Manual de Yanmar Us45d

FOREWOR
This Service Manual describes the

the procedure of maintenance nd service of the Yanmar industrial
industrial
TNE series engine (Special swirl precombustion chamber (hereinafter Indirect injection system )
nd Direct injection systems}.
Before starting service nd maintenance of TNE engine

engine,, you are requested
r equested to read this Service
Manual carefully to your
you r full understanding nd to take careful note that the standard TNE engine
may differ n the structure nd applicable specification from that loaded on each o f individual driven
machines (such as the generator, pump, compressor, nd combine, etc.).
For further information,

information, carefully read the Service Manual issued for each driv
driven
en machine.
machine.
This Service Manual n subject to changes, with or without notice,

notice, with respect
r espect to the structure nd
the content of maintenance for the purpose of improving engine quality.
Setup before work

To perform work
wor k efficiently, the following setup preparation) is necessary.
1 Customer ledger check
1) Previous date of service

2) Check on
on which month
month and at
at what time)
time) the last service was performed, what
problem occurred, and what the history of the customer
custome r engine) is.
2. Stock control o f parts

1) Stock
Sto ck check for consumable parts, periodic replacement parts, etc., that are
required for service.
2) Provision of check list,
list, parts list a
and
nd parts card.
card.
3. Provision o f service record

1) Wor
Work k process) time table
2) Chec k sheet including used
used parts list
list))
~ ~ . u f f i m e n t d ~ ~ p ~ 1 . .
4) Operation
Operat ion data
dat a and quality for maintenance of performance and quality)
4. Disassembly and reassembly tools

1) Tools
2) Measuring devices
3) Other instruments and equipment necessary for service
This product has been developed, designed and produced in

accordance with the Standards for Quality System of ISO 9001
International
Interna tional Organization for Standardization) under the
following authorized instituti ons: JMI Japan Machine ry and
Metals Inspectio n Institute), SSI British Standar ds Institution)
Institut ion)
Institution)
Institution) and EQNET The European Network tor Qual Quality
ity
FM23056 JQA-0099 System Assessment and Certification).
ISO 9 1 Certified
Certified
Certified unde r the following standards:
ISO 9 1 - 19871 BS 575 : Part 1 : 19871
EN 29 1 - 19871 JIS Z99 1 -1991
ONTENTS
1. Specifications and Performance •..•...................•.•...•.•.....••••....•••.•.•...........•.......•.•...•.•. 1-1

1-1 2TNE68.............................................................................................................. 1-1
1-2 3TN
3TNE68 ..... ....................... ...................... ....................
E68 .... ... .........................................
.....................................
................ 1-2
1-3
1-4 3TNE74
3TNE78A..............................................................................................................
.. ................................. .....
........
... ............ .......................... .....
........
... .......... ........ 1-3
1-4
1-5 3TNE82A ........................................................................................................... 1-5
1-6 3TNE82 .............................................................................................................. 1-6
1-7 3TNE84.............................................................................................................. 1-7
1-8 3TNE88 .............................................................................................................. 1-8
1-9 4TNE82.............................................................................................................. 1-9
1-10 4TNE84.............................................................................................................. 1-10
1-11 4TNE88.............................................................................................................. 1-11
1-12 3TNE84T............................................................................................................ 1-12
1-13 4TNE84T............................................................................................................ 1-13
2. ross Sectional Views .................•.........••.•..•••.•••...•...........•.......•...•••••....•...•...•.....•.....•. 2-1

2-1 Special Swirl Pre-c
Pre-comb
ombustiustionon Chamber System ... ......................
......................................
.........................
...... 2-1
2-2 Direct Injection System.
System..... ........
...... ................................ ......
...... ......
........
.. ........................
..............................
...... 2-2
3. Cooling Wat
Water
er Lubricating Oil and Fuel Oil .............................................................. 3-1
3-1 Cooling water ..................................................................................................... 3-1
3-2 lubricating oil.......................
oil........................................
................. ........................
.................................................
.....................................
............ 3-1
3-3 Fuel oil .................... ............. .............. .............. .............
............... .....
..... ............................... 3-3
4. Troubles
Trou bleshooti
hooting
ng .........
...................
....................
....................
....................
....................
....................
....................
....................
...................
...................
.......... 4-1
4-1 Trouble cause
ca use s and remediremedies.......
es.................
.....................
......................
......................
.....................
.....................
................
..... 4-1
4-2 Trouble diagnosis through measurement of compres compression sion pressur
pressuree .................. 4-3
5. Speci
Special
al Service Tool
Toolss and
an d Measuring Instr Instrumen
uments ts .........
..................
.................
.................
..................
................
....... 5-1
5-1 Speciall service tools.....
Specia tools..........
..... ...................... ..................... .................... .............
........... ..... 5-1
5-2 Measu
Measurin
ringg instru
instruments
ments ...................
......................................
......................................
......................................
..............................
........... 5-3
6. Measurement Inspection and Adjustme Adjustment nt .........

..................
..................
...................
...................
..................
..................
......... 6-1
6-1 Measu
Mea surin
ring
g the compressi
compression on pressur
pressuree ......... ................. .......................... ............ 6-1
6-2 Adjusting the val
valve
ve head cleara
clearance nce .................. ......................
.............................................
...........................
.... 6-3
6-3 Checking the -belt tension ...... ............................. ................ ............................ 6-4
6-4 Measuring and checking the injection pressure and spray patterns
of the fuel injection val
valveve .......................
...........................................
.................... ........................... .............. 6-4
6-5 Checking and adjusting the fuel injection timing ................................................ 6-8
6-6 Adjusting the no-load maximum or minimum) revo revolutilutions
ons .....
..........
..........
..........
..........
..........
.......
.. 6-10
6-7 Checking the COOling water system and radiator for water leakage .................. 6-1
6-100
6-8 Checki
Che cking
ng the batt
battery
ery ............................. ....................
.........................................
.........................................
.................... 6-11
6-9 Checki
Che cking
ng sen
sensor
sorss ..................
....................................
....................................
....................................
...................................
......................
..... 6-13
6-10 Checking the oil cooler .................
..................................
..................................
...................................
...................................
................... 6-1
6-14
4
6-11 Checking the piston cooling nozzle ................................................................... 6-15
7. Measur
Measuring
ing Procedures, Service
Servic e Data and Correcti Corre ctive ve Action
Acti on ..............
........
........
........
........
........
........
......
.. 7-1
7-1 Cylinder head ... ..............•.........
........•.....................................
......... ..................... ........ .. ........................... 7-1
7-2 Cylinder
Cylinder block ..........................
............. ..........................
..........................
..........................
..........................
..........................
......................
......... 7-7
7-3
7-4 Valve
Val
Pistve
on rocker
Piston rocker arm.....
and piston rin
ringg........
........ ......
............ .......... ......
...... ..............
...................... .................................
................ ...............................
..................................
....................... ........... ..............
....... .................. 7-10
7-12
7·5 Connecting
Connecting rod................ ............ ..........
.......... ............. ............. ...................................
.......................... ......... 7-17
7-6 Camshaft.........................
Camshaft............ .........................
.........................
.........................
.........................
.........................
........................
.....................
......... 7-20
7-7 Crankshaft.........................
Crankshaft............. ........................
.........................
.........................
.........................
.........................
.........................
...................
...... 7-22
7-8 Gears ................................................................................................................ 7·25
7-9 Trochoid pump ................................................................................................. . 7-27
8. Dis assemb
Disass embly
ly and Reassemb
Reas sembly ly ......................
.................................
......................
......................
......................
......................
..................
....... 8 1
8-1 Disassembly ...................................................................................................... 8-1
8-2 Precautions
Precautions before
before and during reassemblreassembly y .................................
................ .................................
....................
.... . 8-6
9. Service
Serv ice Data ..................
..............................
.........................
.........................
.........................
..........................
.........................
.........................
....................
....... 9 1
9-1 Cylinder head ................................................................................................... . 9·1
9-2 Cylinder block ................................................................................................... 9-2
9-3 Valve rocker arm ............................................................................................... 9·2
9-4 Piston ................................................................................................................ 9-3
9-5 Piston ring ........................................................................................................ . 9 4
9-6 Connecting rod ................................................................................................. . 9-5
9-7 Camshaft ........................................................................................................... 9-5
9-8 Crankshaft
Crankshaft ..........................
............. ..........................
..........................
..........................
..........................
...........................
..........................
............ . 9-5
9-9 Side gap and backlash
backlash ...........................
............. ............................
...........................
...........................
...........................
...................
...... 9-6
9-1 0 Others
Others ..........................
............. ..........................
.........................
.........................
..........................
..........................
..........................
......................
......... 9-6
10. Tigh
Ti ghte
teni
ning
ng Torq
To rque
ue ........................
...................................
.......................
........................
........................
.......................
.......................
......................
.......... 10-1
10-1 Main bolVnut ...................................................................................................... 10-1
10-2 Standard
Standard bolt
bolt and nut..
nut.. .................. ......
...... ..................... ...............................
............... ...........................
........... 10-1
11.
11. Fuel Injecti on Pump or Indirect Injection System .................................................... 11-1
11·1 Exploded views YPFR type) .. ................................ ................................. ...... •.. 11-1
11-2 Disassembly
Disassembly ..........................
............ ...........................
..........................
...........................
...........................
..........................
........................
........... 11-2
11·3 Inspection......... ..............................
............... ..............................
..............................
..............................
.............................
.......................
......... 11-3
11-4 Reassembl
Reassembly y ..............................
................ .............. .................. ................. ........................ ............. 11-5
12.
12. Fuel Injection Pump or Direct Injection System ....................................................... 12-1
12-1 Exploded
Exploded Views YPES type).........................
type)............ .........................
........................
........................
........................
................
.... 12·1
12-2 Special
Special service tools
tools for disassembly
disassembly and reassembly.... ..................................
...................... ............ 12·2
12-3 Disassembly.......................... ........
........ .................
...................................
...................................
............................
........... ..... 12-3
12-4 Inspection..........................
Inspection............. .........................
........................
.........................
.........................
.........................
.........................
...................
....... 12-7
12-5 Reassembly
Reassembly ..............................
............... ..............................
............................
............. ......................... ........
........ ....
......
.. ...... 12·9
13. Govern
Gove rnor
or ..........................
............ ...........................
...........................
............................
...........................
......................
......... .............................. 13·1
13 1 Exploded
Expl oded viewsviews of o f govern
go vernorf orforor indirect injection
injection system ... ............................... 13 1
13
13-2
-2 Explode
Exploded d views of governor for direct injection system system .....................................
................... .................. 13-2
13-3 Disassembly................
Disassembly................ ............................. .... ...... .... .......................... .... .........
...........
.. ....... 13-3
13-4 Inspection........................................................................................................... 13-7
13-5 Reassembly.... .......
....... ......
...... ......
...... .................... ........
........ ...........
........... ................. ................ .... .... 13-9
14. Turboc
Tur bochar
harger
ger .......................
..................................
.......................
.......................
.......................
.......................
.......................
.......................
.....................
.......... 14·1
14 1 Specifications ..................................................................................................... 14·1
14-2 Construction
Construction ...........................
............. .............................
.............................
............................
............................
............................
...................
..... 14 1
14-3 Waste gate valve adjustingadjust ing method .... .... .... ........ ...... .... .......
...............
.......... ..... ......... ....... 14-3
14·4 Exploded view of Turbocharger
Turbocharge r wI waste gate .. ... ........ .... .... .......... .............. .......... ..... 14-5
14-5 Tightening
Tightening torque
torque ............................. ................ ........... ............ ........................... 14-6
14-6
14-6
14-6 Service
Service standards
standards ..............................
............... ..............................
.............................
.............................
........................
......... .......... 14-6
15. Service Information or CARS ULG

ULG regulat
regu lation
ion ...................
.............................
....................
....................
...................
......... 15·1
15 1 .. 15 1
15-2 Emissionthecontrol
Limiting labels
high idle and...................................................................................
low idle adjustment
adjustment screw.................
screw......... ................
.................
................
....... 15-6
15-6
15-3 Limiting the fuel volume limiter screw....
screw. ... ............................
............. ..............................
..............................
.................
.. 15-7
Attached Drawing 1. Exploded Views o Engine Components ..................................... A·1

Attached Drawing 2. Exploded Views o Engine Componen
Comp onents
ts ....................
..............................
.................
....... A·2
Descriptive Breakdown of Model Name
T E 0 0 (A) (T) - 0 0
------. Shippin
Shipping
g identifier
Turbocharger
L Model subdivision
Cylinder bore mm)
Model code
Number of cylinders 3 or 4)
pplication Category
Application code Usage Eng. Rev. type Revolution

Revolu tion speed rpm)
CL 1500 1800
Generator drive Constant
CH 3000 3600
2000 3000
VM General use Variable
VH 3000 3600
or engine application category described in

in Chapter 1 Specifications and Performance.
1 Specifications and erformance
1. Specifications and Performance

11 TNE68 * Output conditions: Intake back pressure $ 250 mmAq, Exhaust back pressure $ 550 mmAq,
other conditions complying with JIS 0 1005-1986. After minimum 30 hour s run·in.
Model
2TNE68
Item Unit
Application - VM I CH VH
Type - Vertical, 4·cycle water·cooled diesel engine
Vertical,
Combustion system - Special swirl
swirl pre·combustion chambe r
No. of cylinde
cylinders
rs - Bor
Bore
e x Str
Stroke
oke mm 2 68x72
Displacement e 0.523
Firing_order - 1 2
Revolution speed rpm 2000 2200 2400 2600 2800 3000 3000 3600 3200 3400 3600
Continuous
rating
kW(HP) - - - - 7.72
- (10.5) - 9.12
(12.4)
- - -
Output*
5.74 6.25 6.84 7.43 7.94 8.46 8,46 10.0 8.68 9.19 9.64
Max. rating kW(HP)
(7.8) (8.5) (9.3) (10.
(10.1
1 ) (10.8) (11.5) (11.5) (13.6) (11.8
(11.8)) (12.5) (13.1 )
Max. revolution speed at
2 1 8 0 ~ 2 3 7 5 ~ 2 5 7 0 ~ 2 7 8 0 + ~ 2 9 7 0 ~ 3 1 8 0 + ~ 3 1 8 0 ~ 3 7 8 0 + ~ 3 4 2 5 ~ 3 6 4 0 ~ 3 8 5 0 + ~
no load
rpm
Min. revolution speed at
5800 51500 5800
no load
Direction of rotation - Counterclockwise (viewed from flywheel)
Power take off - Flywheel
z
n
Compression ratio - 23.0
0 Fuel injection timing
~ (FlO, b.T.D.C.) deg 14±1 16±1
C,
Compression pressure MPa
u 3.24±O.1 (33±1), at 250 rpm
i3 IlkQficm
w
.. Fuel injection pressure MPa 11.8· g (120· g)
n .Ikgf/cm )
Recommended diesel gas oil - ISO 8217 DMA, BS 2869 AI or A2 (Cetane No. 45 min.)
Lubrication system - Forced lubrication with trochoid pump
Lubricating oil capacity
Max/Effective
e 1.6/0.6 2.311.0
Recommended lubricating oil - API grade CC class or higher

Cooling system - Liquid coolinglRadiator
Cooling water capacity e 0.6 (for engine only)
Cooling fan
mm Discharg e type, 5 x $290
No. of blade x dia.
Crank V·pulley dia.l
mm 95/ 85
Fan V·pulley dia.
Governor - Mechanical centrifugal governor (All speed y ~
Starting system - Electrical
373.5 x 417 x 540 I
*1 DimenSions L x W x H mm 373.5 x 417 x 4 9 8 / 3 8 3 5 x 417 x 498 383 5 x 409 x 540
383.5x417 x 540
*1 Dry weight kg 55/65 65 55/65
Transient speed
$12 510 512
difference
I 58
w Governing Steady state
z
,
{
perform·
ance
speed band 59 57
I 56 $5 $7
: (full speed Recovery time sec 56

0 range)
u.
a: Fluctuation of
w rpm 530 520 530
revolution
0..
0.25±0.05 0.29±0.05
ated operation MPa O . 3 4 ± O · ~ r
(2.5±O.5))
(2.5±O.5 (3.0±
(3.0±0.5)
0.5) (3.5±O.5
L.a.
I
press. Idling (kgf/cm )
,,0.06 (;>0.6)
* 1 . Designation of engine dimension and d ry weight in numerals.

CUCH application: engine with flywheel housing
VMNH applica
application:
tion: engine with back plateiwith flywheel hausing
1-1
1 Specificallons and Performance
1 2 3TNE68 • Output conditions: Intake back pressure 250 mmAq, Exhaust back pressure 550 mmAq,
other conditions complying with JIS D 1005-1986. After minimum 30 hour's run-in.
Model
3TNE68
Item Unit
Application - VM CH T VH
Type - Vertical, 4-cvcle water-cooled diesel en line
Combustion svstem - Special swirl
swirl pre-combustion cha mber
No. of cvlind
cvlinders
ers - Bor
Bore
e x Strok
Stroke
e mm 3 68x72
Displacement € 0.784
Firing order - 1 3 2 1
Continuous
rating
kW(HP) - - -- - 11.7 13.7
- (15.7) (18.4)
- - -
Output*
8.6 9.4 10.3 11.2 12.0 12.9 12.9 15.1 13.1 13.8 14.5
Max. rating 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 : 3 1 8 0 ~ 3 7 8 0 ~ 3 4 5 5 ~ 3670 : 3890 :
no load
rpm
$800 $1500 $800
no load
Direction of rotation - Counterclockwise
Counterclockwise (viewed from flywheel)
z
Ul
~ (FlO, b.T.D.C.) deg 14±1 16±1
u
u: Compression pressure MPa
3.24±0.1 (33±1), at 250 rpm
5 (kaf/cm')
w
l. Fuel injection pressure MPa
Ul 1 1 . 8 + ~ (120+'g)
(kaf/cm')
Recommended diesel g as oil - ISO 8217 DMA, BS 2869 A I or A2 (Cetane No. 45 min.)
Max/Effective
€ 2.4/1.0 3.0/1.0
Recommended lubricating oil - API lrade CC class or higher
Cooling system - Liquid
Liquid coolinglRad iator
Cooling water capacity € 0.9 (for engine only)
Coolingfan
mm Pusher type, 5 x $310
No. of blade x dia.
Crank V-pulley dia.
mm 105/ 85
overnor
Fan V-pulley dia.
- Mechanical centrifugal governor (All speed type)
463.5 x 401 x 4961
*1 Dimensions Lx WxH mm 463.5 x 401 x 496 I 473.5 x 401 x 496 473.5x401 x 96
473.5 x 401 x 496
*1 Dry weight kg 70 81 81 70 81
Transient speed
difference $12 SID s12
w Governing
z
«;;
perform-
ance
Steady state
sDeed band $9 I $8 I 7
I $6 $5 $8
(full speed Recovery time sec $6

0 range)
- Fluctuation of
rpm :>30 :>20 $30
Il .
revolution
Rated operation MPa ~ 2 5 ± 0 ~ ~ I ~ : 2 9 ± O . ~ ~ ~ : 3 4 ± 0 . ~ ~

L.O. press.
Idling
(kgf/em') 2.5±O.5 3.0±0.5
I
>0.06 (?0.6)-
3.5±O.5
* 1 . Designation of engine dimension and dry weight in numerals.

CUCH applica
application:
tion: engine with flywheel housing
VMNH applicati
application:
on: engine with back platelwith flywheel hausing
1-2
1 3 3TNE74 Output conditio

conditions:
ns: Intake back pressure 250 mmAq, Exhaust back pressure 550 mmAq,
other conditions complying with JIS 0 1005-1986. After minimum 30 hour's run·in.
Model
3TNE74
Item Unit
Application - VM CH VH
Type - Vertical, 4·cycle water·cooled diesel engine
Combustion system - Special swirl pre·combustion chamber
No
No.. of cylinders
cylinders - Bore
Bore x Stroke
Stroke mm 3-74x78
Displacement f 1.006
Firing order - 1-3-2-1
Continuous 15.1 17.4
rating
kW(HP) - - - - - - (20.2) (23.3)
- - -
Output*
11.0 12.1 13.2 14.3 15.5 16.6 16.6 19.1 16.6 17.1 17.7
Max. rating kW(HP)
(14.8) (16.2) (17.7) (19.2) (20.8) (22.3) (22.3) (25.6) (22.3) 22.9 (23.7)
Max. revoluti
revolution
on speed at
2 1 8 0 + ~ 2 3 7 5 ~ 2 5 7 0 ~ 2780 : 2 9 7 0 ~ 3180 : 3 1 8 0 ~ 3780 : 3 4 5 5 ~ 3670 : 3 8 9 0 ~
no load
rpm
~ 8 0 0 ~ 1 5 0 0 ~ 8 0 0
no load
z
/)
~ (FlO, b.T.D.C.) deg 14±1 16±1
)
iL: ompression pressure MPa
3.43±O.1 (35±1), at 250 rpm
(3 (kgf/cm')
UJ
- Fuel injection pressure MPa
11.8· g (120·'g)
/)
kgf/cm')
Recommended diesel gas oil - ISO 8217 DMA, BS 2869 A l a r A2 (Cetane No.: 45 min.)
Lubrication system
Lubrication - Forced lubrication with trochoid pump
Lubricating
Lubricating oil capac ity
f 2 411 0 3 311 4
Max/Effective
Cooling system - Liquid coolinQ/Radiator
Coolil1g water capacity f 0.9 (for engine only)
Cooling fan
mm Pusher type, 5 x ~ 3 1 0 Pusher type, 6 x ~ 3 3 5
No. of blade x dia.
Crank V·pulley dia.
mm ~ 1 1 0 < 1 > 8 S ~ 1 1 0 ~ 9 7
Fan V·pulley dia.
Governor - Mechanical centrifugal governor LAII speed type)
469.1 x 440 x S021
*1 Dimensions L x W x H mm 469.1 x 440 x S02/476.6 x 440 x S02 476 6 x 44 x 502
476.6x 440 x 502
*1 Dry weight kg 8SI102 100 8SI100
Transient speed
$12 $10 ,;12
difference
UJ Governing
)
z perform·
..: ance
Steady state
speed band ,,9 I ,8 ,;7
I ,,6 "S ,,8
: (full speed Recovery time sec ,,6

range)
0: Fluctuation of
rpm ,,30 ,;20 ,,30
UJ revolution
"-
Rated operation 0.29±O.05 0.34±O.OS
MPa ~ : 2 S ± 0 ~ ~
I
L.O. press. Idling (kgf/cm') 2.S+0.S . (3.0±O.S) (3.S±O.S)
>0.06 (;'0.6)
*1. Designation of engine dimension and dry weight in numerals.

