40 Yanmar Tier4F - Service Procedures

Service procedures Tier 4
CR engines
Date 26 March 2013
Vico de Bres
Customer Service Department
Yanmar Europe B.V.
Contents
A. Service for CR system
B. Service for DPF
C. Service tool (SMARTASSIST-Direct)
The information and figures in this document are the exclusive property of YANMAR Corporation. Page1
Unauthorized copying and reprinting prohibited.
Service for the CR system
Contents of Service for CR system
1. Outline of service for CR system

2. Service procedure
3. Investigation of failed parts
Outline of CR-System
DOC DOC SF
Inlet temp Outlet temp. Pressure difference
EGR valve sensor sensor sensor
Intake air EGR
Temp. Temp. DPF
DOC SF
Rail Pressure Sensor

Rail Pressure regulator
Supply pump
CR Injector
ECU
Speed sensorx2 Intake air FO CW

(Crank, Cam) throttle Temp. Temp.
sensor sensor
Feature of CR-System (1) : Injector Trim Data
The trim data for guaranteeing Injector characteristics

Target
predetermined injection quantity quantityPc=P3 Pc=P2
for every individual injector is
indicated. And these data are Injection
Pc=P1
quantity
registered in the ECU
（Bosch）
Top of injector（）：Rail pressure
Pc：
Adjustment
Value Control pulse width
Data
Matrix ECU
Code
＃1 INJ
＃2 INJ
Alpha-num-code ＃3 INJ
＃4 INJ
ECU has an injector Trim data for each cylinder.

At the time of injector exchange, the trim data in ECU needs to be rewritten
using a service tool.
Feature of CR-System (2) : Engine Trim Data
In order to apply to emission

control regulation,
there is the injection quantity injection
quantity
trim data corresponding to the Adjustment
performance for each single value
engine in the ECU. Engine Speed
ECU
＃1 INJ
＃2 INJ
＃3 INJ
＃4 INJ
Engine
trim
It is necessary to write these trim data in new ECU

using a service tool at the time of ECU exchange.

Feature of CR engine service:Complete parts replacement
Rail
Supply pump
Injector
ECU
Service Parts in Red color box are prepared as complete parts only.
When service is required, complete part replacement is required.
Feature of CR engine service: Re-write Trim data in ECU

DPF
DOC SF
Supply pump
Injector
ECU
It is necessary to re-write Trim Data in ECU, if replacement of injector are required.

And it is also necessary to reset DPF information in ECU, if replacement or cleaning
of DPF is required.
Feature of CR engine service: Flash the ECU with software and data
ECU
Service ECU, which is prepared to the field service, does not have software or data.
ECU software and Engine trim data are able to be downloaded from the data server
(SA-C) through the SA-D
Then complete ECU is flashed from Service ECU using SA-D
CR engine service in the field: (Example1: Troubleshooting)
ECU
I/F Box
Connect service tool to

ECU Display DTC
Failure code and detail
occurred. failure mode
CR engine service in the field: (Example2: Parts replacement)
Nozzle tip CR Injector repair is

replacement not available
Nozzle clogged
Injector complete Re-write the

replacement Injector trim
data in ECU
PC Software
(SMARTASSIST-Direct)
ECU
I/F Box
Connect service
tool to ECU
Feature of CR engine service
The service tool is necessary for Troubleshooting and

parts replacement (CR parts and DPF)
I/F Box
General part table related to CR system (1/2) :
kW<56(Bosch) remark
Rail 2types (3cyl,4cyl) Replace as assy.
assy.
Pressure sensor 1type
Pressure Regulator 1type
Fuel Supply Pump 1type Replace as assy.
Fuel Oil Temp. 1type
Fuel Injector 4types For 3TNV88C & 4TNV88C
For 3TNV86CT & 4TNV86CT
For 4TNV98C
For 4TNV98CT
HPP(High Pressure Pipe) 3types For 3TNV86CT & 3TNV88C
For 4TNV86CT & 4TNV88C
For 4TNV98C & 4TNV98CT
Intake Air Throttle Valve (sensor 1type
equipped)
EGR Valve 3types For 3TNV86CT & 3TNV88C
(Valve diameter is varied) For 4TNV86CT & 4TNV88C
For 4TNV98C & 4TNV98CT
Service ECU 1type
DPF Case 3types (size)
Diesel Oxidation Catalyst 5types (size)
Soot Filter 3types (size)
General part table related to CR system (2/2) :

