accelerator sensor serves as the governor lever
.p"J"o**und signal (voltage signal) to the E-ECU for engine soeed
machine.
cfntrot. lt is installei in the operator cabin of the driven
engines for e.g' generator use do not require
Constant speed
shifted via a
acceleratoi sensors because the engine speed can be
switch on the oPerator's console
CAN rnication capability is available as an option'
"o*t lf a fault occurs in the E-ECU or
Fault indicator
ffionsole. t"
f"o-gou*rnor, the fault indicator flashes alerting the operator 3 l'Yl]
pattern vary depending on
The iumber o{ flashes anclior the flashing
the type or source of the fault, enabling quick-fix'

Ail"*t th" to troubleshoot the cause oi a problem based on

Engine diagnosis tool "perator regarding the problem occurring in the E-ECU or
detailed information
i"o-gou"rnot. This tool can also be used for data maintenance tasks
Chart on
incluiing programming and mapping' See Troubleshooting
page'104.

Engine coolant temperature sensor

nLfo*.tt","CsDandERGtobecontrolledinenginecold-start

Wh* th" l*y switch is turned to the ON position, the glow plugslair
Glow plugs
heater arelis energized for up to 15 seconds (glow plugs) or up to 23
Air heater on the
seconds (air heatJr). The duration of energization depends
indicator is on during
engine coolani temperature. The HEAT
to the
enlrgization. When the indicator goes out, turn the key switch
START position to start the engine.

38
rltv cp",ation Manual W$trffi€ffi
 PROEUCT OVERVIEW
ComponenUfeature Description
After heaier Optional ln extreme cold start conditions, the after heater is energized for up to
80 seconds or untll 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
(ra1ed) load in steady state operation. The same percentage droop is
maintained even when the-load increases at any no-load speed.
lsochronous control Standard with CL series Offers a constant engine speed from no load to full load. The engine
Optional with VM series speed does not decrease even when the load increases at any no-load
speed.
Low-idling speed up lncreases the low-idling speed to up to 1000 ,;n't (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, ihus reducing the warm-rlp time.
High-idling speed down Optional Decreases the high-idling speed depending on the engine coolant
temperature. When the coolant temperature falls to a predetermined
value, this feature returns the engine speed to the normal high idle
setting, thus rninimizing ihe emission of white smoke at low
temperatures.
Auto deceleration Optional Brings the running engine in low idle mode automatically vrrhen the
acceleraior 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.

HsBtrffi€ffi rNV operaiion Manuar 39

PRODUET OVERVIEW

GAUGES AND INDICATORS

the unit and a series of gauges and
The operator,s console provides you with the means to start and stop
is a required engine component'
indicators thai inform you about t-he current status of the engine. This
an application
sin." t1.," operator,s ctnsole is application specific, it must be carefully selected byfactory'
the YANMAR
engineer. lt is not part of the basicengine package as shipped from

such as the operator's console, are

The illustrations and descriptions of optional equipment in this manual,
by the optional equipment
for a typical engine installaiion. Refer to the documentation supplied
manufacturer for specific operation and maintenance instructions'

Gauges
consoles may not have
The following gauges are located on a typical operator's console. Some operator's
the gauges described here or may have different gauges'

EE Tachometer
The iachometer display shows the engine speed in
revolutions per minute (RPM)'

El Engine coolant temPerature

The engine coolant temperature display shows the
temperature of the engine coolant'
6%
EE EnEine oiE Pressure
The engine oil pressure display shows the pressure
of the engine oil. Figure 7

B Hourmeter
The hour meter display shows the total number of
hours the engine has run. This is useful for , \4,
planning lhe Periodic Maintenance Procedures on
page 80.
a/@
EE ,:- .zz-\.
.z.;z_s\. -^_E-
///1.:i',^:,,,N ///*,"f t,jN
(((\*J)))
-Y
((((\'rrir
VV
\\\\o )-ozl// \\\\e T ):9///

*ot-ffi
7--K
16(/
=8
o@\_-/.). @

(000 0 024401

Figure I

40
rNV operation Manuar }flffiffiffiffiffi
 PRODUET OVEHVIEW

lndicators
The following indicators are located on a typical operator's console.

&! HEAT indicator

(AA'
The pre-heat function is automatically activated
when the key switch is turned to the ON position.
The indicator flashes for several seconds (4 sec.
for lDl models with glotn plugs, 15 sec. for Dl
models with glow plugs or air heater) and when it
goes out you can turn the key switch to START.
VV, (rc#'r)l

@@
Some electronically controlled engines have the
optional capability of controlling the glow plug/air
heater energization time via the key switch. For
details, consult the operation manual for the driven
machine.

Ef HEAT indicator
Note that on this type of panel you must turn the
key to the HEAT position E to activate the inlet air
heater or glow plugs. The indicator will flash for
several seconds (4 sec. for lDl models with glow
plugs, 15 sec. for Dl models with glow plugs or air
heateQ when you turn the key to HEAT and when it Figure I
goes out, you can turn the key switch to START.

El Battery charge
This indicator will cofire on if there is a problem in
the charging system. This indicator does not
indicate if the baitery is discharged. See
Troubleshooting Chart on page 104. )@
fll Engine o!! pressune
This indicator will come on if the engine oil pressure
is below or exceeds normal limits. See
Troubleshaoting Chart on page 104.

