Documente Academic
Documente Profesional
Documente Cultură
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.
.
.
(for maintenance of performance and quality)
FM23056
JQA-0099
CONTENTS
1. Specifications and Performance .............................................................
1-1
2TNE68..............................................................................................................
1-2
3TNE68 .... .... ....................... ...................... .........................................................
1-3
3TNE74 ..............................................................................................................
1-4
3TNE78A .. ................................. ........ ............ .......................... ........ .......... ........
1-5
3TNE82A ...........................................................................................................
1-6
3TNE82 ..............................................................................................................
1-7
3TNE84..............................................................................................................
1-8
3TNE88 ..............................................................................................................
1-9
4TNE82..............................................................................................................
1-10 4TNE84..............................................................................................................
1-11
4TNE88..............................................................................................................
1-12 3TNE84T............................................................................................................
1-13 4TNE84T............................................................................................................
1-1
1-1
1-2
1-3
1-4
1-5
1-6
1-7
1-8
1-9
1-10
1-11
1-12
1-13
2-1
2-1
2-2
3-1
3-1
3-1
3-3
4. Troubleshooting ............................................................................................................
4-1
Trouble causes and remedies............................................................................
4-2
Trouble diagnosis through measurement of compression pressure ..................
4-1
4-1
4-3
5-1
5-1
5-3
6-1
6-1
6-3
6-4
6-4
6-8
6-10
6-10
6-11
6-13
6-14
6-15
7-1
7-1
7-7
7-10
7-12
7-17
7-20
7-22
725
7-27
8.
8-1
8-1
8-6
9-1
91
9-2
92
9-3
9-4
9-5
9-5
9-5
9-6
9-6
10-1
10-1
10-1
11-1
11-1
11-2
11-3
11-5
12-1
121
122
12-3
12-7
129
131
13-1
13-2
13-3
13-7
13-9
141
141
14-1
14-3
14-5
14-6
14-6
151
15-1
15-6
15-7
A1
A2
o TN E 0
(A) (T) - 0 0
-,-
Model subdivision
Cylinder bore (mm)
Model code
Number of cylinders (3 or 4)
Application Category
Application code
Usage
Generator drive
Constant
1500/1800
CL
CH
VM
General use
VH
Variable
3000/3600
2000
3000
3000
3600
* 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 runin.
Model
Unit
Item
Application
Type
~
u::
C,)
i3
w
0.. Fuel injection pressure
en
9.12
(12.4)
10.0 8.68 9.19 9.64
(13.6) (11.8) (12.5) (13.1 )
2180'~ 2375'~ 2570'~ 2780+~ 2970'~ 3180+~ 3180'~ 3780+~ 3425'~ 3640~ 3850+~
5800
51500
23.0
141
deg
161
MPa
IlkQficm"
MPa
.Ikgf/cm')
11.8'g (120'g)
Liquid coolinglRadiator
0.6 (for engine only)
mm
mm
$95/$85
Starting system
*1 DimenSions L x W x H
mm
*1 Dry weight
kg
difference
Steady state
speed band
perform
ance
(full speed
0 range)
u.
a:
w
0..
L.a. press.
Recovery time
sec
Fluctuation of
revolution
rpm
Rated operation
Idling
5800
w Governing
rpm
Cooling system
Transient speed
a:
Governor
C,)
kW(HP)
Lubrication system
Lubricating oil capacity
Max/Effective
Recommended lubricating oil
Cooling water capacity
Cooling fan
No. of blade x dia.
z
<{
kW(HP)
VH
0.523
1-2
rpm
CH
mm
Displacement
Firing_order
Revolution speed
Continuous
rating
Output*
Max. rating
VM
Combustion system
No. of cylinders - Bore x Stroke
en
z
2TNE68
MPa
(kgf/cm')
1.6/0.6
2.311.0
ty~
Electrical
383.5 x 409 x 540
55/65
65
55/65
$12
510
512
$5
$7
520
530
59
I 58
57
56
56
530
0.250.05
(2.5O.5)
0.290.05
(3.00.5)
O.34O~r
(3.5O.5
,,0.06 (;>0.6)
1-1
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
Unit
Item
Application
Type
mm
Firing order
Revolution speed
Continuous
rating
Output*
Max. rating
Max. revolution speed at
no load
Min. revolution speed at
no load
Direction of rotation
Power take off
Ul Compression ratio
z
u Compression pressure
u:
5w
Il.
Ul
VM
Combustion svstem
3TNE68
CH
VH
rpm
2000 2200 2400 2600 2800 3000 3000 3600 3200 3400 3600
11.7 13.7
- (15.7)
kW(HP)
(18.4)
8.6
9.4 10.3 11.2 12.0 12.9 12.9 15.1 13.1 13.8 14.5
kW(HP)
(11.5) (12.6) (13.8) (15.0) (16.1) (17.3) (17.3) (20.2 (17.6) (18.5) (19.4)
2180": 2375 ": 2570": 2780 ": 2970": 3180": 3180'~ 3780'~ 3455'~ 3670 ": 3890 ":
rpm
$800
$800
$1500
Flywheel
23.0
141
deg
161
MPa
(kaf/cm')
MPa
(kaf/cm')
11.8+'~ (120+'g)
2.4/1.0
3.0/1.0
mm
mm
$105/$85
Starting system
*1 Dimensions Lx W x H
mm
*1 Dry weight
kg
difference
Steady state
sDeed band
Governor
Transient speed
w Governing
u performz
::;; ance
a: (full speed
0 range)
"a:
w
Il.
L.O. press.
Recovery time
sec
Fluctuation of
revolution
rpm
Rated operation
Idling
MPa
(kgf/em')
Electrical
473.5x401 x 496
70/81
81
70/81
$12
SID
s12
$5
$8
:>20
$30
$9
I $8 I
57
$6
$6
:>30
~.250.~~
2.5O.5
~:29O.~~
3.00.5
I
>0.06 (?0.6)-
~:340.~~
3.5O.5
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 runin.
Item
Application
Type
Combustion system
No. of cylinders - Bore x Stroke
Displacement
Firing order
Revolution speed
Continuous
rating
Output*
Max. rating
(/)
()
(3
UJ
()
rr
0:
VM
CH
VH
~
Vertical, 4cycle watercooled diesel engine
Special swirl precombustion chamber
3-74x78
mm
1.006
f!
1-3-2-1
2000 2200 2400 2600 2800 3000 3000 3600 3200 3400 3600
rpm
15.1 17.4
- (20.2)
kW(HP)
(23.3)
11.0 12.1 13.2 14.3 15.5 16.6 16.6 19.1 16.6 17.1 17.7
kW(HP)
(14.8) (16.2) (17.7) (19.2) (20.8) (22.3) (22.3) (25.6) (22.3) 22.9 (23.7)
2180+~ 2375'~ 2570'~ 2780": 2970'~ 3180": 3180'~ 3780": 3455~ 3670": 3890~
rpm
MPa
(kgf/cm')
MPa
kgf/cm')
3.311.4
2.411.0
f!
mm
Pusher type, 5 x
~310
Pusher type, 6 x
~110/<1>8S
mm
~335
~110/~97
kg
8SI102
100
8SI100
$12
$10
,;12
"S
,,8
,;20
,,30
Fluctuation of
revolution
rpm
Idling
f!
sec
Rated operation
11.8'g (120'g)
mm
161
3.43O.1 (351), at 250 rpm
Recovery time
L.O. press.
141
deg
~800
(full speed
range)
"-
~1500
~800
Governing
perform
UJ
3TNE74
difference
Steady state
speed band
..: ance
0:
Model
Unit
MPa
(kgf/cm')
,,9
,;7
,,8
,,6
,,6
,,30
~:2S0.~~
2.S+0.S
0.29O.05
. (3.0O.S)
0.34O.OS
(3.SO.S)
>0.06 (;'0.6)
1-3
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
Unit
item
Application
Type
Combustion system
No. of cylinders - Bore x Stroke
Displacement
Firing order
Revolution speed
Continuous
rating
Output*
Max. rating
Max. revolution speed at
no load
Min. revolution speed at
no load
Direction of rotation
Power take off
en
z
~
u::
()
Compression ratio
Fuel injection timing
(FID, b.T.D.C.)
Compression pressure
3TNE78A
CL
VM
CH
Vertical, 4-cycle water-cooled diesel engine
VH
mm
t!
,.
0
21.0
(28.2)
23.2 20.5 21.6 23.2
(31. t) (27.5) (29.0) (31.1)
..,
rpm
~1200
deg
~800
~1500
~800
121
141
161
241
MPa
(kgf/cm')
en
I(kgf/cm')
19.6+'g (200+'g )
w
a. Fuel injection pressure
Recommended diesel gas oil
Lubrication system
Lubricating oil capacity
Max/Effective
Recommended lubricating oil
Cooling system
Cooling water capac~y
Cooling fan
No. of blade x dia.
Crank V-pulley dia.!
Fan V-pulley dia.
Governor
Starting system
*1 Dimensions L x W x H
*1 Dry weight
w Governing
()
performance
::0
cr: (full speed
0 range)
c(
"cr:
w
a.
L.O. press.
MPa
t!
t!
mm
mm
~120/~90
Electrical
mm
553x489x565
kg
138
S10
S8
Steady state
speed band
,,5
S4
Recovery time
sec
,,5
Fluctuation of
revolution
rpm
S15
MPa
(kgf/cm')
1121128
Idling
~110/~110
Transient speed
difference
Rated operation
5.0/1.7
3.6/1.3
1-4
,,6
112/124
~10
~8
,,12
S5
S4
s8
,,6
,,5
~6
525
0.29O.05
(3.00.5)
124
~12
,,91 S8 1
>0.06 (?0.6)
S30
O.34O.OS
(3.SO.5)
1-5 3TNE82A
*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
Output*
mm
1.330
1-3-2-1
Firino order
Revolution speed
rpm
1500
1800
2000
2200
2400
2600
2800
3000
Continuous
rating
kW(HP)
9.9
(13.3)
Max. rating
kW(HP)
11.0
(14.8)
12.0
(16.1)
13.2
(17.7)
14.6
(19.6)
16.0
(21.5)
17.5
(23.5)
19.0
(25.5)
20.5
(27.5)
21.9
(29.4)
()
VM
Vertical, 4-cycle water-cooled diesel engine
Displacement
CL
Combustion system
No. of cylinders - Bore x Stroke
C/J
3TNE82A
Unit
Item
Application
Type
Compression pressure
rpm
';800
18.0
Flywheel
deg
101
121
141
161
t5
MPa
(kgf/cm')
C/J
MPa
IlkQf/cm')
19.6+'g (200+'g)
u:
w
0- Fuel injection pressure
Recommended diesel gas oil
Lubrication system
Lubricating oil capacity
Max/Effective
Recommended lubricating oil
Cooling system
Cooling water capacity
Cooling fan
No. of blade x dia.
Crank V-pulley dia.!
Fan V-pulley dia.
Governor
::;;
cr:
"cr:
3.6/1.3
5.0/1.7
API grade CC class or higher
Liquid cooling/Radiator
mm
mm
<1>110/<1>110
Electrical
*1 Dimensions L x W x H
mm
*1 Dry weight
kg
138
1121128
w Governing
z
<{
Starting system
Transient speed
()
perform-
ance
(full speed
range)
0-
l.0. press.
difference
,;10
,;8
Steady state
speed band
,;5
,;4
';12
,;9
,;8
,;7
Recovery time
sec
,;5
,;6
Fluctuation of
revolution
rpm
';15
';25
Rated operation
Idling
0.25 0.05
MPa
(2.5 +0.5)
(kgf/cm')
,;6
0.29O.05
(3.00.5)
>0.06 (>0.6)
1-5
1-6 3TNE82
Item
Application
TYl'.e
Combustion system
No. of cylinders - Bore x Stroke
Displacement
Firing order
Revolution speed
Continuous
rating
Output*
Max. rating
til
~u::
w
<>. Fuel injection pressure
til
Model
Unit
mm
rpm
1500
10.5
kW(HP)
(14.1
11.6
kW(HP)
(15.6
<>.
L.a. press.
~1200
deg
~800
25.6 26.9
(34.3) (36.1)
0
~1500
~800
121
MPa
(k9t/cm')
MPa
141
161
241
~kgf/cm')
6.9/2.1
mm
mm
<1>120/<1>90
<1>110/<1>110
161
138/155
~10
$5
$4
149
$12
$8
$7
sec
~5
~6
Fluctuation of
revolution
rpm
~15
$25
Rated operation
3400 3800
Recovery time
Idling
0.29O.05
MPa
(3.00.5)
(kgf/cm')
1-6
VH
rpm
kg
f2
VM
I CH
Vertical, 4-cycle watercooled diesel engine
Direct injection system
3-82x90
1.425
1-3-2-1
2000 2200 2400 2600 2800 3000 3000 3800 3200
21.0 24.4
- (28.2)
(32.7)
15.5 16.9 18.4 19.9 21.3 23.2 23.2 26.9 24.4
(20.8) (22.7) 24.7) (26.7) (28.6) (31.1\ (31.1 ) (36.1) (32.7)
2160+~ 2375+~ 2570 2780~ 2970~ 3180'~ 3150~ 3745~ 3455 3670 3890~
*1 Dry weight
a:
1800
12.7
(17.0)
14.0
(18.8)
1570+~ 1870
mm
w Governing
()
Z perform
::; ance
a: (full speed
range)
CL
*1 Dimensions L x W x H
Transient speed
difference
Steady state
speed band
3TNE82
$6
1381149
~10
$12
~5
$4
$5
~6
~30
~:34O.~~
3.5O.5
>0.06j>0.6L
1-7 3TNE84
*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 runin.
