TNV series Product & Service training

by:
Yanmar Europe BV
Industrial Engines
Vico de Bres

for: Distributor
 YANMAR Periodic Maintenance
Maintenance interval is;
Daily service check
50 hours service check
Every 250 hrs
Every 500 hrs
Every 1000 hrs
Every 1500 hrs
Every 2000 hrs
Do check service manual for maintenance advise!
Maintenance & adjustment
 Maintenance
Maintenance highlights;
After initial 50 hours of operation
Replace engine oil and oil filter
Check and adjust cooling fan V-belt
Coolant system (1000hrs / every year)
Use LLC or ELC (SAE J814C, J1941, J1034 or J2036)
Capacity engine: 0,6 – 4,2 L (see spec each engine)
Level should be FULL/ HOT Operating conditions (hot engine), coolant temp normal

Maintenance & adjustment

 Maintenance
Maintenance highlights;
Engine oil (lubricant) (250hrs / 1st at 50hrs.)
Also replace filter Oil capacity: 1,8 – 10,5L)
(use oil like CF,CF-4,CI-4)

Fuel system
Drain fuel tank (250hrs)
Replace fuel filter (500hrs)

Maintenance & adjustment

Adjustments on Yanmar engines

Following adjustments are covered:

 Low idle
 High idle
 Start amount limiter
 Full load and fuel limiter
 Fuel injection timing
 Gear timing
 Nozzle opening pressure
 Valve clearances
 Fuel injection pump calibration

Maintenance & adjustment

Adjustments on Fuel Injection Pump (FIP)
Low idle:
The Low Idle bolt sets the control
lever in its return position. It is
located outside the governor and is
not sealed.

Maintenance & adjustment

 Adjustments on Fuel Injection Pump
High idle:
When this sealed bolt is adjusted,
the warranty voids; Adjusting
effects the performance and
emission levels. Therefore
adjusting is only allowed by FIE
dealers
Setting is depending on engine
specification

Maintenance & adjustment

Adjustments on Fuel Injection Pump (FIP)
Low idle:
The Low Idle bolt sets the control
lever in its return position. It is
located outside the governor and is
not sealed.

High idle:
When this sealed bolt is adjusted,
the warranty voids; Adjusting
effects the performance and
emission levels. Therefore
adjusting is only allowed by FIE
dealers
Setting is depending on engine
specification
Maintenance & adjustment
 Adjustments on Fuel Injection Pump
Start amount limiter (only
TNV-DI):
This bolt is not sealed and can
therefore be adjusted if necessary

Maintenance & adjustment

 Adjustments on Fuel Injection Pump

Full load bolt / Fuel limiter or torque spring:

 When this sealed bolt is adjusted, the warranty voids; Adjusting
effects performance and emission levels. Therefore adjusting is
only allowed by FIE dealers

Maintenance & adjustment

 Tamper resistance
FULL LOAD SET
1. Case
2. Locking plate
3. Load adjusting screw

FULL MAX SPEED SET

1. Case
2. Nut
3. Speed adjusting screw

Maintenance & adjustment

Fuel Injection Pump (FIP) exchange
 Timing indicating in “Yanmar terms”
FIC:
 Fuel Injection timing of Closing the main plunger port

FID:
 Fuel Injection timing of opening the Delivery valve

FIT:
 Fuel Injection Timing mentions exact stroke
[mm] at exact CA [deg. of Crankshaft
Angle] for Mono Plunger pump

FIR:
 Fuel Injection timing of Real injection (lift of
nozzle-needle)
Maintenance & adjustment
Checking FIT timing
used for MP pumps on DI engines

Maintenance & adjustment

 Checking FIT-timing (TNV-DI)

First we need to know what the FIT for the specific engine should be:
For getting the FIT, we need FIR and the Timing index number.
We calculate the FIT with formula:
FIT = (FIP Timing Index Number x 2) + FIR number