kW<56(Bosch) remark
Sensors CWT (Coolant Water Temp.) 1type
IAT (Intake Air Temp) 1type
NAT (Intake Air temp., after 1type
Intake throttle )
EGT (Exhaust Gas Temp.) 3types
(Harness length)
EGRT (between EGR valve 1type
and EGR Cooler)
DOC In Temp. 1type or more Planning
(Harness length)
DOC Out Temp. 1type or more Planning
(Harness length)
Pressure difference sensor 1type
(between Intake and
Exhaust.)
Pressure difference sensor 1type
(between SF in and out)
Cam speed 1type
Crank speed 1type
Required condition of Fuel Oil and Lubrication oil
Fuel Oil
- Cetane number should equal 45 or higher
- Sulfer content of the diesel fuel should be less than 15 ppm.
Classification of Lubricating Oil

- API classification CJ-4
TBN Value > under confirmation(CJ-4)
- ACEA classification E-6
TBN Value > 7(E-6)
- JASO classification DH-2
TBN Value > 5.5(DH-2)
*TBN: Total Base Number
It is unable to guarantee, in case a problem occurs using

unsuitable fuel or lubricating oil.
Tier4 (CR) Engine sales out of a regulated area is not allowed.

Investigation flow for failed CR parts
Since CR-related parts are not able to be disassembly

investigated, the failed CR parts will be collected and
investigated by the following route.
Yanmar group
User Dist/Dealer OEM RHQ YJ QA Bosch
Service for DPF
Contents of Service for DPF
1. Outline of DPF
2. Service procedure for DPF
Outline of DPF
1. Diesel Particulate Filter (DPF)

Diesel Particulate Filter (DPF) is consisting of DOC and SF.
･DOC(Diesel Oxidation Catalyst)

･SF(Soot Filter)
※ It turned out as DPF that it was a registered trademark of

Mitsubishi Fuso.
Please use the expression named
“DIESEL PARTICULATE FILTER (DPF) “provisionally.
Outline of Diesel Particulate Filter (DPF)
◆ Diesel Particulate Filter (DPF) Structure
Pressure difference sensor

Silencer portion
Exh. Gas temp sensors
Exh. Gas in
Hold mat
Exh.
Gas
out
(Option parts)
external view cross-section view
Case, DOC DOC SF(soot

(diesel oxidation filter)
catalyst)
Case, SF
Contents of Service for DPF
1. Outline of DPF
2. Service procedure for DPF
DPF service (Plan)
Service for DPF

DPF can be separated to DOC, SF and the silencer.
The each complete part replacement will be available (Plan)
DPF is registered as emissions-related parts and periodic maintenance
of DPF is required.
If SF is replaced, it is necessary to update DPF information in ECU
due to the management of the history.
DPF Cleaning
To remove Ash in SF, it is necessary to perform a periodic SF cleaning.
DPF cleaning service is scheduled to be performed from the Yanmar
service network (Plan).
If SF is cleaned, it is also necessary to update DPF information in ECU
due to the management of the history.
DPF service
DOC：：maintenance-free parts
Replacement only, every 9000hrs
DOC SF
of operation
SF ： maintenance is required parts Silencer
Perform the cleaning every

3000hrs of operation
Exhaust
gas
Engine Emission warranty Periodic Maintenance Interval

Item
Type （Useful Life）
） Clean
Replacement
5000hrs or 7years,
19-37kW whichever comes first. Every 9000hrs Not
DOC necessary
≧37kW
8000hrs or 10years, of operation
whichever comes first.
5000hrs or 7years,
19-37kW whichever comes first. Every 9000hrs Every 3000hrs
SF of operation of operation
8000hrs or 10years,
≧37kW whichever comes first.
Service tool (SMARTASSIST-Direct)
Contents of Service tool (SMARTASSIST-Direct)
1. Background
2. Outline of Service tool (SA-D)
3. Service policy
4. Operations Guidelines of SA-D
Background
To enhance security and user management, Yanmar developed new service tool,
SMARTASSIST-Direct.
The service tool shifts from YDT to SMARTASSIST-Direct.
With this shift, operation method of user management and fee charge will be
changed.
C-1. Background
C-2. Outline of Service tool (SA-D)
C-3. Service policy
C-4. Operations Guidelines of SA-D
Outline of Yanmar Service tool (SMARTASSIST-Direct)
SA-Core
(Service data server
for field service)
I/F Box
ECU PC Software
CR engine (SMARTASSIST-Direct)
2G-ECO engine
• Connector (Deutsch-DTM Series)
• Special Signal Converter (USB-CAN)
• Software Provided by CD-ROM initially,
And download to update through Internet
Screen image of Troubleshooting
DTC Historical data
System information
Outline of CR engine service using SA-D
Office Yanmar
Automatic update of SA-D software
ECU rewrite / register