Item
Application
Type
Combustion system
No. of cylinders - Bore x Stroke
Displacement
Firing order
Revolution s eed
Continuous
rating
Output*
Max. rating
en
z
()
u:
Model
Unit
3TNE84
CL
mm
e
rpm
1500
11.3
kW(HP)
(15.2)
12.4
kW(HP)
(16.6)
1800
13.5
(18.1)
14.8
(19.8)
1600~ 1900
.~
VM
I CH
Vertical, 4-cycle water-cooled diesel engine
Direct injection system
3-84x90
1.496
1-3-2-1
2000 2200 2400 2600 2800 3000 3000 3600 3200
22.4 26.1 - - (30.0)
(35.0)
16.4 18.1 19.7 21.3 23.0 24.6 24.6 28.7 25.6
(22.0) (24.3) (26.4) (28.6) (30.8) (33.0) (33.0 (38.5) (34.3\
VH
3400 3600
.~
27.0 28.3
(36.2) (38.0)
3455~ 3670
$1200
$1500
$800
101
121
MPa
141
161
241
en
MPa
(kgf/cm'
19.6+': (200+': )
e
e
mm
mm
<1>120/<1>90
*1 Dry weight
kg
w Governing
()
performance
a: (full speed
0 range)
z
..:
:;
LL
a:
w
a.
L.a. press.
6.9/2.1
mm
Transient speed
4.7/1.8
*1 Dimensions L x W x H
difference
Steady state
speed band
<1>110/<1>110
161
138/155
$10
$8
$5
54
S9
S8
sec
,;5
,;6
Fluctuation of
revolution
rpm
,;15
,;25
Rated operation
MPa
0.29O.05
(3.00.5)
(kgf/cm')
149
$12
Recovery time
Idling
deg
$800
I(kgf/cm'!.
.., 3870~
rpm
(3
w
a. Fuel injection pressure
$7
0.34O.05
(3.5O.5)
>0.06 r"O.6)
1381149
S10
S8
S12
,;5
,;4
,;8
,;5
,;6
,;30
O.39O.O5
(4.00.5)
1-7
1-8 3TNE88
*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.
Item
Application
Twe
Combustion svstem
No. of cylinders - Bore x Stroke
Model
Unit
rpm
1500
VM
Vertical, 4-cycle water-cooled diesel enqine
Direct injection system
3-88x90
1.642
1-3-2-1
1800
2000
2200
2400
2600
2800
CL
Continuous
rating
kW(HP)
12.3
(16.5)
14.8
(19.8)
Max. rating
kW(HP)
13.5
(18.1)
(21.9
16'~1
18.0
(24.1 )
19.9
(26.7)
mm
DisDiacement
.irir1.9 order
Revolution speed
Output*
3TNE88
rpm
23.5
(31.5)
(33.8
21.6
(29.0)
~1200
Flvwheel
18.0
deg
u:
Compression pressure
UJ
U
"en
::<
a:
0
u.
121
MPa
(kOi/cm')
MPa
4.7/1.8
6.9/2.1
mm
Electrical
Governing
performance
(full speed
range)
UJ
"-
L.O. press.
<1>120/$90
<1>110/<1>110
kg
difference
Steady state
speed band
161
138/155
~10
$8
$5
$4
$12
$9
$8
Recovery time
sec
$5
$6
Fluctuation of
revolution
rpm
$15
$25
Rated operation
Idling
161
I(kOi/cm')
mm
27.1
(36.3)
Starting system
a:
0.29 0.05
MPa
(3.0 0.5)
(kgf/cm')
1-8
141
Governor
Transient speed
z<{
101
mm
*1 Dry weight
()
*1 Dimensions L x W x H
UJ
25.~)
~800
~
()
1600+'g 1900 +'00 2175+500 2375 +'g 2600+'g 2800+'g 3000+'g 3225+'g
en
z
3000
0.34O.05
(3.5O.5)
>0.06 (>0.6)
$7
1-9 4TNE82
*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
Unit
Item
Application
Type
Combustion system
No. of cylinders - Bore x Stroke
Displacement
Firing order
Continuous
rating
en
z
Compression ratio
u:
ti
w
a.
en
CL
1.901
1-3-4-2-1
rpm
1500
14.3
kW(HP)
(19.2)
15.7
kW(HP)
(21.1)
$1200
..,
$1500
5800
aaw":
Flywheel
18.0
101
deg
141
121
241
161
MPa
I (kgf/cm')
MPa
(kgf/cm')
19.6"g (200"g )
t!
mm
mm
Governor
Starting system
*1 Dimensions L x W x H
mm
*1 Dry weight
kg
5800
t!
7.9/2.5
5.8/2.3
~120/~90
~110/~110
658 x 498.5
x618
160/170
170
160/170
184
Transient speed
difference
510
58
u periormz
..: ance
::e (full speed
a:
Steady state
speed band
55
54
revolution
Recovery time
rpm
w Governing
32.7
(43.9)
1575+~ 1870'~ 2160'~ 237S.sg 2570~ 2780~ 2970+~ 3180+~ 3150'~ 374S.sg 3455~ 3670
VH
mm
Cooling fan
12a:
VM
CH
Vertical, 4-cycle water-cooled diesel engine
Max. rating
t!
Revolution seed
Output*
4TNE82
512
58
$7
sec
,;5
56
rpm
$15
,;25
56
510
58
512
55
$4
58
56
55
range)
Fluctuation of
a.
L.a.
press.
Rated operation
Idling
0.29O.05
MPa
(3.00.5)
(kgf/cm')
530
0.34O.05
(3.5O.5)
>0.06 (>0.6)
1-9
1-10. 4TNE84
* 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.
Item
Application
Type
Combustion system
No. of cylinders - Bore x Stroke
Displacement
Firing order
Revolution speed
Continuous
rating
Output*
Max. rating
Max. revolution speed at
no load
Min. revolution speed at
no load
Direction of rotation
Power take off
Compression ratio
Fuel injection timing
(FID, b.T.D.C.)
Compression pressure
C/l
~
0
u::
Q
w
0.. Fuel injection pressure
C/l
w Governing
perform::;: ance
a: (full speed
0 range)
<C
u..
a:
w
0..
L.O. press.
Model
Unit
CL
mm
e
rpm
1500
14.9
kW(HP)
(200)
16.4
kW(HP)
(22.0)
1800
17.7
(23.7)
19.5
(26.1)
VM
CH
I
Vertical, 4-cycle water-cooled diesel engine
Direct injection system
4-84x90
1.995
1-3-4-2-1
2000 2200 2400 2600 2800 3000 3000 3600 3200
29.9 34.7
(40.1) (46.5)
21.9 24.1 26.3 28.5 30.7 32.9 32.9 38.2 33.9
(29.4) (32.3) (35.3) (38.2) 41.2 (44.1) (44.1) (51.2) (45.5)
,.
,,1200
deg
101
MPa
(kgf/Cm'1
MPa
kgf/cm')
121
35.8 38.2
(48.0) (51.2)
,,1500
,,800
141
161
241
19.6+'g (200+'g)
5.8/2.3
7.9/2.5
mm
mm
<1>120/<1>90
mm
<1>"0/<1>"0
184
SIO
S8
$5
,,4
160/170
,,9
sa
$5
$6
Fluctuation of
revolution
rpm
$15
$25
0.29O.05
MPa
(3.00.5)
(kgf/cm')
160/170
170
S12
sec
Idling
3210
3400 3600
,,800
Recovery time
Rated operation
VH
rpm
kg
Transient speed
difference
Steady state
speed band
4TNE84
$7
$10
$8
$12
$5
$4
$8
,,6
$5
$30
(:34O.05
3.5O.5)
>0.06 (>0.6)
1-11. 4TNE88
* output conditions: Intake back pressure ~ 250 mmAq, Exhausl back pressure ~ 550 mmAq,
other conditions complying with JIS D 1005-1986. After minimum 30 hours runin.
Item
flpplication
Tvoe
Combustion system
No. 01 cvlinders - Bore x Stroke
Displacement
Firin" order
Revolution speed
Continuous
ratina
Output*
Max. rating
Max. revolution speed at
no load
Min. revolution speed at
no load
Direction 01 rotation
Power take off
C/l Compression ratio
z
u:
Fuel injection;.~iming
(FlO, b.T.D.C.
Compression pressure
w
a.
~
()
(3
C/l
w
z
Goveming
pertorm-
II:
(lull speed
range)
()
::;:
0
LL
ance
II:
w
a.
L.O. press.
Model
Unit
4TNE88
CL
VM
Vertical, 4-cvcle water-cooled diesel engine
Direct injection system
4-88x90
mm
2.189
f!
1-3-4-2-1
1500
1800
2000
2200
2400
2600
2800
3000
rpm
16.4
19.6
kW(HP)
(22.0)
(26.3)
18.0
21.6
24.1
26.5
31.3
33.7
28.8
36.0
kW(HP)
(32.3)
(35.5)
(24.1 )
(29.0)
(42.0)
(45.2)
(48.3)
(38.6)
1575+5~ 1870+sg 2180+5~ 2400+5~ 2590+5~ 2810+5~ 2995+~ 3210+5~
rpm
~1200
~800
deg
121
101
MPa
(kiii/cm')
MPa
,'kiii/cm')
141
19.6+1~ (200+1~)
5.812.3
f!
7.9/2.5
f!
mm
$110/$110
mm
kg
184
160 /170
difference
,,10
,,8
Steady state
speed band
,,5
,,4
';12
,,9
,;;a
Recovery time
sec
';5
';6
Fluctuation 01
revolution
rpm
,,15
,;25
Rated operation
Idling
161
mm
0.290.05
MPa
(3.0 i O.S)
(kgl/cm')
,;;7
~:34O.~~
3.5O.5
>0.06 (;,(l.6)
1-11
Intake back pressure ~ 250 mmAq, Exhaust back pressure ~ 550 mmAq,
other conditions complying with JIS D t 005-1986, After minimum 30 hour's run-in.
Item
Application
Type
Combustion system
No. of cylinders - Bore x Stroke
Displacement
Firing order
Revolution s eed
Continuous
rating
Output*
Max. rating
Max. revolution speed at
no load
Min. revolution speed at
no load
Direction of rotation
Power take off
en Compression ratio
z
0 Fuel injection timing
(FID, b.T.D.C.)
Compression
pressure
iI
U
w
"- Fuel injection pressure
en
performance
::;:
II: (full speed
0 range)
<C
u.
II:
"-
L.O. press.
Transient speed
difference
Steady state
speed band
3TNE84T
CL
mm
f!
rpm
1500
14.0
kW(HP)
(18.8)
15.8
kW(HP)
(21.2)
1800
16.6
(22.3)
18.8
(25.2)
VM
I CH
Vertical. 4-cycle water-cooled diesel engine
Direct inection system
3-84x90
1.496
1-3-2-1
2000 2200 2400 2600 2800 3000 3000 3600 3200
28.0 30.5
- - - (37.5)
(40.9)
21.0 22.8 25.0 26.9 29.1 30.9 30.9 34.2 32.0
(28.2) (30.6) (33.5) (36.1) (39.0) (41.4) (41.4) (45.9) (42.9)
rpm
1200+~
~800
deg
101
MPa
(kgf/cm'i
MPa
I(k!'lf/cm')
-
121
- - --
161
--
4.8/1.9
f!
mm
<1>110/<1>110
Mechanical centrifugal governor (All speed type)
Electrical
589x54.0x629
147/160
166
,;10
~8
~5
~4
~12
~9
~8
$5
~6
Fluctuation of
revolution
rpm
~15
~22
0.29O.05
MPa
(3.00.5)
(kgf/cm')
,;8
---
1-12
33.1 34.2
(44.4) (45.9
f!
mm
19.6+1g (200+'g )
mm
3400 3BOO
sec
Idling
+50
0
141
Recovery time
Rated operation
VH
kg
*1 Dry weight
w Governing
Model
Unit
---
0.34O.05(3.5O.5)
>0.06 (?0.6)
Intake back pressure 5 250 mmAq, Exhaust back pressure 5 550 mmAq,
other conditions complying with JIS D 1005-1986. After minimum 30 hour's run-in.