VMNH application: engine with back plate/with flywheel hausing
1- 3
1 Specincations and erformance
1 4 3TNE78A * Output conditions Intake back pressure 250 mmAq, Exhaust back pressure 550 mmAq,
other conditions complying with JIS D 1005-1
complying 1005-1986.
986. After minim
minimum
um 30 hou
hou(s
(s run-
run-in.
in.
Model
3TNE78A
item Unit
Application - CL VM I CH VH
Type - Vertical, 4-cycle water-cooled diesel engine
Combustion system - Direct injection system
No
No.. of cyl
cylinders
inders - Bor
Bore
e x Strok
Stroke
e mm 3 78x84
Displacement t 1.204
Firing
Firing orde r - 1 3 2 1
Revolution speed rpm 1500 1800 2000 2200 2400 2600 2800 3 3 3600 3200 3400 3600
Continuous
rating
kW(HP)
9.1 10.8
12.2) 14.5)
- - - - - - 18.0 21.0
24.1) 28.2)
- - -
Output*
9.9 11.9 13.2 14.6 15.9 17.2 18.5 19.9 19.9 23.2 20.5 21.6 23.2
Max. rating kW(HP)
13.3 17.7) 19.6) 21.3) 23.1) 24.8) 26.7) 26.7) 31. t) 27.5) 29.0) 31.1)
16.0) 17.7)
Max. revolution speed at . ..
1 5 7 5 ~ 1 8 7 0 ~ 2 1 8 0 ~ 2 3 7 5 ~ 2 5 7 0 ~ 2 7 8 0 ~ 297 3 1 8 0 ~ 3 1 5 0 ~ 3 7 4 5 ~ 3455 , 3 6 7 0 ~ 3 8 0 0 + ~
no load
rpm
~ 1 2 0 0 ~ 8 0 0 ~ 1 5 0 0 ~ 8 0 0
no load
Direction of rotation - Counterclockwise (viewed from f l y ~ h e e l

n
z Compression ratio - 18.0
0
Fuel injection
(FID, b.T.D.C.)timing deg 10±1 12±1 14±1 16±1 24±1 18±1 20±1 24±1
~ )
u
3.14±O.1 (32±1), at 250 rpm
U (kgf/cm')
w Fuel injection pressure
. MPa
19.6+ g (200+'g )
n I kgf/cm')
Recommended diesel gas oil - ISO 8217 DMA, BS 2869 A l or A2 (Cetane No.: 45 min.)
Max/Effective
t 3.6/1.3 5.0/1.7
Recommended lubricat
lubricating
ing oil - API grade CC class or higher
Liquid cooling/Radiator
Cooling water a p a c ~ y t 1.8 (for engine only)
Cooling fan
mm Pusher type, 6 x ~ 3 3 5
No. of blade x dia.
Crank V-pulley dia.
~ 1 2 0 ~ 9 0 ~ 1 1 0 ~ 1 1 0
Fan V-pulley dia. mm
Governor - Mechanical centri
centrifuQal
fuQal Qover
Qovernor
nor (All speed type)
520.5 x 489 x 565/
* 1 Dimensions L x W x H mm 553x489x565 520.5 x 489 x 565 528 x 489 x 565 5 8 x4a9 x 565
528 x 489 x 565
*1 Dry weight kg 138 1121128 124 112/124
Transient speed
difference S10 S8 ~ 1 2 ,,12
)
z perform- ,,5 S4 ,,9 1 S8 1 ,,6 S5 S4 s8
speed band 1
c ( ance
::0
r: (full speed Recovery time sec ,,5 ,,5 ,,6
0 range)
"- Fluctuation of
cr: rpm S15 S30
w revolution 525·
a.
0.29±O.05 O.34±O.OS
Rated operation
L.O. press. MPa
(kgf/cm') (3.0±0.5) (3.S±O.5)
Idling >0.06 (?0.6)
VMNH applica
application:
tion: engine with back plateiwith flywheel hau sing
1 4
1 5 3TNE82A * utput 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
3TNE82A
Item Unit
Application - CL VM
Type - Vertical,, 4-cy cle water-cooled diesel engine
Vertical
.
No. of cylin
cylinders
ders - Bore x Stro
Stroke
ke mm 3 82x84
Firino order - 1 3 2 1
Revolution
Revolution speed rpm 1500 1800 2000 2200 2400 2600 2800 3000
Continuous
rating
kW(HP)
9.9
(13.3)
12.0
(16.1) - - - - - -
Output*
11.0 13.2 14.6 16.0 17.5 19.0 20.5 21.9
Max. rating kW(HP)
(14.8) (17.7) (19.6) (21.5) (23.5) (25.5) (27.5) (29.4)
Max. revolution speed at 1575+500 1870+500 2180+500 2375+500 2570+500 2 7 8 0 ~ 2970+500 3180+500
no load
rpm
';1200 ';800
no load
CJ
z Compression ratio
ratio - 18.0
0 Fuel injection timing deg

de g 10±1 12±1 14±1 16±1
~ (FID, b.T.D.C.)
)
3.04±O.
3.04±O.1
1 (31±1), at 250 rpm
t5 (kgf/cm')
MPa 19.6+ g (200+ g)
CJ IlkQf/cm')
Recommended diesel ga s oil - ISO 8217 DMA, BS 2869 A l or A2 (Cetane No. 45 min.)
Lubrication
Lubrication system - Forced lubrication with
with trochoid pump
€ 3.6/1.3 5.0/1.7
Max/Effective
Cooling system - Liquid cooling/Radiator
Cooling fan
mm Pusher type, 6 x <1>335
No. of blade x dia.
Crank V-pulley dia.
<1>120 <1>90 <1>110 <1>110
Fan V-pulley dia. mm
Governor - Mechanical centrifugal governor (All speed type)
*1 Dimensions L x W x H mm 553 x 489 x 565 520.5 x 489 x 565/ 528 x 489 x 565
*1 Dry weight kg 138 1121128

Transient speed
,;10 ,;8 ;12
difference
w Governing
I I I
) Steady state
z perform- ,;5 ,;4 ,;9 ,;8 ,;7 ,;6
speed band
<{ nce
;;
r
(full speed Recovery time sec ,;5 ,;6
0 range)
"- Fluctuation of
cr
w rpm ';15 ;25
revolution
0
0.25 ± 0.05 0.29±O.05
l . 0 . press. Rated operation MPa
(kgf/cm')
2.5 +0.5) (3.0±0.5)
Idling >0.06 (>0.6)
* 1 . Designation of engine dimension and dry weight in numerals.

application:
1 5
1 6 3TNE82 *Output conditions: Intake back pressure 250 mmAq, Exhaust back pressure ~ 5 5 mmAq,
Model
3TNE82
Item Unit
Application - CL VM CH I VH
TYl'.e - Vertical, 4-cycle water·cooled diesel engine
No. of cylinders - Bore x Stroke mm 3-82x90
Continuous
rating
kW(HP)
10.5
14.1
12.7
(17.0) - - - - - - 21.0 24.4
(28.2) 32.7) - - -
Output*
11.6 14.0 15.5 16.9 18.4 19.9 21.3 23.2 23.2 26.9 24.4 25.6 26.9
Max. rating kW(HP)
(15.6 (18.8) (20.8) (22.7) 24.7) (26.7) (28.6) (31.1\ (31.1 ) (36.1) (32.7) (34.3) (36.1)
Max. revolution speed at 1 5 7 0 + ~ 2 1 6 0 + ~ 2 3 7 5 + ~ 2 9 7 0 · ~
187 257 2 7 8 0 ~ 3 1 8 0 ~ 3 1 5 0 ~ 3 7 4 5 ~ 3455 367 3 8 9 0 ~
no load
0 0
. rpm
~ 1 2 ~ 8 ~ 1 5 ~ 8
no load
ti l
0 Fuel injection timing deg 10±1 12±1 14±1 16±1 24±1 18±1 20±1 24±1
(FID, b.T.D.C.)
~ Compression pressure MPa
u 3.04 ± 0.1 (31 ± 1), at 250 rpm
U (k9t/cm')
w Fuel injection pressure MPa
>. 1 9 . 6 + 1 ~ 2 0 0 + 1 ~ )
til ~ k g f / c m )
Max/Effective € 4.7/1.8 6.9/2.1
Cooling fan
No. of blade x dia. mm Pusher type, 6 x <1>335
Crank V-pulley dia.
Fan V-pulley dia. mm <1>120/<1>90 <1>110/<1>110
556 x 486 x 623
*1 Dimensions L x W x H mm 589x486><623 556 x 486 x 623/ 564 x 486 x 623 ;s4 x 486 x 623 564 x 486 x 623
*1 Dry weight kg 161 138/155 149 1381149

Transient speed
difference $12 $12
I I
)
perform- speed band $5 $4 $8 7 $6 $4
«
Z
::;
ance
: (full speed Recovery time sec $5
f2a: range) Fluctuation of
w r volution
rpm ~ 1 5 25
<>.
0.29±O.05
L.a. press. Rated operation MPa
(kgf/cm')
(3.0±0.5) ~ : 3.5±O.5
3 4 ± O . ~ ~
Idling >0.06j>0.6L
1 6
1 7 3TNE84 * utput conditions: Intake back pressure $ 250 mmAq, Exhaust back pressure $ 550 mmAq,
D 1005-1986. After
other conditions complying with JIS 30 run·in.
minimum hour's
Model
3TNE84
Item Unit
Displacement 1.496
Revolution s eed rpm 1500 1800 2000 2200 2400 2600 2800 3000 3000 3600 3200 3400 3600
Continuous
rating
kW(HP)
11.3 13.5
(15.2) (18.1)
- - - - - - 22 4 26 1
(30.0) (35.0)
- - -
Output*
12.4 14.8 16.4 18 1 19.7 21.3 23.0 24.6 24.6 28.7 25.6 27.0 28.3
Max. rating kW(HP)
(16.6) (19.8) (22.0) (24.3) (26.4) (28.6) (30.8) (33.0) (33.0 (38.5) (34.3\ (36.2) (38.0)
Max. revolution speed at ..
1 6 0 0 ~ 19 0 217S sg 2 3 7 5 · ~ 2600 sg 2 8 0 0 ~ 3 0 0 0 ~ 3225 • 3 2 0 0 ~ 3800 0 3 4 5 5 ~ 3670 0 3 8 7 0 ~
no load
rpm
Min. revolution speed at $1200 $800 $1500 $800
no load
Power take
take ooff
ff - Flywheel
z Compression ratio
n
- 18.0
(FID, b.T.D.C.)
)
3.24 ± 0.1 (33 ± 1), at 250 rpm
3 I kgf/cm' .
. MPa 19.6+' : (200+': )
n
(kgf/cm'
4.7/1.8 6.9/2.1
Max/Effective
Recommended
Recommend ed lubricating oil - API grade CC class or higher
Cooling water capacity 2.0 (for engine only)
Cooling fan
Crank V-pulley dia.l
Fan V-pulley dia. mm <1>120/<1>90 <1>110/<1>110

556 x 486 x 623
1 Dimensions L x W x H mm 589x486x623 556 x 486 x 6231 564 x 486 x 623 564 x 86 x 23
564x 486 x 623
1 Dry weight kg 161 138/155 149 38 49
Transient speed
% $10 $8 $12 S10 S8 S12
difference
w Governing
) Steady state
% $5 S9
, S8
, $7 ,;5 ,;4 ,;8
z perform- speed band 54
..: ance
:;
: (full speed Recovery time sec ,;5 ,;6 ,;5 ,;6
0 range)
LL
a: Fluctuation of
w rpm ,;15 ,;25 ,;30
revolution
a.
0.29±O.05 0.34±O.05 O.39±O.O5
(kgf/cm )
(3.0±0.5) (3.5±O.5) (4.0±0.5)
Idling >0.06 r O.6)
1. Designation of engine dimension and dry weight in numerals.
VMNH application: engine with back platelwith flywheel hausing
1 7
1 Specificatl ns and Perf rmance
1 8 3TNE88 * utput conditions Intake back pressure 250 mmAq, Exhaust back pressure 550 mmAq,
other conditi
conditions
ons comply
complying
ing with JIS 0 1005-
1005-1986.
1986. After m
minim
inimum
um30 hour's run-in.
Model
3TNE88
Item Unit
Application - CL VM
Twe - Vertical, 4-cycle water-cooled diesel enqine
Combustion svstem Direct injection system
No. of cylinde
cylinders
rs - Bor
Bore
e x St
Stroke
roke mm - 3-88x90
DisDiacement € 1.642
.£irir1.9 order - 1-3-2-1
Revolution
Revolut ion speed rpm 1500 1800 2000 2200 2400 2600 2800 3000
Continuous
rating
kW(HP)
12.3
(16.5)
14.8
(19.8)
- - - - -
Output*
13.5 18.0 19.9 21.6 23.5 27.1
Max. rating kW(HP) 1 6 ~ 1 2 5 . ~ )
(18.1 )
(18.1) (21.9 (24.
(24.1
1) (26.7) (29.0) (31.5) (33.8 (36.3)
1600+ g 1900 +'00 2175+ 0 2375 + g 2600+ g 2800+ g 3000+ g 3225+ g
50
no load
rpm
~ 1 2
no load
Direction of rotation Counterclo ckwise (viewed from flYW
flYWhee
heel)
l)
Power take off - Flvwheel
z
n
0 Fuel injection timing deg 10±1 12±1 14±1 16±1
(FlO, b.T.D.C.)
)
3.43 ± 0.1 (35 ± 1), at 250 rpm
U (kOi/cm')
UJ
-n Fuel injection pressure MPa
I kOi/cm') 19.6 +'g (200+'g )
Recommended diesel ga s oil - ISO 8217 DMA, BS 2869 A l or A2 (Cetane No. 45 min.)
Lubrication svstem - Forced lubrication with trochoid pum
€ 4.7/1.8 6.9/2.1
Max/Effective
Recommended lubricating oil - API qrade CC class or hiqher
Liquid cooling/Radiator
Cooling fan
No. of blade x dia.
Crank V·pulley dia.i
Fan V-pulley dia. mm <1>120/ 90 <1>110 <1>110
Governor - Mechanical centrifuQal qovernor (All speed type)

1 Dimensions L x W x H mm 589 x 486 x 623 556 x 486 x 623 / 564 x 486 x 623
1 Dry weight kg 161 138/155

Transient speed
% $8 $12
difference
UJ Governing Steady state
I
)
z perform- % $5 $4 $9 $8 $7
speed band
<{
ance
::<
: (full speed Recovery time sec $5 $6
0 range)
u.
: Fluctuation of
rpm
rpm $15 $25
UJ revolution
-
0.29 ± 0.05 0.34±O.05
L.O. press. Rated operation MPa 3.0 ± 0.5) (3.5±O.5)
(kgf/cm')
Idling >0.06 (>0.6)
1. Designation of engine dimension and d ry weight in numerals.
application:
VMNH application:
applica tion: engine with ba ck plate/with flywheel hausing
1 8
1 9 4TNE82 * utput con dit ions:

io ns: Intake back pressure
other conditions complying with
pressure 250 mmA
with JIS D 1005-1986
mmAq, q, Exhaust back pressure
pressure 550 mmAq,
1005- 1986.. After minimum 30 hour's run-in.
Model
4TNE82
Item Unit
Application - CL I VM CH I VH
Type - Vertical, 4-cycle water-cool ed diesel engine
Vertical,
Combustion system Direct injection system
No. of cylin
cylinders
ders - Bor
Bore
e x Stroke -
mm 4 82x90
Displacement t 1.901
Firing order - 1 3 4 2 1
Revolution s e e d rpm 1500 1800 2000 2200 2400 2600 2800 3000 3000 3600 3200 3400 36
Continuous
rating
kW(HP)
14.3 17.1
19.2) 22.9)
- - - - - - 27.7 32.7
37.1) 43.9)
- - -
Output*
15.7 18.8 20.6 22.6 24.5 26.5 28.5 30.5 30.5 36.0 32.4 34.2 36.0
Max. rating kW(HP)
21.1) 25.2) 27.6) 30.3) 32.9) 35.5) 38.2) 40.9 40.9) 48.3) 43.4) 45.9) 48.3)
Max. revolution speed at ..,
1 5 7 5 + ~ 1 8 7 0 ~ 2 1 6 0 ~ 237S sg 2 5 7 0 ~ 2 7 8 0 · ~ 2 9 7 0 + ~ 3 1 8 0 + ~ 3 1 5 0 ~ 374S sg 3 4 5 5 ~ 3670 0 aaw :
no load
rpm
1200 5800 1500 5800
no load
z
n
Compression ratio
ratio - 18.0
a Fuel injection timing
deg 10±1 12±1 14±1 16±1 24±1 18±1 20±1 24±1
(FID, b.T.D.C.)
u Compression pressure MPa
u: 3.04±O.1 (31±1), at 250 rpm
ti I (kgf/cm')
. MPa
1 9 .6 " g (200"g )
n (kgf/cm')
Recommended diesel gas oil - ISO 8217 DMA, BS 2869 Alar A2 (Cetane No. 45 min.)
t 5 8/2 3 7 9/2 5
Max/Effective
Recommended l ubricating oil - APlJlrade CC class or higher
Cooling system - Liquid coolinQiRadiator
Cooling water capacity t 2.7 (for engine only)
Cooling fan
mm Pusher type, 6 x ~ 3 7 0
No. of blade x dia.
Crank V-pulley
Fandia.
V-pulley dia. mm ~ 1 2 0 ~ 9 0 ~ 1 1 0 ~ 1 1 0
overnor - Mechanical centrifuQal governor (All speed type)

683 x 498.5 658 x 498.5 650 x 498.5 x 6181
*1 Dimensions L x W x H mm 632 x 448.5 x 618/658 x 498.5 x 618
x 618 x618 658 x 498 x 618
* 1 Dry weight kg 184 160/170 170 160/170
Transient speed
510 58 512 510 58 512
difference
z
..:
periorm-
ance
speed band 55 54 58
I 7
I 56 55 4 58
e
: (full speed Recovery time sec ,;5 56 55 56
range)
2 Fluctuation
Fluctuation of
a: rpm 15 ,;25 530
w revolution
a.

(kgf/cm') I0.29±O.05
3.0±0.5) 0.34±O.05
(3.5±O.5)
Idling >0.06 (>0.6)
* 1 . Designation of engine dimension and d ry weight in numerals.

VMNH applicat
application:
ion: engine with back platelwith fly wheel hausing
1-9
1 Spocifications and erformance
1 10. 4TNE84 * Output conditions: Intake back pressure" 250 mmAq, Exhaust back pressure" 550 mmAq,
Model
4TNE84
Item Unit
Application - CL I VM CH I VH
Displacement 1.995
Firing order - 1 3 4 2 1
Revolution
Revolutio n speed rpm 1500 1800 2000 2200 2400 2600 2800 3000 3000 3600 3200 3400 3600
Continuous
rating
kW(HP)
14.9 17 7
(200) (23.7)
- - - - - 29.9 34 7
(40.1) (46.5)
- - - -
Output*
16.4 19.5 21.9 24 1 26.3 28.5 30 7 32.9 32.9 38.2 33.9 35.8 38.2
Max. rating kW(HP)
(22.0) (26.1) (29.4) (32.3) (35.3) (38.2) 41.2 (44.1) (44.1) (51.2) (45.5) (48.0) (51.2)
Max. revolution speed at .
1 5 7 5 · ~ 1 8 7 0 ~ 2 1 8 0 ~ 2 4 0 0 ~ 2 5 9 0 ~ 2 8 1 0 ~ 995 0 321 ••0 3 1 5 0 ~ 3 7 4 5 ~ 3 4 5 5 ~ 3 6 7 0 ~ 3890 :
no load
rpm
,,1200 ,,800 ,,1500 ,,800
no load
C/l
(FID, b.T.D.C.)
0
u
(kgf/Cm'1 3.24±O.1 (33±1), at 250 rpm
Q
w
Fuel injection pressure MPa 19.6+ g (200+'g) 19.6+ ·g (200+'g)
C/l kgf/cm')
5.8/2.3 7.9/2.5
Max/Effective
Cooling water capacny 2.7 (for engine only)
Cooling fan
Crank V-pulley dia.
Fan V-pulley dia. mm <1>120/<1>90 <1> 0/<1> 0
683 x 498.5 658 x 498 5 650 x 498.5 x 6181
1 Dimensions L x W x H mm 632 x 498.5 x 618/658 x 498.5 x 618 65B x 498.5 x 618
x618 x618
1 Dry weight kg 184 160/170 170 160/170
Transient speed
difference % SIO S S12 $10 $8 $12
I I
z perform- speed band % $5 ,,4 ,,9 sa 7 $5 $4 $8
<C
::;:
ance
: (full speed Recovery time sec $5 $6 $5 ,,6
0 range)
u..
: Fluctuation of
revolution rpm $15 $25 $30
0
0.29±O.05
L.O. press. Rated operation (kgf/cm') (3.0±0.5)
MPa (:34±O.05
3.5±O.5)
Idling >0.06 (>0.6)
*'. DeSignation of engine dimension and dry weight in numerals.
*'. DeSignation of engine dimension and dry weight in numerals.
1-10
1 Specifications and P rformanClJ
1-11. 4TNE88 * output condi

conditions:
tions: Intake back pressure 250 mmAq Exhausl back pressure 550 mmAq
other conditions complying with JIS D 1005-1986. After minimum 30 hours run·in.
Model
4TNE88
Item Unit
flpplication - CL I VM
Tvoe - Vertical, 4-cvcle water-cooled diesel engine
Combustion system
No. 1 cvli
cvlinders
nders - Bore
Bore x Stroke
Stroke -
mm
Direct injection system
4-88x90
Firin" order - 1-3-4-2-1
Revolution speed rpm 1500 1800 2000 2200 2400 2600 2800 3000
Continuous
ratina
kW(HP)
16.4
(22.0)
19.6
(26.3)
- - - - - -
Output*
18.0 21.6 24.1 26.5 28.8 31.3 33.7 36.0
Max. rating kW(HP)
(24.1
(24.1) (29.0) (32.3) (35.5) (38.6) (42.0) (45.2) (48.3)
Max. revolution speed at 1870 s
1 8 0 + 5 ~ 2 5 9 0 + 5 ~
1 5 7 5 + 5 ~ 2 4 0 0 + 5 ~ 2 8 1 0 + 5 ~ 2 9 9 5 + ~ 3 2 1 0 + 5 ~
no load
rpm
~ 1 2
no load
Direction 01 rotation - Counterclockwis
Counterclockwise
e (viewed Irom Ilvw heel)
Power take off - Flvwheel
z
C/l Compression ratio - 18.0
0 Fuel i n j e c t i o n ; . ~ i m i n g
deg 10±1 12±1 14±1 16±1
~ (FlO, b.T.D.C.
)
3.43±O.1 (35±1), at 250 rpm
(3 (kiii/cm')
. MPa 19.6 (200 1 9 . 6 + 1 ~ 2 0 0 + 1 ~ )
C/l , kiii/cm )
Recommended diesel cas oil - ISO 8217 DMA, BS 2869 A l or A2 (Cetane No. 45 min.)
Lubrication system
Lubrication - Forced lubrication with trochoid pum
f 5 812 3 7.9/2.5
Max/Effective
Recommended lubricating oil - API arade CC class or hiaher
Coolina system - Liquid coolin-aiRadiator
Cooling water capacity f 2.7 (lor enQine only)
Cooling Ian
No. 01 blade x dia.
Crank V-pulley
Fandia.
V-pulley dia. mm $120/$90 $110/$110
Governor - Mechanical centriluaal covemor (All speed type)
*1 DimenSions L x W x H mm 683 x 498.5 x 618 632 x 498.5 x 618/658 x 498.5 x 618
*1 Dry weight kg 184 160 /170

Transient speed
,,10 ,,8 ';12
difference
I
w Goveming Steady state
) ,;;a
z pertorm- % ,,5 ,,4 ,,9 ,;;7
speed band
«
::;:
nce
I: (lull speed Recovery time sec ;5 ;6

0 range)
LL
II: Fluctuation 01
w rpm ,,15 ,;25
revolution
a.
L.O. press. Rated operation MPa 0.29±0.05

3.0 i O.S ~ : 3.5±O.5
3 4 ± O . ~ ~
(kgl/cm')
Idling >0.06 (;,(l.6)
*1 . Designation 01 engine dimension and dry weight in numerals.
CUCH applicati
application:
on: engine with flywheel housing
VMNH application: engine with back plate/with Ilywheel haus ing
1-11
1-12. 3TN E84T Output conditions 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.
Model
3TNE84T
Item Unit
Type - Vertical. 4-cycle water-cooled diesel engine
Combustion system - Direct inection syste
system
m
Firing order - 1 3 2 1
Revolution s eed rpm 1500 1800 2000 2200 2400 2600 2800 3000 3000 3600 3200 3400 BOO
Continuous 14.0 16.6 28.0 30.5
rating
kW(HP)
(18.8) (22.3)
- - - - - - (37.5) (40.9)
- - -
Output*
15.8 18.8 21.0 22.8 25.0 26.9 29 1 30.9 30.9 34.2 32.0 33 1 34.2
Max. rating kW(HP)
(21.2) (25.2) (28.2) (30.6) (33.5) (36.1) (39.0) (41.4) (41.4) (45.9) (42.9) (44.4) (45.9
no load
1 6 0 0 ~ 1 9 0 0 ~ 2 1 7 5 · ~ 2 3 7 5 · ~ 2 6 0 0 ~ 2 8 0 0 ~ 3 0 2 0 · ~ 3 2 4 0 ~ - - - - -
rpm
Min. revolution speed at 50
no load
1 2 0 0 ~ 0 -
n
5 - - -
FID, b.T.D.C.) deg 10±1 12±1 14±1 16±1 -
iI Compression
Compressi on pressure MPa
2.94 ± 0.1 (30 ± 1), at 250 rpm
U (kgf/cm'i
w
"-n Fuel injection pressure MPa 19.6+1g (200+ g )
I k 'lf/cm')
Recommended diesel gas oil - ISO 8217 DMA, BS 2869 Al or A2 (Cetane No. 45 min.)
f 4.8/1.9
ax/Effective
Cooling water capacity f 2.0 (for engine only)
Cooling fan
No. of blade x dia. mm Pusher type,
type, 6 x <1>335
Crank V-pulley
V-pulley dia.l
dia. l
Fan V·pulley dia. mm <1>110/<1>90 <1>110/<1>110

*1 Dimensions L x W x H mm 589x54 0x629 632 x 540 x 629 632 x 540 x 629 - -
*1 Dry weight kg 166 147/160 - -
Transient speed
ifference % ,;10 - -
w Governing
perform-
Steady state
speed band ~ 4 ~ 9
I I
,;8 - -
<C
::;:
ance
I: (full speed Recovery time sec $5 -
0 range)
u.
Fluctuation of
I:
rpm ~ 1 5 ~ 2 2
revolution
-
0.29±O.05 0.34±O.05(3.5±O.5)
L.O. press. Rated operation MPa (3.0±0.5)
(kgf/cm')
Idling >0.06 (?0.6)
1-12
1-13. 4TNE84T Output con dit ion s: Intake bac

backkppress
ressure
ure 5 250 mmAq, Exhaust back pressure 5 550 mmAq,
other conditions complying with JIS D 1005-1986.
1005-198 6. After m
minimum
inimum 30 hour's ru
run-in.
n-in.
Model
4TNE84T
Item Unit
AEPlication - CL I VM CH VH
Type - Vertical,
Vertical, 4· cycle water-cooled diesel engine
No. of cyl
cylinders
inders - Bore x Strok
Stroke
e mm 4 84x90
Firingorder - 1 3 4 2 1
Continuous
rating
kW(HP)
19.1 24.3
25.6) 32.6)
- - - - - - 37.1 40.6
49.8) 54.7)
- - -
Output*
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
Max. rating 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)
no load
1 6 0 0 + ~ 19
.
0 2 1 7 5 ~ 2 3 7 5 ~ 2 6 0 0 ~
.
2800 • 3 0 0 0 + ~ 3 2 2 5 · ~ - - - - -
rpm
o load
1200
50
0 800
,50
0 - -
n
Compression ratio
Z - 18.0
0
~
Fuel injection timing
(FID, b.T.D.C.)
deg 10±1 12±1 14±1 16±1 - - - -
0
u 2.94±O
2.94±O.1
.1 (30±1), at 25 0 rpm
(3 (kgf/cm')
w
Fuel injection pressure MPa
1 9 . 6 ~ ( 2 0 0 ~ ) 1 9 . 6 ~ 2 0 0 + 1 ~ )
n {kgf/cm'\
Recommended diesel gas oil - ISO 8217 DMA, BS 2869 A1 or A2 (Cetane No. 45 min.)
ax/Effective
€ 5.8/2.3 -
Cooling water capacity € 2.7 (fo r engine only)
Cooling fan
mm Discharge type, 6 x $370
No. of blade x dia.
Crank V-pulley dia. mm $110/$90 $110/$110
Fan V-pulley dia.
overnor - Mechanical centrifugal
centrifugal g overnor (All speed type)
*1 Dimensions L x W x H mm
674 x 498.5
x713
641 x 498.5 x 713/649 x 498.5 x 713 - -
*1 Dry weight kg 184 165/ 175 - -
Transient speed
difference 510 ,,8 512 - - -
w Governing
perfonm-
Steady state
speed band
55 ,;;4 59
I 58
I 57 - - -
::; ance
r: (full speed
0 range)
Recovery time sec 55 56 - -
- Fluctuation of
cr: rpm 515 522
revolution
Rated operation MPa 0.29±O.05 O.34±O.O5

L.O. press. (3.0±0.5) (3.5+0.5)
(kgf/cm')
Idling ;'0.06 (;'0.6)
1. Designation of engine dimension and dry weight in numerais.