Download ECU software
Ｉ/Ｆ
Ｆ
Upload Parts replacement info.
SA-Core
(data server)
Manual link
SA-D
Retrieve ECU data

Market
New set up of special server
Troubleshooting
Direct access to server from SA-D
Ｉ/Ｆ
Ｆ
Search technical information
SA-D
Save all screen
Comparison of YDT and SA-D
YDT SA-D
Function Operativity - improved
Manual link - available
Applicable Tier3 Tier3, Tier4(CR)
engine
License User manage per manage per
management company individuals
Security - Every 3 month
check through internet
Fee Initial fee * charged charged
Annual fee - charged
* Initial fee is not required if you already have I/F Box.
Necessity of annual fee charge
Annual fee is necessary for the maintenance of SA-D system.

Collected fee is used for following reasons.
Maintenance of server system

-new server is established for SA-D system
User management
-for security reason, individual user is registered and managed
Update of SA-D software
-correspondence to new Windows version
-development of new function
Improvement of data handling
YDT
Service persons have to use many screens

one by one during maintenance.
SA-D It is possible to re-display

the screen in SA-D at the
Necessary data are
office.
automatically saved while
connecting with engine.
It is possible to e-mail the data to

third party for confirmation.
Manual link function
SA-D has function that links to maintenance and service information data in
addition to YDT trouble display function. You can use the function by clicking
display item.
This function enables immediate trouble-shooting and provides a hands-on
solution.
Diagnosis Online
Display of relating
information
Main additional function for Tier4
CR Parts replacement (re-write data in ECU)

Injector
Diesel Particulate Filter

(Soot Filter, Diesel Oxidation Catalyst)
Active control
It is possible to control engine run /off operation and fuel cutting of
supply pump by SA-D Compression test is available.
It is possible cylinder cut off test by SA-D troubleshooting for each

cylinder is available.
1. Background
3. Service policy
Background of service policy for CR engine
It will increase the frequency in use service tool in

the market (troubleshooting, injector replacement
etc.) through CR engine service
New service tool and data management system

are created in order to comply strictly with security
for CR service information in between OEMs.
Data writing/flashing into ECU is possible by OEM

Proactive engine service support by OEM will be
also required in order to prevent the down time from
end users.
Yanmar’s proposal of CR engine service
Service of the CR engine is performed by

OEM service network
It is also possible to serve the Yanmar brand engine from the Yanmar network.
However, Yanmar cannot support the demand of service excluding the sales
specification region
Service tool (SA-D) is indispensable to the CR engine

Service tool can be provided to OEM with charge.
1. Background
3. Service policy
Outline of license mode
SA-D has the following modes

according to user’s usage pattern.
Mode Outline
It is possible to use the function of
Standard
troubleshooting only.
It is possible to use all function like
Advanced troubleshooting and writing/flashing
ECU and so on.
License mode function

OEM
Mode Standard
Advanced
Security period 90 days 90 days
Security check Temporary relief of
7 days 7 days
expiration
License update O O
OEM model
Usable engine model All models
only
Troubleshooting Basic troubleshooting O O
Rewrite parameter X O
Parts replacement
ECU writing X O
Logging data save and re-display X O
ECU maintenance information upload O O
ECU all data save and re-display O O
ECU information ECU data save O ∆
Service information Manual link X ∆
：Possible to use、
O：、X：
：Impossible to use, △：Depending
△： on discussion with
OEM
Time chart of annual fee charge （example）
2013 2014 2015

Contract
Case 1
Contract
Case 2
Free of Charge Charge

Annual fee
charge
The first year of contract, the annual fee is free of charge.