Model
AEPlication
Type
Continuous
rating
Output*
Max. rating
u:
Compression pressure
0
0
CL
Combustion system
No. of cylinders - Bore x Stroke
Displacement
Firingorder
Revolution speed
en
4TNE84T
Unit
Item
(3
w
0- Fuel injection pressure
en
mm
1.995
1-3-4-2-1
1500 1800 2000 2200 2400 2600 2600 3000 3000 3600 3200 3400 3600
rpm
37.1 40.6
19.1 24.3
- (49.8)
kW(HP)
(25.6) (32.6)
(54.7)
21.3 26.9 26.0 30.5 33.5 35.7 36.6 41.2 41..2 45.6 42.7 44.1 45.6
kW(HP)
(26.6) (36.1t (37.5) (40.9) (44.9) (47.9) (51.8) (55.3) (55.3) (61.2) (57.3) (59.1) (61.2)
1600+~ 1900
rpm
,.
0
,.
,50
+50
1200 0
Flywheel
- -
18.0
101
MPa
(kgf/cm')
MPa
{kgf/cm'\
121
141
161
19.6"~ (200"~ )
19.6"~ (200+1~ )
5.8/2.3
Liquid cooling/Radiator
mm
mm
- -
800 0
deg
$110/$110
$110/$90
Starting system
*1 Dimensions L x W x H
mm
674 x 498.5
x713
*1 Dry weight
kg
184
165/175
w Governing
Transient speed
difference
510
,,8
55
,;;4
512
perfonm-
Steady state
speed band
cr:
(full speed
Recovery time
sec
55
56
Fluctuation of
revolution
rpm
515
522
~
::; ance
0 range)
"cr:
w
0-
L.O. press.
Rated operation
Idling
*1.
VH
Governor
VM
CH
Vertical, 4cycle water-cooled diesel engine
Direct injection system
4-84x90
59
0.29O.05
MPa
(3.00.5)
(kgf/cm')
58
57
-O.34O.O5
(3.5+0.5)
;'0.06 (;'0.6)
1-13
Fuel injection
Cylinder head
Piston
Camshaft
Connecting rod
If
=
r-
Ur
~f-
r==
r--
~~
it
lIB
r--
2-1
Piston
Fuel
injection
pump
Camshaft
motor
Connecting rod
.LD
2-2
3.
1.
1.
2.
li
Sub-tank
Cylinder block
L-ff0+----1
L.O. cooler (opUon)
30
-20
J
-I.
I
10
20
3.
,
40
I
3-1
('C)
2.
-l
r -- I
L.O. cooler
(Option)
I
Pressure
regulating valve
Fuel injection
pump
LO. suction
pipe (strainer)
______
Oilpan _ _ _ _ _
--- ---- -- --- --- --- --- --- --- -- --- ----- --- --- --- - - --- --- --- --- --- -
~----1
~--~f~~=:---,:
I
r--.,-~I
~=;--il'
L.O. filter
(with bypass valve)
r-----I
Turbocharger
L----r~
(w/turbocharged
eng ine only)
I
I
I
I
I __ _
L
I
w/tubocharged
engine only
\
3-2
~~~
faces
Oil pan
~\~~~_~_~_==_~_~==~r~_~_~_~~_~_~_~_~=_==_=_~~if
1.
2.
to tank _ - - - -_ _....
Fuel filter
to t a n k - - - . - - - -....
-L---I
Airbleed pipe----,L
4. Troubleshoollng
4.
Troubleshooting
Carefully read Chapter 6, Measurement, Inspection and Adjustments, and Chapter 7, Measuring Procedures,
Service Data and Countermeasures. Familiarize yourself with Chapter 6 and Chapter 7, which practice is
extremely important for extending the service life of the engine.
The following table summarizes the symptoms and causes of general troubles. If any symptom of trouble is
found, a corrective action shall be taken before the said symptom develops into a serious accident.
'"','.".
Fails to start
Poar iii
15
engine
output
color
Sy mptom of trouble
Engine
starts but
"."."
vh
Exhaust
color
Ii
IDUring,~]
work:J.~ Iii
~ f-,st_op_sso_o_n-t---r-o"_t--.---I] ~ ~
g
~ .~ ~
Exhaust
'j; I--S,m_O..,.ke---l
""
~Ci'if~::J
13:
000
o
o
10 0
10
10
10
10
Corrective action
c5
&.ii
O:?..J::'O
o 0
Poor
,0
00
00
00
o
o
o
o
10
10
'6,6-2,)
~h~nt~r
7, 7-1-2,)
Correct or replace.
Replace the
(Refer to
no<kAi
v, "'fHCr
.,. 7-2:4-3,4,(5))
or
i'
7, 1-4-\,'))
(Refer to
7,7-4-(5) )
reassemble. (Reier to
, j
Mp~o",,,
and
8, o-Z-t I U) )
honing and use oversize parts, (Reier to Chapter 7, 7-2-3. & 7-4-(8) )
~epair
10
o
o
1010 0
o
o
o
o
o
o
gear backlash
o
o
intake
l:l
~[ ~ i i i I~
10
en
g. ,- I ~
ifJ
Q)
,5,
ill
Air
water
'*
;=
~vvli;,~
1)
18 ~:I~ t j~' i l ~ I; 3 ~ 1
'wi-z-..Jl:lQ)~-a:~~~ro~~~.cc
o~ ~~~g~
Cause
Lubricating oil
13,)
~ r~DirtY~'b_llo__
wer________________________~~~+-+-4-~04-~04-4--r-r-r-r-r-r-r-r-+-+-+-+-+~~O~~r-~~~C~lea~nth~e~b'"I~o,.e~r,______________________~
l!
o
~
:J
0
0
I-
E
~
!
00
"~ effect of
Cooling effect of radiator, insufficient
.0
10
10
belt IRef~)'
~ln~s~uffffi~ci~e~nt~,v~v,~.v"",,~~w:a~t~er~l~ev:e~I---------r-l-r-l-_t~r_tOr:r_t_II_t--I-t-II_t_jj_t_II_t_]j_t_Il_tro~-j--t-ico~-j~t-II~v~~~\~,~~~~~1~:r.~:3~;~I '.at" I
Cracked water jacket
en
(5
Poor thermostat
-"
'"
1~1e'
.~ ~~~--------------------------------t-~-+~~+-~-+--~+-~-+--t-+-~-+--r-t--r-t--r-t-~-+~~-r-+~--t-~-+--~~------~--~~--~--~~~--~--------1
()
4-1
4. TroubleShooting
Symptom of trouble
Insufficient Poor 0
engine !exhaust ~
Fails to start
il
output
calor E
1ij
Engine
starts but
stops soon
Exhaust
calor
During c
:J
work "0
-g
1;)
Cause
15
c
~>-
U)
Exhaust
smoke
'J:
Q>
C
0)
C
:J
0
g>
~c
a;
U)
U)
'"
...J
::;:
"S
0)
'"
0:
.l!!
;;::
-'"
1;l
(jj
-'"
.l!! -'" .<::
;;::
1;l
(jj
'c"
c
''""
:J
0
"0
U)
U)
.s; .Q
:J
.0
0
0
Q>
0)
.S
:
0)
g> c
:0
:J
e ::Jc'"
.21
I
f-
'~"
~
;:
.0
.Q
1;)
.<::
Air
intake
'6>
water
"0
0>
~ooling
Lubricating oil
Hunting
aE
:J
U)
c
0
0
Q)
.B .2
0
E Q)
;: '6>
c 2 >
0)
"
"
'"
''"~" e(;
'iii
U)
l'x3
a. w
c
0
li
E
U)
'0
0
0
.2
."'"
.0
"0
:J
U)
U)
'"
w
0
Q)
>-
.$
.2
is
[l>
*e
;:
.<::
:J
U)
U)
[l>
a.
x
:<
.J
;:
...J
.<::
0
:J
c
[l>
aE
T!!
'
gj
0>
~ 0 ,2~ "iii
Q>
:J
'"
U)
e
:J
Sl
I
~
.<::
::;: 0
:J
a.
0
"0
[l>
:J
Q)
U)
:J
E
Sl
1i)
:J
(J)
(5
0)
~
'c
Cleaning or replace
.0
:J
...J
0 0
0 0
Cleaning or replace.
>-
Cleaning or replace.
Q)
Inspect the fuel tank valve ccck, fuel filter, fuel piping, and fuel feed pump.
E
Sl
U)
(J)
:J
LL
0 0
~g
'" >U)
.<::
X(J)
.!.
~(I)
0 0
0
0
Cleaning
Cleaning
.'"
0)
0)
c
.;::
:
.2 E
~
Q>
Q)
U)
0-
. Repair or replace
Malfunction alternator
Repair or replace
Opencircuit of wires
Repair
UiOl
42
4. Troubleshooting
*;For the compression pressure measuring procedure. refer to chapter 6. 6-1. Measurement of
compression pressure.
Reduction in compression pressure of the cylinder is one of major causes of an increase in blowby gas (which causes contamination and increased consumption of lubricating oil, and other
trouble) as well as the engine starting failure.
The compression pressure is influenced by the
following factors;
1. Degree of clearance between the piston and
cylinder.
2. Degree of clearance around intake/exhaust
valve seats.
(1)
Causes and countermeasures to be taken when the compression pressure is less than
the limit value.
* Forthe compression pressure limit values, relerto Chapter6, 6-1 Measurementol compression pressure.
No.
Item
Cause
Countermeasures
Filter element of
air cleaner
Valve clearance
Excessive valve
clearance or no clearance
Valve timing
Intake/exhaust valve
Valve seat
Piston
Piston ring
Cylinder
Tool name
Valve guide
extraction tool
Illustration
I~ Dimension
Model
............
I,
I,
d,
d,
213TNE68
20
55
3TNE74
20
75
6.5
10
3TNE78N82A
20
75
6.5
10
3/4TNE82
3/4TNE84(T)
3/4TNE88
20
75
7.5
11
''
,.
\Y'
.'
Locally manufactured
2
(mm)
~Dimensjon
I,
I,
d,
d,
2/3TNE68
60
11
17
3TNE74
60
13
19
3TNE78N82A
12
60
13
19
Model
............
3/4TNE82
3/4TNE84(T)
3/4TNE88
15
65
14
20
"
,'
~
"".
~)1..J
.'
9-"
Locally manufactured
3
Connecting rod
bushing replacer
(mm)
~ Dimension
Model
............
I,
I,
d,
d,
213TNE68
22
62
3TNE74
20
80
.(l.3
20.(l.'
21.(l3
.(l.'
3TNE78N82A
25
85
23~:~
26~:~
3/4TNE82
3/4TNE84(T)
3/4TNE88
20
100
26:g:~
29 ~:~
22.(l3
.(l.'
23.(l3
.(l.,
, ,.
.'
''
.'
Locally manufactured
4
Model
All model
129100-92630
"-
e;."~
5-1
No.
Filter wrench
(Removal and
installation of L.O.
filter)
Camshaft bushing
tool
(Extraction of
camshaft bushing)
Illustration
'---, ,(B(mm)
I~ Dimension
Model
'---..
213TNE68
3TNE74
3TNE78A182A
3/4TNE82
3/4TNE84(T)
3/4TNE88
d,
d,
I,
I,
13
14
18
SO
SO
70
3S-O.s
45~:~
39 ~:~
43 -0.3
-o.s
48 -0.3
18
70
45~:~
48 -0.3
-o.s
-0.3
40 :g:~
L!'
"
~
-0."
0'
Locally manufactured
Flex-Hone
(for honing cylinder
liner)
*:
Model
213TNES8
3TNE74
3TNE78A182A
3/4TNE82
3/4TNE84(T)
3/4TNE88
Model
All model
95550-002476
( Idr=
~
"
Sold on market
~
5-2
.....,
Instrument name
Dial gauge
Test indicator
Magnetic stand
Micrometer
Cylinder gauge
Vernier callipers
Illustration
Purpose of use
Depth Micrometer
Square
~::::::!D!)::)===~
~~& i
;""""1111",'"
')
9
V-block
5-3
Instrument name
10
Torque wrench
Illustration
Purpose of use
Used for tightening bolts and
nuts to the specified torques.
~
II
~
11
Thickness gauge
12
Cap tester
13
14
Battery coolant
tester
Nozzle tester
i=
i0J
q.
c.L
~
~
15
Digital thermometer
l~~l~
proC~D
16
Contact type
~H
(0111111111111 [
I~ l
*
E
0
.t:
os
I-
Photoelectric type
Revolving body
~w{~~ ml
Reflecting tape
5-4
Instrument name
Purpose of use
16
High pressure
fuel pipe
clamping type
1I1ustration
High-pressure pipe
r~/=~.:
17
Circuit tester
18
Compression
gauge kit
5-5
*:
1. Measuring Procedure
(1) Warm up the engine. Remove the fuel
injection pipe and fuel injection valve from
the cylinder to be measured.