VMNH applicati
application:
on: engine with back plateiwith flywheel hausing
1-13
2 Cross Sec/ional View
2 Cross Sectional Views
2-1. Special Swirl Pre-combustion Cham. Cham.ber

ber System
I n d i r ~ c t Injection System
rocker arm cover
Fuel injection I
Valve rocker arm
Cylinder head
Fuel injection pump
Piston
Camshaft
Connecting rod
If
Ur
t I
oil suction pipe
21
2 Cross Sec/lonaf View
2 2. Direct Injection System
Valve rocker arm cover

Fuel injection valve
Valve rocker arm
Cylinder head
Fuel Piston
injection
pump
Camshaft
motor
L
Connecting rod
.LD
Lube oil suction pipe
2 2
3 Cooling Water Lubricating Oil and Fuel all
3. Cooling Water, Lubricating Oil and Fuel Oil

3-1. Cooling water 3-2. Lubricating oil
1. Proper use of cooling water 1. Proper use o f lubricating oil

Impurities in cooling water are deposited in Use of proper lubricating oil brings about the
the engine and radiator in the form of scale following effects.
and cause rusting. For this reason, heat
conduction ol ththe
e cooling system
system and cooling
cooling (1) The friction part of the engine is protected
water flow are impaired, and cause cooling from friction and wear.
functions to reduce and the engine to over (2) The engine parts is protected
protecte d ffrom
rom rusting
rusting
heat. Therefore, drain the cooling water at and corrosion.
intervals
interva ls of 400 hours or one year. Never
Nev er use
use (3) The high temperature
tempe rature part
par t of the engine is
hard water as the cooling water.
water. effectively cooled.
In order to prevent the cooling water from (4) The engine is protected
protec ted from leakage of
freezing in cold weather, be sure to use an combustion gas.
antifreeze agent. For further information on (5) The engine parts are protected from
and proper usage and type of rust-preventive
rust-preven tive sludge deposits.
agents, antifreezes, and cleaning agents,
contact your nearest dealer. Forthe above reasons, use lubricating oil API
2. ooling water system diagram Service Classification Class CC or better.

Indirect injection system and direct injection
system
Reference : Lubricating oil to be used a t]

[ ambient temperature
li Sub-tank Select the viscosity of lubricating oil depend
Cylinder block ing on ambient temperature at which the
engine is used, according to SAE Service
I
Cooling water pump
Grade shown below.
I
I 1
L-ff0+----1
L.O. cooler opUon)
·30 20 I. 1 2 3. 4 ( C)
, • ,
J I I I I
Ambient temperature at which the engine is used. C
~ Recommended SAE Service Grade
3-1
3. Cooling Water Lubrlcallng all and Fuel Oil
2. Lubrication system diagram
1) Indirect Injection system
r -- -
I
-l L.O. cooler I Option)
I
Pressure Fuel injection
Idle gear shaft
regulating valve pump
LO. suction
pipe strainer)
\ ilpan
2)
2 ) Direct Injection system
Option)
L.O. cooler ~ 1 r Turbocharger

I L r ~
~ - - ~ f ~ ~ = : - - - , : I w/turbocharged
I I I eng ine only)
I
I
r - - . - ~ I filter
L.O. = ; - - i l I
with
with b ypass valve) L _
I
I
l
w/tubocharged
engine only
aces
Oil pan
\ ~ \ ~ ~ ~ _ ~ _ ~ _ _ ~ _ ~ ~ r ~ _ ~ _ ~ _ ~ ~ _ ~ _ ~ _ ~ _ ~ _ _ _ ~ ~ i f /
3 2
3. Cooling Water Lubricating Off and Fuel 11
3-3. Fuel oil
1. Proper use of diesel gas oil 2) Deposits in the piston ring groove
Use a diesel gas oil equivalent to or better Deposits in the piston ring groove cause
than IS08217 DMA, 8S2 8S2869
869 Part
Part 1 ciassA1
ciassA1 blow-by gas, poor lubrication, imperfect
or Part 2 class A2. Cetane Number:
Number: 45 min.) combustion, excessive fuel consumption,
Give your customers instructions on proper contamination of lubricating oil, premature
use of fuel oil, or the customers may suffer wear, etc. of the cylinder liner and piston
from troubles stated below. ring.
1) Deposits on the exhaust valve 3) Clogging o r corrosion o f nozzle hole

Deposits on the exhaust valve cause in fuel Injection valve
unburnt oil mixture in exhaust gas and Imperfect combustion causes the fuel in-
erosion of the exhaust valve seat, to occur jection mechanism to wear and corrode
in addition to poor compression, imperfect and the nozzle to be clogged.
combustion, excessive fuel consumption,
etc.
2. Fuel system diagram
1) Indirect injection system
Fuel injection pip
Fuel oil return pipe
to tank _ _ ... Fuel injection pump
~ i l separator option)
Fuel filter
Fuel feed pump from fuel tank
2) Direct Injection system

Fuel injection pipe
.Fuel oil return pipe
Fuel injection pump

to t a n k .
L I
Air·bleed p i p e - - - - L
Oil separator option)

Fuel filter
Fuel feed pump from fuel tank
4 Troubleshoollng
4 Troubleshooting
4 1. Trouble causes and remedies 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
The following table summarizes the symptoms and causes of general troubles. If any symptom of trouble
trouble is
extremely important for extending the service life of the engine.
found, a corrective action shall be taken before the said symptom develops into a serious accident.
' ','. . P ar iii

§
~ v v l i ; , ~ Air
Fails to start engine vh 15 "."." Lubricating oil
water intake
output color E
Sy mptom of trouble
Engine
starts but
Exhaust
color
I D U r i n g , ~ ]
w o r k : J . ~ Iii
Ii E
Corrective action
f-,st_op_sso_o_n-t---r-o"_t--.---I] ;= g. ,- I l:l
g ~ [ iii ;
1) t i l
Exhaust en
I; 3 1
i
Cause
'j; I--S,m_O..,.ke---l ] i U
wi-z-..Jl:lQ)~-a:~·~~ro~·~~.cc
13: ~ C i ' i f ~ : : J
·
c5 &.ii
~ ~ ~ g ~
O:?..J:: O
Improper clearance of intake/exhaust valve o 0 o o o o Adjust valve clearance (Refer to '6,6-2,)

Compression leakage from the valve seat o o o o o Rap valve seat (Refer to ~ h ~ n t ~ r 7, 7-1-2,)
Seized intake/exhaust valve o 10 0 0 0 o o 0 o o ,0 Correct or replace.

Blowout 01 cylinder head gasket o o 0 Replace the no<kAi (Refer to v, "'fHCr 8, o - Z - t I U) )
Seized or broken piston ring o 10 0 0 o o 0 00 00 o the piston ring. (Refer to r .,. 7 -2 :4 -3 , 4 , 5 ))

Worn piston ring, piston and ~ 1 v v ' 10 10 0 00 o honing and use oversize parts, (Reier to Chapter 7, 7-2-3. & 7-4-(8) )
Seized crank pin metal and vVQ' o 1010 0 o ~ e p a i r or
E Improper of piston ring joints o 10 o o Correct the ring joint i' (Refer to 7, 1-4-\, ))
*
a a ~ v , , , ,
Reverse assembly of the piston ring 10 0 o o reassemble. (Reier to 7,7-4-(5) )

if Worn crank pin and journal_ ~ c,al
' ' o o o Measure and r e p ~ e . Refer t a _ ~ ' r 7, 7-5-3. and 7 - 7 : ~ l . l
,5, I ' W ' ' ' ' C v ' ' ' ' ~ rod bolt 10 10 Tighten bolt to the , j torque, (Refer to C ~ t O , - t O : 1 . : )
ill r
atter 'I-'''v in combustion chamber 0 o o o Disassemble and repair the combustion chamber. Eliminate loreign matte ,
1
i gear backlash o Adjust meshing 01 gears, (Reier to Chapter 7, 7-8·(2) )
Worn valve guide of intake/exhaust valves o o o M p ~ o , , , and , (Refer to Chapter 7, 1-1-1 ) )
Poor 10 Repair and adjust. (Refer to ' 13,)

Improper open/close timing of intake/exhaust valves o o
r~DirtY~ b_ll_ er _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _
o _ ~ ~ + - + - 4 - ~ 0 4 - ~ 0 4 - 4 - - r - r - r - r - r - r - r - r - + - + - + - + - + ~ ~ O ~ ~ r - ~ ~ ~ C ~ l e a ~ n t h ~ e ~ b ' I ~ o , . e ~ r , ______________________
l Waste gate malfunction 0 0 0 Disassemble and inspect the waste gate,
o
Worn journal vca,,, 0 0 Disassemble and inspect t h e ~ bearing.
:J
I
E effect of .0 10 0 Molf . octian of,,, : (kept closed). Iho,o, 'v . 6, 6-9)

Cooling effect of radiator, insufficient 10 0 0 belt I R e f ~ ) ,lReler to cnapler b, 6·9) SI'I'p'ng Ian
00 ~ l n ~ s ~ u f f f f i ~ c i ~ e ~ n t ~ , v ~ v , ~ . v , , ~ ~ w : a ~ t ~ e r ~ l ~ e v : e ~ I - - - - - - - - - r - l - r - l - _ t ~ r _ t O r : r _ t _ I I _ t - - I - t - I I _ t _ j j _ t _ I I _ t _ ] j _ t _ I l _ t r o ~ - j - - t - i c o ~ - j ~ t - I I ~ v ~ ~ ~ \ ~ , ~ ~ ~ ~ ~ 1 ~ : r . ~ : 3 ~ ; ~ .at - ' 1 ~ 1 e
Cracked water jacket 0 0 0 Repair and replace.

en Slackened fan belt tension 0 0 0 Adjust Ian belt tension. (Refer to Chapter 6, 6-3)
~ ~ ~ - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - t - ~ - ~ ~ - ~ - - - ~ - ~ - - - t - - ~ - - - r - t - - r - t - - r - t - ~ - ~ ~ - r - ~ - - t - ~ - - - ~ ~ - - - - - - ~ - - ~ ~ - - ~ - - ~ ~ ~ - - ~ - - - - - - - - 1
5 Poor thermostat 0 0 0 Check or replace, (Refer to Chapter 6, 6-9)
o
()
4-1
4 TroubleShooting
c
Insufficient Poor 0
~ o o l i n Air
Fails to start engine exhaust Hunting Lubricating oil
output
il
calor E
water intake
Symptom of trouble 8 0
c
0
c
Engine Exhaust During
0>
:J 0 U)
starts but calor 'cc '" ac E c0

e '"
·c
·c 0 c
work :J U
0 '6>
1ij
0 :J
stops soon -g
c U) li :J [>
.Q
U)
E '§ :J
;:
a
[>
'
*
1;) :J 1;) 0 :J '0 :J gj T
£'
.0 0
:J .s; .Q U)
5 ;:
U) 0>
Exhaust U
.0 Q) c Q) U) E a.
c g> E .B 0 0 Q)
.<:: .2 [> Sl
' E Q)
0)
Cause moke .S c .2 0 .<::

a. ·c
U) E
I
0 0
J: 0
: '6> >- Sl
;
0
c
:§ c 2 >
.' .0
e 0 ,2 iii [> e
'' e(;
> c Q>
'iii U) Q> 1i)
g> c 0 :J :J
e
0) 0)
C S .l -' .l -' -' :0 c U) U)
.$ .J .<:: .<:: :J
U
1;l 1;l x
:J
ll ll .<::
e '" l3 ' 'x
.<:: :J
§ § ;:
e
) 0)
U 0 0
'" c .2
W Z '"
...J ::;: 0: ;;:: (jj ;;:: (jj
.21
I f- ::J 0 0 j 0
a. w w is :<
x x 0
...J
:J
::;: 0 a. a. w
[>
Improper properties of lubricating oil 0 0 0 0 0 0 Use proper lube oil (Refer to Chapter 3, 3-2.)
E Leakage from lubricating oil piping system 0 0 Repair
- Insufficient delivery capacity of trochoid pump
J) Check and repair (Refer to Chapter 7,7-9)
- Clogged lubricating oil filter
(5 0 0 Cleaning or replace
0)
Poor pressure control valve 0 Clean, Adjust or replace
Insufficient lubricating oil capacity 0
c Proper lube oil supply
.0
:J
...J
Excessively early timing of fuel injection pump 0 0 0 0 Check and adjust. (Refer to Chapter 6,6-5.)
Excessively late timing of fuel injection pump 0 0 0 0 0 0 Check and adjust. (Refer to Chapter 6, 6-5.)
Improper properties of diesel gas oil 0 0 0 0 0 0 Use proper diesel gas oil. (Refer to Chapter 3, 3-3.)
Water entering fuel system 0 0 0 0 0 0 0 Inspect and repair (Refer to Chapter 6, 6-7)
Clogged fuel filter 0 0 0 Cleaning or replace.
E Air entering fuel system 0 0 0
l Perform air bleed.
U)
- Clogged or cracked fuel pipe 0 0 0
J) Cleaning or replace.
Q) Fuel insufficiently supplied to fuel injection pump 0 0 0
J Inspect he fuel tank valve ccck, fuel filter, fuel piping, and fuel feed pump.
LL
Uneven injection volume of fuel injection pump 0 0 0 0 0 0 0 0 0 Inspect and adjust (Refer to Chapter and 12)
Excessive fuel injection volume 0 0 0 0 0 0 0 Inspect and adjust (Refer to Chapter and 12)
Poor spray pattern from fuel injection nozzle 0 0 0 0 0 0 0 0 0 Inspect and adjust (Refer to Chapter 6, 6-4-(2) )
Clogged air filter 0 0 0 0 0 Cleaning

.. E
Engine used at high temperature or at high altitude 0 0 0 0 0 Use more high-output engine
' U)
<:: >- Clogged exhaust pipe 0 0 0
X J) 0 Cleaning
~ I )
.-
«0
'"
Malfunction starting motor 0 . Repair or replace

Malfunction alternator 0
0)
.;::
Repair or replace
Open·circuit of wires 0
: Repair
.2 E Under voltage of battery 0
Q> Recharge of battery (Refer to Chapter 6, 6-8.)
0-
Q) U)
UiOl
4·2
4. Troubleshooting
4 2. Trouble diagnosis through measurement of

compression pressure
* or the compression pressure measuring

measur ing proce 3. Gas leak through
through the nozzle gasket or cylin-
cylin-
dure. refer to chapter 6. 6-1. Measurement o f der head gasket.
compression pressure. In addition, the compression pressure decreases
as the engine parts are worn and lose durability
Reduction in compression pressure of the cylin through use of the engine for a long period.
der is one of major causes of an increase in blow
Scratches on the the cylinder or piston
piston caused by
by gas which causes contamination and in
dust or foreign matter through the soiled air
creased consumption
consumpti on of lubricating oil,
oil, and other
cleaner element, and wear or breakage of piston
trouble) as well as the engine starting failure.
rings also decrease the compression pressure.
The compression pressure is influenced by the
For this reason, diagnose the engine status by
following factors;
measuring the compression pressure.
1 Degree of clearance between the piston and
cylinder.
2 Degree of clearance around intake/exhaust
valve seats.
1) auses and countermeasures to be taken when the compression pressure is less than
the limit value.

* Forth e compression pressure limit value
values,
s, relert o Chapter6, 6-1 Meas
Measurem
urem entol compression pressure.
No. Item Cause Countermeasur

Counte rmeasures
es
1 · Filter element of · Clogged filter element · Clean the filter element.

air cleaner
clean er · Broken filter element · Replace the filter
filte r element with a
· Defective filter elemen
elementt new one.
seal
2 · Valve clearance · Excessive valve · Adjust the valve clearance

clearance or no clearance ReIer to Chapter 6,6-2.
3 · Valve timing · Improper valve timing · Adjust the valve clearance

· Improper valve clearance Refer to Chapter 6, 6-2.
· Inspect and adjust of the valve
rocker arm. Refer to Chapter 7
7-3, 7-6 and 7-8.)
4 · Cylinder head gasket · Gas leak through the · Replace the gasket.
· Nozzle gasket gasket · Re-tighten the cylinder head
and nozzle to the specified
torque.
ReIer to Chapter 10 10-1.)
5 · Intake/exhaust valve · Gas leak caused by · Rap valve seats.

· Valve seat worn valve seats or Referto Chapter 7 7-1. 2.
trapped foreign matter · Replace the intake/exhaust
· Seizure of valves valves.
6 · Piston · Gas leak caused by · Perform honing and use oversize

· Piston ring scratches and wear of parts.
· Cylinder piston, piston ring and Refer to Chapter 7 7-2. 3. and
cylinder 7-4.8.
5 Special Service Tools and Measuring Inslrumenls
5 Special Service Tools and Measuring Instruments

Although main engine parts can be disassembled and reassembled only with standard service
tools, it is recommended to provide the following
following special service tools and measuring instruments
for more efficient and accurate work, correct measurement, diagnosis, and troubleshooting.
5 1. Special service tools
No. Tool name Applicable model and tool dimension Illustration
1 Valve guide (mm)

extraction tool ~ Dimension
I I d, d,
Model ............
213TNE68 20 55 5 8 ''
3TNE74 20 75 6.5 10 ,. \Y
3TNE78N82A 20 75 6.5 10
.
3/4TNE82
/4TNE84(T) 20 75 7.5 11
3/4TNE88
• Locally manufactured
2 Valve guide insertion (mm)

tool ~ i m e n s j o n
I I, d, d,
Model ............
2/3TNE68 7 60 11 17 ,
3TNE74 9 60 13 19
.
3TNE78N82A 12 60 13 19
3/4TNE82
~ 1 . . J
. 9-
3/4TNE84(T) 15 65 14 20
3/4TNE88
3 Connecting rod (mm)

bushing replacer Dimension
I I d, d,
Model ............
.
.(l.3 22.(l·3 ' '
213TNE68
TNE74
22
20
62
80
20.(l.'
21.(l·3
.(l.'
23.(l·3
.(l.,
, .
.(l.'
3TNE78N82A 25 85 3 ~ : ~ 6 ~ : ~
3/4TNE82
/4TNE84(T) 20 100 6 : g : ~ 9
.
3/4TNE88
4 Valve spring com·

pressor Model Yanmar Code No.
-
(Replacement of
valve spring) All model 129100-92630
e;.
5-1
5. Special Service Tools and Measuring Instruments

Instruments
No. Tool name Applicable model and tool dimension Illustration
5 Filter wrench Sold on market

(Removal and
installation of L.O.
filter)
---, ,(B-
6 Camshaft bushing (mm)

tool
~ Dimension d, d,
(Extraction of I, I
Model ---..
camshaft bushing) -0.3
13TNE68 13 SO 3S-O.s 39 ~ : ~ •
L'
3TNE74 14 SO 4 43 -0.3
o.s
TNE78A182A 18 70 5 ~ : ~
48 -0.3
-0.
3/4TNE82
18 70 48 -0.3
3/4TNE84(T) 5 ~ : ~ -o.s
0
3/4TNE88
7 Flex-Hone Yanmar Code No.

Model
(for honing cylinder
liner) 213TNES8 129400--92400
*: For the usage
3TNE74 129400--92410
procedure o the
Flex-Hone refer 3TNE78A182A
3/4TNE82 129400--92420
to Chapter 7 3/4TNE84(T)
7-2,3.
3/4TNE88 129400--92430
( Idr=
Model Yanmar Code No.
8 Piston insertion tool
(Insertion of piston) All model 95550-002476 .....,
Note: The above piston insertion tool is applica·
ble to pistons 60 125 mm in diameter.
E
Sold on market
9 Piston ring replacer
5-2
5 Special Service Tools and Measuring nstruments
5 2. Measuring instruments
No. Instrument name Purpose of use Illustration
1 Dial gauge Measures bent shafts distorted

flat surface gaps etc.
2 Test indicator Measures the limited small

portions and deep portions
unmeasurable with dial gauge.
3 Magnetic stand Used together with the dial

gauge: holds the dial gauge at
different angles.
4 Micrometer Measures the outsid

outside
e diameter
of the crankshaft piston and
piston pin etc.
5 Cylinder gauge Measures the inside diameter

of the cylind
cylinder
er liner connecting
rod metal etc.
: : : : : : D ) : : ) ~
6 Vernier callipers Measures the outside diameter

depth thickness width etc. of
various Hems. ~ ~ ; 1111 ,'
7 Depth Micrometer Measures the sinkage of the

valve.
8 Square Measures inclination of valve

spring square ness of engine
parts etc.
9 V-block Measures bent shaft.

53
5 Special SetVlce Tools and Measuri ng Inslruments

M easuring
No Instrument name Purpose of use Illustration
10 Torque wrench Used for tightening bolts and

uts to the sp ecified torques.
II
11 Thickness gauge Measures gaps between the
i
ings and mating ring grooves
and around shaft couplings
during installation
12 Cap tester Checks the fresh water system

or leakage.
i J
q. cL
13 Battery coolant Checks the antifreeze for

tester concentration and the battery
lectroly1e for speCific gravity.
and charging state
14 Nozzle tester Checks the fuel injection valve

for spray patterns and injection
pressure.
15 Digital thermometer Measures temperature of each

art.
~ ~ ~
p r o ~ D
16 Contact type Measures RPM of the rotary
shaft by bringing the gage
head into contact wnh the
mortise.
0111111111111 [ I l
0 Photoelectric type Applies a reflecting tape on the Revolving body

t:
circumference of the rotating
s
parts to measure RPM
~ w { ~ ~ § m
Reflecting tape
5-4
5 Special Service Tools and Measuring Instruments
No. Instrument name Purpose of use 1I1ustration
16 High pressure Measures engine RPM s using

fuel pipe pulse system, irrelevantly to the
clamping type center of the rotary shaft and the
circumference of the rotary object. High pressure pipe :
r ~ / = ~ · :
7 Circuit tester Measures the resistance voltage,

and continuity of electric circuits.
18 Compression Measures compression pressure.

gauge kit
Yanmar Code No.
TOL-97190080
55
6 Measurement Inspection and Adjustment
6. Measurement Inspection and Adjustment
6-1. Measuring the compression pressure
1. Measuring Procedure : Never fail to attach the gasket to the tip

(1) Warm up the engine. Remove the fuel of the adapter.
injection pipe and fuel injection valve from

the cylinder to be measured.
(2) Crank the engine before attaching the

compression gauge adapter.
*: Crank the engine when the regulator
handle has been turned to STOP'
position (no injection state).
2 or the compression gauge and
compression gauge adapter, refer to
Chapter 5, 5·2.
(3) Attach the compression gauge adapter Measuring

Measuring tthe
he compression pressure
and compression gauge to the cylinder to
be measured. (4
(4)) Crank the engine by the starting moter until
until
the reading of the compression gauge is
stabilized,
stabilized, by taking steps shown
s hown in 2), 1.
[Reference List o Engine Compression Pressures]
Compression pressure at 250 rpm

Model Dispersion of compression
(kgflcm )
pressure among cylinders
Standard Umit 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
6-1
6 Measurement InspectlDn and Adjustment
Reference: VariatiOn of Compression ]

[ Pressure with Engine Speed
1) Indirect Injection system
3 ~ ~ \ 4
40 ... . •......... - ....................... ....... .
5 ~ :: : : : i ~ :=:
~ ~ t : =
~ : ~ : J : : : : = =1 J
~
................ ···· i~ ···
\
············ ······-t··' ·········' ·-··
213TNE68
....................... .........
..............
.........
......
..-... -.---
- , . .. .. . .. ____ 1. .
25
,
20 ... . ..... -_.- .