FIT = Fuel Injection Timing in °crankshaft angle

FIP Timing Index Number = Number stamped on FIP
FIR number = Given on engine datasheet (see Yanmar “D” site)
Checking FIT-timing (TNV-DI)
FIP Timing index Number
Timing index number shoold be read with a decimal point
between the 2 digits (7.0 here)

NOTE: If the injection

pump (old production) does
not have a timing index
number,please use the
injection pump ID
(Example: XK42 ) this can
be found on a Timing Index
list. (as shown on next slide)
Checking FIT-timing (TNV-DI)

Example: Timing index list

Pump ID Timing index Pump ID Timing index Pump ID Timing index

XG05 82 XK26 67 BT16 32
XG10 63 XK27 68 BT17 52
XG12 74 XK28 71 BT18 57
XG13 73 XK30 71 BT19 54
XG16 72 XK31 79 BT21 53
XG17 68 XK33 66 BT22 52
XG18 68 XK34 64 BT23 52
XG20 65 XK35 67 BT98 50
XG21 68 XK42 78 BT99 52
XG22 63 XKXB 63 TQ87 32
XG23 67 XM01 74 TQ92 53
 Checking FIT-timing (TNV-DI)

FIR number
Checking FIT-timing (TNV-DI)

FIP Timing Index Number = 7.0

FIR number = 4.0

FIT = (7.0 x 2) + 4.0

= 14 + 4.0
= 18°
Checking FIT-timing (TNV-DI)
Remove plug above delivery plunger
and install adapter with dial gauge
Attach a wrench or ratchet with socket
to the crank pulley bolt
Turn clockwise until the dial gauge
reaches the LOWEST point, at this
point turn dial to set at zero
 Checking FIT-timing (TNV-DI)
- Remove the plug at the flywheelhousing
- Turn crank pulley clockwise until the mark on the flywheel that indicates the
FIT crank angle and the mark on the fly wheel housing are aligned

Maintenance & adjustment

 Checking FIT-timing (TNV-DI)
The dial gauge should now indicate 2,5mm lift

If the dial gauge does not indicat 2,5mm lift,

then
the pump needs to be adjusted:

- Loosen the pump-fixing nuts, and turn the

Pump until the dial gauge indicates 2.5 mm lift.
- Fix the pump fixing nuts

Final check after adjustment:

Turn the crankshaft 720° and recheck the FIT
If timing is okay, tighten the pump fixing nuts to
the specified torque
Maintenance & adjustment
 Checking FIT-timing (TNV-DI)
Re-assemble all other removed items:
 First reassemble Oil line, remove dial
gauge and reinstall plug.
 After that: Reassemble support bracket at
back of FIP, high pressure lines, coolant
plug, fuel inlet and outlet rubber hoses.
 Re-assemble fuel gear cover with liquid
gasket.
1) Perform air bleeding of fuel system

Maintenance & adjustment

 Removal of the FIP
When should we remove the FIP?
- In case of FIP check at FIE center.
- In case of pump break down

What causes Yanmar FIP to break down?

- Contaminated fuel (bad quality fuel filter used)
- Water in the fuel (no maintenance on the water separator)
- Bad fuel quality
-

Maintenance & adjustment

 Preparation removal of pump
1) Mark position of FI-pump
related to gear case
 Scratch alignment marks on Pump-
flange and Gear case
OR use mark sticker (p/n 158090-51990)

Maintenance & adjustment

 Preparation removal of pump
2) Remove fuel high pressure lines
3) Remove cover of Coolant line attached to the
pump at the CSD
4) Remove fuel pump gear cover
5) Remove plug above delivery plunger and
install adapter with dial gauge

Maintenance & adjustment

 Preparation removal of pump
6) Attach a wrench or ratchet with socket to the
crank pulley bolt
7) Turn clockwise until the dial gauge reaches the
LOWEST point, at this point turn dial to set at
zero (This is bottom dead center of plunger)

if forgotten, the FIP camshaft will turn due

to the force by delivery plunger spring and
timing gear needs adjustment

Maintenance & adjustment

 Removal of Fuel Injection Pump
Before removing the drive gear from the pump, mark the relative position of the
drive gear with the gear case opening or on the relative position of the gear with
the idler