*:
Standard
Umit
Dispersion of compression
pressure among cylinders
(kgflcm2)
2TNE68
33 1
25
2-3
3TNE68
33 1
25
2-3
3TNE74
35 1
27
2-3
3TNE78A
32 1
25
2-3
3TNE82A
31 1
24
2-3
3TNE82
31 1
24
2-3
3TNE84
33 1
25
2-3
3TNE88
35 1
27
2-3
4TNE82
31 1
24
2-3
4TNE84
33 1
25
2-3
4TNE88
35 1
27
2-3
3TNE84T
30 1
24
2 -3
4TNE84T
30 1
24
2 -3
Model
(kgflcm')
6-1
:3~~\4,
40 ...
:i~~~t:~:-:J::::==J
:=:
. . . . .~
. . .'=
. . ~----1
35~:::
...
. .
~\
213TNE68
30 ................
''i~
-t''-
'
25" -
20
... .,.....
-_.-
. . . . . . . . . . . .1.
..... ! ........................,..... .
.. .. i
'
250
300
350
400
l3/4TNE88
40
~ 1::,::~~4;TNiE~8~4~~~~~~~~~~~~~
3TNI078A
a
'"5.:"
Ii
.:::::
351,\
30
.........,... .
t1~
i-
25 .....
.................. ;....
3/4TNE84T:
201,
200
...... ...............
~
250
-,
300
62
......................,... .
350
..........
J. . . .
... 1 ..
400
Normal
Abnormal
Lock nut
Valve clearance
*:
0.15 - 0.25
63
10-15mm
Adjuster
Crankshaft pulley
A1temator
*:
*:Chapter
For injection pressure of each engine,referto
1, "Specifications and Performance".
(3) If the measured injection pressure is
lower than the specified value, replace
the pressure adjusting shim with a thicker
one.
6-4
Nozzle tester
Injection nozzle
Type of pressure
adjusting shim
thickness (mm)
Indirect
injection
system
O. t, 0.2, 0.3,
0.4,0.5
Direct
injection
system
0.13,0.15,
0.18,0.4,
0.5,0.8
t-~"'".~
I-
Nozzle holder
I--
Nozzle spring
iJ-
0-
Nozzle valve
Nozzle
Nozzle body
e ~~-""'
Dowel pin--l1
I valve}-
Nozzle
r-J.-N.nzle body
6-5
----.
. ~\
..\
:.. .~,
( . OJ
~v
"
--- 150o--~
6-6
4.
Y DN -
0 S D YD1
TL
I,
\
No code:
D:
Size
pintle type
throttle type
: size P
: sizeS
Injection angle
YANMAR
/1_--.
Design code
Identification
number
,
(Direct Injection system)
Y DLL
A -
150 P 244JO
U[
I
TDeSign code
Size
: size P
: sizeS
Injection angle
Identification
number
6-7
[;;;;"---C,'iindler No.1
(2) When the crankshaft is turned in the specified direction, oil level rises at the tip of the
delivery valve spring holder. At that lime,
stop the crankshaft ..
(3) Identify the timing mark stamped on the
flywheel through the access hole of the
flywheel housing.
Flywheel housing
Access hole
6-8
J
<~~~~~
Cylinder No.1
(2) When the crankshaft is turned in the specified direction, the oil level rises at the tip of
the delivery valve spring holder. At that
time, stop the crankshaft.
(3) Identify the timing mark stamped on the
flywheel through the access hole of the
flywheel housing.
Access hole
6-9
Regulator handle
6-7. Checking the coaling water system and radiator for water leakage
1.
Cap tester
Radiator cap
6-10
Cover
Cathode plate
Separator
Glass mat
Battery case
Anodeplale
Acceptable
Too low
Too high
,y~
Upper limit
Liquid level
Lower limit
Battery tester
611
Rubber bulb
Glass tube
Float
LMeasured
electrolyte
(Hydrometer)
temperature
,~
----. "l>-
6-12
Discharged level
(%)
Remaining level
(%)
1.260
100
1.210
25
75
1.160
50
50
1.110
75
25
1.060
100
(4) Fittings
Repair or replace the fittings if corroded.
Retighten them if loosened.
(5) Appearance of the battery
Replace the battery if cracked ordeformed.
Clean it using fresh water if contaminated.
(2) Thermoswltch
Put a thermoswitch into an antifreeze or oil
in a container. While measuring liquid
temperature. heat the liquid. If the tester
shows continuity at a temperature of 107113C. the thermoswitch is acceptable.
1 - - - Thermometer
,~-'2"'--i-
to radiator
Thermostat
2. LO pressure switch
Remove the connector from the LO pressure
switch.
While running the engine. bring the tester
probes into contact with the switch terminal
and cylinder block. If the tester shows
continuity. the LO pressure switch is defective.
Cylinder block
(flywheel side)
&~ver
~
~Thermostat
<0
,,0..
(Continuity test)
Thermoswitch
p~
6-13
146".
(3) Cooling tube leak check
Close either the in let or out let of the coo ling
tube. Apply an air pressure (5.0 kg/cm')
from the other end and check if air is
leaking by immersing the tube in water. If
leaking. repair or replace the cooling tube.
Cooling
water inlet .....~~I+
Cooling
water outlet
Oil inlet
6-14
1.3 I min
3.5 kg I em'
Piston
Spray
Cooling nozzle
6-15
(mm)
2.
Valve
sinking
depth
Wear limit
All models
0.05 or less
0.15
0.3-0.5
Exhaust 0.75-0.95
valve
Standard
Valve
sinking
depth
3TNE74
Wear
Wear
Standard
limit
lim~
1.0
0.4-0.6
1.0
1.0
VM:O.75-0.95
CH:OAO-O.60
1.0
VH:O.40-0.60
3TNE78A
3TNE82A
(mm)
Standard
Standard
Intake
valve
2/3TNE68
3/4TNE82.
3/4TNE84(T),
3/4TNE88
Wear
Wear
Standard
limit
lim~
Intake
valve
0.296
-0.496
1.0
0.306
-0.506
1.0
Exhaust
valve
0.3-0.5
1.0
0.3-0.5
1.0
Depth-Micrometer
Straight-edge
Thickness gauge
J
(2) Width and angle of the valve seat
Remove carbon deposits from the seat
surface. Measure width and angle of the
seat using vernier calipers and an angle
gauge.
(mm)
213TNE68
Slandard
3TNE74
Wear
Wear
Standard
limit
limit
Valve
seat
width
Intake
1.15
1.65
1.44
1.98
Exhaust
1.41
1.91
1.77
2.27
Valve
seat
angle
Intake
120'
120'
Exhaust
90'
90'
3TNE78A
3TME82A
Standard
Valve
seat
width
Valve
seat
angle
(2) When the seat surface is worn or roughened heavily, correct seat surface using a
seat grinder or seat cutter, and finish it
according to step (1).
seat grinder
Wear
Wear
Standard
limit
limit
1.36
-1.53 1.98
1.07
-1.24 1.74
Exhaust
1.66
-1.87 2.27
1.24
-1.45 1.94
Exhaust
3/4TNE82,
3/4TNE84(T),
3/4TNE88
Intake
Intake
120'
120'
90'
90'
Angle (e)
Intake valve
30'
Exhaust valve
45'
7-2
Grind
Grind to the same dimension
)
( as the fitting diameter of the cotter
width
Valve seat
* 1. After the valve seat is corrected, thoroughly clean the valve and cylinder head
using diesel oil or the like. Thoroughly
remove the valve compound or grindstone
powder.
2. For slightly poor contact, take steps (3)
and (4).
2/3TNE68:
3 TNE74:
Direct injection system:
All
With valve
seat
3TNE74 (101):
Direct injection system:
Turbocharged engine:
CH andVH
CH andVH
VM
CL and VM
Valve seat
All
7-3
Standard
3/4TNE82,
3/4TNE84(T),
3I4TNE88
Wear
Wear
Standard
limit
limit
6.945
-6.960 6.9
7.000
-7.015 7.08
0.040
-0.070 0.18
7.955
-7.975
8.010
-8.025
0.035
-0.070
7.955
-7.970
7.9
8.015
-8.030
8.1
0.045
-0.075
0.2
Stem 0.0.
Intake
valve
Guide 1.0.
Oil
clearance
7.9
8.1
0.2
(mm)
~
Intake
valve
2I3TNE68
Standard
3TNE74
Wear
Wear
Standard
limit
limit
6.960
-6.975 6.9
7.005
-7.020 7.08
0.030
-0.060 0.18
6.945
-6.960 6.9
7.005
-7.020 7.08
0.045
-0.075 0.18
Exhaust
Guide 1.0.
valve
Oil
clearance
5.4
5.500
-5.515 5.58
0.040
-0.070 0.18
(mm)
~
Thickness of
valve
head
3TNE74
Standard
Wear
Wear
Standard
limit
limit
0.85
-1.15
0.99
-1.29
0.50
Exhaust 0.95
-1.25
Valve
Intake
valve
0.50
0.95
-1.25
3TNE78A
3TNE82A
Thickness of
valve
head
7-4
Intake
valve
2I3TNE68
3/4TNE82,
3/4TNE84(T),
3/4TNE88
Standard
Wear
Wear
Standard
limrt
limrt
1.244
-1.444
1.244
-1.444
0.50
0.50
Exhaust 1.35
Valve
-1.55
1.35
-1.55
Projection
(2) In a container containing liquefied nitrogen, ether or alcohol together with dry ice,
put the valve guide to cool it. Then hit the
sufficiently cooled valve guide to fit into the
cylinder head using the valve guide insertion tool.
4.
[Time of Replacement]
213TNE68
Standard
Valve guide
projection
3TNE74
Wear
Standard
limit
Wear
limit
[Precautions on Installation]
Make sure that the entire surface of valve
stem is smooth, and sufficiently apply
lubricating oil to the valve stem before
reassembling intake/exhaust valves.
3/4TNE82,
3/4TNE84(T),
3/4TNE88
3TNE78A
3TNE82A
Standard
Wear
limit
Standard
Wear
limit
15
Valve guide
Cylinder head
Valve guide
projection
12
<'
Val~e ~uide
cll-"====1 projection
'f,
~ Valve guide
Hatched portion indicates
)
( where to apply lubricating oil.
7-5
213TNE68
Wear
Wear
Standard lim~ Standard
lim~
Free length
Valve Inclination
spring
Tension (kg)
(when compressed
toby 1 mm)
3TNE74
28
0.8
*2.37/
1.87
1.14
-1.40
37.4
t.O
Inclination
Square
3TNE78A
3TNE82A
Standard
Free length
44.4
Valve Inclination
spring
Tension (kg)
(when cOrTl>ressed
toby1 mm)
*3.61
/2.71
Surface plate
Wear
Wear
Standard
limit
limit
42
1.1
1.1
*2.36
/3.101
7-6
~I
3/4TNE82,
314TNE84(T),
3/4TNE88
~,
Free length
Cylinder gauge
o
o
Roundness:
Difference between max. and min. bore
values on the same cross section of
each liner.
Cylindricity:
Difference between max. and min. bore
values in the same direction of each
liner.
20mm
7-7
I~
213TNE68
Standard
Cylinder bore
68.000
Cylinder roundness
0.00
Cylindricity
~68.030
0.00
Wear
Wear
Standard
limit
limit
68.20 74.000
74.20
~74.030
~0.01
0.03
~0.01
0.03
3TNE82A
3/4TNE82
3TNE78A
Standard
Cylinder bore
78.000
Cylinder roundness
0.00
Cylindricity
0.00
~78.030
0.03
~0.01
0.03
Cylinder bore
Cylinder roundness
0.00
Cylinder cylindricity
0.00
3/4TNE84(T)
3/4TNE88
Wear
Standard
Standard
limit
~84.030
78.20 82.000
82.20
~82.030
0.03 0.00 ~0.01
84.000
(Flex-Hone)
Wear
Wear
Standard
limit
limit
~0.01
3.
3TNE74
Wear
lim~
84.20 88.000
88.20
~88.030
~0.01
0.03
~0.01
0.03
Honing
1.
Necessary items
Flex-Hone. power drill. and honing fluid
Flex-Hone
Yanmar code No.
Model
2/3TNE68
129400-92400
63~70
3TNE74
129400-92410
70~76
3TNE78A/82A
3/4TNE82
3/4TNE84(T)
129400-92420
76~89
3/4TNE88
129400-92430
83~95
Flex-Hone
EJ
Honing liquid
7-8
Applicable bore
(mm)
Engine oil
50%
Diesel oil
50%
=~+U
Handling procedure
Apply the honing fluid to the Flex-Hone.
Insert the Flex-Hone into the cylinder while
turning it, move it up and down for about 30
sec for a cross hatch angle of 30-40'. Extract the Flex-Hone while turning it.
Use the Flex-Hone at a speed of 300-1200
4.
Increase in L.O.C.
or blowby
c=)
Honing
Boring
Consideration
on the applicability
( of oversized
pistons and piston rings
7-9
Measuring the outside diameter of rocker arm shaft and inside diameter
of rocker arm
Oil clearance is the difference between the rocker arm inside diameter measured with a cylinder
gauge and the rocker arm shaft outside diameter measured with a micrometer. When the oil
clearance is near the limit, replace the rocker arm shaft and rocker arm with new ones.