EE Engine coolant temperature

FiEwre 10
This indicator will come on if the engine coolant
temperature exceeds normal limits. See
Troubleshooting Chart on page 104.

&E Aux!gEaEy
Used for special applications.

W#trffi&ffi rNV operation Manuar 41

PRODUCT OVERVEEW

GAUGES AND ITSDIEATGffiS GF ELEETffiGNEC GOT*TROL SYSTEtrE

EE Fault (optiona!)
4TNV84T-2, 4TNV98-8, 4TNV98.Z,
This indicator will flash if a fauit occurs in the
4TNV98T-Z
E-ECU or Eco-governor. The number of flashes
and/or the flashing pattern vary depending on the
Gauges type or source of the fault. See Troubleshoating
Chart on page 104.
The following gauges are located on a typical
operator's console of the elecironically controlled Auxillary
EE
engines. Some operator's consoles may not have
the gauges described here or may have different Reserved as an optionalfault indicator.
gauges.
E3 r{EAr
This indicator will come on when the key switch is
turned to the HEAT position E and stay on as long
The illustrations and descriptions of optional as the glow plurgs (of model 3TN84T-Z only) or air
equipment in this manual, such as the operator's heater arelis energized (15 sec. for models with
console, are for a typical engine installation' Refer glow plugs or air heater) during engine cold star1.
to the documentation supplied by the optional When the indicator goes out, you can turn the key
equipmeni manufacturer for specific operation and switch to START.
mai ntenance instructions.
Turning the optional key switch EE to Oru aliows
you to energize the glow plugs for ilp to 15 sec. or
the air heater up to 23 sec. depending on the
lndicators engine coolant temPerature.
The following indicators are located on a typical
When an optional after heater is installed, it is
operator's console.
energized for up to 80 sec. after the engine has
See the Gauges and lndicators section for started, during which, however, the indicator is not
description of indicators that are not described on.
below.
Gthers (optional)
O'iher opiionai inciicaioi's incluciing those for
indicating the air cleaner is clogged or the water
separator is filled with water can also be installed
on the console. See the operation manual for the
driven machine for details.
Machine events including alarms and faults are all
stored in memory of ihe E-ECU and can be loaded
into the service tool.

Optional key switch: Turning it

to ON energizes the glow Plugs
or air heater automaticallY.

Figwre 11
Flgure 11 Typical Operator's Console

42 rNV operation Manual Y&#ffi3ffiffi

 PROD!.JCT OVEHVIEW

CONTROLS
Key Switeh
The key sr.vitch for the operator's console illusirated in Figure 12 has four positions - OFF, ON, START,
and HEAT.

E OFF (key straight up and down)

When you turn the key to this position the engine
shuts down. Electric current to the gauges and
indicators is shut off. You can insert and remove
the key in this Position.

goN
This is the position the key will be in when the
engine is running. When the engine is not running,
use this position to energize the gauges, indicators,
electric fuel pump and auxiliary devices,

G START
Turn the key to this position to start the engine. As
KC!!!02 140 1
soon as the engine starts, release the key and it will
automatically return to the ON position. Some key Figure 12
switches may be equipped with a feature that
prevents you from turning the key to the START
position while the engine is running. When
operating a key switch with this feature, you cannot For maximum engine life, YANMAR recommends
turn the key to the START position without first that when shutting the engine down, you allow the
returning the key to the OFF position. engine to idle, without load, for five minutes. This
will allow the engine components that operate at
EE I.IEAT high temperatLrres, such as the turbocharger (if
You must turn the key to the HEAT position io equipped) and exhaust system, to cool slightly
activate the inlet air heater. The indicator wiil flash before the engine itself is shut down.
for several seconds when you turn the key to
HEAT. You can turn the key to START when the
indicator goes out.
Never hold the key in the START position for longer
than 15 seconds or the starter motor will overheat.

Wffiffiffi#ffi rNV operation Manuat 43

 =
PHODUCT OVERVIEW
The key switch for the operator's console illustrated in Figure 13 has three positions - OFF, ON and
START.

EE Off (key straight up and down)

When you turn the key to this position the engine

o@'
shuts down. Electric current to the gauges and
indicators is shut off. You can insert and remove
the key in this position.

E otl
This is the position the key will be in when the
engine is running. When the engine is not running,
use this position to energize the gauges, indicators,
electric fuel pump and auxiliary devices.

EI START
Turn the key to this position to start the engine. As
soon as the engine stafts, release the key and it will
automatically return to the ON position. Some key a
switches may be equipped with a feature that
prevents you from turning the key to the START
position while the engine is running. When
KC 00 0011A0
operating a key switch with this feature, you cannot
iurn the key to the START position without first Figure 13
returning the key to the OFF position.

For maximum engine life, YANMAR recommends

that when shutting the engine down, you allow the
engine to idle, without load, for five minutes. This
will allow the engine components that operate at
high temperatures, such as the turbocharger (if
equipped) and exhaust system, to cool slightly
before the engine itself is shut down.

Never hold the key in the START position for longer

than 15 seconds or the starter motor will overheat.

44 rNV operation Manuar ffitrffiJffiffi$