TNV82-88 models TNV94-106 models

Note : Do not rotate the crankshaft after these marks are made!
Maintenance & adjustment
CAUTION : never loosen the 4 bolts that fasten the
pump flange and pump drive gear
 Removal of Fuel Injection Pump

1) Loosen (not remove!) center nut; Don’t

touch the 4 bolts!!!!!
2) Screw in M8 bolts and pull FIP gear from
shaft with FIP gear puller
 Be careful not to turn gear inside gear case!
3) Remove center nut

M8 threads to
mount FIP gear
puller

Maintenance & adjustment

Removal of Fuel Injection Pump
Possible FIP-Gear pullers:

Maintenance & adjustment

Removal of Fuel Injection Pump
Possible FIP-Gear puller – compact version:
 Removal of Fuel Injection Pump
Removal of secondary parts

4) Remove supporting bracket at back of FIP

5) Remove Oil line

6) Remove fuel inlet and outlet rubber hose.
Fuel might drain out of the hoses!

Maintenance & adjustment

 Removal of Fuel Injection Pump
7) Remove pump-mount fixing nuts. Because of
sound insulation between pump and engine
block, a wrench with a 15° angle and/or
ratchet with flexible coupling may be
necessary
8) Remove pump

15°
15

Maintenance & adjustment

 Installing new pump
IMPORTANT: After removing the existing injection pump, locate and record the timing index number on the
injection pump. This number is stamped into the forward boss on the engine side of the upper injection pump housing.

NOTE: If the injection pump (old production) does not have a timing index number,please use the injection pump ID
(Example: XK42 ) this can be found on a Timing Index list.

Maintenance & adjustment

 Installing new pump

Example: Timing index list

Pump ID Timing index Pump ID Timing index Pump ID Timing index

XG05 82 XK26 67 BT16 32
XG10 63 XK27 68 BT17 52
XG12 74 XK28 71 BT18 57
XG13 73 XK30 71 BT19 54
XG16 72 XK31 79 BT21 53
XG17 68 XK33 66 BT22 52
XG18 68 XK34 64 BT23 52
XG20 65 XK35 67 BT98 50
XG21 68 XK42 78 BT99 52
XG22 63 XKXB 63 TQ87 32
XG23 67 XM01 74 TQ92 53

Maintenance & adjustment

 Installing new pump
Example of Calculation
The timing index number on the new pump is 78 7.8
The timing index number on the old pump was 70 - 7.0
(NOTE :You treat the timing index number as if it has a decimal point) + 0.8

To “advance” the injection timing, you need to rotate the pump ‘away’ from the engine
To “retard/delay” the injection timing, you need to rotate the pump ‘ towards’ the engine

Maintenance & adjustment

 Installing replacement pump
1) Mount the new pump provisionally,
turn until the alignment of the mark on
the new pump on the same position as
at the removed pump ADJUST as
calculated!
2) Hand tighten pump fixing nuts

Maintenance & adjustment

Checking FIT-timing (TNV-DI)
Remove plug above delivery plunger
and install adapter with dial gauge
Attach a wrench or ratchet with socket
to the crank pulley bolt
Turn clockwise until the dial gauge
reaches the LOWEST point, at this
point turn dial to set at zero
 Checking FIT-timing (TNV-DI)
- Remove the plug at the flywheelhousing
- Turn crank pulley clockwise until the mark on the flywheel that indicates the
FIT crank angle and the mark on the fly wheel housing are aligned

Maintenance & adjustment

 Checking FIT-timing (TNV-DI)
The dial gauge should now indicate 2,5mm lift

If the dial gauge does not indicat 2,5mm lift,

then
the pump needs to be adjusted:

- Loosen the pump-fixing nuts, and turn the

Pump until the dial gauge indicates 2.5 mm lift.
- Fix the pump fixing nuts

Final check after adjustment:

Turn the crankshaft 720° and re-check the FIT
If timing is okay, tighten the pump fixing nuts to
the specified torque
Maintenance & adjustment
 Checking FIT-timing (TNV-DI)
Re-assemble all other removed items:
 First reassemble Oil line, remove dial
gauge and reinstall plug.
 After that: Reassemble support bracket at
back of FIP, high pressure lines, coolant
plug, fuel inlet and outlet rubber hoses.
 Re-assemble fuel gear cover with liquid
gasket.
 Add 150-200cc of new clean engine oil to
the FIP at the fill plug at top of the
governor housing.