·· .. ················· . i··· ..... ........................ , .... .
250 3 35 400
Engine speed rpm)
2) Direct Injection system
40··
l3/4TNE88
351···················,\
'
5.:
Ii
1 : : : : ~ ~ 4 ; T N i E ~ 8 ~ 4 ~ ~ ~ ~ ~ 3TNI078A
~~~~~~~~
§::::: 3 ......... .
i
t ~
25 . ; . J .
o
u 3/4TNE84T: ,
201···················, ...... ............... - , ...................... , .. . ... ··········1··· . ···
200 250 3 35 400
Engine speed (rpm)
2. Action to e taken when the measured

compression pressure Is below the
limit value.
Trouble occurs in a part of the engine. For

troubleshooting. refer to Chapter 4. 4-2 trouble
diagnosis through measurement of compres
sion pressure.
6·2
6. Measurement tnspectlon and Adjustment
6 2.
2. Adjusting the valve head
clearance
1) Inspect and adjust a valve head clearance

while the engine is in cold state.
2) Raise the piston in the cylinder to be

measured to the top dead center TDC) Normal Abnormal
of compression.
3) Loosen the lock nut and adjusting

adjusting screw.
Make sure that the valve cap is free from
inclination
inclination o r trapped dirt.
4) Insert a thickness gauge in between the

rocker arm and valve cap. Tighten the
adjusting screw until the clearance listed
below is attained.
djusting screw
Valve clearance Lock nut
Adjusting the valve head clearance)

mm)
All models
Intake/exhaust valve 0.15 0.25
head cleaarance
: 1. If the valve cap is worn or otherwise

damaged on the head replace it with a
ne
neww one.
one.
2. Make sure that

tha t tthe
he valve cap is nested
nest ed on
the head o ntake/ex
ntake/exhaust
haust valves.
6·3
6. Measurement, Inspecllon and Adjustment
6 3.
3. Checking
Check ing the V belt tension
Push the center of the V-belt between the

alternator and cooling water pump with a
finger. If the deflection is 10-15 mm, the
V-belt tension is acceptable. If not, adjust the
V-belt tension using the adjuster at the
alternator.
10-15mm
Adjuster
Cooling water pump
Crankshaft pulley
A temator
Adjustment 01 the V-belt tension)
6 4. Measuring and checking the injection pressure and spray

patterns of the fuel injection valve
*
1. Measuring the Injection pressure
horoughly remove carbon deposits from the
injection nozzle before making measurement.
1) Connect the fuel injection valve to the high

pressure pipe of the nozzle tester.
tester.
2) While pumping the lever of the nozzle

Nozzle tester
tester slowly, read the pressure
pres sure gauge on
the nozzle tester the moment the nozzle
starts fuel injection.
* or injection pressure of each engine referto

Injection nozzle
Chapter 1 Specifications and Perfor
Performance
mance .
3) If the measured injection pressure is

lower than the specified value, replace
the pressure adjusting shim with a thicker Measuring
Measu ring the Injection
Injecti on pressure w i t h
one. a nozzle tester
6-4
6. Measurement tnspection and Adjustment
Type of pressure
adjusting shim Injection pressure adjustment
thickness (mm)
Indirect O t 0.2, 0.3, Increase the pressure adjusting shim the

injection 0.4 0.5 thickness by 0.1 mm and the injection
system pressure is increased by 7-10 kgflcm .
Direct 0.13,0.15, Increase the pressure adjusting shim
injection thickness 0.1 mm and the inject

pressure isbyincreased injection
ion
0.18 0.4
system 0.5 0.8 by about 19 kgflcm .
[Reference: Structure of fuel Injection valve]
(Indirect Injection system) (Direct Injection system)
F.O. return pipe jOint
t I- ~- ' . ~
Pressure adjusting shim
Nozzle holder
I Nozzle spring
~ - j - - - P r e s s u r e adjusting shim
Nozzle spring seat

® Valve stop spacer
Nozzle spring
iJ Nozzle valve }
t:
r
J - - - -
Nozzle spring seat
Valve stop spacer
Nozzle
Nozzle body I valve}
e
Dowel p i n · - · - l 1
Nozzle
~ - ' r J. N.nzle body
Nozzle case nut
2. Checking the spray patterns (1) Make sure thatthe

thatth e pattern is neither
neithe r stream
While pumping the lever of the nozzle tester nor sliver.
4-6 times per second atthe
att he specified injection
pressure (Refer to Chapter 1, specifications (2) Ensure thatfuel
thatf uel is sprayed conically around
and performance), check the spray patterns. the nozzle center
cente r line and that a fuel injec
If the following trouble is found, clean or tion spreading angle is 5-1 O in the indirect
replace the nozzle. injection
injection system or approx.
approx. 15
150 0 in the
the
direct injection system.
65
6 Measurement Inspecllon and Adjustment
[Normal spray pattern]
.
.
\
/
( :
.• O 1 5 0 o - - ~
~
Indirect Injection
Injecti on system) Direct Injection system)
[ bnormal spray patterns]
Indirect Injection system) Direct injection system)

system)
3) Place a sheet
she et of
of white paper 30 cm
cm below
the nozzle. The injection spray should
form a perfect circle.
4) No oil should drip from the nozzle aiter

injection.
5) Oil should not ooze

ooze from
from the injection
inject ion hole
when the pressure is raised to a little less
than the specified 20 kgflcm 2 •
6) Test the injection with a nozzle tester; re
re
tighten and test again if there is excessive
oil leak from the overflow coupling.
Replace the nozzle as a set if the leak
ing oil is still excessive.
6-6
6. Measurement Inspection and Adjustment
3. Nozzle valve sliding test 4. Nozzle body Identific

Identification
ation num ber
Thoroughly wash the nozzle valve using
clean diesel oil. Hold the nozzle body ver Indirect Injection system)
tically, and lift the nozzle valve approx. 1/3
of its length with one hand. Y DN - 0 S D YD
Check to see if the nozzle falls smoothly by
itself gravity when released.
released . If so, the
the nozzle TL Design code
In
L
valve is good. case of a new nozzle,
remove the seal peel, and immerse it in clean No code: pintle type
diesel oil or the like to clean the inner and D: throttle type
outer surfaces and to thoroughly remove
Size : size P
rust-preventive oil before using the nozzle. : sizeS
Note that a new nozzle is coated with rust Injection angle
preventive
preven tive oil and is pasted with the seal peel
to shut off outer air.
Type: pintle type
YANMAR Identification
number
I
\
/1_ . , Direct Injection system)
Y LL A - 150 P 244JO
Nozzle valve sliding check y gravity

for indirect injection system
I
Nozzle insertion angle
Nozzle
Code A: angled
No code: no angle
T e S i g n code
Size : size P
: sizeS
Injection angle
Type: DLL semi-long type)
YANMAR
Identification
Nozzle valve sliding check by gravity number
for direc
directt Injection system
6 7
6. Measurement Inspection and Adjuslmenl
6 5. Checking and adjusting the fuel injection timing
1. Indirect Injection system

1) Using the crankshaft pulley,
pulley, turn the en
gine in the specified direction. Check the
injection timing
timi ng at the delivery
delive ry valve
valve of the
fuel injection pump for cylinder No.1.
Cylinders are numbered sequentially
from cylinder No.1 from the flywheel side).
liming m rk
4) If the present injection timing differs from

[;;;; - - - C,'iindler No.1
the specified timing. remove the fuel in
jection pump. and adjust the timing by
increasing or decreasing the adjusting
shim thickness between the fuel injection
pump and gear
gea r case .
• Increase the shim thickness to delay
the injection timing.
2) When the crankshaft is turned in the speci o Decrease the shim thickness to ad
fied direction, oil level rises at the tip of the vance the injection timing.
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.
* : Forthe fuel njection timing of each engine
model refer to Chapte r

model 1 Specifications
nd Performance.
Flywheel housing
Access hole
6-8
2. irect injection system

1) Using the crankshaft pulley, turn thethe en
gine in the specified
specified direction.
direction. Check the
injection timing at the delivery valve of the
fuel injection pump for cylinder
cylind er No.1. Cyl
inders are numbered se-quentially from
cylinder No.1 from the flywheel side).
TIming mark
J
4) If the measured injection timing differs
from the specified timing, adjust
adj ust the injec
~ ~ ~ ~ ~ Cylinder No.1 tion timing by turning down the fuel injec
tion pump toward the engine or to
the opposite side after loosening the lock
nut of the fuel injection
injecti on pump .
• If injection timing is late, turn down the
fuel injection pump away
awa y from the engine .
• If the injection timing too early, turn the
injection pump down toward
towar d the engine.
2) When the crankshaft
crankshaf t is turned in the speci
fied direction, the oil level rises at the tip of
the delivery valve spring holder. At that
time, stop the crankshaft.
3) Identify the
the timing mark stamped on
on the
flywheel through the access hole of the
flywheel housing.
: For fuel injection timing for each engine model
refer to hapter 1 Specifications and
Performance.
Lock
ccess hole
6 9
6. Measurement tnspecllon and Adjustment
6-6. Adjusting the no-load maximum or minimum) revolutions
1) First warm up the engine. Then, gradually

increase the engine speed up t the no
load max. revolution Refer to Chapter
Chapt er 1.
1.
Specifications and Performance).
2) If the present no-load max. revolution

revolution dif
fer from the specified one, adjust the no
load max. revolution using the no-load
max. revolution adjusting bolt.
3) Set the engine to the idling revolution,

Refer to Chapter 1. Specifications and Regulator handle
Performance) by turing the nO-load min.
revolution adjusting bolt.
* he illustration shows the partial perspective

view o the governor for the direct injection
system
6-7. Checking the coaling water system and radiator for water leakage
1. hecking the cooling water system for

water leakage
* : The cooling water system can be checked

effectively while the engine is warm
1) Supply cooling water up to the normal

water level in the radiator. Attach the cap
tester body to the
t he radiator.
Cap tester
2) Start the cooling wat er pump. and setse t it to
apre ssure
ssu re ofO.9±O.15 kgff
kgffcm
cm2.
2. Any
A ny lower
Checking the cooling
Checking cool ing water system )
reading of the pressure gauge on the cap for water leakage
leakage
tester ndicates water leak from the cooling
cooling
water system. Then, detect the portion
where cooling water
wa ter leaks from the cooling
cooling
water system.
system.
2. hecking the radiator cap

Attach the radiator cap t a cap tester. Setthe
testerto
test erto apres
a pressure
sure ofO.9±O.
ofO.9±O.15
15 kgffc
kgffcm2
m2.. Check
Chec k
to see ifthe cap is opened althe set pressure.
pressure. Radiator cap
If not.
not. replace the cap. because it is defective.
Checking the radiator
radia tor cap)
6 10
6 8. Checking the battery
1. Structure o f the battery
Terminal
Cover
Cathode
Cathode plat
platee
Separator
Battery case Glass mat
Anodeplale
2. Checking the battery

1) Electrolyte level
Check the electrolyte level in each cell. If
the level is low, add deionized water to
bring the level to the UPPER level as
illustrated below.
Acceptable Too high
y ~
Too low
iquid level
Upper limit - UPPER LEVEL -
- LOWER LEVEL - Lower limit
2) Battery charge
Using a battery tester or hydrometer, check
the state of the battery. If the battery is
discharged, recharge it
o Measurement with a battery tester

To check the battery with a battery tester,
tester,
securely hold the ll terminal of the battery
with the red clip of the battery tester and
the e terminal with the black clip. Judge
battery charge level from the indicator
position:
Green zone: normal
Yellow zone: somewhat discharged
Battery tester
Red zone: abnormal or much
discharged Measuring the battery Charge
with battery tester
6·11
6. Measurement Inspecllon and Adjustment
o Measurement with a hydrometer

When using a hydrometer, correct the
measured specific gravity
gravi ty according to the
temperature. The specific gravity of the Rubber bulb
electrolyte of the battery is the standard
when measured at 20·C. Correct the Glass tube
specific gravity according to the following
equation, as it changes by 0.0007 per
l·C. Float
+ 0.0007 (t-20)
l
S2 = SI
LMeasured
electrolyte (Hydrometer)
temperature
Measured specific gravity
Specific gravity converted to 20'C
~ . l>-
(How to read a hydrometer)
(3) Terminals
Repair or clean
clean the terminals
termi nals if corroded or
soiled.
Measuring the remaining battery)
Measuring
( charge with hydrometer (4) Fittings
Repair or replace the fittings if corroded.
Hydrometer and remaining Re·tighten them if loosened.
battery charge
(5) Appearance o f the battery
Specific · r v ~ y Discharged level Remaining level
Replace the battery
batter y if cracked ordeformed
ordefo rmed..
(at 2 C) ( ) ( ) Clean
Clean it using fresh water
wate r if contaminated.
1.260 0 100
1.210 25 75
1.160 50 50
1.110 75 25
1.060 100 0
6-12
6 Measurement Inspection and Adjustment
6 9. Checking the sensors (2) Thermoswltch

Put a thermoswitch into an antifreeze or oil
in a container. While measuring liquid
1. Checking the thermostat and temperature. heat the liquid. f the tester
thermoswltch shows continuity at a temperature of 107-
113·C. the thermoswitch is acceptable.
(1) Thermostat
Put a thermostat
While measuring into wate
water
water r in a container.
temperature. heat
the water. Make sure that the thermostat
functions at a temperature of 69.5-72's"C.
69.5-7 2's"C.
(80.5 - 83.5°C are used
used as option parts)
Thermometer
2. O pressure switch
Remove the connector from the LO pressure
, ~ - ' 2 ' - - i - hermostat
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.
ylinder block
(flywheell side)
(flywhee
to radiator
~ v e r
~ T h e r m o s t a t
<
0 (Continuity test)
Thermoswitch
~
6-13
6 Measurement tnspectlon and Adjustment
6 10. Checking the Oil Cooler

The oil cooler is of the core type and cooled
by fresh water. It is installed as a standard
component on turbocharged engines in the
TNE series
series..
(1) Replace the packing at the joint and 0

rings
rings at the
the time o
off reassemb
reassembly
ly afterd
afterdisas
isas--
sembly.
(2) When the oil cooler is disass

disassemble
embledd and
cleaned for periodic inspection. remove
the scale by using descaling agent Unicon
146 .
3) Cooling tube leak check

Close either the in let or out et of the coo ing
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.
- --.,",,,, for draining
ooling ooling
water inlet ..... water outlet
Oil in l t
6-14
6 Measurement tnspection and Ad/ustment
6 11. Checking the Piston Coolin

Coolingg Nozzle
No zzle
The piston cooling nozzle is installed as a
standard component on turbocharged en
gines in the TNE series.
(1) Piston cooling

coolin g nozzle function
A nozzle made of a steel pipe is installed
below the main gallery in the cylinder
body. The lubricating oil from the main
gallery is constricted at the nozzle hole
( 1.77 mm) at the tip end of the steel pipe
to be jet-sprayed. This jet spray comes
into contact with the rear face of the piston
for cooling it.
Jet flow rate 13€ min
Jetting pressure 3.5 kg I em
Piston
Spray
ooling nozzle
(2) Checking the piston cooling nozzle

1 Check the nozzle hole at the tip end for
clogging with dirt or foreign
foreign matter. and
clean it.
2 Check the brazed portion of the steel

pipe for loosening or freeing by vibra
vib ra
tion. Replace
R eplace with a new part if defectiv
defective.
e.
6-15
7 Measuring Procedure Service Data and Corrective Action
7. Measuring Procedure Service Data and

Corrective Action
In maintaining various parts. make measure 2. Intake/exhaust valve seats
ment according to the following measure
ment procedure. If any troub
trouble
le is found and if 1) Valve sinking
any part deviates from the standard size. Over long periods of use and repeated
replace it with a new one. However. if any lappings. combustion efficiency
ef ficiency may drop.
part within the limit is expected to deviate Measure the sinking depth and replace the
from the standard presumably because of valve and valve seat if the valve sinking
the record of
o f its use.
use. be sure to replace such depth exceeds the standard value.
a part beforehand.
mm)
7 1. Cylinderr head
Cylinde
2/3TNE68 3TNE74
1. Distortion and inspection o f the Standard

Wear
Standard
Wear
combustion surface limit l m ~
Valve Intake 1.0

0.3 0.5 0.4 0.6 1.0
1) Remove intake/exhaust valves and fuel sinking valve
VM:O.75-0.95
depth Exhaust 0.75 0.95 1.0
injection valve from the engine. Clean the valve 1.0 CH:OAO-O.60
VH:O.40 0.60
surface of the cylinder head.
2) Place a straight
stra ight-edge
-edge along each of the 3/4TNE82.
3TNE78A
3/4TNE84 T),
four sides and each diagonal of the cylin 3TNE82A
3/4TNE88
der head. Measure the clearance be
tween the straight-edge and combustion Standard
Wear
Standard
Wear
limit
surface with a thickness gauge. l m ~
mm)
Intake 0.296 0.306
1.0 1.0
Cylinder head Valve valve 0.496 0.506
combustion Standard Wear limit sinking Exhaust
depth 0.3 0.5 1.0 0.3 0.5 1.0
surface distortion valve
All models 0.05 or less 0.15
Depth-Micrometer
Straight-edge
Thickness
Thickness gauge
Measuring the CombuStiOn) Measuring the valve sinkage)

surface
surface distortion
3) Visually check to see if the combustion

surface is free from discoloration. cracks.
and crazing. In addition. use the color
check kit for cracks and crazing.
71
7. Measuring Procedure Service Data and Corrective Action
Valve sinking depth
(2
J
(2)) Width and angle o f the valve seat
(Measuring the valve seat width)
Remove carbon deposits from the seat
surface. Measure width and angle of the [Valve Seat Correction Procedure]
seat using vernier calipers and an angle 1) When the seat surface is worn or rough
gauge. ened slightly, lap the seat surface with a
valve compound mixed with oil to a
(mm) smooth state.
213TNE68 3TNE74
2) When the seat surface is worn or rough
Wear Wear
ened heavily, correct seat surface using a
Slandard Standard seat grinder or seat cutter, and finish it
limit limit
Valve
according to step (1).
Intake 1.15 1.65 1.44 1.98
seat
width Exhaust 1.41 1.91 1.77 2.27
Valve
seat
Intake 120 - 120 se t grin er
angle Exhaust 90 - 90 -
3/4TNE82,
3TNE78A
3/4TNE84(T),
3TME82A
3/4TNE88
Wear Wear
Standard Standard
limit limit
1.36 1.07 [Procedure for USing The Seat Grinder
Valve Intake -1.53 1.98 -1.24
1.74
and Seat Cutter]
seat
width 1.66 1.24 (1) Correc
Correctthe
tthe roughened seat surface with a
Exhaust -1.87
2.27 -1.45
1.94
seat grinder or seat cutter.
Valve Intake 120 - 120 -
seat Seat grinder Angle e)
angle Exhaust 90 - 90 - Intake valve 30
Exhaust valve 45
(2) When th
the
e seat wi
width
dth is enlarged from th
the
e
initial value, correct it by grinding
the seat surface with a 70 seat grinder or
seat cutter. Then, grind the seat to the
standard width with a 15 grinder,
* When using a seat cutter evenly apply pres-
sure taking care of avoidi
avoiding
ng uneven culling.
7 2
Grind
Grind to the same dimension )
as the fitting diameter of the cotter
wi th
Valve seat
Grind to a smaller dimension
than the outer diameter of the
valve seat
(Valve
(Valve seat correction
corre ction angle)
angle)
with oil and finish

(3) Knead valve compound with
the valve seat by lapping.
* f any valve requires correction, be sure to
Weld the valve with valve seat
at three positions
measure the oil oi l clearance between
betw een the valve
stem outside
outs ide dia. and valve guide inside dia.
f the oil clearance exceeds the limi
limit,
t, replace
the valve or valve guide before correcting
correct ing the
valve seat surface
surface.. Foroil
For oil clearance belween Valve seat
the valve and valve guide, refer to section
3 in this chapter.)
(4) Finally, lap the valve using only oil.

* 1 After
Aft er the val
valve
ve seat is corrected, thorou-
[Insertion o f valve seat]
(1) Put the valve seat in a container which
ghly clean the valve and cylinder head
using diesel oil or the like. Thoroughly contains liquefied nitrogen. or ether or
remove the valve compound
compou nd or grindstone alcohol with dry ice to cool it sufficiently.
powder. (2) Heat the cylinder
cylin der head around the portion
2. For slightly
slight ly poo r contact, take steps 3) for valve seat insertion to 80 1 OO·C with a
and 4). dryer.
(3) With the new intake/exhaust valve, se-
[Extraction o f Valve seat] curely insert the sufficiently cooled valve
seat into the cylinder head by tapping the
Withou t valve
Without 2/3TNE68: All
head of the intake/exhaust valve.
seat 3 TNE74: VM
Direct injection system: CL and VM (4) Stand
St and the cylinder head until the entire
With valve 3TNE74 101): CH andV
cylinder head is cooled to normal tem-
seat Direct injection system: CH andV perature.
Turbocharged engine: All
(1) Grind the circumference of the intake/

exhaust valve head being or having been
used to the dimension smaller than the
valve seat outer
o uter diameter.
(2) Grind the circumference
circumfe rence of the stem end
end of
the valve to the same dimension as the
fitting diameter of the cotter.
(3) Weld the intake/exhaust valve head with
the valve seat at three positions.
(4) Hit the stem end of the intake/exhau
intake /exhaust
st
valve to extract the valve seat.
(Insertion of valve seat)
7-3
7 Measuring Procedure, Service Data and Corrective Ac/fon
3. Intake/exhaust valve
3TNE78A 3/4TNE82,
3TNE82A 3/4TNE84 T),
1) Wear and bend o f the valve stem 3I4TNE88
Replace a valve stem if bent orworn
orwor n badly.
badly.
Wear Wear
In this case, replace the valve guide at the Standard Standard
limit limit
same time.
6.945 7.955
Stem 0 0 6.9 7.9
2) Valve stem and valve guide 6.960 7.975
Intake 7.000 8.010
Oil clearance is a difference between the valve
Guide 1 0
7.015
7.08 8.025
8.1
valve guide inside diameter measured with Oil 0.040 0.035
clearance 0.070
0.18 0.070
0.2
a three-point
three-poi nt micrometer
micromet er capable of
Stem 0 0 6.940 7.955
measuring inside diameter between 6.955
6.9 7.970
7.9
Exhaust
4 mm and 8 mm or a cylinder gauge valve Guide 1.0. 7.015 8.015
7.08 8.1
capable of measuring 6 mm or greater 0.045 8.030
Oil 0.045 0.045
inside diameter) and the stem outside clearance 0.075
0.18 0.075
0.2
diameter measured with a micrometer.
When oil clearance is near the limit, re- 3) Thickness of valve head
place both the intake/exhaust valve and Measure the thickness of the valve head
valve guide with new ones. with a micrometer.
When the measured value is near the
wear limit, replace the valve with a new
one.
Measuring
Measuring the valve stem outside
o utside diameter)
Seat angle
mm) mm)
2I3TNE68 3TNE74 2I3TNE68 3TNE74
Wear Wear Wear Wear

Standard Standard Standard Standard