For example, in both case 1 and 2, the annual fee for 2013 is free of charge.
Application form of SA-D

Application form for SMARTASSIST-Direct
** : Required for new applications, changes or cancelations
Application type ** New Change Cancel
Application date **
Company name **
Department
Country **
Delivery address for the interface box, contract and application documents:
Postal Code **
Address**
Telephone** Country Code ( )
Fax** Country Code ( )
Name**
E-Mail**
Service (before the change)
* : Required for changes Agriculture < Mode >
Marine/Ocean Standard
Click on the box and choose the Mode Energy System Expert
Construction YDT mode
Industrial Engine
Service (after the change)
* : Required for new applications, for changes
Click on the box and choose the Mode

Agriculture
Marine/Ocean
Energy System
Yanmar send Application form
Construction
Industrial Engine
* Under the Expert Service agreement, the annual

for SMARTASSIST-Direct by e-
Mail or electronic media.
service fee depending on the number of interface
boxes applies. Please contact YANMAR for details.
Number of necessary interface boxes pcs

Desired date
* : Required for new applications, for changes
* The annual service fee depends on the number of interface boxes. Please contact YANMAR for details.
License serial number for cancelation * : Required for cancelation

Fill the form and send back to
YANMAR by e-Mail.
* To find the license serial number, go to Help (H) of SMARTASSIST Direct, click Version Information, open the
Workstation Information screen, and check under License Information.
Use * : Required for new applications for changes Click on the box and choose the condition
Type of
No. Name (local language) (English) E-mail change YDS user ID
Ex Kyoko Nomura kyoko_nom ura@ yanm ar.co.jp Delete Yes AA12345
Ex Tomy Jhonson tjhonson@ yanm ar.com Add No
1
2
3
4
5
6
7
8
9
10
Memo
Parts exchange
Page46
Processing the DPF regeneration after the parts replacement

The following devices are used for the calculation of the accumulated PM amount
using the method C, so when there is a fault in these devices, the accumulated
PM amount may be miscalculated. Therefore, be sure to process the DPF
regeneration in order to eliminate the calculation error of the accumulated PM
amount when you replace the parts for these devices.
- Injector - DOC
- Supply pump - Rail
- EGR valve - Intake throttle
- DPF differential pressure sensor - DPF inlet temperature sensor
- DPF inside temperature sensor - ER pressure sensor
- Intake manifold temperature sensor - EGR gas temperature sensor
- Exhaust manifold temperature sensor - Crankshaft speed sensor
- Fuel temperature sensor - Cooling water temperature sensor
(1) Start and warm-up the engine until the cooling water temperature is 60℃ or
higher.
(2) When the accumulated PM amount is judged by the ECU as 12g/l or more, the
recovery regeneration request is displayed. Perform the recovery regeneration.
stationary regeneration request is displayed. Perform the stationary regeneration.
(4) When none of the above regeneration requests are displayed by the ECU,
perform the stationary regeneration using SMARTASSIST-Direct.
Flow Chart (Processing the DPF regeneration after the parts replacement)
Terminate the method C calculation error
Warm-up operation
(Cooling water temperature > 60℃)
Accumulated PM amount
12g/l or more
Recovery regeneration
10g/l or more Stationary regeneration
Stationary regeneration using SA-D
END : Preparation
: Work using SA-D
: Other work
Processing after the ECU replacement (when it is impossible to inherit from the old ECU)
When the history data could not be inherited from the old ECU at
the time of replacing the ECU, process the DPF regeneration and
check the accumulated ash amount in accordance with the
following procedures.
(1) Start and warm-up the engine until the cooling water temperature is 60℃ or higher.
recovery regeneration request is displayed. Perform the recovery regeneration.
stationary regeneration request is displayed. Perform the stationary regeneration.
(4) When none of the above regeneration requests are displayed by the ECU, perform
the stationary regeneration using SMARTASSIST-Direct.
(5) After the completion of the above regeneration, operate the engine at high idling
for 10 minutes or more until the method P is stabilized.
(6) Check the accumulated amount of the method P using SMARTASSIST-Direct.
(7) When the accumulated amount exceeds 5g/l, there is a possibility that ash is
overaccumulated in the DPF. Clean the SF.
Flow Chart (Processing after the ECU replacement )
(when it is impossible to inherit from the old ECU)
Initialization of the method C
(1) Warm-up operation

(Cooling water temperature > 60℃)
12g/l or more (2) Recovery regeneration
10g/l or more (3) Stationary regeneration
(4) Stationary regeneration using SA-D
(5) Operate the engine at high idling

for 10 minutes or more
(6) Check the accumulated PM amount

(method P) : Preparation
: Work using SA-D

5g/l or more (7) Clean the SF
: Other work
END
Required processing at the CR-related parts replacement