(mm)
3TNE74
213TNE68
Intakelexhaust
rocker arm
3TNE78A182A
3/4TNE82,
314TNE84(T).
3/4TNE88
Standard
Wear
limit
Standard
Wear
limit
Standard
Wear
limtt
Rocker arm
shaft outside diameter
9.972
-9.987
9.95
11.966
-11.984
11.95
15.966
-15.984
15.95
10.000
-10.020
10.09
12.000
-12.020
12.09
16.000
-16.020
16.09
Oil clearance
0.013
-0.048
0.14
0.016
-0.054
0.14
0.016
-0.054
0.14
2.
Thickness gauge
7-10
3/4TNE82,
3TNE74
314TNE84(T),
3/4TNE68
Standard
0.03 or less
Tappet
Wear
limit
Standard
0.03 or less
Wear
limit
Wear
limit
Standard
0.03 or less
17.950
-17.968
17.93
20.927
-20.960
20.90
11.975
-11.990
11.93
18.000
-18.018
18.05
21.000
-21.021
21.05
12.000
-12.018
12.05
Oil clearance
0.032
-0.068
0.12
0.040
-0.094
0.15
0.010
-0.043
0.12
3. Other checks
(1) Valve rocker arm shaft spring
Check to see if the rocker arm shaft spring
is free from corrosion and wear. If not,
replace it with a new one.
(2) Wear of Intake/exhaust valve rocker
arm and valve cap
Check the intake/exhaust valve rocker
arm for their contact surfaces with valve
cap. If any of them is abnormally worn or
partially flaked, replace it.
(3) Check the portion where the valve clearance adjusting screw is in contact with the
push rod. If the portion is worn and flaked,
replace the pushrod or adjusting screw.
Adjusting screw
,a.::I:r~
Push rod
Abnormal contact surface
7-11
-t
Y'"
(
"1
l~ ~J
I
1/
'\
Measurement
position
22- 25mm
213TNE68
VM.VH
3TNE74
Wear
Standard
lim"
3TNE78A
3TNE82A
3/4TNE82
3/4TNE84(T)
3/4TNE88
CH
Wea
Wear
Wear
Wear
Wear
wear
Standard limit Standard
Standard limit Standard limit Standard limit Standard tim.
limit
lim"
Wear
Stan dar<
Piston outside
diameter
67.960
67.940
73.940
77.950
81.950
81.945
83.945
87.945
-67.990 67.90 -67.970 67.90 -73.970 73.90 -77.980 77.90 -81.980 81.90 -81.975 81.90 -83.975 83.90 -87.975 87.90
Minimum dearance
between piston and
cylinder
0,025
-0.055
0.045
-0.075
.045
-0.075
0.035
-0.065
0.035
-0.065
0.040
-0.070
Model
~~
2nd ring
(Common to all models)
~W--\....I
Application
Oil ring
(Common to all models)
7-12
Top ring
IJ
:::
Top ring
Model
0.040
-0.070
VM.CH.VH
~ Topring
213TNE68.3TNE74
Application
----I
0.040
-0.070
3TNE78A182A.
3/4TNE82.
CL. VM
3/4TNE84{T)
3/4TNE88
TI
. . .L Side clearance
Piston
Ring
End dearance
Approx. 30 mm
Piston ring
Cylinder block
7-13
~
Ring groove
width
Ring width
Top ring
Min. side
clearance
End clearance
Ring groove
width
Ring width
2nd ring
Oil ring
5.
Min. side
2i3TNE68
3TNE82A.
3/4TNE82,
3/4TNE84(T)
3/4TNE88
Wear
Wear
Wear
Wear
Standard Wear Standard
Standard
Standard
Standard
limit
limit
limit
limit
limit
1,550
-1.570
1.470
-1.490
0.060
-0.100
0.100
-0.250
1.540
-1.555
1.430
-1.450
1.5
1.550
-1.570
1.470
-1.490
0.060
-0.100
0.200
-0.400
1.520
-1.535
1.410
-1.430
0.090
-0.125
clearance
0.090
-0.125
End clearance
0.150
-0.350
1.5
Ring groove
width
3.010
-3.025
Ring width
2.970
-2.990
clearance
0.020
-0.055
2.970
-2.990
0.020
-0.055
End clearance
0.150
-0.350
1.5
0.150
-0.350
Min. side
3TNE78A
3TNE74
0.200
-0.400
3.010
-3.025
2.035
-2.050
1.940
-1.960
0.075
-0110
0.200
-0.400
2.025
-2.040
1.975
-1.990
0.035
-0.065
1.5
1.5
0.250
-0.400
3.015
-3.030
2.065
-2.080
1.970
-1.990
0.075
-0.110
0.200
-0.400
2.035
-2.050
1.970
-1.990
0.045
-0.080
1.5
0.200
-0.400
1.5
4.015
-4.030
1.5
1.5
3.970
-3.990
2.970
-2.990
0.025
-0.060
0.025
-0.060
1.5
0.200
-0.400
1.5
0.200
-0.400
2.060
-2.075
1.970
-1.990
0.070
-1.105
0.200
-0.400
2.025
-2.040
1,970
-1.990
0.035
-0.070
0.200
-0.400
4.015
-4.030
7-14
1.5
1.5
1.5
0.200
-0.400
1.5
Top ring
2nd ring
Oil ring
Top ring
2nd ring
3.970
-3.990
0.025
-0.060
t~~~~?
Oil ring
t
(Measuring the piston pin outside diameter)
213TNE68
3TNE74
Wear
Wear
Standard limit Standard limit
19.991
20.991
-20.000 19.90 -21.000 20.90
20.000
21.000
-20.008 20.02 -21.008 21.02
0.000
-0.017
0.12
3TNE78A
3TNE82A
0.000
-0.017 0.12
3/4TNE82,
3/4TNE84(T),
3/4TNE88
circliP--O
Wear
Wear
Standard limit Standard limit
Piston pin outside 22.991
25.987
-23.000 22.90 -26.000 25.90
Piston diameter
and
Piston pin hole
23.000
26.000
piston dia.
-23.008 23.02 -26.009 26.02
pin
0.000
0.000
Oil clearance
-0.017 0.12
-0.022 0.12
7.
~
Top clearance
213TNE68
Standard
0.610
-0.730
Wear
Wear
Standard
limit
limtt
3TNE78A
3TNE82A
Standard
Top clearance
0.650
-0.770
3TNE74
0.658
-0.778
3/4TNE82,
3/4TNE84(T),
314TNE88
Wear
Wear
Standard
limtt
limit
0.660
-0.780
7-15
Model
VM
VH
0.2508
CH
0.2508
119265-22900
3TNE74
VM
CH
VH
0.2508
119623-22900
119623-22950
3TNE78A
CL
VM
CH
VH
0.2508
119818-22910
119818-22950
3TNE82A
CL
VM
0.2508
119813-22900
129003-22950
CL
VM
0.2508
129003-22900
129003-22950
CH
VH
0.2508
129003-22910
129003-22950
CL
VM
0.2508
129002-22900
129002-22950
CH
VH
0.2508
129002-22910
129002-22950
CL
VM
0.2508
129001-22900
129001-22950
213TNE68
119265-22930
119265-22950
3/4TNE82
3/4TNE84(T)
3/4TNE88
7-16
3.
1. Visual Inspection
Inspect the portion near the boundary of the
chamfered portion and I-beam section of the
big and small ends of the connecting rod as
well as the portion near the oil hole of the
bushing at the small end for cracks, deformation, and discoloration.
2. . Measuring the twist and parallelism
Measure the twist and parallelism by use of
the connecting rod aligner.
(mm)
~
Twist and parallelism
All models
Standard
0.03 or less
per 100 mm
To measure the inside diameterofthe crankpin metal, reassemble the crankpin metal
to the connecting rod and tighten the rod
bolt to the speCified torque, making sure
each metal is fitted on the correct position.
Wear
limit
0.08
J;
I~
Rod bolt tighten
ing torque
(Apply Ube oil
to the rod boU)
213TNE68 3TNE78A
3TNE74 3TNE82A
3I4TNE82,
3I4TNE84(T),
3I4TNE88
Specified torque
2.3-2.8
3.8-4.2
4.5-5.5
~
Crankpin
side
4.
213TNE68
Standard
3TNE78A
4TNE82A
3TNE74
Wearlim~
Standard
Wearlim~
Standard
Wearlim~
3/4TNE82.
314TNE84(T).
3/4TNE88
Standard
Wearlim~
Crankpin bushing
inside dia.
39.000
-39.016
43.000
-43.016
46.000
-46.016
51.000
-51.010
Crankpin metal
thickness
1.487
-1.500
1.487
-1.500
1.487
-1.500
1.492
-1.500
Crankpin outside
diameter
35.970
-35.980
35.91
39.970
-39.980
39.91
42.952
-42.962
42.91
47.952
-47.962
47.91
Oil clearance
0.033
-0.059
0.15
0.033
-0.059
0.15
0.Q38
-0.0900
0.16
0.038
-0.074
0.16
(mm)
'~
Piston pin bushing
Piston inside diameter
Piston pin out
pin
side side diameter
Oil clearance
213TNE68
Standard
Wear
limit
3TNE74
Standard
Wear
limit
20.025
21.025
-20.038 20.10 -21.038 21.10
20.991
19.991
-20.000 19.90 -21.000 20.90
0.025
-0.047
0.2
3TNE78A
3TNE82A
0.025
-0.047
3/4TNE82,
3/4TNE84(T),
3/4TNE88
7-18
0.025
-0.047
0.2
0.025
-0.051
0.2
Wear
Wear
Standard limit Standard lim~
Oil clearance
Cylinder gauge
0.2
5.
chamber recess
1.0. mark
.......... Fuel injection
pump side
Assemble so
that the punched
mark of large
end faces the
fuel injection
pump.
Crankpin metal
7.
Side gap
0.2-0.4
Camshaft side
-"
1.0. mark
,~~
Crankshaft
/
Fuel injection pump side
7-19
3.
(0.25mm. oversized)
'~
Crankpin metal
Part code No.
Metal thickness
(mm)
Standard
213TNE68
119260-23350
1.625
3TNE74
119620-23350
1.625
3TNE78A182A
11981 0-233~0
1.625
3/4TNE82
3/4TNE84(T)
3/4TNE88
129150-23350
1.625
~~
Camshaft bend
All models
Standard
Wear
0.02 or less
7-6. Camshaft
Dial gauge
4.
Side gap
(mm)
All models
0.05-0.25
7-20
Cam height
lim~
0.05
213TNE68
3TNE78A182A,
314TNE82,
314TNE84(T),
3/4TNE88
3TNE74
Standard
Wear
limit
Intake cam
29.970
-30.030
29.75
33.950
38.635
33.75
-34.050
-38.765
Exhaust cam
29.970
-30.030
29.75
33.950
-34.050
Standard
Wear
limit
Standard
Wear
limit
38.40
Cam height
33.75
38.635
38.40
-38.765
Flywheel side
Measure the outside diameter of the camshaft with a micrometer. Calculate the oil
clearance from measured camshaft outside
diameter and the camshaft bushing inside
diameter measured with a cylinder gauge
after inserting the camshaft bushing into the
cylinder block.
Intermediate bearing
Gear side
(mm)
2/3TNE68
Standard
Intermediate
3TNE74
Wear
limit
Standard
Wear
limit
Standard
Wear
limit
39.85
44.925
-44.950
44.85
35.940
35.85
-35.960
39.940
-39.960
Oil clearance
0.040
-0.085
0.040
-0.085
35.910
-35.935
Oil clearance
0.065
-0.115
35.940
-35.960
35.85
Oil clearance
0.040
-0.125
Gear side
Flywheel side
3TNE78A182A,
3/4TNE82,
3/4TNE84(T),
3/4TNE88
35.85
39.910
-39.935
0.065
-0.115
39.85
0.040
-0.130
44.910
-44.935
44.85
0.065
-0.115
39.940
39.85
-39.960
44.925
44.85
-44.950
0.040
-0.125
0.040
-0.100
7-21
7-7. Crankshaft
1. Side gap around the crankshaft
Before extracting the crankshaft and when
reassembling it, bring a dial gauge into
contact to the end of the crankshaft. Force
the crankshaft to both sides in the axial
direction to measure the thrust gap. Alternatively, insert a thickness gauge directly
into a thrust gap between the thrust metal in
the standard part and crankshaftto measure
the side gap.
If the limit is exceeded, replace the thrust
metal with a new one.
(mm)
All models
Thrust gap
0.090-0.271
4.
(mm)
All models
r--------i
Standard
Bend
0.02 or less
Dial gauge
Crankshaft
Bend
2.
Deflection
Dial gauge
V-block
V-block
7-22
Crankpin
~~~~~~
Crankpin
Crank
journal
213TNE68
3TNE74
3TNE78A
4TNE82A
3/4TNE82.