limit limit limit limit
Stem 0 0 5.460 5.4 6.960 6.9 Intake 0.85 0.99

5.475 6.975 Thick-
valve 1.15 1.29
Intake Guide 1 0 5.500 7.005 7.08 ness of 0.50 0.50
5.515
5.58 7.020
valve valve Exhaust 0.95 0.95
Oil 0.025 0.030 head Valve
cle r nce 0.055
0.18 0.060
0.18 1.25 1.25
Stem 0 0 5.445 5.4 6.945 6.9

5.460 6.960
Exhaust 3/4TNE82,
5.500 7.005 3TNE78A
valve Guide 1 0 5.58 7.08 3/4TNE84 T),
5.515 7.020 3TNE82A 3/4TNE84 T),
3/4TNE88
Oil 0.040 0.045
0.18 0.18
clearance 0.070 0.075
Wear Wear
Standard Standard
limrt limrt
Thick- Intake 1.244 1.244

valve 1.444 1.444
ness of 0.50
0.50
valve Exhaust 1.35 1.35
head Valve 1.55 1.55
7 4
[Replacing the Valve Guide]

(1) Extract the valve guide from the cylinder
head using the valve guide extraction tool. rojection
* For the
the valve guide extraction tool,
tool, refer to
Chapter 5, 5·1.
(2) In a container containing liquefied nitro

gen, ether or alcohol together wit
withh dry ice,
put the valve guide to cool it. Then hit the
sufficiently
sufficientl y cooled valve guide to fit into the
valve
cylinder head using the valve guide inser
tion tool.
(Valve
(Valve guide projectio
projection)
n)
* For the valve guide insertion tool, refer to
Chapter 5, 5-1.
4. Valve stem seal
(3) Afte
Afterr inserting the valve guide, finish the
inside of the valve guide with a reamer.
[Time of Replacement]
(4) Check the projecti
projection
on of the va
valve
lve guide.
(1) When oil loss is found excessive
(mm) (2) When

(3) When intake/exh
the valveaust
stem
intake/exhaust seal a
valves is
re removed
are removed
213TNE68 3TNE74
[Precautions on Installation]
Wear Wear
Standard
limit
Standard
limit Make sure that the entire surface of valve
stem is smooth, and sufficiently apply
Valve guide
7 - 9 - lubricating oil to the valve stem before
projection
reassembling intake/exhaust valves.
3/4TNE82,
3TNE78A
3/4TNE84 T),
3TNE82A Valve stem seal
3/4TNE88
Wear Wear
Standard Standard
limit limit Valve guide
Cylinder head
Valve guide
projection
12 - 15
Valve guide insertion tool

<
t a l ~ e ~ u i d e
cll- ====± projection f, /
Valve guide
Hatched
Hatched portio
portionn indicates )
( where to apply lubricating oil.
7 5
7 Measurfng Procedure Service Data and Corrective Action
5. Checking the valve spring
1) Visually check tto

o see if the valve spring is
free from flaws and corrosion.
2) Mea
Measure
sure the free length length of the
spring) and inclination squareness of the
side of the coil).
mm)
213TNE68 3TNE74
Wear Wear
Standard l m ~ Standard
l i m ~
Measuring the valve spring inclination)

Free length 28 - 37.4 -
Valve Inclination - 0.8 - t.O
spring
Tension kg) 1.14 *2.37/ Inclination
when compressed
toby 1 mm)
1.40 1.87 -
* Tension at variable p ~ c h
Square
~ Free length
~
3/4TNE82,
3TNE78A 314TNE84 T),
3TNE82A 3/4TNE88 Surface plate
Wear Wear
Standard Standard
limit limit Measurin
Measuring
g the in
inclinati
clination
on of valve spring)
Free length 44.4 42
6. Checking valve spring holder and
Valve Inclination - 1.1 - 1.1 cotter
spring Check contact of the inner surface of the
Tension kg)
when cOrTl>ressed
*3.61 *2.36 valve spring holder with the circumference
toby1 mm) /2.71 - /3.101 -
of the cotter as well as contact of the inner
circumference of th
the
e cotter with the notch on
* Tension at variable pitch.
the head of the valve stem. If such contact is
uneven
cotter or aif new
with the one.
cotter sinks, replace the
Measuring the free length)
7 6
7 2. Cylinder block
block
Cylinder gauge
1. Checking the cylinder block
1) Visually check to see

see if the cylinder block
is free from water leak, oil leak and
cracks. If any cylinder block is suspected

to be cracked, check it by color check.
2) Replace the
the cylinder block if badly dam
aged and incorrectable.
3) Thoroughl
Thoro ughly y clean each
each oil
oil hole. Make sure
that it is not clogged.
2. Measuring the bore and distortion of

the cylinder
o
Measure the bore of each cylinder with a •
cylinder gauge. Measure the cylinder at
point a approx. 20 m m below the crest of •
the liner, and at points band c at equal
pitch a-b = b-c).
Obtain distortion roundness and cylindricity
of each cylinder) from the measured values
as follows: Measuring the cylinder bore)
o Roundness:
Difference
Differe nce between max. and min. bore
20mm
values on the same cross section of
each liner.
o Cylindricity:
Difference
Differ ence between max. and min. bore
b
values in the same direction of each
liner.
Honing honing and

and boring) is requiredwh
requi redwhen
en
the measured value exceeds the limit. c
For oversized piston nd piston ring refer

to this chapter, 7-4 8.
A
B
Note: Measurement should be made at a band c

in the directions of A and B.
Cylinder bore
bore measuring )
positions
7-7
7 Measuring Procedure Service Dala and Correcllre Action
(mm)
213TNE68 3TNE74
I ~
Cylinder bore
Standard
68.000
~ 6 8 0 3 0
Wear
limit
Standard
68.20 74.000
~ 7 4 0
Wear
limit
3 0
74.20
Cylinder roundness
roundness 0.00 ~ 0 0 1 0.03 0.00 ~ 0 0 1 0.03
Cylindricity
0.00 0.03 0.00 ~ 0.03
~ 0 0 1 0 0 1
3TNE82A
3TNE78A
3/4TNE82
(Flex-Hone)
Wear Wear
Standard Standard
limit limit
(2) Procedure for using the FleX-Hone
Cylinder bore 78.000 78.20 82.000 82.20
~ 7 8 0 3 0 ~ 8 2 0 3 0 It is common practice to use the Flex
Cylinder roundness 0.00
0.03
0.00 0.03 Hone for honing. The procedure for using
~ 0 0 1 ~ 0 0 1
0.00 0.00
it appears in the following table. Any ma
Cylindricity 0.03 0.03
~ 0 0 1 ~ 0 0 1 terial must allow for approx. 1/1000 mm
when honed with the Flex-Hone.
3/4TNE84 T) 3/4TNE88
1. Necessary items
Wear Wear Flex-Hone. power drill. and honing fluid
Standard Standard
limit l m ~
Cylinder bore 84.000 84.20 88.000 88.20

~ 8 4 0 3 0 ~ 8 8 0 3 0 Flex-Hone Applicable bore
Model Yanmar code No. (mm)
Cylinder roundness 0.00 0.03 0.00 ~ 0.03
~ 0 0 1 0 0 1
2/3TNE68 129400-92400 6 3 ~ 7 0
Cylinder cylindricity 0.00 0.03 0.00 ~ 0.03
~ 0 0 1 0 0 1
3TNE74 129400-92410 7 0 ~ 7 6
3. Honing 3TNE78A/82A
3/4TNE82 129400-92420 7 6 ~ 8 9
3/4TNE84(T)
(1) Practice of honing
Honing or boring the cylinder if unevenly 3/4TNE88 129400 92430 8 3 ~ 9 5
worn. flawed. or otherwise

otherwis e damaged. Slight
uneven worn. flaws. etc. may well be only
honing with a Flex-Hone. However. sig Flex-Hone
nificant uneven wear should be first
bored and then honed. It is important to
take into careful consideration as to
whether the cylinder can attain perfect
roundness after honing. boring. or both.
considering maximum wear. In addition.
carefully study as to whether prepared Engine oil Diesel oil
oversized pistons and piston rings are 50 50
applicable. (For the oversized piston and
piston ring. refer to this chapter 7-4.8.)
J
Honing liquid = ~ U
7-8
2. andling 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 . Ex
tract the Flex-Hone while turning it.
o 300 1200
Use the
rpm. UseFlex-Hone at a speed
o he Flex-Hon
Flex-Hone e at a higher speed
may be hazardous.
Never insert into or extract from the cylinder
the Flex-Hone with the power drill eftstopped.
eft stopped.
4. Overhaul o f cylinder (Reference)
Service life of sleeveless cylinder block Hl)

(H, = 3H,)
Time for boning and honing H 2 )

H2 = 1.5H,)
Time for honing H1)
Increase in L.O.C.
or blow·by
Honing
c=»
Boring
Consideration )
on the applicability
( o oversized
pistons and piston rings
7-9
7 Measuring Procellure Service Data anll Corrective Action
7 3. Valve rocke
rockerr arm
1 Measuring the outside di meter o f rocker rm sh ft nd inside di meter

of rocker rm
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)
3TNE78A182A
3/4TNE82,
213TNE68 3TNE74
314TNE84 T).
3/4TNE88
Wear Wear Wear

Standard Standard Standard
limit limit limtt
Rocker arm 9.972 11.966 15.966
9.95 11.95 15.95
shaft outside diameter 9.987 11.984 15.984
Intakelexhaust Rocker arm bushing 10.000 12.000 16.000

10.09 12.09 16.09
rocker rm inside di meter 10.020 12.020 16.020
0.013 0.016 0.016

Oil cle r nce 0.048 0.14 0.054 0.14 0.054 0.14
2. Checking push rod bend, measuring

tappet outside diameter and checking
contact surface
Put the push rod on the stool. and measure

the gap between the push rod and stool to
make sure the push rod is in close contact
with the stool. Also. measure the outside
diameter of the tappet with a micrometer.
Measuring the rocker arm shaft )

outsid e diameter
outside diameter
Thickness gauge
Measuring the push rod bend)
Measuring the rocker arm

arm )
inside diameter
diameter
7 10
7 Measuring Procedure. Service Data and Corrective Action
mm)
3TNE78A182A,
3/4TNE82
213TNE68 3TNE74
314TNE84 T),
3/4TNE68
Wear Wear Wear

limit limit limit
Push rod bending 0.03 or less - 0.03 or less - 0.03 or less -
Tappet stem outside 17.950 20.927 11.975

17.93 20.90 11.93
diameter 17.968 20.960 11.990
Tappet guide hole inside 18.000 21.000 12.000

Tappet 18.05 21.05 12.05
diameter
18.018 -21.021 12.018
0.032 0.040 0.010

Oil clearance 0.12 0.15 0.12
0.068 0.094 0.043
3. Other checks
1) Valve rock er arm shaft spring
Check to see if the rocker
r ocker arm shaft spring
is free from corrosion and wear. If not,

replace it with a new one.
2) Wear of Intake/exhaust valvevalve ro cker

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
Chec k the portion where
wher e the
the valve clear Measuring the tappet outside diameter)
ance adjusting screw is in contact with the
push rod. If the portion is worn and flaked,
replace the pushrod or adjusting screw.
djusting screw
a . : : I : r ~ v <; Of contact surface
Push rod
bnormal contact surface Normal contact surface
Checking
Checking the tappet contact
cont act surface)
7 11
7 Measuring Procedure Service Dala and Correcllve Action
7-4.
7-4. Piston
Pisto n and piston
pis ton ring
1. Checking the piston
1) Remove carbon deposits
depos its from
from the head
and combustion surface of the piston so as
1
not to impair the piston. Check to see if I
there is any crack or damage.

-t ~
Y'
2) Check the circumference and ri ring

ng groove
l ~ ~ easurement
of the piston, and replace if worn or dam
aged. I I
1/ position
2. Measuring the piston outside diameter

T o measure the piston outside diameter,
{ \
2 2 - 25mm
measure the long diameter of the oval hole

in vertical direction to the pin hole and at a
position 22-25 mm from the lower
l ower end of the
piston.
(MeaSuring the piston outside diameter)
mm)
213TNE68 3TNE74 3TNE78A 3TNE82A 3/4TNE82 3/4TNE84 T) 3/4TNE88

VM.VH CH
Wear Wear Wea Wear Wear Wear Wear wear

Standard Stan dar Standard Standard Standard Standard Standard Standard
lim lim limit limit limit limit limit tim.
Piston outside 67.960 67.940 73.940 77.950 81.950 81.945 83.945 87.945
diameter -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
0,025 0.045 .045 0.035 0.035 0.040 0.040 0.040
between piston and
cylinder 0.055
- 0.075 0.075
- 0.065
- 0.065
- 0.070 0.070 - 0.070
-
3. Shapes of piston rings Model 213TNE68.3TNE74
Application VM.CH.VH
Topring
----I _ Top ring J

2nd ring
Common to all models) 3TNE78A182A. 3/4TNE84{T)
Model
~ W \ . . . . I 3/4TNE82. 3/4TNE88
Application CL. VM CH. VH. wfturbocharged
Oil ring
Common to all models) Top ring
D TI
7 12
4. Measuring the ring groove width ring

width and end clearance
To measure the piston ring groove width,
first measure the width of the piston ring.
Then, insert the piston ring into the ring
groove that has been carefully cleaned.
Insert a thickness gauge in between the
piston ring and groove to measure the gap
between them. Obtain the ri
ring
ng groove width
by adding ring width to the measured side
clearance.
Measuring the side clearance)
Thickness
To measure the end clearance, push the . . L Side clearance

piston ring into the sleeve using the piston Piston Ring
head,
hea d, insert a thickness gauge in end clear
ance to measure. If the sleeve is worn,
measure the end clearance after pushing
the piston ring to the portion of the sleeve nd dearance
which is less worn approx. 30 mm from the

lower end of the sleeve).
Approx 30 mm
Piston ring
Cylinder block
Measuring
Measurin g the end clear
clearanCe
anCe))
of piston rin
ring
g
7-13
7 Measuring Procedure Service Data and Correcllve Acllon
mm)
3TNE82A.
2i3TNE68 3TNE74 3TNE78A 3/4TNE82, 3/4TNE88
3/4TNE84 T)
Wear Wear Wear Wear Wear

Standard Standard Standard Standard Standard
limit limit limit limit limit
Ring groove 1,550 1.550 2.035 2.065 2.060

width 1.570 - 1.570
- 2.050 - 2.080 - 2.075
-
Ring width 1.470
1.490 - 1.470
1.490
- 1.940
1.960 - 1.970
1.990 - 1.970
1.990
-
Top ring
Min side 0.060 0.060 0.075 0.075 0.070
clearance 0.100
- 0.100
- 0110
- 0.110
- 1.105
-
End clearance 0.100 1.5 0.200 1.5 0.200 1.5 0.200 1.5 0.200 1.5
0.250 0.400 0.400 0.400 0.400
Ring groove 1.540 1.520 2.025 2.035 2.025

width 1.555
- -1.535 - 2.040
- 2.050
- 2.040
-
1.430 1.410 1.975 1.970 1,970
Ring width
1.450
- 1.430
- 1.990
- 1.990
- 1.990
-
2nd ring Min side 0.090 0.090 0.035 0.045 0.035
clearance 0.125
- 0.125
- 0.065
- 0.080
- 0.070
-
0.150 0.200 0.250 0.200 0.200
End clearance 1.5 1.5 1.5 1.5 1.5
0.350 -0.400 0.400 0.400 0.400
Ring groove 3.010 3.010 3.015 4.015 4.015

width 3.025 - -3.025 - 3.030
- 4.030 - 4.030 -
2.970 2.970 2.970 3.970 3.970
Ring width
2.990
- 2.990
- 2.990
- 3.990
- 3.990
-
Oil ring
Min side 0.020 0.020 0.025 0.025 0.025
clearance 0.055
- 0.055
- 0.060
- 0.060
- 0.060
-
0.150 0.150 0.200 0.200 0.200
End clearance 1.5 1.5 1.5 1.5 1.5
-0.350 -0.350 0.400 0.400 0.400
5. eassembly of piston ring
1) Using the piston ring replacer, insert the

Top ring
piston ring into the ring groove, with the
manufacturer s mark near the joint of the
piston ring facing up to the combustion
2nd ring
chamber side.
side. After fitting
fitting the piston ring,
make sure that the piston ring moves
freely.
Oil ring
Top ring
2nd ring t ~ ~ ~ ~
The side with manufacturer s Oil ring
mark shall face upward.
2) Stagger the piston rings jOints at 120

intervals, making sure that they are not
aligned along the piston. Apply lube oil to
the circumference of the piston.
7 14
6. Measuring the outsi e diameter o f the

piston pin and the pin hole diameter
Meas.ure outside diameter
diamete r of the
the piston pin
and pin hole diameter. Replace the piston
pin if the wear limit is exceeded.
Apply lubricating oil to the piston pin before
inserting it into the piston.
• • •
t t t
Measurin
Measuring
g the piston pin ou tside diameter)
MeaSuring point of the piston pin O. D.)
(mm)
213TNE68 3TNE74
Wear Wear
Standard limit Standard limit
Piston pin outside 19.991 20.991
diameter -20.000 19.90 -21.000 20.90
Piston
and Piston pin hole 20.000 21.000
piston dia. -20.008 20.02 -21.008 21.02
pin
0.000 0.000
0 1 c arance
-0.017 0.12 -0.017 0.12
3/4TNE82,
3TNE78A
3/4TNE84(T), c i r c li P O
3TNE82A
3/4TNE88
Wear Wear Insertion of piston pin)
Standard limit Standard limit
Piston pin outside 22.991 25.987
Piston diameter -23.000 22.90 -26.000 25.90
and Piston pin hole 23.000 26.000 7. [Reference) op clearance
piston dia. -23.008 23.02 -26.009 26.02
pin (mm)
0.000 0.000
Oil clearance -0.017 0.12 -0.022 0.12
213TNE68 3TNE74
Wear Wear
Standard Standard
limit limtt
0.610 - 0.658 -
Top clearance -0.730 -0.778
3TNE78A 3/4TNE82,
3TNE82A 3/4TNE84(T),
314TNE88
Wear Wear
Standard Standard
limtt limit
Top clearance
0.650
0.770 - 0.660
-0.780 -
7 15
8 ist of the oversized piston and piston ring

0.2508: Oversized by 0.25 mm)
8ize Piston assy code

Model including piston ring assy) Piston ring assy code
classification
VM
VH 0.2508 119265 22930
119265 22950
2 3TNE68
CH 0.2508 119265 22900
VM
3TNE74 CH 0.2508 119623 22900 119623 22950
VH
CL
VM
3TNE78A 0.2508 119818 22910 119818 22950
CH
VH
3TNE82A CL 0.2508 119813 22900 129003 22950

VM
CL
0.2508 129003 22900 129003 22950
VM
3/4TNE82
CH
0.2508 129003 22910 129003 22950
VH
CL
0.2508 129002 22900 129002 22950
VM
3/4TNE84 T)
CH
0.2508 129002 22910 129002 22950
VH
CL
3/4TNE88 0.2508 129001 22900 129001 22950
VM
7-16
7 5. Connecting ro 3. Measuring the crankpln and bushing

clearance
To measure the oil clearance of the crank
1. Visual Inspection
pin and bushing, measure the inside diam
Inspect the portion near the
the boundary
boun dary of the eter of the crankpin metal and outside di
chamfered
chamfer ed portion and I-beam section
section of the ameter olthe
ol the crankpin,
crankpin, and obtain the differ
differ
big and small ends of the connecting rod as ence between them.
well as the portion near the oil hole of the If the measured oil clearance exceeds or
bushing at the small end for cracks, defor near the wear limit replace the
mation, and discoloration. crankpin metal. If the crankpin is exces
sively or unevenly worn, grind the crankpin,
2. . Measuring the twist and parallelism and use an oversized crankpin metal.
Measure the twist and parallelism by use of To measure the
the inside
inside diamet erofthe
erof the crank-
the connecting rod aligner. pin metal, reassemble the crankpin metal
mm) to the connecting rod and tighten the rod
All models
bolt to the speCified torque, making sure
each metal is fitted on the correct position.
Wear
Standard
limit
Twist and parallelism 0.03100

per or less
mm 0.08
Cylinder gauge
, \
J
Measuring the twist and parallelism) Measuring the inside

Measuring ins ide diameter of )
the crankpin metal
(kgf m)
3I4TNE82,
213TNE68 3TNE78A
213TNE68 3TNE 78A 3I4TNE84 T),
3TNE74 3TNE82A 3I4TNE88
~
Rod bolt tighten·
Specified torque
ing torque
2.3-2.8 3.8-4.2 4.5-5.5
Apply Ube oil
to the rod boU)
Measuring the twist With)

connecting rod aligner
7· 7
7 Measuring Procedure service Data and Corrective Action
mm)
3/4TNE82.
3TNE78A
213TNE68 3TNE74 4TNE82A 314TNE84 T).
3/4TNE88
Standard e a r l i m ~ Standard e a r l i m ~ Standard e a r l i m ~ Standard e a r l i m ~
Crankpin bushing 39.000 43.000

inside dia. 39.016 - 43.016 - 46.000
46.016 - 51.000
51.010 -
Crankpin metal 1.487 1.487 1.487 1.492
Crankpin thickness 1.500
- 1.500
- 1.500
- 1.500
-
side Crankpin outside 35.970 39.970 42.952 47.952
diameter 35.91 39.91 42.91 47.91
35.980 39.980 42.962 47.962
Oil clearance 0.033 0.033 0.Q38 0.038

0.15 0.15 0.16 0.16
0.059 0.059 0.0900 0.074
4. Measuring the 11 clearance between

the piston pin bushing and piston pin
To measure of oil clearance between the

piston pin bushing and piston pin. measure
the inside diameter
diamete r of the
the piston pin bushing
and outside diameter of the piston pin. and
obtain the difference between them.
mm)
~
213TNE68 3TNE74 Cylinder gauge
Wear Wear
Standard Standard
limit limit
Piston pin bushing 20.025 20.10 21.025 21.10
20.038 21.038
Piston inside diameter
pin Piston pin out· 19.991 19.90
20.991
20.90
side side diameter 20.000 21.000
Oil clearance
0.025
0.2
0.025
0.2 Measuring the inside
Measuring i nside diameter of )
0.047 0.047 ( the piston pin bushing
3/4TNE82,
5. hecking the crankpin metal for
3TNE78A
3/4TNE84 T), contact
3TNE82A
3/4TNE88
Apply a blue ink or a minium to the crankpin
Wear Wear metal upper surface. Attach the crankpin
Standard limit Standard l m ~
metal to the connecting rod, and tighten the
Piston pin bushing 23.025 26.025
inside diameter 23.038
23.10
26.038
26.10 rod bolt to the crankshaft to the specified
Piston
pin Piston pin out· 22.991 25.987 torque (Refer to this section 3) to check the
side side diameter 23.000 22.90 26.000
25.90
metal for contact. If the contact surface
Oil clearance 0.025 0.025 occupies 75 or more of the total surface,
0.2 0.2
0.047 0.051
the crankpin metal is acceptable in terms of
contact.
7 18
Indirect injection system piston)
Camshaft side
chamber recess
1.0. mark
Fuel injection
pump side
Assemble s
that the punched Crankpin metal
mark of large
end faces the 7. Side gap o f the connecting rod
fuel injection
pump.
After attaching the connecting rod to the
crankshaft, tighten the rod bolt to the speci-
fied torque see this section 3 . Measure the
side gap by inserting a thickness gauge into
the side gap. If the standard is exceeded,
replace the crankpin metal or connecting
rod.
mm)
All models
6. ssembling the piston and connecting
rod Side gap 0.2-0.4
Assemble the piston with the connecting
rod, with the mark at the big end of the
connecting
connecti ng rod facing the ffuel
uel injection pump.
Reassemble the piston so that the recess of
the combustion chamber is on the side olthe
fuel injection pump as seen from the top.
Direct injection system piston) {
Camshaft side
-
~ ~
1.0. mark
Crankshaft
/
uel injection pump side
hickness gauge
Measuring the connecting rod side gap)
7-19
8. Oversized crankpln metal 3. Measuring the bend of the camshaft

0.25mm. oversized) Support the camshaft with V blocks. Using a
dial gauge, measure the runout of the
the jour-
Crankpin metal
~
nal at the center of the camshaft, while
Metal thickness
rotating the camshaft.
Part code No. mm)
Take 50 of the measured runout as
Standard bend.
213TNE68 119260 23350 1.625
1.625 mm)
3TNE74 119620 23350
3TNE78A182A 11981 - 2 3 3 ~ 0 1.625 All models

3/4TNE82
3/4TNE84 T) 129150 23350 1.625 Wear
Standard
3/4TNE88 l m ~
Camshaft bend 0.02 or less 0.05

7 6. Camshaft
Dial gauge
1. Camshaft side gap

Before extracting the camshaft. bring a dial
gauge into contact with the camshaft
gear and measure the side gap around the
camshaft. If the measured value exceeds
the limit, replace the thrust
thru st metal with
with a new
one.
amshaft gear
Thrust metal
Measuring the camshaft bend)
4. Measuring the intake/exhaust cam

height
Side gap
mm)
ll models
Measuring the cam height)
Side gap 0.05 0.25
2. Checking
Checking the camshaft for appearance
Check the camshaft for the contact surfac
surface
e
Cam height
of the tappet to the cam. seizure and wear
wea r of
the bearing. and damage of the cam gear.
7 20
mm)
3TNE78A182A,
314TNE82,
213TNE68 3TNE74
314TNE84 T),
3/4TNE88
Wear Wear Wear

limit limit limit
29.970 33.950 38.635
Intake cam 29.75 33.75 38.40
30.030 34.050 38.765
Cam height
29.970 33.950 38.635
Exhaust cam 29.75 33.75 38.40
30.030 34.050 38.765
5 Measuring the outside diameter of the

Flywheel side
camshaft bearing
Measure the outside diameter of the cam
Intermediate bearing
shaft with a micrometer. Calculate the oil
clearance from measured camshaft outside Gear side
diameter and the camshaft bushing inside
diameter measured with a cylinder gauge
after inserting the camshaft bushing into the
cylinder block.
mm)
3TNE78A182A,
3/4TNE82,
2/3TNE68 3TNE74
3/4TNE84 T),
3/4TNE88
Wear Wear Wear

limit limit limit
35.940 39.940 44.925
Camshaft journal outside diameter 35.85 39.85 44.85
35.960 39.960 44.950
Gear side
0.040 0.040 0.040
Oil clearance