Maintenance & adjustment

Multi-hole Injector for TNV
Nozzle identification
Y DDL A-150 P 165 VAE1
• Y yanmar
• DDL: hole (long) DL: hole (short) DN: pintle
• A: installed in angle - : not at angle
• 150: spray angle
• P 165: nozzle hole (P/S type, 0.16mm, 5 holes)
• VAE1 : design code

Maintenance & adjustment

Multi-hole Injector for DI-engines

Maintenance & adjustment

 Checking Injectors (DI-injector)
• Clean carbon from nozzle-tip with scotchbrite
• Check Spray pattern & angles
– Use injectors tester

Maintenance & adjustment

Single hole Injector for IDI-engines

Maintenance & adjustment

 Checking Injectors (IDI-injector)
• If necessary: Dis- & Re-assemble and Clean nozzle
• Check Spray pattern
– Use injectors tester
– Or test on engine: Turn flywheel back and forth around injection point
– Hold a paper underneath injector: spray pattern should form a perfect circle

Maintenance & adjustment

Readjusting valve opening pressure and/or change
nozzle
• If valve pressure testing was not OK, clean & check
nozzle (needle should drop by gravity)

or

In case of pressure adjustment:

• Disassemble according to explosion
• Determine how much shims need to be added/removed
Add / remove shims:
• DI: adding 0.1mm shim equals 20 Bar higher opening
pressure
• IDI: adding 0.1mm shim equals 7~10 Bar higher opening
pressure
• Reassemble nozzle case nut with metric 12-sided Metric
socket 15

Maintenance & adjustment

 Re-assembling injector (DI)
 Always use new gasket (seat & protector) when  Check condition of O-ring
reinstalling. of nozzle body

Maintenance & adjustment

Valve clearances – order of adjustment
Measure and adjust when ENGINE is cold
Firing order 3 Cylinder: 1-3-2
4 Cylinder 1-3-4-2
Valve clearance to be checked at TDC of related cylinder

Question: (4-stroke diesel engine)

At what CS rotation is the engine fired again? 2 cylinder and 4 cylinder ENGINE

Maintenance & adjustment

 Valve clearances (2-valve)
• Both Intake AND exhaust valves:
Model Standard valve clearance (mm)
2TNV70~3TNV76
0,20 ± 0,05
3TNV82A~4TNV88

Maintenance & adjustment

Valve clearances (4-valve)

Maintenance & adjustment

 Valve clearances (4-valve)
First adjust zero clearance at both valves:
1) Loosen lock nut, screw adjusting bolt
counterclockwise one turn
2) Tighten rocker arm until touching (HOLD)
3) Turn adjusting bolt clockwise until touching

4) Tighten Lock nut with help of a wrench

4-valve engine:
4TNV84T, 4TNV94L,
4TNV98(T), 4TNV106(T)

Maintenance & adjustment

 Valve clearances (4-valve)
Model Standard valve clearance (mm)
4TNV84T
• Both Intake AND exhaust valves: 4TNV94L~4TNV98
0.20 ± 0.05

4TNV106(T) 0.30 ± 0.05

Rocker arm Adjusting bolt

Valve
Adjusting bolt clearance

Lock nut

Valve bridge

Lock nut
“0” clearance

Maintenance & adjustment

Calibration of Fuel Injection Equipment

Yanmar injection pumps (equipment)

 Bring/send to the injection pump shop after
getting the address from the Yanmar
distributor. Each pump has his specific
calibration code referring to the data-sheet.

Maintenance & adjustment

Questions ?