3/4 TNE84(T).
3/4TNE88
Standard
Wearlim~
Crankpin outside
diameter
35.970
-35.980
35.91
39.970
-39.980
39.91
42.952
-42.962
42.91
47.952
-47.962
47.91
Crankshaft journal
outside diameter
39.970
-39.980
39.90
43.970
-43.980
43.90
46.952
-46.962
46.91
53.952
-53.962
53.91
Bearing metal
thickness
1.487
-1.500
1.987
-2.000
1.987
-2.000
1.995
-2.010
0.033
-0.059
0.15
0.033
-0.059
0.15
0.038
-0.093
0.038
-0.068
0.15
0.25
7-23
-n
Un
~
(baSiC)~U
~
AAA
7. Undersized main metal by 0.25 mm and the oversized thrust metal by 0.25 mm
Main metal
Part code
Thrust metal
Metal thickness (mm)
Part code
Standard
7-24
213TNE68
719260-02870
1.625
119260-02940
2.125
3TNE74
719620-02870
2.125
119620-02940
2.125
3TNE78A182A
119810-02870
2.125
119810-02940
2.125
3/4TNE82
3/4TNE84(T)
3/4TNE88
129150-02870
2.125
129150-02940
2.125
7-8. Gears
1. Checking gears
~
Crankshaft gear.
Camshaft gear.
Back- Idle gear and
lash Fuel injection
pump drive gear
213TNE68,
3TNE74
0.04-0.12
3.
3TNE78A182A,
3/4TNE82,
3/4TNE84(T),
3/4TNE88
0.07-0.15
0.11-0.19
3TNE78A182A.
3i4TNE82,
314TNE84(T),
314TNE88
Wear
Wear
Standard I' . Standard
Imlt
limit
Idle
gear
0.15
0.025
0.15
-0.075
(2) Make sure that the oil hole 01 the idle gear
shaft and bushing is a through hole.
7-25
Gear train
After installing each gear, make sure that
aligning marks ,@ and of the idle gear
are aligned with those of the fuel injection
pump gear, cam gear and crank gear..
(View the gear case)
Fuel injection pump drive gear
Camshaft gear
\
,
~'
Idle gear
* PTO (option)
7-26
I~
Clearance between outer
rotor and pump body
"
Standard
Wear
limit
0.10-0.16
0.25
314TNES2,
314TNE84(T),
3/4TNE88
3TNE78A
3TNES2A
213TNE68
3TNE74
All models
Wear
Wear
Standard Wear
limit Standard limit Standard limit
Pump body and
inner-, outer-tOtor
side clearance
0.03
-0.09
0.13
0.05
-0.10 0.15
0.03
-0.09
0.15
Straight edge
Outer rotor
Pump body
Thickness gauge
(mm)
~
Clearance between outer
rotor and inner rotor
All models
Standard
Wear
limit
0.15
~
Clearance between rotor
shaft and side cover hole
All models
Standard
0.013
-0.043
Wear
lim~
0.2
5.
Inner rotor
Outer rotor
Thickness gauge
/
Others
(1) Check for looseness of drive gear/rotor
shaft fitting, and replace the entire assembly if loose or wobbly.
(2) Push the oil pressure regulating valve
piston from the oil hole side, and replace
the entire assembly if the piston does not
return due to spring breakage, etc.
(Engine with oil cooler only)
(3) Make sure that the rotor shaft rotates
smoothly and easily when the drive gear is
rotated,
7-27
8-1. Disassembly
* For the number following the part name, refer to attached drawing 1 and 2, "Exploded Views of Engine
Components"
Step
Removal Parts
Remarks
1. Remove turbocharger
exhaust manifold CD .
and
8-1
8. Dlsassemblyand Reassembly
Step
Remarks
Removal Parts
@ and V-pulley
l.
@.
2. Remove fuel filter @ .
10
@.
.~
a;
.s=
"
u::
Camshaft side
'w"
"0
CD
(J)
-8
"u
'"~
'w
"
a;
.s=
"
(!)
\.
"
'w
lID
@
@
(J)
"0
"u
~
CD)
'~"
"
(!)
Camshaft side
~
0
a;
.s=
"
u::
CD
(J)
8-2
"
'w
"0
"
'"
!j
~
"
(!)
Step
Remarks
Removal Parts
"
@ .........
Valve spring compressor
Removeintakevalve
@.
3. Remove gear case @ .
13
14
15
16
2. Remove flywheel @.
17
8-3
8. Disassemblyand Reassembly
Step
18
Removal Parts
1. Remove oil pan
and spacer i@ .
Remarks
1. Put the cylinder block with the attaching surface of the
cylinder head facing down.
2. Carefully protect the combustion surface of the cylinder
block from damage.
3. For indirect injection system, be careful to the possibility
.of the tappet to drop off when the cylinder block is turned
upside down, because the tappet is cylindrical in shape.
19
20
21
22
23
1. Removemainbearingcapbolt @.
While shaking main bearing cap @,
remove main bearing cap @ togetherwHh lower main bearing metal
@.
2. Extract crankshaft @ ,taking care
not to damage H.
3. Remove upper main bearing metal
@.
~~:>~
-1C---~L
I tOLI~
, r~ _~~
'-Io~
""f /Y;fJiii~~\~
I~ o~l\
~
Ill>-
'~~~~YV
, ~1\"1 \R~ ~ ~
~\l
,
\0
'\1.'>0
Crankshaft
8-4
<'
Dial gauge
8. Dlsassemblyand Reassembly
Step
Removal Parts
Remarks
-------
Thrust gap
(mm)
All models
0.090 - 0.271
25
1. Remove tappet @ .
85
(mm)
All models
Thrust gap
0.090 - 0.271
Oial gauge
Crankshaft
j
Idle gear
Crankshaft gear
Direction of rotation
8-6
*PTO (option)
Top ring
2nd ring
Oil ring
Valve guide
Top ring
2nd ring
-K~~~
Oil ring
8-7
(8)
(9)
213TNE68,3TNE74
1.0. mark
-8
.;;
~-t.lJ'-+l~ff'-"t-t--+--
..
~
(.)
Cylinder
size mark
8-8
Flywheel side
Cylinder
size mark
Flywheel side
I-I---Embossed marl<
(Flywheel side)
Alignment mark
Alignment mark
(Flywheel side)
Tighten cylinder heads in numerical order shown below to the specified torque.
Camshaft side
-8
'0;
a;
(2 cylinder)
"0
'0;
<J)
"'~
u::
"'~"
@)
"
FO pump side
Camshaft side
<J)
-8
'0;
( 3 cylinder)
a;
<D
-8
'0;
"
'~"
'"
~
Q)
J-"'
"
FO pump side
Camshaft side
fl
( 4 cylinder)
a;
"'~
:1l
u::
@)
FO pump side
Q)
~
"
Q)
"
(kgf-m)
~
Tightening
torque
213TNE68
3TNE74
3TNE78A
3TNE82A
3/4TNE82
3/4TNE84(T)
3/4TNE88
3.8 -4.2
6.0-6.5
6.8-7.2
8.7-9.3
8-9
9. Service Data
9. Service Data
9-1 Cylinder Head
(Unit: mm)
~
Item
Cylinder head combustion surface
distortion
Valve seat
angle
Valve seat
width
Standard
Wear
limit
Standard
Wear
limit
Standard
Wear
limit
Standard
Wear
limit
0.05
or less
0.15
0.05
or less
0.15
0.05
or less
0.15
0.05
or less
0.15
120
120
120
120
Exhaust
90
90
90
90
Intake
1.15
1.65
1.44
1.98
1.36-1.53
1.98
1.07-1.24
1.74
Exhaust
1.41
1.91
1.77
2.27
1.66-1.87
2.27
1.24-1.45
1.94
Exhaust valve
5.460
-5.475
5.500
-5.515
0.025
-0.055
5.445
-5.460
5.500
-5.515
0.040
-0.070
7
Valve sinking
Thickness of
valve head
Intake valve
timing
5.4
5.58
0.18
5.4
5.58
0.18
6.960
-6.975
7.005
-7.020
0.030
-0.060
6.945
-6.960
7.005
-7.020
0.045
-0.075
0.3-0.5
Intake valve
depth
Valve spring
6.9
7.08
0.18
6.9
7.08
0.18
6.945
-6.960
7.000
-7.015
0.040
-0.070
6.940
-6.955
7.000
-7.015
0.045
-0.075
12
6.9
7.08
0.18
6.9
7.08
0.18
7.955
-8.025
8.010
-7.975
0.035
-0.070
7.955
-8.030
8.015
-7.970
0.045
-0.075
0.296
-0.496
0.4-0.6
15
VM: 0.75-0.95
CH: Q.40-0.60
VH: 0.40-0.60
Intake valve
0.85-1.15
0.99-1.29
Exhaust valve
0.95-1.25
0.95-1.25
1.35-1.55
1.35-1.55
7_17
10_20
10_20
0.5
Open
b.TDC
5_15
Close
a.BOC
37_47
1.0
0.5
1.0
0.3-0.5
0.3-0.5
1.244
-1.444
1.244
-1.444
0.5
40_50
35_45
37-47"
40_50
51 _60
51_61
Close
a.TOC
5_15
8_18
13_23
13_23
Inclination
0.8
Tension (kg)
(when compressed to
1mm length)
Intake & exhaust valve clearance
37.4
1.0
2.37
1.14 -1.40
(variable p~ch)
0.15-0.25
3.61
(variable p~ch)
0.15-0.25
8.1
0.2
0.5
42
1.1
1.1
2.36
(variable pitch)
13.101
12.71
11.87
0.15-0.25
44.4
7.9
b.BOC
28
0.2
40_50
Open
Free length
8.1
1.0
0.75-0.95
1.0
7.9
0.306
-0.506
Exhaust valve
Exhaust valve
timing
3/4TNE82.
3/4TNE84(T).
3/4TNE88
3TNE78A
3TNE82A
3TNE74
Intake
2I3TNE68
0.15-0.25
9-1
9. Service Data
~
Item
Cylinder bore
Lmark
Cylinder bore
Mmark
S mark
Cylinder roundness
Cylindric~y
~
Item
Cylinder bore
Lmark
Cylinder bore
Mmark
S mark
Cylinder roundness
Cylindricity
213TNE68
3TNE74
Wear
limit
Standard
68.000
-68.030
68.020
-68.030
68.Q10
-68.020
68.000
-68.010
0.00
-0.01
0.00
-0.01
68.20
0.03
0.03
3TNE82A
3/4TNE82
Standard
82.000
-82.030
82.020
-82.030
82.010
-82.020
82.000
-82.010
0.00
-0.01
0.00
-0.01
Standard
74.000
-74.030
74.020
-74.030
74.010
-74.020
74.000
-74.010
0.00
-0.01
0.00
-0.01
3TNE78A
Wear
limit
74.20
0.03
0.03
3/4TNE84(T)
Wear
limit
82.20
0.03
0.03
Standard
84.000
-64.030
84.020
-84.030
84.010
-84.020
84.000
-84.010
0.00
-0.01
0.00
-0.01
Wear
limit
Standard
78.000
-78.030
78.020
-78.030
78.010
-78.020
78.000
-78.010
0.00
-0.01
0.00
-0.01
78.20
0.03
0.03
3/4TNE88
Wear
limit
84.20
0.03
0.03
Standard
88.000
-88.030
88.020
-88.030
88.010
-88.020
88.000
-88.010
0.00
-0.01
0.00
-0.01
Wear
limit
88.20
0.03
0.03
~
Item
Intake &
Exhaust
rocker arm
Oil clearance
Pushrod bending
Tappet
9-2
213TNE68
3TNE74
3TNE78N82A,
3/4TNE82,
3/4TNE64(T),
314TNE88
Wear
Standard
limit
Standard
Wear
limit
Standard
Wear
limit
9.972-9.987
9.95
11.966-11.964
11.95
15.966-15.964
15.95
10.000-10.020
10.09
12.000-12.020
12.09
16.000-16.020
16.09
0.013-0.048
0.14
0.016-0.054
0.14
0.016-0.054
0.14
0.03 or less
0.03 or less
0.03 or less
17.950-17.968
17.93
20.927-20.960
20.90
11.975-11.990
11.93
18.000-18.018
18.05
21.000-21.021
21.05
12.000-12.018
12.05
0.032-0.088
0.12
0.040-0.094
0.15
0.010-0.043
0.12
9. Service Data
9-4 Piston
(Unit: mm)
~
Item
Lmark
Piston
outside dia.
ML mark
MS mark
S mark
Piston and
piston pin
Piston pin
outside dia.
Piston pin hole
dia.
Oil clearance
213TNE68
VM, VH
67.960
-67.990
67.980
-67.990
67.975
67.90
-67.980
67.970
-67.975
67.960
-67.970
0.025
-0.055
0.610
-0.730
19.991
-20.000
20.000
-20.008
0.000
-0.017
Item
3TNE78A
3TNE82A
~~~:
Piston
outside dia.