0.085
- 0.085
-
0. 130
-
35.910 39.910 44.910
35.935 39.935 44.935
Intermediate
Oil clearance 0.065 0.065 0.065
0. 115
- 0.115
- 0.115
-
35.940 39.940 44.925
35.960 39.960 44.950
Flywheel side
0.040 0.040 0.040
Oil clearance
0. 125
- 0. 125
- 0. 100
6 Extracting the camsh

camshaft
aft bushing
Extract the
the bushing with camshaft bushing
tooll refe
too referr to Chapter 5,5- 1.)
7-21
7 7. Crankshaft
Cranksha ft
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. Alter
natively, insert a thickness gauge directly
into a thrust gap between the thrust
t hrust metal in
the standard part and
and crankshaf
crankshaftto
tto measure
the side gap.
If the limit is exceeded, replace the thrust
metal with a new one.
mm) Color check Inspection)
All models 3. hecking the metal
Thrust gap 0.090 0.271

Check the metal for flaking, melting, seizure,
and the state of the contact face. Replace

the metal if found defective.
4. Bend o f the crankshaft

Support the crankshaft with V-blocks at
both ends of the journals
journals;; measure th
the
e runout
at the center journal with a dial gauge while
rotating the crankshaft to check the extent
of crankshaft bend.
mm)
All models
r i
Standard
Bend 0.02 or less
ial gauge
Crankshaft
end
2. olor check o f crankshaft

Clean the crankshaft and check it using a
color check kit or a magnaflux inspector. eflection
Replace the crankshaft if cracked or badly
Dial gauge
damaged. If the crankshaft is slightly dam
aged, correct it by re-grinding.
V block V block
Measuring
Measuring the crankshaf
crankshaftt bend)
7 22
5. Measurement o f cr nkpin and Journal

Journal
Measure the outside diameter, roundness,
taper angle of the crankpin and the journal.
If uneven wear or roundness exceeds the
wear limit but measured
measured outside diameter
diameter is
within the limit, use

after correcting themthe
bycrankpin andReplace
regrinding. journal
them with new ones, if any of the limit is
exceeded.
n oversized crankpin metal by 0.25 mm
is available.
available. See
See this Chapter 7-5 ,8. )
rankpin
Measurin
Meas uring
g positio
pos ition
n of the crankpin )
and crankjournal
mm)
3/4TNE82.
3TNE78A
213TNE68 3TNE74
4TNE82A 3/4 TNE84 T).
3/4TNE88
Standard e a r l i m ~ limit Standard Wear limit

Standa rd Wear limit limit Stand
Standard
ard Wear limit
limit
Crankpin outside 35.970 39.970 42.952 47.952

Crankpin 35.91 39.91 42.91 47.91
diameter 35.980 39.980 42.962 47.962
Crankshaft journal 39.970 39.90 43.970 43.90 46.952 46.91 53.952 53.91
outside diameter 39.980 43.980 46.962 53.962
Bearing metal 1.487 1.987 1.987 1.995

Crank thickness 1.500
- 2.000
- 2.000
- 2.010
-
journal
rank journal and 0.033 0.033 0.038 0.038
0.15 0.15 0.25 0.15
bushing oil clearance 0.059 0.059 0.093 0.068
7 23
7. Measuring Procedure Service oala and Corrective Action
6. Precautions In mounting the metal cap

1) The lower metal cap side) has no oil
groove.
(2) The upper metal
metal cylinder block side) has
an oil groove.
(3) Check the cylinder block alignment No.
(4) Place the relief mark FW of the cap on
the flywheel side.
5) Place the main
main bearing metal on the fly·
wheel side.
Main bearing metal basic)
-n
Thrust metal gear side)
Thrust metal flywheel side)
Un ® Main bearing metal
Main bearing cap b a S i C ) ~ U ®

® Main bearing cap
7. Undersized
Under sized main metal by 0.25 mm and the oversized thrust metal by 0.25 mm
Main metal Thrust metal

Metal thick- Metal thick-
Part code ness (mm) Part code ness (mm)
Standard Standard
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) 129150 02870 2.125 129150 02940 2.125
3/4TNE88
7-24
7 8. Gears
1. hecking gears Indirect Injection system)

Inspe ctthe gears and repla
Inspectthe replace
ce il th
thee tee
teeth
th are
damaged, worn, or chipped.
2. Measuring the backlash

Apply a dial gauge onto the pitch circle 1 the
gear, and measure the backlash.
(mm)
3TNE78A182A,
213TNE68, 3/4TNE82,
3TNE74 3/4TNE84(T),
3/4TNE88
Crankshaft gear.
Camshaft gear.
0.04-0.12 0.07-0.15
Back- Idle gear and
lash Fuel injection
pump drive gear
L.O. pump gear 0.11-0.19
3. hecking and measuring the idling Direct Injection system)

gear shaft and idling gear
1) Measure the bushing inside diameter and
the idle gear shaft outside diameter, and
replace the bushing or idling gear shaft if
the oil clearance exceeds the wear limit.
(mm)
3TNE78A182A.
213TNE68, 3i4TNE82,
3TNE74 314TNE84(T),
314TNE88
Standard Wear
I . Standard Wear
mlt limit
Shaft outside 19.959 19.93
45.950
45.93
dia. -19.980 -45.975
Idle Bushing 20.000 46.000
ear inside dia. -20.021 - -46.025
46.08
Oil clearance 0.020 0.025

0.15 0.15
-0.062 -0.075
2) Make sure that the oil hole 1 the idle gear
shaft and bushing is a through hole.
7-25
4. 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
* T option)
L O pump gear
irection of rotation
7 26
7 Measuring Procedure Service Dala and Correclive Acllon
7-9. Trochoid pump 3. Side clearance between pump body

and Inner rotor, outer rotor
Place a straight-edge against the end of the
1. Clearanc e betwee n outer rotor and
pump and insert a thickness gauge between
pump body
the straight-edge and the rotors to measure
Insert a thickness gauge between the outer
the side clearance.
rotor and pump body to measure
measur e the clear -.lm' l.
ance. (mm)
314TNES2,
3TNE78A
~
213TNE68 314TNE84 T),
All models 3TNE74 3TNES2A 3/4TNE88
Wear
Standard Wear Standard Wear
limit Standard Wear Standard limit
limit limit
Clearance between outer
rotor and pump ody 0.10 0.16 0.25 ump body and 0.03 0.05 0.03 0.15
0.13
nner-, outer-tOtor
side clearance
-0.09 -0.10 0.15 -0.09
, " /
Straight edge
Outer rotor
Pump body
- > f - - - Pump body

Thickness gauge
Thickness
Thickness gaug e
Measuring the clearance between)

( outer rotor and pump body Measuring the clearance between the pump)
( body and Inner-, outer-rotor
2. Clearan ce betwe en outer rotor and 4. Cleara nce betwee n rotor shaft and side
inner rotor
cover hole
Insert a thickness gauge between the top of
Measure the rotor shaft outside diameter
the inner rotor tooth and the top of the outer and the side cover hole diameter, and calcu
rotor tooth to measure the clearance.
late the difference between the hole diam
(mm)
eter and the outside diameter. (mm)
All models
All models
Wear
Standard
limit Wear
Standard
Clearance between outer l m ~
otor and inner rotor - 0.15
Clearance between
between ro tor 0.013
0.2
shaft and side cover hole 0.043
5. Others
Inner rotor
(1
(1)) Check for looseness of drive gear/rotor
gear/rotor
shaft fitting,
fitting, and replace the entire assem
Outer rotor bly if loose or wobbly.
(2) Push the oil pressure regulating valve
piston from the oil hole side, and replace
Thickness
Thickness ga uge 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,
Measuring the clearance between)
( outer rotor and Inner rotor
7 27
8 Disassembly and Reassembly
8. Disassembly and Reassembly
Peripheral parts such as air cleaner, muffler Perform the procedure, with reference to the
and radiator differ in installation and types
type s for attached drawings, Engine
Engine c component
omponent
each application. Therefore, description in Exploded View.
this Chapter is started with the steps to be
taken just after the peripheral parts have
been removed.
8 1. Disassembly
* For the number following the p rt name
name,, refer to attached drawing 1 nd 2 Exploded Views of Engine
Components
Step Removal Parts Remarks
1 1. Thorough
Thor oughly
ly remove sand, dust, dirt
and soil from the surface of the
engine.
2 Drain cooling
cooling water and lubricating
oil from the engine.
2 1. Remove turbo
turbocharge
chargerr ® and
manifold D .
exhaust manifold
2 Remove intake manifold @ and

surge tank @ .
3 1. Close the fuel cock valve of the fuel 1. If nozzle seat (j) is left on the cylinder head, remove the
tank. cylinder head before extracting nozzle seat (j).
2 high-p ressure fuel pipe © .

Remove high-pressure 2 To prevent dust from entering fuel injection nozzle ®
fuel injection pump ® and high-pressure fuel pipe ©
3. Remove fuel return pipe ®. seal their respective threads with a tape or the like.
4 Loosen the tightening nut on fuel 3. Whenever extracting fuel injection nozzle ® replace
injection nozzle retainer ® and ex- nozzle protector ® with a new one.
tract the retainer and fuel injection
nozzle ®.
* jection
Fuel injection nozzle for Indirect in-
system is scre wed type.
type.
4 1. Remove bonnet assernbly @ .
5 1. Remove valve rocker arm shaft as- 1 Attach a tagto push rod @ for each cylinder
cyli nder No. to put
sembly @ . the push rod in order.
2 2
Remove push rod @ . Rernove valve cap @ from the intake/exhaust valve
head.
3. Note that tappet @l of the indirect injection system can

be removed at the same time when push rod @ is
extracted.
4 Attach a tag t o tappet @l for each cylinder No. to put

Attach
the tappet in order.
81
8. Dlsassemblyand Reassembly
6 1. Remove fan mounting bolt ®. 1. Never turn down alternator @ vigorously toward the
and then remove fan @ . cylind er block. Otherwise. y ur finger may be nipped
cylinder
and alternator @ broken.
2. Loosenadjustingbolt @ fortheV-
belt adjuster. and then remove V-
belt @ .
3. Remove aHernator
aHernator @ .
4. Remove the spacer for cooling fan

@ and V-pulley ®l.
7 1. Remove lubricating oil filter assem-

bly @
2. Extract dipstick @ from the oil dip-

stick hole.
8 1. Disconnect fuel return pipes @ to

@.
2. Remove fuel filter @ .
9 1. Disconnect cooling water

wa ter pipe @
from the cooling water pump.
2. Remove thermostat assembly @ .
3. Remove cooling water pump @.
10 1. Remove cylinder head tightening 1 Lay a cardboard or the like on the floor and place
bolt @ . cylinder head assembly @ on it so as not to damage
the combustion surface.
2. Remove cylinder head assembly
@ 2. Order of loosening the cylinder head tightening bolts
3. Remove cylinder head gasket @.
amshaft side amshaft side
® ® 0
w 8 ® ® lID 0
w
a; ® @ @ w
® @ @
- - a; ®
s=
'u - - - u
@ ® D
.s=
@ @ @ '
u:: ® J) CD
® @ J)
\.
) ()
Fuel injection pump side Fuel injection pump side
Camshaft side
J) @ ® 0
®-
0
a; D ® @ @ @ w
- -
'j
s=
@ @ ® @ ®
u:: ® @ @ ® )
Fuel injection pump side
8-2
3. To remove the intake/exhaust valves from cylinder

head assembly ® , ake the following steps.
1 ) Using a valve spring compr

compresso
essorr see Chapte
Chapterr 5,
5·1). compress valve spring @ and remove
valve cotter @ .
@
alve spring compressor
2) Remove valve retainer @ and valve spring @ .
3) Removeintakevalve ® and exhaust

exhau st valve @
11 1. Remove crankshaft V·pulley 1. Extract crankshaft V-pulley @ by hitting the bolt olthe
clamping bolt @ puller using a plastic hammer or the like.
2. Using a puller, extract crankshaft V-

pulley @
12 1. Remove oil pan mounting bolt @ 1. Never fail to remove stiffner bolt @ at the center of
under ge ar case @ the gear case.
2. Remove gear case mounting bolt 2. When removing

removing the gearcas
gearcase,
e, care
carefully
fully protect oil seal
@ @ from damage.
3. Remove gear case @ .
13 1. Remove the nut from fuel injection 1. Before removing fuel injection pump ®,
make sure of
pump drive gear @ . Extract fuel the position of the arrow of the pump bo dy for adjusting
injection pump drive gear @ using fuel injection timing as well as the position of the
a puller. scribed line of the gea
gearr case flange. Applie
Appliess onl
onlyy to
direct injection system.)
14 1. Remove lubricating oil pump @ .
15 1. Remove starting motor i from

flywheel housing @ .
16 1. Remove flywheel mounting bolt ® 1. Carefull
Carefully
y protect the ring ge
gear
ar from damage.
2. Remove flywheel @
17 1. Remove flywheel housing @ . 1. Carefully protect

protect the oil seal from damag
damage.
e.
2. Remove oil seal case ® with a

screwdriver or the like by utilizing
grooves on both sides of oil seal
case ®
8-3
8. isassemblyand Reassembly
18 1. Remove oil pan ®I and spacer i@ . 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 1. Remove idle gear shaft @ and 1. Turn the cylinder block aside and carefully prevent
then remove idle gear @ . tappet i@ from jamming on the cam.
2. Remove mounting bon @ ofthrust 2. Preheat camshaft gear J and camshaft assembly
bearing ® through the hole of the @l to 180 C 200 Cwhich are shrink fitted, before
camshaft gear @J. Remove cam- removing them.
shaft assembly @l .
20 1. Remove gear case flange @ .
21 1. Remove lubricating oil strainer @ .
22 1. Remove crankpin side cap @ of 1. Before extracting piston @ remove carbon deposits
the connecting rod. from the upper wall
wall ofthe
oft he cylinder using fine sandpaper,
o While turning crankshaft @ , place while taking care not to damage the inner surface of
piston @ inthebottomdeadcenter the cylinder.
BDC).
2. Make sure that cap No. of connecting rod @ agrees
with cylinder No.
3. Take care not to let crankpin metal @ fall when

removing connecting rod crankpin side cap @ .
1. @. 1.
23 Removemainbearingcapbolt
While shaking main bearing cap @ Before
around extracting
it. crankshaft @ ,measure the side gap
remove main bearing cap @ to-
getherwHh lower main bearing metal
m etal
@.
2. Extract crankshaft @ ,taking care

not to damage H
~ ~ > ~
- 1 C - - - ~ L
3. Remove upper main bearing metal
I t O L I ~
, .
.
r ~ ~ ~
- I o ~
f Y ; f J i i i ~ ~ \ ~
I ~ o ~ l \
Ill>-
~1\ 1 \ R ~ ~
~ \ l
~ ~ ~ ~ Y V
\0
\1. >0
0 <
Dial gauge
Crankshaft
8-4
8 lsassemblyand Reassembly
Apply a dial gauge to the end of crankshaft @ . Force

the crankshaft on both sides in the axial direction to
measure the thrust gap. Alternatively, insert a thickn
thickness
ess
gauge directly between the base thrust metal and the
thrust surface of the crankshaft to measure the gap.
lithe limit size is exceeded, replace the thrust metal with
a new one.
mm)
- All models
I Thrust gap
I 0.090
0.090 - 0.
0.27
271
1
I
2. Notice on the removal of thrust metal @
1) When removing thrust metal @ ascertain the

position and direction where thrust metal is installed
in relation to the cap.
2) Make sure that the thrust metal

me tal groove is outwar
outwardd in
relation to the cap.
24 1. Remove piston @ and connecting

connecting 1. To selectively remove a desired piston and connecting
rod ® assembly. rod assembly without extracting crank
crankshaft
shaft @ take
the steps itemized below:
1) Remove carbon deposits from the upper wall of the

cylinder using fine sandpaper, taking care not to
damage the inner surface of the cylinder.
2) While turning the crankshaft, with the crankpin side

cap i@ removed, raise the piston up to the top dead
center TOC).
3) Extract the piston/connecting rod assembly while

connectin g rod ® at the large end wnh
tapping the connecting
the handle of a plastic hammer or the like.
25 1. Remove tappet @ .
8·5
8 2. Precautions before and during reassembly

To reassemble engine components, reverse directly between the base thrust metal and
the procedure of diassembly. However,
However, fol
fol the thrust surface of the crankshaft to meas
low the
the precautions
precau tions below particularly
particul arly before ure the gap. If the limit size is exceeded,
and during reassembly. replace the thrust metal with a new one.
1) Cleaning the component mm)
Use particular care to clean the cylinder All models
block, cylinder head, crankshaft, and cam
shaft. Ensure that they are free from chips, Thrust gap 0.090 0.271
dust, sand, and other foreign matter.
2) Parts to be replaced during

reassembly
Be sure to replace the following parts with
new ones during assembly.
1) Valve stem seal
2) Head gasket
gask et packing
3) Nozzle protector of the fuel injection
valve
4) Various copperpackings,
copperpa ckings, O-rings and
gasket packings.
3) Measurin
Measuring g the side g p around
crankshaft
Apply a dial gauge to the end of the crank Oial gauge
shaft. Force the crankshaft on both sides in rankshaft

the axial direction to measure the thrust gap.
Alternatively, insert a thickness gauge Measurement of side gap
gap around )
crankshaft
4) Gear train
@
After shaving
marks
mark of the installed eachpump
fuel injection gear, drive
makegear,
sure camshaft ®,and crankshaf
that marksgear and © oft the
crankshaft idle
gear asgear align
shown with
below.
Viewed from gear case

Fuel injection pump drive gear
Camshaft gear
* TO option)
Idle gear
Crankshaftt g ear
Crankshaf
Lubricating oil pump gear

Direction of rotation
8-6
(5) Where to use liquid packlngs 2. Assemble tthe

he piston rings to the cylinder.
1. Between the cylinder block and gear case staggering the piston rings jOints at 120
fiange intervals, making sure that they are not
2. Between the gear case flange and gear aligned along the piston. Apply lube oil
case cover to the circumference of the piston.
3. Between the cylinder block and oil seal
case (indirect injection system only)
4. Oil pan installation surface
*Use Three No. ondNo. 005 Yanmar part Top ring
code: 97777·001212) as the liquidpacking.
* Apply the liquid packing so as not to form
any bre ak on the midway. Otherwise,
2nd ring
oil leakage, etc., may result.
6) Coating the lubricating oil on intake/

exhaust valve stem Oil ring
Valve guide
Top ring
nd ring K ~ ~ ~
Apply lubricating
lu bricating oil down to the lower surface Oil ring
(hatched portion in the figure) of the valve
guide before reassembling the valve stem.
(7) Reassembly o the piston ring

1. Insert the piston ring into the ring groove,
where the side with the manufacturer
manufactu rer s
mark on the matching ends facing up (to
the combustion chamber side), using a
piston ring replacer. After fitting the piston
ring, make sure it moves easily and
smoothly.
The side with the manufacturer s
mark shall face upward
8 7
8 Disassembl
Disassemblyy and Reassembly
8) Coating the lubricating oil to

push rod adjusting screw contact
Apply lubricating oil to the hatched portion

ofthe puSh rod as shown in the figure, before
reassembly. Apply lubricating oil
9) ssembly direction of piston and connecting rod
3TNE78A, 3TNE82A, 3/4TNE82

213TNE68,3TNE74
3/4TNE84 T),3/4TNE88
1 0 mark 1 0 mark
8
.;;
~ - t . l J - + l ~ f f - t - t - - + - -
E
.)
Cylinder Cylinder
size mark Flywheel side size mark Flywheel side
I I Embossed lli 1 :7
marl<
Flywheel side) Embossed mark
Flywheel side)
lignment mark lignment mark

8-8
8 isassembly and Reassembly
10) Order of tightening cylinder heads

heads
and tightening torque
Tighten cylinder heads in numerical order shown below to the specified torque.
amshaft side
-8 @ ®
0
0;
0;
a;
@ <J
( 2 cylinder)
' ® ® '
u ® @
FO pump side
amshaft side
-8 <J <D @ -8
'0; '0;
@ @
( 3 cylinder) a;
Q)
' @ @ '
® @ ® '
J-
FO pump side
amshaft side
fl @ @ ® @ :l
a; @ @ Q)
( 4 cylinder)
' @ @
)
u @ ® @ @
FO pump side
(kgf-m)
3/4TNE82
3TNE78A
213TNE68 3TNE74 3/4TNE84(T)
3TNE82A 3/4TNE88
Tightening
3.8 -4.2 6.0-6.5 6.8-7.2 8.7-9.3
torque
11) After having reassembled the cylinder
heads, carry out confirmation running
to see if they are free from leakage of
water and oil.
8-9
9 Service ata
9. Service Data
91 Cylinder Head
(Unit: mm)
3/4TNE82.
3TNE78A
2I3TNE68 3TNE74 3/4TNE84(T).
3TNE82A 3/4TNE88
Wear Wear Wear Wear
Standard Standard Standard Standard
tem limit limit limit limit
Cylinder head combustion surface 0.05 0.05 0.05 0.05
0.15 0.15 0.15 0.15
distortion or less or less or less or less
Intake 120° - 120° - 120° - 120° -

Valve seat
angle
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

Valve seat
width
Exhaust 1.41 1.91 1.77 2.27 1.66-1.87 2.27 1.24-1.45 1.94
5.460 6.960 6.945 7.955

Valve stem outside dia. 5.4 6.9 6.9 7.9
-5.475 -6.975 -6.960 -8.025
5.500 7.005 7.000 8.010

Intake valve Valve guide inside dia. -5.515 5.58 -7.020 7.08 -7.015 7.08 -7.975 8.1
0.025 0.030 0.040 0.035
Oil clearance 0.18 0.18 0.18 0.2
-0.055 -0.060 -0.070 -0.070
5.445 6.945 6.940 7.955

Valve stem outside dia. 5.4 6.9 6.9 7.9
-5.460 -6.960 -6.955 -8.030
5.500 7.005 7.000 8.015

Exhaust valve Valve guide inside dia. 5.58 7.08 7.08 8.1
-5.515 -7.020 -7.015 -7.970
0.040 0.045 0.045 0.045

Oil clearance 0.18 0.18 0.18 0.2
-0.070 -0.075 -0.075 -0.075
Valve guide projection 7 9 - 12 - 15 -

0.296 0.306
Intake valve 0.3-0.5 0.4-0.6
-0.496 -0.506
Valve sinking
1.0 VM: 0.75-0.95 1.0 1.0 1.0
depth Exhaust valve 0.75-0.95 CH: Q.40-0.60 0.3-0.5 0.3-0.5
VH: 0.40-0.60
Intake valve 0.85-1.15 0.99-1.29 1.244

-1.444 1.244
-1.444
Thickness of 0.5 0.5 0.5 0.5
valve head Exhaust valve 0.95-1.25 0.95-1.25 1.35-1.55 1.35-1.55
Open b.TDC 5°_ 5° 7°_ 7° 10°_20° 10°_20°

Intake valve
timing
Close a.BOC 37°_47° 35°_45° 40°_50° 40°_50°
- - -
Open b.BOC 37°-47
37°-47 40°_50° 51 °_60° 51°_61°
Exhaust valve
timing 5°_ 5° 8°_ 8° 13°_23° 13°_23°
Close a.TOC
Free length 28 - 37.4 - 44.4 - 42 -
Valve spring Inclination - 0.8 - 1.0 - 1.1 - 1.1
Tension (kg) 2.37 3.61 2.36

(when compressed to
1mm length)
1.14 -1.40
- variable p
11 87
~ c h
- variable p ~ c h
12.71
- variable pitch)
13 101
-
Intake exhaust valve clearance 0.15-0.25 0.15-0.25 - 0.15-0.25 - 0.15-0.25
91
9 Service ata
9 2 Cylinder Block
(Unit· mm)
213TNE68 3TNE74 3TNE78A
Wear Wear Wear

Item limit limit limit
68.000 74.000 78.000
Cylinder bore
-68.030 -74.030 -78.030
68.020 74.020 78.020
mark
-68.030 -74.030 -78.030
68.20 74.20 78.20
68 Q10 74.010 78.010
Cylinder bore Mmark
-68.020 -74.020 -78.020
68.000 74.000 78.000
S mark
-68.010 -74.010 -78.010
0.00 0.00 0.00
Cylinder roundness 0.03 0.03 0.03
-0.01 -0.01 -0.01
0.00 0.00 0.00
y l i n d r i c ~ y
-0.01 0.03 -0.01 0.03 0.03
-0.01
3TNE82A
3/4TNE84(T) 3/4TNE88
3/4TNE82
Wear Wear Wear
82.000 84.000 88.000
Cylinder bore
-82.030 -64.030 -88.030
82.020 84.020 88.020
mark
-82.030 -84.030 -88.030
82.20 84.20 88.20
82.010 84.010 88.010
Cylinder bore Mmark
-82.020 -84.020 -88.020
82.000 84.000 88.000
S mark
-82.010 -84.010 -88.010
0.00 0.00 0.00
Cylinder roundness 0.03 0.03 0.03
-0.01 -0.01 -0.01
0.00 0.00 0.00
Cylindricity 0.03 0.03 0.03
-0.01 -0.01 -0.01
9 3 Valve rocker arm

(Unit· mm)
3TNE78N82A,
3/4TNE82,
213TNE68 3TNE74
3/4TNE64(T),
314TNE88
Wear Wear Wear
Item Standard Standard Standard
limit limit limit
Rocker arm shaft
9.972-9.987 9.9
9.95
5 11.966-11.96 4 11.95 15.966-15.964 15
15.95
.95
outside dia.
Intake
Rocker arm bushing
Exhaust 10.000-10.020 10.09 12.000-12.020 12.09 16.000-16.020 16.09
inside dia.
rocker arm
Oil clearanc
clearance
e 0.013-0.04 8 0.14 0.016-0.054 0.14 0.016-0.054 0.14
Pushrod bending 0.03 or less - 0.03 or less - 0.03 or less -

Tappet stem outside
17.950-17.968 17.93 20.927-20.960 20.90 11.975-11.990 11.93
dia.
Tappet Tappet guide hole