Replacement parts SA-D operation
Bosch DENSO
ECU Processing ECU Processing
rewrite DPF rewrite DPF
regeneration regeneration
ECU ○ ○ *2 ○ ○ *2
Injector ○ ○ ○ ○
DPF ○ ○ ○ ○
SF ○ ○ ○ ○
DOC ○ ○ ○ ○
Rail ○ ○ - ○
Supply Pump - ○ ○ ○
Other *1 - ○ - ○
*1 EGR valve, intake throttle, DPF differential pressure sensor, DPF inlet temperature sensor, DPF inside temperature sensor, EGR
pressure sensor, intake manifold temperature sensor, EGR gas temperature sensor, exhaust manifold temperature sensor,
crankshaft speed sensor, fuel temperature sensor, cooling water temperature sensor.
*2 When the history data could not be inherited from the old ECU, processing the DPF regeneration is required.
Furthermore, it is required to clean the SF when the accumulated amount by method P after the DPF regeneration exceeds 5g/l.
Front Gear Drive Train
Page52
Front Gear Train *
B2 E
C B2 C
E B1 D
B1 D
F
A A
F
3TNV88C/86CT, 4TNV98C/98CT
4TNV88C/86CT
A – Crank Shaft
B1 – Idler Gear
B2 – Idler Gear
C E
C – Fuel Pump Drive Gear
D
B1
D – Cam Gear
F
E – Hydraulic Pump Drive Gear (optional) A
F – Lubricating Oil Pump Drive Gear

4TNV94CHT
* Viewed from the front gear
case
Page53
Front Gear Drive Train
Number of teeth
Code Gear Name 3TNV88C/86CT
4TNV88C/CT 4TNV98 C/CT 4TNV98 C/CT
4TNV94CHT
A Crank Shaft Gear S 28 32 32
B1
B2
Idler Gear
Idler Gear
Charging System
S
S
37
31
42
31
50
*
C Fuel Pump Drive Gear S 28 32 64
D Cam Shaft Gear S 56 64 64
E Hydraulic Pump Drive Gear O 31 26 26
F Lubricating Pump Drive Gear S * 29 29
Page54
THANK YOU FOR YOUR ATTENTION.
2011年3月22日

40 Yanmar Tier4F - Service Procedures

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Service procedures Tier 4

Date 26 March 2013

A. Service for CR system

B. Service for DPF

C. Service tool (SMARTASSIST-Direct)

Contents of Service for CR system

1. Outline of service for CR system

Rail Pressure Sensor

Speed sensorx2 Intake air FO CW

Feature of CR-System (1) : Injector Trim Data

The trim data for guaranteeing Injector characteristics

ECU has an injector Trim data for each cylinder.

In order to apply to emission

It is necessary to write these trim data in new ECU

Contents of Service for CR system

1. Outline of service for CR system

Feature of CR engine service: Re-write Trim data in ECU

It is necessary to re-write Trim Data in ECU, if replacement of injector are required.

CR engine service in the field: (Example1: Troubleshooting)

Connect service tool to

Nozzle tip CR Injector repair is

Injector complete Re-write the

Feature of CR engine service

The service tool is necessary for Troubleshooting and

General part table related to CR system (2/2) :

Classification of Lubricating Oil

It is unable to guarantee, in case a problem occurs using

Contents of Service for CR system

1. Outline of service for CR system

Since CR-related parts are not able to be disassembly

User Dist/Dealer OEM RHQ YJ QA Bosch

Service for DPF

1. Diesel Particulate Filter (DPF)

･DOC(Diesel Oxidation Catalyst)

※ It turned out as DPF that it was a registered trademark of

◆ Diesel Particulate Filter (DPF) Structure

Pressure difference sensor

Case, DOC DOC SF(soot

Contents of Service for DPF

Service for DPF

Perform the cleaning every

Engine Emission warranty Periodic Maintenance Interval

Contents of Service tool (SMARTASSIST-Direct)

Contents of Service tool (SMARTASSIST-Direct)

Screen image of Troubleshooting

DTC Historical data

Automatic update of SA-D software

ECU rewrite / register

Retrieve ECU data

Comparison of YDT and SA-D

Annual fee is necessary for the maintenance of SA-D system.

Maintenance of server system

Improvement of data handling

Service persons have to use many screens

SA-D It is possible to re-display

It is possible to e-mail the data to

Main additional function for Tier4

CR Parts replacement (re-write data in ECU)

Diesel Particulate Filter