3TNE74
CH
67.940
73.940
77.950
81.950
-67.970
-73.970
-77.980
-81.980
73.960
77.970
81.970
67.960
-67.970
-73.970
-77.980
-81.980
73.955
77.965
81.965
67.955
-67.960 67.90 -73.960 73.90 -77.970 77.90 -81.970 81.90
73.950
81.960
67.950
77.960
-67.955
-73.955
-77.965
-81.965
67.940
73.940
77.950
81.950
-67.950
-73.950
-77.960
-81.960
0.045
0.035
0.035
0.045
-0.075
-0.075 -0.065
-0.065
19.90
20.02
0.12
3/4TNE82
Standard
3/4TNE84(T)
Wear
limit
81.945
-81.975
81.965
-81.975
81.960
-81.965
81.955
-81.960
81.945
-81.955
0.040
-0.070
0.660
-0.780
25.987
-26.000
26.000
-26.009
0.000
-0.022
0.658
0.650
- 0.650
-0.770
-0.778
-0.770
20.991
22.991
22.991
20.90
22.90
22.90
-21.000
-23.000
-23.000
21.000
21.02 23.000 23.02 23.000
23.02
-21.008
-23.008
-23.008
0.000
0.12 0.000
0.12 0.000
0.12
-0.017
-0.017
-0.017
81.90
25.90
26.02
0.12
Standard
83.945
-83.975
83.965
-83.975
83.960
-83.965
83.955
-83.960
83.945
-83.955
0.040
-0.070
0.660
-0.780
25.987
-26.000
26.000
-26.009
0.000
-0.022
3/4TNE88
Wear
limit
83.90
25.90
26.02
0.12
Standard
87.945
-87.975
87.965
-87.975
87.960
-87.965
87.955
-87.960
87.945
-87.955
0.040
-0.070
0.660
-0.780
25.987
-26.000
26.000
-26.009
0.000
-0.022
Wear
limit
87.90
25.90
26.02
0.12
9-3
9. Service Data
~
Item
Top ring
Min. side clearance
End clearance
Ring groove width
2nd ring
Ring width
Min. side clearance
End clearance
Ring groove width
Ring width
Oil ring
Min. side clearance
End clearance
~'
Item
Ring groove width
Ring width
Top ring
Min. side clearance
End clearance
Ring groove width
2nd ring
Ring width
Min. side clearance
End clearance
Ring groove width
Oil ring
Ring width
Min. side clearance
End clearance
9-4
3TNE74
213TNE6B
Standard
1.550
-1.570
1.470
-1.490
0.060
-0.100
0.100
-0.250
1.540
-1.555
1.430
-1.450
0.090
-0.125
0.150
-0.350
3.010
-3.025
2.970
-2.990
0.020
-0.055
0.150
-0.350
Wear
limit
1.5
1.5
1.5
3TNEB2A
3/4TNEB2
Standard
2.065
-2.0BO
1.970
-1.990
0.075
-0.110
0.200
-0.400
2.035
-2.050
1.970
-1.990
0.045
-O.OBO
0.200
-0.400
4.015
-4.030
3.970
-3.990
0.025
-0.060
0.200
-0.400
3TNE7BA
Wear
limit
Standard
1.550
-1.570
1.470
-1.490
0.060
-0.100
0.200
-0.400
1.520
-1.535
1.410
-1.430
0.090
-0.125
0.200
-0.400
3.010
-3.025
2.970
-2.990
0.020
-0.055
0.150
-0.350
1.5
1.5
1.5
3/4TNEB4(T)
Wear
limit
-
1.5
1.5
1.5
Standard
2.065
-2.0BO
1.970
-1.990
0.075
-0.1100
0.200
-0.400
2.035
-2.050
1.970
-1.990
0.045
-O.OBO
0.200
-0.400
4.015
-4.030
3.970
-3.990
0.025
-0.060
0.200
-0.450
Standard
2.035
-2.050
1.940
-1.960
0.075
-0.110
0.200
-0.400
2.025
-2.040
1.975
-1.990
0.035
-0.065
0.250
-0.400
3.015
-3.030
2.970
-2.990
0.025
-0.060
0.200
-0.400
Wear
limit
1.5
1.5
1.5
3/4TNEBB
Wear
limit
1.5
1.5
1.5
Standard
2.060
-2.075
1.970
-1.990
0.070
-0.105
0.200
-0.400
2.025
-2.040
1.970
-1.990
0.035
-0.070
0.200
-0.400
4.015
-4.030
3.970
-3.990
0.025
-0.060
0.200
-0.400
Wear
limit
1.5
1.5
1.5
9. Service Data
Item
Crankpin side
Crankpin bushing
inside dia.
Crankpin metal
thickness
Wear
limit
Standard
39.000
-39.016
1.487
-1.500
35.970
-35.980
0.033
-0.059
20.025
-20.038
19.991
-20.000
0.025
-0.047
Less than
0.03 per
100mm
Wear
limit
Standard
43.000
-43.016
1.487
-1.500
39.970
35.91
-39.980
0.033
0.15
-0.059
21.025
20.10
-21.038
20.991
19.90
-21.000
0.025
0.2
-0.047
Less than
0.08 0.03 per
100mm
Wear
limit
Standard
46.000
-46.016
1.487
-1.S00
42.952
39.91
-42.962
0.038
0.15
-0.090
23.025
21.10
-23.038
22.991
20.90
-23.000
0.025
0.2
-0.047
Less than
0.08 0.03 per
100mm
3/4TNE82.
3/4TNE84(T}.
3I4TNE88
3TNE78A
3TNE82A
3TNE74
2/3TNE68
Standard
51.000
-51.010
1.492
-1.500
47.952
42.91
-47.962
0.038
0.16
-0.074
23.10 26.025
-26.038
25.987
22.90
-26.000
0.025
0.2
-0.051
Less than
0.08 0.03 per
lOOmm
Wear
limit
47.91
0.16
26.10
25.90
0.2
0.08
9-7 Camshaft
~~
Item
Gear side
Camshaft journal
outside dia.
Oil clearance
Intennediate
Camshaft journal
outside dia.
Oil clearance
Flywheel side
Camshaft journal
outside dia.
Oil clearance
2/3TNE68
3TNE74
Wear
limit
Standard
35.940
-35.960
0.040
-0.085
35.910
-35.935
0.065
-0.115
35.940
-35.960
0.040
-0.125
(Unit mm)
3TNE78N82A.
3/4TNE82.
3/4TNE84(T}.
3/4TNE88
Wear
Standard
limit
44.925
44.85
-44.950
0.040
-0.130
44.910
44.85
-44.935
0.065
-0.115
44.925
44.85
-44.950
0.050
-0.100
35.85
35.85
35.85
Standard
39.940
-39.960
0.040
-0.085
39.910
-39.935
0.065
-0.115
39.940
-39.960
0.040
-0.125
Wear
limit
39.85
39.85
39.85
9-8 Crankshaft
(Unit: mm
Item
Crank journal
Bend
Crankshaft journal
outside dia.
Bearing metal
thickness
Crank journal and
bushing oil clearance
213TNE68
Standard
Wear
limit
3TNE74
Standard
Wear
limit
3/4TNE82.
3I4TNE84(T).
3/4TNE88
3TNE78A
3TNE82A
Standard
Wear
limit
Standard
Wear
limit
39.970
43.970
46.952
53.952
39.90
46.91
53.91
43.90
-46.962
-53.962
-39.980
-43.980
1.487
1.987
1.987
1.995
-1.500
-2.000
-2.000
-2.000
0.033
0.033
0.038
0.038
0.15
0.15
0.25
0.15
-0.059
-0.059
-0.093
-0.068
0.02
0.02
0.02
0.02
or less
or less
or less
or less
9-5
9. Service Data
~I
All models
Standard
Item
0.090-0.271
Crankshaft
0.05-0.25
Camshaft
Side gap
Connecting rod
0.2-0.4
Idle gear
0.1-0.3
(Unit: mm)
~el
2/3TNE68,
3TNE74
Item
Backlash
Crankshaft gear,
Camshaft gear,
Idle gear and
Fuel injection pump
drive gear
0.04 - 0.12
3TNE78A182A,
3/4TNE82,
3/4TNEB4(T),
3/4TNE88
0.07 - 0.15
0.11 - 0.19
9-10 Others
(Unit mm)
~el
213TNE68
3TNE74
Item
High speed
operation
Low speed
operation
Pressure control valve
opening pressure
L.O. pressure switch
operating pressure
Lubricating
oil pump
discharge
volume
Thenmoswttch
operating
temperature
9-6
3/4TNE82,
3/4TNE84(T),
3/4TNE88
kgf/cm'
3.0-4.0
3.0-4.0
3.0-4.0
3.0-4.0
kgf/cm'
0.4-0.6
0.4-0.6
0.4-0.6
0.4-0.6
f! Imin
Opening
temperature
69.5-72.5
69.5-72.5
69.5-72.5
69.5-72.5
Lift height
mm
Thermostat
valve opening
temperature
f! Imin
3TNE78A
3TNE82A
ON
Min. 8.0
Min. 8.0
Min. 4.5
Min. 8.0
(at 85C and above) (at 85C and above) (at 85C and above) (at 85C and above)
107-113
107-113
107-113
107-113
C
OFF
Item
213TNE68
3TNE74
3TNE78A
3TNE82A
314TNE82.
314TNE84(T).
314TNE88
3.8-4.2
(M8x 1.25)
6.0-6.5
(M9 x 1.25)
6.8-7.2
(M9 x 1.25)
8.7-9.3
(MIO x 1.25)
2.3-2.8
(M7 x 1.0)
2.3-2.8
(M7 x 1.0)
3.8-4.2
(M8 x 1.0)
4.5-5.5
(M9 x 1.0)
8.2-8.8
(Ml0x 1.25)
8.0-9.0
(Ml0 x 1.25)
8.5-9.0
(MIO x 1.25)
8.5-9.0
(Ml0 x 1.25)
5.3-5.7
(M9 x 1.25)
8.0-8.5
(Ml0 x 1.25)
7.8-8.2
(Ml0 x 1.5)
9.8-10.2
(M12 x 1.5)
11.5-12.5
(M14 x 1.5)
11.5-12.5
(M14 x 1.5)
5.0-5.4
(M20 x 1.5)
0.7-0.9
(M6 x 1.0)
0.7-0.9
(M6 x 1.0)
6.0-7.0
(M12 x 1.75)
6.0-7.0
(M12 x 1.75)
1.5-2.0
(Ml0 x 1.25)
1.5-2.0
(Ml0 x 1.25)
5.5-6.5
(MIO x 1.5)
5.5-6.5
(Ml0 x 1.5)
7.0-7.5
(M12 x 1.25)
7.0-7.5
(M12 x 1.25)
4.5-5.0
(M12 x 1.25)
4.5-5.0
(M12 x 1.25)
3.0-3.5
(MI2xl.5)
3.0-3.5
(M12 x 1.5)
3.0-3.5
(M12 x 1.5)
3.0-3.5
(M12 x 1.5)
Torque
Flywheel clamping
bolt
Crankshaft V-pulley
clamping bolt
Fuel injection
nozzle nut
Glow plug
5.0-5.4
(M20 x 1.5)
10 Governor weight
support nut
11
Item
PTplug
Tightening torque
Remarks
M6xl
1.0-1.2
M8 x 1.25
2.3-2.9
Ml0 x 1.5
4.5-5.5
M12 x 1.75
8.0-10.0
1/8
1.0
1/4
2.0
3/8
3.0
1/2
6.0
M8
1.3-1.7
M12
2.5-3.5
MI4
4.0-5.0
MI6
5.0-5.5
10-1
Fuel connel
'PI"n"ern"j,c!e stopper
11-1
11-2. Disassembly
o
(3) Remove the right plunger roller guide
assembly.
11-2
11-3. Inspection
Before inspection, thoroughly clean the
parts, using new diesel oil. Be careful to avoid
damage to the sliding surface of the plunger
and delivery valve, etc.
0rg}
QO(]
Plunger guide
outer roller
Oc
~
11-3
/--"'-.
Lead
I ,
(Plunger)
Approx.60
."
I'
11-4
11-4. Reassembly
(1) Insert the plunger barrel packing into the
fuel injection pump body.
4.0 -4.5
(6) Insert the plunger adjusting shim. Press
the plunger guide assembly by hand. While
aligning the plunger guide stopper pin
with the mating hole of the stopper pin of
the fuel injection pump body, attach the
plunger guide stopper pin.
11-5
~ Holder stopper
O-ring
O-ring
Check bolt
O~
Deflector
Circlip
Spacer
Control rack spring
Rack bushing
valve
}-
Control rack
f- C;orltrol sleeve
Plunger spring upper retainer
Fuel injection
pump body
Plunger spring
.
.