18.000-18.018 18.05 21.000-21.021 21.05 12.000-12.018 12.05
inside dia.
Oil clearanc
clearance
e 0.032-0 .088 0.12 0.040-0.094 0.15 0.010-0.043 0.12
9-2
9 Service ata
9 4 Piston
Unit: mm)
213TNE68
3TNE74 3TNE78A 3TNE82A
VM, VH CH
Wear Wear
Standard Wear Standard Standard Wea Standard Wear Standard
Item limit limit limit limit limit
67.960 67.940 73.940 77.950 81.950
Piston outside dia. -67.970 -73.970 -77.980 -81.980
-67.990
67.980 67.960 73.960 77.970 81.970
Lmark
-67.990 -67.970 -73.970 -77.980 -81.980
67.975 67.955 73.955 77.965 81.965
ML mark 67.90 -67.960 67.90 -73.960 73.90 -77.970 77.90 -81.970 81.90
Piston -67.980
outside dia. 67.970 67.950 73.950 77.960 81.960
MS mark
-67.975
-67.97 5 -67.955 -73.955 --77.965
77.965 -81.965
67.960 67.940 73.940 77.950 81.950
S mark -67.950 -73.950 -77.960 -81.960
-67.970
Min. clearance between piston 0.025 0.045 0.045 0.035 0.035
-0.055
- -0.075 - -0.075 - -0.065 -0.065
and cylinder
Top clearance 0.610 0.658 0.650 0.650
-0.730 -0.778 -0.770 -0.770
Piston pin 19 991 20 991 22 991 22 991
19.90 20.90 22.90 22.90
outside dia. -20.000 -21.000 -23.000 -23.000
Piston and Piston pin hole 20.000 21.000 23.000 23.000
piston pin 20.02 21.02 23.02 23.02
dia. -20.008 -21.008 -23.008 -23.008
0.000 0.000 0.000 0.000
Oil clearance 0.12 0.12 0.12 0.12
-0.017 -0.017 -0.017 -0.017
~ ~ ~
3/4TNE82 3/4TNE84 T) 3/4TNE88
Wear Wear Wear

Item lmt limit limit
81.945 83.945 87.945
Piston outside dia.
-81.975 83.975 87.975
81.965 83.965 87.965

Lmark
81.975 83.975 87.975
81.960 83.960 87.960

Piston ML mark 81.965 81.90 83.965 83.90 87.965 87.90
outside dia. 81.955 83.955 87.955
MS mark
81.960 83.960 87.960
81.945 83.945 87.945

S mark
81.955 -83.955 87.955
Min. clearance between piston 0.040 0.040 0.040

and cylinder 0.070
- 0.070
- 0.070
-
0.660
Top clearance
0.660
0.780
- 0.660
0.780
- 0.780
-
25.987 25.987 25.987
Piston pin outside dia. 25.90 25.90 25.90
26.000 26.000 26.000
Piston and Piston pin hole 26.000 26.000 26.000

26.02 26.02 26.02
piston pin dia. 26.009 26.009 26.009
0.000 0.000 0.000

Oil clearance 0.12 0.12 0.12
0.022 0.022 0.022
9 3
9 Service Data
9 5 Piston ing
Unit: mm)
13TNE6B 3TNE74 3TNE7BA
Wear Wear Wear

1.550 1.550 2.035
ing groove width
1.570
- -1.570
- -2.050
-
1.470 1.470 1.940
ing width
-1.490 - -1.490
- -1.960
-
Top ring
0.060 0.060 0.075
Min. side clearance
-0.100
- -0.100
- -0.110
0.100 0.200 0.200
End clearance 1.5 1.5 1.5
-0.250 -0.400 -0.400
1.540 1.520 2.025
ing groove width 1.555
- -1.535 -2.040
-
1.430 1.410 1.975
Ring width 1.450
- -1.430 -1.990
-
2nd ring
0.090 0.090 0.035
in. side clearance -0.125
- -0.125 -0.065
-
0.150 0.200 0.250
End clearance 1.5 1.5 1.5
-0.350 -0.400 -0.400
3.010 3.010 3.015
Ring groove width -3.025 -3.025 - 3.030 -
2.970 2.970 2.970
Ring width 2.990 - -2.990 - -2.990
Oil ring
0.020 0.020 0.025
Min. side clearance -0.055 - -0.055 - -0.060 -
0.150 0.150 0.200
nd clearance 1.5 1.5 1.5
-0.350 -0.350 -0.400
~ tem
3TNEB2A
3/4TNEB2
Standard
Wear
limit
3/4TNEB4 T)
Standard
Wear
limit
3/4TNEBB
Standard
Wear
limit
2.065 - 2.065 2.060
ing groove width -2.0BO -2.0BO - -2.075
1.970 1.970 1.970
ing width
-1.990 - -1.990
- -1.990
Top ring
0.075 0.075 0.070
in. side clearance
-0.110
- -0.1100
- -0.105
-
0.200 0.200 0.200 1.5
End clearance 1.5 1.5
-0.400 -0.400 -0.400
2.035 2.035 2.025
ing groove width -2.050 - -2.050
- -2.040
-
1.970
ing width -1.990
- 1.970
-1.990
1.970
-1.990 -
2nd ring
0.045 0.045 0.035
in. side clearance O.OBO
- O.OBO -0.070
-
0.200 0.200 0.200 1.5
End clearance 1.5 1.5
0.400 -0.400 -0.400
4.015 4.015 4.015
Ring groove width - - -
-4.030 -4.030 -4.030
3.970 3.970 3.970
Ring width -3.990 -3.990 - -3.990 -
Oil ring
0.025 0.025 0.025
Min.. side clearance
Min -0.060 - -0.060 - -0.060 -
nd clearance 0.200 0.200 0.200
-0.400 1.5 -0.450 1.5 -0.400 1.5
9-4
9 Service ata
9 6 Connecting od
Unit: mm)
3/4TNE82.
3TNE74 3TNE78A
2/3TNE68 3/4TNE84 T}.
3TNE82A 3I4TNE88
Wear Wear Wear Wear
Item Standard limit Standard limit Standard limit Standard limit
Crankpin bushing 39.000 43.000 46.000 51.000
inside dia. -39.016 -43.016
- -46.016
- -51.010
-
Crankpin metal 1.487 1.487 1.487 1.492
thickness -1.500
- -1.S00
- -
Crankpin side 1.500 1.500
35.970 39.970 42.952 47.952

Crankpin outside dia. 35.91 39.91 42.91 47.91
-35.980 -39.980 -42.962 -47.962
0.033 0.033 0.038 0.038
Oil clearance 0.15 0.15 0.16 0.16
0.059 0.059 0.090 0.074
Piston pin bushing 20.025 21.025 23.025

20.10 21.10 23.10 26.025 26.10
inside dia.
inside dia. -20 .038 -21.038 -23.038 -26.038
19 991 20.991 22.991 25.987
Piston pin side Piston pin outside dia. 19.90 20.90 22.90 25.90
-20.000 -21.000 -23.000 -26.000
0.025 0.025 0.025 0.025
Oil clearance 0.2 0.2 0.2 0.2
0.047 0.047 0.047 -0.051
Less than Less than Less than Less than
Twist and parallelism 0.03
100mm
per 0.08 0.03
100mm
per 0.08 0.03
100mm
per 0.08 0.03
lOOmmper 0.08
9 7 Camshaft
Unit· mm)
3TNE78N82A.
3/4TNE82.
2/3TNE68 3TNE74
3/4TNE84 T}.
3/4TNE88
Wear Wear Wear
Camshaft journal 35.940 39.940 44.925
35.85 39.85 44.85
outside
outside dia.
dia. -35.9 60 -39.9 60 -44 .950
Gear side
0.040 0.040 0.040
Oil clearance
-0.085
- 0.085
- 0.130
-
35.910 39.910 44.910
Camshaft
outside
outsid diajournal
e dia.. -35.9 35 35.85 -39.935 39.85 -44.935 44.85
Intennediate
Oil clearance 0.065 0.065 0.065
-0.115
- 0.115
- 0.115
-
Camshaft journal 35.940 39.940 44.925
35.85 39.85 44.85
Flywheel side outside dia. 35.960 -39.960 -44.950
0.040 0.040 0.050
Oil clearance
0.125
- 0.125
- 0.100
-
9 8 Crankshaft
Unit: mm
3/4TNE82.
3TNE78A
213TNE68 3TNE74 3I4TNE84 T).
3TNE82A 3/4TNE88
Wear Wear Wear Wear
Item Standard Standard Standard Standard
limit limit limit limit
Crankshaft journal 39.970 43.970 46.952 53.952
39.90 43.90 46.91 53.91
outside dia. -39.980 -43.980 -46.962 -53.962
Bearing metal 1.487 1.987 1.987 1.995
Crank journal
thickness -1.500
- 2.000
- 2.000
- 2.000
-
Crank journal and 0.033 0.033 0.038 0.038
0.15 0.15 0.25 0.15
bushing oil clearance 0.059 0.059 0.093 -0.068
0.02 0.02
Bend
or less - 0.02
orless
- 0.02
or less - or less
-
9 5
9 Service Data
9 9 Side Gap and Backlash

Backlash
~
(Unit: mm)
All models
Standard
Item
Crankshaft 0.090-0.271
Camshaft 0.05-0.25
Side gap
Connecting rod 0.2-0.4
Idle gear 0.1-0.3
(Unit: mm)
~ l 2/3TNE68,
3TNE74
3TNE78A182A,
3/4TNE82,
3/4TNEB4(T),
Item 3/4TNE88
Crankshaft gear,
Camshaft gear,
Idle gear and 0.04
0.04 - 0.12
0.12 0.07
0.07 - 0.15
0.15
Backlash Fuel injection pump
drive gear
L.O. pump gear 0.11 - 0.19
9 10 Others
(Unit· mm)
Item
~ e l 213TNE68 3TNE74
3TNE78A
3TNE82A
3/4TNE82,
3/4TNE84(T),
3/4TNE88
Lubricating High speed
oil pump operation 11.9 (at 3600rpm) 15.8 (at 3600rpm) 19.6 (at 3600rpm) 25.0 (at 3000rpm)
f min
2.5 (at 750rpm) 4.4 (at 800rpm) 8.0 (at 800rpm)
discharge
Low speed
volume operation
Pressure control valve
opening pressure kgf/cm' 3.0-4.0 3.0-4.0 3.0-4.0 3.0-4.0 .
L.O.. pressure switch

L.O
kgf/cm' 0.4-0.6 0.4-0.6 0.4-0.6 0.4-0.6
operating pressure
45 (at 4320- 55 (at 4320-
Cooling water pump 4380 rpm) 4380 rpm) 35 (at 3220- 70 (at 3220-
f min
discharge volume 32 (at 3320- 40 (at 3320- 3280 rpm) 3280 rpm)
3380 rpm) 3380 rpm)
Opening
Thermostat °C 69.5-72.5 69.5-72.5 69.5-72.5 69.5-72.5
temperature
valve opening
temperature Min. 4.5 Min. 8.0 Min. 8.0 Min. 8.0
Lift height mm
at 85°C and above) at 85°C and above) at 85°C and above) at 85°C and above)
Thenmoswttch ON 107-113 107-113 107-113 107-113

operating °C
temperature OFF 100 and above 100 and above 100 and above 100 and above
9 6
10 Tightening Torque
10. ightening orque

10-1 Main bolt/nut
(Unit: kgf-m)
314TNE82.
3TNE78A
o. Item Torque 213TNE68 3TNE74 3TNE82A 314TNE84
314TNE88 T).
Lubricating oil applied 3.8-4.2 6.0-6.5 6.8-7.2 8.7-9.3
I Cylinder head bolt Thread dia. x pitch) M8x 1.25) (M9 x 1.25) (M9 x 1.25) (MIO x 1.25)
Lubricating oil applied 2.3-2.8 2.3-2.8 3.8-4.2 4.5-5.5
2 Connecting rod bolt Thread aa. x pitch) (M7 x 1.0) (M7 x 1.0) (M8 x 1.0) (M9 x 1.0)
Flywheel clamping Lubricating oil applied 8.2-8.8 8.0-9.0 8.5-9.0 8.5-9.0
3 Thread dia x pitch)
bolt M l 0 x 1.25) Ml0 x 1.25) (MIO x 1.25) Ml0 x 1.25)
Metal cap clamping Lubrtcating oil applied 5.3-5.7 8.0-8.5 7.8-8.2 9.8-10.2
4
bolt (Thread dia x pitch) (M9 x 1.25) Ml0 x 1.25) Ml0 x 1.5) (M12 x 1.5)
S48C: 11.5-1 2.5 S48C:l1.5-12.5 11.5-12.5 11.5-12.5
Crankshaft V-pulley Lubricating oil applied
5 Thread dia. x pitch)
FC25: 8.5-9.5 FC25: 8.5-9.5 (M14 x 1.5) (M14 x 1.5)
clamping bolt
(M12 x 1.5) (M12 x 1.5)
Fuel injection Lubricating oil not applied 5.0-5.4 5.0-5.4 0.7-0.9 0.7-0.9
6 Thread dia. x pitch)
nozzle nut (M20 x 1.5) (M20 x 1.5) (M6 x 1.0) (M6 x 1.0)
7 Timer clamping nut Lubricating oil not

Thread dia. applied
x pitch) - 6.0-7.0
(M12 x 1.75) 6.0-7.0
(M12 x 1.75)
Lubricating oil not applied
8 Glow plug Thread dia. x pitch)
1.5-2.0
Ml0 x 1.25)
1.5-2.0
Ml0 x 1.25) -
Lubricating oil not applied 5.5-6.5
9 Stub shaft bolt Thread dia. x pitch) (MIO x 1.5)
5.5-6.5
Ml0 x 1.5)
- -
Governor weight Lubricating oil not applied 7.0-7.5 7.0-7.5 4.5-5.0 4.5-5.0
10
support nut Thread dia. x pitch) (M12 x 1.25) (M12 x 1.25) (M12 x 1.25) (M12 x 1.25)
High pressure pipe Lubricating oil not applied 3.0-3.5 3.0-3.5 3.0-3.5 3.0-3.5
11
sleeve clamping nut Thread dia. x pitch) MI2xl.5) (M12 x 1.5) (M12 x 1.5) (M12 x 1.5)
10-2 Standard bolt and nut

* : ubricating oil not applied
(Unit: kgf-m)
Item Thread dia. x pitch Tightening torque Remarks

M6xl 1.0 -1. 2 1) When bolting the aluminum parts. tighten
M8 x 1.25 the bolts with 80 of the tightening torque
Hexagon headed bolt 2.3-2.9
specified in the Table.
(7T) and nut M l 0 x 1.5 4.5-5.5 2) 4T bolt and lock nut should e tightened
M12 x 1.75 8.0-10.0 with 60 of the torque shown in the table.
1/8 1.0
1/4 2.0
PTplug
3/8 3.0
1/2 6.0
M8 1.3-1.7
M12 2.5-3.5
Pipe joint bolt
MI4 4.0-5.0
MI6 5.0-5.5
10 1
11 Fuellnjecllon pump for Indirect tnjectlon System
11 Fuel Injection Pum

Pump for Indirect Injection System
p for
11-1. Exploded vie

vieww yPFR
yPF R type
type))
Delivery valve spring holder "
Delivery valve spring
Delivery valve - - - - 1 ; 1
Delivery valve pa,;klng @
Delivel)' valve h o l , j e r - - - { ", , e j
Plunger o a rre l - -----{
Plunger barrel pa,;kln g - - - - - { ; l ; l )
Fuel injection pump boelv -----

Fuel injection volume adjusting plate
Eccenttic screw for adjusting
Fuel connel
'PI"n"ern"j,c e stopper
Injection timing ajusting shim - - - \ ~
\Phmo,erguide stopper
st opper pin
Fuel connel pln"on'---1IDllI
Plunger spring upper re"'"ne·r ~ ~ : . J

Plunger spnlng
Plunger spring lower re"'''ne'r-----{
Plunger positioning shim -f--<' e j )
Plunger roller gu",. - - - - - - j

Plunger guide roller pin
/ , ) I 0 L } - - Plun,ger guide outer roiler
"'-1'lun,ger guide inner roller
11-1
11 Fuellnjec/lon Pump or IndirectlnjeCllon System
11 2. Disassem
Disa ssembly
bly (4) Remove the plunger spring and plunger
plun ger
spring lower retainer.
To disassemble the fuel injection pump,
classify disassembled
disasse mbled parts for each
each cylinder
and carefully avoid allowing them to be mixed
with one another. Identifiably classify paired
parts supplied as assemblies, such as plunger
and plunger barrel and delivery valve and
delivery
deliv ery valve holder
holder for each cylinder. Use
particular
particu lar care to prevent the assembly from
from
going to pieces and being scattered.
(1) Remove the fuel

fuel injection pump.
(2) Extract the plunger guide stopper pin

pin an
and
d
remove the plunger guide stopper and
(5) Remove the plungerspr
plunge rspring
ing upper retainer
plunger barrel stopper.
and the fuel control pinion.
(6) Remove the delivery

deliv ery valve spring holder
(3) Remove the right plunger roller guide and then remove fuel control rack, deliv
assembly.
ery valve holder, delivery valve spring
and delivery valve.
11-2
11. Fuel Injection Pump for Indirect Injection System
7) Remove the plunger barrel assembly. 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.
rg} 1) Plunger guide outer roller, Inner roller

and plunger roller guide.
Inspect for wear and scratches with the
plunger guide outer
out er roller, inner roller and
and
plunger roller guide. a gap between the
fuel injection pump camshaft and plunger
guide outer roller exceeds 0.3 mm, re
place the plunger roller guide assembly
8) Remove the other plungers by repeating with a new one.
the above steps.
* Never loosen the eccentric screw for
adjusting nd set screw for the fuel
injection volume adjusting plate. Plunger roller guide
QO ]
Plunger guide Plunger guide Plunger guide
roller pin inner roller outer roller
2) Fuel ontrol rack and fuel control

pinion
1. Inspect for bending of fuel control rack
and wear or deformation of engaged
surface of fuel control pinion and fuel
control rack.
[ c
Fuel contr
control
ol rack) Fuel contro
con troll pinion)
2. Check to see if the fuel control rack

moves smoo
smoothly.
thly. If not, replace the fuel
control rack with a new one.
11-3
11 Fuellnjecllan Pump for Indirect Injection Syslem
3) lunger
1. Thoroughly clean the plunger. If any 2. Stop up the hole in the bottom of the
plunger lead is scratched or discolored, delivery valve holder and keep the seat
replace the plunger
plu nger assembly with a new as it is.
is. Insert the delivery
delive ry valve to the
one. holder. While releasing your
you r upper finger,
check to see if the

the delivery
deli very valve springs
back. If so, it is acceptable.
/-- '-.
Lead
I ,
Plunger) \ I
2. To test the plunger, hold the plunger

barrel tilted approx. 60 and check
che ck to see
if it slides down smoothly. If so, the
the plun I
ger is acceptable. While turning the
plunger, repeat the test several times. If Inspection of deliveryI valve)
any plunger slides down too quickly
slowly) or jams in the midway, correct 3. Likewise as described in item 2, stop up
it or replace the whole plunger
plun ger assembly. the hole in the bottom of the delivery
valve holder and check to see if the
delivery valve perfectly falls by gravity,
when the finger is released from the
bottom hole.
Approx.60·
If so, the delivery valve is acceptable. If
.
not, replace it.
Fall by gravity test of plunger) \.
4) Delivery
Delive ry valve
1. If the suck-back collar or seat of the
delivery valve is found scratched, dented,
worn, or otherwise damaged, replace the
whole delivery valve assembly.
(Fall by gravity test of delivery

deliver y valve)
- - - ; : ; - r - - Seat
Suck-back collar
11 4
11 Fuellnjecllon Pump for Indirect Injection System
11 4. Reassembly 5) Fit the

the plunger mounted with
with the plunger
spring u pper retainer,
retainer, plunger spring and
plung er spring
spring lower retainer.
retainer.
1) Insert the plunger barrel packing into the
Ensure that the mat
matchch ma rkofthe plunger
fuel injection pump body.
align s with
with that of the fuel
fue l control pinion.
2) Insert the plun ger barrel assembly.
3) Fit the delivery valve assembly, delivery

valve spring and delivery valve spring
holder.
kgf-m)
Matching mar <:s
Delivery valve spring holder

4.0 4.5
lightening torque.
6) Insert the plunger

plung er adjusting shim. Press
the plun ger guide assembly by hand. While
While
aligning the plunger guide stopper pin
with the mating hole o f the stopper pin
pin of
the fuel injection pump body, attach the
plunger guide stopper pin.
4) Reassemble the fuel control rack and fuel
control pinion.
* 1 Ensure that the match mark o f the fuel
contr ol rack aligns with that o f the fuel
control pinion.
* . Make sure that the fuel control rack
moves smoothly over ll the strokes.
11 5
12 FuellnJec ion Pump for Olrec nJec ion System
12 Inject ion Pump for Direct Injection System

Fuel Injection
12-1. Exploded view yPES

yPE S typ
type)
e)
Holder stopper
Delivery valve spring holder
O ring
O ring
/ Check bolt
· ~ Deflector Delivery valve stopper
Delivery valve spring
. valve
Delivery valve packing Delivery valve assembly
Delivery valve holder
Circlip
pacer Plunger
Control rack spring
barrel Plunger assembly
Rack bushing Plunger
Control rack
- C;orltrol sleeve
Fuel injection
Plunger spring upper retainer pump body Control rack stopper
;
Plunger guide stopper
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
~ \ : 1 t - P I ~ n n ~ r guide inner
Plunger in; , Ct i , , "

Fuel pump
Pump side
eaver
Bottom cover
Bearing holder
12 1
12 Fuellnjecllon Pump for Directlnjecllon System
12 2. Special service tools for disassembly and reassembly

No. Name of tool Shape and size Application
Side clearance Measurement of camshaft side

measuring gauge clearance
~ : ; : ~ ~ 158090·51050
2 Plunger insertion tool
Yanmar 158090 5110

code No. 0
3 Tappet holder tool
Yanmar 158090 5120

code No. 0
4 Rack lock screw
Yanmar 158090 51510

code No.
5 Governor weight
extractor tool
Yanmar
code No.
Governor
weigh1for 3 pes 158090·51400
Governor
weight for 4 pes 158090 51450
12 2
12 Fuellnjeclion Pump for Direct Inject/qn System
12 3. Disassembly
1) Remov
Remove e the bottom cover from the ffuel uel 4) Remove the fuel feed pump.
injection pump to drain lubricating oil from
the fuel injection pump. Do not disassemble the fuel feed pump.
2) Turn the fuel injection pump upside down

to drain fuel oil.
5) Remove the fuel injection pum

pumpsi
pside
de c
cover
over..
3) Take out the governor weight assembly

using the governor weight extractor tool
special service tool)
For separating the governor assembly

from the fuel injection pump, ref
refert
erto
o Chap-
ter 13 13-3.
12-3
12 Fuellnlee/ion pump lor Dlree/lnjeelion System
6) While turning the ffuel

uel injection pump cam-
shaft. raise the plunger guide up to the
max. stroke
stroke.. Insert the tappet holders
special service tool) between the plunger
spring lower retainer and fuel injection
pump body.
9) Turn the fuel inject

injection
ion pump upside down.
Move ll plunger guides toward the plunger.
Then. turn aside the fuel injection pump.
While turning the fuel injection pump
camshaft. find a position where the cams
of each
each cyl
cylinder
inder does not interfere with the
plunger guide outer roller and place the
camshaft in the position.
10)
10) Apply a plate against the governor end
side of the camshaf
camshaft.t. While tapping tthe
he
plate. extract a set of the camshaft and
drive bearing.
Special
Special service too
tool:
l: Tappet Holder
Holder))
7) Extract the woodruff key from the fuel

injection pump camshaft.
8) Extract the fuel injection pump camshaft

bearing horizontally
hori zontally by inserting a screw-
driver into the two grooves on the face
where the bearing holder of the fuel in- 11)
11) Remove the plunger guide stopper.
jection pump camshaft is installed.
1. arefully avoid allowing the thread of

the fuel injection pump camshaft to
damage the oil seal
2. arefully avoid allowing the adjusting
packings andoi
an doill seal betwe
between
en the pump
body and bearing holder to be lost
12 4
12 Fuel Injection Pump for D rec lnjectlon System
12) By using the handle of a hammer, etc., 14) Take out the plunger, plunger
pl unger spring and
push up the plunger guide from the bottom plunger spring lower reteiner from the
of the pump and take out the tappet lower part of the fuel injection pump.
holders special service tool).
Separate these parts for each cylinder.
Use
hol particular
holder
der. care to remove the tappet
. Carefullypreventtheplungerguide,
plunger, etc., from jumpi
jumping
ng out.
out. This
This is
because the plunger spring is powerful
enough to force them out.
15) Remove the stop screw from the fuel

13) Take out the plunger guide assembly. control pinion.
Do no
nott erect the fuel injection pump body,
whereverpossible. Otherwise,
Otherwise, the
the plunger
plung er
guide assembly falls off. Therfore, hold
the fuel injection pump body tilted and
remove the plunger guide assembly.
12-5
12 Fuelln eellon Pump for Dlreet n eellon System
1 . When th
the
e stop screw
scre w o f the fuel control Carefully prevent the control rack spring
pinion is loosened
loosened,, the fuel control
con trol pinion an
andd spacer on the control rack
rack from being
is separated from the control sleeve. missing.
Before loosening, therefore, make sure
that the match mark o f the fuel control
pinion aligns with that o f the control
sleeve. If the match mark is difficult t
identify or the match mark offsets, put
new match marks. This practice helps
adjusting injection volume later on
Small screw on control pinion
ontrol pinion
atch mark
ontrol sleeve
18) Loosen the bolt for the holder stopper.
stopper.
Remove the delivery valve sping holder.
2 . Separate all
al l these
these parts
par ts for each cylinder.
16) Remove the fuel control pinion, control
sleeve and plunger
plu nger spring upper retain
retainer.
er.
: Separate all
al l these parts for each cylinder.
cylinder.
17) Remove the control rack stopper. Extract
the control rack.
12 6
12 Fuel Injection Pump for irect tnjectlon System
(19)) Take out the delivery valve

(19 valve assembly. 12 4. Inspection
* 1. Carefully prevent small parts such as
the delivery valve packing, delivery Before inspection, thoroughly clean the
valve spring and delivery valve stop-
parts, using new diesel oil. Be careful to
* 2.
per from being missing.
Clearly separate the delivery valve
assembly for each cylinder.
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
assem bly with
with a new
one.
2 To testthe
test the plunger, hold the
the plunger barrel
tilted approx. 60 and check to see if it
slides down smoothly. If so, the plunger
is acceptable. While turning the plunger,
repeat the test several times. If any plunger
slides down too quickly (slowly) or jams
in the midway, correct it or replace the
whole plunger assembly.
(20) Take out the plunger barrel toward the

upper part of the fuel injection pump.
Keep the plunger barrel just picked up Approx.60·

together with the plu
plunge
ngerr which
which has been
taken out.
(Fall by gravity test of plunger)
(2) elivery valve

1
If the suck-back collar or seat of the
delivery
deliver y valve is found scratched, dented,
worn,or
worn, or otherwise damaged, replace
replace the
whole delivery valve assembly.
(Check for delivery valve)
12 7
12 Fuel Injection Pump for lrecttnjecllOn System
2. Stop up the hole in the bottom of the

delivery valve holder and keep the seat
as it is. Insert the delivery
deli very valve into the
holder. While releasing your upper finger,
finger,
check to see if the delivery valve springs
back. If so, it s acceptable.
acceptabl e. If not, replace
it.
3. Likewise as described in item 2, stop up

the hole in the bottom of
o f the delivery valve
holder and check to see if the delivery (Plunger guide assembly)
valve falls by gravity perfectly, when the
bottom hole s finger is released. If so, the
(4) Fuel injection pump camshaft and
delivery valve is acceptab
acceptable.
le. If not,
not, replace
bearing
it
1. Fuel injection pump camshaft

Check for damage and wear of the cam
shaft surface, deformation of keyway
and deformation of threads on both ends.
If the camshaft proves to be defective,
replace it.
2. Bearing
If the tape
taperr roller and outer
ou ter race has flak
ing, wear, or any other damage on the
(Fallll by gravity
(Fa gr avity test of delivery valve)
valve) surface, replace the bearing.
When replacing the fuel injection pump

(3) Plunger guide plunger barrel, etc.
camshaft, replace the bearing t the same
1 Check to see i f the
the sliding surface of the time.
plunger guide is free form excessive wear.
2. Check to see if the seat of the plunger

barrel has uneven contact, burrs, the
mark of blow-by ga s or other defects etc.
If so, correct
corre ct or replace the plunger
plunge r barrel.
Otherwise, lubricating oil in use will be
thinned.
3. If the surface of the plunger guide outer

roller indicates wear, flaking, etc., replace
the outer roller.
4 lithe plunger guide

guid e has the circumference
and roller pin hole worn or scratched,
etc., replace it with a new one.
5. II the plunger guide assembly has a

combination of the pin and roller that
indicates chatters, replace the plunger
guide assembly.
12 8
12 Fuellnjec/ion Pump for Direct tnjectlon System
5
5)) Control rack and fuel control pinion 12 5. Reassembly
1. Check the controll rack for bends and
the wear and deformation of the portion 1) Putthe
Putt he plung
plunger
er barrel into
into the fuel injection
where it is engaged with the fuel control pump from its top.
pinion.
* Make sure that the plunger barrel stopper
is snugly fitted with the key way
2. Check to see if the portion where the
control rack is engaged with the fuel
control pinion is free from wear and
deformation.
* If the control rack is in trouble with the

teeth face and sliding part. it encounters
increased resistance. causing the engine
to be out of order such as uneven
revolutionsandabruptrevolutionchanges).
1 ij'lIIIiilllI Mijjjjjliiilliililliiijjjll llmIlW\ ~ \\\
2) Insert the deli

delivery
very valve
valve assembly. deliv
ery valve spring and delivery valve stop
per from the top of the fuel injection pump
in that order.
* Replace the delivery valve packing and

O-ring with new ones before reassembling
the fuel injection pump.
3) Fit the control rack and tighten the
control rack stopper.
1. Never failto
fai lto install the control rack spr
spring
ing..
2. Make sure that the control rack moves
smoothly over the full stroke.
12-9
12 Fuel InJectIon Pump for Irect Injection System
4) Insert a rack lock screw special service

tool) into the thread hole ol
olth
the
e control rack
stopper and fix the control rack.
5) Peep through the bottom of the fuel injec-

tion pump and align the match mark of rU atch
the control rack with that of the fuel
control pinion.
Pinion rack match mark

Fuel control plnlonlcontrol sleeve match mark)
7) Mount the plunger spring upper retainer
1. Mount the plunger spring upper retainer

Fuel control pinion so that its recess faces downward.
2. Once again, ascertain that the control
rack moves smoothly.
Matching mark on the control raCk
and fuel
fuel control pinion
pini on
6) While holding. the fuel control pinion by

one hand so that its match mark may not
be out of position, reassemble the control
sleeve and lightly
lightl y tighten the
the stop screw of
the fuel control pinion.
Reassemble the control sleeve in the

direction in which the holes around the
control
contr ol sleeve face the stop screw.
screw. At the
same time,
time, align the match mar k with that
of fuel control pinion.
8) Mount the plunger

plunge r spring.
12 10
12 FuellnJeclion Pump for Direci Injection Syslem
9) Moun tthe plungerspring

plunge rspring lower retainer on 2 . Check to see if the control rack moves
the top of the plunger. While
Whil e aligning the freely. If no
not,
t, the plunger spring nterferes
match mark
ma rk of the plunger
plun ger flange with that with somethin
some thing
g else. In this case, hold
of the control sleeve, reassemble the the plunger spring in position using a
plunger from the bottom of the fuel injec- screwdriver.
tion pump using a plunger insertion tool 3 . When replacing the plunger guide
assembly with a new one, insert the
special service tool).
standard shim, and temporarily tighten
it
Insertion o plunger with a special )

service tool: Plunger insertion tool
too l
11) Make sure that the plunger guide detent

Special service tool:
Special too l: ) groove is in position.
position. Tighten the plunger
Plunger Insertion tool u ide stopper.
Never reassemble the plunger

plun ger in reverse.
Otherwise, fuel injection volume increases
excessively to the point where fuel injection
excessivelyto
volume becomes uncontrollable.
10) Insert the plunger guide assembly into the

fuel injection pump from its bottom. Push
up the plunger guide using the handle of a
hammer, etc., and put a tappet holder
special service tool) in between the lower
spring retainer and fuel injection pump
body.
1 . While keeping the plunger guide detent

groove facing upward, align with the mating
screw hole of the plunger guide
guide stoppe r
on the fuel injection pump body.
:-------
o t i Stop screw hole
r I
, ·
I etent groove
12·11
12 Fuel Injection Pump for irect Injection System
12) Place the bearings

bearin gs on bot
both
h ends olthe
ol the fuel
fuel
injection pump camshaft. Insert the bear-
ings while tapping them from driving side.
Turn
Turn the fuel
f uel injection pump
pum p upside down.
Move the
the plungerguide
plunger guide toward the plunger
spring and
an d drive in the fuel injection pump
camshaft.
16) Fix the fuel injection pump. Using a mallet,

tap the end of the fuel injection pump
camshaft to adjust the side clearance of
the fuel
fuel injection pump camshaft
camsha ft using an
13) Fit the oil
oil seal to the inner
i nner side of the adjusting packing and a side clearance
bearing holder.
holder. Mount the bearing holder. gauge special service tool).
mm)
Apply lubricating oil to the fuel injection
pump camshaft nd oil seal o f the fuel
All models
injection pump camshaft in advance so Camshaft side clearance 0.02 0.05
as not to damage the oil seal.
[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
fuel injec-
injec -
tion pump camshaft.
15) Turn the fuel injection pump camshaft,

and extract the tappet holder special Special service gauge
Side clearance tool )
service tool).
12·12
12 Fuel Injection Pump for Direct Infection System
17) Mount the fu

fuel
el injection pump side cover.
cover.
20) Tighten the holder stopp

stopper
er to the specified
torque. kgf-m)
All models
Tightening torque 03
18) Mountt
Mou ntthe
he fuel
fuel injection pump b
bottom
ottom cove
cover.
r.
Never tighten the delivery holder exces-
sively. Otherwise, it upsets, causing oi
oill
to leak through it
19) Tighten the delivery valve spring holder

t the specified torque. kgf-m)
All models
Tightening torque 3.
3.5
5 - 4.0
1 . Tighten the delivery valve spring holder
by handas far s possible. If the bolt
21) Mount the ffuel
uel feed pump.
get hard to turn part way the packing
or delivery valve may be out of position.
Remove, correct, and start tighten again.
2 . Never tighten the delivery valve holder
excessively. Excessive tightening causes
the control rack to malfunction.
12-13
13 Governor
13 Governor
13 1. Exploded views of governor for indirect injectio
injection
n system
9
®
®
Governor spring
overnor case )
r « - ~ I ( O J ~
Governor case cover
Anglelch spring assembly

Tension lever
~ h
I
Governor weight assembly
I
Snap pin
overnor l v r®
Governor lever assembly
3·
13 Governor
13-2. Exploded views of governor for direct injection system
l: ever stop pin Stop
y
l v ~ng
. '
Govemor case
Mounting bolt
FO limiter assembly
Control lever
ngleich assembly ontrol l w r shaft
Governor spring
Governor weight
I
Tension lever ~ . Governor weight
assembly
Govemor lever
I- Govemor lever assembly

Governor weight support
13-2
13 Governor
13 3. Disassembly
Disassembl y and reassembly can be carried
Disassembly 3) Remove the governor
gove rnor case mounting bolt.
out similarly for Indirect injection
injection system and Remove the governor case from the fuel
Direct injection system. injection pump while gently tapping the
governor case with a wooden hammer.
1) Remove the governor
gover nor case. Create a gap between the governor case
and fuel
fuel injection pump by moving only the
moving parts of the governor
gover nor lever.
Loosen the stop nut o models with angleich

assembly.
4) Pull
Pull out the governor link snap pin
pin by
Circfip
inserting long nosed pliers between the
. An gleich case fuel injection pump and governor case.
Stop nut
Angleich spring
Washer
Shifter
Shim
Anglelch assembly)
2) Remove the control leverl ever hex.
hex. nut
nu t and
pull out the control lever from the control
lever shaft.
13 3
13 overnor
5) Separate the governor and fuel

fuel injection 7) Use long nosed pliers
plie rs to
to unhook
unho ok the gov
pump by sliding the governor case and ernor spring from the tension lever and
fuel injection pump apart and pulling out control lever shaft.
the snap pin of the governor link
lin k from
from the
control rack.
8) Remove thethe shaft retainer

reta iner on the gover
nor lever shaft. for IDI)
IDI)
Remove the circlips on both ends of the
governor
govern or lever shaft. for DI)
6) Remove the stop lever return
return spring from
the governor lever shaft. DI only)
13-4
13 Governor
9) Put a rod 8 mm in dia. or less in one end

of the governor lever shaft and tap the
gover nor ever shaft un
until
til the O-ring
O-ring comes
comes
out the other
o ther side of the governo r case.
case.
11) Remove the governor

gover nor link from the gover
10) After you

you remove the O-ring, lightly tap the nor lever.
end of the shaft that you removed the Q
ring from, and extract the governor lever

shaft.
The governor assembly conSists o the
governo
gov ernorr lever,
lever, tension lever
lev er and angleich
angleich,,
and is normally not disassembled.
13 5
13 Governor
12) When you need to pull out the the stop lever
lever,, 15) Fix the bearing
bearing holder
holde r with a vise to hold
remove the stop lever shaft stop pin, and the fuel injection pump camshaft. Loosen
lightly tap the inside of the governor
gov ernor case. the governor support nutwith box spanner
DI only) a few turns.
When the taper fit comes apart after you

have removed the nut, the governor weight
may fly out - Be careful.
13)
13) When you need to pull pull outthe
outt he control
control lever
shaft, lightly tap the end of the shaft with a
wooden hammer, and extract the control
lever.
* Do not remove the FO limiter assembly
from the governor case unless necessary.
2 . On models with torque springs.
springs. first remove 16) Remove the governor weight assembly
the box nut, stop nut, and then the torque from the fuel injection purnp camshaft
spring assembly. using the governorwei
gover norweight
ght extractor
extracto r special
service tool).
tool).
Governor weight extractor)
14)
14) Pull
Pull out the gove rnor sleeve on
on the end
end of
the fuel injection pump camshaft
camshaf t by hand.
13 6
13 Governor
13 4. Inspection
1. Inspection o f governor weight assembly
1) Replace the governor weight if it does not

open and close smoothly.
Governor weight
Pin
2) Replace the governor weight assembly if

the contact surface with governor sleeve
is extremely worn.
3) Replace if there is governor weight sup

port and pin wear or the the caulking is
loose.
4) Replace if the governor weight support

stopper is excessively worn.
2. nspection o f governor sleeve
1) Replace the governor

governo r sleeve if the contact
surface with governor weight is worn or
there is pitching.
2) Replace the governor sleeve if the contact

surface with shifter is excessively worn or
there is pitching.
3) If the governor sleeve does not move
smoothly on the fuel injection pump cam
shaft due to governor sleeve inner dia.
wear or other reasons, replace.
Governor weight
contact surface
Shifter contact
surface
Sleeve inner dia
13-7
13 Governor
3. Inspection o f governor lever shaft

assembly
1) Measure the clearance between the gov-

ernor ever shaft and bushing,
bushing, and replace
if it is near the wear limit.
mm)
Standard Standard i m ~
dimension clearance
Shifter
Govemor lever 8:8:m
shaft outer dia
0.065
0.5 6. Inspection o f torque spring assembly
0.124
Bushing inner 8 +0.11
dia. +0.06
1) Inspect the tip of the piston and contact
surface for wear and replace if it is faulty.
2) Inspect the shifter contact surface, and if it
is worn or scorched, remove the spring 2) Replace the asse mbly if the torque spring
pin to disassemble and replace the shifter is broken.
only.
3) Check link parts for bends or kinks

kinks that will Torque spring
cause malfunctioning, and replace if it is

faulty.
* Side gap on top of governor lever shaft.

mm)
Standard side gap 0.4 I

Piston
2 Replace the governor

gover nor lever.
lever. tension lever
bushing shifter nd angleich spring as an
assembly.
4. Inspection o f springs
1) Check the governor spring and other
springs and replace if they are broken,
settled or corroded.
~ { { { { ~
5 Inspection o f anglelch spring assembly
1) Inspect the sliding

sliding surface of shifter and
and
replace if it is faulty.
2) Replace the angleich spring assembly

assemb ly if
the angleich spring is broken.
13 8
13 Governor
13 5. Reassembly
Inspect all parts after disassembly

disassemb ly and replace
any parts as necessary. Before starting
reassembly, clean all parts and put them n
order.
Make sure to readjustthe
readjus tthe unit after reassembly
to obtain the specified performance.
(1) Fix the bearing holder

ho lder with a vise to hold
the fuel injection pump camshaft. Insert \
the governor weight assembly n the taper
portion at the end of the fuel injection
pump camshaft. Mount the washer, and and
tighten the governor weight support nut
with the specified torque. (3) After the stop lever is disassembled,
mount the stop lever return spring on the
stop lever, tap the stop

st op lever lightly with
with a
wooden hammer to insert it, and tighten
the stop lever stop pin. (DI only)
(kg ·m)

nut tightening torque
Indirect injection system 7.0 7.5
Direct injection system 4.5 5.0 (4) After the control lever shaft is removed,
removed,
lightly tap and insert the control lever shaft
(2) Open the governor weight to the outside, and washer from inside the governor
gover nor case,
and insert the sleeve n the end of the fuel using an appropriate plate.
injection pump camshaft.
(5
(5)) If the governor
gover nor lever has been disassem
Make sure that the sleeve moves smoothly bled, tap n the spring pin.
after inserting it
13-9
13 Governor
2. Make sure to insert the governo

gov ernorr ever
eve r shaft
6) Mount the gov
govern
ernor
or lever assembly to the in the correct direction.
governor link.
* . Make sure that the correct governor link

mounting holes are used and that it is
mounted in the correct direction.
2. Make sure that the governor link moves
smoothly.
3. Don t forget to mount the washers on both

sides o the governor lever.
8) After you have mounted the O-ring, tap the

7) Put the govern
governor
or lever shaft assembly in
governor lever in the opposite direction,
the governor case, insert the governor
and mount the circlip on the grooves at
lever shaft and tap it in until the O-ring
both ends. for 01
groove comes out the opposite side of th
the
e
governor
govern or case. for 01
* . Fit the O-ring beforehand to the side you

tap in
13 10
13 Governor
11) Pull the

the governor
gove rnor link as far as possible
towards the governor case mounting sur
face,, insert the governor li nk pin n the fuel
face
control rack pin hole and fitthe snap pin on
it.
After mounting the governor lever

l ever assembl
assembly,
y,
make sure the governor ever assembly moves
moves
smoothly.
9) Fitthe
Fitt he stop lever return spring to the end of
the governor
gover nor lever shaft.
shaft. DI only)
only) 12) Mount
Moun t the governor
gove rnor case
case to the fuel
fuel injec
tion pump while lightly tapping it with a
wooden hammer, and tighten the tighten
ing bolt.
13) Mount
Moun t the governor case
case cover.
On models with idle subspring, insert the
adjusting spring and adjusting rod on the
governor
govern or case cover adjusting bolt.
f the angleich spring assembly has been
removed, tighten the nut temporarily. The

nut should be securely tightened after ad-
justment.
10) Hook the governor spring on the control

lever shaft and tension lever hook with
long nosed pliers.
13-11
13 overnor
14) Insert the control lever in the control lever

shaft and tighten the nut.
Move the control lever back and forth to make

sure that the entire link moves smoothly.
13 12
14 Turbocharger
14. Turbocharger
14 1. Specifications
3TNE84T (Cl, VM) 3TNE84T CH. VH)
Applicable engine model application)
4TNE84T (Cl) 4TNE84T VM. CH, VH)
Turbocharge
Turbo charge r model RH
RHB3
B31
1 RHB51
RHB51
Turbocharger specification
specification Standard wlwaste gate)
Turbine type Radial flow
Blower compressor)
compressor) type Centrifugal
lubrication method External lubrication
Max. continuous
contin uous allowable rpm 250,000 180, 000
Max. continuous allowable gas 750 C

inlet temperature
Dry weight 2.4 kg 4.2 kg

I
Note) VM and VH applications are provided with the waste gate.
14 2. Construction
1 17
Air outlet
No. Part name

1 Turbine shaft
2 Oil thrower
3 Turbine side seal ring
4 Seal plate
5 Journal bearing
as u ~ t
~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ = _ t A i ~ t 6 Thrust bearing
7 Compressor housing
8 MS hexagon bolt
9 M5 spring washer
10 Compressor side clamp
Turbine housing
12 M6 hexagon bolt
13 Turbine side clamp
14 Lock washer
Bearing housing
t
5
6 Retaining ring
17 M countersunk flat head screw
as inlet
18 Compressor wheel
19 Shaft end nut
20 Heat protector
14-1
14 Turbocharger
, ~
~ : ' . ~ : ~
.p ?1
~
' . . ~
,' ..
U
eI
~ I
Waste gate valve ass y
~ > •
. ~ ' . 1 \ / . ) ' - . Waste gate control ass y
U ; 0 /
&:/ ----.,,--
WI
Exploded view of turbocharger waste gate)
[Note]
A waste gate valve is adopted in the turbocharger for VM or V (variable speed) application.
* The waste gate valve is a turbocharger speed control system to maintain the intake air pressure
t a constant level by bypassing a part of the exhaust gas for driving the turbocharger by using
the intake
intake air pressure on th
thee compressor
compres sor sid
side.
e. It consists of a contr ol ass y separated from the
turbocharger nd a valve ass y built in the turbine housing,
1) Turbine 2. Radial uournal bearing)

The exhaust gas from the engine is ac A floating journal bearing is adopted.
celerated at the nozzle portion in the Because the bearing moves with the
turbine housing and blown onto the tur turbine shaft as oil films are formed both
bine impeller to rotate the turbine shaft. inside and outside of the bearing, the
This is called the turbine. A seal ring and bearing sliding speed is slower than the

Manual de Yanmar Us45d

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Manual de Yanmar Us45d

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FOREWOR

This Service Manual describes the

Before starting service nd maintenance of TNE engine

For further information,

This Service Manual n subject to changes, with or without notice,

Setup before work

1 Customer ledger check

1) Previous date of service

2. Stock control o f parts

3. Provision o f service record

4. Disassembly and reassembly tools

This product has been developed, designed and produced in

1. Specifications and Performance •..•...................•.•...•.•.....••••....•••.•.•...........•.......•.•...•.•. 1-1

2. ross Sectional Views .................•.........••.•..•••.•••...•...........•.......•...•••••....•...•...•.....•.....•. 2-1

6. Measurement Inspection and Adjustme Adjustment nt .........

15. Service Information or CARS ULG

Attached Drawing 1. Exploded Views o Engine Components ..................................... A·1

Cylinder bore mm)

Application code Usage Eng. Rev. type Revolution

or engine application category described in

1. Specifications and Performance

Recommended lubricating oil - API grade CC class or higher

*1 Dry weight kg 55/65 65 55/65

: (full speed Recovery time sec 56

* 1 . Designation of engine dimension and d ry weight in numerals.

1 Specificallons and Performance

(full speed Recovery time sec $6

Rated operation MPa ~ 2 5 ± 0 ~ ~ I ~ : 2 9 ± O . ~ ~ ~ : 3 4 ± 0 . ~ ~

* 1 . Designation of engine dimension and dry weight in numerals.

1 Specifications and erformance

1 3 3TNE74 Output conditio

*1 Dry weight kg 8SI102 100 8SI100

: (full speed Recovery time sec ,,6

*1. Designation of engine dimension and dry weight in numerals.

1 Specincations and erformance

Power take off - Flywheel

*1 Dry weight kg 138 1121128 124 112/124

1 Specifications and erformance

0 Fuel injection timing deg

*1 Dry weight kg 138 1121128

* 1 . Designation of engine dimension and dry weight in numerals.

1 Specifications and erformance

*1 Dry weight kg 161 138/155 149 1381149

1 Specifications and erformance

Governor - Mechanical centrifugal governor (All speed type)

1 Dry weight kg 161 138/155 149 38 49

1 Specificatl ns and Perf rmance

Governor - Mechanical centrifuQal qovernor (All speed type)

1 Dry weight kg 161 138/155

1 Specifications and erformance

1 9 4TNE82 * utput con dit ions:

overnor - Mechanical centrifuQal governor (All speed type)

* 1 Dry weight kg 184 160/170 170 160/170

L.a. press. Rated operation MPa

* 1 . Designation of engine dimension and d ry weight in numerals.

1 Spocifications and erformance

1 Specifications and P rformanClJ

1-11. 4TNE88 * output condi

*1 Dry weight kg 184 160 /170

I: (lull speed Recovery time sec ;5 ;6

L.O. press. Rated operation MPa 0.29±0.05

1 Specifications and erformance

Governor - Mechanical centrifugal governor (All speed type)

1 Specifications and erformance