Plunger barrel
Plunger spring lower retainer stopper
Adjusting bolt
Plunger adjusting shim
r1i="-!--PI,unoler roller guide
1-~,",,",- Plun".r guide outer roller
~\:1t- PI~n,n~r guide inner
Plunger
Pump side
eaver
Bottom cover
Bearing holder
12-1
Name of tool
Side clearance
measuring gauge
~:;:~~.
158090-5120
0
code No.
158090-5110
0
15809051050
158090-51510
Governor weight
extractor tool
Yanmar
code No.
Governor
weigh1for 3 pes. 15809051400
Governor
weight for 4 pes. 158090-51450
12-2
Application
Measurement of camshaft side
clearance
12-3. Disassembly
(1) Remove the bottom cover from the fuel
injection pump to drain lubricating oil from
the fuel injection pump.
12-3
*2.
12-4
holder. Carefullypreventtheplungerguide,
plunger, etc., from jumping out. This is
because the plunger spring is powerful
enough to force them out.
12-5
Control pinion
Match mark
12-6
12-4. Inspection
Before inspection, thoroughly clean the
parts, using new diesel oil. Be careful to
avoid damage to the sliding surface of the
plunger and delivery valve, etc.
(1) Plunger
1. Thoroughly clean the plunger. If any
plunger lead is scratched or discolored,
replace the plunger assembly with a new
one.
Approx.60
12-7
12-8
2. Bearing
If the taper roller and outer race has flaking, wear, or any other damage on the
surface, replace the bearing.
12-5. Reassembly
(1) Putthe plunger barrel into the fuel injection
pump from its top.
1!ij'lIIIiilllI!!Mijjjjjliiilliililliiijjjll!llmIlW\!~ \ \ \ ~ ~
(2) Insert the delivery valve assembly. delivery valve spring and delivery valve stopper from the top of the fuel injection pump
in that order.
12-9
(5) Peep through the bottom of the fuel injection pump and align the match mark of
the control rack with that of the fuel
control pinion.
Pinion/rack match mark
JrU
Match
ma~
12-10
:-------,
'rc I,
I
Detent groove
1211
0.02 - 0.05
[Adjustment Procedurel
If a clearance is found small, remove the
adjusting packing.
If a clearance is found large, add one or
more adjusting packing.
Thickness of adjusting packing: 0.5, 0.4,
0.3, and 0.15 mm.
(14) Drive the woodruff key into the fuel injection pump camshaft.
(15) Turn the fuel injection pump camshaft,
and extract the tappet holder (special
service tool).
1212
)
Special service tool:
( Side clearance gauge
0.3
* Never tighten the delivery holder excessively. Otherwise, it upsets, causing oil
to leak through it.
3.5 - 4.0
12-13
13. Governor
13. Governor
13-1. Exploded views of governor for indirect injection system
Governor spring
Governor case
')
r-~I(O'J'~
Tension lever
~<h
Snap pin
Governor lever
131
13. Governor
l:.
FO limiter assembly
Control lever
Angleich assembly
Mounting bolt
.y
Stop
leve~ng ~
~."'
Govemor case
Governor weight
I
~.--+- Governor weight
"Tension lever
assembly
Govemor lever
I'-___~__I
Govemor lever assembly
13-2
13. Governor
13-3. Disassembly
Disassembly and reassembly can be carried
out similarly for Indirect injection system and
Direct injection system.
(1) Remove the governor case.
Angleich spring
Washer
Shifter
Shim
(Anglelch assembly)
13-3
13. Governor
(5) Separate the governor and fuel injection
pump by sliding the governor case and
fuel injection pump apart and pulling out
the snap pin of the governor link from the
control rack.
(7) Use long nosed pliers to unhook the governor spring from the tension lever and
control lever shaft.
(8) Remove the shaft retainer on the governor lever shaft. (for IDI)
Remove the circlips on both ends of the
governor lever shaft. (for DI)
13-4
13. Governor
13-5
13. Governor
13-6
13. Governor
13-4. Inspection
1. Inspection of governor weight assembly
(1) Replace the governor weight if it does not
open and close smoothly.
Governor weight
Pin
13-7
13. Governor
3.
(1) Measure the clearance between the governor lever shaft and bushing, and replace
if it is near the wear limit.
(mm)
Standard
dimension
Govemor lever
shaft outer dia
8:8:m
Bushing inner
dia.
Standard
clearance
Lim~
Shifter
0.065
-0.124
0.5
+0.11
+0.06
Torque spring
0.4
I
Piston
4.
Inspection of springs
~{(({{{((~
5.
13-8
13. Governor
13-5. Reassembly
Inspect all parts after disassembly and replace
any parts as necessary. Before starting
reassembly, clean all parts and put them in
order.
Make sure to readjustthe unit after reassembly
to obtain the specified performance.
(1) Fix the bearing holder with a vise to hold
the fuel injection pump camshaft. Insert
the governor weight assembly in the taper
portion at the end of the fuel injection
pump camshaft. Mount the washer, and
tighten the governor weight support nut
with the specified torque.
--------
(kg!m)
Governor weight support
nut tightening torque
7.0 -7.5
4.5 - 5.0
13-9
13. Governor
*2.
(6) Mount the governor lever assembly to the
governor link.
*2.
13-10
tap in.
13. Governor
(11) Pull the governor link as far as possible
towards the governor case mounting surface, insert the governor link pin in the fuel
control rack pin hole and fitthe snap pin on
it.
(12) Mount the governor case to the fuel injection pump while lightly tapping it with a
wooden hammer, and tighten the tightening bolt.
(13) Mount the governor case cover.
On models with idle subspring, insert the
adjusting spring and adjusting rod on the
governor case cover adjusting bolt.
13-11
13. Governor
(14) Insert the control lever in the control lever
shaft and tighten the nut.
13-12
14. Turbocharger
14. Turbocharger
14-1. Specifications
3TNE84T (Cl, VM)
4TNE84T (Cl)
Turbocharger model
RHB31
RHB51
Turbocharger specification
Turbine type
Radial flow
Centrifugal
lubrication method
External lubrication
250,000
180,000
750'C
Dry weight
2.4 kg
4.2 kg
14-2. Construction
17
10
Air outlet
No.
Part name
1 Turbine shaft
2 Oil thrower
Gas ou~et
~~t---~-- ~~~~~~~~~~=-_tAi~t
...
Gas inlet
___
MS hexagon bolt
M5 spring washer
Compressor side clamp
Turbine housing
M6 hexagon bolt
Turbine side clamp
Lock washer
Bearing housing
Retaining ring
M3 countersunk flat head screw
Compressor wheel
Shaft end nut
Heat protector
14-1
14. Turbocharger
,~
~(:~
:#'.~
~
~I
",'
..
-U
&:/
-~.~. "'.1\/
>
~.
f -~ ----.,,--
..p!?1
#'
..-~
eI
.)#-.
;'
~-
Q~
./-
(1) Turbine
The exhaust gas from the engine is accelerated at the nozzle portion in the
turbine housing and blown onto the turbine impeller to rotate the turbine shaft.
This is called the turbine. A seal ring and
heat insulating plate are installed to
prevent the bearing from being adversely influenced by the gas.
(2) Compressor
The compressor wheel installed on the
turbine shaft is rotated with the shaft to
suck and compress air for feeding into the
intake manifold. This is called the blower
or compressor.
(3) Bearing
1. Thrust bearing
As the turbine shaft is constantly applied with a thrust force, this bearing
prevents the shaft from being moved by
the thrust force.
14-2
14. Turbocharger
Manometer
Pressure
regulating valve
Pressure gage
Rod
Clip
r;~n~
Compressed air
Hose
~;'-'..-7---'-'7--,1'-r\:7---r-jUSV~::A::da::p::te::r===;-;===:::::j,--,.,......,
Waste gate valve
=r
,;5
kg/em' '---,,",
pc
Manometer
<?
{Nate]
14-3
14. Turbocharger
3. Check method
(j) Setthe manometer control pressure
(Pc) applied to the waste gate
actuator to 0 and set the dial gage
to the zero point.
@
4. Precautions
(j) Set the dial gage on the extension
line of the actuator rod.
@
14-4
14. Turbocharger
.r~28
~29
10
G-27
U
6J-
19
29
'--\"Tl----~~.~,7
,,~8
~/
16
.~';;
26
No.
Part name
32'----"/
30
No.
Part name
Turbine shaft
17
Bolt
Thrust bushing
18
Lock plate
Oil thrower
19
Bearing housing
Seal ring
20
Retaining ring
Seal ring
21
Screw
22
Screw
Lock nut
23
Lock washer
Impeller
24
Heat protector
Seal plate
25
Liquid gasket
10
Journal bearing
26
11
Thrust bearing
27
Hose
12
Compressor housing
28
Adapter
13
Flanged bolt
29
Clip
14
Spring washer
30
Retaining ring
15
Clamp
31
16
Turbine housing
32
Link plate
14-5
14. Turbocharger
Size
RHB31
RHB51
18 - 22
Lock nut
9 - 11
13
Flanged bolt
M5
40 - 50
17
Bolt
M6
<--
120 - 130
M8
120 -130
275 - 295
21
Screw
M3
12 - 14
<--
22
Screw
M3
12 - 14
<--
G, G,
Unit: mm
Standard dimension
1ij
.<=
!J)
Q)
Wear limit
RHB31
RHB51
RHB31
RHB51
6.257 - 6.263
7.99 - 8.00
6.25
7.98
1.038 - 1.062
1.25 -1.28
1.07
1.29
c:
1.02 - 1.03
1.22 - 1.23
1.04
1.31
::J
0.82 - 0.83
1.02 - 1.03
0.84
1.11
0.002
0.002
0.005
0.011
6.275 - 6.285
8.01 - 8.03
6.29
8.04
9.93
12.31
10.01
12.42
:e
I--
'"
c:
'c
co
Q)
CD
-2''"
!J)
.<= co
3.59 - 3.61
3.99 - 4.01
3.58
3.98
3.632 -3.642
4.04 - 4.05
3.65
4.07
11.03
15.05
cag
10.04
12.45
cn~
Q) . -
7.968 - 8.00
10.00 - 10.02
8.01
10.05
0.022 - 0.053
0.03 - 0.06
0.07
0.09
0.061 - 0.093
0.08 -0.13
0.12
0.17
14-6
--
-==-
[Example]
79
15-1
Location
of the
No.
labels
15-2
1
2
3
4
SYD493U6D2RA
SYD739U6D2RA
SYD784U6D2RA
SYD1.0U6D2RA
2TN66C, 2TNE66KC
3TN66C 3TNE66KC
3TNE68C
3TNA72C/3TNE74C
3TNE72KC
5
6
7
8
SYD1.3U6D2RA
SYD1.4U6D2RA
SYD1.6U6D2RA
SYD1.5U6D2RA
3TNE78AC/3TNE82AC
3TNE82C
3TNE84C/3TNE88C
3TNE84TC
9
10
SYD1.9U6D2RA
SYD2.2U6D2RA
4TNE82C
4TNE84C/4TNE88C
Location: A
15-3
Location: B
15-4
Location: C
EMI
15-5
15-2 Limiting the high idle and low idle adjustment screw
15-2.1 High idle speed
(1) First warm up the engine. Then, gradually increase the engine speed up to
the high idle speed (Refer to Chapter
1, Specifications and Performance).
Increase
cp
Plug
Lock nut
High idle
adjustment screw
Regulator handle
15-6
limiter screw
Lock nut
Plug
15-7
Attached Drawing 1.
Exploded Views of Engine Components
No.
Engine Component
No.
Engine Component
Exhaust manifolj:1
27
Fuel filter
Intake manifold
2B
29
Thermostat assembly
30
31
32
Nozzle seat
33
Nozzle protector
10
Bonnet assembly
3'
35
Valve cotter
11
36
Valve retainer
12
Push rod
37
Intake valve
13
,.
Valve cap
38
Exhaust valve
54
Flywheel housing
15
Fan
55
Starting motor
16
Adjusting bolt
56
17
V-belt
57
Flywheel
18
Alternator
58
19
Spacer
66
Piston
20
V-pulley
Connecting rod
22
Dipstick
67
7.
23,
26
Valve spring
Turbocharger (3TNE84T,
.TNE8.T)
Fuel return pipe
j(r~
@<
A-1
75
Attached Drawing 2.
. e Components
Exploded Views of Engln
---r
No.
No.
Engine Component
52
Mounting bolt
21
53
Camshaft assembly
39
. bolt
Vpulley damping
59
Tappel
40
Cran.kshaft V-pulley
60
OUpan
41
Gear case
61
Spacer
42
62
43
63
bolt
44
Stiffner bolt
64
45
0"1 seal
65
Crankshaft
46
I
Fuel
injection pump d'egear
nv
68
47
69
. 9 cap boll
Main beann
48
70
49
Idle gear
50
51
71
. bearing metal
lower main
tal
Camshaft gear
72
Thrust bearing
73
Thrust metal
60
A-2
Printed in Japan
AOA5063-2 T 9701